YASKAWA YRC1000micro Startup Manual

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Page 1 Yaskawa YRC1000micro Startup Guide...
Page 2 VERSION 1.0.0 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
Getting Robot Files From Forge/OS ..........21 Changing Yaskawa Motoman Settings To Prepare For Forge/OS ......25 Transferring Configuration Files .
Page 4: Overview
VERSION 1.0.0 OVERVIEW This guide helps you set up your Yaskawa Motoman controller to work with Forge/OS 5. This startup guide covers the collaborative and non-collaborative YRC1000micro options. For collaborative robots, the YRC1000micro is taller because it comes with Power and Force Limiting (PFL) features.
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.
Page 6: Back Up And Upgrade The Yaskawa Controller
Save a backup of your robot controller software settings before you make any changes. Yaskawa Motoman controllers can save backups to either a USB drive or SD card. Refer to the Yaskawa Motoman controller guides for more information. We recommend using an empty USB storage drive with at least 2 GB of storage.
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...
Page 10: Confirming Your Yaskawa Safety I/Oexpansion
CONFIRMING YOUR YASKAWA SAFETY I/O EXPANSION Your YRC1000micro must include the Functional Safety Unit (FSU) Accessory Kit to work with Forge/OS through the KEBA pendant. Make sure you have these components in place. For collaborative robots (YRC1000micro with PFL): Functional Safety Unit Accessory Kit...
Page 11: Installing The Keba Pendant With A Ready Product
If you would like to perform the integration yourself, please contact READY Robotics for the correct startup guide. A Forge hub (Forge/Ctrl shown) YRC1000micro Controller KEBA pendant KEBA Pendant Junction Box (if not 12-Pin M12 Cable, Plug x Flying...
Page 12 VERSION 1.0.0 Electric Shock Warning: Disconnect all components from power sources before attempting this installation. Position your READY product 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. 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.
Page 13 VERSION 1.0.0 If you are using external safety fencing: Connect fence channel 1 to connector pins 61 and 63. Connect fence channel 2 to connector pins 65 and 67. 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.
Page 14: Connecting The Yrc1000 And Forge/Os Through Ethernet
Route Ethernet cabling from the Forge hub to the Yaskawa controller. 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.
Page 15: Setting Up Forge/Os
VERSION 1.0.0 SETTING UP FORGE/OS This section walks you through setting up Forge/OS on a KEBA pendant. Here, you will learn how to startup Forge/OS, sign in, activate a license, update the software version, and change settings. You may skip this section if Forge/OS is installed, activated, and up to date. On the KEBA pendant, tap PAIR PENDANT.
Page 16 VERSION 1.0.0 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. On the Settings app main screen, tap License Info. Tap Generate Certificate.
Page 17 VERSION 1.0.0 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. Open an internet browser and go to the Forge/OS 5 License Portal. Note: Access the license portal at www.activationportal.me/selfservice/ activation.aspx?Type=1&cid=7461&pid=8933&lang=en-US Paste the contents of the activation certificate file and click Activate.
Page 18 VERSION 1.0.0 On the KEBA pendant, tap Import Unlock Certificate. Insert the USB into your Forge hub. Click Load Unlock Certificate from USB Drive. Enter your license code. Tap Load Unlock Certificate. Note: Forge/OS will return you to the licensing home screen and show an active license.
Page 19 VERSION 1.0.0 Connect your USB drive to the Forge hub and wait for Forge/OS to detect it. 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.
Page 20 VERSION 1.0.0 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 21: Getting Robot Files From Forge/Os
VERSION 1.0.0 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.
Page 22 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 23 VERSION 1.0.0 Enter a Device Name and enter the device IP Address 172.16.255.251. A Description is optional. Then select your Robot and Controller models. If you are using a force sensor device, select it from the dropdown. 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.
Page 25: Changing Yaskawa Motoman Settings To Prepare For Forge/Os
Forge/OS and to enable the Safety I/O Expansion Board. These steps are only required if this is your first time setting up Forge/OS, or if your Yaskawa controller has been factory reset. On the Motoman pendant, turn the key to the "TEACH" position (fully counter clockwise).
Page 26 VERSION 1.0.0 From the Main Menu, select SYSTEM INFO, then SECURITY. Tap the field next to MODE or press SELECT. Scroll to SAFETY MODE from the drop down list and press the SELECT button on the pendant keypad. Enter the Safety Mode password and press ENTER. If successful, the visible mode will change to SAFETY MODE.
Page 27 VERSION 1.0.0 From the MAIN MENU, select SETUP, then choose FUNCTION ENABLE. Scroll down to highlight the field next to SAVE DATA CRC CHECK FUNC. (FSU) and press the SELECT button to set it to INVALID. 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.
Page 28 VERSION 1.0.0 Change the security mode to Safety Mode again: From the Main Menu, select SYSTEM, then SECURITY. Tap the field next to MODE or press SELECT. Scroll to SAFETY MODE from the drop down list and press the SELECT button on the pendant keypad.
Page 30 VERSION 1.0.0 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.
Page 31 VERSION 1.0.0 At the Modify? prompt tap YES. 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. ©...
Page 32 VERSION 1.0.0 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. Save settings to the PFL board (collaborative robots only): HighlightPFL Board FLASH Reset and press the SELECT button.
Page 33: 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.
Page 34 VERSION 1.0.0 Load the MotoPlus app. From the Main Menu, tap MotoPlus APL, then tap LOAD (USER APPLICATION). Highlight the MotoPlusYRC1..out file on the USB and press the SELECT button. Verify that a small black star icon appears to the left of the file name and press the ENTER button on the pendant keypad.
Page 35 If successful, the visible mode will change to SAFETY MODE. If the password is incorrect, you will get an Error 1030 message. Try again. 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.
Page 36 From the Main Menu, tap EX. MEMORY , then 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.
Page 37 VERSION 1.0.0 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 38 VERSION 1.0.0 If you get ERROR 2040 - Defined JOB name, you need to delete the existing "RR_x" jobs on the controller. While the software is in Safety Mode and the pendant is set to Teach Mode, go to Main Menu > JOB > SELECT JOB. Tap the JOB tab in the upper left toolbar and choose DELETE JOB.
Page 39 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 40 VERSION 1.0.0 At the Load? prompt tap YES. 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.
Page 41 VERSION 1.0.0 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 42 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 44 VERSION 1.0.0 At the Update the file? prompt tap YES. 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. ©...
Page 45 VERSION 1.0.0 Highlight and press the SELECT button on C.IO PRGM (CIOPRG.LST) and YSF 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.
Page 46 VERSION 1.0.0 From the Main Menu, tap SAFETY FUNC., then tap SAFETY LOGIC CIRCUIT . 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.
Page 47 VERSION 1.0.0 Tap SYSTEM DATA and press SELECT. Scroll down and highlight the IP NETWORK SET DATA file and press the SELECT button. Press the ENTER button. At the Load? prompt tap YES. 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.
Page 48 VERSION 1.0.0 Save changes to the Safety I/O board. From the Main Menu tap FILE and then tap INITIALIZE. Highlight Safety Board FLASH Reset and press SELECT. At the Reset? prompt tap YES. Wait for the flash reset to complete. This process can take up to 60 seconds to complete.
Page 49 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 50 VERSION 1.0.0 ADDING YOUR ROBOT IN DEVICE CONFIGURATION In these steps, you will save the robot in the Device Configuration app and finish the setup. In Forge/OS, confirm your device settings and tap SAVE to add the robot. Forge/OS attempts to communicate with the robot controller. When the robot connects, you can add Tool Center Points (TCPs) or Payloads for the robot.
Page 51 VERSION 1.0.0 (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. If you want a signal to appear in the Device Control Panel, check the DCP box next to that signal.
Page 52: Tool Loading Procedure
(TCPs) or Payloads are added. Follow these instructions to add new TCPs/Payloads in Forge/OS and update the Tool configuration on the Yaskawa Motoman controller. These are the basic steps to adding new tools to your Yaskawa robot in Forge/OS and on the Yaskawa controller: ▪...
Page 53 Tap SAVE again to exit the robot configuration. Forge/OS will upload a new tool data file with all of these TCPs and Payloads onto the USB attached to the Yaskawa Motoman pendant. If you didn't see one before, you will see a Tool Mismatch error now.
Page 54 VERSION 1.0.0 Turn the key to the “TEACH” position (fully counter clockwise). From the Main Menu, navigate to SYSTEM INFO, then SECURITY. Select SAFETY MODE from the drop down list. Enter the SAFETY MODE password and press the ENTER button on the pendant keypad.
Page 55 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 56 VERSION 1.0.0 programming pendant to boot in Maintenance Mode. Continue to hold the button until the Yaskawa Motoman programming pendant beeps. On the Yaskawa Motoman programming pendant: Make sure that the key is still in the "TEACH" position (fully counter clockwise).
Page 57 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 58 VERSION 1.0.0 HighlightPFL Board FLASH Reset and press the SELECT button. At the Reset? prompt, tap YES. 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"...
Page 59 VERSION 1.0.0 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 60: Troubleshooting
"Collaborative Password Agreement" If you do not have that on hand, call Yaskawa with your Warranty ID number and they will provide it to you. If you are using a non-collaborative robot, try re-entering the default safety mode password (5555 5555 5555 5555).
Page 61 Motoman teach pendant, select EX.MEMORY, and select DEVICE. If you find that the 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.
Page 62 Issue #4: "Tooling Mismatch" alarm in Task Canvas. This alarm occurs if an end-of-arm tool is attached to the robot, and you have not completed the Tool Loading Procedure. Make sure a USB drive is connected to the Yaskawa Motoman teach pendant and reapply the Device Configuration in Forge/OS. Then re-run the Tool Loading Procedure.
Page 63: Resources
VERSION 1.0.0 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 For software manuals and hardware integration guides, check out our Support page:...

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