ABB IRC5 Compact User guide

ABB IRC5/IRC5C Startup Guide
(PROGRAM Mode)

Contents
Chapter 1. Overview............................................................................................................................................................. 3
Chapter 2. Hardware Requirements................................................................................................................................... 4
Chapter 3. Software Requirements.................................................................................................................................... 5
Confirming Ooftware Requirements................................................................................................................................ 5
Chapter 4. Connecting the READYpendant......................................................................................................................8
Chapter 5. Connecting the IRC5 and IPC........................................................................................................................ 11
Chapter 6. Powering On the System................................................................................................................................12
Chapter 7. Signing In to Forge/OS................................................................................................................................... 13
Chapter 8. Getting Robot Files from Forge/OS...............................................................................................................15
Chapter 9. Configuring the ABB Controller in RobotStudio..........................................................................................17
Chapter 10. Adding the Robot in Device Configuration................................................................................................ 27
Chapter 11. Appendix A: Setting Up Forge/OS ..............................................................................................................31
Installing ForgeO......................................................................................................................................................... 31
Activating ForgeO with a License Code..................................................................................................................... 39
Choosing Preferences................................................................................................................................................... 41
Chapter 12. Contacting READY........................................................................................................................................ 44

Chapter 1. Overview
This guide will help you set up an ABB robot controller for use with ForgeO5.
This guide assumes that you have installed the ABB robot and controller following ABB instructions. Make sure the robot
and controller are in working order before moving on. Also make sure you have the required hardware and software.
You will complete these steps:
1. Oet up Forge/O.
2. Transfer robot configuration files to the robot.
3. Program your robot with Forge/O!
Note:
We recommend backing up your ABB controller. You can save a backup first by following ABB instructions or you
can save a backup using Robot Otudio later in these steps.

Chapter 2. Hardware Requirements
Image Part Name Description Vendor Part Number
Industrial PC (IPC) Hosts Forge/O.
Note:
Refer to the
Forge/O 5
User Manu
al for IPC re
quirements.
READYpendant The touch screen in
terface for Forge/O.
READY Robotics 112563
IRC5 Robot Controller Controls the robot in
its native software.
ABB Robotics
Windows Computer
(or other)
Loads Forge/O con
figuration files on the
robot controller.
24V Power Oupply Powers the
READYpendant.
Oiemens (orother)
Cat5e Ohielded Ether
net Cable (x2) •Connects the
robot controller
to an IPC.
•Connects the
READYpen
dant to an IPC.
UOB flash drive Required to transfer
robot files from Forge/
O to the robot.
READY Robotics
(orother)
R-400030

Chapter 3. Software Requirements
ABB Robotics Options
You need these options to run Forge/O software on the ABB robot controller and to safely operate the robot with the
READYpendant.
Requirement Part Number Description Supplier
PC Interface (incl. Oocket
Messaging)
616-1 (incl. 672-1) Required to run Forge soft
ware on the ABB controller.
Multitasking 623-1 Required to run Forge pro
grams in parallel on the ABB
controller.
RobotOtudio, Basic License 2019.5.2 or later Required on a PC to config
ure the ABB controller and
control hardware.
RobotWare 6.06.01 or later Minimum controller version
supported by Forge/O.
ABB Robotics
Confirming Software Requirements
Follow these steps to check the software version and ABB options on an IRC5 or IRC5C robot controller.
1. Plug the ABB controller into a power source. Follow ABB instructions for powering the ABB controller.
2. Turn the power switch on the ABB controller clockwise to power the controller on. Wait for the controller to boot up.
3. n the ABB teach pendant, follow these steps to find the RobotWare version:
a. Tap the menu button, then tap System Info.

ABB IRC5/IRC5C Startup Guide (PROGRAM Mode) | 3 - Software Requirements | 6
b. In the Oystem Info menu, tap System properties. Look for the RobotWare version on the right.
c. If you see a version number below the minimum supported version, contact ABB Robotics to upgrade.
4. n the ABB teach pendant, follow these steps to view installed ABB options:
a. In the Oystem Info menu, under System properties, tap Control module.
b. Tap Options, then view the list of installed options on the right. Check for each of the required options.

ABB IRC5/IRC5C Startup Guide (PROGRAM Mode) | 3 - Software Requirements | 7
c. If you are missing any of the required ABB options, contact ABB Robotics to upgrade.

Chapter 4. Connecting the READYpendant
The READYpendant includes these safety outputs:
1. Key Owitch (Robot peration Mode)
2. Three-Position Enabling Owitch
3. Emergency Otop Button
The end of the READYpendant cable includes:
1. ne RJ45 Ethernet cable for communication with the IPC.
2. 15 Flying leads—2 for power, 12 for safety I/, and 1 unused lead.

ABB IRC5/IRC5C Startup Guide (PROGRAM Mode) | 4 - Connecting the READYpendant | 9
Electric Shock Warning: Disconnect all components from power sources before attempting
this installation.
1. Follow these substeps to connect the READYpendant communication, power, and safety wiring.
You will route the READYpendant flying leads to the destinations in this table:
Pendant Flying Leads Function Controller Terminal
Brown Enabling Owitch Circuit 1 N/A
Yellow Enabling Owitch Circuit 1 N/A
Green Enabling Owitch Circuit 2 N/A
Grey Enabling Owitch Circuit 2 N/A
Pink 24V DC Power Oupply
Grey/Pink Emergency Otop Circuit 1 XO7 (terminals 1 and 3)
Red/Blue Emergency Otop Circuit 1 XO7 (terminal 2)
White/Green Emergency Otop Circuit 2 XO8 (terminals 1 and 3)
Green/Brown Emergency Otop Circuit 2 XO8 (terminal 2)
Black 0V DC Power Oupply
Violet Key Owitch Circuit 1 N/A
White/Pink Key Owitch Circuit 1 N/A
White Key Owitch Circuit 2 N/A
Blue Key Owitch Circuit 2 N/A
White/Blue - N/A
a. Connect the READYpendant's Ethernet cable to the IPC. You may connect the pendant through an Ethernet
switch to increase the number of Ethernet ports.
b. Connect the pendant's power leads to a 24V DC, 2.5A source. Connect the Pink wire to +24V and the Black
wire to 0V.
c. Connect the remaining safety I/ leads to your control panel or safety cabinet. Make your own cable/wiring
for the 12 safety signals long enough to reach their destinations in the table. Include ferrules at the end of
your wiring to insert in the terminal blocks.
2. If you install external safety fencing, connect the fence contact safety inputs as shown below:

ABB IRC5/IRC5C Startup Guide (PROGRAM Mode) | 4 - Connecting the READYpendant | 10
Function Terminal
Fence: Circuit 1 XO9 (terminals 10 and 12)
Fence: Circuit 1 XO9 (terminal 11)
Fence: Circuit 2 XO9 (terminals 4 and 6)
Fence: Circuit 2 XO9 (terminal 5)
3. If you do not install external safety fencing:
a. Connect XO9 terminals 10, 12 and 11 with a jumper wire.
b. Connect XO9 terminals 4, 6 and 5 with a jumper wire.