Yaskawa YRC1000 Startup Guide

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. You may wish to use the methodology found in the ANSI/RIA
TR R15.306 Task-based Risk Assessment Methodology.

© 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 2

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CONTENTS
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Hardware Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Confirming Hardware Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Confirming Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Back Up and Upgrade the Robot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Connecting the READY pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Connecting to the IPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Signing In to Forge/OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Powering On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Getting Robot Files from Forge/OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Changing Robot Settings to Prepare for Forge/OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Transferring Configuration Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Adding your Robot in Device Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Appendix A: Setting Up Forge/OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Installing Forge/OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Activating Forge/OS with a License Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Choosing Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Appendix B: Tool Loading Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Appendix C: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

© 2022 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 3

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OVERVIEW
This guide helps you set up your Yaskawa Motoman controller to work with Forge/OS 5.

For specific software and hardware requirements, go to support.ready-robotics.com.

You will follow these steps:

1. Backup and update the Yaskawa controller.

2. Connect the READY pendant to your IPC and Yaskawa controller.
3. Power on your system.
4. Start up Forge/OS.
5. Get robot files from Forge/OS.
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.

Tip: For non-collaborative robots, the default Safety Mode password is "5555 5555 5555 5555"

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HARDWARE REQUIREMENTS
Image Part Name Description Vendor Part Number

Hosts Forge/OS.

Industrial PC Note: Refer to the Forge/OS 5

(IPC) 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 Yaskawa 177716-1
Note: Forge/OS does NOT
Pendant
support the Smart Pendant.

Powers the READY pendant and

24V/2.5A Siemens 6EP1332-5BA00
more. Min./Max. current: 2.5/5.0
Power Supply (or other) (or similar)
Amps.

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Image Part Name Description Vendor Part Number

Required to connect the

READY pendant safety features and 179909-1,
Functional fence. includes:
Safety Unit Includes: ▪ 178277-1
▪ FSU I/O Board Yaskawa ▪ 179765-1
(FSU)
Expansion Kit ▪ FSU I/O Breakout ▪ 183418-1
▪ FSU I/O Breakout Cable ▪ 176790-2
▪ FSU I/O Control Signal Cable

Yaskawa
Standard I/O, Required to connect the
40 IN/40 OUT, READY pendant safety features and Yaskawa 180700-1
2 Safety IN/2 fence.
Safety OUT

▪ Connects the robot controller to

Cat5e Shielded an IPC.
Ethernet Cable
(x2) ▪ Connects the READY pendant to
an IPC.

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.

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CONFIRMING HARDWARE REQUIREMENTS

Follow these steps to check if you have the required Yaskawa safety hardware.

1 Power off the YRC1000. Follow your facility's lockout/tagout procedure.

2 Use a flat-blade screwdriver to turn the Yaskawa controller door lock clockwise. Open the door.

3 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.

Tip: You may see a General Purpose Safety I/O board, which will not work.

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4 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.

5 If you don't have the required hardware, contact a Yaskawa Motoman distributor.

6 If you have the required hardware, move on to the next section.

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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.

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CONFIRMING SOFTWARE REQUIREMENTS

Follow these steps to check the software version and options on your robot controller.

1 Plug the Yaskawa controller into a power source. Power the controller on and wait for it to boot up.

2 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.

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3 Follow these steps to find the firmware version:

a Select SYSTEM INFO, then select VERSION.

Tip: Use the arrows and SELECT button, or tap the screen to select.

b 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.

Important: Before upgrading, take a backup of your controller.

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4 On the Yaskawa teach pendant, follow these steps to view Yaskawa options:

a Select SYSTEM INFO, then select CONTROLLER INFORMATION.

b 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.

Tip: Hold SHIFT and press the up/down arrows to scroll quicker.

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c 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.

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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.

1 Insert a USB drive into the back of the Yaskawa pendant.

Note: Use an empty USB drive (FAT-32 file format) with at least 2 GB of storage.

2 Turn the pendant key to TEACH mode.

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3 In the Main Menu, select EX.MEMORY, then select SAVE.

4 Scroll down to highlight SYSTEM BACKUP(CMOS.BIN), then press SELECT.

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5 At the Save? prompt, tap YES on the screen.

6 The bottom notification bar reads Saving system backup file. Don't turn the power off. Wait for the backup to
finish.

7 Power off the robot controller.

8 Remove the USB flash drive from the pendant.

Tip: Keep your USB backup drive in a secure location. You can save the backup files from the USB onto a
workstation.

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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. 15 Flying leads—2 for power, 12 for safety I/O, and 1 unused lead.

Electric Shock Warning: Disconnect all components from power sources

before attempting this installation.

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1 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 Three-Position Enabling Switch Circuit 1

Green FSU Breakout - 23 Three-Position Enabling Switch Circuit 2

Grey FSU Breakout - 24 Three-Position Enabling Switch Circuit 2

Pink Power Supply (+24V) +24V DC

Green/Brown FSU Breakout - 5 Emergency Stop Circuit 1

White/Green FSU Breakout - 6 Emergency Stop Circuit 1

Grey/Pink FSU Breakout - 7 Emergency Stop Circuit 2

Red/Blue FSU Breakout - 8 Emergency Stop Circuit 2

Black Power Supply (0V) 0V DC

Violet FSU Breakout - 25 Key Switch Circuit 1

White/Pink FSU Breakout - 26 Key Switch Circuit 1

White FSU Breakout - 27 Key Switch Circuit 2

Blue FSU Breakout - 28 Key Switch Circuit 2

White/Blue N/A Not Connected

a Connect the READY pendant's Ethernet cable to the IPC. You may connect the pendant through an
Ethernet switch to increase the number of Ethernet ports.

b Connect the pendant's power leads to a 24V DC, 2.5A source. Connect the Pink wire to +24V and the
Black wire to 0V.

c Connect the remaining safety I/O leads to your control panel or safety cabinet. Make your own cable/
wiring for the 12 safety signals long enough to reach their destinations in the table. Include ferrules at the
end of your wiring to insert in the terminal blocks.

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2 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.

3 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.

4 Connect your flying leads to the the FSU Expansion Breakout Board destinations on the table in Step 1.

5 If you are using external safety fencing:

a Connect fence channel 1 to connector pins 41 and 42

b Connect fence channel 2 to connector pins 43 and 44

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6 If you are not using external safety fencing:

a Bridge pins 41 and 42 with a jumper wire.

b Bridge pins 43 and 44 with a jumper wire.

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CONNECTING TO THE IPC

Forge/OS must communicate with the Yaskawa controller. This section will help you connect the IPC device and
YRC1000 using a Cat5e STP Ethernet cable.

1 Find a Cat5e STP Ethernet cable long enough to reach from the IPC to inside the Yaskawa controller.

2 Remove another cable covering plate. Make a hole on the plate for the Ethernet cable.

Tip: Install a cable gland for strain relief.

3 Feed the Ethernet cable through the plate. Refer to Yaskawa's YRC1000 Instructions for proper cable sealing and
routing.

4 Mount the plate in place.

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5 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.

6 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.

7 Zip-tie the added cables along the base of the robot controller. Zip-tie the Functional Safety I/O Cable along the
base of the door.

Important: Make sure the robot controller door can shut without pinching or bending any cables.

8 Close the controller and use a flat-blade screwdriver to turn the door lock counterclockwise.

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SIGNING IN TO FORGE/OS
Follow these steps to pair the READY pendant with the IPC and sign in to Forge/OS 5.

1 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.

2 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).

▪ Forge/OS IPC Detected: This condition is satisfied when the READY pendant detects a Forge/OS IPC on
the network.

▪ Forge/OS IPC Paired: This condition is satisfied when the READY pendant successfully pairs with the
IPC. If pairing fails, it is automatically retried indefinitely.

When a condition is not satisfied, the LED is red. When a condition is in progress of becoming satisfied, a
spinner around a READY logo appears to the right of the text. When a condition becomes satisfied, the LED
turns green.

The UI shows the real-time state of each step. For example, if the pendant loses its network connection during
pairing, all steps become undone.

If the READY pendant spends more than 60 seconds on any step, troubleshooting text displays. Common things

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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.

Note: The READY pendant IP Address is preset to 172.16.255.253. The network interface that the pendant
connects to should use IP Address 172.16.255.250 and Subnet mask 255.255.255.0.

3 Tap Admin and sign in. The default Admin password is "forgeadmin".

4 If Forge/OS is inactive, it opens the Settings app and prevents you from opening other apps. If you see the
screen below, follow Activating Forge/OS with a License Code in Appendix A.

5 With Forge/OS active, move on to the next section.

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POWERING ON
1 Reconnect the Yaskawa controller to a power source and turn it on.

2 Plug your IPC power cable into a power outlet.

3 Power on your IPC and other devices.

4 If there are issues, power off each device, disconnect from power supplies, and check your wiring.

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GETTING ROBOT FILES FROM FORGE/OS

In this section, you add the robot in Forge/OS and copy configuration files to the robot controller.

1 In the Admin role, open the Device Configuration app.

2 Tap New + to open the Device Library.

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3 In the Device Library list, select Yaskawa Motoman industrial robot. Then tap NEXT.

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4 Select the robot Controller Model, then select the Robot Model. You can fill in the other information later.

5 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.

6 Tap Start Transfer and wait for it to finish.

7 Remove the USB flash drive when prompted.

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8 Insert the USB drive into the USB port on the back of the Yaskawa pendant.

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CHANGING ROBOT SETTINGS TO PREPARE FOR

FORGE/OS
In this section, you'll change some robot controller settings to enable Safety I/O Expansion Board and
communication with Forge/OS. Follow these steps if this is the first time setting up Forge/OS with your Yaskawa
controller, or if your controller has been factory reset.

1 On the Yaskawa pendant, turn the key to TEACH position.

2 If there are active alarms on the Yaskawa pendant, tap the RESET button at the bottom-right corner of the
screen to clear them.

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.

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3 Change the security mode to Safety Mode:

a From the Main Menu, select SYSTEM INFO, then SECURITY.

b Tap the field next to MODE or press SELECT.

c Scroll to SAFETY MODE from the dropdown list and press the SELECT button on the pendant keypad.

d Enter the Safety Mode password and press ENTER.

Tip: For non-collaborative robots, the default Safety Mode password is "5555 5555 5555 5555"

e If successful, the visible mode changes to SAFETY MODE. If you enter the wrong password, you get an
Error 1030 message. Try again.

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4 Set parameters S2C0701, S2C0425, S2C0430, S2C1419, and S2C1586:

a From the Main Menu, find and select PARAMETER. Select the S2C option.

b To "Jump to" parameter S2C0701, you can highlight a parameter name in the first column and press the
SELECT button on the keypad. Then enter the number 0701 and press ENTER.

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c Set S2C0701 to 1. Highlight the box to the right of the parameter name and press SELECT, then enter 1
and press ENTER.

d Repeat the process above to set the parameter S2C0425 to 1.

e Repeat the process above to set the parameter S2C0430 to 4.

f Repeat the process above to set the parameter S2C1419 to 1.

g Repeat the process above to set the parameter S2C1586 to 1.

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5 Set parameters S4C0287 - S4C0295.

a From the PARAMETER menu, select S4C.

b Set parameter S4C0287 to 511.

c Set parameters S4C0288 - S4C0295 to 0.

6 (Optional): If your controller has the SETUP > SPEED OVERRIDE SETTING menu, you can check if the
parameters were correctly set:

a Verify that Setting Method = I/O.

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b Verify that Continuous Cycle Operation = Valid.

c Verify that Automatic Setting = Invalid.

d Verify that Initial Speed Ratio = 100%.

e Verify that GP. Input = 511.

f Verify that all Speed Ratio parameters = 0%.

7 Follow these steps to disable the CRC check function.

a From the MAIN MENU, select SETUP, then choose FUNCTION ENABLE.

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b Scroll down to highlight the field next to SAVE DATA CRC CHECK FUNC. (FSU) and press the SELECT
button to set it to INVALID.

8 Power off the Yaskawa controller and wait 10 seconds.

9 Press and hold the MAIN MENU button while powering on the robot controller to enter Maintenance Mode.
Release MAIN MENU when you hear the teach pendant beep.

10 Change the security mode to Safety Mode:

a From the Main Menu, select SYSTEM, then SECURITY.

b Tap the field next to MODE or press SELECT.

c Scroll to SAFETY MODE from the dropdown list and press the SELECT button on the pendant keypad.

d Enter the Safety Mode password and press ENTER.

e If successful, the visible mode changes to SAFETY MODE. If you enter the wrong password, you get an
Error 1030 message. Try again.

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11 From the Main Menu, select SYSTEM, then select SETUP.

a Highlight OPTION FUNCTION and press the SELECT button.

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b Highlight DETAIL next to LAN INTERFACE SETTING and press the SELECT button.

c Set the IP ADDRESS SETTING to MANUAL SETTING.

d Set the IP Address to 192.168.1.20 and set the Subnet Mask to 255.255.255.0.

f Set both the DEFAULT GATEWAY SETTING and DNS SETTING to NOT USED.

g Press ENTER to save the settings. At the Modify? prompt tap YES.

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h 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.

i At the Modify? prompt tap YES.

j Back in the OPTION FUNCTION menu, highlight the field next to MotoPlus FUNC and set it to USED.

k At the Modify? prompt tap YES.

l At the Initialize related files? SRAMDRV.DTA prompt tap YES.

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m Select the field next to SAFETY I/O BOARD SETTING.

n Select the ASF02 board.

o Press the ENTER button on the keypad to apply this choice.

p At the Modify? prompt, tap YES.

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12 Save settings to the Safety I/O board. From the Main Menu, tap FILE, then tap INITIALIZE.

a Highlight Safety Board FLASH Reset and press the SELECT button.

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b At the Reset? prompt tap YES. Wait for the flash reset to complete and the pendant to beep. This process
takes up to 60 seconds to complete. The arrow buttons are disabled until the reset completes.

TRANSFERRING CONFIGURATION FILES

This section assumes that your Yaskawa pendant is still booted in Maintenance Mode and that you have selected
the Safety Security Mode.

1 Follow these steps to load the Forge MotoPlus APL.

a From the Main Menu, tap MotoPlus APL, then tap FOLDER to select the folder to load files from.

b 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.

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c From the Main Menu, tap MotoPlus APL, then tap LOAD (USER APPLICATION).

d Highlight the MotoPlusYRC1....out file on the USB drive and press the SELECT button.

e Verify that a small black star icon appears to the left of the file name and press the ENTER button on the
pendant keypad.

f At the Load prompt tap YES. If asked to overwrite an existing file, select YES.

2 Power off the Yaskawa controller and wait 10 seconds.

3 Power up the Yaskawa controller (not in Maintenance Mode).

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4 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.

5 Change the security mode to Safety Mode:

a From the Main Menu, select SYSTEM INFO, then SECURITY.

b Tap the field next to MODE or press SELECT.

c Scroll to SAFETY MODE from the dropdown list and press the SELECT button on the pendant keypad.

d Enter the Safety Mode password and press ENTER.

e If successful, the visible mode changes to SAFETY MODE. If you enter the wrong password, you get an
Error 1030 message. Try again.

6 If you have loaded Forge/OS files onto this robot controller before, make sure the correct MotoPlus application
is running and no other apps are running:

a From the Main Menu, select MotoPlus APL., then MotoPlus MONITOR.

b Tap Application Run Flow. Make sure the ONLY file listed under "Active Application" is
MotoPlusYRC1_5.out .

c If MotoPlusYRC1_5.out is in the "Inactive Application" section, highlight it and press "-> Add" to set the
app as active.

d If you see any other apps listed under "Active Application," highlight them and press "<- Remove."

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e Press Set Flow, then tap Close until you are out of the Monitor.

f If you made any changes, restart the robot controller. Once the robot controller restarts, enable Safety
Mode and check again to make sure the correct application is running..

7 From the Main Menu, tap EX. MEMORY , then tap FOLDER to select the folder to load files from.

a 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.

b From the Main Menu tap EX. MEMORY and then tap LOAD.

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c Highlight JOB and press the SELECT button.

d Highlight each file and press the SELECT button on the keypad so that it is marked with a star.

e Press ENTER on the keypad.

f At the Load? prompt tap YES.

g If you get ERROR 2040 - Defined JOB name, you need to delete the existing "RR_x" jobs on the robot
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. Then select the
job to delete. Delete each job that starts with "RR" then try step 8 again.

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8 From the Main Menu, tap EX. MEMORY, then tap LOAD.

a Highlight FILE/GENERAL DATA and press the SELECT button.

b Select TOOL DATA and press the SELECT button on the pendant keypad.

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c Verify that the file is marked with a star.

d Press the ENTER button on the pendant keypad.

e At the Load? prompt tap YES.

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f The screen changes to the EXTERNAL MEMORY DEVICE screen, then to the EX. MEMORY screen.

9 From the Main Menu, tap EX. MEMORY, then tap LOAD.

a Highlight FILE/GENERAL DATA and press the SELECT button.

b Highlight the SPEED LIMIT DATA file and press SELECT. Make sure the file is marked with a star.

c Press ENTER.

d At the Load? prompt tap YES.

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10 From the Main Menu, tap SAFETY FUNC, then choose SPEED LIMIT.

a Highlight 2 in the File column and press the SELECT button.

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b Select the field next to FILE VALID COND and select SIGNAL (2) and press the SELECT button.

c Tap the READBACK button on the screen.

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d Tap the WRITE button on the screen.

e At the Update the file? prompt tap YES.

11 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.

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12 From the Main Menu, tap EX. MEMORY, then tap LOAD.

a Highlight I/O DATA and press the SELECT button.

b Highlight and press the SELECT button on C.IO PRGM (CIOPRG.LST) and YSF LOGIC FILE
(YSFLOGIC.DAT).

c Press the ENTER button on the pendant keypad.

d At the Load? prompt, tap YES.

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13 From the Main Menu, tap SAFETY FUNC., then tap SAFETY LOGIC CIRCUIT .

a Tap the WRITE button on the bottom of screen.

b Tap the CONFIRM button on the bottom of screen.

c At the Update the file? prompt tap YES.

14 Power off the Yaskawa controller and wait 10 seconds.

15 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.

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16 Change the security mode to Safety Mode:

a From the Main Menu, select SYSTEM, then SECURITY.

b Tap the field next to MODE or press SELECT.

c Scroll to SAFETY MODE from the dropdown list and press the SELECT button on the pendant keypad.

d Enter the Safety Mode password and press ENTER.

e If successful, the visible mode changes to SAFETY MODE. If you enter the wrong password, you get an
Error 1030 message. Try again.

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17 Save changes to the Safety I/O board. From the Main Menu tap FILE and then tap INITIALIZE.

a Highlight Safety Board FLASH Reset and press SELECT.

b At the Reset? prompt tap YES.

c Wait for the flash reset to complete and the pendant to beep. This process takes up to one minute to
complete.

18 Power off the Yaskawa robot controller and wait 10 seconds

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19 Turn the Yaskawa pendant key to REMOTE.

20 Power on the Yaskawa robot controller.

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ADDING YOUR ROBOT IN DEVICE

CONFIGURATION
In these steps, you save the robot in the Device Configuration app and finish the setup.

1 In Forge/OS, finish entering your device information:

a Give your device a name.

b For the IP Address, enter 192.168.1.20 or the IP address you assigned to the robot, if different.

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2 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. Ignore these for now. You will clear them after you finish adding the robot to Forge/OS.

a If the robot controller fails to connect, you see this pop-up.

Click DISMISS, do the following, then try to tap SAVE again:

▪ Check the Ethernet connection between the robot controller and IPC.
▪ Check the network settings on the robot controller.
▪ Check if the robot controller is on and in the correct operating mode (in auto or remote mode).
▪ Select the correct robot controller and robot models in Device Configuration.

3 When the robot connects, you can add Tool Center Points (TCPs) or Payloads for the robot. You can come back
to this later by editing the device's configuration. Tap SAVE to continue.

Note: The default TCP is at the robot's tool flange. The default Payload is zero.

4 (Optional): Set up the robot controller's Input/Output (IO) signals for use in the Device Control Panel and Task

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Canvas.

a 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.

b 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.

c Tap SAVE. Forge/OS returns to the Configured Devices list, which shows the new robot as enabled.

Note: A device is enabled when its switch is green and toggled to the right.

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5 Follow these steps to clear robot errors:

a Tap the Device Status button on the Toolbar to expand the Device Status Panel. The robot is listed with
two buttons: MORE and RESET.

b Tap RESET to try to recover from the errors. If you can't RESET an error, tap MORE to get more details
and instructions.

6 Review the steps in Appendix B: Tool Loading Steps. Refer back to the Tool Loading Procedure whenever you
create new Tool Center Points or Payloads. To save time, decide all the TCPs and Payloads you need for your
application/workcell ahead of time and add them at one time.

Congratulations! You are ready to control your robot in the Device Control Panel and Task Canvas apps.

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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.

1 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.

a Connect a monitor, keyboard, and mouse to the IPC where you want to install Forge/OS.

b Plug the Forge/OS installation USB flash drive into the IPC.

Tip: If you need more USB ports, use a USB 3.0 hub.

c Restart the IPC. While the IPC is powering on, press the keyboard hotkey that takes you to the Boot Menu.

Tip: The key that opens the Boot Menu depends on the IPC model. The most common keys that do this
are ESC, F10, F11, or F12. Refer to your computer's documentation for boot options.

d From the boot options, select Install Forge/OS to boot from the installation USB flash drive.

e The installer may take several minutes to load. Wait until the installation wizard opens.

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f Select your language. Then click Install Forge.

g Choose a keyboard layout. Then click Continue.

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h Select Minimal installation. Uncheck Download updates while installing forgeos. Then click Continue.

i 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.

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j Select the IPC hard drive for Forge/OS and click Install Now.

k Confirm that you want to erase the entire disk by clicking Continue.

l 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.

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m Choose your timezone. Then click Continue.

n 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.

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o Wait for the installer to copy and install Forge/OS.

p Once the installation completes, click Restart Now.

q When prompted, remove the installation flash drive. Then reboot.

r Wait for Forge/OS to finish booting.

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s 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.

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2 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).

▪ Forge/OS IPC Detected: This condition is satisfied when the READY pendant detects a Forge/OS IPC on
the network.

▪ Forge/OS IPC Paired: This condition is satisfied when the READY pendant successfully pairs with the
IPC. If pairing fails, it is automatically retried indefinitely.

When a condition is not satisfied, the LED is red. When a condition is in progress of becoming satisfied, a
spinner around a READY logo appears to the right of the text. When a condition becomes satisfied, the LED
turns green.

The UI shows the real-time state of each step. For example, if the pendant loses its network connection during
pairing, all steps become undone.

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.

Note: The READY pendant IP Address is preset to 172.16.255.253. The network interface that the pendant
connects to should use IP Address 172.16.255.250 and Subnet mask 255.255.255.0.

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3 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.

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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

▪ An internet-connected Forge/OS ▪ An internet-connected PC
▪ 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/
OS.

1 On the Settings app main screen, tap License.

2 Type in your license code.

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3 Choose ONLINE LICENSE ACTIVATION if Forge/OS is connected to the internet. If not, choose OFFLINE
LICENSE ACTIVATION.

4 If you chose online license activation, you're done!

5 If you chose offline license activation, follow these substeps:

a Insert the USB flash drive into your IPC. Tap START WRITING CERTIFICATE TO USB DRIVE.

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b 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.

c Insert the USB flash drive back into your IPC. Tap UNLOAD UNLOCK CERTIFICATE FROM USB DRIVE.

d Wait for the file to finish transferring. When the file transfer is complete, remove the USB flash drive and
tap SAVE.

e 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.

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CHOOSING PREFERENCES
These steps help you choose system preferences, including language, units, time, and network settings.

1 To change preferences for the first time, go to General Settings:

a On the Settings app main screen, tap General Settings.

b 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.

c Tap SAVE to save changes and exit the General Settings menu.

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2 Check the Network settings in Forge/OS and set them as you want.

a On the Settings main screen, tap Network.

b 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.

c Change the network interface to match the settings in the image below. Connect robots and other devices
to this interface through an Ethernet switch.

d Tap SAVE.

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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.

Here is an outline of the tool loading process:

▪ Add TCPs/Payloads to the robot's configuration in Forge/OS and save.

▪ Forge creates a TOOL.CND file and saves it to the USB drive on the robot controller.
▪ Load the tool file onto the robot controller while in Safety mode.
▪ Reset the safety systems on the robot controller in Maintenance-Safety mode.

1 Make sure there is a USB flash drive in the Yaskawa pendant.

2 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.

3 Tap TCP AND PAYLOAD CONFIGURATION.

4 Add all the TCPs and Payloads you need for your workcell and tap SAVE.

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5 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.

6 Switch the Yaskawa pendant to TEACH and select Safety Mode:

a Turn the key to TEACH.

b From the Main Menu, navigate to SYSTEM INFO, then SECURITY.

c Select SAFETY MODE from the dropdown list.

d Enter the SAFETY MODE password and press the ENTER button on the pendant keypad.

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7 From the Main Menu, tap EX. MEMORY, then tap LOAD.

a Select FILE/GENERAL DATA.

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b Highlight TOOL DATA and press SELECT. Then press ENTER.

c At the Load? screen select YES.

8 Power off the robot controller and wait 10 seconds.

9 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.

10 On the Yaskawa pendant:

a Make sure the key is still in the "TEACH" position (counterclockwise).

b From the Main Menu, tap SYSTEM, then tap SECURITY.

c Select SAFETY MODE from the dropdown list.

d Enter the SAFETY MODE password and press ENTER.

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11 Save changes to the Safety I/O board. From the Main Menu, tap FILE, then INITIALIZE.

a Select Safety Board FLASH Reset.

b When prompted select YES.

c Wait for the flash reset to complete and the pendant to beep. This process takes up to one minute to
complete.

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12 Turn the key to the REMOTE.

13 Power off the robot controller and wait 10 seconds.

14 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.

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APPENDIX C: TROUBLESHOOTING
Issue #1 "Unauthorized User" error. This issue occurs when you input an incorrect safety mode
password.

1 If you are using a collaborative robot, enter in your 16-digit custom safety mode password from the
"Collaborative Password Agreement" If you do not have that on hand, call Yaskawa Support with your
Warranty ID number and they will provide it to you.

2 If you are using a non-collaborative robot, try re-entering the default safety mode password (5555 5555
5555 5555). If this doesn't work, contact Yaskawa Support.

Issue #2: “Alarm 4751 unmatch of general safety input signal functionality is detected by ASF02
board". This alarm occurs when there is a mismatch of safety I/O signals.

1 Check the Functional Safety Breakout wiring against the wiring diagram in the READY pendant wiring
section.

2 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.

1 Boot the Yaskawa controller in Maintenance Mode. Go to the Main Menu on the Yaskawa pendant, select
EX.MEMORY, and select DEVICE.

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2 If the Target Device is set to read an SD card (SD: Pendant), change the field to USB:Pendant.

3 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.

1 Make sure a USB drive is connected to the Yaskawa pendant and reapply the Device Configuration in
Forge/OS. Then re-run the Tool Loading Procedure.

2 If you continue getting this alarm, make sure the following are true:

▪ The Yaskawa software is in the SAFETY operating mode.

▪ The Yaskawa pendant key switch is in TEACH position.

▪ CRC checks for uploaded files is set to disabled.

Issue #5 The robot hits an unnecessary protective stop when jogging.

1 Check if you set the correct active payload correctly in Forge/OS. Make sure the Device Configuration
provides accurate payload mass and center-of-mass settings for the tool.

2 If using a custom tool, calculate its tool center point offset and rotation, and label the tool with these values.
Incorrect values will lead to the robot not moving accurately relative to its tool center point.

3 For collaborative robots: If the Device Configuration and active payload are accurate, check the maximum
collaborative force permitted. The Yaskawa “Collaborative Robot Password Agreement” indicates that the
default maximum force threshold is set to 50N. Update the maximum force permitted setting in accordance
with safety assessment.

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Issue #6 “MotoPlus failed to create task” message appears on the Yaskawa pendant.

1 Reboot the Yaskawa robot controller.

2 If you continue getting this alarm, contact Yaskawa Motoman Support.

Issue #7 Forge/OS cannot connect to the robot device after adding it.

1 Check the Ethernet cable to the Yaskawa controller.

2 Check the network settings on the Yaskawa pendant.

1 Boot the robot controller in maintenance mode and switch to the Safety security mode.

2 Select LAN Interface Settings in Option Functions.

3 Check the IP address of your robot in Forge/OS Device Configuration.

4 Reboot the Yaskawa robot controller.

Issue #8: Loading the Configuration File (CIOPRG.LST) fails. If an old copy exists on the Yaskawa
pendant (so that the robot otherwise works with Forge/OS, such as when updating from Forge/OS
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.

1 In SAFETY MODE with the Yaskawa pendant in TEACH mode, navigate to the IN/OUT > LADDER EDITOR
menu.

2 Scroll down to the bottom of the list of signals. Highlight the last entry. On the right side of the screen,
select EDIT > INSERT NEW RUNG.

3 With the new rung highlighted, open the Ladder Editing Window (either by double tapping on the new rung
or pressing the SELECT button).

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4 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).

5 Change the input signal to 15090. You can do this either by double tapping the signal or by highlighting it,
selecting INPUT > INPUT VALUE, and then pressing the SELECT button.

6 Change the output signal to 05110.

7 Save the changes by navigating to the EDIT > SAVE RUNG (OVERWRITE) on the right side of the screen.

8 Repeat steps 2-7, increasing the signal number by one until the last entry has 15097 for the read signal and
05117 for the write signal. There are to be 8 new entries total.

9 Select EDIT > COMPILE.

Tip: If compiling fails, check that the pendant is in TEACH mode and that all the signals are correct.

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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.

Visit our Resources page (ready-robotics.com/resources) for articles, whitepapers, and other resources.

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: +1-833-732-3977

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