Course Descriptions

Note: It is highly recommended to bring a backup of your system to classes you attend.

Click each subject below to learn more about the courses we offer.

Robot Operations

Programming

Electrical Troubleshooting

Body in White Flexlifter and PLP

Robotic Washer

Online Interactive Web Based Training Robot Operations
for Material Handling, Arc Welding, LaserCutting, Spot Welding

Course Code: US519

The goal of this Web Based Training is to teach students how to operate the robot and modify positions using the FlexPendant.

Topics include:
- Safety
- System Description
- Event Messages
- Performing Basic Operations
- Movement Instructions
- Inputs and Outputs Introduction

Course objectives: After successfully completing the course, the participant should be able to:

- Identify personal safety solutions
- Identify robot safety features
- Identify robot system components
- Move/Jog the robot using the joystick
- Interpret and respond to event messages
- Perform basic operations
- Modify movement instructions in a basic program 
- Demonstrate how to use the input and output instructions in a basic program 
- Demonstrate how to save robot information

Student profile: This course is intended for personnel responsible for starting and operating the robot.

Operators and non-skilled laborers

Prerequisites: No formal requirements.

Duration:
Course duration is 5-6 hours. It is self paced and must be taken within 30 days of enrollment.

Robot Operations for Material Handling, Arc Welding, LaserCutting, Spot Welding

IRC5 – 2 days – Course Code: US419
S4/S4C/S4C+ - 2 days – Course Code: US302

Topics include:
- Safety precautions used while programming and program execution
- Operating controls and indicators on the robot controller
- Instruction identification and program flow
- Positioning the robot by use of joystick control
- Basic program modification techniques

Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Identify and use the teach pendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages
- Load, save, and edit basic programs using the teach pendant
- Modify movement instructions in a basic program
- Use input and output instructions in a basic program
- Manually execute portions of a basic program

Student profile: This course is intended for personnel responsible for starting and operating the robot.
- Operators and non-skilled laborers

Prerequisites:
- No formal requirements.

Robot Operations for Paint

Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Identify and use the paint teach pendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages
- Load, save, and edit basic programs using the paint teach pendant
- Use input and output instructions in a basic program
- Use, describe and edit paint process instructions

Student profile: This course is intended for personnel responsible for starting and operating the robot.
- Operators and non-skilled laborers

Prerequisites:
- No formal requirements

Programming I for Material Handling

IRC5 – 4½ days – Course Code: US420
S4/S4C/S4C+ - 4½ days – Course Code: US312

The course goal is to teach students how to operate and program the robot using the teach pendant.

Topics include:

Course objectives
After successfully completing the course, the participant should be able to:

Student profile: This course is intended for personnel responsible for operating the robot, creating programs and editing programs. Such as:

Prerequisites:
No formal requirements

Programming II for Material Handling

Topics Include:
- Building and configuring Robot Software
- Online and offline program editing
- Advanced declarations of modules, routines and data
- Programming with interrupts and Traps
- Searching and program displacements
- Error handling, backward handling, and undo handling
- Advanced motion instruction
- World zones

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Create, Configure, and Download system software
- Create and Use Modules, Routines, and Data
- Create advanced Tool Center Points
- Program with Search Instructions
- Program with Position Displacement Instructions
- Program using Error Handling
- Program Interrupt Instructions, Traps, and Events
- Use Joint Configuration Instructions
- Setup and program World Zones
- Use Motion Control Instructions

Student profile: This course is intended for people that have attended the Programming I for Material Handling class course but require greater knowledge of programming features.
- System programmers or technicians with existing / developing programming skills

Prerequisites:
- Programming I for Material Handling class (US312 or US420)

Programming III for Material Handling

The goal of this course is to provide instruction in high level programming features and techniques. Designed for students who have successfully completed the IRC5 Programming II for Material Handling (US425) or S4 Programming II for Material Handling (US313) class, and who need a greater depth of knowledge. This course does not provide a review of any previous programming class. This class starts where the S4 / IRC5 Programming II for Material Handling course left off.

Topics include:
- Multitasking programming techniques
- Creating instructions, functions, and data
- Serial communication capabilities
- Load ID and collision detection
- Advanced program displacement
- World zones
- Uploading and downloading of programs
- Using OPC
- User Authorization System

Course objectives: After successfully completing the course, the participant should be able to:
- Create background tasks
- Create custom instruction
- Create custom functions
- Create custom data types
- Transfer information via serial channel
- Setup load ID and collision detection
- Manipulate data values
- Program robot to load and unload programs
- Define zones for monitoring
- Setup and basic use of OPC
- Setup user levels and grants

Student profile: This training is targeted for system programmers or engineers with advanced programming skills.

Prerequisites:
- Programming II for Material Handling (US425 or US313).

Programming for Paint

Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Identify and use the controls necessary for robot operation
- Run robot system in manual or automatic mode
- Interpret and respond to error codes
- Load, create, save, delete, check and edit basic programs using the paint teach pendant, RobotStudio, ShopFloor Editor and Robview 5 software
- Verify robot synchronization using the calibration method
- Use movement instructions in a basic program
- Use input and output instructions in a basic program
- Learn proper use of routine instructions
- Add and use PaintWare functionally into a program
- Teach line tracking with a moving conveyor
- Teach object tracking with a moving conveyor

Student profile: This course is intended for students that are required to start and operate the robot, create programs, and edit programs.
- Engineers
- Service personnel
- System integrators
- Supervisory personnel

Prerequisites:
- No formal requirements
- Understanding of Windows or computer programming is helpful

Programming I for Spot Welding

IRC5 – 4½ days – Course Code: US491

Topics include:
- Safety precautions while programming and operating the robot system
- Operator controls and indicators on the FlexPendant and operators panel
- Overview of spot cell functionality
- Overview of spot process equipment functionality
- Program Creation Procedures
- Utilization of the spot welding instructions
- Equipment setup
- Correct positioning of the robot using the FlexPendant and various motion types
- FlexPendant menus and displays for entry of welding routines, program commands and spot data

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the Robot and the welding system
- Safely start up the controller and move the Robot using the joystick
- Identify and use all the buttons on the FlexPendant
- Interpret and respond to Event Messages
- Load, create, save, delete, check or edit programs using the Robot FlexPendant
- Verify Robot calibration offsets
- Define a TCP, using the 5 point method
- Use movement and spot welding instructions in a basic welding routine
- Set up the spot weld equipment
- Create and execute routines
- Use work objects for Jogging and movement reference

Student profile:
- Welding cell programmers and engineers

Prerequisites:
- Spot welding experience
- Microsoft PC operating training or experience for Windows 3.1, 95, or NT

Programming I for Arc Welding

IRC5 – 4½ days – Course Code: US490

Topics include:
- Safety precautions while programming and operating the robot system
- Operator controls and indicators on the FlexPendant and operators panel
- Correct positioning of the robot using the FlexPendant and various motion types
- Creating and using Work Objects
- Setting up Base Frames
- Production Manager structure and operation
- ArcWare program commands and functions
- FlexPendant menus and displays for entry of welding routines, program commands and weld data
- Positioning of the part using a positioner
- Setting-up and using the ABB “BullsEye” device to create and check tool center points

Course objectives: After successfully completing the course, the participant should be able to:
- Safely operate robot welding cell
- Create routines using proper structure
- Operate and use the “Production Manager” program to create new welded part programs and modify existing programs
- Save and load part programs to and from disk
- Setup Base Frame
- Use work objects for position reference
- Perform and save system parameters
- Use the positioner to properly orient the part for welding
- Recognize and recover from basic system errors

Student profile:
- Welding cell programmers and engineers

Prerequisites:
- GMAW training or similar welding experience
- Microsoft PC operating training or experience for Windows 3.1, 95, or NT

Programming II for Arc Welding

IRC5 – 4½ days – Course Code: US495

Topics include:
- Safety precautions used while programming and program execution
- Operating controls and indicators on the robot controller
- Positioning the robot by use of joystick control
- Program creation procedures
- Setup and configure the robot
- Program displacement instructions
- Use interrupt instructions and trap routines
- Production Manager and GAP
- Use instructions to enhance robot performance
- Weld Guide III
- SmarTac to include 1D searching and touch sensing, and laser searching

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify and use FlexPendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages
- Set-up and download software
- Create and define tool center point/BullsEye
- Setup coordinated motion
- Discuss multi-move concepts
- Use error handlers for welding and interrupts and trap routines
- Use welding instructions
- Perform robot searches, displacements, using the SmarTac concepts, and the Search 1D with the touch sensor and laser sensor
- Set-up the Weld Guide III and weld a part

Student profile: This course is intended for personnel responsible for starting and operating the robot, creating programs and editing programs.
- Engineers
- Service personnel
- System integrators
- Supervisory personnel

Prerequisites:
- Programming I for Arc Welding (US490)

Accelerated Programming for Material Handling (Integrators Only)

IRC5 – 4½ days – Course Code: US426

This course is designed for students with strong programming skills (not necessarily ABB products). A quick paced combination of our IRC5 Programming I for Material Handling (US420) & IRC5 Programming II for Material Handling (US425) courses, this course provides a brief overview of IRC5 Programming I for Material Handling (US420), then instruction in IRC5 Programming II for Material Handling (US425) features and techniques.

Topics include:
- Safety precautions used wile programming and program execution
- Operating controls and indicators on the robot controller
- Positioning the robot by use of joystick control
- Program creation procedures
- Program modification techniques
- Setup programmable keys
- Interpret and respond to error codes
- Creating and using Tool Center Points
- Creating and using Work Objects
- Identify and manipulate data values
- Apply the theory of singularity at a basic level to anticipate problem areas in programs
- Use the search instruction and error handling instructions
- Use program displacement instructions
- Use interrupt instructions and trap routines
- Use event handling routines
- Use advanced I/O instructions
- Use instructions to enhance robot performance
- Use the Multitasking

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify and use the FlexPendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages
- Load, create, save, delete, check, and edit basic programs using the FlexPendant and RobotStudio Online software
- Verify robot synchronization using a calibration routine
- Create and Define a tool center point
- Use movement instructions in a basic program
- Use input and output instructions in a basic program
- Create routines, and use routine instructions in a basic program
- Use decision making instructions in a basic program
- Use registers and math instructions in a basic program
- Use FlexPendant communication instructions in a basic program
- Use time instructions in a basic program
- Use offsets for movement instructions
- Use work objects for position reference
- Dynamically change data values
- Use instructions to avoid singularity
- Perform robot searches, displacements, and error handling
- Program interrupts and Trap routines
- Create and use background tasks

Prerequisites:
- This course is intended for someone who has a strong robot programming background, but is not familiar with ABB robots.

Programming I for LaserCutting

IRC5 – 4½ days – Course Code: US496

The goal of the course is to train the student to safely use the FlexPendant to create laser cut routines, set and change cut data and edit existing programs.

Topics include:
- Overview of laser cell functionality
- Overview of laser process equipment functionality
- Program Creation Procedures Within the Production Manager Environment
- Utilization of the Laser Cut Instructions
- Shape Tuning Methods

Course objectives: After successfully completing the course, the participant should be able to:
- Operate the functionality of the laser cell
- Perform the functionality of the laser process components of the cell
- Operate the functionality and use of Production Manager
- Set up the Laser Cell and equipment
- Create new laser cut programs from the FlexPendant

Student profile:
- Engineers
- Maintenance technicians

Prerequisites:
- Laser processing knowledge is recommended

Electrical Troubleshooting (non-Paint Robots)

IRC5 – 4½ days – Course Code: US421
S4C+ – 4½ days – Course Code: US357

Topics include:
- Theory of operation of the robot controller
- Safety precautions used while troubleshooting the robot controller electrical system
- Description of components in the robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo-system
- Input/output interfacing between the robot controller and peripheral equipment

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify and use the teach pendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages. Use event logs
- Identify different parts of the robot modules and arm
- Load system software
- Troubleshoot Power ON circuits
- Troubleshoot computer and drive system to a board level
- Troubleshoot Motors ON / Run Chains circuits
- Troubleshoot the Motors, brakes, and resolvers
- Properly calibrate the robot after a motor change

Interface an input device and an output device to the robot

Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- Programming I for Material Handling (US420), Programming I for Arc Welding (US490), Programming I for LaserCutting (US496), or Programming I for Spot Welding (US491) is strongly recommended.

Electrical Troubleshooting (Paint Robots)

Topics include:
- Theory of operation of the robot controller
- Safety precautions used while troubleshooting the IRC5P robot controller electrical system
- Description of components in the robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo-system
- Input/output interfacing between the IRC5P robot controller and peripheral equipment

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify different parts of the robot controller and manipulator
- Troubleshoot computer and drive system to a board level
- Load system software and system operating parameters
- Interface an input and an output device to the robot controller
- Interpret and respond to event message – use event logs
- Troubleshoot power ON circuits
- Troubleshoot purge circuits
- Troubleshoot Motors ON / run chains circuits
- Troubleshoot the motors, brakes, and resolvers

Student profile:
- Industrial electricians
- Electrical Troubleshooting technicians
- Engineers
- Supervisory personnel

Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- Programming I for Paint (US340 or US341) is strongly recommended

Electrical Troubleshooting (Panel Mounted Controller)

IRC5 – 4½ days – Course Code: US439

Topics include:
- Theory of operation of the IRC5 robot controller
- Safety precautions used while troubleshooting the IRC5 robot controller electrical system
- Description of components in the IRC5 PickMaster robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo-system
- Input/output interfacing between the IRC5 robot controller and PickMaster 3 equipment

Course objectives: After successfully completing the course, the participant should be able to:
- Operate the IRC5 control panel and programming unit
- Read and interpret ABB circuit diagrams on the IRC5 robot controller
- Calibrate resolvers and revolution counters
- Analyze and interpret system fault codes
- Troubleshoot and repair basic electrical faults
- Analyze servo-system
- Diagnose and rectify emergency stop conditions
- Make I/O connections to peripheral equipment and safety devices
- Repair and replacement of systems components
- Review “Cold-Boot” procedure

Student profile:
- Industrial electricians
- Electrical service technicians
- Engineers
- Supervisory personnel

Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- PickMaster 3 (Vision) (US418) is strongly recommended

IRB 120 Electrical & Mechanical Maintenance

IRC5 – 4½ days – Course Code: US370

Topics include:
- Theory of operation of the IRC5 Compact robot controller
- Safety precautions used while troubleshooting the IRC5 Compact robot controller electrical system
- Description of components in the IRC5 Compact robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo system
- Input / Output interfacing between the IRC5 Compact robot controller and peripheral equipment
- Proper safety precautions used while performing mechanical repair
- Operation of robot control and mechanical unit
- Description and operation of mechanical components
- How to use manual for repair and ordering of spare parts

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify and use the FlexPendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages, use event logs
- Identify different parts of the robot modules and arm
- Load system software
- Troubleshoot Power ON circuits
- Troubleshoot computer and drive system to a board level
- Troubleshoot Motors ON/Run Chains circuits
- Troubleshoot the Motors, brakes, and resolvers
- Calibrate the robot
- Interface an input device and an output device to the robot
- Perform safety precautions used while doing mechanical repair
- Properly start-up, operate and shutdown the robot
- Describe the operation of mechanical components
- Disassemble and reassemble mechanical unit
- Use the manual for repair and ordering of spare parts
- Describe preventive maintenance procedures on the robot
- Calibrate robot

Student profile:
- Industrial electricians
- Electrical Troubleshooting technicians
- Engineers
- Supervisory personnel
- Industrial personnel required to mechanically repair the robots and to perform regular preventive maintenance

Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- Programming I for Material Handling (US420) is strongly recommended
- Mechanical background or experience is helpful

Flexlifter and PLP Operations and Maintenance

IRC5 – 4½ days – Course Code: US479

Topics include:
- Proper safety precautions used while working with the equipment
- Description and operation of mechanical components
- Description and operation of electrical components including the IRC5 Controller
- Setting up and accurately running an existing and a new job / recipe

Course objectives: After successfully completing the course, the participant should be able to:
- Perform safety precautions used while doing periodic maintenance
- Start-up and shut-down the robot correctly
- Describe the operation of mechanical and electrical components
- Make modifications to the program for new positions
- Perform preventive maintenance procedures on the robot
- Perform a backup of the programs on the IRC5 controller side

Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive maintenance
- Operations personnel required to operate and modify existing jobs

Prerequisites:
- Mechanical background or experience is helpful
- Industrial and HMI experience is helpful

Robotic Washer, Electrical Maintenance

IRC5 – 1 day – Course Code: US471
The course goal is to provide skilled trades personnel and overview of the ABB Robotic Washer, and instruction on how to troubleshoot and repair the ABB Robotic Washer. The training will also include diagram overview and system component interfaces. This course provides instruction to personnel involved with the operations of the ABB Robotic Washer and is structured to provide a combination of classroom lecture and hands-on training. Task certification sheets will be documented to ensure understanding course content.

Topics:
- Safety precautions used while operating the ABB Robotic Washer
- ABB Robotic Washer component location and description
- Operating procedures (start-up, shut-down, e-stop, etc.)
- Preventive maintenance requirements
- Basic troubleshooting & fault recovery
- Electrical architecture (PLC) and PLC/robot interface of the cells
- Review cell electrical diagrams
- Review HMI screens
- Electrical troubleshooting techniques
- Fault recovery techniques

Course Objectives: After successfully completing the course, the participant should be able to:
- State the purpose, function, location, and operating characteristics of major electrical and controls components associated with the ABB Robotic Washer
- Demonstrate the ability to identify and locate safety devices on the cell
- Recognize requirements for safe operation and maintenance
- Demonstrate the ability to read and interpret the system electrical schematics
- Identify control devices and process screens in HMI operator panels
- Identify PLC/robot interface used in the cell
- Demonstrate the ability to interpret fault messages and repair the fault
- Identify electrical failures and possible cell failures

Student Profile: This course is intended for personnel responsible for starting, operating and electrically maintaining the ABB Robotic Washer.
- Skilled Trades Electricians
- Supervisors

Prerequisites- One of the following courses listed must be taken:
- ABB Robotic Washer, On-Line Operator Course
- Programming I for Material Handling (US420)
- Electrical Troubleshooting (US421)
- Electrical schematic reading
- Basic knowledge of automated assembly equipment
- Basic understanding of Windows operating systems and computer skills (identification of hardware and terminology)
- Electrical Journeymen Status

Robotic Washer, Mechanical Maintenance

IRC5 – 1 day – Course Code: US472
The course goal is to provide skilled trades personnel and overview of the ABB Robotic Washer, and instruction on how to mechanically maintain the ABB Robotic Washer. This course provides instruction to personnel involved with the operations of the ABB Robotic Washer and is structured to provide a combination of classroom lecture and hands-on training. Task certification sheets will be documented to ensure understanding course content.

Topics:
- Proper safety precautions used while performing mechanical repair
- Maintenance and mechanical repair of cell components
- Operating procedures (start-up, shut-down, e-stop, etc.)
- Basic review of PM requirements
- Mechanical fault identification
- Mechanical troubleshooting techniques
- Hydraulic and pneumatic cell adjustments
- Cell component lubrication

Course Objectives: After successfully completing the course, the participant should be able to:
- Demonstrate knowledge of equipment safety features
- Demonstrate knowledge of system operating procedures
- Demonstrate the ability to operate the cell using HMI control screens and manual push button panels
- Locate and identify all major system components
- Demonstrate the ability to perform preventive maintenance tasks
- Demonstrate the ability to maintain the washer mechanical components (media roll, filters, UV light, valves)
- Demonstrate the ability to troubleshoot the system using the HMI fault codes
- Locate each cell component lubrication point and describe lube requirement
- Demonstrate knowledge of cell hydraulic HPU’s and components
- Demonstrate knowledge of pneumatic cell components
- Demonstrate the ability to troubleshoot mechanical, hydraulic and pneumatic problems associated with the cell components

Student Profile: This course is intended for personnel responsible for starting, operating, maintaining, and mechanically repairing the ABB Robotic Washer.
- Skilled trades personnel required to mechanically repair and adjust the components

Prerequisites - One of the following courses listed must be taken:
- ABB Robotic Washer, On-Line Operator Course
- Basic knowledge of automated assembly equipment
- Basic understanding of Windows operating systems and computer skills (identification of hardware and terminology)
- Basic engine assembly buildup operation and processes
- Mechanical Journeymen Status
- Mechanical component blueprint reading and understanding capabilities
- Hydraulic and pneumatic schematic reading

Mechanical Maintenance

Advanced Applications

RobotStudio

Mechanical Maintenance (non-Paint Robots)

IRB 140 – 2 days – Course Code: US423
IRB 360 – 2 days – Course Code: US424
IRB 1600 – 2½ days – Course Code: US415
IRB 1520ID / IRB 1600ID / IRB 2600ID – 2½ days – Course Code: US372
IRB 2400 / IRB 4400 – 2½ days – Course Code: US377
IRB 2600 / IRB 4600 – 2½ days – Course Code: US374
IRB 6600 / IRB 6650 / IRB 7600 – 2½ days – Course Code: US416
IRB 6640 – 2½ days – Course Code: US432
IRB 6700 - 2½ days- Course Code: US433
IRB1200 - 2½ days - Course Code: US454

Topics include:
- Proper safety precautions used while performing mechanical repair
- Operation of robot control and mechanical unit
- Description and operation of mechanical components
- How to use manual for repair and ordering of spare parts

Course objectives: After successfully completing the course, the participant should be able to:
- Perform safety precautions used while doing mechanical repair
- Properly start-up, operate, and shutdown the robot
- Describe the operation of mechanical components
- Disassemble and reassemble mechanical unit
- Use the manual for repair and ordering of spare parts
- Describe preventive maintenance procedures on the robot
- Calibrate robot
- Perform assembly disassembly of the upper arm according to product manual

Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive maintenance

Prerequisites:
- Mechanical background or experience is helpful

Mechanical Maintenance (Paint Robots)

Topics:
- Proper safety precautions used while performing mechanical repair
- Operation of robot control and mechanical unit
- Description and operation of mechanical components
- How to use manual for repair and ordering of spare parts

Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive maintenance

Prerequisites:
- Mechanical background or experience is helpful

Mechanical Maintenance with Process Arm (Paint Robots)

Topics include:
- Proper safety precautions used while performing mechanical repair
- Theory of operation of robot controller and mechanical unit
- Description and operation of mechanical components
- Overview of paint process arm components
- How to use manual for repair and ordering of spare parts

Course objectives: After successfully completing the course, the participant should be able to:
- Perform safety precautions used while doing mechanical repair
- Properly start-up, operate, and shut-down the robot
- Describe the operation of mechanical components
- Disassemble and reassemble mechanical unit
- Use the manual for repair and ordering of spare parts
- Identify and describe the paint process components
- Overview the 2x2 valves
- Overview of paint process arm preventive maintenance procedures
- Perform preventive maintenance procedures on the robot
- Calibrate robot with calibration fixtures

Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive maintenance

Prerequisites:
- Mechanical background or experience is helpful.
- Ability to navigate through the paint teach pendant

ABB Integrated Vision

4½ days – Course Code: US460

ABB Robotics training is here to help you utilize your robot’s full potential. The ease of use of ABB robots is unmatched but there are still many benefits to further training. Training on ABB products and systems can be provided to students on site, in an external training facility, or through e-learnings & webinars.

Course goal
The goal of this course is to teach the students how to use the ABB Integrated Vision hardware and software for use with IRC5 controllers. This class will cover everything that the general user would need to know.

Included content
• ABB Integrated Vision Overview
• ABB Integrated Vision Installation
• Basic Lighting and Optics
• Getting Started
• Calibrate Camera and Robot
• Find It, check it, track it
• Programming the Robot
• Error Handling
• Multiple Targets
• Distinguishing Between Parts
• The FlexPendant Interface
• Using the Film Strip
• Backup and Restore Vision Information
• Changing Image Parameters on the Fly
• Parallax Compensation
• Virtual Robot, Real Camera

Course objectives
After successfully completing the course, the participant should be able to:
• Describe ABB Integrated Vision components
• Install and setup ABB Integrated Vision Components
• Describe common vision applications
• Describe the fundamentals of lighting and optics
• Use RobotStudio® Integrated Vision software
• Calibrate a camera
• Train a part for location
• Perform part inspection
• Perform code reading
• Output results to RAPID
• Create RAPID program using Vision results
• Use FlexPendant interface
• Troubleshoot common vision problems

Student profile
• Engineering personnel that are interested in ABB Robot Vision
• Those responsible for programming and maintaining ABB Robot Vision

Prerequisites
• IRC5 Programming I (US420) within last 12 months
-- OR IRC5 Programming I for Integrators (US426)
-- OR IRC5 Programming I for Welding (US490)
-- OR IRC5 Programming I for Spot Welding (US491)
• Working knowledge of RobotStudio is helpful
• IRC5 Programming II (US425) is recommended

US428 FlexVision

4½ days – Course Code: US428

ABB Robotics training is here to help you utilize your robot’s full potential. The ease of use of ABB robots is unmatched, but there are still many benefits to further training. Training on ABB products and systems can be provided to students on site, in an external training facility, or through e-learnings & webinars.

Course goal
The purpose of this course is to provide personnel with a better understanding of how the FlexVision system functions, how to create vision tasks and validate the performance efficiency of the program. This will enable personnel to program and safely maintain the vision equipment.
Included content
• Safety precautions while working with FlexVision
• Interfaces between FlexVision system and robot
• Vision components and how they work
• System operation
• Validating program efficiency
• Troubleshooting and recovery

Course objectives
After successfully completing the course, the participant should be able to:
• Describe ABB FlexVision components
• Install and setup ABB FlexVision components
• Describe the fundamentals of lighting and optics
• Describe FlexVision camera alignment/configs
• Calibrate a camera
• Describe pattern recognition and teaching features
• Be able to train and modify features
• Be able to improve feature performance & accuracy
• Be able to reference features (3D coord)
• Use vision system to locate part
• Use validation tools to understand results and improve performance
• Teach positions relative to the part
• Use runtime validation to improve part detection and accuracy

Student profile
This course is intended for students that are required to start and operate the FlexVision equipment
• Engineers, service personnel, supervisory personnel, or System Integrators

Prerequisites
• (US420) or (US312) IRC5/S4 Programming I
• (US425) IRC5 Programming II is recommended
• Student review of AIA videos on lighting, optics, and machine vision recommended

Cartridge Bell System

4½ days – Course Code: US346

Topics include:
- Safety precautions used while programming and program execution
- System overview of the controls and indicators on the CBS
- Installation requirements of the CBS equipment
- Preventive maintenance
- Repair procedures
- Calibration of dispensing equipment

Course objectives: After successfully completing the course, the participant should be able to:
- Identify all equipment associated with the CBS application
- Learn operation sequencing and functionality
- Observe wearable items and frequency of maintenance
- Troubleshoot and repair faulty equipment
- Learn calibration procedures
- Disassemble and assemble IFS, Cartridge, and Cartridge Bell
- Identify wearable components

Student profile: This course is intended for students that are required to start and operate the CBS dispensing equipment
- Engineers
- Service personnel
- Supervisory personnel
- System integrators

Prerequisites:
- S4P Programming for Paint (US340) or IRC5P Programming for Paint (US341) is strongly recommended

Integrated Process Solution (IPS)

4½ days – Course Code: US308

Topics include:
- Safety precautions used when making changes on the fluid control parameters
- General overview of Gun Control, Open and Closed Loop signal configuration
- Editing the IPS.cfg and Elo.cfg files

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot and fluid controls
- Identify hardware and describe the purpose of the Applicator and fluid control system
- Operate and setup software and monitor robot configuration across the CAN bus
- Make changes to the IPS.cfg and Elo.cfg files to establish
- Gun Control, Open and Closed Loop Fluid Control using a text editor
- Download the configuration file to the MCOB
- Monitor operation from a computer using the Terminal software
- Make adjustments to the Applicator Control for delays in the fluid system

Student profile:
- This course is intended for students that are required to finalize and adjust the systems paint process for fluid applications
- Engineers
- Service Personnel
- System Integrators

Prerequisites:
- Prior knowledge of S4P or IRC5P pendant operation, Robot Programming and System Parameter Configuration is helpful

Robot Framework Gen 2

IRC5 – 1 day – Course Code: US446

Topics include:
- Theory of operation of IFWC
- ABB IRC5 robot integration with IFWC
- ABB IRC5 robot to PLC communication

Course objectives: After successfully completing the course, the participant should be able to describe how IFWC functions when it comes to:
- ABB IRC5 robot creation and usage
- Setup IFWC in user’s computer
- Create IFWC robot system
- Download IFWC system to ABB IRC5 controller
- Configure a user RAPID module to interface with IFWC
- ABB IRC5 robot to PLC communication and usage
- Simple PLC demonstration in integrating IFWC
- Simple HMI demonstration in using IFWC

Student profile:
- Engineers
- System integrators

Prerequisites:
- Programming I for Material Handling (US420)
- Understanding of Microsoft Windows 7 operation within a PC
- Knowledge of PLC functionality
- Siemens STEP7 (for demonstration purpose)
- WinCC (for HMI controls)

Force Control (Machining) (US435)

IRC5 – 4½ days – Course Code: US435

Topics include:
- Loading computer software
- Setup Force Control graphical user interface
- FC commands
- Force Controlled pressure applications
- Force Controlled speed change applications

Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Properly start-up, operate, and shut-down the robot
- Load computer software
- Use the graphic user interface
- Create machining routines
- Edit programmed positions

Prerequisites:
- Understanding of the machining process is helpful

PickMaster 3 (Vision)

IRC5 – 4½ days – Course Code: US418

Topics include:
- Presentation and overview of PickMaster 3
- Feature scope of PickMaster 3
- Conveyor set-up
- Vision calibration, modeling and tuning
- Line creation
- PickMaster 3 RAPID program
- Project creation
- Hardware components and writing
- Logging
- Performance and limiting factors

Course objectives: After successfully completing the course, the participant should be able to:
- Describe hardware components
- Describe wiring configurations
- Explain basic performance capabilities
- Explain licensing procedures
- Setup a Line
- Calibrate a conveyor
- Calibrate a camera
- Verify accurate Calibrations
- Train part models
- Configure PickMaster using common variations
- Setup containers
- Modify RAPID code
- Setup Indexed Work Areas
- Create Backups
- Explain Load Balancing
- Explain Adaptive Task Completion (ATC)
- Use PickMaster for Inspections
- Perform diagnostics on system

Student profile:
- This training is targeted to the people that will be applying and integrating PickMaster 3, as well as those who will use and maintain an installed PickMaster 3-based system.

Prerequisites - One of the following courses listed must be taken:
- Programming I for Material Handling (US420)
- Programming II for Material Handling (US425) is strongly recommended
- Advanced PC user

MultiMove

IRC5 – 2 days – Course Code: US494

This course is designed for students who have successfully completed our IRC5 Programming 1 class or equivalent and who need to only know about MultiMove. This course DOES NOT provide a review of basic programming. This class is intended for those who are already familiar with ABB robot programming but need MultiMove knowledge.

Topics include:

- MultiMove Overview
- MultiMove Basics
- Coordinate Systems
- Base Frame Definition
- Coordinated Jogging
- MultiMove Instructions and Data
- Independent Motion Programming
- Synchronized Motion Programming
- Coordinated Motion programming
- MultiMove Programming with RobotStudio

Course objectives: After successfully completing the course, the participant should be able to:
- Describe the features of Multi-Move
- Setup Robot Base Frames for Multi-Move
- Jog the Robot in Coordinated Motion
- Use the Multi-Move Instructions
- Program the Robot in Independent, Synchronized and Coordinated motion
- Use RobotStudio to create a Multi-Move program

Student Profile: This course is intended for students that have attended the IRC5 Programming 1 course but require knowledge of MultiMove programming features.
- Suitable for system programmers or technicians with existing / developed programming skills

Prerequisites - One of the following courses listed must be taken:
- Attendees must have attended the IRC5 Programming 1 class (US420) within the last six to twelve months or have adequate past programming experience. This course DOES NOT provide a review of basic programming.Shop Floor Editor

Shop Floor Editor

3 days – Course Code: US305

Topics include:
- Safety precautions while operating and programming with Shop Floor Editor software
- Graphic digitalizing of brush files and color display of programs
- File editing functions such as point modification, speed or velocity adjustments and Applicator trigger positions adjustments as well as advanced logic functions
- Adjustments of paint parameters
- Creating and converting programs into work pieces or importing CAD drawings for robot program editing

Course objectives: After successfully completing the course, the participant should be able to::
- Demonstrate the ability to practice all areas of safety as they pertain to the robots and using the Shop Floor Editor software
- Describe the function of the Shop Floor Editor software
- Demonstrate the ability to manipulate programs files, brush files, system files, and IPS files
- Demonstrate the ability to edit and save files
- Edit program data such as position, velocity, acceleration, Applicator triggering, and process parameters on the robot from the Shop Floor Editor software

Student profile: This course is intended for people that are familiar with Windows
- Engineers
- Service personnel
- System integrators

Prerequisites:
- S4P Programming for Paint (US340) or IRC5P Programming for Paint (US341)
- Microsoft PC operation training or equivalent PC experience

RobotStudio I

IRC5 – 4½ days – Course Code: US399

The goal of this course is to teach the students how to use the ABB RobotStudio 5 software for use with IRC5 controllers. This class will cover everything that the general user would need to know.

Topics include:
- Basic controls
- Building a station
- Robot moves
- Robot programs
- Local origin
- Tools
- Task Frames
- Auto Path Feature

Course objectives: After successfully completing the course, the participant should be able to:
- Start and utilize RobotStudio 5 Software
- Create a simulation station
- Create and attach tooling to robot simulation
- Create robot motion
- Create robot programs
- Create basic geometry modeling
- Import external graphic files
- Use the I/O simulator
- Create work objects
- Set local origin Set task frames
- Use Auto Path feature
- Use Signal Analyzer
- Record simulations
- Edit RAPID code using RAPID editor
- Watch data values while simulation executes
- Set-up and use Event Manager
- Create simulation of real robot

Student profile: This course is intended for
- Engineering personnel that are interested in computer simulation software.
- Those responsible for simulating robot layout and reach capabilities and robot program simulation.
- Any one responsible for creating new part programs for existing robots with computer experience.

Prerequisites - One of the following courses listed must be taken:
•IRC5 Programming I for Material Handling (US420)
•IRC5 Accelerated Programming for Material Handling (Integrators Only) (US426)
•IRC5 Programming I for Arc Welding (US490)
•IRC5 Programming I for Spot Welding (US491)
- The attendee must have a good, working knowledge of Windows

RobotStudio II

IRC5 – 4½ days – Course Code: US401

The goal of this course is to teach the students how to use more advanced features of ABB
RobotStudio 5 software for use with IRC5 controllers. This course is an extension of the
US399 RobotStudio I course.

Topics include:
- Smart Components
- Multi Move
- Conveyor Tracking
- Screen Maker
- Graphic Tools
- Advanced Modeling
- Mechanisms
- Non-ABB external axis
- System Builder
- Code Snippets
- Rapid Profiler

Course objectives: After successfully completing the course, the participant should be able to:
- Create simulations with interactive
objects such as conveyors, in-feeders,
grippers, and more.
- Create simulations and program multiple
robot applications.
- Setup and program conveyor tracking
- Use graphic tools to change lighting,
textures, and the look of objects.
- Create complex 3 dimensional objects
- Create objects that move in simulations
other than robots.
- Create external axis that are not
standard ABB axes.
- Use System Builder to create virtual
robot systems.
- Advanced RAPID Editing techniques

Student profile: This course is intended for
- Engineers
- Maintenance technicians
- Robot Programmers

Prerequisites - Must have completed one of the following courses before attending:
o US399 RobotStudio
o US402 RobotStudio with Paint PowerPac
o US404 RobotStudio with Cutware PowerPac
o US405 RobotStudio with ArcWare PowerPac
o US406 RobotStudio with Palletizing PowerPac

RobotStudio I with Paint PowerPac

IRC5P – 4½ days – Course Code: US402

Topics include:
- Basic controls
- Building a station
- Creating robot moves
- Creating basic geometry modeling
- Creating robot programs
- Creating work objects
- Set Up Conveyor Tracking
- Set Up Smart Components
- Using I/O simulator
- Using external axis
- Setup a Paint Simulation Station with Paint Power Pac

Course objectives: After successfully completing the course, the participant should be able to:
- Start and utilize the RobotStudio 5 software
- Create simulation station
- Create and attach tooling to robot simulator
- Create robot motion
- Create robot programs
- Create basic geometry modeling
- Import external graphic files
- Use the I/O simulator
- Create work objects
- Simulate Conveyor Tracking
- Create simulations with paint motions
- Utilize the Paint PowerPac

Student profile: This course is intended for
- Engineering personnel that are interested in computer simulation software.
- Those responsible for simulating robot layout and reach capabilities and robot program simulation.

Prerequisites:
- Programming I for Paint (US341)
- The attendee must have a good, working knowledge of Windows

RobotStudio I with CutWare PowerPac

IRC5 – 4½ days – Course Code: US404

Topics include:
- Basic controls
- Building a station
- Robot moves
- Robot programs
- Local origin
- Tools
- Task Frames
- Auto Path Feature
- Simulations
- Event Manager
- Work objects
- I/O simulator
- External axis
- Geometries
- Station Signals
- Off-line to online calibration
- Laser Cutting Off-line Programming with RobotStudio

- Successfully create laser cutting program offline for their part

Prerequisites:

Programming I for Material Handling (US420) OR IRC5 Programming I for LaserCutting (US496)

RobotStudio I with ArcWare PowerPac

IRC5 – 4½ days – Course Code: US405

Topics include:
- Basic controls
- Building a station
- Robot moves
- Robot programs
- Local origin
- Tools
- Task Frames
- Auto Path Feature
- Arc Welding PowerPac Off-line Programming with RobotStudio

- Successfully create welding program offline for their part

Prerequisites:
- Programming I for Material Handling (US420) OR Programming I for Arc Welding (US490)
- The attendee must have a good, working knowledge of Windows

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