YASKAWA YRC1000 Startup Manual

Forge/os 5

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Yaskawa YRC1000 Startup Guide

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Page 1 Yaskawa YRC1000 Startup Guide...
Page 2 VERSION 5.3.0 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
VERSION 5.3.0 CONTENTS Overview ................. . . 4 Hardware Requirements .
Page 4: Overview
6. Make changes to Yaskawa settings and upload robot configuration files. 7. Finish Device Configuration in Forge/OS. Note: This guide assumes you have installed the robot and robot controller following Yaskawa instructions. Make sure the robot controller is in working order before moving on.
Page 5: Hardware Requirements
User Manual for IPC requirements. The touch screen interface for READY READY pendant 112563 Forge/OS. Robotics YRC1000 Robot Controls the robot in its native Yaskawa Controller software. Required for Forge/OS to load and set tools (payloads and TCPs). Yaskawa Standard...
Page 6 Required to transfer robot files from Forge/OS to the robot. READY USB flash drive, Tip: Use a different USB flash Robotics R-400030 8GB or larger drive (2GB or larger) for backing (or other) up the Yaskawa controller. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 7: Confirming Hardware Requirements
Power off the YRC1000. Follow your facility's lockout/tagout procedure. Use a flat-blade screwdriver to turn the Yaskawa controller door lock clockwise. Open the door. Look for the FSU I/O Expansion Board. It should have a cable connector labeled CN222 on the board. If you don't see the cable headers or cable labeled CN222, you don't have the proper expansion board.
Page 8 VERSION 5.3.0 The Safety Unit I/O cable leads to the FSU Expansion Breakout Board on the Yaskawa controller door panel. Look for this Breakout Board with the connector labeled CN220. If you don't have the required hardware, contact a Yaskawa Motoman distributor.
Page 9: Software Requirements
VERSION 5.3.0 SOFTWARE REQUIREMENTS Controller Minimum Software Version YRC1000 YAS4.10 REQUIRED OPTIONS Part Requirement Description Number FSU Software Option (non- Required to jog the robot with the 179908-1 collaborative) READY pendant. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 10: Confirming Software Requirements
Follow these steps to check the software version and options on your robot controller. Plug the Yaskawa controller into a power source. Power the controller on and wait for it to boot up. On the Yaskawa teach pendant, press the MAIN MENU button. Then press the black right arrow key until you have a gray menu on the left side of the screen.
Page 11 Tip: Use the arrows and SELECT button, or tap the screen to select. The system version information appears on the screen. Look for the version number at the top by SYSTEM:. If your system version is older than the requirement, contact your Yaskawa Motoman distributor to upgrade.
Page 12 Use the down arrow on the keypad to scroll down until you find IO MODULE. ▪ For the YRC1000, look for the ASF01 board. If you don't see the FSU IO Module for your controller, contact your Yaskawa Motoman distributor to upgrade.
Page 13 Use the down arrow on the keypad to scroll down until you find OPTION FUNCTION. Keep scrolling to look for 046 MotoPlus FUNC. and 049 Functional Safety in the list of options. If you don't see these options in the list, contact your Yaskawa Motoman distributor to upgrade. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 14: Back Up And Upgrade The Robot Controller
Save a backup of your Yaskawa controller software settings before you make any changes. Yaskawa controllers can save backups to either a USB flash drive or SD card. Refer to Yaskawa documentation for more information. Insert a USB drive into the back of the Yaskawa pendant.
Page 16 VERSION 5.3.0 At the Save? prompt, tap YES on the screen. The bottom notification bar reads Saving system backup file. Don't turn the power off. Wait for the backup to finish. Power off the robot controller. Remove the USB flash drive from the pendant. Tip: Keep your USB backup drive in a secure location.
Page 17: Connecting The Ready Pendant
VERSION 5.3.0 CONNECTING THE READY PENDANT The READY pendant includes these safety outputs: 1. Key Switch (Robot Operation Mode) 2. Three-Position Enabling Switch 3. Emergency Stop Button The end of the READY pendant cable includes: 1. One RJ45 Ethernet cable for communication with the IPC. 2.
Page 18 VERSION 5.3.0 Follow these sub-steps to connect the READY pendant communication, power, and safety wiring. You will route the READY pendant flying leads to the destinations in this table. Pendant Flying Leads Destination Terminal Function Brown FSU Breakout - 21 Three-Position Enabling Switch Circuit 1 Yellow FSU Breakout - 22...
Page 19 VERSION 5.3.0 Remove one of the covering plates on the right side or back side of the YRC1000. Make a hole on the plate for the flying leads cable to enter. Tip: Install a cable gland for strain relief. Feed your safety I/O wiring through the gland and set the plate back in place. Refer to Yaskawa's YRC1000 Instructions for proper cable sealing and routing.
Page 20 VERSION 5.3.0 If you are not using external safety fencing: Bridge pins 41 and 42 with a jumper wire. Bridge pins 43 and 44 with a jumper wire. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 21: Connecting To The Ipc
YRC1000 using a Cat5e STP Ethernet cable. Find a Cat5e STP Ethernet cable long enough to reach from the IPC to inside the Yaskawa controller. Remove another cable covering plate. Make a hole on the plate for the Ethernet cable.
Page 22 VERSION 5.3.0 Connect one end of the Ethernet cable to the LAN port labeled “CN106 (LAN2)” on the CPU Unit inside the robot controller near the left wall of the enclosure. Plug the other end of the Ethernet cable into a LAN port on the IPC or on a network switch you connect to the IPC.
Page 23: Signing In To Forge/Os
VERSION 5.3.0 SIGNING IN TO FORGE/OS Follow these steps to pair the READY pendant with the IPC and sign in to Forge/OS 5. If you need to install Forge/OS 5 on your IPC, stop here and follow all the steps in Appendix A, then come back to these steps.
Page 24 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 25: Powering On
VERSION 5.3.0 POWERING ON Reconnect the Yaskawa controller to a power source and turn it on. Plug your IPC power cable into a power outlet. Power on your IPC and other devices. If there are issues, power off each device, disconnect from power supplies, and check your wiring.
Page 26: Getting Robot Files From Forge/Os
VERSION 5.3.0 GETTING ROBOT FILES FROM FORGE/OS In this section, you add the robot in Forge/OS and copy configuration files to the robot controller. In the Admin role, open the Device Configuration app. Tap New + to open the Device Library. ©...
Page 28 VERSION 5.3.0 Select the robot Controller Model, then select the Robot Model. You can fill in the other information later. Insert a USB flash drive into the IPC as instructed on the screen. Use an empty flash drive with at least 2GB of storage.
Page 30: Changing Robot Settings To Prepare For Forge/Os
Note: You may ignore minor alarms if they can't be cleared right away. If there is a major alarm, you need to resolve it before moving on. When you press RESET, the Yaskawa pendant warns you if there is a major alarm.
Page 31 VERSION 5.3.0 Change the security mode to Safety Mode: From the Main Menu, select SYSTEM INFO, then SECURITY. Tap the field next to MODE or press SELECT. Scroll to SAFETY MODE from the dropdown list and press the SELECT button on the pendant keypad. Enter the Safety Mode password and press ENTER.
Page 32 VERSION 5.3.0 Set parameters S2C0701, S2C0425, S2C0430, S2C1419, and S2C1586: From the Main Menu, find and select PARAMETER. Select the S2C option. To "Jump to" parameter S2C0701, you can highlight a parameter name in the first column and press the SELECT button on the keypad.
Page 33 VERSION 5.3.0 Set S2C0701 to 1. Highlight the box to the right of the parameter name and press SELECT, then enter 1 and press ENTER. Repeat the process above to set the parameter S2C0425 to 1. Repeat the process above to set the parameter S2C0430 to 4. Repeat the process above to set the parameter S2C1419 to 1.
Page 34 VERSION 5.3.0 Set parameters S4C0287 - S4C0295. From the PARAMETER menu, select S4C. Set parameter S4C0287 to 511. Set parameters S4C0288 - S4C0295 to 0. (Optional): If your controller has the SETUP > SPEED OVERRIDE SETTING menu, you can check if the parameters were correctly set: Verify that Setting Method = I/O.
Page 35 VERSION 5.3.0 Verify that Continuous Cycle Operation = Valid. Verify that Automatic Setting = Invalid. Verify that Initial Speed Ratio = 100%. Verify that GP. Input = 511. Verify that all Speed Ratio parameters = 0%. Follow these steps to disable the CRC check function. From the MAIN MENU, select SETUP, then choose FUNCTION ENABLE.
Page 36 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 Yaskawa controller and wait 10 seconds. Press and hold the MAIN MENU button while powering on the robot controller to enter Maintenance Mode.
Page 38 VERSION 5.3.0 Highlight DETAIL next to LAN INTERFACE SETTING and press the SELECT button. Set the IP ADDRESS SETTING to MANUAL SETTING. Set the IP Address to 192.168.1.20 and set the Subnet Mask to 255.255.255.0. Set both the DEFAULT GATEWAY SETTING and DNS SETTING to NOT USED. Press ENTER to save the settings.
Page 39 VERSION 5.3.0 Back in the OPTION FUNCTION menu, 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. At the Modify? prompt tap YES.
Page 40 VERSION 5.3.0 Select the field next to SAFETY I/O BOARD SETTING. Select the ASF02 board. Press the ENTER button on the keypad to apply this choice. At the Modify? prompt, tap YES. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 41 VERSION 5.3.0 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. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 42: Transferring Configuration Files
From the Main Menu, tap MotoPlus APL, 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 43 At the Load prompt tap YES. If asked to overwrite an existing file, select YES. Power off the Yaskawa controller and wait 10 seconds. Power up the Yaskawa controller (not in Maintenance Mode). © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 44 VERSION 5.3.0 An alarm may appear up to two minutes after restarting: ALARM 8001[10]; Speed FB enabled, reboot now. Do NOT reboot now, tap the RES button on the screen and continue. Change the security mode to Safety Mode: From the Main Menu, select SYSTEM INFO, then SECURITY. Tap the field next to MODE or press SELECT.
Page 45 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 46 VERSION 5.3.0 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. If you get ERROR 2040 - Defined JOB name, you need to delete the existing "RR_x" jobs on the robot controller.
Page 47 VERSION 5.3.0 From the Main Menu, tap EX. MEMORY, then tap LOAD. Highlight FILE/GENERAL DATA and press the SELECT button. Select TOOL DATA and press the SELECT button on the pendant keypad. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 49 VERSION 5.3.0 The screen changes to the EXTERNAL MEMORY DEVICE screen, then to the EX. MEMORY screen. From the Main Menu, tap EX. MEMORY, then tap LOAD. Highlight FILE/GENERAL DATA and press the SELECT button. Highlight the SPEED LIMIT DATA file and press SELECT. Make sure the file is marked with a star. Press ENTER.
Page 51 VERSION 5.3.0 Select the field next to FILE VALID COND and select SIGNAL (2) and press the SELECT button. Tap the READBACK button on the screen. © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 52 VERSION 5.3.0 Tap the WRITE button on the screen. At the Update the file? prompt tap YES. Repeat all sub-steps in the previous step for 3 in the File column (READYP-OFF). The limit and input signal are different for READYP-OFF. This is normal. ©...
Page 53 VERSION 5.3.0 From the Main Menu, tap EX. MEMORY, then tap LOAD. Highlight I/O DATA and press the SELECT button. Highlight and press the SELECT button on C.IO PRGM (CIOPRG.LST) and YSF LOGIC FILE (YSFLOGIC.DAT). Press the ENTER button on the pendant keypad. At the Load? prompt, tap YES.
Page 54 At the Update the file? prompt tap YES. Power off the Yaskawa controller and wait 10 seconds. Press and hold the MAIN MENU button while powering up the Yaskawa controller to enter Maintenance Mode. Release MAIN MENU when you hear the teach pendant beep.
Page 55 VERSION 5.3.0 Change the security mode to Safety Mode: From the Main Menu, select SYSTEM, then SECURITY. Tap the field next to MODE or press SELECT. Scroll to SAFETY MODE from the dropdown list and press the SELECT button on the pendant keypad. Enter the Safety Mode password and press ENTER.
Page 56 At the Reset? prompt tap YES. Wait for the flash reset to complete and the pendant to beep. This process takes up to one minute to complete. Power off the Yaskawa robot controller and wait 10 seconds © 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...
Page 58: Adding Your Robot In Device Configuration
VERSION 5.3.0 ADDING YOUR ROBOT IN DEVICE CONFIGURATION In these steps, you save the robot in the Device Configuration app and finish the setup. In Forge/OS, finish entering your device information: Give your device a name. For the IP Address, enter 192.168.1.20 or the IP address you assigned to the robot, if different. ©...
Page 59 VERSION 5.3.0 In Forge/OS, confirm your device settings and tap SAVE. Forge/OS attempts to connect with the robot controller for up to 20 seconds. Note: When you first connect to a robot, it's normal to see some robot errors and/or warnings on the READY pendant.
Page 60 VERSION 5.3.0 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. Note: To use these I/O signals, integrate your I/O devices with the robot controller.
Page 61 VERSION 5.3.0 Follow these steps to clear robot errors: Tap the Device Status button on the Toolbar to expand the Device Status Panel. The robot is listed with two buttons: MORE and RESET. Tap RESET to try to recover from the errors. If you can't RESET an error, tap MORE to get more details and instructions.
Page 62: Appendix A: Setting Up Forge/Os
VERSION 5.3.0 APPENDIX A: SETTING UP FORGE/OS INSTALLING FORGE/OS Follow these steps to install Forge/OS and sign in to the Admin role. Installation takes about 30 minutes, depending on the resources of the 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.
Page 64 VERSION 5.3.0 Select Minimal installation. Uncheck Download updates while installing forgeos. Then click Continue. 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.
Page 65 VERSION 5.3.0 Select the IPC hard drive for Forge/OS and click Install Now. 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.
Page 66 VERSION 5.3.0 Choose your timezone. Then click Continue. 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.
Page 67 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 68 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 69 VERSION 5.3.0 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 70 VERSION 5.3.0 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 71: Activating Forge/Os With A License Code
VERSION 5.3.0 ACTIVATING FORGE/OS WITH A LICENSE CODE There are two methods to activate Forge/OS: Online license activation and offline license activation. The table below lists the requirements for each method. Online License Activation Offline License Activation ▪ A 2GB or larger USB flash drive ▪...
Page 72 VERSION 5.3.0 Choose ONLINE LICENSE ACTIVATION if Forge/OS is connected to the internet. If not, choose OFFLINE LICENSE ACTIVATION. 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. ©...
Page 73 VERSION 5.3.0 When the files finish transferring, tap NEXT. Follow the instructions on the screen to convert the Activation Certificate to an Unlock Certificate using an internet-connected PC. Insert the USB flash drive back into your IPC. Tap UNLOAD UNLOCK CERTIFICATE FROM USB DRIVE. Wait for the file to finish transferring.
Page 74: Choosing Preferences
VERSION 5.3.0 CHOOSING PREFERENCES These steps help you choose system preferences, including language, units, time, and network settings. To change preferences for the first time, go to General Settings: 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.
Page 75 VERSION 5.3.0 Check the Network settings in Forge/OS and set them as you want. On the Settings main screen, tap Network. The table below lists the available network interfaces on your IPC. By default, the first interface is for the READY pendant.
Page 76: Appendix B: Tool Loading Steps
APPENDIX B: TOOL LOADING STEPS You must update the tool files on the Yaskawa controller each time you add new Tool Center Points (TCPs) or Payloads. Follow these steps to add new TCPs/Payloads in Forge/OS and update the Tool configuration on the Yaskawa controller.
Page 77 Tap SAVE to exit the robot configuration. Forge/OS uploads a tool data file to the USB drive attached to the Yaskawa pendant. If you didn't see one before, you will see a Tool Mismatch error now. Note: Forge/OS saves the updated TCPs and Payloads to tool.cnd in the USB drive root directory, not in the forge-os folder.
Page 79 At the Load? screen select YES. Power off the robot controller and wait 10 seconds. Power on the robot controller while holding the Main Menu button on the Yaskawa pendant to boot in Maintenance Mode. Continue to hold the button until the pendant beeps.
Page 80 VERSION 5.3.0 Save changes to the Safety I/O board. From the Main Menu, tap FILE, then INITIALIZE. Select Safety Board FLASH Reset. When prompted select YES. Wait for the flash reset to complete and the pendant to beep. This process takes up to one minute to complete.
Page 81 VERSION 5.3.0 Turn the key to the REMOTE. Power off the robot controller and wait 10 seconds. Power on the robot controller. When Forge/OS reconnects to the robot controller after the final power cycle, you can clear the "TOOL MISMATCH" warning. ©...
Page 82: Appendix C: Troubleshooting
Check the safety fence jumper wires on the safety terminal block. Issue #3 "I/O Media Error". This error occurs if the Yaskawa pendant cannot read the USB flash drive you inserted. Boot the Yaskawa controller in Maintenance Mode. Go to the Main Menu on the Yaskawa pendant, select EX.MEMORY, and select DEVICE.
Page 83 If 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 Support. 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.
Page 84 5.2 to 5.3), you can follow the manual workaround outlined below. Otherwise, the robot's speed will not immediately adjust with the speed slider. In SAFETY MODE with the Yaskawa pendant in TEACH mode, navigate to the IN/OUT > LADDER EDITOR menu.
Page 85 VERSION 5.3.0 There are two signals in this rung: the input signal located on the left (row 00 column 00) and the output signal on the right (row 00 column 09). Change the input signal to 15090. You can do this either by double tapping the signal or by highlighting it, selecting INPUT >...
Page 86: Resources
VERSION 5.3.0 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.

YASKAWA YRC1000 Startup Manual

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