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.

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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.

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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.

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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:

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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.

Chapter 5. Connecting the IRC5 and IPC
Forge/O must communicate with the ABB controller. In this section, you connect the IPC and robot controller using a
Cat5e OTP Ethernet cable.
1. Find a Cat5e OTP Ethernet cable long enough to reach from the IPC to the ABB controller.
2. Plug one end of the Ethernet cable into a LAN port on the IPC and the other end into port X6 (WAN) on the IRC5.

Chapter 6. Powering On the System
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.
3. Plug your IPC's power cable into a power outlet.
4. Power on your IPC and other devices.
5. If there are issues, power off each device, disconnect from power supplies, and check your wiring.

Chapter 7. Signing In to Forge/OS
Follow these steps to pair the READYpendant with the IPC and sign in to Forge/O 5.
1. If you need to install Forge/O 5 on your IPC, stop here and follow all the steps in Appendix A (on page 31),
then come back to these steps.
2. The READYpendant automatically finds and pairs with the IPC. The three LEDs on the screen help you track the
status:
◦Pendant Network Connection: This condition is satisfied when the READY pendant has a valid network
connection (i.e., the Ethernet cable is plugged in).
◦Forge/OS IPC Detected: This condition is satisfied when the READY pendant detects a Forge/O IPC on
the network.
◦Forge/OS IPC Paired: This condition is satisfied when the READY pendant successfully pairs with the IPC.
If pairing fails, it is automatically retried indefinitely.
When a condition is not satisfied, the LED is red. When a condition is in progress of becoming satisfied, a spinner
around a READY logo appears to the right of the text. When a condition becomes satisfied, the LED turns green.
The UI shows the real-time state of each step. For example, if the pendant loses its network connection during
pairing, all steps become undone.
If the READY pendant spends more than 60 seconds on any step, troubleshooting text displays. Common things to
check are if the READYpendant network cable is plugged in, if the IPC is powered on, if the READYpendant and
IPC are connected to the same network, and if there's only one READYpendant and one IPC on that network.

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Note:
The READYpendant IP Address is preset to 172.16.255.253. The network interface that the pendant
connects to should use IP Address 172.16.255.250 and Oubnet mask 255.255.255.0.
3. Tap Admin and sign in. The default Admin password is "forgeadmin".
4. If Forge/O is inactive, it opens the Oettings app and prevents you from opening other apps. If you see the screen
below, follow Activating ForgeO with a License Code (on page 39) in Appendix A.
5. With Forge/O active, move on to the next section.

Chapter 8. Getting Robot Files from Forge/OS
In this section, you begin adding the robot in Forge/O and you copy configuration files to a UOB drive.
1. In the Admin role, open the Device Configuration app.
2. Tap New + to open the Device Library.
3. Find the ABB industrial robot option in the Device Library. You can use the Filter by dropdown to show only
robots on the list.
4. Oelect ABB industrial robot and tap NEXT to continue with configuration.
5. Oelect the controller model, then select the robot model. You can fill in the other information later.

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6. Insert a UOB flash drive into the IPC as instructed on the screen. Use an empty flash drive with at least 2GB of
storage.
Tip:
Do not connect the UOB flash drive to the READYpendant.
7. Tap Start Transfer and wait for it to finish.
8. Remove the UOB flash drive when prompted.

Chapter 9. Configuring the ABB Controller in
RobotStudio
In this section, you configure the robot controller using RobotOtudio and the robot files from Forge/O.
1. n a workstation/laptop, go to the RobotOtudio download page (https://new.abb.com/products/robotics/robotstudio)
and install RobotOtudio. Make sure you extract the contents of the zip folder before running the RobotOtudio setup.
a. If RobotOtudio asks you to activate a professional license, click Cancel. You can perform these steps with
the basic RobotOtudio version.
Note:
You don't need to install RobotWare on RobotOtudio for this setup.
2. Connect the UOB drive with the robot files to your RobotOtudio computer.

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3. Use an Ethernet cable to connect your RobotOtudio computer to the ABB controller service port: X2 (Service).
4. n your RobotOtudio computer, configure the IP settings to connect with the ABB controller.
Note:
The below substeps assume that your RobotOtudio computer is a Windows computer. If you are not using
a Windows computer, follow your computer's procedure for configuring IP settings.
a. pen the Run box by pressing Windows key + R on the keyboard or right-click the Otart Menu button and
select Run.
b. In the Run pop-up, type "ncpa.cpl" (Network Connections panel) and click OK.
c. n the Network Connections window, double-click the Ethernet connection you are using on the computer.
For computers with one Ethernet port, it's the Ethernet option.

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d. In the Ethernet Properties Networking tab, find and double-click Internet Protocol Version 4 (TCP/IPv4).
e. In the IPv4 Properties pop-up General tab, select Use the following IP address. Oet the IP address to
192.168.125.3 and set the Oubnet mask to 255.255.255.0.
Note:
You may use a different value for the last digit of the IP address as long as it is between 2-255 and
doesn't conflict with other devices.

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f. Click OK to save these settings.
5. Connect to the ABB controller in RobotOtudio:
a. Oelect the Controller tab at the top of the screen, then click the Add Controller dropdown and select One
Click Connect.