ABB IRC5 Safe Move Setup

1. Measure out the fence line (in millimeters) in relation to robot base with robot
base coordinates. If your robot is on a 7th axis, make your measurements in
world coordinates, not base coordinates. With a 7 th axis robot, X+ will be in
the Positive direction on the track with Z+ Upward. If there is a fence that the
robot cannot reach such as the opposite fence on the other side of the
transfer, just make an imaginary fence line at 5000mm from robot.
2. In robot studio, click Authenticate , Log In As A Different User, and then
logon as the Safety User. On the MX1 line, the password is
BMW_ABB_Safety. All F25 lines are BMW_F25_Safety. Click on Safety
Configuration. Select SafeMove1. Click on the Configuration tab and
select Upload From Controller If there is not currently a configuration in the
controller a message will be displayed stating that. Skip this step and just
start inputting your data as described in the following steps on the blank form
that came up when you opened the Safety Configuration.
3. You will always be dealing with MTZ1 & MTZ2. MTZ1 is 18 inches (460mm)
from the actual fence line and MTZ2 is the physical fence line. If there are no
operator load areas and no places where a HiLo loads racks, you will be
dealing with only MTZ1 and MTZ2. If there are operator load areas or areas
where a HiLo loads racks, those will be MTZ3 - MTZx. Click on Activation and
I/O. For each MTZ used, assign the corresponding Output ID to that MTZ.
NOTE : If a fence line is an internal fence, you do not have
to reduce it by 460mm for MTZ1;
4. Click on Monitor Tool Zone. Set Max Tool Speed In Zone to 6000 (6000 for
all MTZs). Fill out the dimensions for each MTZ that you mapped. For all
MTZs, for Top under Zone Height, input 5000mm. Bottom will be 0 if
robot is on the floor. If the robot is on a riser, this will be the negative of the
height of the riser. Check Allow Inside for MTZs 1 & 2 and uncheck Allow
Inside for all Op-Load MTZs. If you shorten the height of the Op-Load MTZ so
that the robot can pass over without breaking the zone, make sure you are
doing so WITHOUT a part in the gripper, especially a large one.
5. Click on the Synchronization tab. In the box labeled Synchronization,
select the type of sync you are using on this robot. In most cases, this needs
to be set to Software Synchronization.
6. Create a Sync position near HOME but is far enough that it is out of the
HOME world zone. Mod Pos this position in the program mvSyncSwitch.
With the robot at your sync position, Click on the Synchronization tab in
robot studio. Click Get Current Axis Positions.
7. Click the Cyclic Break Check tab. Make sure Enable Cyclic Break Check is
NOT checked.
8. If you are using the ToolBox feature, Click on Mechanical Units and fill in the
dimensions of the virtual box encompassing your tool. Each point in your tool

box you measure out needs to be input into the Safe Move configuration as it
is depicted in the diagram on that page.
9. If you have a 7th axis robot, Click on Mechanical Units then click the Track
1 tab and set Servo Lag (rad) to 20.
10.Click on Calibration Offsets, click Get From Manipulator, click Download
To Safe Move.
11.Click the Configuration Tab and select Save to save this configuration.
Make sure to name it with the robot name because all Safe Move
Configurations for all robots have the same default save name so it will
overwrite a previous one you have saved if you do not rename it.
12.Click Configuration, Download To Controller. Save the Safety
Configuration Report that pops up to your computer and record the PIN
number that is displayed. Make sure to name it with the robot name because
all Safe Move Configurations for all robots have the same default save name
so it will overwrite a previous one you have saved if you do not rename it.
Click OK on the bottom of the report. NOTE: You have to click OK on the
report that pops up or the configuration will not be loaded.
13.Another screen will pop up that has the PIN number on it and asks if you
would like to restart the robot. If you have Write Access you can restart by
clicking YES. If you do not have Write Access, click No and do a Warm Start
from the teach pendant. When the robot comes back up after the restart,
Login as Safety User then click the ABB button in the top left of the teach
pendant screen. Select Control Panel, and select Safety Controller. Input
the PIN you were given from the Configuration Report. Another window will
pop up saying the PIN was accepted and that another restart is needed.
Select restart.
14.When the robot comes back up after that restart, it will not be Syncd and you
will need to push the motors button on the robot cabinet before you can
move the robot. On the teach pendant, run the program mvSyncSwitch.
The robot will now be syncd.
15.Open the I/O screen, select Units, select Safety Signals and scroll down to
the PSC1DO(X) outputs. Jog the robot around watching the outputs
PSC1DO(X) where X corresponds to the MTZ number. Jog to the fence lines
you programmed to verify that they are accurate. When you reach the fence
lines, you should see the corresponding PSC1DO output drop. Same goes with
the Operator/HiLo load areas.

Mechanical Units
Servo Lag 7th axis 20.00
Start Speed 100