ABB IRC5 Compact Operating instructions

Type
Operating instructions
ROBOTICS
Operating manual
Troubleshooting IRC5
Trace back information:
Workspace R18-2 version a12
Checked in 2018-10-16
Skribenta version 5.3.008
Operating manual
Troubleshooting IRC5
RobotWare 6.08
Document ID: 3HAC020738-001
Revision: AA
© Copyright 2005-2018 ABB. All rights reserved.
Specifications subject to change without notice.
The information in this manual is subject to change without notice and should not
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 2005-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
Table of contents
7Overview of this manual ...................................................................................................................
111 Safety
111.1 Safety signals in the manual ................................................................................
131.2 Safety symbols on product labels .........................................................................
191.3 Safety symbols on controller labels ......................................................................
231.4 Safety during troubleshooting ..............................................................................
241.5 Applicable standards .........................................................................................
261.6 Safety tools ......................................................................................................
271.7 Safe troubleshooting ..........................................................................................
271.7.1 Robot without axes' holding brakes are potentially lethal ................................
281.7.2 Live voltage inside Drive Module ................................................................
301.7.3 Hot parts may cause burns .......................................................................
312 Introduction to troubleshooting
312.1 Overview of troubleshooting ................................................................................
332.2 Standard toolkit ................................................................................................
342.3 Tips and tricks while troubleshooting ....................................................................
342.3.1 Troubleshooting strategies ........................................................................
362.3.2 Work systematically .................................................................................
372.3.3 Keeping track of history ............................................................................
382.4 Filing an error report ..........................................................................................
413 Troubleshooting by fault symptoms
413.1 Start-up failures ................................................................................................
433.2 Controller not responding ...................................................................................
443.3 Low controller performance .................................................................................
463.4 All LEDs are off at controller ................................................................................
483.5 No voltage in service outlet .................................................................................
503.6 Problem starting the FlexPendant .........................................................................
513.7 Problem connecting FlexPendant to the controller ...................................................
523.8 Erratic event messages on FlexPendant ................................................................
533.9 Problem jogging the robot ...................................................................................
543.10 Reflashing firmware failure ..................................................................................
553.11 Inconsistent path accuracy .................................................................................
563.12 Mechanical noise or dissonance ..........................................................................
583.13 Manipulator crashes on power down .....................................................................
593.14 Problem releasing Robot brakes ..........................................................................
613.15 Intermittent errors .............................................................................................
623.16 Force starting of Boot Application ........................................................................
634 Troubleshooting by unit
634.1 Troubleshooting LEDs in the controller ..................................................................
654.2 Troubleshooting the FlexPendant .........................................................................
664.3 Troubleshooting communications .........................................................................
674.4 Troubleshooting fieldbuses and I/O units ...............................................................
684.5 Troubleshooting the computer unit .......................................................................
704.6 Troubleshooting the panel board ..........................................................................
724.7 Troubleshooting the drive system .........................................................................
744.8 Troubleshooting the axis computer .......................................................................
764.9 Troubleshooting the system power supply .............................................................
814.10 Troubleshooting the power distribution board .........................................................
864.11 Troubleshooting the contactor interface board ........................................................
884.12 Troubleshooting the customer I/O power supply .....................................................
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Table of contents
915 Troubleshooting by event log
915.1 Event log messages ..........................................................................................
925.2 How to read RAPID event log messages ................................................................
945.3 1 xxxx .............................................................................................................
1205.4 2 xxxx .............................................................................................................
1605.5 3 xxxx .............................................................................................................
2125.6 4 xxxx .............................................................................................................
3255.7 5 xxxx .............................................................................................................
3665.8 7 xxxx .............................................................................................................
4055.9 9 xxxx .............................................................................................................
4505.10 11 xxxx ............................................................................................................
5385.11 12 xxxx ............................................................................................................
5415.12 13 xxxx ............................................................................................................
5805.13 15 xxxx ............................................................................................................
5815.14 17 xxxx ............................................................................................................
5836 Circuit diagrams
5836.1 Circuit diagrams ................................................................................................
587Index
6 Operating manual - Troubleshooting IRC5
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© Copyright 2005-2018 ABB. All rights reserved.
Table of contents
Overview of this manual
About this manual
This manual contains information, procedures and descriptions, for troubleshooting
IRC5 based robot systems.
Usage
This manual should be used whenever robot operation is interrupted by malfunction,
regardless of whether an error event log message is created or not.
Who should read this manual?
This manual is intended for the following personnel:
• Machine and robot operators qualified to perform very basic troubleshooting
and reporting to service personnel.
• Programmers qualified to write and change RAPID programs.
• Specialized troubleshooting personnel, usually very experienced service
personnel, qualified for methodically isolating, analyzing and correcting
malfunctions within the robot system.
Prerequisites
The reader should:
• Have extensive experience in troubleshooting industrial electro-mechanical
machinery.
• Have in depth knowledge of the robot system function.
• Be familiar with the actual robot installation at hand, its surrounding
equipment and peripherals.
References
Document IDReference:
3HAC021313-001Product manual - IRC5
IRC5 of design M2004
3HAC047136-001Product manual - IRC5
IRC5 of design 14
3HAC027098-001Operating manual - Emergency safety information
3HAC031045-001Operating manual - General safety information
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC032104-001Operating manual - RobotStudio
3HAC027097-001Operating manual - Getting started, IRC5 and RobotStudio
3HAC050948-001Technical reference manual - System parameters
3HAC050961-001Application manual - MultiMove
The product documentation is available in several languages.
Continues on next page
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© Copyright 2005-2018 ABB. All rights reserved.
Overview of this manual
Revisions
DescriptionRevision
First edition.-
Information has been added.A
The document has been partly restructured.
Information on how to submit error report has been changed.B
Information on RAPID change logs have been added.
Event log messages have been added.
Updated Event log messages.C
Updated Event log messages.D
Updated Event log messages.E
Minor corrections. Updated Event log messages.F
Minor corrections. Updated Event log messages.G
New information in section Serial Measurement Unit regarding the battery
pack.
H
More detailed information about troubleshooting power supplies DSQC
604, 661 and 662.
Removed safety I/O signals: DRV1PANCH1, DRV1PANCH2, DRV1SPEED.
New drive system introduced. Drive System 04 and Drive System 09 are
both described.
Released with RobotWare 5.13.J
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 11.
• New safety labels on the manipulators, see Safety symbols on
product labels on page 13.
• Updated the graphic in the section Live voltage inside Drive Module
on page 28.
The contents in the following sections were updated:
• Corrections regarding drive system information in chapter Descrip-
tions and background information.
• Restructured the chapters as per the new document startergy.
• Updated the graphic in the Recommended actions of the section No
voltage in service outlet on page 48.
• Updated the Possible causes in the section Problem starting the
FlexPendant on page 50.
• Updated the graphics in the section LEDs in the Control Module.
• Updated the graphic in Possible causes of the section Problem re-
leasing Robot brakes on page 59.
Updated Event log messages.K
Released with RobotWare 5.14.L
Event number series on page 92 added.
Released with RobotWare 5.14.02.M
Updated Event log messages.
Released with RobotWare 5.15.N
Updated Event log messages.
Released with RobotWare 5.15.01.P
Updated the section Overview of troubleshooting on page 31.
Continues on next page
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Overview of this manual
Continued
DescriptionRevision
Released with RobotWare 5.60.
• The document has been partly restructured.
• New main computer DSQC1000 is introduced.
• Old main computer DSQC 639 is removed throughout the manual.
• The dual controller is removed throughout the manual.
• Updated Event log messages.
Q
Released with RobotWare 5.61.
• Added a note in the section Event number series on page 92.
• Added Slovenian Event log messages.
• Added the Event log message io_elogtext.xml.
• Updated the name of the connectors and other minor updates in
Troubleshooting the system power supply on page 76 and
Troubleshooting the power distribution board on page 81.
R
Released with RobotWare 6.0.
• Added information on Restarting a locked FlexPendant on page 65.
• Added information on Type of event log messages on page 91.
• Added the Event log message pymc_elogtext.xml.
S
Released with RobotWare 6.01.
• Added the description of event log message types. See Type of
event log messages on page 91.
• Added a note on the possibility of a slight difference between the
English event logs and translated event logs in Type of event log
messages on page 91.
T
Released with RobotWare 6.02.
• Added Safety tools on page 26.
U
Released with RobotWare 6.03.
• Added event logs for functional safety, see 9 xxxx on page 405.
• Added event logs for Connected Service Embedded, see 17 xxxx
on page 581.
V
Released with RobotWare 6.04.
• Updated event logs for RobotWare 6.04.
W
Released with RobotWare 6.05.
• New main computer DSQC1024 is introduced.
• Updated event logs for RobotWare 6.05. Added the event logs for
Integrated Vision.
X
Released with RobotWare 6.06.
• Updated event logs for RobotWare 6.06.
• Removed main computer DSQC1024.
Y
Released with RobotWare 6.07.
• Updated event logs for RobotWare 6.07.
• Safety section restructured.
Z
Released with RobotWare 6.08.
• Updated event logs for RobotWare 6.08.
AA
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Overview of this manual
Continued
This page is intentionally left blank
1 Safety
1.1 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.
SignificanceDesignationSymbol
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)
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1 Safety
1.1 Safety signals in the manual
SignificanceDesignationSymbol
Describes important facts and conditions.NOTE
Describes where to find additional information or
how to do an operation in an easier way.
TIP
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1 Safety
1.1 Safety signals in the manual
Continued
1.2 Safety symbols on product labels
Introduction to labels
This section describes safety symbols used on labels (stickers) on the product.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 13.
The information labels can contain information in text (English, German, and
French).
Symbols on safety labels
DescriptionSymbol
Warning!
xx0900000812
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly 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.
Caution!
xx0900000811
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.
Prohibition
xx0900000839
Used in combinations with other symbols.
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1 Safety
1.2 Safety symbols on product labels
DescriptionSymbol
See user documentation
xx0900000813
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
Before disassemble, see product manual
xx0900000816
Do not disassemble
xx0900000815
Disassembling this part can cause injury.
Extended rotation
xx0900000814
This axis has extended rotation (working area) compared to
standard.
Brake release
xx0900000808
Pressing this button will release the brakes. This means that
the robot arm can fall down.
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1 Safety
1.2 Safety symbols on product labels
Continued
DescriptionSymbol
Tip risk when loosening bolts
xx0900000810
The robot can tip over if the bolts are not securely fastened.
xx1500002402
Crush
xx0900000817
Risk of crush injuries.
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1 Safety
1.2 Safety symbols on product labels
Continued
DescriptionSymbol
Heat
xx0900000818
Risk of heat that can cause burns. (Both signs are used)
3HAC 4431-1/06
!
xx1300001087
Moving robot
1
2
3
4
5
6
xx0900000819
The robot can move unexpectedly.
xx1000001141
1
2
3
4
xx1500002616
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1 Safety
1.2 Safety symbols on product labels
Continued
DescriptionSymbol
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
Chain sling with shortener
xx1000001242
Lifting of robot
xx0900000822
Oil
xx0900000823
Can be used in combination with prohibition if oil is not allowed.
Mechanical stop
xx0900000824
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1 Safety
1.2 Safety symbols on product labels
Continued
DescriptionSymbol
No mechanical stop
xx1000001144
Stored energy
xx0900000825
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
Pressure
xx0900000826
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
Shut off with handle
xx0900000827
Use the power switch on the controller.
Do not step
xx1400002648
Warns that stepping on these parts can cause damage to the
parts.
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1 Safety
1.2 Safety symbols on product labels
Continued
1.3 Safety symbols on controller labels
Introduction to labels
This section describes safety symbols used on labels (stickers) on the controller.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The safety and health symbols on the labels on the product must be observed.
Additional safety information given by the system builder or integrator must also
be observed.
Types of labels
Both the manipulator and the controller are marked with several safety and
information labels, containing important information about the product. The
information is useful for all personnel handling the robot, for example during
installation, service, or operation.
The information labels can contain information in text (English, German, and
French).
Symbols on safety labels
DescriptionLabel
Electrical shock
xx1400001151
ESD sensitive components inside the controller.
xx1400001162
Disconnect power supply before servicing the controller.
xx1400001161
Disconnect power supply before servicing the controller (only
for welding equipment).
xx1400001160
Disconnect power supply before servicing the controller (for
controllers without UL mains switch).
xx1700000354
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1 Safety
1.3 Safety symbols on controller labels
DescriptionLabel
High voltage inside the module even if the main switch is in
the OFF position.
xx1400001156
Lifting instruction for the IRC5 controller.
xx1400001157
Required installation space.
xx1400001155
QR code for ABB Basic Care service agreement.
xx1400001154
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1 Safety
1.3 Safety symbols on controller labels
Continued
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ABB IRC5 Compact Operating instructions

Type
Operating instructions

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