3HAC024534-001 Revr en

Product specification
Robot User Documentation
IRC5
Product specification
Robot User Documentation

3HAC024534-001
Rev R
IRC5
M2004
© Copyright 2004-2010 ABB. All rights reserved.
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, fit-
ness 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 per-
mission, and contents thereof must not be imparted to a third party nor be used for any unau-
thorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
©Copyright 2004-2010 ABB All rights reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of Contents
1 Introduction 5
1.1 Easy-to-use Information Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 User Documentation DVD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Ordering User Documentation DVD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Type of manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Robotics manuals 11
2.1 Languages and article number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 DVD documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Operating manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Technical reference manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Application manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Product manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Product specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3HAC024534-001 Revision: R 3
4
Table of Contents
3HAC024534-001 Revision: R
1 Introduction
1.1 Easy-to-use Information Products
1 Introduction
1.1 Easy-to-use Information Products

Introduction to Robot User Documentation
The Robot User Documentation is aimed at all robot users, providing easy to use
information and guidelines as well as in-depth descriptions and detailed reference
literature.
There is a robot user document for each stage of use, from installation and commis-
sioning, through programming, operation and maintenance to troubleshooting and
decommissioning of your robot system.
ABB’s group of skilled editors provide professional user documentation, ensuring
efficient communication of robot expertize, from our engineers to your personnel.
Key benefits
• Easy-to-use user documentation
• In-depth reference information
• Detailed product information
• Maintenance and service procedures
1 Introduction
1.2 User Documentation DVD
1.2 User Documentation DVD

There is one documentation DVD including all robot user documentation.
Robot user documentation is translated into 17 languages, including a number of
Asian languages, according to the EU machine directive. Documents that are not
translated are available in English.
Updates of the documentation DVD are released at every major product change
(Robot, Controller, and RobotWare).
The documentation browser appears automatically on your PC screen at startup of
the DVD. The DVD format provides advantages such as easy search, copy and paste,
printing pages, etc.
6 3HAC024534-001 Revision: R
1 Introduction
1.3 Ordering User Documentation DVD
1.3 Ordering User Documentation DVD

DVD
All robot user documentation can be ordered on a DVD. The DVD is ordered using
the standard Robot Specification form.
The documentation DVD can also be ordered through Robotics Aftersales. Send the
order to: Robotics Aftersales/SEROP/ABB@ABB
ABB Library
Updated versions of all user documentation can be found in ABB Library
(inside.abb.com/library). ABB Library is a fast and easy way to find updated robot
information and can be accessed by all ABB employees.
Printed manual
There is one manual that is delivered also as a printed version together with the robot
system. The manual is Emergency safety information, which is translated to 17 lan-
guages.
1 Introduction
1.4 Type of manual
1.4 Type of manual

Operating manuals
The Operating manuals are directed to persons with first hand contact with the robot
system, that is production operators, programmers, and service personnel.
Technical reference manuals

The Technical reference manuals include reference information on RobotWare, the
controller software. The manuals include syntax and detailed information on instruc-
tions, functions, and data types in the RAPID language and on system parameters.
For reference information on mechanics and electronics, please refer to the Product
Manual.
Application manuals
The Application manuals describe RobotWare base functionality and options,
directed to specific applications, such as RobotWare Arc, Spot, Dispense.
The content includes:
• Purpose of the option: For what is the option intended?
• What is included in the option, for example RAPID instructions, system parameters.
• Which hardware is required, for example cables and I/O boards.
• Setup, programming, and configuration examples.
Application manual - Motion functions and events (3HAC18152-1)

This manual explains the basics of RobotWare base functionality and options:
• World Zones
• Fixed Position Events
• Independent Axis
• Path Recovery
• Path Offset © Copyright 2004-2010 ABB. All rights reserved.
Application manual - Motion performance (3HAC18153-1)

This manual explains the basics of RobotWare options:
• Advanced Shape Tuning
• Absolute Accuracy
• Wrist Move
Application manual - Motion coordination and supervision (3HAC18154-1)

This manual explains the basics of RobotWare options:
• Collision Detection
• Sensor Synchronization
• Analog Synchronization
1 Introduction
1.4 Type of manual
Application manual - Servo motor control (3HAC020436-001)

• Servo Tool Change
• Servo Tool Control
• Electronically Linked Motors
Application manual - Robot communication and I/O control (3HAC020435-001)

• File and Serial Handling
• Fieldbus Command Interface
• Logical Cross Connections
• Analog Signal Interrupt
• PC Interface
• FTP and NFS Client
• Socket Messaging
• RAPID Message Queue
Application manual - Engineering tools (3HAC020434-001)

• Multitasking
• Advanced RAPID
• Sensor Interface
• Auto Acknowledge Input
Product manuals
There is a Product Manual for each robot and controller.
The content includes:
• Safety information
• Installation and commissioning

• Maintenance (Service schedules and preventive maintenance routines)
• Repair (Lists of spare parts and repair procedures)
• Calibration procedures
• Decommissioning procedures
• Reference Information
• Part list
• Foldouts or exploded views
• References to circuit diagrams
1 Introduction
1.4 Type of manual
2 Robotics manuals
2.1 Languages and article number
2 Robotics manuals
2.1 Languages and article number
Article numbers
The article number for a manual or the documentation DVD is the same for all lan-
guages except for the subnumber (language code).
Example:
Art. no. Manual

3HAC16590-2 Operating manual - IRC5 with FlexPendant
(Swedish)
3HAC16590-7 Operating manual - IRC5 with FlexPendant
(Italian)
3HAC026320-011 Product manual - IRB 1410
(Korean)
3HAC026320-005 Product manual - IRB 1410
(Spanish)
Language codes
The manuals are available in the following languages (with matching subnumber).
Language Subnumber/language code

English 1
Swedish 2
German 3
French 4
Spanish 5
Portuguese 6
Italian 7
Danish 8
Dutch 9
Chinese 10
Korean 11
Japanese 12
Finnish 13
Czech 14
Polish 15
Russian 16
Hungarian 17
2 Robotics manuals
2.2 DVD documentation
2.2 DVD documentation

The Documentation DVD contains all languages.
Art. no. DVD Documentation Option no.

3HAC032875-001 DVD Documentation, M2004 808-1
2 Robotics manuals
2.3 Operating manuals
2.3 Operating manuals
Art. no. Manual

3HAC027098-001 Emergency safety information
(English, Swedish, German, French, Spanish, Portuguese, Italian, Danish,
Dutch, Chinese, Korean, Japanese, Finnish, Czech, Polish, Russian, Hungarian)
3HAC031045-0xx General safety information
Dutch, Chinese, Korean, Japanese, Finnish, Czech, Polish, Russian)
3HAC027097-0xx Getting started, IRC5 and RobotStudio
3HAC16590-x IRC5 with FlexPendant
3HAC020738-0xx Trouble shooting - IRC5
3HAC024764-0xx Plastics Mould and DieCast
(English, Swedish, German, French, Spanish, Italian, Dutch, Chinese, Japanese)
3HAC16578-x Calibration Pendulum
(English, German, French, Spanish, Italian)
3HAC025709-00x Service Information System - IRC5
3HAC029364-00x Introduction to RAPID
3HEA801212-00x AW Introduction and safety, IRC5
(English, Swedish, German, French, Spanish, Italian, Dutch)
3HAC031146-00x System description - Arc Welding Products, IRC5
3HAC031147-00x Arc Welding Products, IRC5
3HEA802921-00x Weldguide - Seam tracking with Weldguide and Multi Pass functionality
3HAC032104-00x RobotStudio
(English, German, French, Spanish, Italian, Japanese)
3HAC030420-001 Machining PowerPac
(English)
3HAC026808-001 MachineTending PowerPac
(English)
3HAC028931-001 ArcWelding PowerPac
(English)
3HAC036590-001 Bending PowerPac
(English)
2 Robotics manuals
2.4 Technical reference manuals
2.4 Technical reference manuals
Art.no. Manual
3HAC16585-1 RAPID kernel
(English)
3HAC16580-x RAPID overview
3HAC16581-x RAPID Instructions, functions and data types
3HAC17076-x System parameters
2 Robotics manuals
2.5 Application manuals
Art.no. Manual Option no.

3HAC021395-00x Additional axes and stand alone controller 435-99, 766-1, 753-1,
(English, German) 753-2, 753-3, 754-1,
754-2, 754-3, 755-1,
755-2, 755-3, 770-1,
770-2, 770-3, 770-4,
771-1, 771-2, 771-3,
771-4, or 907-1
3HAC020676-00x DeviceNetTM 709-1, 709-2, 709-4,
(English, German) or 709-5
3HAC034095-001 DeviceNet LeanTM 748-1
(English)
3HAC023008-00x PROFIBUS-DP master/slave 711-1
(English, German)
3HAC023009-00x INTERBUS master/slave
(English, German)
3HAC031975-001 PROFINET master/slave 888-1
(English, German)
3HAC033466-001 EtherNet/IPTM master/slave 841-1
(English)
3HAC028509-001 EtherNet/IPTM Fieldbus Adapter 840-1
(English)
3HAC029338-001 PROFIBUS Fieldbus Adapter 840-2
(English, German)
3HAC031974-001 PROFINET Fieldbus Adapter 840-3
(English)
3HAC037311-001 Integrated PLC 923-1, 924-1, 925-1,
(English) 926-1, 934-1
3HAC18152-x Motion functions and events 608-1, 610-1, 611-1,
(English, German) or 612-1

3HAC18153-x Motion performance 602-1, 603-1, or
(English, German) 603-2
3HAC18154-1 Motion coordination and supervision 607-1, 607-2, or
(English) 613-1
3HAC16587-x Conveyor tracking 606-1 or 606-2
(English, German)
3HAC020436-001 Servo motor control 629-1 or 630-1
(English)
3HAC020435-00x Robot communication and I/O control 614-1 or 616-1
(English, German)
3HAC020434-00x Engineering tools 623-1, 628-1, or
3HAC021272-00x MultiMove 604-1 or 604-2
3HAC16591-x Arc and Arc Sensor 633-1
(English, German)
2 Robotics manuals

3HAC16593-x Dispense 641-1
(English, German)
3HAC024762-00x Spot options 635-1, 635-3, or
3HAC16584-1 Continuous Application Platform 624-1
(English)
3HAC16586-1 Discrete Application Platform 625-1
(English)
3HAC025093-00x Plastics Mould and Diecast 675-1 or 875-1
(English)
3HAC024846-00x BullsEye 652-1
(English, German)
3HAC024844-001 Production Manager 633-1 or 812-1
(English)
3HAC024845-001 SmarTac 657-1 or 657-2
(English, German)
3HAC024847-001 Torch Services 653-1 or 653-2
(English)
3HAC025810-001 Navigator 814-1
(English)
3HAC025057-001 Force Control Assembly 661-2
(English)
3HAC027595-001 Force Control Machining 877-1
(English)
3HAC026806-001 Production Monitor 659-1
(English)
3HAC026820-001 Servo Gun Tuning 629-1
(English)
3HAC027711-001 Weld Data Monitor 659-1
(English)
3HAC027709-00x Electronic Position Switches 810-1 © Copyright 2004-2010 ABB. All rights reserved.
3HAC031978-001 PickMaster 3 (Picking) 642-1
3HAC025829-001 PickMaster 5 (Palletizing) 642-2
(English)
3HAC036957-001 PC SDK
(English)
3HAC036958-001 FlexPendant SDK
(English)
3HAC028797-001 Mechanical Unit Manager
(English)
3HAC030053-00x SafeMove 810-2
3HAC030266-001 SoftMove 885-1
(English)
2 Robotics manuals

3HAC031094-001 Laser Tracker Calibration 1250-1
(English)
3HAC032189-001 Tool Change Support 630-1
(English)
3HAC031973-001 Robot Reference Interface 897-1
(English)
3HAC031149-001 Signal description - Arc Welding Products, IRC5
(English)
3HEA802578-001 Software installation - Arc Welding System, IRC5
Design 2006
(English)
3HAC031148-001 System settings - Welding Robot System, IRC5
(English)
3HEA802924-001 Programming Integrated Power Source, IRC5
(English)
3HEA802920-001 Fronius TPS 4000/5000 IRC5 Interface 650-9
(English)
3HAC028879-001 Remote Service 890-1
(English)
2 Robotics manuals
2.6 Product manuals
2.6 Product manuals
Art. no. Manual

3HAC035728-001 IRB 120
(English, German, French, Spanish, Italian, Chinese, Japanese)
3HAC027400-00x IRB 140 Type C
3HAC026320-00x IRB 1410
(English, German, French, Spanish, Italian, Chinese, Korean)
3HAC023637-00x IRB 1600 Type 0
3HAC026660-00x IRB 1600 Type A
(English, German, French, Spanish, Italian, Polish)
3HAC022031-00x IRB 2400
3HAC035504-00x IRB 2600
(English, German)
3HAC022032-00x IRB 4400/4450S
3HAC033453-00x IRB 4600
3HAC027076-00x IRB 6400RF
3HAC020993-00x IRB 6650S
3HAC027151-00x IRB 6620
3HAC035737-00x IRB6620LX
3HAC026876-00x IRB 6640
(English, German, French, Spanish, Italian, Japanese) © Copyright 2004-2010 ABB. All rights reserved.
3HAC028197-00x IRB 6660
3HAC022033-00x IRB 7600
3HAC030005-00x IRB 360
3HAC026048-00x IRB 260
3HAC025755-00x IRB 660
(English, German, French, Spanish, Italian, Russian)
3HAC021313-00x IRC5 Robot Controller
(English, German, French, Spanish, Italian, Russian, Japanese)
3HAC027707-00x IRC5 Panel Mounted Controller
2 Robotics manuals
2.6 Product manuals
Art. no. Manual

3HAC035738-001 IRC5Compact
(English, German, French, Spanish, Italian, Chinese)
3HAC032103-00x DressPack/SpotPack IRB 6650S, 7600
3HAC027309-00x Dresspack/SpotPack IRB 6620
3HAC028638-00x DressPack/SpotPack IRB 6640
3HAC028506-00x IRBT 4004/6004/7004/IRT104
3HEA800973-00x Motor Unit, MU 10/20/30
(English, Swedish, German, French, Spanish, Italian)
3HEA802345-00x Positioner control equipment, Design 2006
3HEA802346-00x Safety equipment, IRBP B/C/D/K/R, Design 2006
3HEA802348-00x Safety equipment, IRBP A/L/S, Design 2006
501105-50x Torch cleaner TC96
3HAC029959-00x Process interface
3HEA801225-00x IRBP 250A/500A/750A
3HEA801226-00x IRBP 250B/500B/750B
3HEA801223-00x IRBP 500C/1000C
3HEA801227-00x IRBP 250D/500D

3HEA801222-00x IRBP 250K/500K/750K
3HEA801220-00x IRBP 250L/500L/750L/2000L/5000L
3HEA801221-00x IRBP 250R/500R/750R
3HAC035232-001 IRBP Y-X
(English)
3HEA801228-00x MTC 250/500/750/2000/5000
3HAC031150-00x RTT 1600/2400L, IRC5
3HEA802350-00x Operator panel, IRC5 Design 2006
3HEA802351-00x Manual jog, IRC5 Design 2006
2 Robotics manuals
2.6 Product manuals
Art. no. Manual

3HAC026930-00x Bullseye, IRC5
3HAC028299-001 Remote Service
(English)
2 Robotics manuals
2.7 Product specifications
Art. no. Specification

3HAC022349-001 Controller Software IRC5, RobotWare 5.0
3HAC022871-001 (English, German, French, Spanish, Italian, Japanese)
3HAC023049-001
3HAC022845-001
3HAC022844-001
3HAC022349-012
3HAC021785-001 Controller IRC5 with FlexPendant
3HAC022903-001 (English, German, French, Spanish, Italian)
3HAC022906-001
3HAC022904-001
3HAC022905-001
3HAC035960-00x IRB 120
(English, German, French, Spanish, Italian, Chinese)
3HAC9041-1 IRB 140
3HAC10320-1
3HAC10319-1
3HAC10323-1
3HAC026366-001 IRB 1410
(English)
3HAC023604-00x IRB 1600
3HAC9112-1 IRB 2400
3HAC10766-1
3HAC10759-1
3HAC10780-1
3HAC035959-00x IRB 2600

3HAC9117-1 IRB 4400
3HAC10768-1
3HAC10761-1
3HAC10782-1
3HAC032885-00x IRB 4600
3HAC026552-00x IRB 6400RF
3HAC030822-00x IRB 6650S
3HAC025861-00x IRB 6620
3HAC036094-00x Linear Axis
2 Robotics manuals
Art. no. Specification

3HAC028284-00x IRB 6640
3HAC028207-00x IRB 6660
3HAC023934-00x IRB 7600
3HAC029963-00x IRB 360
3HAC024046-00x IRB 260
3HAC023932-00x IRB 660
3HAC028283-00x Positioner IRBP Stand alone
3HAC034078-00x Positioner IRBP Y-X
3HEA802965-00x Track motion, IRBT 4004/6004/7004
3HAC028561-001 Track motion, RTT 1600/2400
3HAC5842-12 PickMaster 3
(English)
3HAC5842-9 PickMaster 5
(English)
3HAC025595-001 Robot Application Builder
(English)
3HAC026932-001 RobotStudio
(English)
3HAC025796-001 WebWare Server
(English)
3HAC024534-001, Revision R, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000

3HAC024534-001 Revr en

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Product specification

Robot User Documentation

Robot User Documentation

©Copyright 2004-2010 ABB All rights reserved.

1.1 Easy-to-use Information Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Languages and article number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Easy-to-use Information Products

1.2 User Documentation DVD

© Copyright 2004-2010 ABB. All rights reserved.

1.3 Ordering User Documentation DVD

1.4 Type of manual

Technical reference manuals

Application manual - Motion functions and events (3HAC18152-1)

Application manual - Motion performance (3HAC18153-1)

Application manual - Motion coordination and supervision (3HAC18154-1)

Application manual - Servo motor control (3HAC020436-001)

Application manual - Robot communication and I/O control (3HAC020435-001)

Application manual - Engineering tools (3HAC020434-001)

• Installation and commissioning

© Copyright 2004-2010 ABB. All rights reserved.

2.1 Languages and article number

Art. no. Manual

Language Subnumber/language code

2.2 DVD documentation

Art. no. DVD Documentation Option no.

© Copyright 2004-2010 ABB. All rights reserved.

2.3 Operating manuals

Art. no. Manual

2.4 Technical reference manuals

© Copyright 2004-2010 ABB. All rights reserved.

2.5 Application manuals

Art.no. Manual Option no.

(English, German) or 612-1

Art.no. Manual Option no.

Art.no. Manual Option no.

2.6 Product manuals

Art. no. Manual

Art. no. Manual

(English, Swedish, German, French, Spanish, Italian, Dutch)

Art. no. Manual

© Copyright 2004-2010 ABB. All rights reserved.

2.7 Product specifications

Art. no. Specification

(English, German, French, Spanish, Italian)

Art. no. Specification

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