ready robotics Forge/OS 5 Startup Manual
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ready robotics Forge/OS 5 Startup Manual

Abb irc5/irc5c
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ABB IRC5/IRC5C Startup Guide

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Summary of Contents for ready robotics Forge/OS 5

  • Page 1 ABB IRC5/IRC5C Startup Guide...
  • Page 2 The documentation, best practices, and recommendations provided by READY Robotics do NOT constitute safety advice. Products sold through READY Robotics are not by themselves a fully integrated workcell. As required in ISO 10218-2, READY Robotics strongly recommends performing a complete risk assessment of the integrated workcell per ISO 12100.

  • Page 3: Table Of Contents

    Resources ............... . 48 © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 4: Overview

    VERSION 1.0.0 OVERVIEW This guide will help you set up an ABB robot controller for use with Forge/OS 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. Check whether the ABB controller options and software version meet Forge/OS requirements.
  • Page 5 Prepared for ABB CI502 1241-1 ABB (Software Option) ProfiNet IO Module CI502-PNIO Ethernet Terminal Unit TU508-ETH Safety IO Module DX581-S Safety Terminal Unit TU582-S RobotStudio, Basic License (any version with RW 6.06.01 support) © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 6 ABB Library Link RobotStudio download page, new.abb.com/products/robotics/robotstudio Application Note: Setting Up the IRC5 with "Prepared for CI502", 3ADR010316 Rev A, ABB Library Link AC500-S F_iPar_CRC Calculator tool download page, ABB Library Link © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 7: Installing Abb Safety I/O Modules

    Enclosure or Control Panel for Safety I/O Hardware In your safety I/O enclosure, install the safety I/O modules together onto a DIN rail. For assembly instructions, see "References" (section 1.5) in ABB's Unbundled S500 Safety I/ Os [1]. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 8 CI502/TU508: 1.9 (ZP) DX581/TU582: 1.8 (UP) +24V DX581/TU582: 1.9 (ZP) Use an Ethernet cable to connect either ETH1 or ETH2 on the TU508-ETH Terminal Unit to port X4 (LAN2) on the IRC5. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 9: Wiring The Keba Pendant With A Ready Product

    If Forge/OS is installed on a READY device (e.g Forge/Hub or Forge/Ctrl), follow these steps to connect with your robot controller. If you would like to perform the integration yourself, please contact READY Robotics for the correct startup guide. Forge hub (Forge/Ctrl shown)
  • Page 10 Ctrl to the KEBA pendant using the KEBA Pendant Junction Box. Attach the M12 connector on the flying lead cable to the port on the KEBA Pendant Junction Box or the Safety connector on the Forge/Hub. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 11 If you install external safety fencing, connect the fence contact safety inputs to the DX581-S: Function DX581-S Terminal Fence: Contact 11 DX581-S: 1.2 (T1) Fence: Contact 12 DX581-S: 2.3 (I3) Fence: Contact 21 DX581-S: 3.2 (T3) Fence: Contact 22 DX581-S: 4.3 (I7) © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 12 If you do not install external safety fencing: Connect DX581-S terminals 1.2 (T1) and 2.3 (I3) with a jumper wire. Connect DX581-S terminals 3.2 (T3) and 4.3 (I7) with a jumper wire. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 13: Connecting The Irc5 And Forge Hub Through Ethernet

    ABB controller. Plug in and turn on your Forge hub device and other integration hardware. If there are issues, power off each device, disconnect from power supplies, and check your wiring. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 14: Setting Up Forge/Os

    Note: If you try to open another app, you will be redirected to the Settings app until you activate a valid user license. Find another USB drive to use for Forge/OS license activation. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 15 VERSION 1.0.0 Note: Contact READY Robotics for your license code. You can use any USB format for these steps. Don't use the USB installer that you installed Forge/OS with unless you clean and reformat it. On the Settings app main screen, tap License Info.
  • Page 16 Find the USB in your PC file explorer. Open the new "Forge_OS-License-Activation- Certificate.txt" file from the USB and copy all the contents. Open an internet browser and go to the Forge/OS 5 License Portal. Note: Access the license portal at www.activationportal.me/selfservice/ activation.aspx?Type=1&cid=7461&pid=8933&lang=en-US...
  • Page 17 If you need to update Forge/OS from a USB drive, you can do that through the System Update screen. Note: Contact READY Robotics for an update file. Update files are too large for the FAT32 file format. Use an exFAT or NTFS formatted USB drive to download and install the update.
  • Page 18 When the update files show under Available Versions, tap the version to install. Wait for the update to finish and restart Forge/OS using the power button at the bottom of the screen. You can change system preferences from the Settings app before moving on. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 19 Change the Time and Date settings or the Admin login password. Note: If you later forget what you change your password to, contact READY Robotics to reset it. Tap SAVE to save changes and exit the General Settings menu. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 20: Getting Robot Files From Forge/Os

    In this section, you will start to add the robot in Forge/OS and get the robot files to put onto the robot controller. In the Admin role, tap the Device Configuration icon to open the Device Configuration app. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 21 Select the ABB industrial robot option and tap NEXT to continue with configuration. Enter the device name and IP address of the ABB controller, and select the correct robot and controller models. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 22 Insert a USB flash drive into the Forge hub as instructed on the screen. Use an empty flash drive with at least 2GB of storage. Tap Start Transfer and wait for it to finish. Remove the USB drive when prompted. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 23: Configuring The Abb Controller In Robotstudio

    If you are asked to activate a professional license, click Cancel. You can perform these steps with the basic RobotStudio version. Note: You don't need to install RobotWare on RobotStudio for this setup. Change RobotStudio preferences: © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 24 Connect your RobotStudio computer to the ABB controller service port: X2 (Service). Connect to the ABB controller in RobotStudio: Select the Controller tab, then click the Add Controller dropdown and select One Click Connect. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 25 Reset the controller to its factory default settings. Note: The rest of this guide assumes the ABB controller is set to factory settings. If you don't factory reset the system, you might experience errors because of conflicting settings. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 26 Note: These sub-steps are based on ABB's instructions in Setting Up the IRC5 with "Prepared for CI502" [3]. You can look at the ABB guide for reference if you need to, but follow these sub-steps. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 27 Tool (called "I/O Configurator" in older versions of RobotStudio). Open the PROFINET Network properties by selecting PROFINET Network in the Configuration tree. You can find PROFINET Network by expanding Communication, then IP Setting. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 28 Open the PROFINET station properties by selecting PROFINET in the Configuration tree. You can find PROFINET by expanding I/O System. Set the Network Connection to Private Network. For the PROFINET Station Name, enter irc5-pnio. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 29 Add the DX581-S module: Select PROFINET > Controller > CI502_PNIO_V3 in the Configuration tree. Select the Device Catalogue tab in the Properties window. Double-click on the "DX581-S InputOutput" option. Make sure it appears in the Configuration tree under the CI502 device. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 30 In the image below, the tens place is set to 0x10H and the ones place is set to 8x01H, so the Destination address is 08H (or 08 in decimal). The station name is "ci502-pn-08". © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 31 VERSION 1.0.0 Open DX581 module properties: Select "DX581_S_InputOutput_Safety" in the Configuration tree and choose the Properties tab. Under PROFIsafe F-Parameters, find the Destination address box. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 32 PROFIsafe F-Device identification. The default setting of the rotary switches is 02H in hexadecimal, or 2 in decimal. You can find a hexadecimal to decimal converter online if you don't know how to convert the number. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 33 (Safety)" in the Configuration tree and choose the Properties tab. Use the channel settings shown in this image. Set all the Input x, Channel configurations to "2 channel equivalent" and set the Discrepancy times to "100 ms". © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 34 Open DX581 module properties: Select "DX581_S_InputOutput_Safety" in the Configuration tree and choose the Properties tab. Under PROFIsafe F-Parameters, find the I Par CRC (hex) box. Click the Vendor Tool button to open the calculator. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 35 Check the confirmation checkbox and copy the Hex value at the bottom. Go back to the DX581 module properties and paste the hex value into the I Par CRC (hex) box. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 36 Follow these steps to set up the IRC5 SafeMove configuration. This is how you assign the safety signals to actions on the IRC5. These steps are crucial for safe operation of the robot through Forge/OS. From the Controller tab, click the Safety dropdown and open Visual SafeMove. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 37 Click Global signals to expand the list of signals and add these signals. To add a signal, double-click on Create new signal (the blank row), then type a signal name and press enter. ▪ FullSpeedActive, 0, BOOL ▪ MotionActive, 0, BOOL ▪ StopMotion, 0, BOOL © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 38 FullSpeedActive := KEY_AUTO Add a new expression called "Stop_Logic". In the bar at the bottom of the window, enter: MotionActive := ((FENCE_CLOSED AND KEY_AUTO) OR ((NOT KEY_AUTO) AND THREE_POS_ENABLED)) © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 39 StopMotion := NOT ((FENCE_CLOSED AND KEY_AUTO) OR ((NOT KEY_AUTO) AND THREE_POS_ENABLED)) On the left side configuration tree, right click over Stop Configurations and click Stop Configuration to add an item. Set the Stop Configuration as shown below. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 40 Right click over Tool Speed Supervisions and click Global Tool Speed Supervision to add an item. Right click over Global_TSP and rename to "T1_Supervision". Change the settings to match the image below. Leave the Min. speed box empty. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 41 When you are asked to restart the controller, click Yes and wait for it to restart. Follow these steps to copy the robot driver files onto the controller. These are the programs that run on the ABB controller to allow Forge/OS control. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 42 Open READY and transfer all of the driver files into the READY folder. Follow these steps to copy the controller parameters onto the controller. These settings allow Forge/OS to communicate with the ABB controller. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 43 If RobotStudio asks you to restart the controller, ignore it. Follow these steps to check the controller network settings to allow communication with Forge/OS. In the Controller tab, click the Configuration dropdown and select Communication. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 44 If something is wrong, double-click on a row to edit the IP Setting or right-click and add a new IP Setting. Restart the ABB controller. As it's restarting, make sure the ABB controller is set to AUTO mode. Wait for the controller to fully restart. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 45: Adding The Robot In Device Configuration

    When the robot connects, you can add Tool Center Points (TCPs) or Payloads for the robot. You can come back to this later by editing the device's configuration. Tap SAVE to continue. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 46 (Optional): Set up the robot controller's Input/Output (IO) signals for use in the Device Control Panel and Task Canvas. Enter a Display Name (i.e. "Open Machine Door", "Open Pneumatic Vise", or "Start Machining Cycle") to show what each signal does in other apps. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 47 If you successfully completed this robot configuration, congratulations! You are ready to control your robot in the Device Control Panel and Task Canvas apps. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 48: Resources

    For products and services offered by READY and our partners, visit READY.Market: market.ready-robotics.com If you encounter a problem and need to talk to someone, reach out to us. ▪ Email READY Robotics: support@ready-robotics.com ▪ Call READY Robotics: 833-732-3977 © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 49 VERSION 1.0.0 © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

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