ABB Setup Instructions (RobotWare 6)

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This guide shows you how to set up Master-Control communication with an ABB robot.

Check Controller and Software Compatibility

The robot controller is IRC5, and the version of RobotWare is 6.02 or above.

Follow the steps below to check the RobotWare version.
The following control modules should be installed:
- 623-1 Multitasking
- 616-1 PCInterface
Follow the steps below to check whether the control module options are installed.

The above control module options must be installed to realize Master-Control of an ABB robot.

Set up the Network Connection

Connect the Hardware

Plug the Ethernet cable of the IPC into the X6 (WAN) port of the robot controller, as shown below.

Set the IP Address

You can set the IP on the teach pendant or via RobotStudio.

Set the IP address on the teach pendant

Please follow the instructions in the figure below to set the IP address.
After restarting, you will see the interface as shown below. Follow the instructions below to complete configuring the IP address. The IP addresses of the robot and the IPC must belong to the same subnet.

Set the IP address via RobotStudio

Follow the steps as shown below to configure the robot IP, and restart the robot after configuration.

Check if the IP configuration was successful

Go to System Info Network connections WAN to check if the IP configuration was successful after restarting.

Please ensure that the Ethernet cable is connected to the X6 (WAN) network port of the robot controller.
When setting the IP address, be careful not to confuse the IP address of the WAN port with the LAN port.

Load the Program Files to the Robot

Prepare the Files

Backup

Before operating the robot, please follow the backup instructions below to back up the system so that the robot system can be restored if an incorrect operation occurs. You can backup the robot system via the teach pendant or RobotStudio.

Backup on the teach pendant
1. Go to the home page using the menu in the upper-left corner, and then select Restart.
2. Select Backup Current System….
3. Specify the backup file name by pressing on ABC…, and specify the directory for saving the file by pressing the button below. Then, press Backup in the lower-right to start the backup process.
Backup in RobotStudio
1. In the main interface of RobotStudio, select the controller you want to backup, and then select Backup Create Backup….
2. In the pop-up window, confirm the backup name and location and then click OK.

Reset

There are two types of resets, which are resetting the system and resetting RAPID.

Resetting the system will restore the default system parameters and RAPID program, and the I/O configuration will be reset too. If a communication board or other communication devices are used, they should be re-configured after the system is reset.
Resetting RAPID will delete the current RAPID program and data, while the system parameter settings will be retained.

Reset RAPID

Please determine whether you should reset RAPID according to the following flowchart.

Go to the home page using the menu in the upper-left corner, and then select Restart.
Select Advanced… in the lower-left.
Select Reset RAPID, and then press Next in the lower-right.
Press Reset RAPID.

Reset System

Resetting the system will restore the factory settings. Please make sure that you have completed the backup operation.

Go to the home page using the menu in the upper-left corner, and then select Restart.
Select Advanced… in the lower-left.
Select Reset system, and then press Next in the lower-right.
Press Reset system.

Obtain the Program Files

Copy the program files into a USB flash drive. Please locate the folder where Mech-Mind Software Suite is installed and the files are stored in Mech-Center/Robot_Server/Robot_FullControl/abb/server on ABB.

The config files in the server on ABB folder should be compatible with the I/O Unit in use. Please choose the right config files from the config folders according to the actual situation.
- If a DSQC 652 I/O unit is used, please select D652.cfg and SYS.cfg.
- If a DSQC 1030 I/O unit is used, please select DSQC1030.cfg and SYS.cfg.
- If other I/O unit is used or the program is only used for automatic calibration, please select EIO.cfg and SYS.cfg.
The files in the MM folder in the server on ABB folder are robot program modules.

Load the Files to the Robot

Open RobotStudio on the IPC and connect to the controller.
- If the robot controller is connected via the LAN port, click One Click Connect….
- If the robot controller is connected via the WAN port or a switch, click Add Controller and then select the controller and click OK. If the controller is added successfully, RobotStudio will be connected to the service port of the controller automatically.
Request Write Access

Click Request Write Access to request the write access to the teach pendant.

Press Grant in the Request Write Access window on the teach pendant.
Import the config files as shown below. Click Confirm in the pop-up windows.
Copy the whole MM folder in the server on ABB folder and paste it to the HOME directory of the robot system, as shown below. Restart the controller to complete loading the program files.
Modify the safe zone threshold (in mm) in the safe_area.mod program according to the actual on-site work space of the robot.

Configure I/O System

If an I/O unit other than DSQC 652 or DSQC 1030 is used, you should configure the robot I/O system after loading the program. Please follow the steps below to proceed:

In the main interface of RobotStudio, select Configuration IO System.
Locate and click Signal in the Type column, locate gi16 and go16 in the Name column on the right, and then double-click to enter the edit window.
After confirming the corresponding devices and device mapping, modify the values of Assigned to Device and Device Mapping for gi16 and go16 respectively.
After the configuration, click OK. Then restart the controller to make the changes take effect.

Run the Program

Move the PP of tasks T_ROB1 and safe_area to Main respectively. After selecting PP to Main, if a window as shown below pops up, please tap Yes to confirm.
Run the program manually or automatically. The program pointer is shown in the figure below.

Test Robot Connection

Please refer to Test Robot Connection.

Troubleshooting

If the program has been loaded but the robot cannot be connected successfully, please check whether the following requirements have been met.

IPC side:
- The firewall is turned off.
- The IPC can communicate with the robot IP address with the ping command in the command prompt.
- There is no interference from any antivirus software.
- Two network ports of the IPC belong to different subnets and there is no conflict.
- If the IPC is connected via a router, there is no interference from other network cables.
Robot side:
- The Ethernet cable is connected to the WAN port of the controller properly.
- The robot IP address is set correctly. Please ensure that the set IP address is that of the WAN port instead of others.
- You have run the program on the robot side.

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