[Albert]

I recommend you to reduce the number of lines per program.

1. Select Tools-Options-Program
   
2. Check "Limit the maximum lines per program" and set it to 5000 or less.
   

The default number of lines per program is usually defined by the post processor. For ABB IRC5 controllers it is 20000 lines.

When you split a program in subprograms you'll see a main program module that loads/unloads each subprogram automatically. The folder must be placed in the controller (automatic transfer from RoboDK or using a USB drive). Make sure to set the programs path in your main program or post processor (select Program-Add/Edit Post processor, select the ABB IRC5 post and change the variable RAPID_REMOTE_PATH).