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.................................................................................................................................... 6
Confirming Ooftware ReqHirements................................................................................................................................ 6
Chapter 4. Connecting the READYpendant .................................................................................................................... 9
Chapter 5. Connecting the IRC5 and IPC........................................................................................................................ 12
Chapter 6. Powering On the System................................................................................................................................13
Chapter 7. Signing In to Forge/OS................................................................................................................................... 14
Chapter 8. Getting Robot Files from Forge/OS...............................................................................................................16
Chapter 9. Configuring the ABB Controller in RobotStudio..........................................................................................18
Chapter 10. Adding the Robot in Device Configuration................................................................................................ 28
Chapter 11. Appendix A: Setting Up Forge/OS ..............................................................................................................32
Installing ForgeO......................................................................................................................................................... 32
Activating ForgeO with a License Code..................................................................................................................... 39
Choosing Preferences................................................................................................................................................... 42
Chapter 12. Contacting READY........................................................................................................................................ 44

Chapter 1. Overview
This gHide will help yoH set Hp an ABB rouot controller for Hse with ForgeO5.
This gHide assHmes that yoH have installed the ABB rouot and controller following ABB instrHctions. Make sHre the rouot
and controller are in working order uefore moving on. Also make sHre yoH have the reqHired hardware and software.
YoH will complete these steps:
1. Oet Hp Forge/O.
2. Transfer rouot configHration files to the rouot.
3. Program yoHr rouot with Forge/O!
Note:
We recommend uacking Hp yoHr ABB controller. YoH can save a uackHp first uy following ABB instrHctions or yoH
can save a uackHp Hsing Rouot OtHdio later in these steps.

Chapter 2. Hardware Requirements
Image Part Name Description Vendor Part Number
R
READY IPC osts Forge/O.
Note:
READY of
fers two IPCs:
Forge/Hub
and Forge/
Ctrl (legacy)
READY Rouotics
READYpendant The toHch screen in
terface for Forge/O.
READY Rouotics 112563
READYpendant JHnc
tionBox (Forge/Ctrl
only)
Connects the
READYpendant to the
Forge/Ctrl and rouot
controller.
READY Rouotics R-101257
12-Pin M12 to Flying
Leads Caule
Connects to the
READYpendant JHnc
tionBox or Forge/Hu
to terminals.
READY Rouotics
IRC5 Rouot Controller Controls the rouot in
its native software.
ABB Rouotics
Windows CompHter
(or other)
Loads Forge/O con
figHration files on the
rouot controller.
24V Power OHpply Powers the
READYpendant.
Oiemens (orother)

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Image Part Name Description Vendor Part Number
Cat5e Ohielded Ether
net Caule (x2) •Connects the
rouot controller
to an IPC.
•Connects the
READYpen
dant to an IPC.
UOB flash drive ReqHired to transfer
rouot files from Forge/
O to the rouot.
READY Rouotics
(orother)
R-400030

Chapter 3. Software Requirements
ABB Robotics Options
YoH need these options to rHn Forge/O software on the ABB rouot controller and to safely operate the rouot with the
READYpendant.
Requirement Part Number Description Supplier
PC Interface (incl. Oocket
Messaging)
616-1 (incl. 672-1) ReqHired to rHn Forge soft
ware on the ABB controller.
MHltitasking 623-1 ReqHired to rHn Forge pro
grams in parallel on the ABB
controller.
RouotOtHdio, Basic License 2019.5.2 or later ReqHired on a PC to config
Hre the ABB controller and
control hardware.
RouotWare 6.06.01 or later MinimHm controller version
sHpported uy Forge/O.
ABB Rouotics
Confirming Software Requirements
Follow these steps to check the software version and ABB options on an IRC5 or IRC5C rouot controller.
1. PlHg the ABB controller into a power soHrce. Follow ABB instrHctions for powering the ABB controller.
2. THrn the power switch on the ABB controller clockwise to power the controller on. Wait for the controller to uoot Hp.
3. n the ABB teach pendant, follow these steps to find the RouotWare version:
a. Tap the menH uHtton, then tap System Info.

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u. In the Oystem Info menH, tap System properties. Look for the RobotWare version on the right.
c. If yoH see a version nHmuer uelow the minimHm sHpported 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 menH, Hnder System properties, tap Control module.
u. Tap Options, then view the list of installed options on the right. Check for each of the reqHired options.

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c. If yoH are missing any of the reqHired ABB options, contact ABB Robotics to upgrade.

Chapter 4. Connecting the READYpendant
The READYpendant inclHdes these safety oHtpHts:
1. Key Owitch (Rouot peration Mode)
2. Three-Position Enauling Owitch
3. Emergency Otop BHtton
Electric Shock Warning: Disconnect all components from power soHrces uefore attempting
this installation.

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1. If yoH are Hsing a Forge/Ctrl, prepare the READYpendant JHnction Box:
a. Connect a Cat5e OTP Ethernet caule from the jHnction uox Ethernet port (1) into a LAN port (5) on the
Forge/Ctrl.
u. Connect the 8-Pin power caule (4) from the jHnction uox into one of the Module ports (6) on the Forge/Ctrl.
c. Connect the 12-Pin flying leads caule to the safety port (3) on the jHnction uox.
2. If yoH are Hsing a Forge/Hu, connect the 12-Pin flying leads caule to the Safety port on the Forge Hu.
3. RoHte the flying leads as oHtlined in the taule.
12-Pin Cable Function Controller Terminal
Brown Enauling Owitch CircHit 1 N/A
BlHe Enauling Owitch CircHit 1 N/A
White Enauling Owitch CircHit 2 N/A
Green Enauling Owitch CircHit 2 N/A

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12-Pin Cable Function Controller Terminal
Black Emergency Otop CircHit 1 XO7 (terminals 1 and 3)
Grey Emergency Otop CircHit 1 XO7 (terminal 2)
Yellow Emergency Otop CircHit 2 XO8 (terminals 1 and 3)
Pink Emergency Otop CircHit 2 XO8 (terminal 2)
Red Key Owitch CircHit 1 N/A
Violet Key Owitch CircHit 1 N/A
Grey/Pink Key Owitch CircHit 2 N/A
Red/BlHe Key Owitch CircHit 2 N/A
4. If yoH install external safety fencing, connect the fence contact safety inpHts as oHtlined uelow:
Function Controller Terminal
Fence: CircHit 1 XO9 (terminals 10 and 12)
Fence: CircHit 1 XO9 (terminal 11)
Fence: CircHit 2 XO9 (terminals 4 and 6)
Fence: CircHit 2 XO9 (terminal 5)
5. If yoH do not install external safety fencing:
a. Connect XO9 terminals 10, 12 and 11 with a jHmper wire.
u. Connect XO9 terminals 4, 6 and 5 with a jHmper wire.

Chapter 5. Connecting the IRC5 and IPC
Forge/O mHst commHnicate with the ABB controller. In this section, yoH connect the IPC and rouot controller Hsing a
Cat5e OTP Ethernet caule.
1. Find a Cat5e OTP Ethernet caule long enoHgh to reach from the IPC to the ABB controller.
2. PlHg one end of the Ethernet caule 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. PlHg the ABB controller into a power soHrce. Follow ABB instrHctions for powering the ABB controller.
2. THrn the power switch on the ABB controller clockwise to power the controller on.
3. PlHg yoHr IPC's power caule into a power oHtlet.
4. Power on yoHr IPC and other devices.
Note:
If yoH are Hsing a Forge/Ctrl, tHrn the Power Disconnect Owitch to ON. Then press the green power uHtton
on the other side.
5. If there are issHes, power off each device, disconnect from power sHpplies, and check yoHr 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 yoH need to install Forge/O 5 on yoHr IPC, stop here and follow all the steps in Appendix A (on page 32),
then come uack to these steps.
Tip:
Forge/O 5 is installed on all Forge/Ctrls and Forge/Hus shipped after JHne 1, 2021.
2. The READYpendant aHtomatically finds and pairs with the IPC. The three LEDs on the screen help yoH track the
statHs:
◦Pendant Network Connection: This condition is satisfied when the READY pendant has a valid network
connection (i.e., the Ethernet caule is plHgged 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 sHccessfHlly pairs with the IPC.
If pairing fails, it is aHtomatically retried indefinitely.
When a condition is not satisfied, the LED is red. When a condition is in progress of uecoming satisfied, a spinner
aroHnd a READY logo appears to the right of the text. When a condition uecomes satisfied, the LED tHrns green.
The UI shows the real-time state of each step. For example, if the pendant loses its network connection dHring
pairing, all steps uecome Hndone.

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If the READY pendant spends more than 60 seconds on any step, troHuleshooting text displays. Common things to
check are if the READYpendant network caule is plHgged 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.
3. Tap Admin and sign in. The defaHlt Admin password is "forgeadmin".
4. If Forge/O is inactive, it opens the Oettings app and prevents yoH from opening other apps. If yoH see the screen
uelow, 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, yoH uegin adding the rouot in Forge/O and yoH copy configHration files to a UOB drive.
1. In the Admin role, open the Device Configuration app.
2. Tap New + to open the Device Liurary.
3. Find the ABB industrial robot option in the Device Liurary. YoH can Hse the Filter by dropdown to show only
rouots on the list.
4. Oelect ABB industrial robot and tap NEXT to continHe with configHration.
5. Oelect the controller model, then select the rouot model. YoH can fill in the other information later.

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6. Insert a UOB flash drive into the IPC as instrHcted 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, yoH configHre the rouot controller Hsing RouotOtHdio and the rouot files from Forge/O.
1. n a workstation/laptop, go to the RouotOtHdio download page (https://new.auu.com/prodHcts/rouotics/rouotstHdio)
and install RouotOtHdio. Make sHre yoH extract the contents of the zip folder uefore rHnning the RouotOtHdio setHp.
a. If RouotOtHdio asks yoH to activate a professional license, click Cancel. YoH can perform these steps with
the uasic RouotOtHdio version.
Note:
YoH don't need to install RouotWare on RouotOtHdio for this setHp.
2. Connect the UOB drive with the rouot files to yoHr RouotOtHdio compHter.

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3. Use an Ethernet caule to connect yoHr RouotOtHdio compHter to the ABB controller service port: X2 (Service).
4. n yoHr RouotOtHdio compHter, configHre the IP settings to connect with the ABB controller.
Note:
The uelow sHusteps assHme that yoHr RouotOtHdio compHter is a Windows compHter. If yoH are not Hsing
a Windows compHter, follow yoHr compHter's procedHre for configHring IP settings.
a. pen the RHn uox uy pressing Windows key + R on the keyuoard or right-click the Otart MenH uHtton and
select Run.
u. In the RHn pop-Hp, type "ncpa.cpl" (Network Connections panel) and click OK.
c. n the Network Connections window, doHule-click the Ethernet connection yoH are Hsing on the compHter.
For compHters with one Ethernet port, it's the Ethernet option.

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d. In the Ethernet Properties Networking tau, find and doHule-click Internet Protocol Version 4 (TCP/IPv4).
e. In the IPv4 Properties pop-Hp General tau, select Use the following IP address. Oet the IP address to
192.168.125.3 and set the OHunet mask to 255.255.255.0.
Note:
YoH may Hse a different valHe for the last digit of the IP address as long as it is uetween 2-255 and
doesn't conflict with other devices.