IRC5
Electrical
Maintenance
IRC5 Programming Basic
ABB Electrical
Maintenance
Revised: 7-12-2010. REMAT L.L.C
© ABB Inc. 1
Notes
IRC5 Electrical Maintenance
Contents
Chapter
© ABB Inc. 2
Description
Page
1
Course Objectives
3
2
Safety
4
3
System Description
18
4
Event Messages - Exercise 1
31
5
Product Information - Exercise2
45
6
ESD
52
7
Backup and Restore - Exercise 3
58
8
Computer Unit
77
9
Restart Procedures -
88
13
Power On - Exercise 6
93
14
Run Chains - Exercise 7
102
15
Motor Drive System - Exercise 9
113
16
Resolvers -
126
17
Calibration -
140
18
I/O in IRC5
- Exercise 10
160
IRC5 Electrical Maintenance
Course Objectives
Upon completion of this course the student will be able to
successfully:
© ABB Inc. 3

Practice safety as it pertains to the robot system.

Identify and use the Flexpendant.

Run the robot system in manual mode and automatic mode.

Interpret and respond to event messages. Use event logs.

Identify different parts of the robot modules and arm.

Load system software.

Troubleshoot Power ON circuits.

Troubleshoot computer and drive system to a board level.

Troubleshoot Motors ON / Run Chains circuits.

Troubleshoot the Motors, brakes, and resolvers.

Properly calibrate the robot after a motor change.

Interface an input device and an output device to the robot.
Notes
IRC5 Electrical
Maintenance
IRC5 Programming Basic
Safety
ABB Electrical
Maintenance
© ABB Inc. 4
IRC5 Electrical Maintenance
Policies
In addition to information
presented in this course,
students need to be familiar
with Safety Procedures from
Operator’s Manual and
Product Manual.
© ABB Inc. 5
Notes
Notes
IRC5 Electrical Maintenance
Avoid Pinch Points

While:

Modifying program within robot cell

Test running

Fault tracing

Repair
Always avoid PINCH POINTS
© ABB Inc. 6
IRC5 Electrical Maintenance
Notes
Lock Outs
 Use Lock out devices
Single Lock Out
Multiple Lock Outs
© ABB Inc. 7
IRC5 Electrical Maintenance
Integrated Robot Safety Topics

Emergency stop

Operating mode

Auto

Manual < 250 mm/s

Manual 100%

Enabling device
(Dead mans grip)

Safeguard stop
(Auto and Manual)

Limiting the workspace
© ABB Inc. 8
Notes
Notes
IRC5 Electrical Maintenance
Information Sources
 The robot is designed to comply with requirements that are
stated in ISO 10218, Jan 1992, industrial robot safety. Robot
also comply with requirements for ANSI/RIA 15.06-1999.
 Definition of safety function / regulations:
 Emergency stop – IEC 204-1, 10.7
 Enabling device – ISO 11161, 3.4
 Safeguard – ISO 10218 (EN 775), 6.4.3
 Reduced speed – ISO 10218 (EN 775), 3.2.17
 Interlock – ISO 10218 (EN 775), 3.2.8
 Hold to run – ISO 10218 (EN 775), 3.2.7
ANSI: American National Standards Institute
RIA: Robotics Industries Association
ISO: International Standards Organisation
IEC: International Electrotechnical Commission
EN: European Normalisation
© ABB Inc. 9
IRC5 Electrical Maintenance
Emergency Stop IRC5
 Built in emergency stop
pushbuttons are found both on
the FlexPendant and Control
module as default.
 Extra emergency stops can be
connected to the robot
systems safety chain.
Remember an E-Stop is:

Fastest way to stop a Robot

! Not considered a Lockout !

requires a physical reset

A safety interlock that can be connected via the Run Chain
Recover by resetting pushbutton and
pressing the Motors On button.
© ABB Inc. 10
Notes
IRC5 Electrical Maintenance
Operating Modes
 Automatic mode
 Production mode (no speed limit)
 Manual mode
 < 250 mm/s – max velocity 250 mm/s
 100 % – Option, robot can be
jogged/tested with no speed limit.
© ABB Inc. 11
Notes
Notes
IRC5 Electrical Maintenance
Enabling Device

The enabling device is a press switch with three positions

The switch must be in the middle positions in order to activate the
motors

All robot movement will immediately stop if the switch is released or
pressed to the bottom
Enabling device
© ABB Inc. 12
IRC5 Electrical Maintenance
Safeguard Stop

Definition: The connection of safeguard stops enable interfacing of external
safety equipment, such as: doors, photo-electric devices, photo cells or pressure
mats.

Categories:


Manual – Can always stop the robot regardless of operating modes. Emergency Stop,
General Stop and Superior Stop are safeguard stops that can be used with safety mats,
Light screens, ect.

Auto – Only active when automatic mode is selected. Example: safety gates
Delayed Safeguard Stop – Allows for a more controlled stop. Can be activated in
system parameters. It is not acceptable to activate Delayed Safeguard Stop for
Emergency Stop in the United States.
© ABB Inc. 13
Notes
IRC5 Electrical Maintenance
Limiting the Workspace

To avoid the risk of getting caught between
the robot and other equipment, e.g. a fence,
the robot’s workspace can be limited:

Hard Stops
Is an excellent method for eliminating pinch
points.
 Axis 1–3 can be limited by adjustable
mechanical stops
 Only available on IRB 2400 and larger robots


Electrical Switches


Software Stops


© ABB Inc. 14
Can be added to axes 1-3 to monitor robot
position
Axis on all robots can be software controlled
Safe Move
Notes
IRC5 Electrical Maintenance
Notes
Safety Regarding Grip Device
 All grip devices should be designed so the work piece will be
held during a power failure or other disturbances in the robot
system
 Be familiar with the output used to activate the gripper
 Mind your fingers when manually operating gripper from
Pendant
© ABB Inc. 15
IRC5 Electrical Maintenance
Notes
Electrical Safety
 Hazardous power in both the cabinet and the robot
 Power Source – 480 VAC
 Power supply – 230 VDC
 Power supply to robot motors –370 VDC for small robots and 700 VDC for
large Robots
 Customer equipment – Varies by installation
 Must also be aware of 24V remaining on the ultra Cap.
 Must pay attention to the 24V incoming to keep the bus running.
© ABB Inc. 16
Notes
IRC5 Electrical Maintenance
Safety Regarding Releasing the Brakes

The brakes on the robot motors can be manually released if the Main
Disconnect is ON or an external battery is connected.

Before the brakes are released, be sure that the weight of the robot arm
is supported and will not cause damage to personnel or equipment
6 Buttons for larger than IRB1600
© ABB Inc. 17
System Description
ABB Electrical
Maintenance
© ABB Inc. 18
IRC5 Electrical
Maintenance
Notes
IRC5 Electrical Maintenance
Robot System
Dual Cabinet
Single Cabinet
IRC5 Controllers
IRB 6600 Robot Manipulator
© ABB Inc. 19
Notes
IRC5 Electrical Maintenance
IRC 5 Controller
FlexPendant
Robot Studio Online
Main power switches
© ABB Inc. 20
IRC5 Electrical Maintenance
IRC5 Single Cabinet Controller
Main Disconnect
E-Stop
Motors On
Mode Selector
Run Chain Status (opt.)
USB Port
Ethernet Service
© ABB Inc. 21
Notes
IRC5 Electrical Maintenance
Example of an Industrial Robot – IRB 6600
© ABB Inc. 22
Notes
Notes
IRC5 Electrical Maintenance
IRC5 – FlexPendant
Graphical color touch screen
4 Hard keys for fast access
Programmable
E-Stop
3-way joy stick
4 Hard keys for running programs
Start
Execute Backward/Forward
Stop program
© ABB Inc. 23
Notes
IRC5 Electrical Maintenance
IRC5 – FlexPendant
ABB Menu
Main menu
Windows style
“switch between
open windows/views”
© ABB Inc. 24
Status bar
Quickset or
“COG” Menu
IRC5 Electrical Maintenance
Quickset or COG button
© ABB Inc. 25
Notes
IRC5 Electrical Maintenance
Jogging the robot
Remember that the joystick assumes you are facing the front of the robot.
© ABB Inc. 26
Notes
Notes
IRC5 Electrical Maintenance
Jogging the robot
+3
-2
+4
-4
+1
+4
-4
+1
-6
+6
-3
+3
-5
-2
+Z
Z
Y
+Y
-X
-X
-Z
+X
+Y
-Y
+Y
-Y
+Z
© ABB Inc. 27
-6
+5
+5
-1
-1
+6
-3
+2
+2
-5
+X
-Z
+Z
+X
X
IRC5 Electrical Maintenance
IRC5 – FlexPendant
 ABB Main Menu
© ABB Inc. 28
Notes
IRC5 Electrical Maintenance
IRC5 – FlexPendant
 Inputs and Outputs (I/O Window).
© ABB Inc. 29
Notes
IRC5 Electrical Maintenance
IRC5 – FlexPendant
 Jogging window
© ABB Inc. 30
Notes
Event Messages
ABB Electrical
Maintenance
© ABB Inc. 31
IRC5
Electrical
IRC5 Controller
Maintenance
Maintenance
IRC5 Electrical Maintenance
Handling Events

When a problem or possible problem occurs in the robot an Event
Message is displayed and saved in an event log.
© ABB Inc. 32

To Clear the Event press “Acknowledge”

If an event is ignored a message will show in the Status bar.
Notes
Notes
IRC5 Electrical Maintenance
Introduction
I
Event Messages are divided into.

Information
 E.g: Hold to run must be pressed.
Information of how to proceed

Warning
 E.g: Manual movement full speed is selected.
The operator is informed about a potential risk.

Error
 E.g: Motor On when Emergency Stop is active.
The system cannot operate before a measure is
carried out.
© ABB Inc. 33
IRC5 Electrical Maintenance
Information

E.g. Information at program start:
© ABB Inc. 34
Notes
IRC5 Electrical Maintenance
Warning

When the computer detects a situation that can cause a problem or is a
safety risk
© ABB Inc. 35
Notes
Notes
IRC5 Electrical Maintenance
Error Message

When the computer detects a problem or possible problem, it generates
an error message with description and action.

Unacknowledged message is displayed in red on the status bar
Unacknowledged
message displayed
© ABB Inc. 36
Notes
IRC5 Electrical Maintenance
Event Message Content
 An Event Message consists of
Description
 Consequences
 Probable causes
 Action

(optional)
(optional)
(optional)
Tap arrow to scroll down
in message!
© ABB Inc. 37
Notes
IRC5 Electrical Maintenance
Reading Event Logs on the FlexPendant

Via ABB - Main menu

Tap status bar – Short cut
Tap on Status Bar to see
Event log.
Or Tap ABB then Event
Log to see Event log.
© ABB Inc. 38
Notes
IRC5 Electrical Maintenance
Event Log
Symbol
© ABB Inc. 39
Code
Title
Time stamp
IRC5 Electrical Maintenance
Event Log
 Scroll the list with the yellow arrows
 Tap on a specific message to get more information
 The time stamp is not reliable on hundredth of seconds
© ABB Inc. 40
Notes
IRC5 Electrical Maintenance
Event Log

Logs are stored under different topics

Tap view and select the topic of interest

© ABB Inc. 41
Topic common consist of a mixture of the last created logs
Notes
Notes
IRC5 Electrical Maintenance
Event Categories
Category
Error number
Area__________________
Operational
10xxx
Operational Status
System
20xxx
Panel unit
Hardware
30xxx
Board Failure
Program
40xxx
Programming
Motion
50xxx
Movement problem
Operation
60xxx
Flex Pendant Handling
I/O communication 70xxx
I/O board communication errors
ArcWeld
11xxx
Process
SpotWeld
12xxx
Process
Paint
13xxx
Process
 Refer to the error number when support is
needed!
© ABB Inc. 42
IRC5 Electrical Maintenance
Logs - Events in R.S.O

The logs or events are avalible in R.S.O

Refered to as Events in your RobotView
© ABB Inc. 43
Notes
Notes
IRC5 Electrical Maintenance
Exercise 1
1.
© ABB Inc. 44
Exercise 1
Product Information
ABB Electrical
Maintenance
© ABB Inc. 45
IRC5 Electrical Maintenance
Notes
IRC5 Electrical Maintenance
DCX Single Cabinet Inside
Computer System
Control Power Supply
Panel Unit
Ultra Cap
Drive Power Supply
Drive Rectifier
Drive Capaciter
External Axis Drive
Drive 6 Pack
© ABB Inc. 46
Axis Computer
Notes
IRC5 Electrical Maintenance
DCX Single Cabinet Inside
K42
K43
K44
Panel Unit
Axis Computer
Note: Our Robots also have a Safe move Card
Contactor Unit
© ABB Inc. 47
IRC5 Electrical Maintenance
Cabinet Features



Door

Sealed front door

Hatch on rear side to access transformer and cooling fans
Cabling

Quick floor front connection for external signals

Just required to connect Ethernet and safety between control & drive cabinet
in Flexible controller
Sealing


Fan module


Cabinet tested for IP54 category 1 (i e withstands intrusion of dust during
under-pressure)
Easy to replace with snap-in holder
Front Access

© ABB Inc. 48
All normal maintenance parts accessible from front. All units are accessible
without disconnecting any cables
Notes
Notes
IRC5 Electrical Maintenance
IRC5 HW Overview
Control module
Power &
UPS
USB
LAN
Service
Drive module
Power
Panel
Safety
MC
Drive
Safety
AXC
IRB xxx
SMB
Resolver
Drives
I/O, I/O Power, Sensors
and
Process equipment
Rectifier
© ABB Inc. 49
Motor
IRC5 Electrical Maintenance
Reliability

Drive system

6-pack main servo drive




Single pack units for additional axes
Carrier for mass memory unit


54 % less connectors, 7% less components, 42 % less PCB:s compared with S4Cplus (IRB 6600,
6 axes)
Easy to swap solid state drive / hard drive in computer unit
Cooling system

Reduced number of fans: S4Cplus = 8 IRC5 = 7

No fan on main computer CPU

Drive system fans are on-off controlled to extend lifetime

Standard +45 C ambient T, option +52 C

No air filters required
Non-battery UPS for power failure backup

© ABB Inc. 50
UltraCap™ unit with min. 8 years lifetime => maintenance free (S4Cplus: battery pack
with 3 years lifetime)
Notes
IRC5 Electrical Maintenance
System functions

System functions

USB memory
 Make use of solid state mini USB memory for file transfer

User Authorization System
 Allowing different user groups valid access for their needs

System Property Browser
 All system information of your IRC5 controller in one view

Controller Name
 Identify the controller by a user defined names
© ABB Inc. 51
Notes
IRC5 Electrical
Maintenance
IRC5 Controller
ESD
Maintenance
ABB Electrical
Maintenance
© ABB Inc. 52
IRC5 Electrical Maintenance
ESD - Electrostatic Discharge
 ESD Information
© ABB Inc. 53
Notes
IRC5 Electrical Maintenance
ESD - Electrostatic Discharge
 What is ESD?
© ABB Inc. 54

A person walking around in isolated shoes on a isolated floor can get charged
with several thousand volts.

When this person gets close to a conducting object e.g. printed card, the
charge will discharge through the air in form of a spark.

The high electric current that is produced under a short period of time is
devastating for electronic components.

The damage can show at once if the component simply is destroyed, or it can
become a so called latent fault.

Latent faults can show up, after a day, a week, few months
even years.
Notes
IRC5 Electrical Maintenance
ESD - Electrostatic Discharge
 Where can components and equipment get exposed to ESD?
 On the factory where the components are produced
 At the distributor
 During shipping
 In the factory where the components are mounted
 Under normal operation
 During service and maintenance
© ABB Inc. 55
Notes
Notes
IRC5 Electrical Maintenance
ESD - Electrostatic Discharge

How to avoid ESD!


© ABB Inc. 56
Reduce Charging

Shoes:
shoe sole of leather is best – Rubber
and plastic worst

Clothing:
Use cotton clothes instead of wool
and synthetics
Diverse charging

Conductive bags or boxes for printed
cards

Grounded ESD mat that printed
cards can be placed on

Always use a wrist strap during
service and maintenance!
ESD VIDEO
Notes
IRC5 Electrical Maintenance
Exercise 2
1.
© ABB Inc. 57
Exercise 2
Backup & Restore
ABB Electrical
Maintenance
© ABB Inc. 58
IRC5 Electrical
Maintenance
IRC5 Controller
Maintenance
IRC5 Electrical Maintenance
Topics

Backup
 Why?
 When?
 How?

Safety aspects

Precautions

What is stored
© ABB Inc. 59
Notes
Notes
IRC5 Electrical Maintenance
Backup – IRC5
 Having a valid backup is necessary for fast recovery:

If the system behaves suspicious!

After software upgrades
replacement

Tap ABB

Tap Backup and Restore

Tap BackUp Current
System
© ABB Inc. 60
or
Notes
IRC5 Electrical Maintenance
Backup – IRC5 Body shop additional steps.
From Main:
- Click on maintenance
© ABB Inc. 61
- Click on backup UI
IRC5 Electrical Maintenance
Backup – IRC5
 What does a backup contain?
 All of the files/folders stored under Home directory in your system.
 The system parameters (e.g naming of I/O signals)
 A backup contains the info that allows your system to go back to
behave as it did when the backup was taken.
© ABB Inc. 62
Notes
IRC5 Electrical Maintenance
Backup – IRC5
 What to think of before taking a Backup!
 IRC5 can have several systems installed! Here at BMW, we should
have only one. Always check which is the active system.
© ABB Inc. 63
Notes
IRC5 Electrical Maintenance
Backup – IRC5
 When taking your backups:
 Give your backup a good descriptive name
 Keep the date when backup was created
 Store the finished Backup in a safe place
© ABB Inc. 64
Notes
IRC5 Electrical Maintenance
Restore – IRC5
 Remember
 A backup taken on a S4 isn’t possible to restore in IRC5.
 Always check if you are restoring to correct system.
© ABB Inc. 65
Notes
IRC5 Electrical Maintenance
Backup and Restore – Backup the System
 ABB recommends performing a backup:
 Before installing new RobotWare
 Before making any major changes to instructions and/or
parameters to facilitate the previous setting
 After making any changes to instructions and/or parameters and
testing the new settings to retain the new successful settings
© ABB Inc. 66
Notes
Notes
IRC5 Electrical Maintenance
Backup
 Procedure
Step Action
1
Tap ABB.
2
Tap Backup and Restore.
xx0300000469
© ABB Inc. 67
Info/Illustration
Notes
IRC5 Electrical Maintenance
Backup (2)
 Procedure
Step Action
3
Tap Backup.
Xx0300000440
The set backup directory is displayed.
© ABB Inc. 68
Info/Illustration
Notes
IRC5 Electrical Maintenance
Backup (3)
 Procedure
Step Action
4
Is the displayed directory the correct one?
If YES: Tap Backup at the bottom of the screen to perform
the backup to the selected directory.
If NO: Tap … to the right of the directory and proceed below.
xx0300000441
A backup file named according to the current date is created.
© ABB Inc. 69
Info/
Illustration
Notes
IRC5 Electrical Maintenance
Backup (4)
 Procedure
Step Action
5
Select the desired directory.
6
When the desired directory is shown, tap OK.
xx0300000443
© ABB Inc. 70
Info/
Illustration
IRC5 Electrical Maintenance
Backup and Restore – Restore the System
 ABB recommends performing a restore:
 If, for any reason you suspect the program file corrupt
 If any changes made to the instructions’ and/or parameters’
settings did not prove successful, and the previous settings is
desired
 During the restore, all system parameters are replaced
and all modules from the backup directory are loaded
 The Home directory is copied back to the new systems
HOME directory during the warm start
© ABB Inc. 71
Notes
Notes
IRC5 Electrical Maintenance
Restore
 Procedure
Step Action
1
Tap ABB.
2
Tap Backup and Restore.
xx0300000439
© ABB Inc. 72
Info/Illustration
Notes
IRC5 Electrical Maintenance
Restore (2)
 Procedure
Step Action
3
Tap Restore.
Xx0300000440
The set backup directory is displayed.
© ABB Inc. 73
Info/Illustration
Notes
IRC5 Electrical Maintenance
Restore (3)
 Procedure
Step Action
4
Is the displayed directory the correct one?
If YES: Tap Backup at the bottom of the screen to perform
the backup to the selected directory.
If NO: Tap … to the right of the directory and proceed below.
xx0300000441
A backup file named according to the current date is created.
© ABB Inc. 74
Info/
Illustration
Notes
IRC5 Electrical Maintenance
Restore (4)
Step Action
5
Select the desired directory.
6
When the desired directory is shown, select the correct
backup file and tap OK.
xx0300000444
The Restore is performed, and the system is warm
started automatically.
© ABB Inc. 75
Info/
Illustration
Notes
IRC5 Electrical Maintenance
Exercise 3
1.
© ABB Inc. 76
Exercise 3
Computer Unit
ABB Electrical
Maintenance
© ABB Inc. 77
IRC5 Electrical
Maintenance
IRC5 Controller
Maintenance
Notes
IRC5 Electrical Maintenance
Computer Unit DSQC 623- Old version- not at BMW
Status during Startup:

RED Flashing – Main Computer self testing.
RED Steady – Main Computer loading operating system.
GREEN Flashing – Main Computer is warm starting.
GREEN Steady – The Main computer system is operating.
Computer unit based on
industrial PC
Status during Operation:
© ABB Inc. 78

Built-in DC power supply

PCI bus

Ethernet 10/100 Mbps

3rd party field bus cards

Standard mass memory units (Flash
disk, Hard drive)

Cooling fans for +45 / +52 °C (113 /
125 °F) ambient T
RED Steady – Internal failure. The unit needs to be replaced.
RED Flashing – Communication failure.
GREEN Steady – The unit is functioning OK.
Computer
Power On
SSD/HDD
Active
Notes
IRC5 Electrical Maintenance
Computer Unit DSQC 623- Old version- not at BMW
 Top view of Computer Unit with cover removed.
1
2
2 Fans
1 intake, 2 outlet
Power supply
SSD
HDD
PCI slots
MotherboardMain Computer
Incoming power (24V PC)
© ABB Inc. 79
Notes
IRC5 Electrical Maintenance
Computer Unit DSQC 639 – Used at BMW
The new design features:
Status during Startup:
RED Flashing – Main Computer self testing.
RED Steady – Main Computer loading operating system.
GREEN Flashing – Main Computer is warm starting.
GREEN Steady – The Main computer system is operating.
 Industrial CompactFlash memory replaces IDE
flash memory or optional hard drive. Accessible
from the computer front.
Status during Operation:
RED Steady – Internal failure. The unit needs to be replaced.
RED Flashing – Communication failure.
GREEN Steady – The unit is functioning OK.
 Simplified cooling
 Improved serviceability
 Built in functions of Robot Communication Card
(PCI card)
 Built in DC/DC converter from 24V power intake
Computer
Power On
SSD/HDD
Active
to desired board voltages
 Lean ABB Robotics design without
unnecessary PC components
Ethernet
Connection – Commuication
LEDs
© ABB Inc. 80
Panel Unit
No LEDs
Notes
IRC5 Electrical Maintenance
Computer Unit DSQC 639
Fan
Incoming power
(24V PC)
PCI slots
SSD
Flash Drive
MotherboardMain Computer
© ABB Inc. 81
IRC5 Electrical Maintenance
Main computers

DSQC 639 (2007 - current )








DSQC 623 (2005 - 2007 )






Same Processor and memory as DSQC 623
Standard mass memory is an industrial CompactFlash 256 MB, optional 2 GB Flash
Simplified cooling
Improved serviceability
Built in functions of Robot Communication Card (PCI card)
Built in DC/DC converter from 24V power intake to desired board voltages
Lean ABB Robotics design without unnecessary PC components
Available (RW5.05) => 3 times performance boost compared with Celeron 566. Used for all models.
Pentium M 1.3 GHz. Processor.
256 MB RAM
Path planning of up to 36 axes (4* (6 robot + 3 external axes) )
Handling of 7 simultaneous 10/100 Mbps Ethernet channels
DSQC 600 (earlier versions 2004-2005)


Standard Intel motherboard with CPU socket 370 and DIMM sockets
Single robot configuration – DSQC 600



Multi robot configuration (MultiMove™) - DSQC 600A


© ABB Inc. 82
Intel Celeron 566 MHz (~3 times S4Cplus)
64 MB DRAM (2 times S4Cplus)
Intel Pentium III 933 MHz (~2 times Celeron)
256 MB DRAM
Notes
Notes
IRC5 Electrical Maintenance
Robot Communication card DSQC602
 RCC (DSQC 602) Connection points
Service port
FlexPendant
Axis
computer
Panel unit
© ABB Inc. 83
Notes
IRC5 Electrical Maintenance
Robot Communication card

DSQC 602




Interface between computer system and other sub-systems
Three 10/100 Mbps Ethernet channels for connecting drive system, service port and FlexPendant
One RS-485 channel for connecting panel unit (safety system)
DSQC 612

Depopulated version with Ethernet channels only is available for MultiMove option (connection of
additional drive systems)
DSQC612
DSQC602
© ABB Inc. 84
Notes
IRC5 Electrical Maintenance
Computer System Overview
ATA -100
SSD/HDD
FlexPendant
Ethernet
10 Mbps
Service port
(for laptop)
USB flash
memory (opt.)
LAN port
10/100 Mbps
Main
computer
Serial
converter (opt.)
USB 1.1
Units in the
computer box
Customer
RS-422
PCI bus 32-bit / 33 MHz
+ safety
Robot
communication
card
Junction
board
Ethernet
10/100 Mbps
Serial card
Ethernet card
(with Main computer
DSQC 600)
(optional
DSQC 612)
MC console
RS-232
Ethernet
100 Mbps
RS-485
250 kbps
Customer
RS-232
3x Ethernet 100
Mbps to Axis
computer 2-4
Axis computer
2 x RS-422
1 Mbps
Contactor
board
1 x SPI
10 Mbps
Drive unit
(x 6 power
stages)
SMB
I/O units or
PLC
Field bus card
#2 (optional)
• DeviceNet M/S
• Profibus DP M/S
• Interbus Cu/Opto M/S
Run chain #1
Panel board
RS-485
250 kbps
RS-485
250 kbps
Field bus card
#1 (optional)
E-stop, A-stop, Gstop, mode
selector switch, 8
DI + 8 DO
LED panel
(optional)
Run chain #2
PTC, Limit
switches, brake
contactor
Optional drives
(x 2-3 power
stages)
Rectifier unit
Capacitor unit
Rx6
© ABB Inc. 85
Mx6
IRC5 Electrical Maintenance
Field bus adapters

3rd party field bus cards

DSQC 658/659 DeviceNet-PCI adapter
 DSQC 658 One channel DeviceNet Master/Slave
 DSQC 659 Two channel DeviceNet Master/Slave
 ODVA certified, supports up to 500 kBaud

DSQC 637 Profibus PCI-adapter
 Two channel Profibus DP Master/Slave
 Supports up to 12 Mbps

DSQC 512/529 Interbus PCI-adapter
 Two channel Interbus Master/Slave
 Both copper-wire and fiber-optic
interface available

DSQC 678 PROFINET PCI-adapter
© ABB Inc. 86
Notes
IRC5 Electrical Maintenance
Mass memory units

Solid state drive (flash memory based) as standard mass
memory
 256 MB => 2 times S4Cplus
 Plugged in directly on motherboard / main computer

Optional hard drive
 >20 GB
 High temperature specification (+60 ºC)
 Shock protection integrated in carrier
 Auto spin down function in SW to extend lifetime of
bearings

Carrier for mass memory unit
 Allows quick replacement of hard drive

USB port for connection of external mass memory
 USB memory (bd0:)
© ABB Inc. 87
Notes
Restart Procedures
IRC5 Electrical
Maintenance
IRC5 Controller
Maintenance
ABB Electrical
Maintenance
© ABB Inc. 88
IRC5 Electrical Maintenance
Restart

In ABB/Main menu select restart
© ABB Inc. 89
Notes
IRC5 Electrical Maintenance
Restart Menu
 If a restart other than Warm Start is required
Tap Advanced
© ABB Inc. 90
Notes
IRC5 Electrical Maintenance
Summary of Restart Alternatives

W-start (Warm start) Normal restart
When: New hardware, SYSFAIL or change in configuration


Result: Current system is restarted. Program pointer are restored
I-start (Installation start) (ok to Use at BMW body shop, but needs further
backup reloading)
When: Add RobWare for a new process


Restart with default parameters. Loose what is in memory.

Modules & program not loaded
P-start (Program restart) (Not Used at BMW body shop)
When: E.g. Changing data in parallel tasks
© ABB Inc. 91

All data saved on image file for loading purpose

RAPID programs not reloaded
Notes
IRC5 Electrical Maintenance
Summary of Restart Alternatives

Shutdown
When: The UPS system is not working

An image file is carried out as a normal Power Off
 To start: Turn Power Off & On to restart the system

B-Start (ok to Use at BMW)
When: E.g. Recommend action from an error message


Returns the system to the state after the most recent shutdown by either Power Off or
Shutdown

In this case no saving is carried out as for Warm Start
X-start (Extra Restart) (ok to Use at BMW, but only to change the IP address)
When: Change to an existing system: E.g: Glue to Arcweld


All data is saved on an image file. System can be reloaded with all program and
parameters.
C-Start (Cold start) (Do not Use at BMW body shop) Removes all Programs,
parameters, and the robot software
When: E.g: A new BaseWare for a system shall be loaded

© ABB Inc. 92
All data is erased. A boot is necessary if no other system exists in the controller
Notes
IRC5 Electrical
Maintenance
IRC5 Controller
Power On
Maintenance
ABB Electrical
Maintenance
© ABB Inc. 93
Notes
IRC5 Electrical Maintenance
Power System Overview
Control Module
Main Switch
Power supply
24V DC
Panel Board
ACON
3-phase
Drive Module
200- 600 V AC
2-phase
Transformer
230V AC
10A CB
Power supply
K41
3-phase
To Drive
System
25A CB
K42 K43
© ABB Inc. 94
From
Contactor
Board
IRC5 Electrical Maintenance
Power Supplies (Control Module) –Not at BMW
Control Power Supply
•DSQC 604
•230V AC Input
•Only one rectifier
•3 current limiters
•24VSYS (5A)
•24VCOOL (1A)
•24VPC (5A)
•24V Charge
•DCOK LED
•Communicates USB1.1
Ultra Cap
•DSQC 624
•8 Year life
•Supplies 24VPC
•20 sec. Hold up time
•Will discharge on shelf
© ABB Inc. 95
Notes
IRC5 Electrical Maintenance
Notes
Power Supplies (Control Module)
DeviceNet Power Supply
Customer I/O
•DSQC 634
•DSQC 608 or DSQC 609
•176 – 264 VAC Input
•230V AC Input
•DCOK LED
•24VIO (8A)
•Required in USA not Europe
•DCOK LED
DSQC 608
DSQC 609
© ABB Inc. 96
IRC5 Electrical Maintenance
Power Supplies (Drive Module)- Not at BMW
Drive System Power Supply
•DSQC 626 (20ms Hold up)
•DSQC 627 (800ms Hold up)
(Used on 340, 6600, 7600)
•173-276V AC Input
•24V COOL (5A)
•24V Brake (9A)
•24V Drive (5A)
•DCOK LED
•May hear “ticking” upon short
circuit
•ACOK Monitored
•Over Temp Monitored (latched
until next power up)
•Brake OK Monitored
© ABB Inc. 97
Notes
Notes
IRC5 Electrical Maintenance
Power Supply (Single Cabinet) – Used at BMW
G2 – DSQC 662
Distribution Unit
These two units take the place of
three power supplies in a dual
cabinet configuration. (Control,
Drive, and I/O)
G1 – DSQC 661
Power Supply Unit
© ABB Inc. 98
IRC5 Electrical Maintenance
Batteries
CMOS Battery
•On Main computer
•3V Button Cell
•No Supervision
•Minimum 8 year life
SMB Battery
•Lithium Battery
•10.8 V
•No Charger
•SMB DSQC 620
•Battery Voltage is supervised by SMB
•2 - 5 year life
© ABB Inc. 99
Notes
IRC5 Electrical Maintenance
Circuit Diagrams
© ABB Inc. 100
Notes
Notes
IRC5 Electrical Maintenance
Exercise 6
1. Exercise 6
© ABB Inc. 101
IRC5 Electrical
Maintenance
IRC5 Controller
Run Chains
Maintenance
ABB Electrical
Maintenance
© ABB Inc. 102
Notes
IRC5 Electrical Maintenance
Run Chains
The Run Chains consist of two loops that Monitor:
1.
Emergency Stop
(ES)
2.
Superior Stop
(SES)
3.
General Stop
(GS)
4.
Limit Switch (Working area for each axis)
5.
Main Computer is running
(Enable1)
6.
Axis Computer is running
(Enable2)
7.
Depending of the position of the Key Switch

Auto Stop
(AS)

Enable Device on the FlexPendant
(EN)
All these conditions have to be OK/Closed to send power to
the Drive system.
An event message is generated and Motors are turned off:
 If any condition is not fulfilled.
 If run chain status differs from each other.
© ABB Inc. 103
IRC5 Electrical Maintenance
Notes
Run Chains
 Panel Board
Connection
terminals for the
Run Chains
Run Chain
Status
© ABB Inc. 104
IRC5 Electrical Maintenance
Key Switch and Indicators
 Key Switch and Indicators
Option:
Run Chain Status
outside the cabinet
© ABB Inc. 105
Notes
Notes
IRC5 Electrical Maintenance
Run Chains
Soft Stop

Selected by system parameter

Robot stops on path before Motors are turned off
Alternatives

Soft Emergency Stop = Soft ES

Soft Auto Stop = Soft AS

Soft General Stop = Soft GS

Soft Superior Stop = Soft SS (Identical to GS)
 Can be used to indicate from where the stop originates.
© ABB Inc. 106
IRC5 Electrical Maintenance
Run Chain Overview
© ABB Inc. 107
Notes
Notes
IRC5 Electrical Maintenance
Run Chains
Contactor Board
Computer Control
Run
Chain 1
K42
Self1
Interlocking on
contactor
board
Control Module

Enable1 = Enable from Panel Board

Enable Device = EN1 and EN2
Drive Module
 Enable2 from Axis computer
 Self1 from Contactor K42
 Self2 from Contactor K43
© ABB Inc. 108
Self2
Run
Chain 2
K43
Notes
IRC5 Electrical Maintenance
Run Chains
 Functionality in Control Module or Drive Module
 Control Module
 Panel Board
 Contactor Board
 Emergency Stop
Limit Switch
 Auto Stop
 Relays K41,K42,K43, and
Manual Stop
General Stop
 Superior Stop
 Flex Pendant
© ABB Inc. 109
 Drive Module
K44
 Interlocks (1A, 1B)
PTC
Axis computer
Notes
IRC5 Electrical Maintenance
Run Chain Communication between boards
Main
Computer
Control Module
Drive Module
(via RCC)
Run Chain 1 & 2, Speed
Panel Board
RS 485
Contactor
ENABLE 1 & 2
Board
ENABLE 1 & 2
Ethernet
© ABB Inc. 110
RS485
Axis Computer
IRC5 Electrical Maintenance
Circuit Diagrams
© ABB Inc. 111
Notes
Notes
IRC5 Electrical Maintenance
Exercise 7
1. Exercise 7
© ABB Inc. 112
Motor Drive System
ABB Electrical
Maintenance
© ABB Inc. 113
IRC5 Electrical
Maintenance
IRC5 Controller
Maintenance
Notes
IRC5 Electrical Maintenance
Motor Drive Circuits
Drive Module
Motor
Axis Computer
Main Servo Drive
© ABB Inc. 114
Notes
IRC5 Electrical Maintenance
Drive system overview
BLOCK DIAGRAM OF DRIVE SYSTEM.
Control Module
MAIN COMPUTER
PROFILE
GENERATOR
Drive Module
AXIS COMPUTER
POSITION
CONTROLLER
SPEED
CONTROLLER
Robot
DRIVE UNIT
MOTOR
CURRENT
CONTROLLER
M
R
RESOLVER
Serial
Measurement
Board
© ABB Inc. 115
Notes
IRC5 Electrical Maintenance
Drive module: Small robot with external axes
K42 K43
*Capacitor
Main Servo
Drive unit
Rectifier
Axes
computer
Drive units
for ext axis
* Empty for small robots, if no external axes
© ABB Inc. 116
Notes
IRC5 Electrical Maintenance
Axes computer
24 V Drive
(feed)
Power Supply
Status
Drive link 1
Console port
Process I/O
(not used)
Motorola PowerPC 250 MHz or 350 MHz
1
2
Status LED
Measurement link
Contactor board link
© ABB Inc. 117
To control cabinet
Notes
IRC5 Electrical Maintenance
Rectifier
 Rectifier
Busbar to drive units
Power out
To bleeders
Power from Transformer
Power in
* To capacitor
Communication with Drive unit
* Optional
© ABB Inc. 118
Notes
IRC5 Electrical Maintenance
Drive unit
 Drive unit 6 axes, large robot (6-pack)
 Depending on system, connection point can be different. Check label
for reference in Circuit Diagram.
Axis 3
Axis 2
Axis 1
Power going to motor
(XS/XP1)
Axis 6
© ABB Inc. 119
Axis 5
Axis 4
Notes
IRC5 Electrical Maintenance
Drive unit
 Drive units 6 axes, small robot (3-pack)
IRB 140
Axis 3 and 1
IRB 340
Axis 2 and 1
IRB 1400
1600
2400
Axis 1 and 2
Axis 6 and 4
Axis 2 and 5
Axis 3 and 4
Axis 4 and 6
Axis 3 and 5
Check label for reference to contact names in circuit diagram
Also applies for the 6 pack
© ABB Inc. 120
Notes
IRC5 Electrical Maintenance
Motor – IRC5
 The rectifier supplies 370 or 700 VDC to the drive units across
the buss bar.
Rectifier
Buss bar
Drive units
© ABB Inc. 121
Notes
IRC5 Electrical Maintenance
Some Drive system configurations
Small system (IRB140–2400)
Small system with external axes
Empty place
C_2
RC_1
Rectifier
R_2
Drive unit 6 axes
6-axes drive unit
(3-pack)
6-axes drive unit
(3-pack)
External axis
D1_X D1_X D1_X
Large system (IRB 4400– 7600)
C_2
Large system with external axis
C_2
R_2
D_1X D1_X
R_2
RC1 = Rectifier + capacitor
C2 = capacitor
R2 = Rectifier
6-axes drive unit
(6-pack)
© ABB Inc. 122
6-axes drive unit
(6-pack)
IRC5 Electrical Maintenance
Motor – IRC5
 Example of a Motor
© ABB Inc. 123
Notes
Notes
IRC5 Electrical Maintenance
Motor – IRC5
 Motor structure
Rotor Magnets
Stator Coils
Bearings
Output Shaft
Brake
© ABB Inc. 124
Resolver
IRC5 Electrical Maintenance
Circuit Diagrams
© ABB Inc. 125
Notes
IRC5 Electrical
Maintenance
IRC5 Controller
Resolvers
Maintenance
ABB Electrical
Maintenance
© ABB Inc. 126
Notes
IRC5 Electrical Maintenance
Resolvers
The resolvers on the robot are used for _________________.
Position Feedback
The robot has ______
resolver(s) per axis.
1
Approx. : 14VPP
X + Y = Approx. : 7 VPP
14 V P-P
The resolver exciter voltage is ____________.
The frequency of the exciter is _____________.
10KHZ
The sum of the feedback signals is ___________.
7 V P-P
© ABB Inc. 127
Notes
IRC5 Electrical Maintenance
Resolver Cross Section
RESOLVER CROSS SECTION
Exciter
Primary
Exciter
Secondary
© ABB Inc. 128
X Feedback
Y Feedback
Notes
IRC5 Electrical Maintenance
Functional principle of resolver
Synchro resolver section
Input
voltage
Transformer
α
Output
voltages:
Usin=ü•U0•sin(p•α)
Ucos=ü•U0•cos(p•α)
ü = transformation ratio
p = number of pairs of poles
© ABB Inc. 129
Notes
IRC5 Electrical Maintenance
Functional principle resolver
Stator
Rotor
j
j
Uin ~
Resolver part
Transformer
© ABB Inc. 130
Ucos
Usin
Notes
IRC5 Electrical Maintenance
Functional principle of resolver
1st scan
2nd scan
U
cos
U
t
125 μs
t
U
sin
Rotor infeed: 10kHz
t
© ABB Inc. 131
Notes
IRC5 Electrical Maintenance
Functional principle of resolver
1st scan
2nd scan
U
cos
U
t
125 μs
t
U
sin
Rotor infeed: 10 kHz 30°
t
© ABB Inc. 132
Notes
IRC5 Electrical Maintenance
Functional principle of resolver
1st scan
2nd scan
U
U
cos
t
125
μs
t
U
90°
sin
Rotor infeed: 10 kHz
t
© ABB Inc. 133
Notes
IRC5 Electrical Maintenance
Functional principle of resolver
1st scan
2nd scan
U
cos
U
t
125 μs
t
U
135°
sin
Rotor infeed: 10 kHz
t
© ABB Inc. 134
Notes
IRC5 Electrical Maintenance
Functional principle of resolver
1st scan
2nd scan
U
cos
U
t
125 μs
t
U
180°
sin
Rotor infeed: 10 kHz
t
© ABB Inc. 135
Notes
IRC5 Electrical Maintenance
Functional principle of resolver
Input voltage U0 ( f = 10 kHz):
Time t
U0
j
Ucos
90°
180°
270°
j
Usin
90°
© ABB Inc. 136
360°
electrical
180°
270°
360°
electrical
Notes
IRC5 Electrical Maintenance
Serial Measurement Board
Robot
The serial measurement board is located on the _________.
Resolver
The serial measurement board converts the _____________
information
Axis Computer
and sends it to the ___________________
board.
Axis
Computer
Rev.
Counter
Rev.
Counter
A/D
Converter
Serial
Converter
Battery
© ABB Inc. 137
IRC5 Electrical Maintenance
Circuit Diagrams
© ABB Inc. 138
Notes
Notes
IRC5 Electrical Maintenance
Exercise 8
1. Exercise 8
© ABB Inc. 139
IRC5 Electrical
Maintenance
IRC5 Controller
Calibration
Maintenance
ABB Electrical
Maintenance
© ABB Inc. 140
IRC5 Electrical Maintenance
Topics

Revolution counters

Fine calibration
© ABB Inc. 141
Notes
IRC5 Electrical Maintenance
Calibration – IRC5
 Fine Calibrate or Rev.Count update?
 Rev.Count update can easily be made with eye measurement.
 Fine calibration needs special tools.
© ABB Inc. 142
Notes
Notes
IRC5 Electrical Maintenance
Calibration – IRC5
 Rev.Counters
 Tells how many turns the motor shaft has rotated in the gearbox.
 If value is lost the robot cannot run any programs. (ie: when SMB
battery is drained)
 An event message is displayed when the Rev.Counters need to be
updated.
If Event message The
system informs about
difference:
Update so that the robot
and the controller have
the same calibration
values
© ABB Inc. 143
Notes
IRC5 Electrical Maintenance
Calibration – IRC5
 Update Rev.Counters
 Jog each of the 6 axis to the sync marks
 Tap ABB : Calibration : select robot : Rev. Counters : Update
Revolution Counters… : YES : select axes to be updated : Update :
Update
 It is recommended that the calibration be checked.
 It is possible to update the axis one by one, if the cell is cramped
Example of witness mark
© ABB Inc. 144
IRC5 Electrical Maintenance
Checking Calibration – IRC5
 MoveAbsJ instruction can be used to move the robot to the
calibration position.
 Insert MoveAbsJ instruction into the program.
 Tap the asterisk : Edit : View Value, enter a 0 for all 6 axes
 Then run the robot to the position.
 If the witness marks line up accurately the robot is OK.
 If the marks do not line up something is wrong.
© ABB Inc. 145
Notes
Notes
IRC5 Electrical Maintenance
Fine Calibration (Only after motor or gearbox replacement)
 Fine Calibration
 Is the angle of motor shaft when robot is in sync position
 Is created by ABB or on site with special equipment. The value is
stored on Serial Measurement Board (SMB), in the computer, in the
backup files, and written on the back of the robot arm.
 Only needs to be recalibrated if a motor / gearbox is replaced
Requires special tools!
Cannot be made
correctly
by eye Measurement.
© ABB Inc. 146
IRC5 Electrical Maintenance
Calibration Offset values
 If Motor Calibration Offset values are lost:
 The values can be typed in manually.
 The values can be found in the moc.cfg file and on the silver label in
back of manipulator with 6 values.
© ABB Inc. 147
Notes
Notes
IRC5 Electrical Maintenance
Serial Measurement Board (SMB)

The SMB and the computer(cabinet) stores the calibration offset values. You can
update the SMB or the computer(cabinet) calibration values:
1.
If SMB is replaced or manipulator is fine calibrated the offset values should be sent to
the SMB. (Pic 1)
2.
If the cabinet is moved to another manipulator, or after an X-start and then activating
different system is performed the offset values should be sent to the
computer(Cabinet). (Pic 2)
2.
1.
© ABB Inc. 148
Notes
IRC5 Electrical Maintenance
Calibration Status
 Procedure to view calibration status
Step Action
Info/Illustration
1
On the ABB menu, tap Calibration .
2
In the displayed list of mechanical units, check the
calibration status.
 What kind of calibration is needed?
If the calibration status is …
… then …
Not calibrated
Robot is missing calibration offsets. Either restore a good
backup or load the MOC.cfg parameters or manually enter the
offsets from the silver tag on the back of the robot.
Rev. counter update needed
You must updated the revolution counters.
Do not fine calibrate unless motor or gearbox has been
replaced.
© ABB Inc. 149
IRC5 Electrical Maintenance
Reset Revolution Counters
 Set up calibration position
 Before you reset the revolution counters you must run each robot
axis to its calibration position.
 The calibration position is indicated by scribed lines or vernier scales,
but are placed differently for each robot model.Study how the
calibration position looks on robot models you work with. Please see
the Product Manuals delivered with the robot for details.
 Use axis-by-axis jogging to position each axis separately.
DANGER!
To reset revolution counters without the robot set in the calibration
position will result in incorrect positioning and may cause injuries and
damage property.
© ABB Inc. 150
Notes
Notes
IRC5 Electrical Maintenance
Reset Counters
Info/
Illustration
Step Action
1
On the ABB menu, tap Calibration.
2
Select the mechanical unit whose revolution counters you wish to
update.
3
Tap Revolution Counters, then Reset Revolution Counters.
4
Select the axes whose counters you want to update.
5
Tap Reset to update counters.
6
Tap the Close button in the upper right corner to close the calibration
window.
 How to select axes to update?
If you want to …
… then …
update all axes
tap All
include a specific axis in the selection
tap the corresponding axis label, then Include
remove a selected axis from the selection
tap the corresponding axis label, then Exclude
© ABB Inc. 151
Notes
IRC5 Electrical Maintenance
Calibration Procedure on FlexPendant
Step Action
1
On the ABB menu, tap Calibration .
All mechanical units connected to the system are
shown along with their calibration status.
2
Tap the mechanical unit in question.
The screen below is displayed:
en0400000771
© ABB Inc. 152
Info/
Illustration
IRC5 Electrical Maintenance
Calibration Procedure on FlexPendant (2)
 Initial Procedure
Step Action
3
The illustration shows the screen displayed after tapping Calibration.
Available selections are:
Rev. Counters:
 Update revolution counters… .
Calib. parameters:
 Load motor calibration… .
 Edit motor calibration offset… .
 Fine calibration… WARNING! .
SMB Memory:
 Update Cabinet with SMB memory .
 Update SMB memory with Cabinet Data.
Base Frame:
 4 points XZ… .
 Relative n points… (requires option MultiMove installed). .
© ABB Inc. 153
Notes
IRC5 Electrical Maintenance
Update Revolution Counters…
 Procedure
Step Action
1
Before updating the revolution counters, the robot must be positioned in a position
very close to its calibration position as specified by the calibration marks on each
robot axis.
2
Tap Update revolution counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
 Tap Yes to update the revolution counters.
 Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
3
Select the axis to have its revolution counter updated by:
 Ticking in the box to the left
 Tap Select all to update all axes.
Then tap Update.
A dialog box is displayed.
4
A dialog box is displayed, warning that the updating operation cannot be undone:
 Tap Update to proceed with updating the revolution counters.
 Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.
© ABB Inc. 154
Notes
IRC5 Electrical Maintenance
Notes
Load Motor Calibration…
 This procedure should be used when a specific file with motor
calibration data is available. The file is normally delivered on a
diskette with the robot.
 Entering motor calibration values may be done in one of three
ways:
 From a disk, using the FlexPendant.
 From a disk, using RobotStudioOnline.
 Manually entering the values, using the FlexPendant.
© ABB Inc. 155
Notes
IRC5 Electrical Maintenance
Load Motor Calibration…
 Procedure
Step
Action
1
Tap Load motor calibration... .
A dialog box is displayed, warning that updating
the revolution counters may change
programmed robot positions:
 Tap Yes to proceed.
 Tap No to cancel.
Tapping Yes results in displaying a file selection
window.
2
Select the file containing the motor calibration
data to be loaded into the system.
If a file containing invalid calibration data is
selected, a dialog box to this effect will be
displayed
© ABB Inc. 156
Info/Illustration
If required select:
 Calib. files for systems without
absolute accuracy measurement
system.
 Abs. Acc. files for systems with
absolute accuracy measurement
system.
IRC5 Electrical Maintenance
Edit Motor Calibration Offset…
 This procedure should be used when no specific file with
motor calibration data is available, but just the numerical
values. These values are normally found on a sticker on the
rear of the robot.
 Entering motor calibration values may be done in one of
three ways:
 From a disk, using the FlexPendant.
 From a disk, using RobotStudioOnline.
 Manually entering the values, using the FlexPendant.
© ABB Inc. 157
Notes
Notes
IRC5 Electrical Maintenance
Edit Motor Calibration Offset…
 Procedure
Step
Action
1
Tap Edit motor calibration offset....
A dialog box is displayed, warning that updating
the revolution counters may change
programmed robot positions:
 Tap Yes to proceed.
 Tap No to cancel.
Tapping Yes results in displaying a new screen.
2
Tap the axis to have its motor calibration offset
edited.
The offset value box is opened for that
particular axis.
3
Use the numerical keyboard to enter the
desired value and then tap OK.
After entering new offset values, a dialog box is
displayed, urging you to restart the system to
make use of the new values.
Restart if required.
© ABB Inc. 158
Info/Illustration
Notes
IRC5 Electrical Maintenance
Exercise 9
1. Exercise 9
© ABB Inc. 159
IRC5 Electrical
Maintenance
IRC5 Controller
Maintenance
I/O in IRC5
ABB Electrical
Maintenance
© ABB Inc. 160
IRC5 Electrical Maintenance
I/O in IRC 5
 I/O design structure
 IRC5 Master field buses
 I/O Configuration examples
 Simulated I/O
© ABB Inc. 161
Notes
IRC5 Electrical Maintenance
IRC5 I/O Design Structure
 I/O Fieldbus type is completely optional
 DeviceNet (ODVA Certified)
 Profibus DP (PNO Certified)
 Interbus M/S
 Ethernet IP
 None
 The system may contain 2 Field buses.
 Easy I/O configuration for ABB and non-ABB I/O units.
 Ease the implementation of future field buses.
© ABB Inc. 162
Notes
Notes
IRC5 Electrical Maintenance
I/O System Overview
Bus
giStyle
Bd1
di1
Bd2
Input
Signals
di2
goAckn
Bd3
© ABB Inc. 163
Group
Output
di3
do1
do2
Cross-Connections
Unit types
Unit
=
Group
Input
d327A
d350A
d328A
&
Output
Signals
Notes
IRC5 Electrical Maintenance
I/O System Structure
 Master field Bus *
 Unit type *
 Unit *
 Signals *
 Signal groups
 Cross connections
* Required information
© ABB Inc. 164
DSQC 327
Notes
IRC5 Electrical Maintenance
Example: I/O Bus Configuration
Parameter
Example
-Name
“DeviceNet1”
-BusType
“DeviceNet”
-BoardNumber
“FirstBoard”
-ConnectorLabel
“”
-RecoveryTime
“5”
© ABB Inc. 165
Notes
IRC5 Electrical Maintenance
Example: I/O Unit Type Configuration
Parameter
Example
-Name
“d328”
-BusType
“DeviceNet”
-VendorName
“ABB Robotics”
-ProductName
“24v digital I/O”
© ABB Inc. 166
Notes
IRC5 Electrical Maintenance
Example: I/O Unit Configuration
Parameter
Example
-Name
“GripUnit”
-UnitType
“d328”
-Bus
“BASE”
-UnitLabel
“On arm, U137”
-TrustLevel
“1…”
-DeviceNet Address
“11”
-Disabled
“No”
© ABB Inc. 167
IRC5 Electrical Maintenance
Unit Trust Levels
 TrustLevel 0 (Unit required)
 Loss of unit causes error and stop
 Reconnection and warm start required
 TrustLevel 1 (Default)
 Loss of unit causes an error message
 Program execution stop when the lost module is accessed
 Reconnection of unit and restart of program is required
 TrustLevel 2 (Allow loss)
 No error when the unit is lost
 Error and stop when a signal is accessed (from RAPID)
 TrustLevel 3 (Quick stop)
 As trustlevel1 but stop on path when the unit is lost
© ABB Inc. 168
Notes
Notes
IRC5 Electrical Maintenance
Example: I/O Signal Configuration

Add signal
© ABB Inc. 169

Signal configuration
Notes
IRC5 Electrical Maintenance
The UnitMap parameter
 Replaces the S4Cplus parameters “PhSig” and “Length”
 Describe the mapping of a signal onto a unit
 Makes the tiresome signal mapping of S4Cplus obsolete
Examples:
© ABB Inc. 170
-UnitMap
0
// A one bit mapping (digital signal)
-UnitMap
0-15
// A 16 bit signal (analog or group)
-UnitMap
8-15, 0-7
// A “byte-swapped” signal
Notes
IRC5 Electrical Maintenance
The Internals of a Combi I/O Unit (DSQC327A)
DO DO DO DO DO DO DO DO
1 2 3 4 5 6 7 8 …16
Memory
00010001
AO
1
D/A
16 bits
10011011
16 bits
AO
2
D/A
Fieldbus
CPU
Fieldbus
Connection
10100000
16 bits
Data in fieldbus message
10011011 10100000 00010001
16 bits
16 bits
16 bits
© ABB Inc. 171
Notes
IRC5 Electrical Maintenance
The Unit Mapping and “Bit-values”

A way to describe the “A/D-converter” and the “Fieldbus CPU”
Data in fieldbus message
10011011 10100000 00010001
Configuration of “MyAO_2”
© ABB Inc. 172
-Name
“MyAO_2”
-SignalType
“AO”
-Unit
“MyAODIUnit”
-UnitMap
“16-31”
Configuration of “MyDO_5”
-EncType
“UNSIGNED”
-Name
“MyDO_5”
-MaxPhys
10
-SignalType
“DO”
-MinPhys
0
-Unit
“MyAIDOUnit”
-MaxBitVal
255
-UnitMap
36
-MinBitVal
0
Notes
IRC5 Electrical Maintenance
Simulated I/O
 Simulated bus type – SIM
 Controlled by the bus setting -Bustype
SIM
 All accesses to units on the bus is redirected to a SW-bus
 Predefined bus Virtual1
 Virtual signals
 Signals that are not configured to a unit
 Simulated I/O
 Enabled/disabled from the FlexPendant or RSO
 A way to run programs but to avoid real I/O interaction
© ABB Inc. 173
IRC5 Electrical Maintenance
Circuit Diagrams
© ABB Inc. 174
Notes
Notes
IRC5 Electrical Maintenance
Exercise 10
1. Exercise 10
© ABB Inc. 175
IRC5 Electrical Maintenance
Pilz Wiring Overview
 Pilz Information Power Point Presentation
© ABB Inc. 176
Notes
Notes
IRC5 Electrical Maintenance
Exercise 11
1. Exercise 11
© ABB Inc. 177