ABB IRC5 Startup Manual

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ABB Startup Guide

IRC5 (Program Mode)

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Page 2: Table Of Contents
Table of contents: ABB IRC5 (Program Mode) Hardware Reqs Software Reqs How to Check Software Reqs Wiring the READY Pendant Connecting the Controller to the IPC Powering On Signing Into ForgeOS Getting Config Files Transferring Configuration Files Connecting the Computer to the Controller...
Page 3: Abb Irc5 (Program Mode)
ABB IRC5 (Program Mode) Hardware Reqs Image Name Description Robot Controls the robot in its native Controller software. Hosts ForgeOS. See requirements if you are not using a Forge/Hub or the legacy Forge/Ctrl. READY Touch-screen interface for Pendant ForgeOS. See its specifications.
Page 4: Software Reqs
Image Name Description Windows Loads ForgeOS configuration files Computer on the robot controller. Connects the robot controller to Cat5e the IPC, connects the READY Shielded pendant to the IPC, and connects Ethernet the Windows computer to the Cables (x3) robot controller. USB Flash Transfers configuration files from Drive...
Page 5: How To Check Software Reqs
Required software version for ForgeOS. Minimum ForgeOS version that supports READY ForgeOS 5.4.0 or later ABB robots. Robotics How to Check Software Reqs 1. Tap the menu button, then tap System Info........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........5...
Page 7 CAUTION If you see a version number below the minimum supported version, follow this. 3. In the System Info menu, under System properties, tap Control module........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........7...
Page 9: Wiring The Ready Pendant
CAUTION If you are missing any of the required ABB options, contact ABB Robotics to upgrade. Wiring the READY Pendant The READY pendant includes 3 safety outputs: 1. Key Swtich 2. 3-Position Enabling Switch ........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........9...
Page 10 3. E-Stop The end of the READY pendant cable includes: One RJ45 Ethernet cable for communication with the IPC. 15 Flying leads — 2 for power, 12 for safety I/O, and 1 unused lead. DANGER Electric Shock Warning: Make sure to disconnect everything from power first. For wiring instructions, select which IPC you are using: General IPC Forge/Hub...
Page 11 Pendant Flying Leads Function Controller Terminal Pink 24V DC Power Supply Grey/Pink Emergency Stop Circuit 1 XS7 (terminals 1 and 3) Red/Blue Emergency Stop Circuit 1 XS7 (terminal 2) White/Green Emergency Stop Circuit 2 XS8 (terminals 1 and 3) Green/Brown Emergency Stop Circuit 2 XS8 (terminal 2) Black...
Page 12: Connecting The Controller To The Ipc
Connect XS9 terminals 4, 6 and 5 with a jumper wire. Connecting the Controller to the IPC 1. Find a Cat5e STP Ethernet cable long enough to reach from the IPC to the ABB controller........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........12...
Page 13: Powering On
2. Plug one end of the Ethernet cable into a LAN port on the IPC. 3. Plug the other end into port X6 (WAN) on the controller. Powering On 1. Plug the controller into a power source and turn it on. NOTE Follow the manufacturer's instructions for powering the controller.
Page 14: Signing Into Forgeos
Signing Into ForgeOS INFO If you need to install ForgeOS on your IPC, stop here and follow the installation instructions, then come back to these steps. 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).
Page 15 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. When a condition is not satisfied, the LED is red. When a condition is in the process of becoming satisfied, a spinner around a ForgeOS logo appears to the right of the text.
Page 16 If there's only one READY pendant and one IPC on that network. 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 Subnet mask 255.255.255.0. Tap Admin and sign in. The default Admin password is "forgeadmin".
Page 18: Getting Config Files
If ForgeOS is inactive, it opens the Settings app and prevents you from opening other apps. If you see the screen below, follow this. Getting Config Files Open the Device Configuration app........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........18...
Page 19 Tap New+ to open the Device Library. Find your robot option in the Device Library and tap NEXT. Use the Filter by dropdown to show only robots on the list. Select your controller model, then select your robot model. If applicable, also select your safety configuration.
Page 21: Transferring Configuration Files
Wait for the transfer to finish, then remove the USB drive. Transferring Configuration Files Connecting the Computer to the Controller Open RobotStudio on your workstation/laptop. If you have not purchased a RobotStudio license, click Cancel in the "Activate RobotStudio" pop-up. You can perform these steps with the basic RobotStudio version........
Page 22 You don't need to install RobotWare on RobotStudio for this setup. Click No if you see the below pop-up. Use an Ethernet cable to connect your RobotStudio computer to the ABB controller service port: X2........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........22...
Page 23: Configuring Ip Settings
NOTE Refer to ABB documentation for more information on Ethernet routing. Depending on your setup, you may need to plug this cable into a different port. Configuring IP Settings On your computer, configure the IP settings to connect with the controller: NOTE The below substeps assume that your computer is a Windows computer.
Page 24 On the Network Connections window, double-click the Ethernet connection that you are using on the computer. For computers with one Ethernet port, it's the Ethernet option. In the Ethernet Properties Networking tab, double-click Internet Protocol Version 4 (TCP/IPv4)........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........24...
Page 25 In the IPv4 Properties pop-up General tab, select Obtain an IP address automatically. This allows the DHCP server to automatically assign your computer an IP address for communicating with the robot controller........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........25...
Page 26 Click OK to save these settings. INFO Selecting Use the following IP address instead is also valid, but make sure that the IP address that you are manually entering is compatible with the robot controller and doesn't interfere with other devices. For example, try setting the static IP address to 192.168.125.3 and the Subnet mask to 255.255.255.0.
Page 27: Connecting To The Controller In Robotstudio
Connecting to the Controller in RobotStudio Select the Controller tab at the top of the screen........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........27...
Page 29: Backing Up The Controller
If the controller doesn't connect, follow the instructions in the error pop-up for checking your Ethernet cable connection and your IP configuration settings. NOTE If you see the following pop-up, click Log in as Default User if you don't have a Username and Password.
Page 30: Factory Resetting The Controller
Choose where to save your backup, then click OK to start the backup. Wait for it to finish. Factory Resetting the Controller ........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........30...
Page 31 With the mode switch on the ABB controller set to AUTO, click Request Write Access. This allows you to edit settings on the controller. Reset the controller to its factory default settings: CAUTION A factory reset (I-start) is recommended because it kills all currently-running programs and guarantees that there will be no conflicts during the ForgeOS file transfer.
Page 32: Transferring Files
If the Restart menu is unavailable, try pressing the ABB controller's E-Stop to stop motion programs. Click OK to confirm the factory reset. Wait for the controller to restart and reconnect to RobotStudio. Transferring Files Click Request Write Access to regain access.
Page 33 Connect the USB drive with the ForgeOS robot driver files to your RobotStudio computer. Follow these steps to copy the ForgeOS robot driver files onto the controller: ........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........33...
Page 34 Select the File Transfer button. In the PC Explorer, find the ForgeOS robot driver files on the USB flash drive in forge_os\ready-abb-driver. Select all of the .sys and .mod files. In the Controller Explorer, find the HOME directory. Create a new folder called "READY"...
Page 35 Follow these steps to copy the controller parameters onto the controller: Select the Load Parameters button. At the bottom of the Open window, select Delete existing parameters before loading. Open the folder named Config in the USB drive. Select all of the .cfg files, and then click Open to load them.
Page 36 If RobotStudio warns you that existing parameters will be deleted, press OK. If RobotStudio asks you to restart the controller, press OK to clear the pop-up. However, to save time, wait to reboot until you do the next step........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........36...
Page 37 Click the Configuration dropdown and select Communication. Of the Type options, select IP Setting. Make sure there is a network called FORGE Network on the ABB WAN interface. Double click over FORGE Network to bring up the instance editor. Set the IP Address to 192.168.1.20 and set the Subnet Mask to 255.255.255.0.
Page 38: Finishing Device Configuration
Restart the ABB controller by selecting Restart (Warmstart) in the Restart dropdown. Wait for the restart to finish. Keep the ABB controller set to AUTO mode. You can also use the power switch on the robot controller instead. Finishing Device Configuration In ForgeOS, finish entering your robot device information: ........
Page 39 Give your device a name. For the IP Address, enter 192.168.1.20 or the IP address you assigned to the robot, if different. Tap SAVE. ForgeOS attempts to connect with the robot controller for up to 20 seconds. INFO If the robot controller fails to connect, you see this pop-up........
Page 40 Click DISMISS, do the following, then try to tap SAVE again: Check the Ethernet connection between the robot controller and IPC. Check the network settings on the robot controller. Check if the robot controller is on and in the correct operating mode (in auto or remote mode).
Page 41 INFO View more info of TCPs and Payloads here. Set up the robot controller's Input/Output (IO) signals for use in the Device Control app and Task Canvas. You can come back to this later by editing the device's configuration. Tap SAVE to finish robot configuration.
Page 42: Next Steps
NOTE To use these I/O signals, integrate your I/O devices with the robot controller. Next Steps Congrats! Now that your device is connected in ForgeOS, here are four options of how to proceed: ........© COPYRIGHT READY Robotics ALL RIGHTS RESERVED ........42...
Page 43 Begin using your robot device as is (without custom IO signals) to program Task Canvas tasks. Follow this to wire IO devices to the ABB robot controller and add new IO signals in ForgeOS from scratch. Follow this to restore a backup of a previous IO configuration (instead of re-entering this data from scratch in RobotStudio).

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