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READY FORGE OS5 Startup Manual

Abb irc5/irc5c
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ABB IRC5/IRC5C Startup Guide

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  • 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

    Wiring The KEBA Pendant Without A READY Product ....... . .

  • Page 4: Overview

    9. Control your ABB robot with Forge/OS! Note: We recommend backing up your ABB controller. You can save a backup before starting by following ABB instructions or you can save a backup using RobotStudio later in this guide. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • 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

    INSTALLING ABB SAFETY I/O MODULES You must adapt the factory-configured IRC5 to enable the KEBA pendant's safety features. Find your ABB safety I/O modules before moving on. READY does not sell these items. Please contact your local distributor or sales rep.
  • 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 Without A Ready Product

    ▪ Emergency Stop Button ▪ Robot Mode Key Switch Follow these steps if you want to do all the integration yourself without the use of READY- made Forge hub. If you want to integrate using a READY Kit, contact READY Robotics for the correct startup guide.
  • Page 10 Connect the KEBA pendant's Ethernet connector to the Forge hub PC through your own integration hardware. 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. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 11 DX581-S: 4.3 (I7) When external safety fencing is not required: 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 12: 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 13: Setting Up Forge/Os

    ESC, F10, F11, or F12. Refer to vendor information for boot options. From the boot options, select Forge to boot from the USB installer. The installer may take a while to load. Wait until the installation wizard opens. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 14 VERSION 1.0.1 Select your language. Then click Install Forge. Choose a keyboard layout. Then click Continue. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 15 Select Erase disk and install forgeos. Then click Install Now. Note: If Forge/OS is already installed, the installation wizard may prompt you with additional options. The current goal is to erase the entire disk © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 16 VERSION 1.0.1 Confirm that you want to erase the entire disk by clicking Continue. If you are installing on a Forge/Ctrl, check the checkbox labeled "This hardware is a Forge CTRL". Click Continue. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 17 Note: The username and password that you create here are for accessing the Forge hub computer on a monitor other than the KEBA pendant. They are NOT a username and password for signing in to Forge/OS on the KEBA pendant. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 18 VERSION 1.0.1 Wait for the installation to complete. Once the installation completes, click Restart Now. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 19 You will see a black screen that asks you to remove the USB installer. Unplug the USB installer from your computer and press the Enter key on your keyboard. You will see a black screen with the Forge/OS 5 logo. Wait for Forge/OS to finish booting up. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 20 VERSION 1.0.1 When you see the below blue screen, Forge/OS is officially installed and ready to run on the KEBA pendant! Disconnect the monitor, keyboard, and mouse that you used to install Forge/OS. The Pendant Pairing screen shows on the KEBA pendant. This is where you connect the pendant to Forge/OS each time you reboot.
  • Page 21 Find another USB drive to use for Forge/OS license activation. 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.
  • Page 22 Import the activation certificate and create the unlock certificate. Insert the USB into your PC. 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. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 23 Remove the USB from your PC. Import the unlock certificate in Forge/OS On the KEBA pendant, tap Import Unlock Certificate. Insert the USB into your Forge hub. Click Load Unlock Certificate from USB Drive. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 24 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 25 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 26 On the Settings app main screen, tap General Settings. 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.
  • Page 27 On the Settings main screen, tap Network. The table lists the available network interfaces on your Forge hub. By default, the first interface listed is configured for the KEBA pendant. You can't edit the pendant's interface in Forge/OS. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 28 Select another interface and tap Edit to see the network settings. This will be the interface that you connect the robot to. You can connect more peripheral devices to this interface using a switch. Change the network interface to match these settings: Tap SAVE to finish. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

  • Page 29: 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 30 Select the correct robot and controller models. You will fill in the other information later. Insert a USB flash drive into the Forge hub as instructed on the screen. Use an empty © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
  • Page 31 VERSION 1.0.1 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 32: 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 33 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 34 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 35 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 36 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 37 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 38 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 39 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 40 VERSION 1.0.1 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 41 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 42 (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 43 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 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51 Controller tab, click Request Write Access. In the Controller tab, select the File Transfer button. In the PC Explorer, find the ABB driver files on the USB in forge_os\ready-abb- driver. Select all of the .sys and .mod files.
  • Page 52 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 53 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 54: 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 55 (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 56 Forge/OS returns to the Device Configuration home screen. Make sure the robot appears in the configured devices list and that it is enabled. If you successfully completed this robot configuration, congratulations! You are ready to control your robot in the Device Control Panel and Task Canvas apps.

  • Page 57: Resources

    RESOURCES Want to learn more about how Forge/OS can empower you? READY.Academy offers hands-on courses to help you deploy a robotic system, from laying out the entire workcell to programming robots. With this online academy, you can watch FREE courses whenever it is convenient for you: ready.academy...
  • Page 58 VERSION 1.0.1 © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

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