ABB IRC5 Compact Operating instructions

ROBOTICS

Operating manual

Troubleshooting IRC5

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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

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.

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

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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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3HAC020738-001 Revision: AA

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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3HAC020738-001 Revision: AA

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

Continues on next page

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1 Safety

1.3 Safety symbols on controller labels

Continued

ABB IRC5 Compact Operating instructions

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