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Troubleshooting C203A0 Safety Settings Mismatch Fault

Learn how to apply Beacon safety settings for Universal Robots

Matt Bush avatar
Written by Matt Bush
Updated today

Safety Settings Overview

Universal Robots has a robust safety system to protect you and the cobot. The safety system allows you to limit robot force, power, momentum and speed, apply joint position or speed limits, restrict the robot workspace with safety boundaries, and interface with other equipment through safety rated IO.

Safety Fault Due To Mismatched Settings

When the Beacon URCap is installed or updated, it may adjust the currently loaded safety settings as appropriate for the app and the configured equipment. When PolyScope detects a change to the currently loaded safety settings and the to-be-applied settings then an alert is presented to the operator, and the robot arm status changes to "fault". This is expected, continue reading the article for how to resolve.

In this article, you'll learn:

Apply Safety Settings for PolyScope 5

In 2025, Universal Robot's introduced PolyScope X, a new major version to their operating system as a successor to PolyScope 5. PolyScope X requires new controller hardware. This section is specific to PolyScope 5.

If you receive an error after installing any inputs in the Red or Blue inputs you may need to change the safety input settings in the default installation file. When the cobot is shipped from Universal Robots, the configurable inputs CI0 and CI1 in the default installation file are defaulted as a safeguard resets. Hirebotics configures these for the Red and Blue input in the application installation file included with the system from Hirebotics. If one of these inputs is on when the robot boots it can cause a fault during bootup that can be resolved by changing the behavior of these two inputs in the default installation file.

Set a Safety Password

Before changing any of the safety settings you will need to add a safety password to the system. By default, when the system ships from Hirebotics we do not set this password. Make sure you keep track of the password as we do not have access to this password and so cannot help you recover it.

  1. On the teach pendant at the top-right, tap to open the menu.

  2. Tap Settings.

  3. Tap to expand the Password section, then tap Safety.

  4. Enter the password of your choice.

Load the Default Installation

The installation file that is loaded whenever you boot up the robot will pertain to the application that robot has been configured. For instance, a Cobot Welder will load the welding_program installation and the Cobot Cutter will load cutter_program installation. You need to modify the default installation file to resolve the fault that is occurring.

  1. On the teach pendant at the top-center, tap Open then choose Installation.

  2. Navigate to the root directory.

  3. Choose the installation file labeled default.

  4. Choose Apply and Restart when prompted.

  5. Choose Use for Now when prompted to override the current installation file.

Change the Safety Settings

  1. On the teach pendant at the top-left, tap Installation.

  2. Tap to expand the Safety section, then tap I/O.

  3. Enter the Safety password, then tap Unlock.

  4. On config_in[0], config_in[1] use the drop-down menu to choose Unassigned.

  5. Tap Lock.

  6. Tap Apply and Restart.

  7. Tap Ok.

  8. Tap Confirm Safety Configuration.

  9. On the teach pendant at the top-center, tap Open then choose Installation.

  10. Reopen the correct installation file by navigating the applications folders until you get to either the welding or cutting program, then choose that installation file.

    1. applications -> com.hirebotics.welding -> welding_program

    2. applications -> com.hirebotics.cutting -> cutting_program

  11. Tap Apply and Restart.

  12. On the teach pendant at the top-right, tap to open the menu, then tap Restart.

  13. If there is no error, proceed with standard initialization. If the error persists, check that the safety settings were applied correctly by repeating this section.

Apply Safety Settings for PolyScope X

In 2025, Universal Robot's introduced PolyScope X, a new major version to their operating system as a successor to PolyScope 5. PolyScope X requires new controller hardware. This section is specific to PolyScope X.

  1. Tap OK to dismiss the fault.

  2. Tap Application, then tap Safety.

  3. Tap Unlock.

  4. If prompted, enter the safety password (default is ursafe), then tap Confirm.

  5. Tap Apply.

  6. Tap Apply and restart (this does not reboot the robot).

  7. Tap Confirm Configuration.

  8. Tap to open the menu, then tap Reload.

  9. Tap Reload.

You have successfully applied the safety settings to resolve the fault. You should now be able to play programs as usual.

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