FANUC CRX Start Up Guide (No-DCS Safety)

Welcome to the FANUC Startup Guide. This guide covers the following hardware:

Here are the steps you will follow:

1. Connect the READY pendant.
2. Connect the IPC.
3. Power on the system.
4. Configure your robot for ForgeOS.
5. Control your robot with ForgeOS!

Chapter 2. Hardware Requirements

Chapter 3. Software Requirements

This section explains how to check your FANUC software for these version and option requirements.

1. Plug the FANUC controller into a power source. Follow FANUC instructions for powering the controller.

2. Turn the power switch on the FANUC controller clockwise to power the controller on. Wait for the controller to boot up.

3. On the FANUC tablet teach pendant, open the Tablet TP app. Wait for the tablet to connect.

4. Tap the iPendant icon in the lower right corner to open the virtual iPendant keys.

5. On the teach pendant keypad, press the STATUS button at the bottom.

6. In the STATUS menu, press [TYPE] (F1), then press Version ID (2).

7. Look for Software Edition No. and note the version number next to it. If your system version is older than the requirement, contact your FANUC distributor to upgrade.

8. Press the right arrow on the touchscreen menu bar, then press ORDER FI. The installed options appear with their part numbers.

9. Look for the required options. Under "Continue displaying?", press YES to see more of the installed options. If any of your controller's required options are missing, contact your FANUC distributor to upgrade.

Chapter 4. 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.

Note: CRX collaborative robots don't require the Enabling Switch or Key Switch. You will connect the Emergency Stop Button and an external safeguard (Fence) to the FANUC safety I/O in these steps.

Electric Shock Warning: Disconnect all components from power sources before attempting this installation.

1. Follow these sub-steps to connect the READY pendant communication, power, and safety wiring.

When connecting the READY pendant flying leads, refer to the destinations in this table.

Tip: Only connect the Emergency Stop circuits to the FANUC safety I/O. Where you connect them depends on your controller I/O configuration. See section 2.5.2 in the FANUC Maintenance Manual for details.

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.

2. Feed the flying leads through a controller cable entrance. Refer to FANUC documentation for cable entrance and sealing.

3. Wire the terminal blocks according to the destinations listed on the table in Step 1.

4. Wire the external safety fencing or another safeguarding device.

a. If you are using safety fencing or another safeguard device, connect it to the external Fence Inputs in the FANUC controller.

Tip: Where you find these destinations depends on your controller I/O configuration. See section 2.5.2 in the FANUC Maintenance Manual for details.

b. If you choose to NOT use a safeguard device, jumper the external Fence Inputs to I/O power: use jumpers to connect FENCE1 to 24V-2. Then connect FENCE2 to 0V.

Chapter 5. Connecting the Robot and IPC

Forge/OS must be able to communicate with the FANUC robot controller. This section will help you connect the IPC and robot controller using a Cat5e STP Ethernet cable.

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

2. Plug one end of the Ethernet cable into a LAN port on the IPC device (or a network switch connected to the IPC).

3. On the side of the FANUC controller, remove the cable entry panel and feed the Ethernet cable through one of the holes. See the FANUC Maintenance Manual for details.

4. Plug the cable into LAN Port 1 (CD38A) on the Main Board.

5. Manage the cables.

a. Use zip ties to bind cables at the top and bottom of the controller enclosure.

Important: Ensure that there is enough slack for the door to open and close without creating tension.

b. Cut the zip ties so that the cut-ends are flush with the connectors.

6. Close the controller door. Lock it using a flat head screwdriver.

Chapter 6. Powering On

In this section, you power on the system and prepare the FANUC teach pendant.

1. Reconnect the FANUC controller to power and power it on. Consult your Manufacturer's manual for instructions on powering the FANUC controller.

2. Power on your IPC device and other devices.

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

4. On the FANUC tablet, open the Tablet TP app. Wait for the tablet to connect.

5. Enable the tablet teach pendant by tapping the icon in the upper right corner of the screen.

Chapter 7. 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 (on page 28), 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.

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 ForgeOS with a License Code (on page 36) in Appendix A.

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

Chapter 8. Configuring the Robot for Forge/OS

This section shows you how to add a robot in the Forge/OS Device Configuration app and configure the FANUC controller. Make sure the FANUC controller and Forge/OS devices are powered on.

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

2. Tap New + to open the Device Library.

3. Select the FANUC Robot option. You can use the Filter by dropdown to show robot options. Tap NEXT to continue.

4. Give the robot a Device Name and enter the IP Address.

Note: Enter the same IP address that you set on the FANUC controller.

5. Select the robot Controller Model and Robot Model in the dropdown menus.

Tip: Some FANUC controllers have multiple hardware options for connecting the READY pendant safety devices. Select the one that matches your setup:

• "CIP Safety" - You are using a CIP Safety PLC instead of the FANUC Safety I/O Board.
• "No DCS" - You are using Forge/OS software-driven safety instead of DCS.
• Neither - You installed the FANUC Safety I/O add-ons (except for the CRX, R-30iB Mini Plus).

6. 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.

7. Tap Start Transfer and wait for it to finish.

8. Remove the USB flash drive when prompted.

9. Insert the USB drive into the USB slot on the FANUC controller.

10. Complete these substeps to stop currently-running programs (so that you can later run the ForgeOS installation script):

a. Tap the iPendant icon in the lower right corner to open the virtual iPendant keys.

b. Press the SELECT button. A list of programs appears.

c. Press MONITOR (F4) to show the list of running programs. If any programs appear, press the FCTN button. Then press 1 to ABORT (ALL). Press 1 and ABORT (ALL) at least one more time to make sure that all running programs stop.

Note: If you do not abort all running programs, you may have issues with the Forge installation process (such as a "Specified program is in use" message).

11. (OPTIONAL): If you are setting up a FANUC controller that was using remote control through a User Operator Panel (UOP), complete these substeps. Otherwise, you may have issues with the Forge installation process:

a. Press the MENU button on the FANUC teach pendant

b. Press IO.

c. Press TYPE (F1) then UOP.

d. Press CONFIG (F2). If the STAT field is ACTIV for any entry, set the RACK, SLOT, and START fields to zero.

e. Press IN/OUT to repeat the above substep with other signals.

f. Press the MENU button on the FANUC teach pendant.

g. Press SETUP.

h. Press TYPE (F1) then BG LOGIC. If this option is not visible, press NEXT (0).

i. If the status of any task is RUN, change it to STOP.

j. Press the MENU button on the FANUC teach pendant.

k. Press NEXT (0) then SYSTEM.

l. Press TYPE (F1) then CONFIG.

m. Change "Enable UI Signals" to FALSE.

n. Change "Remote/Local Setup" to LOCAL.

o. Restart the FANUC controller to apply these new settings.

12. Complete these substeps to install the configuration files on the FANUC controller:

a. Press the MENU button on the FANUC teach pendant.

b. Press FILE (7), then FILE (1).

c. Press UTIL (F5), highlight the Set Device (1) option, and press the ENTER button.

d. Choose the USB Disk (UD1:) option.

Note: If you inserted the USB drive into the teach pendant, choose the UT1: option.

e. Highlight the All Files option by using the arrow keys and press ENTER.

Note: If you have trouble accessing the contents of the USB drive, try unplugging the USB and re-inserting it.

f. The contents of the USB drive will appear. Use the arrow keys and the ENTER key to find and highlight FORGE-OS > READY-FANUC-DRIVER > FORGE_INSTALL, then press ENTER.

Note: The menu may sometimes already display the correct folder in the USB file structure. Check the "UT1:" file path displayed at the top of the FANUC pendant screen.

g. Press Yes (F4) for the prompt asking if you want to execute the file.

h. The FANUC Controller first displays # Backing Up Controller Config #. Wait for the FANUC Controller to say Execution is completed successfully. At a later time, you may copy the backup files in the FANUC Backup folder off of the USB drive.

Tip: If you get a "Specified program is in use" message instead of "Execution is completed successfully", try aborting all programs again. Press FCTN then 1 for ABORT (ALL).

Tip: If running FORGE_INSTALL.CM fails in the backup step, reboot the controller and run FORGE_INST_NOBACK.CM instead. This install file doesn't include the backup step, allowing you to bypass the failure.

i. Press OK (F4) and remove the USB drive from the FANUC controller.

13. On the FANUC teach pendant, set the robot's Port 1 IP address for Forge/OS:

a. On the FANUC teach pendant, go to the Host Communication screen: Press the MENU button, then scroll down to SETUP (6). Then scroll right to Host Comm (8), which is on the second menu (titled "SETUP 2"). Press ENTER.

Tip: Or on the SETUP screen, press [TYPE] (F1), select NEXT, then select Host Comm.

b. On the list of Protocols, select TCP/IP and press ENTER.

c. For Port 1, select the line that reads Port#1 IP addr... and press ENTER.

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

14. Disable the tablet teach pendant by tapping the icon in the upper right corner of the screen.

15. Restart the FANUC controller to apply the settings (power the controller off, then power it on). Wait for the tablet to connect to the FANUC controller.

16. Enter the password (default 1111) and follow the prompts to confirm the robot payload.

17. Tap the iPendant icon in the lower right corner to open the virtual iPendant keys.

18. Confirm that the Forge/OS programs are running on the FANUC teach pendant. Press the SELECT button. A list of programs appears.

19. Press MONITOR (F4) to show the list of running programs. There should be three "FOS" programs running. If nothing happens when you press MONITOR (F4) or you see fewer than three "FOS" programs on the monitor, follow these sub-steps.

a. Enable the tablet teach pendant by tapping the icon in the upper right corner of the screen.

b. Tap the iPendant icon in the lower right corner to open the virtual iPendant keys.

c. On the FANUC teach pendant, press the PREV button to return to the list of saved programs.

d. Use the arrow keys to highlight the program labeled Forge_OS.

e. Hold down one of the three-position enabling switches on the back of the FANUC pendant to the middle position.

f. While holding down the enabling switch, press and hold the SHIFT button and then press the FWD button once. Then release SHIFT and the enabling switch.

g. Check the monitor again. Press MONITOR (F4). There should be three programs listed.

h. Disable the tablet teach pendant by tapping the icon in the upper right corner of the screen.

20. 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.

21. 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.

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

23. 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.

Chapter 9. Appendix A: Setting Up Forge/OS

Installing ForgeOS

Follow these steps to install ForgeOS and sign in to the Admin role. Installation takes about 30 minutes, depending on the resources of the IPC.

1. To install ForgeOS, follow these substeps. You need a ForgeOS installation USB flash drive. Contact your READY Robotics distributor for an installation USB drive.

Important: Installing ForgeOS will erase all data on the target hard drive.

a. Connect a monitor, keyboard, and mouse to the IPC where you want to install ForgeOS.

b. Plug the ForgeOS 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 ForgeOS to boot from the installation USB flash drive.

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

f. Select your language. Then click Install Forge.

g. Choose a keyboard layout. Then click Continue.

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 ForgeOS is already installed, the installation wizard will show additional options. The goal is to erase the entire disk for a brand new installation.

j. Select the IPC hard drive for ForgeOS 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.

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 ForgeOS on the READY pendant.

o. Wait for the installer to copy and install ForgeOS.

p. Once the installation completes, click Restart Now.

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

r. Wait for ForgeOS to finish booting.

s. When you see the login screen with the ForgeOS 5 logo, ForgeOS 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 ForgeOS.

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.

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".

Note: After installation, you have limited access to ForgeOS until you activate it with a license code. See Activating ForgeOS with a License Code (on page 36).

Activating ForgeOS with a License Code

There are two methods to activate ForgeOS: Online license activation and offline license activation.

The table below lists the requirements for each method.

Tip: Connect a USB keyboard to the port on the bottom of the READY pendant to type in any text field in ForgeOS.

1. On the Settings app main screen, tap License.

2. Type in your license code.

3. Choose ONLINE LICENSE ACTIVATION if ForgeOS 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.

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. ForgeOS 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.

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.

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.

Chapter 10. Contacting READY

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