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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.

Requirements

Description

Part Number

Vendor

QTY.

ProfiNet I/O Module

CI502-PNIO

ABB

1

Ethernet Terminal Unit

TU508-ETH

ABB

1

Safety I/O Module

DX581-S

ABB

1

Safety Terminal Unit

TU582-S

ABB

1

24V DC Power Supply Module

1

Enclosure or Control Panel for Safety I/O Hardware

1

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]

.

1

VERSION 1.0.0

© 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED

7

Summary of Contents for Forge/OS 5

Page 1: ...ABB IRC5 IRC5C Startup Guide ...

Page 2: ... 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 You may wish to use the methodology found in the ANSI RIA TR R15 306 Task based Risk Assessment Methodology VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 2 ...

Page 3: ...Product 9 Connecting The IRC5 And Forge Hub Through Ethernet 13 Setting Up Forge OS 14 Getting Robot Files From Forge OS 20 Configuring The ABB Controller In RobotStudio 23 Adding The Robot In Device Configuration 45 Resources 48 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 3 ...

Page 4: ...ps 1 Set up ABB safety I O modules 2 Connect the KEBA pendant safety features to the safety I O modules 3 Connect the ABB controller to your Forge hub 4 Power up your systems 5 Install and set up Forge OS 6 Get robot configuration files from Forge OS 7 Connect to the ABB controller with Robot Studio and configure for Forge OS 8 Add the robot in Forge OS 9 Control your ABB robot with Forge OS Note ...

Page 5: ...aging Option 672 1 ABB Software Option 1 Safety Module 996 1 ABB Software Option 1 SafeMove Pro 1125 2 ABB Software Option 1 Prepared for ABB CI502 1241 1 ABB Software Option 1 ProfiNet IO Module CI502 PNIO ABB 1 Ethernet Terminal Unit TU508 ETH ABB 1 Safety IO Module DX581 S ABB 1 Safety Terminal Unit TU582 S ABB 1 RobotStudio Basic License any version with RW 6 06 01 support ABB 1 VERSION 1 0 0 ...

Page 6: ...ary Link 2 RobotStudio download page new abb com products robotics robotstudio 3 Application Note Setting Up the IRC5 with Prepared for CI502 3ADR010316 Rev A ABB Library Link 4 AC500 S F_iPar_CRC Calculator tool download page ABB Library Link VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 6 ...

Page 7: ...Number Vendor QTY ProfiNet I O Module CI502 PNIO ABB 1 Ethernet Terminal Unit TU508 ETH ABB 1 Safety I O Module DX581 S ABB 1 Safety Terminal Unit TU582 S ABB 1 24V DC Power Supply Module 1 Enclosure or Control Panel for Safety I O Hardware 1 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 ...

Page 8: ...power by connecting these terminals to the power supply ABB Safety IO Terminal Connection CI502 TU508 1 8 UP 24V CI502 TU508 1 9 ZP 0V DX581 TU582 1 8 UP 24V DX581 TU582 1 9 ZP 0V 3 Use an Ethernet cable to connect either ETH1 or ETH2 on the TU508 ETH Terminal Unit to port X4 LAN2 on the IRC5 4 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 8 ...

Page 9: ...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 IRC5 KEBA pendant KEBA Pendant Junction Box for Forge Ctrl only 12 Pin M12 Cable Plug x Flying Leads VERSION 1 0 0 2021 COPYRIGHT READY Robotics A...

Page 10: ...uct with attached KEBA pendant Note If you are using a Forge Ctrl this guide assumes you have connected the Forge Ctrl to the KEBA pendant using the KEBA Pendant Junction Box 1 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 2 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 10 ...

Page 11: ...T0 Yellow Emergency Stop Circuit 1 DX581 S 2 1 I1 Black Emergency Stop Circuit 2 DX581 S 3 0 T2 Grey Emergency Stop Circuit 2 DX581 S 4 1 I5 Red Key Switch Circuit 1 DX581 S 1 2 T1 Violet Key Switch Circuit 1 DX581 S 2 2 I2 Grey Pink Key Switch Circuit 2 DX581 S 3 2 T3 Red Blue Key Switch Circuit 2 DX581 S 4 2 I6 3 If you install external safety fencing connect the fence contact safety inputs to t...

Page 12: ... external safety fencing Connect DX581 S terminals 1 2 T1 and 2 3 I3 with a jumper wire 1 Connect DX581 S terminals 3 2 T3 and 4 3 I7 with a jumper wire 2 5 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 12 ...

Page 13: ...rnet cable into a LAN port on the Forge hub device and the other end into port X6 WAN on the IRC5 2 Power on your ABB controller I O modules and Forge hub Reconnect the controller to power and turn it on Follow ABB instructions for powering the ABB controller 1 Plug in and turn on your Forge hub device and other integration hardware 2 If there are issues power off each device disconnect from power...

Page 14: ... the KEBA pendant tap PAIR PENDANT Note The blue PAIR PENDANT button may take some time to appear 1 Tap Admin and sign in The default Admin password is forgeadmin 2 From the Home Screen tap on the Settings icon to open the Settings app Note If you try to open another app you will be redirected to the Settings app until you activate a valid user license 3 Find another USB drive to use for Forge OS ...

Page 15: ...Settings app main screen tap License Info Tap Generate Certificate 1 Enter your license code 2 Insert the USB into your Forge hub 3 Tap Start Writing Certificate to USB Drive when prompted 4 Remove the USB from your Forge hub 5 5 Import the activation certificate and create the unlock certificate Insert the USB into your PC 1 6 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 15 ...

Page 16: ...tal me selfservice activation aspx Type 1 cid 7461 pid 8933 lang en US 3 Paste the contents of the activation certificate file and click Activate 4 The portal generates new text characters Copy all of the text and paste it in the empty Forge_OS License Unlock Certificate txt file 5 Save the unlock certificate file 6 Remove the USB from your PC 7 Import the unlock certificate in Forge OS 7 VERSION ...

Page 17: ...rt these license activation steps 5 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 Don t use the USB installer that you installed Forge OS with unless you clean and reformat ...

Page 18: ...ow under Available Versions tap the version to install 3 Wait for the update to finish and restart Forge OS using the power button at the bottom of the screen 4 You can change system preferences from the Settings app before moving on 9 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 18 ...

Page 19: ...e 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 2 Tap SAVE to save changes and exit the General Settings menu 3 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 19 ...

Page 20: ... 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 1 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 20 ...

Page 21: ...lter by dropdown to show only robots on the list 3 Select the ABB industrial robot option and tap NEXT to continue with configuration 4 Enter the device name and IP address of the ABB controller and select the correct robot and controller models 5 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 21 ...

Page 22: ...ddress is set to 172 16 255 251 by robot configuration files in the next section 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 6 Tap Start Transfer and wait for it to finish 7 Remove the USB drive when prompted 8 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 22 ...

Page 23: ...stall RobotStudio Make sure to extract the contents of the zip folder before running the RobotStudio setup 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 1 Change RobotStudio preferences 2 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESE...

Page 24: ...tions window Connect the USB drive with the robot files to your RobotStudio computer 3 Connect your RobotStudio computer to the ABB controller service port X2 Service 4 Connect to the ABB controller in RobotStudio Select the Controller tab then click the Add Controller dropdown and select One Click Connect 1 5 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 24 ...

Page 25: ... dropdown and select Create Backup 1 Choose where to save your backup then click OK to start the backup and wait for it to finish 2 6 Set the mode switch on the ABB controller to AUTO then in the Controller tab click Request Write Access This allows you to edit settings on the controller 7 Reset the controller to its factory default settings Note The rest of this guide assumes the ABB controller i...

Page 26: ...tudio 2 If you reset and restarted the controller click Request Write Access again 9 Set up the Safety I O modules 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 10 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 26 ...

Page 27: ...lled I O Configurator in older versions of RobotStudio 1 Open the PROFINET Network properties by selecting PROFINET Network in the Configuration tree You can find PROFINET Network by expanding Communication then IP Setting 2 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 27 ...

Page 28: ...NET 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 4 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 28 ...

Page 29: ... on the CI502 PNIO V3 option 5 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 6 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 29 ...

Page 30: ...must be entered as ci502 pn xx where you replace xx with the decimal value of the switches The switches are set to a hexadecimal value Add the rotary hexadecimal values together and convert the number to decimal form 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 8 VERSION 1 0 0...

Page 31: ...ties Select DX581_S_InputOutput_Safety in the Configuration tree and choose the Properties tab Under PROFIsafe F Parameters find the Destination address box 9 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 31 ...

Page 32: ...mage below the tens place is set to 0x10H and the ones place is set to 3x01H so the Destination address is 03H or 3 in decimal Note The destination address is also known as the F_Dest_Add and is used for 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 c...

Page 33: ... in the Configuration tree and choose the Properties tab 11 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 12 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 33 ...

Page 34: ...t the link in the references table 4 before moving on 13 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 14 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 34 ...

Page 35: ...I O channel settings are right Check the confirmation checkbox and copy the Hex value at the bottom 15 Go back to the DX581 module properties and paste the hex value into the I Par CRC hex box 16 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 35 ...

Page 36: ...lick on the other cells to change the Type of Signal and Device Mapping 17 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 1 11 VERSION 1 0 0 2021 COPYRIGHT READY Robotics AL...

Page 37: ...and 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 3 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 37 ...

Page 38: ...ottom of the window enter FullSpeedActive KEY_AUTO 4 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 5 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 38 ...

Page 39: ...OT FENCE_CLOSED AND KEY_AUTO OR NOT KEY_AUTO AND THREE_POS_ENABLED 6 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 7 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 39 ...

Page 40: ...ght 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 9 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 40 ...

Page 41: ...ntroller If the SafeMove Report Window appears check the configuration on the report and click OK at the bottom 11 When you are asked to restart the controller click Yes and wait for it to restart 12 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 12 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL...

Page 42: ... Select all of the sys and mod files 3 In the Controller Explorer find the HOME directory Create a new folder called READY if it does not exist Right click and select New Folder to create READY 4 Open READY and transfer all of the driver files into the READY folder 5 Follow these steps to copy the controller parameters onto the controller These settings allow Forge OS to communicate with the ABB c...

Page 43: ...e USB drive select all of the cfg files and load them 3 If RobotStudio asks you to restart the controller ignore it 4 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 1 14 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 43 ...

Page 44: ...n leave it as the default shown below if you want 3 If something is wrong double click on a row to edit the IP Setting or right click and add a new IP Setting 4 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 15 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 44 ...

Page 45: ...ller default IP address shown 1 In Forge OS confirm your device settings and tap SAVE to add the robot Forge OS attempts to communicate with the robot controller 2 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 3 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RE...

Page 46: ...p 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 1 4 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 46 ...

Page 47: ... in the Device Control Panel check the DCP box next to that signal Note To use these I O signals you must integrate your automation equipment with the robot controller 2 Tap SAVE 3 Forge OS returns to the Device Configuration home screen Make sure the robot appears in the configured devices list and that it is enabled 5 VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 47 ...

Page 48: ...ls and hardware integration guides check out our Support page support ready robotics com For articles whitepapers and other resources check out our Resources page ready robotics com 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 rea...

Page 49: ...VERSION 1 0 0 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 49 ...

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