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Users guide

BaseWare

BaseWare Users guide

RobotWare-OS 4.0

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1 Introduction

2 Safety

3 Basic Operation

4 Jogging

5 Inputs and Outputs

6 Programming and Testing

7 The programming language RAPID

8 Coordinate Systems

9 Production Running

10 System Parameters

11 File Manager

12 Service

13 ScreenViewer

14 Error Management, System and Error Messages

15 Program Examples

16 Index

17 Glossary

UsersGuide

Users guide

3HAC 7793-1

B

BaseWare


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The information in this manual is subject to change without notice and should not be construed as a commitmentby ABB. ABB assumes no responsibility for any errors that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guar-antee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

This manual and parts thereof must not be reproduced or copied without ABB's written permission, and contentsthereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be pros-ecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

2003 ABB All rights reserved.

ABB Automation Technology Products ABRobotics

SE-721 68 VstersSweden

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CONTENTSPage

Users Guide i

1 Introduction ............................................................................................. 1-1

1 Overview............................................................................................................... 1-32 How to Use this Manual ...................................................................................... 1-4

2.1 Organization of chapters ............................................................................... 1-4

2.2 Typographic conventions .............................................................................. 1-6

3 Other Manuals ..................................................................................................... 1-7

2 Safety ........................................................................................................ 2-1

1 Overview............................................................................................................... 2-3

1.1 Introduction................................................................................................... 2-3

2 Applicable Safety Standards............................................................................... 2-3

3 Fire-Extinguishing ............................................................................................... 2-4

4 Definitions of Safety Functions........................................................................... 2-4

5 Safe Working Procedures.................................................................................... 2-5

5.1 Normal operations......................................................................................... 2-5

6 Programming, Testing and Servicing................................................................. 2-5

7 Safety Functions................................................................................................... 2-6

7.1 The safety control chain of operation ........................................................... 2-6

7.2 Emergency stops ........................................................................................... 2-7

7.3 Mode selection using the operating mode selector ....................................... 2-7

7.4 Enabling device............................................................................................. 2-8

7.5 Hold-to-run control ....................................................................................... 2-8

7.6 General Mode Safeguarded Stop (GS) connection....................................... 2-9

7.7 Automatic Mode Safeguarded Stop (AS) connection................................... 2-10

7.8 Limiting the working space........................................................................... 2-10

7.9 Supplementary functions............................................................................... 2-10

8 Safety Risks Related to End Effectors ............................................................... 2-10

8.1 Gripper .......................................................................................................... 2-10

8.2 Tools/workpieces........................................................................................... 2-11

8.3 Pneumatic/hydraulic systems........................................................................ 2-11

9 Risks during Operation Disturbances................................................................ 2-11

10 Risks during Installation and Service .............................................................. 2-11

11 Risks Associated with Live Electric Parts........................................................ 2-13

12 Emergency Release of Mechanical Arm .......................................................... 2-13

13 Limitation of Liability ....................................................................................... 2-14

14 Related Information .......................................................................................... 2-14

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3 Basic Operation........................................................................................ 3-1

1 Overview............................................................................................................... 3-32 The Manipulator.................................................................................................. 3-4

3 The Controller...................................................................................................... 3-4

4 The Operators Panel .......................................................................................... 3-5

5 The Teach Pendant unit ...................................................................................... 3-7

5.1 Entering text using the Teach Pendant unit................................................... 3-9

5.2 Working with windows ................................................................................. 3-9

6 Emergency Stops.................................................................................................. 3-12

6.1 The emergency stop button........................................................................... 3-12

6.2 Recover from emergency stop ...................................................................... 3-12

7 Starting up the robot ........................................................................................... 3-13

7.1 Errors at start-up ........................................................................................... 3-14

7.2 Switching the Power Supply to the MOTORS ON ...................................... 3-14

8 Switching the robot off ........................................................................................ 3-15

9 Selecting the Operating Mode ............................................................................ 3-16

9.1 Automatic mode (production mode)............................................................. 3-16

9.2 Manual mode with reduced speed (programming mode) ............................. 3-16

9.3 Manual mode with full speed (Option, testing mode) .................................. 3-16

10 Jogging the Robot Using the Joystick.............................................................. 3-17

10.1 Linear jogging............................................................................................. 3-17

10.2 Fine positioning .......................................................................................... 3-19

11 Open a Program................................................................................................. 3-21

11.1 Loading an existing program ...................................................................... 3-21

12 Starting the Program......................................................................................... 3-25

13 Stopping the Program........................................................................................ 3-27

14 Automatic Mode ................................................................................................ 3-2815 Editing a Program ............................................................................................. 3-29

15.1 Modifying positions .................................................................................... 3-29

15.2 Changing arguments ................................................................................... 3-31

15.3 Adding instructions..................................................................................... 3-32

15.4 Programming a delay .................................................................................. 3-35

16 I/O Signals .......................................................................................................... 3-38

16.1 Programming an I/O instruction ................................................................. 3-38

16.2 Manually check the state of a signal........................................................... 3-40

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17 Errors.................................................................................................................. 3-41

17.1 Acknowledge error messages...................................................................... 3-41

17.2 Calling up suggestions on how to correct an error...................................... 3-41

17.3 Acknowledge warning messages ................................................................ 3-41

4 Jogging...................................................................................................... 4-1

1 Overview............................................................................................................... 4-3

1.1 The Jogging window..................................................................................... 4-3

1.2 Customising the jogging window ................................................................. 4-4

1.3 Reading the current position ......................................................................... 4-5

1.4 How moving the joystick affects movements ............................................... 4-5

1.5 Locking of joystick axes ............................................................................... 4-5

1.6 Motion Supervision....................................................................................... 4-6

2 Jogging the Robot ................................................................................................ 4-7

2.1 Jogging the robot along one of the base coordinate axes.............................. 4-7

2.2 Jogging the robot in the direction of the tool ................................................ 4-7

2.3 Reorienting the tool....................................................................................... 4-9

2.4 Aligning a tool along a coordinate axis ........................................................ 4-10

2.5 Jogging the robot in the direction of the work object ................................... 4-11

2.6 Jogging the robot along one of the world coordinate axes ........................... 4-12

2.7 Using a stationary tool .................................................................................. 4-13

2.8 Jogging the robot axis-by-axis ...................................................................... 4-14

2.9 Incremental movement.................................................................................. 4-14

2.10 Jogging an unsynchronised axis.................................................................. 4-15

3 Jogging External Axes......................................................................................... 4-16

3.1 Choosing external units................................................................................. 4-16

3.2 Jogging external units axis-by-axis............................................................... 4-16

3.3 Jogging external units coordinated ............................................................... 4-173.4 Jogging external units with dynamic models................................................ 4-17

5 Inputs and Outputs.................................................................................. 5-1

1 Overview............................................................................................................... 5-3

1.1 The Inputs/Outputs window.......................................................................... 5-3

1.2 Choosing an I/O list ...................................................................................... 5-3

1.3 Defining theMost Common I/O list .............................................................. 5-5

2 Changing Signal Values....................................................................................... 5-7

2.1 Changing the value of a digital output.......................................................... 5-72.2 Changing the value of an analog output signal or a group of output signals 5-7

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3 Displaying Information ....................................................................................... 5-9

3.1 To display information on a given signal...................................................... 5-9

3.2 To display a chart of all digital signals of a unit ........................................... 5-9

3.3 To print an I/O list ......................................................................................... 5-10

3.4 Blocked signals ............................................................................................. 5-10

4 I/O bus Recovery ................................................................................................. 5-12

6 Programming ........................................................................................... 6-1

1 Creating a New Program .................................................................................... 6-5

1.1 What is a program? ....................................................................................... 6-5

1.2 The Program window.................................................................................... 6-6

1.3 Creating a new program .............................................................................. 6-6

1.4 Loading an existing program........................................................................ 6-7

2 Defining Tools and Work Object........................................................................ 6-7

3 Creating New Routines........................................................................................ 6-8

3.1 What is a routine? ......................................................................................... 6-8

3.2 TheProgram Routineswindow .................................................................... 6-9

3.3 Creating a new routine .................................................................................. 6-10

3.4 Duplicating a routine..................................................................................... 6-12

4 Creating new instructions................................................................................... 6-13

4.1 Choosing a routine ........................................................................................ 6-13

4.2 TheProgram Instr window........................................................................... 6-13

4.3 What is an instruction?.................................................................................. 6-14

4.4 Getting more information about an instruction............................................. 6-14

5 Programming ....................................................................................................... 6-16

5.1 Choosing from the instruction pick list......................................................... 6-16

5.2 Adding an instruction.................................................................................... 6-17

5.3 Expressions ................................................................................................... 6-195.4 Moving and copying instructions.................................................................. 6-22

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6 Running Programs............................................................................................... 6-23

6.1 Program execution ........................................................................................ 6-23

6.2 TheProgram Test window............................................................................ 6-23

6.3 Choosing the speed correction ...................................................................... 6-24

6.4 Choosing the execution mode ....................................................................... 6-24

6.5 Motion step execution ................................................................................... 6-26

6.6 Starting program execution ........................................................................... 6-27

6.7 Stopping program execution ......................................................................... 6-28

6.8 Where will the program start?....................................................................... 6-28

6.9 Simulating wait conditions............................................................................ 6-30

6.10 Multitasking ................................................................................................ 6-31

6.11 MANFS speed limit .................................................................................... 6-31

6.12 KeepOverride .............................................................................................. 6-32

7 Saving and Printing Programs ........................................................................... 6-33

7.1 Saving the program on diskette or some other type of mass memory .......... 6-33

7.2 Printing a program from the robot ................................................................ 6-34

7.3 Printing a program using a PC ...................................................................... 6-34

8 Changing the Program........................................................................................ 6-35

8.1 Selecting an instruction or an argument........................................................ 6-35

8.2 Modifying the position in a positioning instruction...................................... 6-36

8.3 Tuning position during program execution................................................... 6-36

8.4 Changing an argument .................................................................................. 6-38

8.5 Adding optional arguments........................................................................... 6-40

8.6 Changing the structure of an IF, FOR or TEST instruction .......................... 6-40

8.7 Changing the name or declaration of a routine ............................................. 6-41

8.8 Deleting an instruction or an argument......................................................... 6-41

8.9 Deleting a routine.......................................................................................... 6-428.10 Undo latest action........................................................................................ 6-42

9 Special Editing Functions.................................................................................... 6-44

9.1 Search & replace ........................................................................................... 6-44

9.2 Mirroring routine........................................................................................... 6-45

9.3 Mirroring program or module ....................................................................... 6-51

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10 Creating Data..................................................................................................... 6-54

10.1 What is data?............................................................................................... 6-54

10.2 TheProgram Datawindow (used to manage data).................................... 6-54

10.3 Creating new data ....................................................................................... 6-56

10.4 Creating new array data .............................................................................. 6-58

10.5 Duplicating data .......................................................................................... 6-59

10.6 Storing position data using the robot .......................................................... 6-59

10.7 Routine data ................................................................................................ 6-59

11 Changing Data.................................................................................................... 6-60

11.1 Viewing and possibly changing the current value ...................................... 6-60

11.2 Changing data names or declarations.......................................................... 6-60

11.3 Deleting data ............................................................................................... 6-61

12 Error Handling .................................................................................................. 6-62

13 Using Modules.................................................................................................... 6-64

13.1 What is a module?....................................................................................... 6-64

13.2 Choosing modules....................................................................................... 6-65

13.3 Creating a new module ............................................................................... 6-66

13.4 Changing the name or declaration of a module .......................................... 6-66

13.5 Reading a program module from diskette or some other type of mass memory6-67

13.6 Deleting program modules from the program ............................................ 6-67

13.7 Listing all routines in all modules............................................................... 6-67

13.8 Duplicating a routine from one module to another..................................... 6-68

13.9 Listing all data in the current module ......................................................... 6-68

13.10 Duplicating data from one module to another .......................................... 6-68

13.11 Saving modules on diskette or some other type of mass memory ............ 6-68

13.12 Calling up the complete module list ......................................................... 6-69

14 Preferences ......................................................................................................... 6-7014.1 Defining theMost Common instruction pick list ........................................ 6-70

14.2 Default data Global/Local........................................................................... 6-71

14.3 Defining programming rule for robot positions.......................................... 6-72

7 RAPID....................................................................................................... 7-1

1 Programming a Position...................................................................................... 7-3

1.1 Positioning instructions................................................................................. 7-3

1.2 Programming an offset.................................................................................. 7-6

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2 Programming an I/O instruction........................................................................ 7-8

2.1 Set an output.................................................................................................. 7-8

2.2 Change the value of an output....................................................................... 7-9

2.3 Wating for an input........................................................................................ 7-10

3 Programming a delay .......................................................................................... 7-12

3.1 Waiting a specific amount of time ................................................................ 7-12

4 Controlling the Program Flow............................................................................ 7-14

4.1 Calling a subroutine ...................................................................................... 7-14

4.2 Program control within a routine .................................................................. 7-15

5 Assigning a Value to Data (Registers)................................................................ 7-18

8 Coordinate Systems ................................................................................. 8-1

1 Overview............................................................................................................... 8-3

1.1 Coordinate systems used to determine the position of the TCP ................... 8-5

1.2 Coordinate systems used to determine the direction of the tool ................... 8-10

2 Defining Tools....................................................................................................... 8-13

2.1 Creating a new tool ....................................................................................... 8-13

2.2 Manually updating the TCP and weight of a tool ......................................... 8-14

2.3 Methods of defining the tool coordinate system........................................... 8-15

2.4 Using the robot to change the TCP and orientation of a tool........................ 8-17

2.5 Stationary tool ............................................................................................... 8-19

3 Work Objects and Program Displacements ...................................................... 8-21

3.1 General .......................................................................................................... 8-21

3.2 Using work objects........................................................................................ 8-22

3.3 Creating a new work object .......................................................................... 8-22

3.4 Manually updating the user and object coordinate system of the work object8-23

3.5 Methods of defining a work object ............................................................... 8-24

3.6 Using the robot to change the work object ................................................... 8-243.7 Defining a moveable object frame................................................................ 8-27

3.8 How to use different work objects to get different displacements................ 8-27

3.9 How to adjust the program vertically using the object frame....................... 8-29

3.10 Using program displacement ...................................................................... 8-29

3.11 Creating a new displacement frame ............................................................ 8-30

3.12 Manually updating a displacement frame ................................................... 8-30

3.13 Methods for defining a displacement frame ............................................... 8-31

3.14 Using the robot to change a displacement frame ........................................ 8-31

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4 Base Frame for the Robot ................................................................................... 8-34

4.1 Defining the Base Frame for the Robot ........................................................ 8-34

5 Coordinated axes ................................................................................................. 8-38

5.1 External axes, general ................................................................................... 8-38

5.2 Coordination ................................................................................................. 8-38

6 Coordinated track motion................................................................................... 8-40

6.1 How to get started with a coordinated track motion..................................... 8-40

6.2 Defining the Base Frame for a track motion................................................. 8-40

7 Coordinated external axes .................................................................................. 8-45

7.1 How to get started with a coordinated (moveable) user coordinate system . 8-45

7.2 Defining the User Frame for a rotational axis (single) ................................. 8-45

7.3 Defining the User Frame for a two-axes mechanical unit, Method 1........... 8-49

7.4 Defining the User Frame for a two-axes mechanical unit, Method 2........... 8-52

9 Production ................................................................................................ 9-1

1 Overview............................................................................................................... 9-3

2 The Production Window..................................................................................... 9-3

3 Loading a Program.............................................................................................. 9-5

4 Changing the Override Speed ............................................................................ 9-6

5 Changing the Program Running Mode ............................................................. 9-7

6 Starting the Program........................................................................................... 9-8

6.1 Restarting after a stop ................................................................................... 9-8

6.2 Starting a program from the beginning......................................................... 9-8

6.3 Return to the programmed path .................................................................... 9-9

7 Stopping the Program.......................................................................................... 9-9

8 Tuning positions with HotEdit............................................................................ 9-10

9 Operator Dialogs.................................................................................................. 9-15

10 System Parameters ................................................................................ 10-11 Overview............................................................................................................... 10-3

2 Changing, deleting and adding Parameters...................................................... 10-3

2.1 Subdivision of parameters............................................................................. 10-3

2.2 Changing a parameter ................................................................................... 10-3

2.3 Deleting a parameter ..................................................................................... 10-4

2.4 Adding a parameter....................................................................................... 10-5

2.5 Generating a restart ....................................................................................... 10-5

2.6 Viewing the last changes that were made ..................................................... 10-6

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3 Saving and Loading Parameters ........................................................................ 10-7

3.1 Saving parameters to diskette or some other mass storage device ............... 10-7

3.2 Loading parameters from a diskette or some other mass storage device...... 10-8

4 Topic: Controller.................................................................................................. 10-11

4.1 Specifying regain distances........................................................................... 10-11

4.2 System miscellaneous ...................................................................................10-12

4.3 Activate Hold-To-Run Control ..................................................................... 10-12

4.4 Activate delayed safeguarded space stop......................................................10-13

4.5 Defining event routines.................................................................................10-13

4.6 Automatic loading of modules and programs............................................... 10-17

4.7 Defining multitasking ...................................................................................10-19

5 Topic: Communication........................................................................................ 10-23

5.1 Defining physical channels ...........................................................................10-23

5.2 Defining Transmission Protocol ................................................................... 10-24

5.3 Defining Application Protocol ...................................................................... 10-26

6 Topic: IO Signals.................................................................................................. 10-29

6.1 Defining I/O Units ........................................................................................ 10-29

6.2 Additional parameters for field bus units...................................................... 10-31

6.3 Defining input and output signals ................................................................. 10-34

6.4 Defining signal groups..................................................................................10-37

6.5 Defining system inputs.................................................................................. 10-38

6.6 Defining system outputs................................................................................ 10-42

6.7 Control the robot using digital signals. PLC Communication ...................... 10-44

6.8 Defining cross connections ...........................................................................10-48

6.9 List all available I/O Unit Types ................................................................... 10-52

6.10 IO Buses......................................................................................................10-54

6.11 Physical Signal Configuration..................................................................... 10-56

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7 Topic: Manipulator.............................................................................................. 10-61

7.1 Defining supervision level ............................................................................ 10-61

7.2 Defining teach mode speed........................................................................... 10-62

7.3 Defining independent joints.......................................................................... 10-62

7.4 Defining the base coordinate system ............................................................ 10-63

7.5 Defining a track motion with coordinated motion........................................ 10-64

7.6 Defining the commutation offset and calibration offset of the motors ......... 10-65

7.7 Defining the range of movement and calibration position of each axis ....... 10-65

7.8 Servo parameters........................................................................................... 10-66

7.9 Removing the Warning: Corner Path Failure 50024..................................... 10-66

7.10 Tuning the motion supervision ................................................................... 10-67

7.11 Defining arm load ....................................................................................... 10-68

7.12 Defining arm check point............................................................................ 10-68

7.13 Defining external torque ............................................................................. 10-70

7.14 Defining friction compensation .................................................................. 10-71

7.15 Defining the joystick directions for the robot and external manipulator .... 10-72

7.16 Defining kinematic parameters for general kinematics .............................. 10-75

7.17 Installation optimization of drive system parameters ................................. 10-76

7.18 CPU Optimization....................................................................................... 10-77

8 Topic: TeachPendant ........................................................................................... 10-81

8.1 Defining authorization and confirmation...................................................... 10-81

8.2 Activation of Limited ModPos Function ...................................................... 10-86

8.3 Speed Options ............................................................................................... 10-87

8.4 Defining Optional Packages ......................................................................... 10-87

8.5 Defining File Extensions............................................................................... 10-88

8.6 Defining Running Mode Settings ................................................................. 10-89

8.7 Programmable keys....................................................................................... 10-8911 File Manager........................................................................................... 11-1

1 Overview............................................................................................................... 11-3

2 Program/Data Storage ........................................................................................ 11-3

3 The FileManager Window .................................................................................. 11-4

3.1 Choosing a directory ..................................................................................... 11-4

3.2 Viewing file information............................................................................... 11-5

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4 Creating or Moving Files and Directories ......................................................... 11-6

4.1 Creating a new directory ............................................................................... 11-6

4.2 Renaming a file or a directory....................................................................... 11-6

4.3 Deleting a file or directory ............................................................................ 11-7

4.4 Copying files and directories ........................................................................ 11-7

4.5 Moving files and directories ......................................................................... 11-8

4.6 Printing files .................................................................................................. 11-8

5 Formatting a Diskette.......................................................................................... 11-9

6 File hierarchy ....................................................................................................... 11-9

12 Service..................................................................................................... 12-1

1 Overview............................................................................................................... 12-3

2 The Service Window............................................................................................ 12-3

3 Changing the Current Date and Time ............................................................... 12-4

4 Logs ....................................................................................................................... 12-5

4.1 What is a log?................................................................................................ 12-5

4.2 What types of logs are there? ........................................................................ 12-5

4.3 Viewing all logs ............................................................................................ 12-5

4.4 Viewing messages in a log ............................................................................ 12-6

4.5 Erasing the contents of a log ......................................................................... 12-7

4.6 Erasing the contents of all logs ..................................................................... 12-7

4.7 Updating the contents of a log automatically or by means of a command ... 12-7

4.8 Avoiding normal error reports....................................................................... 12-7

4.9 Saving one of the logs on diskette or some other mass storage device ........ 12-8

4.10 Saving all logs on diskette or some other mass storage device .................. 12-8

5 Calibration............................................................................................................12-10

5.1 What is calibration? ......................................................................................12-10

5.2 Viewing the calibration status ....................................................................... 12-105.3 Checking the calibration ............................................................................... 12-11

5.4 Updating revolution counters........................................................................ 12-11

6 Commutation........................................................................................................12-13

6.1 What is commutation? ..................................................................................12-13

7 Frame Definition..................................................................................................12-13

8 Two Axes Definition............................................................................................. 12-13

9 Obtaining information on the robot system ...................................................... 12-13

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10 Backup and Restore........................................................................................... 12-15

10.1 Perform a Backup ....................................................................................... 12-16

10.2 Perform a Restore ....................................................................................... 12-16

11 Restart................................................................................................................. 12-17

11.1 Normal restart (warm start)......................................................................... 12-17

11.2 I-start ........................................................................................................... 12-18

11.3 P-start (reinstallation of RAPID) ................................................................ 12-19

11.4 C-start (cold start, delete the active system) ............................................... 12-20

11.5 X-start (change active system).................................................................... 12-21

12 Shutdown............................................................................................................ 12-22

13 Screen Viewer......................................................................................... 13-1

1 Overview............................................................................................................... 13-3

2 User screen ........................................................................................................... 13-3

3 The ScreenViewer Window................................................................................. 13-3

4 The Screen Options.............................................................................................. 13-4

5 The Screen Loading............................................................................................. 13-5

6 The Screen Information ...................................................................................... 13-6

7 The Screen Display .............................................................................................. 13-7

14 System and Error Messages.................................................................. 14-1

1 Overview............................................................................................................... 14-3

1.1 Confirming an error message........................................................................ 14-3

1.2 Calling up suggestions on how to correct an error ....................................... 14-3

1.3 Blocking error messages ............................................................................... 14-4

1.4 Acknowledging warning messages............................................................... 14-4

1.5 Symbols used for log messages .................................................................... 14-4

2 Operational log messages.................................................................................... 14-7

3 System log messages ............................................................................................ 14-28

4 Hardware log messages ....................................................................................... 14-43

5 Program log messages ......................................................................................... 14-61

6 Motion log messages ............................................................................................ 14-106

7 Operator log messages......................................................................................... 14-125

8 IO & Communication log messages ................................................................... 14-130

9 Arcweld log messages .......................................................................................... 14-151

10 Spotweld log messages....................................................................................... 14-164

11 Paint log messages..............................................................................................14-166

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15 Examples ................................................................................................ 15-1

1 Simple Material Handling................................................................................... 15-31.1 Create a new program ................................................................................... 15-4

1.2 Add subroutine calls to routine main ............................................................ 15-4

1.3 Add instructions to the subroutines............................................................... 15-5

1.4 Operating the gripper .................................................................................... 15-9

1.5 Test the program............................................................................................15-10

1.6 Save the program .......................................................................................... 15-11

1.7 Documentation .............................................................................................. 15-12

2 Material Handling................................................................................................ 15-13

2.1 Create a new program ...................................................................................15-15

2.2 Add subroutine calls to routine main ............................................................15-15

2.3 Add instructions to the subroutines............................................................... 15-16

2.4 Operating the gripper ....................................................................................15-22

2.5 Test the program............................................................................................15-23

2.6 Save the program .......................................................................................... 15-24

2.7 Documentation .............................................................................................. 15-25

16 Index ....................................................................................................... 16-1

17 Glossary .................................................................................................. 17-1

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CONTENTSPage

Users Guide 1-1

1 Overview...................................................................................................... 3

2 How to Use this Manual ............................................................................. 42.1 Organization of chapters......................................................................................... 4

2.2 Typographic conventions........................................................................................ 6

3 Other Manuals ............................................................................................ 7

Introduction

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Introduction

Users Guide 1-3

Introduction

1 Overview

This manual contains instructions for daily operation of S4C+ based robot systems.

This manual will help you whenever you use the robot.It provides step-by-step instructions on how to perform various tasks, such as howto move the robot manually, how to program or how to start a program when run-ning production.

This manual is intended for

- operators

- product technicians

- service technicians

- robot programmers

The manual is written to suit a standard installation. Differences can therefore occur,depending on the configuration of the system.

Before you start working with the robot, it is essential that you readChapter 2 -Safety.

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2 How to Use this Manual

2.1 Organization of chapters

The manual is organized in the following chapters:

1 IntroductionContains a short introduction.

2 SafetyCovers safety functions, principles and procedures to be used when a robot or robotsystem is operated.It does not cover how to design for safety, nor how to install safety related equip-ment. These topics are covered in the Product Manual.

3 Basic OperationContains ageneral description of the robot. This includes what happens during startup, description of the operators panel and teach pendant, and also some basic oper-ations on the robot.

4 JoggingDescribes how to jog the robot and external axes with different motion settings inthe Jogging window.

5 Inputs and Outputs

Describes the Input/Output window, how to change signal values and display infor-mation for different signal types.

6 Programming and testingContains instructions how to create new programs, routines, instructions, data andmodules and an explanation of what the different parts means. How to test programsis also described here.

7 The programming language RAPIDContains descriptions for some of the RAPID instructions. For a more detaileddescription on the different RAPID instructions, seeRAPID Reference Manual.

8 Coordinate SystemsDescribes how to define tools, work objects, program displacements, base frameand other coordinate systems.

9 Production RunningDescribes how to:- start and stop the program during production- change the override speed and program running mode- tune a robot path with the HotEdit functionin the Production window.

10 System ParametersDescribes the parameters functions and how to define, change, save and load param-eters and parameter types.

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11 File ManagerContains information how to:- view file information- copy, delete or move files and directories- create or renaming directories- printing files or formatting a diskette.

12 ServiceDescribes how to:- change date and time of the system- viewing a message in a log- test and calibrate the measuring system for the robot or external axes- obtain information on the system- perform a backup/restore- perform a restart.

13 Screen ViewerContains information aboutthe option Screen Viewer. For a more detailed description,see theProduct Specification RobotWare.

14 Error Management, System and Error MessagesDescribes how to manage error messages and includes a list of error codes withdescriptions, causes and actions.

15ProgramExamplesContainsa number of RAPID programs that are built up, step by step. Here you canlearn a little about how to program, and also see the instructions in their correct con-text.

16 Index

17 Glossary

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2.2 Typographic conventions

The commands located under any of the five menu keys at the top of the teach pendantdisplay are written in the form of Menu: Command. For example, to activate the Print

command in the File menu, you choose File: Print.

The names on the function keys and in the entry fields are specified in bold italic typeface, e.g.Modpos.

Words belonging to the actual programming language, such as instruction names, arewritten in italics, e.g.MoveL.

Examples of programs are always displayed in the same way as they are output to dis-kette or a printer. This differs from what is displayed on the teach pendant in the fol-lowing ways:

- Certain control words that are masked in the teach pendant display are printed,e.g words indicating the start and end of a routine.

- Data and routine declarations are printed in the formal form, e.g. VAR numreg1;.

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3 Other Manuals

Product Manual

TheProduct Manualprovides information on:

- installation

- robot structure such as its computer system, input and output signals

- preventive maintenance

- troubleshooting

- how to carry out repairs on the manipulator and controller.

This manual also contains Product Specificationsof the manipulator, controller andRobotWare Options,which provide an overview of the characteristics and perform-ance of the robot.

RAPID Reference Manual

TheRAPID Reference Manualcontains a detailed explanation of the programming lan-guage as well as all data types, instructionsandfunctions. They are described in alpha-

betical order for your convenience.If you are programming off-line, theRAPID Reference Manualwill be particularlyuseful in this respect.

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CONTENTSPage

Users Guide 2-1

1 Overview...................................................................................................... 3

1.1 Introduction ............................................................................................................ 32 Applicable Safety Standards...................................................................... 3

3 Fire-Extinguishing...................................................................................... 4

4 Definitions of Safety Functions.................................................................. 4

5 Safe Working Procedures........................................................................... 5

5.1 Normal operations .................................................................................................. 5

6 Programming, Testing and Servicing ....................................................... 5

7 Safety Functions.......................................................................................... 6

7.1 The safety control chain of operation ..................................................................... 6

7.2 Emergency stops..................................................................................................... 7

7.3 Mode selection using the operating mode selector................................................. 7

7.4 Enabling device ...................................................................................................... 8

7.5 Hold-to-run control................................................................................................. 8

7.6 General Mode Safeguarded Stop (GS) connection................................................. 9

7.7 Automatic Mode Safeguarded Stop (AS) connection ............................................ 10

7.8 Limiting the working space .................................................................................... 10

7.9 Supplementary functions ........................................................................................ 10

8 Safety Risks Related to End Effectors ...................................................... 10

8.1 Gripper.................................................................................................................... 10

8.2 Tools/workpieces .................................................................................................... 11

8.3 Pneumatic/hydraulic systems ................................................................................. 11

9 Risks during Operation Disturbances ...................................................... 11

10 Risks during Installation and Service..................................................... 11

11 Risks Associated with Live Electric Parts .............................................. 1312 Emergency Release of Mechanical Arm................................................. 13

13 Limitation of Liability.............................................................................. 14

14 Related Information ................................................................................. 14

Safety

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Safety

1 Overview

This information on safety covers functions that have to do with the operation of theindustrial robot.

The information does not cover how to design, install and operate a complete system,nor does it cover all peripheral equipment, which can influence the safety of the totalsystem.

To protect personnel, the complete system has to be designed and installed in accord-ance with the safety requirements set forth in the standards and regulations of the coun-try where the robot is installed.

The users of ABB industrial robots are responsible for ensuring that the applicablesafety laws and regulations in the country concerned are observed and that the safetydevices necessary to protect people working with the robot system have been designedand installed correctly.

People who work with robots must be familiar with the operation and handling of theindustrial robot, described in applicable documents, that is Userss Guide and ProductManual.

The diskettes which contain the robots control programs must not be changed in

any way because this could lead to the deactivation of safety functions, such asreduced speed.

1.1 Introduction

Apart from the built-in safety functions, the robot is also supplied with an interface forthe connection of external safety devices.

Via this interface, an external safety function can interact with other machines andperipheral equipment. This means that control signals can act on safety signals

received from the peripheral equipment as well as from the robot.

In the Product Manual -Installation and Commissioning,,instructions are provided forconnecting safety devices between the robot and the peripheral equipment.

2 Applicable Safety Standards

The robot is designed in accordance with the requirements of ISO10218, Jan. 1992,Industrial Robot Safety. The robot also fulfils the ANSI/RIA 15.06-1999 stipulations.

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3 Fire-Extinguishing

Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manip-ulator or controller).

4 Definitions of Safety Functions

Emergency stop IEC 204-1,10.7

A condition which overrides all other robot controls, removes drive power from robotaxis actuators, stops all moving parts and removes power from other dangerous func-tions controlled by the robot.

Enabling device ISO 11161, 3.4

A manually operated device which, when continuously activated in one position only,allows hazardous functions but does not initiate them. In any other position, hazardousfunctions can be stopped safely.

Safety stop ISO 10218 (EN 775), 6.4.3

When a safety stop circuit is provided, each robot must be delivered with the necessary

connections for the safeguards and interlocks associated with this circuit. It is necessaryto reset the power to the machine actuators before any robot motion can be initiated.However, if only the power to the machine actuators is reset, this should not suffice toinitiate any operation.

Reduced speed ISO 10218 (EN 775), 3.2.17

A single, selectable velocity provided by the robot supplier which automaticallyrestricts the robot velocity to that specified in order to allow sufficient time for peopleeither to withdraw from the hazardous area or to stop the robot.

Interlock (for safeguarding) ISO 10218 (EN 775), 3.2.8

A function that interconnects a guard(s) or a device(s) and the robot controller and/orpower system of the robot and its associated equipment.

Hold-to-run control ISO 10218 (EN 775), 3.2.7

A control which only allows movements during its manual actuation and which causesthese movements to stop as soon as it is released.

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5 Safe Working Procedures

Safe working procedures must be used to prevent injury. No safety device or circuitmay be modified, bypassed or changed in any way, at any time.

5.1 Normal operations

All normal operations in automatic mode must be executed from outside the safe-guarded space.

6 Programming, Testing and Servicing

The robot is extremely heavy and powerful, even at low speed. When entering into therobots safeguarded space, the applicable safety regulations of the country concernedmust be observed.

Operators must be aware of the fact that the robot can make unexpected movements.A pause (stop) in a pattern of movements may be followed by a movement at highspeed. Operators must also be aware of the fact that external signals can affect robot

programs in such a way that a certain pattern of movement changes without warning.

If work must be carried out within the robots work envelope, the following points

must be observed:

The operating mode selector on the controller must be in the manual mode positionto render the enabling device operative and to block operation from a computer linkor remote control panel.

The robots speed is limited to max. 250 mm/s (10 inches/s) when the operating modeselector is in position < 250 mm/s. This should be the normal position when enteringthe working space. The position 100% full speed may only be used by trained per-sonnel who are aware of the risks that this entails.

Do not change Transm gear ratio or other kinematic parameters from

the teach pendant or a PC. This affects the safety functionReduced speed 250 mm/s.

During programming and testing, the enabling device must be released as soon asthere is no need for the robot to move.

The enabling device must never be rendered inoperative in any way.

The programmer must always take the teach pendant with him/her when enteringthrough the safety gate to the robots working space so that no-one else can take overcontrol of the robot without his/her knowledge.

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7 Safety Functions

7.1 The safety control chain of operation

The safety control chain of operation is based on dual electrical safety chains whichinteract with the robot computer and enable the MOTORS ON mode.

Each electrical safety chain consist of several switches connected in such a way that allof them must be closed before the robot can be set to MOTORS ON mode. MOTORSON mode means that drive power is supplied to the motors.

If any contact in the safety chain of operation is open, the robot always reverts toMOTORS OFF mode. MOTORS OFF mode means that drive power is removed fromthe robots motors and the brakes are applied.

The status of the switches is indicated by LEDs on top of the panel module in the con-

trol cabinet and is also displayed on the teach pendant (I/O window).

After a stop, the switch must be reset at the unit which caused the stop beforethe robot can be ordered to start again.

The time limits for the central two channel cyclic supervisions of the safety controlchain is between 2 and 4 second.

The safety chains must never be bypassed, modified or changed in any other way.

&

&

Interlocking

ENRUN

Drive

Unit M

K1 K2

LIM1 LIM2 ES2ES1

GS1 GS2 AS2AS1

TPU

En1

TPU

En2

Man2Man1

Auto1 Auto2

K1 K2

+ +

Externalcontactors

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7.2 Emergency stops

An emergency stop should be activated if there is a danger to people or equipment.Built-in emergency stop buttons are located on the operators panel of the robot con-

troller and on the teach pendant.

External emergency stop devices (buttons, etc.) can be connected to the safety chainby the user (see Product Manual -Installation and Commissioning). They must be con-nected in accordance with the applicable standards for emergency stop circuits.

Before commissioning the robot, all emergency stop buttons or other safety equipmentmust be checked by the user to ensure their proper operation.

Before switching to MOTORS ON mode again, establish the reason for the stopand rectify the fault.

7.3 Mode selection using the operating mode selector

The applicable safety requirements for using robots, laid down in accordance withISO/DIS 10218, are characterised by different modes, selected by means of controldevices and with clear-cut positions.

One automatic and two manual modes are available:

The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters therobots safeguarded space. The robot must be operated using the teach pendant and, if100% is selected, using Hold-to-run control.

In automatic mode, the operating mode selector is switched to , and all safetyarrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc.,

are active. No-one may enter the robots safeguarded space. All controls, such as emer-gency stops, the control panel and control cabinet, must be easily accessible from out-side the safeguarded space.

Programming and testing at reduced speed

Robot movements at reduced speed can be carried out as follows:

Set the operating mode selector to

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Testing at full speed

Robot movements at programmed speed can be carried out as follows:

Set the operating mode selector to 100%

Programs can only be started using the teach pendant with the enabling device acti-vated.

For Hold-to-run control, the Hold-to-run button must be activated. Releasing the but-ton stops program execution.

The 100% mode may only be used by trained personnel. The applicable laws andregulations of the countries where the robot is used must always be observed.

Automatic operation

Automatic operation may start when the following conditions are fulfilled:

The operating mode selector is set to

The MOTORS ON mode is selected

Either the teach pendant can be used to start the program or a connected remote controldevice. These functions should be wired and interlocked in accordance with the appli-cable safety instructions and the operator must always be outside the safeguardedspace.

7.4 Enabling device

When the operating mode selector is in the MANUAL or MANUAL FULL SPEEDposition, the robot can be set to the MOTORS ON mode by depressing the enablingdevice on the teach pendant.

Should the robot revert to the MOTORS OFF mode for any reason while the enablingdevice is depressed, the latter must be released before the robot can be returned to theMOTORS ON mode again. This is a safety function designed to prevent the enablingdevice from being rendered inactive.

When the enabling device is released, the drive power to the motors is switched off, thebrakes are applied and the robot reverts to the MOTORS OFF mode.

If the enabling device is reactivated, the robot changes to the MOTORS ON mode.

7.5 Hold-to-run control

This function is always active when the operating mode selector is in the MANUALFULL SPEED position. It is possible to set a parameter to make this function active

also when the operating mode selector is in the MANUAL position.

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When the Hold-to-run control is active, the enabling device and the Hold-to-run buttonon the teach pendant must be depressed in order to execute a program. When the buttonis released, the axis (axes) movements stop and the robot remains in the MOTORS ONmode.

Here is a detailed description of how to execute a program in Hold-to-run control:

Activate the enabling device on the teach pendant.

Choose execution mode using the function keys on the teach pendant:

- Start(continuous running of the program)

- FWD(one instruction forwards)

- BWD(one instruction backwards)

Wait for the Hold-to-run alert box.

Activate the Hold-to-run button on the teach pendant.

Now the program runs (with the chosen execution mode) as long as the Hold-to-runbutton is pressed. Releasing the button stops program execution and activating thebutton starts program execution again.

For FWD and BWD execution modes, the next instruction is run by releasing andactivating the Hold-to-run button.

It is possible to change execution mode when the Hold-to-run button is released andthen continue the program execution with the new execution mode, by just activatingthe Hold-to-run button again, i.e. no alert box is shown.

If the program execution was stopped with the Stop button on the teach pendant, theprogram execution continues by releasing and activating the Hold-to-run button.

When the enabling device on the teach pendant is released, the sequence describedabove must be repeated from the beginning.

7.6 General Mode Safeguarded Stop (GS) connection

The GS connection is provided for interlocking external safety devices, such as light

curtains, light beams or sensitive mats. The GS is active regardless of the position ofthe operating mode selector.

When this connection is open the robot changes to the MOTORS OFF mode. To resetto MOTORS ON mode, the device that initiated the safety stop must be interlocked inaccordance with applicable safety regulations. This is not normally done by resettingthe device itself.

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7.7 Automatic Mode Safeguarded Stop (AS) connection

The AS connection is provided for interlocking external safety devices, such as lightcurtains, light beams or sensitive mats used externally by the system builder. The AS

is especially intended for use in automatic mode, during normal program execution.

The AS is by-passed when the operating mode selector is in the MANUAL orMANUAL FULL SPEED position.

7.8 Limiting the working space

For certain applications, movement about the robots main axes must be limited inorder to create a sufficiently large safety zone. This reduces the risk of damage to therobot if it collides with external safety arrangements, such as barriers, etc.

Movement about axes 1, 2 and 3 can be limited with adjustable mechanical stops or bymeans of electrical limit switches. If the working space is limited by means of stops orswitches, the corresponding software limitation parameters must also be changed. Ifnecessary, movement of the three wrist axes can also be limited by the computer soft-ware. Limitation of movement of the axes must be carried out by the user.

7.9 Supplementary functions

Functions via specific digital inputs:

A stop can be activated via a connection with a digital input. Digital inputs can be usedto stop programs if, for example, a fault occurs in the peripheral equipment.

Functions via specific digital outputs:

Error indicates a fault in the robot system.

Cycle_on indicates that the robot is executing a program.

MotOnState/MotOffState indicates that the robot is in MOTORS ON / MOTORSOFF mode.

EmStop - indicates that the robot is in emergency stop state. AutoOn - indicates that the robot is in automatic mode.

8 Safety Risks Related to End Effectors

8.1 Gripper

If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece mustbe prevented.

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8.2 Tools/workpieces

It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure thatguards remain closed until the cutters stop rotating.

Grippers must be designed so that they retain workpieces in the event of a power fail-ure or a disturbance of the controller. It should be possible to release parts by manualoperation (valves).

8.3 Pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy may be present in these systems so, after shutdown, particular care

must be taken.

The pressure in pneumatic and hydraulic systems must be released before starting torepair them. Gravity may cause any parts or objects held by these systems to drop.Dump valves should be used in case of emergency. Shot bolts should be used to pre-vent tools, etc., from falling due to gravity.

9 Risks during Operation Disturbances

If the working process is interrupted, extra care must be taken due to risks other thanthose associated with regular operation. Such an interruption may have to be rectifiedmanually.

Remedial action must only ever be carried out by trained personnel who are familiarwith the entire installation as well as the special risks associated with its different parts.

The industrial robot is a flexible tool which can be used in many different industrialapplications. All work must be carried out professionally and in accordance with appli-cable safety regulations. Care must be taken at all times.

10 Risks during Installation and Service

To prevent injuries and damage during the installation of the robot system, the regula-tions applicable in the country concerned and the instructions of ABB Robotics must

be complied with. Special attention must be paid to the following points:

The supplier of the complete system must ensure that all circuits used in the safetyfunction are interlocked in accordance with the applicable standards for that function.

The instructions in the Product Manual -Installation and Commissioningmustalways be followed.

The mains supply to the robot must be connected in such a way that it can be turnedoff outside the robots working space.

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The supplier of the complete system must ensure that all circuits used in the emer-gency stop function are interlocked in a safe manner, in accordance with the applica-

ble standards for the emergency stop function.

Emergency stop buttons must be positioned in easily accessible places so that the

robot can be stopped quickly. Safety zones, which have to be crossed before admittance, must be set up in front of

the robots working space. Light beams or sensitive mats are suitable devices.

Turntables or the like should be used to keep the operator away from the robots work-ing space.

Those in charge of operations must make sure that safety instructions are available forthe installation in question.

Those who install the robot must have the appropriate training for the robot system inquestion and in any safety matters associated with it.

Although troubleshooting may, on occasion, have to be carried out while the powersupply is turned on, the robot must be turned off (by setting the mains switch to OFF)when repairing faults, disconnecting electric leads and disconnecting or connectingunits.

Even if the power supply for the robot is turned off, you can still injure yourself.

The axes are affected by the force of gravity when the brakes are released. In additionto the risk of being hit by moving robot parts, you run the risk of being crushed by thetie rod.

Energy, stored in the robot for the purpose of counterbalancing certain axes, may bereleased if the robot, or parts thereof, is dismantled.

When dismantling/assembling mechanical units, watch out for falling objects.

Be aware of stored energy (DC link) and hot parts in the controller.

Units inside the controller, e.g. I/O modules, can be supplied with external power.

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11 Risks Associated with Live Electric Parts

Controller

A danger of high voltage is associated with the following parts:

- The mains supply/mains switch

- The power unit

- The power supply unit for the computer system (55 V AC)

- The rectifier unit (260 V AC and 370 V DC. NB: Capacitors!)

- The drive unit (370 V DC)

- The service outlets (115/230 VAC)

- The power supply unit for tools, or special power supply units for the machin-

ing process

- The external voltage connected to the control cabinet remains live even whenthe robot is disconnected from the mains.

- Additional connections

Manipulator

A danger of high voltage is associated with the manipulator in:

- The power supply for the motors (up to 370 V DC)

- The user connections for tools or other parts of the installation (see Product

Manual -Installation and Commissioning, max. 230 V AC)

Tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in theOFF position. Power supply cables which are in motion during the working processmay be damaged.

12 Emergency Release of Mechanical Arm

If an emergency situation occur where a person is caught by the mechanical robot arm,the brake release buttons should be pressed whereby the arms can be moved to releasethe person. To move the arms by manpower is normally possible on the smaller robots(1400 and 2400), but for the bigger ones it might not be possible without a mechanicallifting device, like an overhead crane.

If power is not available the brakes are applied, and therefore manpower might not besufficient for any robot.

Before releasing the brakes, secure that the weight of the arms not enhance thepress force on the caught person.

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13 Limitation of Liability

The above information regarding safety must not be construed as a warranty byABB Robotics that the industrial robot will not cause injury or damage even if all safetyinstructions have been complied with.

14 Related Information

Described in:

Installation of safety devices Product Manual -Installation andCommissioning

Changing robot modes Users Guide - System Overview

Limiting the working space Product Manual -Installation andCommissioning

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CONTENTSPage

Users Guide 3-1

1 Overview...................................................................................................... 3

2 The Manipulator......................................................................................... 43 The Controller............................................................................................. 4

4 The Operators Panel ................................................................................. 5

5 The Teach Pendant unit ............................................................................. 7

5.1 Entering text using the Teach Pendant unit ............................................................ 9

5.2 Working with windows........................................................................................... 9

6 Emergency Stops......................................................................................... 12

6.1 The emergency stop button..................................................................................... 12

6.2 Recover from emergency stop................................................................................ 12

7 Starting up the robot .................................................................................. 13

7.1 Errors at start-up ..................................................................................................... 14

7.2 Switching the Power Supply to the MOTORS ON ................................................ 14

8 Switching the robot off............................................................................... 15

9 Selecting the Operating Mode ................................................................... 16

9.1 Automatic mode (production mode)....................................................................... 16

9.2 Manual mode with reduced speed (programming mode)....................................... 169.3 Manual mode with full speed (Option, testing mode) ............................................ 16

10 Jogging the Robot Using the Joystick ..................................................... 17

10.1 Linear jogging....................................................................................................... 17

10.2 Fine positioning .................................................................................................... 19

11 Open a Program........................................................................................ 21

11.1 Loading an existing program................................................................................ 21

12 Starting the Program................................................................................ 25

13 Stopping the Program .............................................................................. 27

14 Automatic Mode .......................................................................................28

15 Editing a Program .................................................................................... 29

15.1 Modifying positions.............................................................................................. 29

15.2 Changing arguments ............................................................................................. 31

15.3 Adding instructions............................................................................................... 32

15.4 Programming a delay............................................................................................ 35

16 I/O Signals .................................................................................................38

16.1 Programming an I/O instruction ........................................................................... 38

Basic Operation

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16.2 Manually check the state of a signal .................................................................... 40

17 Errors.........................................................................................................41

17.1 Acknowledge error messages ............................................................................... 41

17.2 Calling up suggestions on how to correct an error............................................... 4117.3 Acknowledge warning messages.......................................................................... 41

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Basic Operation

1 Overview

A robot is made up of two principal parts:

Figure 1 The controller and manipulator are connected by two cables.

You can communicate with the robot using a teach pendant unit and/or the operatorspa

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