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READY FORGE OS5, Startup Manual

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READY FORGE OS5 Startup Manual Download Page 69

ERROR RECOVERY

Some errors are not recoverable from Forge/OS. One such error is Error 4066: "Motion
Command was attempted in the prohibited area depended on joint combination." This error
occurs when you move the robot outside of its joint limits.

In these situations, the robot is not movable in Forge/OS or in the EPSON RC+ Robot Manager.
If this is the case, use the following instructions to recover your robot to an operable state.

Restart EPSON RC+ in Program Mode by completing the steps below.

Close EPSON RC+.

1

On startup, select the

Change To Program Mode

button.

2

1

VERSION 5.0.4

© 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED

69

Summary of Contents for FORGE OS5

Page 1: ...EPSON VT6L Startup Guide ...

Page 2: ... 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 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 2 ...

Page 3: ...Your Robot For Control Through A Remote I O Device 43 Build The Driver 51 Start The Driver In Remote I O Mode 53 Device Configuration Pt 2 56 Known Issues 59 Excess Jogging At A Singularity 59 Stop Requests Rejected By The Robot 60 Troubleshooting 61 Driver Kill Switch For Unresponsive Robot 61 Initial Device Configuration Error 62 Rebuilding The Source Code 65 Error Recovery 69 Resources 77 VERSI...

Page 4: ...tall and set up Forge OS 6 Get robot files from Forge OS 7 Import the robot files into EPSON RC 8 Configure the robot for Remote I O control 9 Build and start the robot driver in Remote I O mode 10 Finish adding your EPSON robot in Device Configuration 11 Program your EPSON robot with Forge OS Important Before you start programming please read the Known Issues section The robot may behave unexpect...

Page 5: ...ng on a simulated robot at epson com Support wa00904 Note To check that you have the full version of EPSON RC installed open it in Program Mode Then look for a USB selection in the Connection dropdown menu located in the top right corner The USB option allows your computer to communicate with a real robot via a USB cable VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 5 ...

Page 6: ... Networking USB Cable A B 2m Black 602 1750 ND Digi Key 1 Cat5e Shielded Ethernet Cable 25 Grey 7734T6 McMaster Carr 1 The EPSON Emergency cable with attached 25 pin D Sub Emergency connectors comes with the purchase of your robot Connect a computer with EPSON RC installed Plug the Type B end of the USB cable into the PC port on the EPSON controller 1 Plug the Type A end of the USB cable into a US...

Page 7: ...o the LAN port on the robot controller 1 Plug the other end of the Ethernet cable into your Forge hub Shown here LAN1 port on the Forge Ctrl 2 Connect an EPSON Emergency connector 3 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 7 ...

Page 8: ...Connect a 25 pin D Sub EPSON Emergency connector to the EMERGENCY port on the robot controller VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 8 ...

Page 9: ...net cable Description PN Supplier Qty Controller Emergency Terminal Block Kit to break out to 25 pin terminal Block RE000975 1 EPSON 1 Cat5e Shielded Ethernet Cable 25 Grey 7734T6 McMaster Carr 1 You may use a junction box or cabinet to enclose the wiring and 24V power supply Use cable glands to provide strain relief for cables Your setup may look like the example below VERSION 5 0 4 2021 COPYRIGH...

Page 10: ...VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 10 ...

Page 11: ...connect your EPSON robot from its power source 1 Plug the 25 pin D Sub Emergency connector into the green WAGO board from the EPSON kit 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 11 ...

Page 12: ...nal 24 VDC Power Supply Function Brown Enabling Switch Yellow Enabling Switch Green Enabling Switch Grey Enabling Switch Pink 24V Green Brown Pin 1 Emergency Stop White Green Pin 9 Emergency Stop Grey Pink Pin 10 Emergency Stop Red Blue Pin 14 Emergency Stop Black 0V Violet Key Switch White Pink Key Switch White Key Switch Blue Key Switch White Blue Pin 2 3 Jumper Pin 15 16 Jumper Pin 4 11 Jumper ...

Page 13: ...onnector External 24V Power Supply Safeguard Device Function 24V Safeguard Contact 11 Safeguard Input 1 Circuit Pin 7 Safeguard Contact 12 Safeguard Input 1 Circuit Pin 8 0V Safeguard Input 1 Circuit 24V Safeguard Contact 21 Safeguard Input 2 Circuit Pin 20 Safeguard Contact 22 Safeguard Input 2 Circuit Pin 21 0V Safeguard Input 2 Circuit Pin 18 24V Latch Release Input Jumpered Pin 19 24V Latch Re...

Page 14: ...Refer to EPSON documentation for pin assignments and safeguard latch information 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 14 ...

Page 15: ...ble is a black Ethernet cable Connect it to a longer Ethernet cable to plug into your Forge hub See the example below 6 Power up the robot Forge hub and KEBA pendant 7 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 15 ...

Page 16: ...S installation USB flash drive into the computer Tip If you need to more USB ports use a USB 3 0 hub 2 Power on the computer While the computer is powering on press the keyboard hotkey that takes you to the Boot Menu Note The button that opens the Boot Menu depends on the computer The most common buttons that do this are ESC F10 F11 or F12 Refer to your computer s documentation for boot options 3 ...

Page 17: ...Select your language Then click Install Forge 6 Choose a keyboard layout Then click Continue 7 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 17 ...

Page 18: ... 8 Select Erase disk and install forgeos Then click Install Now Note If Forge OS is already installed the installation wizard may prompt you with additional options The goal is to erase the entire disk for a brand new installation 9 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 18 ...

Page 19: ...he entire disk by clicking Continue 10 If you are installing Forge OS on a Forge Ctrl select the checkbox labeled This hardware is a Forge CTRL Then click Continue 11 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 19 ...

Page 20: ...es the computer on the network Pick a username and password Then click Continue Note The username and password that you create here are for accessing the Forge hub desktop They are NOT for logging into Forge OS on the KEBA pendant 13 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 20 ...

Page 21: ...Wait for the installation to complete 14 Once the installation completes click Restart Now 15 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 21 ...

Page 22: ...When prompted remove the installation flash drive Then reboot 16 Wait for Forge OS to finish booting 17 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 22 ...

Page 23: ...or keyboard and mouse that you used to install Forge OS 18 On the KEBA pendant the Pendant Pairing screen appears This is where you connect the pendant to Forge OS each time you reboot Tap the blue PAIR PENDANT button when it appears It may take up to two minutes to appear 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 23 ...

Page 24: ... 253 The network interface that the pendant connects to should use IP Address 172 16 255 250 and Subnet mask 255 255 255 0 Tap Admin and sign in The default Admin password is forgeadmin 3 From the Home Screen tap on the Settings icon to open the Settings app 4 If your Forge OS license isn t active insert an empty USB flash drive to use for Forge OS license activation and complete steps 6 8 Note Do...

Page 25: ...ote Find your license code on your packing slip On the Settings app main screen tap License Info Tap GENERATE ACTIVATION CERTIFICATE 1 6 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 25 ...

Page 26: ...START WRITING CERTIFICATE TO USB DRIVE when prompted Wait for the process to finish 4 Remove the USB flash drive from your Forge hub 5 Use the activation certificate and create the unlock certificate Insert the USB flash drive into your PC 1 7 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 26 ...

Page 27: ...tivationportal me selfservice activation aspx Type 1 cid 7461 pid 8933 lang en US 3 Paste the contents of the activation certificate file and click Activate 4 The portal generates new text characters Copy all of the text and paste it in the empty Forge_OS License Unlock Certificate txt file 5 Save the unlock certificate file 6 Remove the USB flash drive from your PC 7 Import the unlock certificate...

Page 28: ...t tap IMPORT UNLOCK CERTIFICATE 1 Insert the USB flash drive into your Forge hub 2 Tap LOAD UNLOCK CERTIFICATE FROM USB DRIVE 3 Enter your license code 4 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 28 ...

Page 29: ... Update files are too large for the FAT32 file format Use an exFAT or NTFS formatted USB flash drive with at least 8GB of storage to download and install the update Do not use the Forge OS installation USB flash drive Important After you transfer an update file to your USB flash drive make sure you safely eject it from your computer Early removal of the USB flash drive can interrupt data transfer ...

Page 30: ...2 When the update files show under Available Versions tap the version to install 3 Wait for the update to finish 4 Restart Forge OS using the power button at the bottom of the screen 5 If you need to change system preferences do it through the General Settings screen 10 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 30 ...

Page 31: ...rd Note If you later forget your password contact READY Robotics to reset it 2 Tap SAVE to save changes and exit the General Settings menu 3 If your Forge hub is not a READY made Forge Ctrl or Forge Hub configure the Network settings in Forge OS 11 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 31 ...

Page 32: ... network interfaces on your Forge hub By default the first interface is for the KEBA pendant You can t edit the pendant s interface in Forge OS Select another interface and tap Edit to see the network settings 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 32 ...

Page 33: ...twork interface to match the settings in the image below Connect robots and other devices to this interface through an Ethernet switch 3 Tap SAVE 4 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 33 ...

Page 34: ...ou will add the robot in Forge OS and copy configuration files to the robot controller In the Admin role tap the Device Configuration icon to open the Device Configuration app 1 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 34 ...

Page 35: ...Tap New to open the Device Library 2 In the Device Library list select EPSON industrial robot Then tap NEXT 3 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 35 ...

Page 36: ...er 4 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 5 Tap Start Transfer and wait for it to finish 6 Remove the USB flash drive when prompted 7 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 36 ...

Page 37: ...ve into the computer with EPSON RC installed 1 Open EPSON RC in Program Mode You may see a pop up asking if you want to run in Auto Mode or Program Mode Click Change to Program Mode 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 37 ...

Page 38: ...ond time click No or you ll have to close RC and try again 3 If asked to close the current PC project or to stop other projects choose Stop all tasks in the controller and use the current PC project 4 Transfer the folder ready epson driver from the USB drive into your EPSON RC 7 0 projects folder 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 38 ...

Page 39: ...ready epson driver folder from your USB drive 2 Open the C drive Open the EpsonR70 folder that was made when you installed the EPSON RC software Find the projects folder 3 Paste the ready epson driver folder into the projects folder 4 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 39 ...

Page 40: ...In the menu bar across the top of EPSON RC open the Project tab Click Import 6 Set the import location as PC and click Next 7 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 40 ...

Page 41: ...of EPSON RC 7 x Then select the copied ready epson driver project and click Next 8 Type EPSON_DRIVER in the Destination Project Name field Then click Next 9 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 41 ...

Page 42: ...Check the Open Destination Project After Import checkbox and click Import 10 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 42 ...

Page 43: ...o control your robot with Forge OS In the Connection dropdown in the top right corner click USB to connect to your robot Note This USB option is available in the full version of the Epson RC software 1 If you see this prompt select Stop all tasks in the controller and use the current PC project 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 43 ...

Page 44: ...Auto mode and click Apply Then open the Controller menu 4 In the Controller menu select Configuration Set the IP address and Subnet mask IP mask Set the IP Address to 192 168 1 20 and set the Subnet Mask to 255 255 255 0 1 2 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 44 ...

Page 45: ...Device select Remote I O Note Configuring the driver with a Remote I O control device allows your robot to run independent of a PC 6 Click Apply 7 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 45 ...

Page 46: ...gs in the image below Then click Apply Uncheck Virtual I O to disable it 1 Uncheck Auto safeguard position recovery to disable it 2 Check Independent mode to enable it 3 Check Enable background tasks 4 Check Enable advanced task commands 5 8 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 46 ...

Page 47: ...Once you apply your Controller Preferences you may see the following warning Click OK 9 Open the Inputs Outputs menu 10 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 47 ...

Page 48: ...select Modbus TCP Note If RC won t let you select a Fieldbus Type close the System Configuration window and open it again from the Setup menu 1 Click Apply 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 48 ...

Page 49: ... to the values listed below Leave the IP Address as the default value Set Port 201 to 49152 then Apply 1 Set Port 202 to 49153 then Apply 2 Set Port 203 to 49154 then Apply 3 11 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 49 ...

Page 50: ...Click Close and wait for the controller to reboot 12 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 50 ...

Page 51: ... step sends the program files to the robot In the top menu bar open the Project dropdown Click Build 1 If you see the prompt below select Yes to overwrite the project on the controller 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 51 ...

Page 52: ... successful build by looking for a Build complete no errors message in the Status window Note If you see build errors refer to the Troubleshooting section 3 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 52 ...

Page 53: ... MODE Once you have built the robot driver follow these steps to start it in Remote I O mode to test it In the top menu bar open the Run dropdown Click Run Window 1 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 53 ...

Page 54: ...Remote I O button Click Yes in the pop up window 2 If asked to close the current PC project or to stop other projects choose Stop all tasks in the controller and use the current PC project 3 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 54 ...

Page 55: ...n Remote Console Note If the robot reboots for any reason the driver auto launches and be ready to run 4 If you want to close RC hit Stop and exit RC The EPSON switches to AUTO mode 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 55 ...

Page 56: ... For the IP Address enter 192 168 1 20 2 1 In Forge OS confirm your device settings and tap SAVE Forge OS attempts to communicate with the robot controller 2 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 3 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED...

Page 57: ...e 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 1 4 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 57 ...

Page 58: ...hat signal Note To use these I O signals integrate your I O devices with the robot controller 2 Tap SAVE 3 Forge OS returns to the Device Configuration home screen Make sure the robot appears in the configured devices list and that it is enabled Note A device is enabled when its switch is green and toggled to the right 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 58 ...

Page 59: ...t cannot reach a specified waypoint due to physical limitations This doesn t mean you can t reach the waypoint but the robot is unable to move to the position in that way When you move a robot near a singularity the robot may move unexpectedly speed up or enter an error state There are two behaviors you may see near a singularity excess jogging and rejected stop requests EXCESS JOGGING AT A SINGUL...

Page 60: ...OBOT When you program a circle move where one of the arc points is near a singularity you may see unexpected behavior While executing that circle move the robot may not stop right away when you press the KEBA pendant s Stop button To minimize risk use a low speed as you first build out your task Using a low speed can help you avoid unpredictable collisions Important In emergency situations ALWAYS ...

Page 61: ... the robot when you reboot In order to shut down an unresponsive driver set IO23 pin 27 to HIGH and restart the robot This setting prevents the driver from launching when the robot powers up Then you can reconfigure the robot Set IO23 back to LOW to re enable the driver The table below lists the Epson robot s I O pins See the example I O wiring below VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL...

Page 62: ...INITIAL DEVICE CONFIGURATION ERROR When you set up your robot for the first time you may see build errors VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 62 ...

Page 63: ...p menu bar select Setup Go into System Configuration 1 Expand the Controller menu Open Robot 1 Note what the settings of the configured robot are If they don t match your robot model make a note of that 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 63 ...

Page 64: ... Robot 1 file 3 Click Add Enter the robot s information and then click OK 4 Close out of the System Configuration menu 5 Re build the project as outlined in the next section 6 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 64 ...

Page 65: ...ror if the Epson encounters a stack error in the Epson logs while you are running a task When this happens you will receive a Forge OS message asking you to re build In the top menu bar open the Project dropdown Click Rebuild 1 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 65 ...

Page 66: ... select Yes to overwrite the project on the controller 2 Verify that you have a successful rebuild by looking for Build complete no errors in the Status window 3 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 66 ...

Page 67: ...o the top menu bar open the Run dropdown and click Run Window 4 To start the driver in Remote I O mode click the Enable Remote I O button Click Yes in the pop up window 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 67 ...

Page 68: ...ject or to stop other projects choose Stop all tasks in the controller and use the current PC project 6 Verify that you see something like this in the Run Remote Console 7 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 68 ...

Page 69: ... outside of its joint limits In these situations the robot is not movable in Forge OS or in the EPSON RC Robot Manager If this is the case use the following instructions to recover your robot to an operable state Restart EPSON RC in Program Mode by completing the steps below Close EPSON RC 1 On startup select the Change To Program Mode button 2 1 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIG...

Page 70: ...If you set a password enter your password then press OK 3 If prompted with the warning below click Yes 4 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 70 ...

Page 71: ... 5 In the Connect pop up select Stop all tasks Then click OK 6 Reload your project if necessary In the top menu bar open the Project dropdown 1 Expand the Recent Projects menu 2 2 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 71 ...

Page 72: ... file 3 If prompted to disconnect click No 3 Open the Command Window In the top menu bar open the Tools dropdown 1 Click Command Window 2 4 Turn motors off 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 72 ...

Page 73: ...ding on which joint that you are releasing the brake for and what position that joint is in you may need to catch the robot as it falls Avoid damage to the robot and any nearby objects that it might collide with 2 6 Move the joint and turn its brake back on Use your hands to move the joint back within the movable zone 1 In the Command Window type Brake On JOINT then hit Enter 2 7 Turn motors on 8 ...

Page 74: ...their 0 position In the Command Window type Go JA 0 0 0 0 0 0 then hit Enter 9 Restart the driver in Auto mode by first navigating to the top menu bar and opening the Setup dropdown Go into System Configuration 10 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 74 ...

Page 75: ...at you have configured your robot for control through a Remote I O device Open the Controller tab 1 Navigate to Preferences 2 Uncheck Virtual I O 3 Click Apply 4 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 75 ...

Page 76: ...Click Close Note After the controller restart is complete the robot returns to Auto mode 5 VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 76 ...

Page 77: ...nd hardware integration guides check out our Support page support ready robotics com For articles whitepapers and other resources check out our Resources page ready robotics com resources For products and services offered by READY and our partners visit READY Market market ready robotics com If you encounter a problem and need to talk to someone reach out to us Email READY Robotics support ready r...

Page 78: ...VERSION 5 0 4 2021 COPYRIGHT READY Robotics ALL RIGHTS RESERVED 78 ...

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