ABB Robot Training: IRC5 Operations, Programming and Troubleshooting
ABB IRC5 training schedule
The ABB IRC5 Level 1-2 course is a 5-day, instructor-led class for maintenance technicians, supervisors and plant engineers with 0-1 year of hands-on ABB experience. It covers operations, RAPID programming in RobotStudio, and troubleshooting on the IRC5 controller and FlexPendant. Classes run at our training center in Warren, Michigan, or on-site at your facility if you prefer to train on your own cell. Check the schedule below for open dates and use the Reserve a seat button, or call 1-602-449-1556 to hold seats for your team.
| Dates | Course | Location | Length | |
|---|---|---|---|---|
| Oct 12–16, 2026 | ABB IRC5 Level 1–2Operations, Programming & Troubleshooting | Warren, MI | 5 days | Reserve a seat |
Classes run 7:00 a.m. to 3:30 p.m. with breakfast and lunch provided. Seats are limited and dates can change based on enrollment. Prefer your own plant? We also run these courses on-site.
Request on-site trainingOperation and FlexPendant skills
Lab work is done on ABB IRB 140 and IRB 1400 robots running the IRC5 controller and FlexPendant, so students learn on the same hardware they will support on the plant floor. Topics include:
- Safety procedures and system components
- Control panel and status indicator checks
- FlexPendant navigation and menu structure
- Coordinate systems and efficient jog methods
- Fault recovery and reading the event log
- Routine selection, cycling and the program pointer/cursor
- I/O screen setup and locating I/O points
- Auto-mode preparation and recovery after a stop
Students keep a teach pendant in hand even during theory, so these skills carry directly into the lab exercises and the final project.
RAPID programming and RobotStudio
Each student writes and optimizes a RAPID program in RobotStudio, then deploys it to the robot and runs it on the IRC5 controller. The course covers the difference between routines and modules, data types used in RAPID, and how to structure a program so another technician can follow it.
Motion instructions are covered alongside offset instructions, so students can move a robot to a taught point or run an offset path without touching the original program. The course also covers basic program editing and hot edits made while the robot is running in automatic mode, a skill maintenance techs use to make small corrections without stopping production for a full program reload.
Troubleshooting and recovery
Troubleshooting is built around the event log and I/O screens, so students learn to trace a fault back to its source instead of guessing at a fix. The course covers rev counter updates and calibration, including how to verify calibration and re-calibrate a motor or arm after a repair.
Students also learn the difference between a TCP adjustment and a position modification, and when each one applies. A large part of the week is spent on procedures that avoid position touch-ups after a motor swap, an internal cable change or a tooling crash, plus settings that limit damage to the robot if a collision happens. Backup and restore utilities are covered so a controller can be put back into service quickly after a repair.
How the ABB training runs
Labs run on ABB IRB 140 and IRB 1400 robots loaded with fixtures, parts and end-of-arm tooling, building up to a final project that ties the week’s lessons together. Classes run 7:00 a.m. to 3:30 p.m. for 5 days, with a light breakfast and lunch provided. The class ratio is 8 students to 1 instructor, with 2 students working per robot, and roughly 75% of the week is hands-on lab time.
Each student receives a textbook covering objectives, terminology and theory along with setup, operation and recovery procedures. A pretest and post-test measure progress, and employers can review course evaluations and the sign-in sheet. Students who work safely, pass all exercises and complete the assessments earn a training certificate of completion; this is not an ABB or other OEM certification. ABB S4 controller information can be provided on request.
On-site training, two-week programs and funding
If your plant runs a mix of ABB and FANUC robots, this course can be scheduled back-to-back with a FANUC level as a two-week program, or delivered as a two-week on-site seminar built around your own equipment. On-site training can also be run entirely at your facility; if your own robots are not available during the class, mobile robot cells can be rented for the week.
Michigan’s Going PRO Talent Fund and other state workforce training grants can help offset the cost of sending technicians to this course, whether they train in Warren, Michigan or on-site.
Reserve a seat in the ABB course
Use the Reserve a seat button on the schedule above, or submit the form with the course, date and number of students you want to enroll, to hold seats in an upcoming session. If you are not sure this course fits a technician’s experience, we can help with placement before you book.
On-site delivery is available if you would rather train a group of technicians on your own robots, with mobile robot cells available when needed. For questions about scheduling, placement or on-site training, call Robotics Integration at 1-602-449-1556.
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