ready robotics Forgelos5 Startup Manual

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Yaskawa YRC1000micro Startup Guide

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Page 1 Yaskawa YRC1000micro 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 4: Overview
9. Finish Device Configuration in Forge/OS. Note: This guide assumes that you have installed the Yaskawa robot and controller according to Yaskawa instructions. Make sure the Yaskawa controller is in working order before moving on. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 5 Note: For Collaborative robots, refer to the 16-digit password in the Collaborative Robot Password Agreement. If you cannot locate this document contact Yaskawa Motoman support, provide the Warranty ID on the top of the Yaskawa controller, and they will be able to provide it. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 6: Back Up And Upgrade The Yaskawa Controller
Turn the pendant key to TEACH mode. Turn on the controller and wait for it to power up. Press the MAIN MENU button on the pendant and press the black arrow keys until you © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 8 VERSION 1.0.0 Use the arrows on the pendant to find and highlight EX.MEMORY in the menu list. Select SAVE. Scroll down to highlight SYSTEM BACKUP(CMOS.BIN), then press SELECT. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 9 Keep your USB backup drive in a secure location. You can save the backup files from the USB onto a workstation. Install the Yaskawa software version YBS2.43 following Yaskawa instructions. Note: YBS2.43 is the minimum supported version and the version tested with Forge/OS © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 10: Confirming Your Yaskawa Safety I/Oexpansion
Vendor QTY. FSU I/O Breakout - 68 pin (external) #149259-3 Yaskawa Motoman FSU I/O Board (internal) #185296-1 Yaskawa Motoman FSU I/O Cable #186172-2 Yaskawa Motoman Functional Safety Perimeter Software #179502-22 Yaskawa Motoman © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 11: Installing The Keba Pendant Without Aready Product
▪ 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 12 Connect the remaining safety I/O leads to your hardware and make your own cable/wiring for the 12 safety signals long enough to reach the Safety I/O terminals. Include ferrules at the end of your wiring to insert in the terminal blocks. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 13 If you are not using external safety fencing: Bridge the FSU I/O Breakout pins 61 and 63 with a jumper wire. Bridge the FSU I/O Breakout pins 65 and 67 with a jumper wire. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 14: Connecting The Yrc1000 And Forge/Os Through Ethernet
Connect one end of the Ethernet cable to the LAN port on the back of the YRC1000micro. Plug the other end of the Ethernet cable into a LAN port on the Forge hub device. Reconnect the YRC1000micro, Forge hub, and other devices to their power sources. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 15: 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 17 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 18 VERSION 1.0.0 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 19 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 21 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 22 KEBA pendant! Disconnect the monitor, keyboard, and mouse that you used to install Forge/OS. On the KEBA pendant, tap PAIR PENDANT. Note: The blue PAIR PENDANT button may take some time to appear. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 23 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 24 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 25 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 26 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 27 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 28 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 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 VERSION 1.0.0 Tap Add Device to open the Device Library. In the Device Library list, select Yaskawa Motoman industrial robot. Then tap NEXT. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 31 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 33: Changing Yaskawa Motoman Settings To Prepare For Forge/Os
On the Motoman pendant, turn the key to the "TEACH" position (fully counter clockwise). Clear any active alarms by tapping the RESET button at the bottom right hand corner of the screen. Change the security mode to Safety Mode: © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 34 Enter the Safety Mode password and press ENTER. If successful, the visible mode will change to SAFETY MODE. If an incorrect password was provided, you will get an Error 1030 message. Try again. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 35 Power off the YRC1000 controller and wait 10 seconds. Press and hold the MAIN MENU button while powering up the controller to enter Maintenance Mode. Release MAIN MENU when you hear the teach pendant beep. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 36 Enter the Safety Mode password and press ENTER. If successful, the visible mode will change to SAFETY MODE. If the password is incorrect password, you will get an Error 1030 message. Try again. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 38 Highlight the field next to MOTOMAN DRIVER and make sure it's set to USED. If not, press the SELECT button. At the Modify? prompt tap YES. Back in the OPTION FUNCTION menu, highlight the field next to MotoPlus FUNC and set it to USED. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 39 At the Initialize related files? SRAMDRV.DTA prompt tap YES. Save settings to the Safety I/O board. From the Main Menu, tap FILE, then tap INITIALIZE. Highlight Safety Board FLASH Reset and press the SELECT button. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 40 60 seconds to complete. When the reset is complete, the pendant will beep. Save settings to the PFL board (collaborative robots only): HighlightPFL Board FLASH Reset and press the SELECT button. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 41: Transferring Configuration Files
From the Main Menu, tap MotoPlus APL, tap FOLDER to select the folder to load files from. Tap the forge-os folder to open it, then tap to open the yaskawa folder. At the top of the screen, the TARGET FOLDER should be yaskawa. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 42 Verify that a small black star icon appears to the left of the file name and press the ENTER button on the pendant keypad. At the Load prompt tap YES. If asked to overwrite an existing file, select YES. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 43 If you have loaded Forge/OS files onto the Yaskawa Motoman controller before, you must make sure the correct MotoPlus application is now running and that no other apps are running: From the Main Menu, select MotoPlus APL., then MotoPlus MONITOR. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 44 Tap the forge-os folder to open it, then tap to open the yaskawa folder. At the top of the screen, the TARGET FOLDER should be yaskawa. From the Main Menu tap EX. MEMORY and then tap LOAD. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 45 Highlight JOB and press the SELECT button. Highlight each file and press the SELECT button on the keypad so that it is marked with a star. Press ENTER on the keypad. At the Load? prompt tap YES. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 46 Teach Mode, go to Main Menu > JOB > SELECT JOB. Tap the JOB tab in the upper left toolbar and choose DELETE JOB. Then select the job to delete. From the Main Menu, tap EX. MEMORY, then tap LOAD. HighlightFILE/GENERAL DATA and press the SELECT button. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 47 VERSION 1.0.0 Select TOOL DATA and press the SELECT button on the pendant keypad. Verify that the file is marked with a star. Press the ENTER button on the pendant keypad. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 48 The screen will change momentarily to the EXTERNAL MEMORY DEVICE screen and then you will be returned to the EX. MEMORY SCREEN. From the Main Menu, tap EX. MEMORY, then tap LOAD. Highlight FILE/GENERAL DATA and press the SELECT button. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 49 Highlight the SPEED LIMIT DATA file and press SELECT. Make sure the file is marked with a star. Press ENTER. At the Load? prompt tap YES. From the Main Menu, tap SAFETY FUNC, then choose SPEED LIMIT. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 50 VERSION 1.0.0 Highlight 2 in the File column and press the SELECT button. Select the field next to FILE VALID COND and select SIGNAL (2) and press the SELECT button. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 52 Repeat all sub-steps in the previous step for 3 in the File column (READYP-OFF). From the Main Menu, tap EX. MEMORY, then tap LOAD. Highlight I/O DATA and press the SELECT button. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 53 LOGIC FILE (YSFLOGIC.DAT). Note: For YRC1000micro with PFL option (collaborative robot): also highlight and select PSEUDO INPUT SIGNAL (PSEUDOIN.DAT) Press the ENTER button on the pendant keypad. At the Load? prompt, tap YES. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 54 Tap the WRITE button on the bottom of screen. Tap the CONFIRM button on the bottom of screen. At the Update the file? prompt tap YES. From the Main Menu, tap EX. MEMORY, then tap LOAD. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 55 Enter the Safety Mode password and press ENTER. If successful, the visible mode will change to SAFETY MODE. If the password is incorrect, you will get an Error 1030 message. Try again. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 56 At the Reset? prompt tap YES. Wait for the flash reset to complete. This process can take up to 60 seconds to complete. When the reset is complete, the pendant will beep. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 57 When the reset is complete, the pendant will beep. Power off the YRC1000 controller and wait 10 seconds Turn the Yaskawa Motoman pendant key to REMOTE mode (fully clockwise). Power up the YRC1000 controller. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 58 You can come back to this later by editing the device's configuration. Tap SAVE to continue. Note: The default TCP is located at the robot's tool flange, and the default Payload is 0. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 59 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 60: Tool Loading Procedure
In Forge/OS, go to the Device Configuration app and find the Yaskawa robot under Configured Devices. Select the device and tap Edit to open the robot configuration. Tap TCP AND PAYLOAD CONFIGURATION. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 61 Note: Forge/OS saves the updated TCPs and Payloads to tool.cnd in the USB root directory, not in the forge-os folder. Switch the Yaskawa Motoman pendant to TEACH and select Safety Mode again: © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 62 Select SAFETY MODE from the drop down list. Enter the SAFETY MODE password and press the ENTER button on the pendant keypad. From the Main Menu, tap EX. MEMORY, then tap LOAD. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 63 Highlight TOOL DATA and press SELECT. Then press ENTER. At the Load? screen select YES. Power off the Yaskawa controller and wait 10 seconds. Power on the controller while holding the Main Menu button on the Yaskawa Motoman © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 64 From the Main Menu, tap SYSTEM, then tap SECURITY. Select SAFETY MODE from the drop down list. Enter the SAFETY MODE password and press ENTER. Save changes to the Safety I/O board. From the Main Menu, tap FILE, then INITIALIZE. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 65 VERSION 1.0.0 Select Safety Board FLASH Reset. When prompted select YES. Wait for the reset to complete (15-20 seconds). Save settings to the PFL board (collaborative robots only): © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 66 Wait for the flash reset to complete. This process will take up to 120 seconds to complete. When the reset is complete you'll hear a beep. Turn the key to the "REMOTE" position (fully clockwise). © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 67 Power off the controller and wait 10 seconds. Power on the controller. When Forge/OS reconnects to the robot controller after the final power cycle, you will be able to clear the "TOOL MISMATCH" warning. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 68: Troubleshooting
KEBA pendant wiring section. Ensure that jumpers on safety fencing are fully seated into the terminal block. Issue #3 "I/O Media Error". This error occurs if the pendant cannot read the USB stick you connect. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 69 Target Device is set to read an SD card (SD: Pendant), change the field to USB:Pendant. If the Target Device is set to USB and you continue getting this alarm, contact Yaskawa Motoman Support. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 70 Update the maximum force permitted setting in accordance with safety assessment. Issue #6 “MotoPlus failed to create task” message appears on the Yaskawa Motoman teach pendant. Reboot the YRC1000 controller. If you continue getting this alarm, contact Yaskawa Motoman Support. © 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 71: 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...

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