ABB IRC5 with FlexPendant Operating Manual

RobotWare 6.08 Document ID: 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Specifications subject to change without notice.

be construed as a commitment by 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 guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABB's written permission. Keep for future reference. Additional copies of this manual may be obtained from ABB. Original instructions. © Copyright 2018 ABB. All rights reserved. Specifications subject to change without notice. ABB AB, Robotics Robotics and Motion Se-721 68 Västerås Sweden

9 Overview of this manual ................................................................................................................... 12 Product documentation .................................................................................................................... 15 1 Safety 15 1.1 About this chapter ............................................................................................. 16 1.2 Applicable standards ......................................................................................... 18 1.3 Safety actions ................................................................................................... 18 1.3.1 Stop the system ...................................................................................... 19 1.3.2 Extinguishing fires ................................................................................... 20 1.3.3 Make sure that the main power has been switched off .................................... 21 1.3.4 Moving robots are potentially lethal ............................................................ 22 1.3.5 Recover from emergency stops ................................................................. 23 1.3.6 Enabling device and hold-to-run functionality ............................................... 24 1.4 Working in a safe manner ................................................................................... 24 1.4.1 Handling of FlexPendant .......................................................................... 26 1.4.2 Safety tools ............................................................................................ 27 1.4.3 About the automatic mode ........................................................................ 29 1.4.4 About the manual mode ........................................................................... 32 1.5 Safety terminology ............................................................................................ 32 1.5.1 Safety signals in the manual ...................................................................... 34 1.5.2 Protective stop and emergency stop ........................................................... 35 2 Welcome to IRC5 35 2.1 About this chapter ............................................................................................. 36 2.2 The IRC5 controller ........................................................................................... 37 2.3 The FlexPendant ............................................................................................... 43 2.4 The T10 ........................................................................................................... 45 2.5 RobotStudio Online ........................................................................................... 47 2.6 RobotStudio ..................................................................................................... 48 2.7 When to use different jogging devices ................................................................... 51 2.8 Buttons and ports on the controller ....................................................................... 53 3 Navigating and handling FlexPendant 53 3.1 About this chapter ............................................................................................. 54 3.2 The Main menu ................................................................................................. 54 3.2.1 HotEdit menu ......................................................................................... 56 3.2.2 FlexPendant Explorer ............................................................................... 57 3.2.3 Inputs and Outputs, I/O ............................................................................ 58 3.2.4 Jogging ................................................................................................. 60 3.2.5 Production Window ................................................................................ 61 3.2.6 Program Data ......................................................................................... 63 3.2.7 Program Editor ...................................................................................... 65 3.2.8 Backup and Restore ............................................................................... 66 3.2.9 Calibration ............................................................................................ 68 3.2.10 Control Panel ......................................................................................... 70 3.2.11 Event Log .............................................................................................. 72 3.2.12 System Info ........................................................................................... 74 3.2.13 Restart .................................................................................................. 75 3.2.14 Log Off ................................................................................................. 76 3.3 Operator window ............................................................................................... 77 3.4 Status bar ........................................................................................................ 78 3.5 Quickset .......................................................................................................... 78 3.5.1 The Quickset menu ................................................................................. 79 3.5.2 Quickset menu, Mechanical unit ................................................................ 84 3.5.3 Quickset menu, Increment ........................................................................ 85 3.5.4 Quickset menu, Run Mode ........................................................................ 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87 3.5.6 Quickset menu, Speed ............................................................................. 88 3.5.7 Quickset menu, Tasks ............................................................................. 89 3.6 Basic procedures .............................................................................................. 89 3.6.1 Using the soft keyboard ............................................................................ 91 3.6.2 Messages on the FlexPendant ................................................................... 92 3.6.3 Scrolling and zooming .............................................................................. 93 3.6.4 Filtering data .......................................................................................... 96 3.6.5 Process applications ................................................................................ 97 3.6.6 Granting access for RobotStudio ................................................................ 98 3.6.7 Logging on and off .................................................................................. 100 3.7 Changing FlexPendant settings ........................................................................... 100 3.7.1 System settings ...................................................................................... 100 3.7.1.1 Setting default paths .................................................................... 101 3.7.1.2 Defining a view to be shown during operating mode change or startup ... 102 3.7.1.3 Changing the background image .................................................... 103 3.7.1.4 Defining visibility level for UAS protected functions ............................ 104 3.7.1.5 Defining an additional test view ...................................................... 105 3.7.1.6 Defining position programming rule ................................................ 107 3.7.1.7 Defining which tasks should be selectable in the tasks panel ............... 108 3.7.1.8 Managing the display of controller and system name ......................... 109 3.7.2 Basic settings ......................................................................................... 109 3.7.2.1 Changing brightness and contrast .................................................. 110 3.7.2.2 Adapting the FlexPendant for left-handed users ................................ 112 3.7.2.3 Controller settings ....................................................................... 114 3.7.2.4 Configuring Most Common I/O ....................................................... 115 3.7.2.5 Changing language ...................................................................... 116 3.7.2.6 Changing programmable keys ....................................................... 118 3.7.2.7 Calibrating the touch screen .......................................................... 121 4 Jogging 121 4.1 Introduction to jogging ....................................................................................... 123 4.2 Coordinate systems for jogging ........................................................................... 129 4.3 Joystick directions ............................................................................................. 130 4.4 Restrictions to jogging ....................................................................................... 131 4.5 Coordinated jogging .......................................................................................... 132 4.6 Basic settings for jogging ................................................................................... 132 4.6.1 Selecting mechanical unit for jogging .......................................................... 134 4.6.2 Selecting motion mode ............................................................................. 135 4.6.3 Selecting tool, work object, and payload ...................................................... 136 4.6.4 Setting the tool orientation ........................................................................ 137 4.6.5 Jog axis by axis ...................................................................................... 138 4.6.6 Selecting coordinate system ..................................................................... 139 4.6.7 Locking the joystick in specific directions .................................................... 141 4.6.8 Incremental movement for precise positioning .............................................. 143 4.6.9 Reading the exact position ........................................................................ 145 4.6.10 Aligning tools ......................................................................................... 147 5 Programming and testing 147 5.1 Before you start programming ............................................................................. 148 5.2 Using RAPID programs ...................................................................................... 150 5.3 Programming concept ........................................................................................ 150 5.3.1 Handling of programs .............................................................................. 153 5.3.2 Handling of modules ................................................................................ 157 5.3.3 Handling of routines ................................................................................ 162 5.3.4 Handling of instructions ............................................................................ 166 5.3.5 Example: Add movement instructions ......................................................... 167 5.3.6 About the Program and Motion Pointers ...................................................... 6 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Table of contents

168 5.4.1 Viewing data in specific tasks, modules, or routines ...................................... 169 5.4.2 Creating new data instance ....................................................................... 171 5.4.3 Editing data instances .............................................................................. 175 5.5 Tools .............................................................................................................. 175 5.5.1 What is a tool? ........................................................................................ 176 5.5.2 What is the tool center point? .................................................................... 177 5.5.3 Creating a tool ........................................................................................ 180 5.5.4 Defining the tool frame ............................................................................. 184 5.5.5 Editing the tool data ................................................................................. 187 5.5.6 Editing the tool declaration ........................................................................ 188 5.5.7 Deleting a tool ........................................................................................ 189 5.5.8 Setup for stationary tools .......................................................................... 191 5.6 Work objects .................................................................................................... 191 5.6.1 What is a work object? ............................................................................. 192 5.6.2 Creating a work object ............................................................................. 193 5.6.3 Defining the work object coordinate system ................................................. 197 5.6.4 Editing the work object data ...................................................................... 198 5.6.5 Editing the work object declaration ............................................................. 199 5.6.6 Deleting a work object .............................................................................. 200 5.7 Payloads ......................................................................................................... 200 5.7.1 Creating a payload .................................................................................. 202 5.7.2 Editing the payload data ........................................................................... 204 5.7.3 Editing the payload declaration .................................................................. 205 5.7.4 Deleting a payload ................................................................................... 206 5.8 Testing ............................................................................................................ 206 5.8.1 About the automatic mode ........................................................................ 208 5.8.2 About the manual mode ........................................................................... 211 5.8.3 Using the hold-to-run function ................................................................... 212 5.8.4 Running the program from a specific instruction ........................................... 213 5.8.5 Running a specific routine ........................................................................ 214 5.8.6 Stepping instruction by instruction ............................................................. 217 5.9 Service routines ................................................................................................ 217 5.9.1 Running a service routine ......................................................................... 221 5.9.2 Battery shutdown service routine ............................................................... 222 5.9.3 Calibration Pendulum, CalPendulum service routine ...................................... 223 5.9.4 Service Information System, ServiceInfo service routine ................................. 224 5.9.5 LoadIdentify, load identification service routine ............................................. 233 5.9.6 Brake check service routine ...................................................................... 241 6 Running in production 241 6.1 Basic procedures .............................................................................................. 241 6.1.1 Starting programs ................................................................................... 244 6.1.2 Stopping programs .................................................................................. 245 6.1.3 Using multitasking programs ..................................................................... 247 6.1.4 Using motion supervision and non motion execution ..................................... 250 6.1.5 Using the hot plug option .......................................................................... 253 6.2 Troubleshooting and error recovery ...................................................................... 253 6.2.1 General procedure when troubleshooting .................................................... 254 6.2.2 Returning the robot to the path .................................................................. 256 6.2.3 Running RAPID program with uncalibrated mechanical unit ............................ 257 6.3 Operating modes .............................................................................................. 257 6.3.1 Present operating mode ........................................................................... 259 6.3.2 Switching from manual to automatic mode ................................................... 261 6.3.3 Switching from automatic to manual mode ................................................... 262 6.3.4 Switching to manual full speed mode .......................................................... 263 6.4 Modifying positions ........................................................................................... 263 6.4.1 Modifying and tuning positions .................................................................. 264 6.4.2 Modifying positions in the Program Editor or Production Window ................... Operating manual - IRC5 with FlexPendant 7 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Table of contents

272 6.4.4 Working with displacements and offsets ...................................................... 274 6.4.5 Moving the robot to a programmed position ................................................. 275 7 Handling inputs and outputs, I/O 275 7.1 Viewing signal lists ............................................................................................ 276 7.2 Simulating and changing signal values .................................................................. 279 7.3 Viewing signal group ......................................................................................... 280 7.4 Safety signals ................................................................................................... 280 7.4.1 Safety I/O signals .................................................................................... 283 8 Handling the event log 283 8.1 Accessing the event log ..................................................................................... 284 8.2 Deleting log entries ............................................................................................ 285 8.3 Saving log entries ............................................................................................. 287 9 Backup and restore 287 9.1 Back up the system ........................................................................................... 289 9.2 Important when performing backups! .................................................................... 291 9.3 Restore the system ............................................................................................ 295 10 Calibrating 295 10.1 How to check if the robot needs calibration ............................................................ 296 10.2 Updating revolution counters ............................................................................... 299 Index 8 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Table of contents

About this manual This manual contains instructions for daily operation of IRC5 based robot systems using a FlexPendant. Usage This manual should be used during operation. Some actions that are more advanced, or not used in the daily operation, are described in Operating manual - IRC5 Integrator's guide. Who should read this manual? This manual is intended for: • operators • product technicians • service technicians • robot programmers How to read the operating manual The operating manual is structured in the following chapters. Content Title Chapter Safety instructions and warnings. Safety 1 Descriptions of the IRC5. Welcome to IRC5 2 Descriptions of the FlexPendant’s user interface and basic procedures. Navigating and handling the FlexPendant 3 Procedures for jogging. Jogging 4 Procedures for programming and testing, including descriptions of some concepts for programming. Programming and testing 5 Procedures for running in production. Running in production 6 Procedures for handling I/O. Handling inputs and out- puts, I/O 7 Procedures for the event log. Handling the event log 8 Procedures for backup and restore of systems. Backup and restore 9 Procedures for calibrating the robot system. Calibrating 10 Prerequisites The reader should: • Be familiar with the concepts described in Operating manual - Getting started, IRC5 and RobotStudio. • Be trained in robot operation. Continues on next page Operating manual - IRC5 with FlexPendant 9 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Overview of this manual

IRC5 with main computer DSQC1000. 3HAC047137-001 Product manual - IRC5 Panel Mounted Controller IRC5 with main computer DSQC1000. 3HAC047138-001 Product manual - IRC5 Compact IRC5 with main computer DSQC1000. 3HAC027097-001 Operating manual - Getting started, IRC5 and RobotStudio 3HAC032104-001 Operating manual - RobotStudio 3HAC050944-001 Operating manual - Service Information System 3HAC020738-001 Operating manual - Troubleshooting IRC5 3HAC050940-001 Operating manual - IRC5 Integrator's guide 3HAC050943-001 Operating manual - IRC5 with T10 3HAC16578-1 Operating manual - Calibration Pendulum 3HAC050948-001 Technical reference manual - System parameters 3HAC050947-001 Technical reference manual - RAPID Overview 3HAC050917-001 Technical reference manual - RAPID Instructions, Functions and Data types 3HAC050946-001 Technical reference manual manual - RAPID kernel 3HAC051016-001 Application manual - Additional axes and stand alone controller 3HAC050798-001 Application manual - Controller software IRC5 3HAC050961-001 Application manual - MultiMove Note The document numbers that are listed for software documents are valid for RobotWare 6. Equivalent documents are available for RobotWare 5. Revisions Description Revision Released with RobotWare 6.0. - Released with RobotWare 6.02. • Added information about time limitation to the section Switching to manual full speed mode on page 262. • Added information on Load diagram check in the section LoadIdentify, load identification service routine on page 224. • Updated the section Controller settings on page 112. A Released with RobotWare 6.03. • Updated the section Step mode on page 86. • Updated the section Illustration Control Panel on page 69. • Updated the section System Info on page 72. • Added a warning note regarding load data in the sections Before you start programming on page147, Tools on page175, Payloads on page200, and Service routines on page 217. B Continues on next page 10 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Overview of this manual Continued

• Updated the section Quickset menu, Increment on page 84. • Updated the section Restore the system on page 291. • Updated the section LoadIdentify, load identification service routine on page 224. C Released with RobotWare 6.05. • Added the new section Managing the display of controller and system name on page 108. • Added the new section Brake check service routine on page 233. • Updated the section Defining a view to be shown during operating mode change or startup on page 101. • Updated descriptions of stops in section Protective stop and emergency stop on page 34. • Removed the information about time limitation in the section Switching to manual full speed mode on page 262. D Released with RobotWare 6.06. • Updated the section Brake check service routine on page 233. • Updated the section Backup and restore on page 287. • Updated the section Example of backward execution on page 215. • Updated the section Controller settings on page 112. E Released with RobotWare 6.07. • Safety section restructured. • FlexPendant Home Screen background image is updated. • Updated the section When is backup possible? on page 289 • Updated the section LoadIdentify for 4-axis robots on page 231 • Updated the section Simulating and changing signal values on page276. F Released with RobotWare 6.08. • Updated the section Controller settings on page 112. • Updated the section Editing motion supervision settings on page 248. • Updated the section Changing programmable keys on page 116. • Added information and code example to the section Brake check for MultiMove systems on page 234. G Operating manual - IRC5 with FlexPendant 11 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Overview of this manual Continued

The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents can be found via myABB Business Portal, www.myportal.abb.com. Product manuals Manipulators, controllers, DressPack/SpotPack, and most other hardware is delivered with a Product manual that generally contains: • Safety information. • Installation and commissioning (descriptions of mechanical installation or electrical connections). • Maintenance (descriptions of all required preventive maintenance procedures including intervals and expected life time of parts). • Repair (descriptions of all recommended repair procedures including spare parts). • Calibration. • Decommissioning. • Reference information (safety standards, unit conversions, screw joints, lists of tools). • Spare parts list with corresponding figures (or references to separate spare parts lists). • References to circuit diagrams. Technical reference manuals The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters. Application manuals Specific applications (for example software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful). • What is included (for example cables, I/O boards, RAPID instructions, system parameters, software). • How to install included or required hardware. • How to use the application. • Examples of how to use the application. Continues on next page 12 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Product documentation

are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Operating manual - IRC5 with FlexPendant 13 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. Product documentation Continued

Introduction to safety This chapter describes safety principles and procedures to be used when a robot or robot system is operated. It does not cover how to design for safety nor how to install safety related equipment. These topics are covered in the Product Manuals supplied with the robot. Note The integrator is responsible for the safety of the final application. Operating manual - IRC5 with FlexPendant 15 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.1 About this chapter

Note The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed. Standards, EN ISO The product is designed in accordance with the requirements of: Description Standard Safety of machinery - General principles for design - Risk as- sessment and risk reduction EN ISO 12100:2010 Safety of machinery, safety related parts of control systems - Part 1: General principles for design EN ISO 13849-1:2015 Safety of machinery - Emergency stop - Principles for design EN ISO 13850:2015 Robots for industrial environments - Safety requirements -Part 1 Robot EN ISO 10218-1:2011 Robots and robotic devices -- Coordinate systems and motion nomenclatures ISO 9787:2013 Manipulating industrial robots, performance criteria, and related test methods ISO 9283:1998 Classification of air cleanliness EN ISO 14644-1:2015i Ergonomics of the thermal environment - Part 1 EN ISO 13732-1:2008 EMC, Generic emission EN 61000-6-4:2007 + A1:2011 IEC 61000-6-4:2006 + A1:2010 (option 129-1) EMC, Generic immunity EN 61000-6-2:2005 IEC 61000-6-2:2005 Arc welding equipment - Part 1: Welding power sources EN IEC 60974-1:2012ii Arc welding equipment - Part 10: EMC requirements EN IEC 60974-10:2014ii Safety of machinery - Electrical equipment of machines - Part 1 General requirements EN IEC 60204-1:2006 Degrees of protection provided by enclosures (IP code) IEC 60529:1989 + A2:2013 i Only robots with protection Clean Room. ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots. European standards Description Standard Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles EN 614-1:2006 + A1:2009 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design EN 574:1996 + A1:2008 Continues on next page 16 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.2 Applicable standards

ANSI/RIA R15.06 Safety standard for robots and robotic equipment ANSI/UL 1740 Industrial robots and robot Systems - General safety require- ments CAN/CSA Z 434-14 Operating manual - IRC5 with FlexPendant 17 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.2 Applicable standards Continued

1.3.1 Stop the system Overview Press any of the emergency stop buttons immediately if: • There are any personnel in the robot manipulator area, while the manipulator is working. • The manipulator causes harm to personnel or mechanical equipment. The controller emergency stop button The emergency stop button on the controller is located on the front of the cabinet. However, this can differ depending on your plant design. The FlexPendant also has an emergency stop button. Other emergency stop devices The plant designer may have placed additional emergency stop devices in convenient places. Consult your plant or cell documentation to find out where these are placed. 18 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.3.1 Stop the system

Precautions In case of a fire always make sure both you and your co-workers are safe before performing any fire extinguishing activities. In case of injury always make sure these are treated first. Select fire extinguisher Always use carbon dioxide extinguishers when extinguishing fires in electrical equipment such as the robot or the controller. Do not use water or foam. Operating manual - IRC5 with FlexPendant 19 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.3.2 Extinguishing fires

Description Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. 20 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.3.3 Make sure that the main power has been switched off

Description Any moving robot is a potentially lethal machine. When running, the robot may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot. Safe handling Note Action Emergency stop equipment such as gates, tread mats, light curtains, etc. Before attempting to run the robot, make sure all emergency stop equipment is cor- rectly installed and connected. 1 How to use the hold-to-run function is de- scribed in section How to use the hold-to- run function in the Operating manual - IRC5 with FlexPendant. Usually the hold-to-run function is active only in manual full speed mode. To in- crease safety it is also possible to activate hold-to-run for manual reduced speed with a system parameter. 2 The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the robot before pressing the start button. 3 Operating manual - IRC5 with FlexPendant 21 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.3.4 Moving robots are potentially lethal

Overview Recovering from an emergency stop is a simple but important procedure. This procedure ensures that the robot system is not returned to production while maintaining a hazardous condition. Reset the latch of emergency stop buttons All push-button style emergency stop devices have a latching feature that must be released in order to remove the emergency stop condition of the device. In many cases this is done by twisting the push-button as marked, but there are also devices where you pull the button to release the latch. Reset automatic emergency stop devices All automatic emergency stop devices also have some kind of latching feature that must be released. Consult your plant or cell documentation to see how your robot system is configured. Recover from emergency stops Action Make sure the hazardous situation that resulted in the emergency stop condition no longer exists. 1 Locate and reset the device or devices that gave the emergency stop condition. 2 Press the Motors On button to recover from the emergency stop condition. 3 22 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.3.5 Recover from emergency stops

Three-position enabling device The three-position enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely. The three-position enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, operating the robot is impossible. Note The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state. To ensure safe use of the teach pendant, the following must be implemented: • The enabling device must never be rendered inoperational in any way. • During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. • Anyone entering the working space of the robot must always hold the teach pendant. This is to prevent anyone else from taking control of the robot without his/her knowledge. Hold-to-run function The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Operating manual - IRC5 with FlexPendant 23 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.3.6 Enabling device and hold-to-run functionality

1.4.1 Handling of FlexPendant Handling of FlexPendant The FlexPendant is a high-quality handheld terminal equipped with highly sensitive state-of-the-art electronics. To avoid malfunctions or damage through improper handling, follow these instructions during operation. The FlexPendant may only be used for the purposes mentioned in this manual. The FlexPendant was developed, manufactured, tested and documented in accordance with applicable safety standards. If you follow the instructions regarding safety and use as described in this manual, the product will, in the normal case, neither cause personal injury nor damage to machinery and equipment. The FlexPendant is developed, manufactured, tested, and documented in accordance with the applicable safety standards. Handling and cleaning • Handle with care. Do not drop, throw, or give the FlexPendant strong shock. It can cause breakage or failure. • If the FlexPendant is subjected to shock, always verify that the safety functions (three-position enabling device and emergency stop) work and are not damaged. • When not using the device, hang it on the wall bracket provided for storage so it does not accidentally fall. • Always use and store the FlexPendant in such a way that the cable does not become a tripping hazard. • Never use sharp objects (such as screwdriver or pen) for operating the touch screen. This could damage the touch screen. Instead use your finger or a stylus. • Clean the touch screen regularly. Dust and small particles can clog the touch screen and cause it to malfunction. • Never clean the FlexPendant with solvents, scouring agent, or scrubbing sponges. Use a soft cloth and a bit of water or mild cleaning agent. See the product manual for the robot controller, section Cleaning the FlexPendant. • Always close the protective cap on the USB port when no USB device is connected. The port can break or malfunction if exposed to dirt or dust. CAUTION A disconnected FlexPendant should be stored in such a way that it cannot be mistaken for being connected to the controller. Continues on next page 24 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.1 Handling of FlexPendant

• Turn off the power supply before opening the cable entrance area of the FlexPendant. Otherwise the components could be destroyed or undefined signals could occur. • Make sure that nobody trips over the cable to prevent the device from falling to the ground. • Take care not to squeeze and thus damage the cable with any object. • Do not lay the cable over sharp edges since this can damage the cable sheath. Custom connections for FlexPendant Any means of connecting the FlexPendant with other than the supplied cable and its standard connector must not render the emergency stop button inoperative. Always test the emergency stop button to make sure it works if a custom connection cable is used. Waste disposal Observe the national regulations when disposing of electronic components. When replacing components, dispose of used components properly. Foreseeable misuse of three-position enabling device Foreseeable misuse means that it is not allowed to jam the three-position enabling device in the enabling position. The foreseeable misuse of the enabling device must be restricted. When releasing and then pressing the three-position enabling device again, make sure to wait for the system to go to Motors Off state before pressing again. Otherwise you will receive an error message. Operating manual - IRC5 with FlexPendant 25 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.1 Handling of FlexPendant Continued

Safeguarding mechanisms Your robot system can be equipped with a vast range of safeguards such as door interlocks, safety light curtains, safety mats, and others. The most common is the door interlock of the robot cell that temporarily stops the robot if you open it. IRC5 The IRC5 controller has three separate safeguarding mechanisms, the general mode safeguarded stop (GS), the automatic mode safeguarded stop (AS) and the superior safeguarded stop (SS). are... Safeguards connected to... always active regardless of the operating mode. the GS mechanism only active when the system is in automatic mode. the AS mechanism always active regardless of the operating mode. the SS mechanism See your plant or cell documentation to see how your robot system is configured and where the safeguarding mechanisms are placed and how they work. Safety supervision The emergency stop and safeguarding mechanisms are supervised so that any failure is detected by the controller and the robot is stopped until the problem is solved. Built-in stop functions The controller continuously monitor hardware and software functionality. If any problems or errors are detected the robot is stopped until the problem has been solved. then... If the failure is... a simple program stop is issued (SYSSTOP). simple and can easily be solved a SYSHALT is issued which results in a protective stop. minor and can be solved a SYSFAIL is issued which results in an emergency stop. The controller must be restarted in order to return to normal operation. major, for instance concerns broken hardware Restricting the robot's working range The robot's working range can be restricted by means of mechanical stops or software functions, or by a combination of both. See your plant or cell documentation to see how your robot system is configured. 26 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.2 Safety tools

What is the automatic mode? In automatic mode the safety function of the three-position enabling device is bypassed so that the manipulator is allowed to move without human intervention. WARNING Prior to selecting automatic mode, any suspended safeguards shall be returned to their full functionality. Tasks normally performed in the automatic mode The following tasks are normally performed in automatic mode. • Starting and stopping processes. • Loading, starting, and stopping RAPID programs. • Returning the manipulator to its path when returning to operation after an emergency stop. • Backing up the system. • Restoring backups. • Cleaning tools. • Preparing or replacing work objects. • Performing other process oriented tasks. Limitations in automatic mode Jogging is not possible in automatic mode. There may be other specific tasks that should not be performed in automatic mode. Consult your plant or system documentation to find out which specific tasks should not be performed in automatic mode. Active safeguard mechanisms For IRC5, both the general mode stop (GS) mechanisms, the automatic mode stop (AS) mechanisms, and the superior stop (SS) are all active while operating in automatic mode. Coping with process disturbances Process disturbances may not only affect a specific manipulator cell but an entire chain of systems even if the problem originates in a specific cell. Extra care must be taken during such a disturbance since that chain of events may create hazardous operations not seen when operating the single manipulator cell. All remedial actions must be performed by personnel with good knowledge of the entire production line, not only the malfunctioning manipulator. Continues on next page Operating manual - IRC5 with FlexPendant 27 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.3 About the automatic mode

A manipulator picking components from a conveyer might be taken out of production due to a mechanical malfunction, while the conveyer must remain running in order to continue production in the rest of the production line. This means, of course, that extra care must be taken by the personnel preparing the manipulator in close proximity to the running conveyor. A welding manipulator needs maintenance. Taking the welding manipulator out of production also means that a work bench as well as a material handling manipulator must be taken out of production to avoid personnel hazards. 28 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.3 About the automatic mode Continued

What is the manual mode? In manual mode the manipulator movement is under manual control. The three-position enabling device must be pressed to activate the motors of the manipulator, that is, enabling movement. The manual mode is used when programming and for program verification. There are two manual modes: • Manual reduced speed mode, usually called manual mode. • Manual full speed mode (not available in USA or Canada). What is the manual reduced speed mode? In manual reduced speed mode the movement is limited to 250 mm/s. In addition, there is a limitation on the maximum allowed speed for each axis. These axis limitations are robot dependent and cannot be changed. The three-position enabling device must be pressed to activate the motors of the manipulator. WARNING Wherever possible, the manual mode of operation shall be performed with all persons outside the safeguarded space. What is the manual full speed mode? In manual full speed mode, the manipulator can move in programmed speed but only under manual control. The manual full speed mode is used for program verification only. In manual full speed mode the initial speed limit is up to, but not exceeding, 250 mm/s. This is achieved by limiting the speed to 3% of the programmed speed. Through manual control the speed can be increased up to 100%. The three-position enabling device must be pressed to activate the motors of the manipulator, and the hold-to-run button must be pressed to start program execution. WARNING Wherever possible, the manual mode of operation shall be performed with all persons outside the safeguarded space. Continues on next page Operating manual - IRC5 with FlexPendant 29 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.4 About the manual mode

robots. Note As per the updated standard, ISO 10218-1:2011 Robots and robotic devices – Safety requirements for industrial robots – Part 1 Robots, the following adaptations are made to the manual full speed mode. • Resetting the speed to 250 mm/s every time the three-position enabling device is re-initiated by placing the switch in the center-enabled position after either having been released or fully compressed. • Editing RAPID programs and jogging the manipulator are disabled. Bypassed safeguard mechanisms Automatic mode safeguarded stop (AS) mechanisms are bypassed while operating in manual mode. The three-position enabling device In manual mode the motors of the manipulator are activated by the three-position enabling device on the FlexPendant. This way the manipulator can only move as long as the device is pressed. In order to run a program in manual full speed mode it is necessary, for safety reasons, to keep pressing both the three-position enabling device and the Start button. This hold-to-run function also applies when stepping through a program in manual full speed mode. The three-position enabling device is designed so that its push-button must be pressed just half-way to activate the motors of the manipulator. Both in its all-out and full-in positions the manipulator will not move. The hold-to-run function The hold-to-run function allows stepping or running a program in manual full speed mode. Note that jogging does not require the hold-to-run function, regardless of operating mode. The hold-to-run function can also be activated for manual reduced speed mode. Tasks normally performed in manual reduced speed mode The following tasks are normally performed in manual reduced speed mode. • Jogging the manipulator back on its path when returning to operation after an emergency stop • Correcting the value of I/O signals after error conditions • Creating and editing RAPID programs • Starting, stepping, and stopping program execution, for example while testing a program • Tuning programmed positions Continues on next page 30 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.4 About the manual mode Continued

As per the standard, ISO 10218-1:2011, the following tasks can be performed in the manual full speed mode. • Starting and stopping program execution for final program verification • Stepping program execution • Setting speed (0–100%) • Setting program pointer (to Main, to routine, to cursor, to service routine, etc.) The following tasks cannot be performed in the manual full speed mode: • Changing system parameter values • Editing system data Operating manual - IRC5 with FlexPendant 31 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.4.4 About the manual mode Continued

1.5.1 Safety signals in the manual Introduction to safety signals This section specifies all safety signals used in the user manuals. Each signal consists of: • A caption specifying the danger level (DANGER, WARNING, or CAUTION) and the type of danger. • A brief description of what will happen if the the danger is not eliminated. • Instruction about how to eliminate danger to simplify doing the work. Danger levels The table below defines the captions specifying the danger levels used throughout this manual. Significance Designation Symbol Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, and so on. DANGER Warns that an accident may occur if the instructions are not followed that can lead to serious injury, pos- sibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, etc. WARNING Warns for electrical hazards which could result in severe personal injury or death. ELECTRICAL SHOCK Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, im- pact, fall from height, etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown. CAUTION Warns for electrostatic hazards which could result in severe damage to the product. ELECTROSTATIC DISCHARGE (ESD) Continues on next page 32 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.5.1 Safety signals in the manual

NOTE Describes where to find additional information or how to do an operation in an easier way. TIP Operating manual - IRC5 with FlexPendant 33 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.5.1 Safety signals in the manual Continued

Overview The protective stops and emergency stops are described in the product manual for the controller. 34 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 1 Safety 1.5.2 Protective stop and emergency stop

2.1 About this chapter Overview This chapter presents an overview of the FlexPendant, the IRC5 controller, and RobotStudio. A basic robot consists of a robot controller, the FlexPendant, RobotStudio, and one or several manipulators or other mechanical units. There may also be process equipment and additional software options. This manual describes a basic robot without options. However, in a few places, the manual gives an overview of how options are used or applied. Most options are described in detail in their respective application manual. Operating manual - IRC5 with FlexPendant 35 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.1 About this chapter

The IRC5 controller The IRC5 controller contains all functions needed to move and control the robot. The standard IRC5 controller consists of a single cabinet. The controller is also available in a compact version, IRC5 Compact, and it can also be integrated in an external cabinet, Panel Mounted Controller. When running more than one robot with one controller (MultiMove option), an extra drive module must be added for each additional robot. However, a single control module is used. Related information Product manual - IRC5, IRC5 of design M2004. Product manual - IRC5, IRC5 of design 14. Product manual - IRC5 Panel Mounted Controller, IRC5 of design M2004. Product manual - IRC5 Panel Mounted Controller, IRC5 of design 14. Product manual - IRC5 Compact, IRC5 of design M2004. Product manual - IRC5 Compact, IRC5 of design 14. Application manual - MultiMove. 36 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.2 The IRC5 controller

Introduction to the FlexPendant The FlexPendant is a hand held operator unit that is used for many of the tasks when operating a robot: running programs, jogging the manipulator, modifying programs, and so on. The FlexPendant is designed for continuous operation in harsh industrial environment. Its touch screen is easy to clean and resistant to water, oil, and accidental welding splashes. The FlexPendant consists of both hardware and software and is a complete computer in itself. It is connected to the robot controller by an integrated cable and connector. The hot plug button option makes it possible to disconnect the FlexPendant in automatic mode and continue running without it. Main parts These are the main parts of the FlexPendant. xx1400001636 Continues on next page Operating manual - IRC5 with FlexPendant 37 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.3 The FlexPendant

C Joystick D USB port E Three-position enabling device F Stylus pen G Reset button H Joystick Use the joystick to move the manipulator. This is called jogging the robot. There are several settings for how the joystick will move the manipulator. USB port Connect a USB memory to the USB port to read or save files. The USB memory is displayed as drive /USB:Removable in dialogs and FlexPendant Explorer. Note Close the protective cap on the USB port when not used. Stylus pen The stylus pen included with the FlexPendant is located on the back. Pull the small handle to release the pen. Use the stylus pen to tap on the touch screen when using the FlexPendant. Do not use screw drivers or other sharp objects. Reset button If the FlexPendant freezes during operation, press the reset button to restart the FlexPendant. The reset button resets the FlexPendant, not the system on the controller. Continues on next page 38 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.3 The FlexPendant Continued

own functions to four of the buttons. xx0900000023 Programmable keys, 1 - 4. How to define their respective function is detailed in section Programmable keys,. A - D Select mechanical unit. E Toggle motion mode, reorient or linear. F Toggle motion mode, axis 1-3 or axis 4-6. G Toggle increments. H Step BACKWARD button. Executes one instruction backward as button is pressed. J START button. Starts program execution. K Step FORWARD button. Executes one instruction forward as button is pressed. L STOP button. Stops program execution. M Continues on next page Operating manual - IRC5 with FlexPendant 39 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.3 The FlexPendant Continued

The FlexPendant is typically operated while being held in the hand. A right-handed person uses his left hand to support the device while the other hand performs operations on the touch screen. A left-hander, however, can easily rotate the display through 180 degrees and use his right hand to support the device. en0400000913 Continues on next page 40 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.3 The FlexPendant Continued

The illustration shows important elements of the FlexPendant touch screen. xx1400001446 Main menu A Operator window B Status bar C Close button D Task bar E Quickset menu F Main menu The following items can be selected from the Main menu: • HotEdit • Inputs and Outputs • Jogging • Production Window • Program Editor • Program Data • Backup and Restore • Calibration • Control Panel • Event Log Continues on next page Operating manual - IRC5 with FlexPendant 41 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.3 The FlexPendant Continued

Operator window The operator window displays messages from robot programs. This usually happens when the program needs some kind of operator response in order to continue. This is described in section Operator window on page 76. Status bar The status bar displays important information about system status, such as operating mode, motors on/off, program state and so on. This is described in section Status bar on page 77. Close button Tapping the close button closes the presently active view or application. Task bar You can open several views from the Main menu, but only work with one at a time. The task bar displays all open views and is used to switch between these. Quickset menu The quickset menu provides settings for jogging and program execution. This is described in section The Quickset menu on page 78. 42 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.3 The FlexPendant Continued

Introduction The T10 is a jogging device used to jog manipulators and mechanical units in an intuitive way by pointing the device in the direction of movement. When using a FlexPendant for jogging, a predefined coordinate system is selected, such as world coordinates or tool coordinates, and the manipulator moves in the desired direction along the selected coordinate system. Using the T10 for jogging is quite similar, but instead of selecting a coordinate system, the direction is shown in space with the device itself. For example when jogging vertically the T10 is held in vertical direction, when jogging horizontally the T10 is held in horizontal direction, etc. This is achieved thanks to the built in inertial measurement unit, consisting of accelerometers and gyroscopes, which measure the motion of the device in space. The joystick is used for adjusting the jog speed and the positive or negative direction. The forward and backward movement of the joystick corresponds directly to the movement of the manipulator, which is the most intuitive way. The left and right movement of the joystick is used for reorientation. For more information about the T10, see Operating manual - IRC5 with T10. Prerequisites The RobotWare option 976-1 T10 Support is necessary to run the T10 with the IRC5 robot controller. Overview xx1400002068 Continues on next page Operating manual - IRC5 with FlexPendant 43 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.4 The T10

C Three-position enabling device D 44 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.4 The T10 Continued

Introduction to RobotStudio Online RobotStudio Online is a suite of Windows Store applications intended to run on Windows 10 tablets. It provides functionality for the shop floor commissioning of robot systems. Note Some of the functionality requires use of a safety device such as the T10 jogging device or the JSHD4 three position safety device. For more information on T10, see Operating manual - IRC5 with T10. You can run these apps on a tablet that communicates with the robot controller wirelessly. To enable certain functionality, such as entering manual mode and enabling power to the mechanical unit motors, you need a safety device that is connected to the robot using the same plug that alternatively is used to connect the FlexPendant. The following RobotStudio Online apps are available in the Microsoft Windows Store: Note You must have Windows 8.1 to run these Apps. Description RobotStudio Online Apps Manage is a tool to manage IRC5 controllers on a network. xx1400002047 Calibrate is a tool for calibration and defini- tion of frames with IRC5 controllers. xx1400002049 Continues on next page Operating manual - IRC5 with FlexPendant 45 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.5 RobotStudio Online

Jog is a tool for manual positioning (moving or jogging) with IRC5 controllers. xx1400002048 Tune is a tool for shop floor editing of RAPID programs with IRC5 controllers. xx1400002050 Operate is a tool used in production to view the program code. xx1400002511 YuMi is a tool for programming of the new dual arm and collaborative robot YuMi, IRB 14000, from ABB. xx1500000832 It will help the users to get a fast introduction to robot programming using lead-thru and graphical programming. 46 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.5 RobotStudio Online Continued

RobotStudio is an engineering tool for the configuration and programming of ABB robots, both real robots on the shop floor and virtual robots in a PC. To achieve true offline programming, RobotStudio utilizes ABB VirtualRobot™Technology. RobotStudio has adopted the Microsoft Office Fluent User Interface. The Office Fluent UI is also used in Microsoft Office. As in Office, the features of RobotStudio are designed in a workflow-oriented way. With add-ins, RobotStudio can be extended and customized to suit the specific needs. Add-ins are developed using the RobotStudio SDK. With the SDK, it is also possible to develop custom SmartComponents which exceed the functionality provided by RobotStudio's base components. For more information, see Operating manual - RobotStudio. RobotStudio for real controllers RobotStudio allows, for example, the following operations when connected to a real controller: • Installing and modifying systems on RobotWare 6 controllers, using the Installation Manager. • Text-based programing and editing, using the RAPID Editor. • File manager for the controller. • Administrating the User Authorization System. • Configuring system parameters. Operating manual - IRC5 with FlexPendant 47 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.6 RobotStudio

Overview For operating and managing the robot, you can use any of the following: • FlexPendant: Optimized for handling robot motions and ordinary operation • RobotStudio: Optimized for configuration, programming and other tasks not related to the daily operation. • T10: Intended for jogging the robots in an intuitive way by selecting desired directions of movement. • RobotStudio Online Apps : Optimized for jogging, managing, working with the frames, calibration methods and RAPID programs available in the robot controller. Start, restart and shut down the controller Use... To... The power switch on the controller's front panel. Start the controller The FlexPendant, RobotStudio, RobotStudio Online Apps or the power switch on the controller's front panel. Restart the controller The power switch on the controller's front panel or the FlexPendant, tap Restart, then Advanced. Shut down the controller The FlexPendant. Shut down the main computer Run and control robot programs Use... To... The FlexPendant or T10 . Jog a robot The FlexPendant, RobotStudio or RobotStudio Online Apps. Start or stop a robot program The FlexPendant, RobotStudio or RobotStudio Online Apps. Start and stop background tasks Communicate with the controller Use... To... The FlexPendant or RobotStudio Online Apps. Acknowledge events RobotStudio, FlexPendant or the RobotStu- dio Online Apps. View and save the controller's event logs RobotStudio, FlexPendant or the RobotStu- dio Online Apps. Back up the controller's software to files on the PC or a server The FlexPendant or RobotStudio Online Apps. Back up the controller's software to files on the controller RobotStudio, FlexPendant or the RobotStu- dio Online Apps. Transfer files between the controller and net- work drives Continues on next page 48 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.7 When to use different jogging devices

Use... To... RobotStudio to create the program's structure and most of the source code and the FlexPendant to store robot positions and make final adjustments to the program. Create or edit robot programs in a flexible way. This is suit- able for complex programs with a lot of logic, I/O signals or action instructions When programming, RobotStudio provides the following advantages: • A text editor optimized for RAPID code, with auto-text and tool-tip information about instructions and para- meters. • Program check with program error marking. • Close access to configuration and I/O editing. The FlexPendant. Create or edit a robot program in a supportive way. This is suitable for programs that mostly consist of move instruc- tions When programming, the FlexPendant provides the following advantages: • Instruction pick lists • Program check and debug while writing • Possibility to create robot positions while program- ming The FlexPendant or T10 with a combination of suitable Ro- botStudio Online Apps. Add or edit robot positions The FlexPendant or T10 with a combination of suitable Ro- botStudio Online Apps. Modify robot positions Configure the robot's system parameters Use... To... RobotStudio, FlexPendant or the RobotStu- dio Online Apps. Edit the system parameters of the running system RobotStudio, FlexPendant or the RobotStu- dio Online Apps. Save the robot's system parameters as config- uration files RobotStudio, FlexPendant or the RobotStu- dio Online Apps. Load system parameters from configuration files to the running system RobotStudio, FlexPendant or the RobotStu- dio Online Apps. Load calibration data Create, modify and install systems Use... To... RobotStudio together with RobotWare and a valid Ro- botWare Key for systems based on RobotWare 5. Create or modify a system RobotStudio together with RobotWare and license file for systems based on RobotWare 6. RobotStudio Install a system on a controller The FlexPendant. Install a system on a controller from a USB memory Calibration Use... To... The FlexPendant or the RobotStudio Online Apps. Calibrate base frame etc. Continues on next page Operating manual - IRC5 with FlexPendant 49 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.7 When to use different jogging devices Continued

Apps. Calibrate tools, work objects etc. Related information The table below specifies which manuals to read, when performing the various tasks referred to: Document number for details, see manual... Recommended use... 3HAC050941-001 Operating manual - IRC5 with Flex- Pendant FlexPendant 3HAC032104-001 Operating manual - RobotStudio RobotStudio 3HAC050943-001 Operating manual - IRC5 with T10 T10 50 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.7 When to use different jogging devices Continued

Buttons and ports on the controller These are the buttons and ports on an IRC5 controller. Some buttons and ports are options and might not be available on your controller. The buttons and ports look the same but the placing can differ depending on the controller model (IRC5 Standard, IRC5 Compact, or IRC5 Panel Mounted Controller) and if there is an external operator’s panel. xx0600002782 Main switch A Emergency stop B Motors on C Mode switch D Safety chain LEDs (option) E Service port for PC (option) G Duty time counter (option) H Service outlet 115/230 V, 200 W (option) J Hot plug button (option) K Connector for FlexPendant or T10 L Related information Product manual - IRC5, IRC5 of design 14. Continues on next page Operating manual - IRC5 with FlexPendant 51 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.8 Buttons and ports on the controller

Product manual - IRC5 Compact, IRC5 of design 14. Operating manual - Troubleshooting IRC5. 52 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 2 Welcome to IRC5 2.8 Buttons and ports on the controller Continued

3.1 About this chapter Introduction to this chapter This chapter will help you to work efficiently with the FlexPendant. The important elements for navigation illustrated in Touch screen elements on page 41 are described here. All views of the Main menu, the main element for navigation, are described in overview with references to further details on how to use their functions. In addition, this chapter provides information about basic procedures, such as how to use the soft keyboard for entering text or numbers, how to scroll and zoom the graphical touch screen, and how to use the filtering function. How to log on and log off is also described. Handling and troubleshooting the FlexPendant How to handle and clean the FlexPendant is described in Handling of FlexPendant on page 24. Troubleshooting the FlexPendant is described in Operating manual - Troubleshooting IRC5. Hardware and software options Note that this manual covers only the views of a basic RobotWare system. Process applications such as arc welding, dispense, or plastics are started from the Main menu but not described in this manual. All options are detailed in their respective application manual. Operating manual - IRC5 with FlexPendant 53 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.1 About this chapter

3.2.1 HotEdit menu HotEdit HotEdit is used to tune programmed positions. This can be done in all operating modes and even while the program is running. Both coordinates and orientation can be tuned. HotEdit can only be used for named positions of the type robtarget (see limitations below). The functions available in HotEdit may be restricted by the user authorization system, UAS. Illustration of the HotEdit view en0500001542 Functions available in HotEdit Lists all named positions in a tree view. Select one or several positions to be tuned by tapping the arrow. Notice that if a po- sition is used at several places in your program, any change made to the offset will take effect everywhere it is used. Programmed targets Lists all selected positions and their current offset. To remove a position from the selection you tap it and then tap the trash. Selected targets Saves and loads selections of positions to be tuned. If your system uses UAS, this may be the only way to select positions for HotEdit. File Continues on next page 54 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.1 HotEdit menu

holds the position values currently seen as the original ones. When you are satisfied with your HotEdit session and want to save the new offset values as the original position values, you apply these to the baseline. The old baseline values for these positions are now gone, and cannot be restored. Baseline Displays settings for tuning: Coordinate system, Tuning mode and Tuning increment. Make your choices and then use the plus and minus icons to specify tuning of selected targets. Tune targets Tap Apply to make the settings made in the Tune Targets view take effect. Note that this does not change the baseline values of the positions! Apply CAUTION HotEdit offers advanced functionality, which has to be handled carefully. Be aware that new offset values will be used immediately by a running program once the Apply button has been tapped. Before you start using the HotEdit functionality it is strongly recommended to read Tuning positions with HotEdit on page 268, where HotEdit limitations and procedures as well as the baseline concept is detailed. Related information See section Modifying and tuning positions on page 263 for a general overview on how to modify programmed positions. For modifying positions by jogging the robot to the new position, see section Modifying positions in the Program Editor or Production Window on page 264. For detailed information about HotEdit, see Tuning positions with HotEdit on page 268. Technical reference manual - RAPID Instructions, Functions and Data types. Technical reference manual - System parameters, section TopicController - TypeModPos Settings. Operating manual - IRC5 with FlexPendant 55 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.1 HotEdit menu Continued

FlexPendant Explorer The FlexPendant Explorer is a file manager, similar to Windows Explorer, with which you can view the file system on the controller. You can also rename, delete, or move files or folders. Illustration FlexPendant Explorer The illustration details the FlexPendant Explorer. en0400001130 Simple view. Tap to hide type in the file window. A Detailed view. Tap to show type in the file window. B Path. Displays folder paths. C Menu. Tap to display functions for file handling. D New folder. Tap to create a new folder in current folder. E Up one level. Tap to change to parent folder. F Refresh. Tap to refresh files and folders. G 56 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.2 FlexPendant Explorer

Inputs and outputs Inputs and outputs, I/O, are signals used in the robot system. Signals are configured with system parameters. Illustration Inputs and Outputs view This illustration details the Inputs and Outputs view. en0400000770 What is a signal An I/O signal is the logical software representation of: • Inputs or outputs located on an industrial network I/O device that is connected to an industrial network within the robot system (real I/O signal). • An I/O signal without a representation on any industrial network I/O device (virtual I/O signal). By specifying an I/O signal, a logical representation of the real or virtual I/O signal is created. The I/O signal configuration defines the specific system parameters for the I/O signal that will control the behavior of the I/O signal. Operating manual - IRC5 with FlexPendant 57 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.3 Inputs and Outputs, I/O

are also available under the Quickset menu. Jogging menu The illustration shows the functions available under the Jogging menu: en0400000654 Function Property/button Select mechanical unit active for jogging, described in section Selecting mechanical unit for jogging on page 132. Mechanical unit Absolute Accuracy: Off is default. If the robot has the Absolute Accuracy option, then Absolute Accuracy: On is displayed. Absolute accuracy Select motion mode, described in section Selecting motion mode on page 134. Motion mode Select coordinate system, described in section Selecting coordinate system on page 138. Coordinate system Select tool, described in section Selecting tool, work object, and payload on page 135. Tool Select work object, described in section Selecting tool, work object, and payload on page 135. Work object Select payload, described in section Selecting tool, work object, and payload on page 135. Payload Continues on next page 58 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.4 Jogging

joystick in specific directions on page 139. Joystick lock Select movement increments, described in section Incremental movement for precise positioning on page 141. Increment Displays each axis position in relation to the selected coordinate system, described in section Reading the exact position on page 143. Position If the position values are displayed in red, then the revolution counters must be updated. See section Updating revolution counters on page 296. Select position format, described in section Reading the exact position on page 143. Position format Displays current joystick directions, depending on setting in Motion mode. See section Selecting motion mode on page 134. Joystick directions Align the current tool to a coordinate system. See section Aligning tools on page 145. Align Move the robot to a selected position/target. See section Moving the robot to a programmed position on page 274. Go To Activate a mechanical unit. Activate Operating manual - IRC5 with FlexPendant 59 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.4 Jogging Continued

Overview The Production Window is used to view the program code while the program is running. Illustration Production Window This section illustrates the Production Window. en0400000955 Load a new program. Load Program Move the program pointer to the routine Main. PP to Main The Debug menu is available only in manual mode. Modify Position, see Modifying positions in the Program Editor or Production Window on page264. Show Motion Pointerand Show Program Pointer, see About the Program and Motion Pointers on page 167. Edit Program, see Program Editor on page 63. Note The Visual Step mode icon indicates that the Step Into mode is not selec- ted. This means that if the step mode is Step Out, Step Over, or Next Move the Visual Step mode icon is displayed. Debug 60 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.5 Production Window

Overview The Program Data view contains functions for viewing and working with data types and instances. You can open more than one window of the Program Data, which can be useful when working with many instances or data types. Illustration of Program Data This section illustrates the Program Data view. en0400000659 Changes scope of data types in the list, see Viewing data in specific tasks, modules, or routines on page 168. Change Scope Shows all instances of the selected data type. Show Data Shows all or only used data types. View Continues on next page Operating manual - IRC5 with FlexPendant 61 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.6 Program Data

This section illustrates a list of instances for a data type. en0500001571 Filters the instances, see Filtering data on page 93. Filter Creates a new instance of the selected data type, see Creating new data instance on page 169. New Edits the selected instances, see Editing data instances on page171. Edit Refreshes the list of instances. Refresh Returns to the Program Data menu. View Data Types 62 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.6 Program Data Continued

Overview The Program Editor is where you create or modify programs. You can open more than one window of the Program Editor, which can be useful with the Multitasking option installed. The Program Editor button in the task bar displays the name of the task. Illustration of Program Editor This section illustrates the Program Editor view. en0400001143 Menu for program operations, see Handling of programs on page 150. Tasks and Programs Lists all modules, see Handling of modules on page 153. Modules Lists all routines, see Handling of routines on page 157. Routines Opens instruction menu, see Handling of instructions on page162. Add Instruction Opens edit menu, see Handling of instructions on page 162. Edit Functions for moving the program pointer, service routines etc., see Running a service routine on page217, and About the Program and Motion Pointers on page 167. Debug Functions to search routines and view system data. • Search Routine: Searches all routines across all the modules (except hidden routines). • View System Data: Displays all the tasks. Continues on next page Operating manual - IRC5 with FlexPendant 63 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.7 Program Editor

Window on page 264. Modify Position Hides declarations to make the program code easier to read. Hide Declarations Automatically activate mechanical unit for jogging If Multitasking is installed with more than one mechanical unit and more than one motion task, then when switching between Program Editor windows the selection of mechanical unit for jogging is not effected. This means when jogging then the last used mechanical unit will move, which not neccessarily is the one used in the active Program Editor. This setting can be changed with system parameters of the type Automatically Switch Jog Unit in the topic Man-machine Communication. Turn this setting on to automatically activate the mechanical unit last used in a Program Editor when switching to that window. This means that when jogging, the mechanical unit last used in the active Program Editor moves. Note that when switching between Program Editors in the same task, there is no change. Mechanical units are manually activated for jogging in the Jogging window or in the Quickset menu, see Selecting mechanical unit for jogging on page 132. 64 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.7 Program Editor Continued

About backups The Backup and Restore menu is used for performing backups and restoring the system. See section Backup and restore on page 287. Illustration of Backup and Restore This is the Backup and Restore menu. xx0300000440 See Back up the system on page 287. Backup Current System See Restore the system on page 291. Restore System Operating manual - IRC5 with FlexPendant 65 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.8 Backup and Restore

Calibration can be performed using the option Calibration Pendulum. See Operating manual - Calibration Pendulum. Illustration of Calibration menu This illustration shows the Calibration menu. All mechanical units are listed and their calibration status is displayed in the Status column. en0400001146 Continues on next page 66 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.9 Calibration

This illustration shows the Calibration menu options after selecting mechanical unit. en0400000771 Operating manual - IRC5 with FlexPendant 67 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.9 Calibration Continued

Control Panel The Control Panel contains functions for customizing the robot system and the FlexPendant. Continues on next page 68 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.10 Control Panel

en0400000914 Settings to customize the brightness of the display. See Changing brightness and contrast on page 109. Appearance Settings for motion supervision and execution settings. See Using motion supervision and non motion execution on page 247. Supervision Note When changing the level of collision detection, it is necessary to bring the motors to off state for activating the changes. Settings for configuring the Most Common I/O list. See Configur- ing Most Common I/O on page 114. I/O Settings for current language for the robot controller. See Chan- ging language on page 115. Language Settings for the four programmable keys on the FlexPendant. See Changing programmable keys on page 116. ProgKeys Settings for configuring the network, the date and time for the robot controller, and the ID of the controller. See Controller set- tings on page 112. Controller Settings Recalibration settings for the touch screen. See Calibrating the touch screen on page 118. Touch Screen Configuration of views for operating mode switch and UAS, User Authorization System. See Defining a view to be shown during operating mode change or startup on page 101. FlexPendant Configuration of the system parameters configuration. Configuration Operating manual - IRC5 with FlexPendant 69 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.10 Control Panel Continued

The Event Log Robot systems are often operated without any personnel present. The logging function is a way to store information about past events for future reference in order to facilitate troubleshooting. How to open the event log is described in Accessing the event log on page 283. Illustration Event Log The table is a brief summary of all actions that may be performed with the event log. xx0300000447 Description Function Tap the message. The message structure is described in An event log message on page 71. View a message See Scrolling and zooming on page 92. Scroll or zoom a message See Deleting log entries on page 284. Delete the log See Saving log entries on page 285. Save the log See Accessing the event log on page 283. Close the log Continues on next page 70 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.11 Event Log

Each event log entry consists of a message describing the event in detail, and it often contains advice on how to solve the problem. en0300000454 Event number. All errors are listed by numbers. A Event title. Briefly states what has happened. B Event time marker. Specifies exactly when the event occurred. C Description. A brief description of the event. Intended to assist in understanding the causes and implications of the event. D Consequences. A brief description of any consequences inflicted on the system, transition to other operation mode, emergency stop, caused by the particular event. Intended to assist in understanding the causes and implications of the event. E Probable causes. A list of probable causes, listed in order of probability. F Recommended actions. A list of the recommended correcting actions, based on the “Probable causes” specified above. These may range from “Replace the xx...” to “Run test program xx...”, i.e. may be actions to isolate the problem as well as fixing it. G Acknowledge or OK button. H Related information about logs Event log messages and more information about the event log are described in Operating manual - Troubleshooting IRC5. Operating manual - IRC5 with FlexPendant 71 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.11 Event Log Continued

About System Info System Info displays information about the controller and the loaded system. Here you can find the RobotWare version and options currently in use, current keys for control and drive modules, network connections, and so on. Illustration of System Info view en0400000968 Controller properties It contains controller and network information. When the Controller properties is expanded the following are visible: Service port and Local Area Network properties. Network connections List of installed systems. Installed systems System properties It contains information of the system that is currently in use. When the System properties is expanded the following are visible: Name and key of the Control Module. Control module Installed RobotWare options and languages. Options Lists all Drive Modules. Drive modules Name and key of Drive Module x. Drive module x Drive Module x options, with type of robot and so on. Options Any RobotWare options and Process application options. Additional options Continues on next page 72 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.12 System Info

is expanded the following are visible: Name and key of the Control Module. Controller Contains information of the main computer. Computer system Contains information of the Power supply unit. Power supply system Provides information about the panel board hardware and soft- ware. Panel board It contains information about the axis computer, drive unit, and contactor board. Drive module x Lists the data of Robots or external axes connected to the con- troller. Mechanical units Software resources It contains information about the RAPID. When the Software resources is expanded the following are visible: Contains information about system uptime and memory. System Software used by the controller. RAPID Memory allocated for RAPID programs. RAPID memory Shows the execution load. RAPID performance Contains information about Remote Service Embedded. Communication Operating manual - IRC5 with FlexPendant 73 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.12 System Info Continued

Tap the ABB menu and then Restart to restart the system. en0500001557 74 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.13 Restart

The Log Off menu This section details the Log Off menu. More about using this menu is described in Logging on and off on page 98. Log Off is available under the ABB menu. en0400000947 Operating manual - IRC5 with FlexPendant 75 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.2.14 Log Off

Operator window The operator window displays messages from the program. With Multitasking installed, all tasks’ messages are displayed in the same operator window. If a message requires action then a separate window for that task will be displayed. The operator window is opened by tapping the icon to the right of the ABB logo in the status bar. The illustration shows an example of an operator window: en0400000975 Clears all messages Clear Clears all messages Don’t Show Logs Hides task names Don’t Show Task Name 76 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.3 Operator window

Illustration of status bar The Status bar displays information about the current status, such as operational mode, system, and active mechanical unit. en0300000490 Operator window A Operating mode B System name (and controller name) C Controller state D Program state E Mechanical units. The selected unit (and any unit coordinated with the selected) is marked with a border. Active units are displayed in color, while deactivated units are grey. F Operating manual - IRC5 with FlexPendant 77 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.4 Status bar

Quickset menu The QuickSet menu provides a quicker way to change among other things jog properties rather than using the Joggingview. Each button on the menu shows the currently selected property value or setting. In manual mode, the Quickset menu button shows the currently selected mechanical unit, motion mode, and increment size. Illustration of the Quickset menu This section describes the buttons in the Quickset menu. en0300000471 Mechanical unit, see Quickset menu, Mechanical unit on page 79. A Increment, see Quickset menu, Increment on page 84. B Run Mode, see Quickset menu, Run Mode on page 85. C Step Mode, see Quickset menu, Step Mode on page 86. D Speed, see Quickset menu, Speed on page 87. E Tasks, see Quickset menu, Tasks on page 88. F 78 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.1 The Quickset menu

Illustration Mechanical unit button On the Quickset menu, tap Mechanical unit, then tap to select a mechanical unit. en0300000539 Mechanical unit menu button A Mechanical unit, a selected unit is highlighted. See Selecting mechanical unit for jogging on page 132. B Motion mode settings (axes 1-3 motion mode currently selected), further settings are described in Illustration Motion mode settings on page 80. C Tool settings (tool 0 currently selected), further settings are described in Illustra- tion Tool settings on page 81. D Work object settings (work object 0 currently selected), further settings are de- scribed in Illustration Work object settings on page 81. E Coordinate system settings (world coordinate currently selected), further settings are described in Illustration Coordinate system settings on page 82. F Turn coordination off , further settings are described in Turn coordination off on page 83. G Show details, further settings are described in Illustration Show Details on page 83. H Note The Mechanical unit menu is only available in manual mode. Continues on next page Operating manual - IRC5 with FlexPendant 79 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.2 Quickset menu, Mechanical unit

To view or change any motion mode functionality, tap the Motion mode settings button. These settings are also available in the Jogging window, see Selecting motion mode on page 134. en0300000540 Select motion mode setting: • Axis 1-3 • Axis 4-6 • Linear • Reorient Continues on next page 80 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.2 Quickset menu, Mechanical unit Continued

To view or change the available tools, tap the Tool settings button. These settings are also available in the Jogging window, see Selecting tool, work object, and payload on page 135. en0400000988 Illustration Work object settings To view or change the available work objects, tap the Work object settings button. These settings are also available in the Jogging window, see Selecting tool, work object, and payload on page 135. en0400000989 Continues on next page Operating manual - IRC5 with FlexPendant 81 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.2 Quickset menu, Mechanical unit Continued

Illustration Coordinate system settings To view or change coordinate system functionality, tap the Coordinate system settings button. These settings are also available in the Jogging window, see Selecting coordinate system on page 138. en0300000541 Select a coordinate system setting: • World coordinate system • Base coordinate system • Tool coordinate system • Work object coordinate system Continues on next page 82 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.2 Quickset menu, Mechanical unit Continued

Tap Show Details to display the settings available for a mechanical unit. en0500002354 Override jog speed settings (100% currently selected) A Coordinate system settings B Motion mode settings C Turn on or off user increment D Turn on or off jog supervision E If any of the settings are not available, they will crossed over. Motion mode and coordinate settings can be changed by tapping the buttons. Tap Hide Details to return to the basic display. Turn coordination off To quickly change between coordinated and uncoordinated jogging, use the coordination off button. The button is automatically hidden when you change anything that effects coordination, for example the work object or the coordinate system of the coordinated mechanical unit. To re-enable the button you must setup coordination again manually. For information about coordination between MultiMove robots, see Application manual - MultiMove. Operating manual - IRC5 with FlexPendant 83 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.2 Quickset menu, Mechanical unit Continued

Increment settings The increment settings are also available in the Jogging window. For more details, see Incremental movement for precise positioning on page 141. Illustration Increment en0300000542 No increments None Small movements Small Medium movement Medium Large movements Large User defined movements User Displays/hides increment values Show/Hide Values Defines the unit for the angles. Angle unit Note The Increment menu is available only in manual mode. 84 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.3 Quickset menu, Increment

Run mode By setting run mode you define if the program execution should run once and then stop, or run continuously. For information about run mode in: • Multitasking, see Application manual - Controller software IRC5, section Multitasking. • MultiMove, see Application manual - MultiMove, section User interface specific for Multimove. Illustration Run mode en0300000472 Runs one cycle then stops execution. Single Cycle Runs continuously. Continuous Operating manual - IRC5 with FlexPendant 85 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.4 Quickset menu, Run Mode

Step mode By setting the step mode you can define how the step-by-step program execution should function. For more details, see Stepping instruction by instruction on page214 Illustration Step mode en0300000543 Steps into called routines and executes them step-by-step. Step Into Executes the remains of the current routine and then stops at the next in- struction in the routine from which the current routine was called. Not possible to use in the Main routine. Step Out Called routines are executed in one single step. Step Over Steps to the next move instruction. Stops before and after movement in- structions, for example, to modify positions. Next Move Note If you select the Step Out/Step Over/Next Move step modes, an arrow icon ( ) is also displayed in the QuickSet menu indicating that the selected mode is not a Step Into step mode. 86 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.5 Quickset menu, Step Mode

Speed button The speed settings apply to the current operating mode. However, if you decrease the speed in automatic mode, the setting also applies to manual mode if you change mode. Illustration Speed Tap the Speed button to view or change the speed settings. The current running speed, in relation to max, is displayed above the buttons. en0300000470 Decrease running speed in steps of 1% -1% Increase running speed in steps of 1% +1% Decrease running speed in steps of 5% -5% Increase running speed in steps of 5% +5% Set speed to 0% 0% Run at quarter speed (25%) 25% Run at half speed (50%) 50% Run at full speed (100%) 100% Operating manual - IRC5 with FlexPendant 87 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.6 Quickset menu, Speed

Tasks button If you have the option Multitasking installed there can be more than one task. Otherwise there is only one task. By default, you can activate/deactivate only Normal tasks from the Quickset menu. However, from the Control Panel, you can change the settings so that All tasks can be activated/deactivated. Activated tasks are started and stopped with the Start and Stop buttons on the FlexPendant. The tasks settings are only valid for manual operating mode. Related information Application manual - Controller software IRC5, section Multitasking. How to start and stop multitasking programs is described in section Using multitasking programs on page 245. TrustLevel for tasks are set with system parameters, see section Task in Technical reference manual - System parameters. You can define if all tasks or only normal tasks should be displayed. See section Defining which tasks should be selectable in the tasks panel on page 107. 88 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.5.7 Quickset menu, Tasks

3.6.1 Using the soft keyboard Soft keyboard The soft keyboard is used frequently when operating the system, for example when entering file names or parameter values. The soft keyboard works as an ordinary keyboard with which you can place the insertion point, type and correct typing errors. Tap letters, numbers and special characters to enter your text or values. Illustration soft keyboard This illustration shows the soft keyboard on the FlexPendant. en0300000491 Using international characters All western characters can be used, also in usernames and passwords. To access international characters, tap the Int’l button on the soft keyboard. Continues on next page Operating manual - IRC5 with FlexPendant 89 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.1 Using the soft keyboard

Tap the arrow keys to change the insertion point, for instance when correcting typing errors. then tap... If you need to move... xx0300000492 backward xx0300000493 forward Deleting 1 Tap the Backspace key (top right) to delete characters to the left of the insertion point. xx0300000494 90 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.1 Using the soft keyboard Continued

Overview of messages The FlexPendant displays messages from the system. These can be status messages, error messages, program messages, or requests for action from the user. Some require actions, and some are plain information. Event log messages The event log messages are messages from the RobotWare system about system status, events, or errors. How to work with the event log messages is described in section Handling the event log on page 283. All messages are also described in Operating manual - Troubleshooting IRC5. System messages Some messages sent out by the system are not from the event log. They can come from other applications, such as RobotStudio. To be able to change configurations and settings in the system from RobotStudio, the user must request write access. This generates a message on the FlexPendant where the operator can grant or deny access. The operator can at any time decide to withdraw the write access. How to request access and work with RobotStudio is described in Operating manual - RobotStudio. Program messages RAPID programs can send out messages to the Operator window, see section Operator window on page 76. How to generate program messages is described in Technical reference manual - RAPID Instructions, Functions and Data types. Operating manual - IRC5 with FlexPendant 91 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.2 Messages on the FlexPendant

Overview The entire contents of a screen might not be visible at the same time. To see the entire contents, you can: • Scroll up/down (and sometimes left/right) • Zoom in or out (only available in the Program Editor) en0400000685 Zoom in (larger text) A Scroll up (the height of one page) B Scroll up (the height of one line) C Scroll left D Scroll right E Zoom out (smaller text) F Scroll down (the height of one page) G Scroll down (the height of one line) H 92 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.3 Scrolling and zooming

Filtering data In several of the FlexPendant menus you can use filtering. This can be useful when you are looking at instances of a data type, for example, and there are more available than is possible to overlook. By filtering instances starting with a specific character for example, the number can be greatly reduced. Depending on the type of data, you can filter data either alphabetically or numerically. Illustration of filtering The filter function is switched on until the active filter is removed (For example, by tapping Reset). en0500001539 Note When filtering I/O signals there are more options than for many other types of data. For example, • you can filter data by Name or Category. • filtering function can be displayed automatically if the number of signals displayed exceeds a predefined number. See Illustration of automatic filter display on page 95. Continues on next page Operating manual - IRC5 with FlexPendant 93 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.4 Filtering data

items. Active filter Clears the text within the Active filter text box. Clear Removes the filter string. Reset Depending on type of data, there may be one or several ways to filter data, e.g. numeric, alphabetic. 123 / ABC Applies the filter. Filter Opens and closes the Active filter menu. en1100000506 Continues on next page 94 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.4 Filtering data Continued

The I/O signal filter can be set to be displayed automatically if the number of data exceeds a predefined number. en0600002643 Action Tap Change to edit the setting controlling when the filter dialog should appear. 1. Enter a new number defining the upper limit for not using the filter. Then tap Done. 2. Tap Virtuals to select if all, or only virtual, or only non virtual signals should be listed. 3. Operating manual - IRC5 with FlexPendant 95 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.4 Filtering data Continued

Process applications Custom process applications are started from the ABB menu. Each application is listed as a menu item together with the FlexPendant views. Start a process application Use this procedure to start a process application. Action Tap the ABB button to display the ABB menu. Process applications are listed in the menu. 1 Tap the name of the process application to start. 2 Switch between started process applications A started application has a quick-button in the taskbar, just like FlexPendant views. Tap the buttons to switch between the started applications and views. en0400000768 The views and process application running in this case are: FlexPendant Explorer view A Program Editor view B RobotWare Arc, a process application C Control Panel view D 96 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.5 Process applications

About write access on the controller The controller accepts only one user with write access at a time. Users in RobotStudio can request write access to the system. If the system is running in manual mode, the request is accepted or rejected on the FlexPendant. Granting access for RobotStudio This procedure describes how to grant access for RobotStudio. Action When a user in RobotStudio requests access, a message is displayed on the FlexPend- ant. Decide whether to grant or reject access. 1 If you want to grant access, then tap Grant. The user holds write access until he dis- connects or until you reject the access. If you want to deny access, then tap Deny. If you have granted access and want to revoke the access, tap Deny. 2 Note For a system connected to T10, users in RobotStudio can request write access by pressing the enabling device twice and logging in as a local client. Operating manual - IRC5 with FlexPendant 97 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.6 Granting access for RobotStudio

Logout procedure Use this procedure to log off the system. Action On the ABB menu, tap Log Off. 1 Tap Yesto confirm. 2 Login procedure Use this procedure to log on to the controller, using the User Authorization System, UAS. UAS can limit the available functions for users. After a log off, the Login window is displayed automatically. en0400000947 Information Action If you select Default User, then no pass- word is required, and you are logged on automatically. Tap on the User menu and select a user. If there are more than seven users then the menu is replaced with a button. 1 If the user you have chosen has a pass- word you must use the soft keyboard to enter password. Tap ABC... to display the soft keyboard. 2 Enter the password and tap OK. TapLogin. 3 Continues on next page 98 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.7 Logging on and off

Read more on how to add users or set the authorization in Operating manual - RobotStudio. How to edit what views or functions are hidden for certain users is described in Defining a view to be shown during operating mode change or startup on page101. Operating manual - IRC5 with FlexPendant 99 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.6.7 Logging on and off Continued

3.7.1 System settings 3.7.1.1 Setting default paths Introduction to default paths You can set individual default paths for some actions using the FlexPendant. The following default paths can be set: • Saving and loading RAPID programs. • Saving and loading RAPID modules. • Saving and storing configuration files. This function is available if the user that is logged on is authorized. User authorization is handled via RobotStudio. See Operating manual - RobotStudio. Setting default paths Use this procedure to set a default path. Action On the ABB menu, tap Control Panel and then FlexPendant. 1 Tap File System Default Path. en0500002361 2 Tap the File type menu to choose type of default path: • RAPID programs • RAPID modules • Configurations files 3 Type the default path or tap Browse, to choose the desired location. 4 If required, any previously entered path can be removed by tapping Clear. 5 Tap OK. 6 100 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Revision: G © Copyright 2018 ABB. All rights reserved. 3 Navigating and handling FlexPendant 3.7.1.1 Setting default paths