READY Kawasaki F60 Startup Manual

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Kawasaki F60 Start Up Guide

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Page 1 Kawasaki F60 Start Up 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 3: Table Of Contents
Connecting the READY pendant ........
Page 4: Overview
VERSION 5.3.0 OVERVIEW Welcome to the Kawasaki F60 controller start up guide. Use this guide to set up your robot and Forge/OS 5. Here is an outline of the steps you will follow: 1. Set up safety I/O hardware. 2. Connect the READY pendant.
Page 5: Hardware Requirements
Ethernet/IP) XGPIO to D- Connects the Interface Module to Kawasaki 50979-3497 Sub Cable the robot controller. 50-Pos D-Sub Required for safety devices and tool Phoenix Interface 2315159 selection from Forge/OS. Contact Module © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 6 Note: The safety PLC you choose should meet these minimum requirements: ▪ 4x dual channel safety inputs ▪ 3x PNP safety outputs (or use safety relays) ▪ 2x PNP general purpose outputs ▪ Basic Safety Logic configuration © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 7: Software Requirements
Check the software version on your Kawasaki controller: Press the MENU button on the pendant keypad. Select the Aux Function option. Tap the option on the screen or highlight it with the keypad arrows and press ENTER. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 9 Install the USB driver that comes with the CS-Configurator: Search Kawasaki's Download Center for "... Controller, Cubic-S Instruction Manual". Download the Cubic-S Instruction Manual, then follow section 8.2.1 for Installing the USB Communication Driver. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 10: Installing The Safety Controller
Connect the 24V power supply output to your safety controller power supply inputs. Connect the 24V power supply to external power following power supply instructions. Note: Confirm everything powers up, then disconnect the power supply from external power before moving on. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 11: Connecting The Ready Pendant
VERSION 5.3.0 CONNECTING THE READY PENDANT In this section, you connect the READY pendant safety features to the robot through the safety controller. The READY pendant includes these safety outputs: 1. Key Switch (Robot Operation Mode) 2. Three-Position Enabling Switch 3.
Page 13 White/Blue Not Connected Route the READY pendant's Ethernet cable (RJ45 connector) to the IPC through a network switch or extend it with an adapter and another cable. Connect to a LAN port on the IPC. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 14 Fence Contact 11 (Circuit 1) Test Output 3 Fence Contact 12 (Circuit 1) Safety Input 7 Fence Contact 21 (Circuit 2) Test Output 4 Fence Contact 22 (Circuit 2) Safety Input 8 © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 15 Make your own cabling for the 12 wires that go from the safety enclosure to the XIN1 terminals on the Cubic-S unit. Add ferrule ends to your wires to insert in terminal blocks. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 16 Connect the safety controller output wires to the destinations on the Cubic-S terminals and the safety enclosure. Make your own cabling for the three wires going from the safety enclosure to the XGPIO interface module. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 17 XGPIO port on the back of the Kawasaki controller. Double-check your wiring by referring to the tables above. Fix any mistakes you find. Put the top plate of the Cubic-S box back on and screw it in place. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 18: Connecting The Robot To Forge/Os
Connect your IPC to a power source and power it on. Connect your safety enclosure to a power source and power it on. If there are issues, power off each device, disconnect from power supplies, and check your wiring. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 19: Programming The Safety Controller
Open the configuration software on your PC. Select your safety PLC model and add-on modules as needed. Add the READY pendant and safeguard inputs in the software and give them descriptive names. Set them to the safety input terminals you wired earlier.
Page 20 Mode Switch to robot (HIGH=run speed allowed, Auxiliary Output 1 GPIO Input 1 (I1) LOW=teach speed limit) Enable Switch to robot (HIGH=motion allowed in teach Auxiliary Output 2 GPIO Input 2 (I2) mode) © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 21 In the logic editor or other programming window, add the input and output signals you configured. Usually, you can drag and drop them into the logic editor. Add logic function blocks and connect the blocks to get the required safety logic. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 22 In the configuration software, login or connect to the safety controller and transfer your configuration onto it. If applicable, set the safety controller to "Run" or "Auto" mode. Disconnect your PC from the safety controller. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 23: Setting Up The Robot Controller
Follow these substeps to make sure those digital outputs are available: Press the MENU button on the Kawasaki pendant keypad. Select the Monitor1 option. Tap the option on the screen or highlight it with the keypad arrows and press ENTER. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 24 To free up dedicated signals, first press the MENU button on the pendant. Select the Aux Function option. Tap the option on the screen or highlight it with the keypad arrows and press ENTER. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 25 13-15. Forge/OS uses inputs I1 and I2 for safety signals. Follow these substeps to make sure those digital inputs are available: Press the MENU button on the Kawasaki pendant keypad. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 26 ▪ If signals 1-2 are dedicated (i.e., i1, i2), follow the rest of these substeps. ▪ If signals 1-2 are available (i.e., I1, I2), move on to step To free up dedicated signals, first press the MENU button on the pendant. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 27 In the Input/Output Signal menu, select Dedicated Input Signals. The input signal options appear. Look for the signal numbers 1-2. For each signal using input 1 or 2, change the signal number to another number. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 28 Press the MENU button on the pendant keypad. Select the Aux Function option. Tap the option on the screen or highlight it with the keypad arrows and press ENTER. In the Aux. menu, select System. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 29 Prev. Page buttons at the bottom. To enter numbers, tap on a white box and press the keypad buttons. Set the IP Address to 192.168.1.20 and set the Subnet Mask to 255.255.255.0. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 31: Signing In To Forge/Os
A, then come back to these steps. The READY pendant automatically finds and pairs with the IPC. The three LEDs on the screen help you track the status: ▪ Pendant Network Connection: This condition is satisfied when the READY pendant has a valid network connection (i.e., the Ethernet cable is plugged in).
Page 32 VERSION 5.3.0 to check are if the READY pendant network cable is plugged in, if the IPC is powered on, if the READY pendant and IPC are connected to the same network, and if there's only one READY pendant and one IPC on that network.
Page 33: Getting The Cubic-S File From Forge/Os
In these steps you start to add the robot in Forge/OS and get a Cubic-S parameters file based on your selected robot. In the Admin role, open the Device Configuration app. Tap New + to open the Device Library. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 35 Insert a USB flash drive into the IPC as instructed on the screen. Use an empty flash drive with at least 2GB of storage. Tip: Do not connect the USB flash drive to the READY pendant. Tap Start Transfer and wait for it to finish.
Page 36: Transferring Cubic-S Parameters
Connect the USB flash drive with the Cubic-S file to the Windows PC. On the Windows PC, open CS-Configurator. In the Operation Menu, click Open File. Then find the and open the file called "CubicSConfig.txt" on the USB drive (USB-Drive:\forge-os\ready-kawasaki-driver\CubicSConfig.txt). © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 37 Note: If this is your first time connecting to the Kawasaki controller, you need to install the Kawasaki USB driver. Follow Kawasaki Cubic-S instructions for installing the USB communication driver. In the Operation Menu, click Read Tool Data. This reads tool information from the robot controller. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 38 When you see "Writing to Cubic-S is done," wait for at least 5 seconds, then power off the robot controller. Wait for at least 5 seconds, then power on the robot controller. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 40: Adding The Robot In Device Configuration
Note: When you first connect to a robot, it's normal to see some robot errors and/or warnings on the READY pendant. Ignore these for now. You will clear them after you finish adding the robot to Forge/OS. If the robot controller fails to connect, you see this pop-up.
Page 41 (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. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 42 Payloads. To save time, find all the TCPs and Payloads you need for your application and add them all at once. Congratulations! You are ready to control your robot in the Device Control Panel and Task Canvas apps. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 43: Appendix A: Setting Up Forge/Os
IPC. To install Forge/OS, follow these substeps. You need a Forge/OS installation USB flash drive. Contact your READY Robotics distributor for an installation USB drive. Important: Installing Forge/OS will erase all data on the target hard drive.
Page 45 Select Erase disk and install forgeos. Then click Continue. Note: If Forge/OS is already installed, the installation wizard will show additional options. The goal is to erase the entire disk for a brand new installation. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 46 Confirm that you want to erase the entire disk by clicking Continue. Make a note of the pendant instructions. If you're using a Forge/Ctrl, select the checkbox next to This hardware is a Forge CTRL. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 47 Choose your IPC's host name. The host name identifies the IPC on the network. Pick a username and password. Then click Continue. Note: The username and password that you create here are for accessing the IPC desktop. They are NOT for signing into Forge/OS on the READY pendant. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 48 VERSION 5.3.0 Wait for the installer to copy and install Forge/OS. Once the installation completes, click Restart Now. When prompted, remove the installation flash drive. Then reboot. Wait for Forge/OS to finish booting. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 49 VERSION 5.3.0 When you see the login screen with the Forge/OS 5 logo, Forge/OS is ready to run on the READY pendant! You don't need to sign in to the desktop. Disconnect the monitor, keyboard, and mouse that you used to install Forge/OS.
Page 50 If the READY pendant spends more than 60 seconds on any step, troubleshooting text displays. Common things to check are if the READY pendant network cable is plugged in, if the IPC is powered on, if the READY pendant and IPC are connected to the same network, and if there’s only one READY pendant and one IPC on that network.
Page 51 Tap Admin and sign in. The default Admin password is "forgeadmin". Note: After installation, you have limited access to Forge/OS until you activate it with a license code. See Activating Forge/OS with a License Code. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 52: Activating Forge/Os With A License Code
▪ A valid Forge/OS license code ▪ A valid Forge/OS license code Tip: Connect a USB keyboard to the port on the bottom of the READY pendant to type in any text field in Forge/ On the Settings app main screen, tap License.
Page 53 If you chose online license activation, you're done! If you chose offline license activation, follow these substeps: Insert the USB flash drive into your IPC. Tap START WRITING CERTIFICATE TO USB DRIVE. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 54 Wait for the file to finish transferring. When the file transfer is complete, remove the USB flash drive and tap SAVE. Forge/OS returns to the licensing home screen and shows an active license. If the license status isn't active, restart these license activation steps. Double-check your license code. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 55: Choosing Preferences
On the Settings app main screen, tap General Settings. Change the Units of Measure, Time and Date settings, or the Admin login password. Note: If you later forget your password, contact READY Robotics to reset it. Tap SAVE to save changes and exit the General Settings menu.
Page 56 The table below lists the available network interfaces on your IPC. By default, the first interface is for the READY pendant. You can't edit the pendant's interface in Forge/OS. Select another interface and tap Edit to see the network settings.
Page 57: Appendix B: Tool Loading Steps
Tap SAVE to exit the robot configuration. Find your Type A-to-B USB 2.0 cable. Connect the USB B-side of the cable to the Cubic-S port on the front of the Kawasaki controller. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 58 Cubic-S port. Note: If this is your first time connecting to the Kawasaki controller, you need to install the Kawasaki USB driver. Follow Kawasaki Cubic-S instructions for installing the USB communication driver. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 59 Note: If this is your first time connecting to the Kawasaki controller, you need to install the Kawasaki USB driver. Follow Kawasaki Cubic-S instructions for installing the USB communication driver. In the Operation Menu, click Read Tool Data. This reads tool information from the robot controller. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 60 In the Operation Menu, click Write Parameters to Cubic-S. This saves the safety information to the Cubic-S unit. CS-Configurator asks you to enter your password. Enter the password (the default password is "khi"). Wait for the writing to finish. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 61 When you see "Writing to Cubic-S is done," wait for at least 5 seconds, then power off the robot controller. Wait for at least 5 seconds, then power on the robot controller. In Forge/OS, reset any warnings or errors. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 62: Resources
RESOURCES Want to learn more about how Forge/OS can empower you? Visit READY.academy (ready.academy) for FREE hands-on courses to help you deploy a robotic system. Visit READY.market (market.ready-robotics.com) for products and services offered by READY and our partners. Visit our Support site (support.ready-robotics.com) for robot startup guides, FAQs, and more.

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