C Controller Ops and Programming PDF

Kawasak
C SERIES CONTROLLER
OPERATIONS AND PROGRAMMING MANUAL
MPOCCONTO87E-3
Kawasak
Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted with-
out the express written permission of Kawasaki Robotics (USA), Inc. The contents of this
manual cannot be reproduced, nor transmitted by any means, e.g., mechanical, electri-
cal, photocopy, facsimile, or electronic data media, without the express written permis-
sion of Kawasaki Robotics (USA), Inc.
All Rights Reserved.
Copyright © 2001, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393
The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.
This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.
KAWASAKI ROBOTICS (USA), INC. TRAINING
Training courses covering operation, programming, electrical maintenance, and me-

chanical maintenance are available from Kawasaki Robotics (USA), Inc. These courses
are conducted at our training facility in Wixom, Michigan, or on-site at the customer’s
location.
For additional information contact:
Kawasaki Robotics (USA), Inc.

Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
C SERIES CONTROLLER
Kawasak OPERATIONS AND PROGRAMMING MANUAL
REVISION HISTORY
Revision Release
Description of Change Initials
Number Date
-0 6/3/99 Initial PDF release, based on rev. 4 of print copy KR
-1 4/24/00 Revision based on rev. 6 of print copy KR
-2 9/19/00 Revision based on rev. 7 of print copy CB
-3 7/23/01 Revision based on rev. 8 of print copy CB

Kawasak C SERIES CONTROLLER
INTRODUCTION
I.0 INTRODUCTION.................................................................................................. I-2

I.1 Mechanical Unit ................................................................................................... I-2
I.1.1 Mechanical Unit Design Specifications ................................................................ I-3
I.2 Robot Controller ................................................................................................. I-10
I.2.1 Robot Controller Design Specifications ............................................................. I-11
March 10, 1999 I-1

INTRODUCTION
I.0 INTRODUCTION
The C Controller Operations and Programming Manual is designed to assist the opera-
tor whose primary responsibility is to program and operate the robot on a daily basis.
This manual provides specific information on safety, basic operation, programming path
and auxiliary data, setting the Auxiliary Data screens, and error information.
I.1 MECHANICAL UNIT
The Kawasaki F-series, U-series, and Z-series AC servo driven industrial robots are
articulated coordinate-type robots designed for many applications in the industrial envi-
ronment. The robot with its AC servo closed-loop drive system, is built with high rigidity.
This design allows it to perform tasks that require high accuracy, speed, and wrist load
capacities, while achieving significant energy reduction through the use of high effi-
ciency brushless AC servo motors.
The mechanical unit has six or seven axes depending upon the configuration of the
robot.
The major axes are:
• JT1 (R-axis) rotary; rotation of the base

• JT2 (O-axis) out and in; rotation of the lower arm
• JT3 (D-axis) down and up; rotation of the upper arm
The minor axes are:
• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

• JT5 (B-axis) bend; provides pitch/yaw wrist motion
• JT6 (T-axis) twist; provides rotation of the tool only
The auxiliary axis, if so equipped is:
• JT7 (V-axis) traverse; linear positioning of the mechanical unit
I-2 May 22, 2001

INTRODUCTION
The Kawasaki robot system supports Cartesian coordinate motion which includes:
• Base (World) coordinates

• Tool coordinates
These coordinate systems can be used when manually operating the robot in the teach
mode and with various program instructions for shifting program positional data, defining
tool center points, and recording positional data.
Kawasaki robot systems use the left-hand rule to determine the orientation of the base
or tool coordinate system. For additional information about the left-hand rule, refer to
section 6. 4. 2.
I.1.1 MECHANICAL UNIT DESIGN SPECIFICATIONS
Table I-1 provides the design specifications for the mechanical units that utilize the C
controller.
March 31, 2000 I-3

INTRODUCTION
Table I-1 Robot Specifications
ROBOT MODEL FS02N FS03N FC06N FS06L FS06N FW06N FS10C
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*
JT1 250°/sec 240°/sec 240°/sec 200°/sec 240°/sec 240°/sec 200°/sec

Maximum JT4 600°/sec 360°/sec 430°/sec 360°/sec 430°/sec 430°/sec 360°/sec
Velocity

1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec
JT7
(47.24) (47.24) (47.24) (47.24) (47.24) (47.24) (47.24)
Maximum Linear 9,200 mm/sec 9,200 mm/sec 8,000 mm/sec 9,200 mm/sec 8,000 mm/sec 8,000 mm/sec 6,200 mm/sec
Tool Tip Speed (362.2) (362.2) (314.9) (362.2) (314.9) (314.9) (244)
JT1 ±160° ±160° ±160° ±160° ±160° ±160° ±160°
JT2 +60°/-150° +60°/-150° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°
JT3 +210°/-270° +210°/-270° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

Work
Envelope JT4 ±360° ±360° ±270° ±270° ±270° ±270° ±270°
(Stroke)
JT5 ±135° ±135° ±145° ±145° ±145° ±145° ±145°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload
2 (4.4) 3 (6.6) 6 (13) 6 (13) 6 (13) 6 (13) 10 (22)
(lbs.)
0.59 kg m 21.5 N m
JT4 0.4 kg m (8.8) 12 N m (8.8) 12 N m (8.8) 12 N m (8.8) 12 N m (8.8)
Wrist (8.8) (15.8)
Rated 0.59 kg m 21.5 N m
JT5 0.4 kg m (8.8) 12 N m (8.8) 12 N m (8.8) 12 N m (8.8) 12 N m (8.8)
Torque (8.8) (15.8)
(ft. lbs.) 0.29 kg m
JT6 0.2 kg m (4.4) 6 N m (4.4) 6 N m (4.4) 6 N m (4.4) 6 N m (4.4) 9.8 N m (7.2)
(4.4)
2 2 2 2 2
0.0078 kg m s 2
0.012 kg m s 0.24 kg m s 0.24 kg m s 0.24 kg m s 0.24 kg m s 0.63 kg m s2
JT4
Wrist (1.72 ) (1.72 ) (1.72 ) (1.72 ) (1.72 ) (1.72 ) (4.56)
Rated 0.0078 kg m s2 0.012 kg m s2 0.24 kg m s2 0.24 kg m s2 0.24 kg m s2 0.24 kg m s2 0.63 kg m s2
JT5
Moment of (1.72) (1.72) (1.72) (1.72) (1.72) (1.72) (4.56)
Inertia 0.0020 kg m s2 0.003 kg m s2 0.07 kg m s2 0.07 kg m s2 0.07 kg m s2 0.07 kg m s2 0.15 kg m s2
JT6
(0.51) (0.51) (0.51) (0.51) (0.51) (0.51) (1.08 )
Repeatability (in.) ±0.03 (0.001) ±0.05 (0.002) ±0.05 (0.002) ±0.1 (0.004) ±0.05 (0.002) ±0.05 (0.002) ±0.05 (0.002)
JT1 100 w (0.13) 100 w (0.13) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34)
JT2 200 w (0.27) 200 w (0.27) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34)
JT3 75 w (0.10) 75 w (0.10) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64)
Drive
JT4 30 w (0.040) 30 w (0.040) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13)
Source (hp)
JT5 30 w (0.040) 30 w (0.040) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13)
JT6 30 w (0.040) 30 w (0.040) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13)
JT7 100 w (0.13) 100 w (0.13) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)
Weight 6
20 kg (44) 20 kg (44) 110 kg (243) 125 kg (276) 110 kg (243) 110 kg (243) 110 kg (243)
(lbs.) Axes
I-4 May 22, 2001

INTRODUCTION
Table I-1 Robot Specifications (Continued)
ROBOT MODEL FS10E FS10L FS20C FS20N FS30L FS30N FS45C
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

Velocity

1,200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec
JT7
(47.24) (47.24) (47.24) (47.24) (47.24) (47.24) (47.24)
Maximum Linear 8,800 mm/sec 9,400 mm/sec 6,900 mm/sec 8,500 mm/sec 11,100 mm/sec 8,900 mm/sec 8,900 mm/sec
Tool Tip Speed (346.4) (370) (271.6) (334.6) (437) (350.3) (350.3)
JT1 ±160° ±160° ±160° ±160° ±160° ±160° ±160°
JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°
JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

Work
Envelope JT4 ±270° ±270° ±270° ±270° ±270° ±270° ±270°
(Stroke)
JT5 ±145° ±145° ±145° ±145° ±130° ±130° ±130°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

JT7
Max. Payload (lbs.) 10 (22) 10 (22) 20 (44) 20 (44) 30 (66) 30 (66) 45 (99)
21.5 N m 21.5 N m 39.3 N m 39.3 N m 176.4 N m 176.4 N m 176.4 N m
JT4
(15.8) (15.8) (28.9) (28.9) (130.1) (130.1) (130.1)
Wrist Rated
21.5 N m 21.5 N m 39.3 N m 39.3 N m 176.4 N m 176.4 N m 176.4 N m
Torque JT5
(15.8) (15.8) (28.9) (28.9) (130.1) (130.1) (130.1)
(ft. lbs.)
19.6 N m 19.6 N m 98.0 N m 98.0 N m 98.0 N m
JT6 9.8 N m (7.2) 9.8 N m (7.2)
(14.4) (14.4) (72.2) (72.2) (72.2)
0.63 kg m s2 0.63 kg m s2 0.88 kg m s2 0.88 kg m s2 7.2 kg m s2 7.2 kg m s2 10.8 kg m s2
JT4
(4.56) (4.56) (6.37) (6.37) (52.08) (52.08) (78.12)
Wrist Rated
Moment of JT5
(4.56) (4.56) (6.37) (6.37) (52.08) (52.08) (78.12)
Inertia
JT6
(1.08 ) (1.08 ) (1.81 ) (1.81 ) (23.87 ) (23.87 ) (36.17 )
Repeatability (in.) ±0.1 (0.004) ±0.1 (0.004) ±0.1 (0.004) ±0.1 (0.004) ±0.15 (0.006) ±0.15 (0.006) ±0.15 (0.006)
JT1 1.0 kw (1.34) 2.1 kw (2.82) 2.1 kw (2.82) 2.1 kw (2.82) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63)
JT3 475 w (0.64) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 3.1 kw (4.16) 3.1 kw (4.16) 3.1 kw (4.16)
Drive
JT4 100 w (0.13) 200 w (0.27) 200 w (0.27) 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64)
Source (hp)
JT5 100 w (0.13) 200 w (0.27) 200 w (0.27) 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64)
JT6 100 w (0.13) 200 w (0.27) 200 w (0.27) 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64)
Weight 6
120 kg (265) 220 kg (485) 205 kg (452) 210 kg (463) 580 kg (1279) 540 kg (1191) 540 kg (1191)
(lbs.) Axes
August 2, 2000 I-5

INTRODUCTION
ROBOT MODEL FS45N UT100 UT120 UT150 UX70 UX100 UX120
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

Velocity

1200 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec
JT7
(47.24) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 9,700 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec
Tool Tip Speed (381.8) (94.49) (94.49) (94.49) (94.49) (94.49) (94.49)
JT1 ±160° ±180° ±180° ±180° ±180° ±180° ±180°
JT2 +140°/-105° +55°/-80° +55°/-80° +55°/-80° +70°/-65° +70°/-65° +70°/-65°
JT3 +295°/-225° +95°/-105° +95°/-105° +95°/-105° +90°/-119° +90°/-119° +90°/-119°

Work
Envelope JT4 ±270° ±280° ±280° ±280° ±280° ±280° ±280°
(Stroke)
JT5 ±130° ±125° ±125° ±125° ±125° ±125° ±125°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

JT7 Lengths Lengths Lengths Lengths Lengths Lengths
Lengths
Max. Payload (lbs.) 45 (99) 100 (220) 120 (264) 150 (330) 70 (154) 100 (220) 120 (264)
176.4 N m
JT4 539 N m (398) 686 N m (506) 833 N m (615) 490 N m (362) 539 N m (398) 686 N m (506)
(130.1)
Wrist Rated
176.4 N m
Torque JT5 539 N m (398) 686 N m (506) 833 N m (615) 490 N m (362) 539 N m (398) 686 N m (506)
(130.1)
(ft. lbs.)
98.0 N m
JT6 343 N m (253) 392 N m (289) 441 N m (325) 294 N m (217) 343 N m (253) 392 N m (289)
(72.2)
10.8 kg m s2 4.0 kg m s2 5.0 kg m s2 7.3 kg m s2 5.0 kg m s2 4.0 kg m s 2 5.0 kg m s2
JT4
(78.12) (28.92) (36.15) (52.78) (36.15) (28.92) (36.15)
Wrist Rated
10.8 kg m s2 4.5 kg m s2 5.5 kg m s2 7.3 kg m s2 5.5 kg m s2 4.5 kg m s 2 5.5 kg m s2
Moment of JT5
(78.12) (32.54) (39.77) (52.78) (39.77) (32.54) (39.77)
Inertia
5.0 kg m s2 2.5 kg m s2 2.8 kg m s2 3.2 kg m s 2 2.8 kg m s2 2.5 kg m s 2 2.8 kg m s2
JT6
(36.17 ) (18.08) (20.24) (23.14) (20.24) (18.08) (20.24)
Repeatability (in.) ±0.15 (0.006) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20)
Drive
Source (hp)
Weight 6 1500 kg 1500 kg 1500 kg 1430 kg 1400 kg 1400 kg
550 kg (1213)
(lbs.) Axes (3300) (3300) (3300) (3150) (3080) (3080)
I-6 August 2, 2000

INTRODUCTION
ROBOT MODEL UX150 UX200 UX300 UZ100 UZ120 UZ150 ZT130S
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

Velocity

JT7
(39.37) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2500 mm/sec
Tool Tip Speed (94.49) (94.49) (94.49) (94.49) (94.49) (94.49) (98.42)
JT1 ±180° ±180° ±180° ±180° ±180° ±180° ±180°
JT2 +70°/-65° +70°/-65° +70°/-60° +70°/-75° +70°/-75° +70°/-75° +60°/-75°
JT3 +90°/-119° +90°/-119° +90°/-126° +283°/-105° +283°/-105° +283°/-105° +165°/-95°

Work
Envelope JT4 ±280° ±280° ±280° ±280° ±280° ±280° ±360°
(Stroke)
JT5 ±125° ±125° ±120° ±125° ±125° ±125° ±130°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

JT7 Lengths Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs.) 150 (330) 200 (440) 300 (660) 100 (220) 120 (264) 150 (330) 130 (286.6)
1176 N m 1626 N m
JT4 833 N m (615) 539 N m (398) 686 N m (506) 833 N m (615) 735 N m (542)
(868) (1201)
Wrist Rated
1176 N m 1626 N m
Torque JT5 833 N m (615) 539 N m (398) 686 N m (506) 833 N m (615) 735 N m (542)
(868) (1201)
(ft. lbs.)
421.4 N m
JT6 441 N m (325) 686 N m (506) 715 N m (528) 343 N m (253) 392 N m (289) 441 N m (325)
(310.8)
JT4
(52.78) (91.82) (99.05) (37.56) (45.55) (52.78) (38.3)
Wrist Rated
Moment of JT5
(52.78) (91.82) (99.05) (37.56) (45.55) (52.78) (38.3)
Inertia
JT6
(23.14) (57.12) (53.50) (20.24) (21.69) (23.14) (20.2)
Repeatability (in.) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.3mm (0.12) ±0.3mm (0.12) ±0.3mm (0.12) ±0.3mm (0.12)
Drive
Source (hp)
Weight 6 1500 kg 1550 kg 1700 kg 1400 kg 1400 kg 1400 kg 1750 kg
(lbs.) Axes (3300) (3410) (3740) (3080) (3080) (3080) (3850)
August 2, 2000 I-7

INTRODUCTION
ROBOT MODEL ZT130U ZT165U ZT200S ZX130L ZX130S ZX130U ZX165U
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

Velocity

JT7
(39.37) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec
Tool Tip Speed (98.42) (98.42) (98.42) (98.42) (98.42) (98.42) (98.42)
JT1 ±180° ±180° ±180° ±180° ±180° ±180° ±180°
JT2 +60°/-75° +60°/-75° +60°/-75° +70°/-60° +75°/-60° +75°/-60° +75°/-60°
JT3 +165°/-95° +165°/-95° +165°/-95° +250°/-120° +250°/-120° +250°/-120° +250°/-120°

Work
Envelope JT4 ±360° ±360° ±360° ±360° ±360° ±360° ±360°
(Stroke)
JT5 ±130° ±130° ±120° ±130° ±130° ±130° ±130°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

JT7
130 kg 130 kg 130 kg 165 kg
Max. Payload (lbs.) 130 (286.6) 130 (286.6) 200 (440)
(286.6) (286.6) (286.6) (286.6)
911.4 N m 1274 N m 735 N m 735 N m 735 N m 911.4 N m
JT4 735 N m (542)
(672.2) (939.6) (542) (542) (542) (672.2)
Wrist Rated
911.4 N m 1274 N m 735 N m 735 N m 735 N m 911.4 N m
Torque JT5 735 N m (542)
(672.2) (939.6) (542) (542) (542) (672.2)
(ft. lbs.)
421.4 N m 450.8 N m 686 N m 421.4 N m 421.4 N m 421.4 N m 450.8 N m
JT6
(310.8) (332.5) (505.9) (310.8) (310.8) (310.8) (332.5)
5.3 kg m s2 8 kg m s 2 12 kg m s2 5.3 kg m s2 5.3 kg m s2 5.3 kg m s2 8 kg m s2
JT4
(38.3) (57.38) (86.8) (38.3) (38.3) (38.3) (57.38)
Wrist Rated
5.3 kg m s2 8 kg m s 2 12 kg m s2 5.3 kg m s2 5.3 kg m s2 5.3 kg m s2 8 kg m s2
Moment of JT5
(38.3) (57.8) (86.8) (38.3) (38.3) (38.3) (57.38)
Inertia
JT6
(20.2) (29.6) (47) (20.2) (20.2) (20.2) (29.6)
±0.3 mm ±0.3 mm ±0.3 mm ±0.3 mm
Repeatability (in.) ±0.3mm (0.12) ±0.3mm (0.12) ±0.3mm (0.12)
(0.12) (0.12) (0.12) (0.12)
Drive
Source (hp)
JT7 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35
Weight 6 1750 kg 1750 kg 1800 kg 1550 kg 1500 kg 1500 kg 1500 kg
(lbs.) Axes (3850) (3850) (3960) (3410) (3300) (3300) (3300)
I-8 August 2, 2000

INTRODUCTION
ROBOT MODEL ZX200S ZX200U ZX200W
Number of Axes 6 (7)* 6 (7)* 6 (7)*
JT1 100°/sec 95°/sec 95°/sec
JT2 100°/sec 95°/sec 95°/sec
JT3 95°/sec 95°/sec 95°/sec

Maximum JT4 120°/sec 120°/sec 120°/sec
Velocity
JT5 115°/sec 115°/sec 115°/sec
JT6 180°/sec 180°/sec 180°/sec

1000 mm/sec 1000 mm/sec 1000 mm/sec
JT7
(39.37) (39.37) (39.37)
Max. Linear Tool 2500 mm/sec 2500 mm/sec 2500 mm/sec
Tip Speed (in/sec) (98.42) (98.42) (98.42)
JT1 ±180° ±180° ±180°
JT2 +75°/-60° +75°/-60° +75°/-60°
JT3 +250°/-120° +250°/-120° +250°/-120°

Work
Envelope JT4 ±360° ±360° ±360°
(Stroke)
JT5 ±120° ±130° ±130°
JT6 ±360° ±360° ±360°

Custom Custom Custom
JT7
Lengths Lengths Lengths
Maximum Payload 200 kg 200 kg 200 kg
(lbs.) (440) (440) (440)
1274 N m 980 N m 1274 N m
JT4
(939.5) (722.7) (939.6)
Wrist Rated
1274 N m 980 N m 1274 N m
Torque JT5
(939.5) (722.7) (939.6)
(ft-lb)
686 N m 490 N m 686 N m
JT6
(505.9) (361.4) (505.9)
12 kg m s2 9.5 kg m s2 12 kg m s2
JT4
Wrist Rated (86.8) (68.7) (86.8)
Moment of 12 kg m s2 9.5 kg m s2 12 kg m s2
JT5
Inertia (86.8) (68.7) (86.8)
(ft·lb·s2) 6.5 kg m s2 4.2 kg m s2 6.5 kg m s2
JT6
(47) (30.4) (47)
±0.3 mm ±0.3 mm ±0.3 mm
Repeatability (in.)
(0.12) (0.12) (0.12)
JT1 4.2 kw (5.6) 4.2 kw (5.6) 4.2 kw (5.6)
JT2 4.2 kw (5.6) 4.2 kw (5.6) 4.2 kw (5.6)
JT3 4.2 kw (5.6) 4.2 kw (5.6) 4.2 kw (5.6)

Drive
Source JT4 3.1 kw (4.5) 3.1 kw (4.5) 3.1 kw (4.5)
(HP)
JT5 3.1 kw (4.5) 3.1 kw (4.5) 3.1 kw (4.5)
JT6 3.1 kw (4.5) 3.1 kw (4.5) 3.1 kw (4.5)
JT7 2.5 kw (3.35) 2.5 kw (3.35 2.5 kw (3.35

Weight 1550 kg 1700 kg 1750 kg
6 Axes
(lbs.) (3410) (3740) (3850)
August 2, 2000 I-9

INTRODUCTION
I.2 ROBOT CONTROLLER
The Kawasaki C controller consists of printed circuit boards, optional interface panel,
and servo amplifiers. The C controller is used with a multi function panel or type 2 teach
pendant or small teach pendant. The C controller model used depends on the mechani-
cal unit.
Table I-2 lists the controller type (Cxx) by robot model.
Table I-2 Robot Controller Versions
C Controller Model
N. American
Robot Model Specification
FS02N C70
FS03N C70
FA06E C30
FA06L C30
FA06N C30
FA20N C30
FC06N C30
FS06L C30
FS06N C30
FS10C C30
FS10E C30
FS10L C30
FS20C C30
FS20N C30
FS30L C31
FS30N C31
FS45C C31
FS45N C31
FW06N C31
UT/UX/UZ
C32
100~150
UX200~300 C32
ZT/ZX130 C32
ZT/ZX165 C32
ZT/ZX200 C32
ZT/ZX300 C32
I-10 May 22, 2001

INTRODUCTION
I.2.1 ROBOT CONTROLLER DESIGN SPECIFICATIONS
Control System: 32 bit RISC main CPU

32 bit RISC CPU for multi function panel unit
32 bit RISC servo CPU controller (one per 3 axes)
Software controlled AC servo drive system using PWM
(pulse width modulation) circuitry.
Number of Axes: 6 standard; 7th optional
Motion Control: Teach mode - Joint

Base
Tool
Repeat mode - Joint move

Linear move
Circular move (optional)
FLIN move (optional)
Memory: CMOS RAM
Memory Capacity: Standard - 1024 KB (approx. 4,000 steps)

Optional - 4096 KB (approx. 34,000 steps)
Accuracy: Four levels of accuracy for block step programs
F-series
Adjustable between 0.03 mm - 5,000 mm
UT/UX-series
UZ-series
Z-series
Speed: 10 levels of speed for block step programs

(adjustable between 0% - 100%)
Data Editing: Step insertion and deletion, and rewriting of auxiliary and
positional data.
May 22, 2001 I-11

INTRODUCTION
Software Features: Continuous path motion control - CP ON/OFF

Time delays
Coordinate modification
Process control programs (3)
Peripheral equipment control
Interrupt signal control
Error interrupt control
Input of real, string, and integer variables
Local variables
Subroutine calls with arguments (maximum stack = 20)
Program weld schedules
Servo shutdown timer
Auto start function
I/O Signals: 1GW I/O board 32 inputs/32 outputs (128 maximum)

(including dedicated signals)
Robot internal 256
1FS RI/O board (option)

Robot I/O 256 I/O (including dedicated signals)
Robot internal 256
A-B PLC 64 I/O
Weld controller 32 I/O
Non-retentive 128
Retentive 16
Timers 16
Counters 16
Message display 64
Slogic status 16
Control Net (option)
1HS RI/O board (option)

Robot I/O 256 I/O (including dedicated signals)
Robot internal 256
Mitsubishi PLC 128 I/O CC Link (Mitsubishi proprietary
communications)
Weld controller 64 I/O
Non-retentive 128
Retentive 16
Timers 16
Counters 16
Message display 64
Slogic status 16
I-12 July 7, 1999

INTRODUCTION
Dedicated Signals: Outputs - Motor power ON

Error occurrence
Automatic
CYCLE_START
Teach mode
HOME1
HOME2
Power ON
RGSO
External program select (RPS) enabled
Dedicated Signals: Inputs - External motor power ON,

External error reset
External cycle start
External program select start (JUMP)
JUMP_ON
JUMP_OFF
JUMP_ST
External program select start (RPS)
RPS_ON
RPS_ST
Number of RPS code signal
First signal number of RPS code
Program reset
External Hold (EXT_IT)
External condition wait (EXT_WAIT)
External slow repeat mode
Error Messages: Error code messages, self-diagnosis, error logging, operation

logging
Special Features: Program check mode

Adjustable hard stops - F-series JT1, JT2, JT3
U-, and Z-series JT1
Terminal box on robot arm (optional)
Robot application interface panel (optional)
Overtravel limit switch - JT1 (JT2, JT3 option)
Power lockout
Ethernet (option)
March 10, 1999 I-13

INTRODUCTION
Multi Function Panel: Two-position enabling devices

18 cm (7.2 in) color LCD
Touch panel
Teach-lock function
Emergency stop switch
Pen for touch panel
PC card insertion section
Type 2 Teach Pendant: Three-position enabling devices

18 cm (7.2 in) color LCD
Touch panel
Soft key panel
Teach-lock function
PC card insertion section
Small Teach Pendant: Two-position enabling device

(option) Teach-lock function
Membrane switch keypad
Alphanumeric LCD
Supplemental
Data Storage: PC flash RAM Memory Card 8MB, PCMCIA 2.1 Slot
Floppy disk drive (option)
Personal computer (option)
Power Requirements: N. American Spec.: 3-phase 400/440/460/480/515/575 VAC
Tolerance: +/- 10%
Frequency: 50/60 Hz
Rated Load: 10.5 kVA
Ground: less than 100 ohm ground line separated

from welder power ground
Dimensions: N. American Spec.: WxDxH, 550 mm x 500 mm x 1150 mm

(inches: 21.7 x 19.7 x 45.3)
Weight: N. American Spec.: 250 kg (550 lbs)
I-14 May 22, 2001

OVERVIEW
1.0 OVERVIEW ........................................................................................................ 1-2

1.1 Major Features of the Robot System.................................................................. 1-2
1.2 Major Components of the Robot System ........................................................... 1-4
1.3 User Interface Devices ....................................................................................... 1-7
1.3.1 Multi Function Panel ........................................................................................... 1-8
1.3.2 Type 2 Teach Pendant ........................................................................................ 1-9
1.3.3 Flash RAM PC Card ......................................................................................... 1-10
1.3.4 Small Teach Pendant........................................................................................ 1-11
1.3.5 Controller Operation Panel ............................................................................... 1-12
1.3.6 Personal Computer .......................................................................................... 1-13
1.3.7 Optional Interface Panel ................................................................................... 1-13
1.3.8 Software Interface Panel .................................................................................. 1-14
1.3.9 Floppy Disk Drive Unit ...................................................................................... 1-15
1.4 Robot Controller Main Circuitry Overview ........................................................ 1-16
1.5 C Series Controller Digital Servo Control Overview ......................................... 1-19
1.6 Mechanical Unit Overview ................................................................................ 1-21
May 22, 2001 1-1

OVERVIEW
1.0 OVERVIEW
1.1 MAJOR FEATURES OF THE ROBOT SYSTEM
The Kawasaki F-series, U-series, and Z-series robot systems consist of a mechanical
unit, controller, controller software, and supporting peripheral equipment. The following
major features are supported by C-series controllers:
• Joint coordinate movement
• Linear movement in base and tool coordinate systems
• Fixed linear interpolation (FLIN) movement (optional)
• Circular movement (optional)
• Block step programming
• AS Language programming
• User friendly menu system for programming and system configuration
• Multi-tasking with the capability to run three process control programs
• Error message display, self diagnosis
• Error and operation logging
• Digital input and output interface
• PC programming
• Remote I/O with Slogic programming or ControlNet, Ethernet compatible (option)
• Bilingual menus
• Program editing, storage, and monitoring via personal computer
• Software controlled AC servo drive system and excellent mechanical unit design
provide accurate, repeatable, high speed program playback.
• High mechanical unit efficiency and smooth arm movement are assured through the
use of close tolerance bearings, gears, and speed reducers.
1-2 May 22, 2001

OVERVIEW
The robot system, with proper tooling and interface, is capable of performing many tasks
in the industrial environment including:
• Material handling
• Spot welding
• Servo gun spot welding
• Arc welding
• Sealing
• Spray painting
• Palletizing
May 22, 2001 1-3

OVERVIEW
1.2 MAJOR COMPONENTS OF THE ROBOT SYSTEM
The two major components of the robot system are the controller and mechanical unit.
The C-series controller is illustrated in figure 1-1.
The F-series, U-series, and Z-series mechanical units are illustrated in figures 1-2
through 1-4.
Figure 1-1 North American C Controller
1-4 May 22, 2001

OVERVIEW
Figure 1-2 F-Series Mechanical Units
Figure 1-3 UT, UX, UZ-Series Mechanical Units
May 22, 2001 1-5

OVERVIEW
Figure 1-4 ZD, ZT, ZX-Series Mechanical Units
1-6 May 22, 2001

OVERVIEW
1.3 USER INTERFACE DEVICES
The user interface devices include the following:
• Multi function panel or type 2 teach pendant
• PC card
• Optional small teach pendant
• Controller operation panel
• Personal computer using KCMON or KCWIN monitor software (option)
• Optional interface panel
• Optional software programmed interface panel with multi function panel/type 2

teach pendant
• Optional floppy disk drive
May 22, 2001 1-7

OVERVIEW
1.3.1 MULTI FUNCTION PANEL
The multi function panel, shown in figure 1-5, is equipped with a back lit 18 cm (7.2 in)
color graphics liquid crystal display (LCD) touch panel, PC card slot, teach lock switch,
two, two-position enabling devices, and emergency stop switch.
All of the robot functions are accessible through the multi function panel including sys-
tem configuration, teaching, and program editing.
A flash random access memory (flash RAM) PC card inserted into the multi function
panel is used for program and system configuration upload/download or system soft-
ware download.
Emergency Stop Teach Lock
ON OFF
TEACH LOCK
Two-Position Two-Position
Enabling Device Enabling Device
Touch Panel Pen
PC Card Slot Brightness Control
Figure 1-5 Multi Function Panel
1-8 May 22, 2001

OVERVIEW
1.3.2 TYPE 2 TEACH PENDANT
The type 2 teach pendant (TP), shown in figure 1-6, is equipped with an 18 cm (7.2 in)
color liquid crystal display (LCD) touch panel, touch panel keys, soft keys, and, a PC
card slot. Hard switches include; EMERGENCY STOP, TEACH LOCK, and two three-
position enabling devices.
All of the robot functions are accessible through the type 2 teach pendant including
system configuration, teaching, and program editing.
A flash random access memory (flash RAM) PC card inserted into the type 2 teach
pendant is used for program and system configuration upload/download, or system
software download.
Teach Lock Emergency Stop
Brightness Control
PC Card Slot
1 4
X Rx
2 5
Y Ry
3 6
Three-Position
Z Rz
Three-Position
Figure 1-6 Type 2 Teach Pendant
May 22, 2001 1-9

OVERVIEW
1.3.3 FLASH RAM PC CARD
The flash RAM PC card is used with the multi function panel or the type 2 teach pendant
to upload/download programs and system configuration data, and install AS, multi
function panel/type 2 teach pendant, and servo system software.
An eight MB PC card is supplied with the controller.
To backup data, download the contents of the PC card onto a floppy disk or hard disk of
a personal computer.
A four MB flash RAM PC card is shown in figure 1-7.
Figure 1-7 Flash RAM PC Card
1-10 May 22, 2001

OVERVIEW
1.3.4 SMALL TEACH PENDANT
The small teach pendant, shown in figure 1-8, provides basic teaching and manual
operation capabilities for the robot.
Program editing and system configuration are not accessible through the small teach
pendant.
EMERGENCY
STOP Switch
TEACH/LOCK Switch
Liquid Kawasak
Crystal
Display
ARM
WRIST
3Z 2Y
1
X
1
X
Two-Position
3Z 2Y
TRG TRG
Enabling Devices
W A
J
REC B
T JOG
Jog Key
CL3 CL4
RST S CHK
CL1 CL2
Figure 1-8 Small Teach Pendant
May 22, 2001 1-11

OVERVIEW
1.3.5 CONTROLLER OPERATION PANEL
The controller operation panel, shown in figure 1-9, is composed of switches used to
apply motor power, cycle start programs, hold or stop programs, select operation
modes, and reset errors.
Lamps that indicate an error condition, motor power on, and automatic operation in
repeat mode are included.
An hour meter, that indicates motor power on time, and a control power lamp are lo-
cated to the left of the controller door.
EMERGENCY STOP
ERROR MOTOR POWER
ERROR RESET CYCLE START
TEACH REPEAT HOLD RUN
HOST
AC115V 3A
Figure 1-9 North American Controller Operation Panel
1-12 May 22, 2001

OVERVIEW
1.3.6 PERSONAL COMPUTER
A PC (personal computer) can be linked to the C controller for program upload/down-

load, program editing, and system monitoring. The PC requires the Kawasaki KCMON
or KCWIN interface software to communicate with the robot controller.
1.3.7 OPTIONAL INTERFACE PANEL
The optional interface panels are designed to interface with peripheral equipment that is
connected to the robot.
The interface panel is located on the robot controller door and is available in many
configurations including custom designs to suit specific applications.
Figure 1-10 illustrates an interface panel typically used for spot welding applications.
Figure 1-10 Optional Interface Panel
May 22, 2001 1-13

OVERVIEW
1.3.8 SOFTWARE INTERFACE PANEL
The optional software interface panels are programmed and displayed using the multi
function panel or type 2 teach pendant. The software interface panels are designed to
interface the robot with peripheral equipment used in the automated process.
Figure 1-11 illustrates a software interface panel programmed for a palletizing applica-
tion.
IN TE R FA C E PA N E L (1/2)
AUTO MAN U O F F LIN E ENABLE
OFF AUTO W ORK P R O G R AM
HOME PAL L E T KIND No.
REMOVE 00 22 00 22
MODE MODE
M AN U AL OFF
A U TO O F F-L IN E 02 2 02 2
A U TO
00 00
0 0
Figure 1-11 Software Interface Panel
1-14 May 22, 2001

OVERVIEW
1.3.9 FLOPPY DISK DRIVE UNIT
The optional floppy disk drive unit (figure 1-12) is a portable disk drive used to upload
and download programs to the C controller. The floppy disk drive unit is connected to
the host communication port and the AC outlet on the front of the controller door.
For more information about program upload and download procedures refer to unit 11.
Figure 1-12 Floppy Disk Drive Unit
May 22, 2001 1-15

OVERVIEW
1.4 ROBOT CONTROLLER MAIN CIRCUITRY OVERVIEW
This section provides general information on the C-series controller main circuitry. For
additional information, refer to the C Series Controller Electrical Maintenance Manual
unit 6, Printed Circuit Boards. The Kawasaki C-series controller circuit board block
diagram shown in figure 1-13 illustrates the major printed circuit boards inside of the
controller.
The 1GA board is the main central processing unit (CPU) board in the C controller and
is equipped with a 32 bit reduced instruction set computer (RISC) processor running at
32 MHz. AS system software and servo system software are stored in flash memory.
User programs and system configuration data reside in battery backed SRAM. The
standard 1 MB SRAM can be expanded to 4 MB. Controllers equipped with a second
1GA board can be configured for Ethernet communications. A super capacitor on the
1GA board provides approximately 30 minutes of memory backup when the board is
removed from the card rack. When the board is reinstalled, the super capacitor is re-
charged by the 3.6 volt lithium batteries plugged into the motherboard (1HZ). The 1GA
board processes the data needed for the execution of the AS software, operation plan-
ning, servo position loop operations, coordinate conversions, path planning, and detec-
tion of abnormal +/- 12 VDC and +5 VDC levels. The 1GA board communicates with the
servo board (1GB), power circuit control board (1HP), I/O boards (1GW, 1FS), optional
boards for arc interface, vision, or analog input (IP), multi function panel, small teach
pendant, and external equipment such as a personal computer, and floppy disk drive.
Z-series robots use C controllers equipped with a 1HA CPU board. The specifications
for the 1HA board are similar to the 1GA board, except for a higher 166 MHz processor
speed and single board Ethernet capabilities.
The 1GB board is the servo CPU. The standard 1GB board is equipped with two RISC
processors that control six axes. The optional 1GB board is equipped with a third RISC
processor to control a seventh robot axis and allow a conveyor input for line tracking.
The 1GB board receives path data from the 1GA board, encoder data from the robot
axes and conveyor, and current data from the current detect modules, to generate the
pulse width modulation (PWM) signals that are sent to the intelligent power modules
(IPMs) located on the power block. The IPMs, in turn, allow current to flow through the
three-phase servo motor windings and produce motor rotation. A 1GM board is at-
tached to the 1GB board to provide an interface for the current sensors. In addition, the
1GB board also controls servo motor brake functions, overtravel limit switch signal
processing, and servo system error processing.
The 1GC or 1GD board is the servo system power block. The 1GC board is used for
robots with payload capacities of 30 kg or more and the 1GD board is used for robots
with payload capacities lower than 30 kg.
1-16 May 22, 2001

OVERVIEW
The power block is comprised of two sections: the power unit and the amplifier.
The power unit section rectifies and filters three-phase AC power for use by the servo
motors, monitors DC voltage levels, controls regenerative voltage levels, and reports
voltage level and regenerative resistor circuit errors. The amplifier section receives
PWM signals from the 1GB board. The PWM signals are used by the IPMs to control
current flow through the servo motor windings.
Current detect modules are used to send current level data back to the 1GB board to
indicate robot load. The amplifier section also incorporates various protective functions
that are monitored by the 1GB board.
The 1HP board controls the power up sequence of the controller and serial communica-
tion for the multi function panel or small teach pendant 1GA and 1GB board. In addition,
the 1HP board powers down the controller if an abnormality of the +/-12 VDC, +5 VDC,
or 24 VDC levels exists.
The 1GW board is a parallel I/O board providing 32 input channels and 32 output chan-
nels including dedicated signals. An optional 1GW board is available that provides two
channels of analog output in addition to the 32 parallel input/output channels. Up to four
1GW boards can be installed in the C controller for a total of 128 inputs and outputs and
two channels of analog output.
The 1FS board (optional) is available in two versions: R/IO and RS485 communication
or ControlNet communication. The board is equipped with a 32 bit RISC processor
running at 20 MHz and 2 MB or 4 MB of FLASH memory for software/Slogic program
storage. The RI/O version 1FS board can be configured as a remote rack of a program-
mable logic controller (PLC) and provides serial PLC and weld timer communication.
May 22, 2001 1-17

OVERVIEW
Figure 1-13 Circuit Board Block Diagram
1-18 May 22, 2001

OVERVIEW
1.5 C SERIES CONTROLLER DIGITAL SERVO CONTROL OVERVIEW
This section provides general information on the operation of the digital servo drive
system. For additional information, refer to the C Series Controller Electrical Mainte-
nance Manual unit 7, Servo System.
There are four major components in the C controller servo drive system:
• Power block assembly
• 1GB board and servo software
• AC servo motor assembly
• Hybrid encoder assembly
The 1GB board receives path data from the 1GA board, encoder data from the robot
axes and conveyor, and load data from the current detect modules. The servo software
uses these signals to calculate and produce a digital command signal. The command
signal is combined with a triangular wave reference signal to determine the sampling
rate of the command signal and to generate the PWM (pulse width modulation) signals
that are sent to the IPMs (intelligent power modules) located on the power block.
A PWM signal is a pulsed signal with a width or duration that is changed proportionally
to motor demands. For example, when the motor starts from a stopped condition, the
width of the PWM signals are very wide in order to overcome inertia, in comparison to
the PWM signals required to sustain motor velocity.
The power block is comprised of two sections: the power unit and the amplifier. The
power unit receives 210 VAC/60Hz input power from the main transformer assembly.
This voltage is filtered and rectified to provide 300 VDC to the IPMs. The amplifier
section receives the PWM signals from the 1GB board. The PWM signals are used by
the IPMs to control current flow through the servo motor windings. The IPMs use six
insulated gate bipolar transistors (IGBTs) arranged in pairs, with each pair connected to
a specific motor winding. When the IGBTs are gated by the PWM signals, current flows
through the U, V, and W phases of the AC servo motor causing motor rotation.
Current detect modules located on the power block provide feedback to indicate the
current levels of the U and V phases. Signals from the modules are sent to the 1GB
board where they are used to calculate the W phase current, determine torque require-
ments, and detect overcurrent errors and current limiter conditions that could damage
the servo motor and power block.
May 22, 2001 1-19

OVERVIEW
The hybrid (both absolute and incremental data) encoder assembly is mounted to the
end of the servo motor and coupled to the servo motor shaft. Its function is to sense the
servo motor shaft position, direction of rotation, and velocity. This data is sent to the
1GB board for phase calculation and processing by the software position and velocity
loop amplifiers. Figure 1-14 provides a block diagram of the servo amplifier circuitry.
W
SERVO MOTOR
ENCODER
H20/M21
U
V
CD
CD
IGBT
IGBT
Control
Control
Wø
IC
IC
IGBT
IGBT
IPM
HIC
Control
Control
Vø
+15 VDC
IC
IC
IGBT
IGBT
REGENERATION
SIGNAL
Control
Control
Uø
IC
IC
MONITORING
N
VOLTAGE
P
MODULE
DIODE
R
T
AC 210V
PWM
+12 VDC
ENCODER SIGNAL
IPM ERR
CURRENT FEEDBACK
ERROR SIGNAL
BOARD
1GB
TO
Figure 1-14 Servo Amplifier Block Diagram
1-20 May 22, 2001

OVERVIEW
1.6 MECHANICAL UNIT OVERVIEW
The mechanical unit consists of the arms, linkages, and drive components necessary to
provide smooth, accurate, and repeatable movement for consistent teaching and pro-
gram playback. The typical mechanical unit provides six axes of motion and is available
in a variety of configurations that are suited for numerous applications under a variety of
conditions.
Table 1-1 lists the basic drive components of the robot axes.
Table 1-1 Drive Mechanisms
Robot Drive Mechanisms
FS02/03 FS06/10/20 FS30/40 UT/UX/UZ ZT/ZX
Cycloidal Rota-Vector
JT1 Harmonic Drive Helical Gears Helical Gears
Reduction Unit Reduction Unit
Cycloidal Rota-Vector Cycloidal Cycloidal

JT 2 Harmonic Drive
Reduction Unit Reduction Unit Reduction Unit Reduction Unit
Cycloidal
Cycloidal Rota-Vector Cycloidal
JT3 Harmonic Drive Reduction Unit,
Reduction Unit Reduction Unit Reduction Unit
Spur Gears
Cycloidal Cycloidal
Rota-Vector
JT4 Harmonic Drive Harmonic Drive Reduction Unit, Reduction Unit,
Reduction Unit
Spur Gears Spur Gears
Cycloidal Cycloidal
Rota-Vector Reduction Unit, Reduction Unit,
JT 5 Harmonic Drive Harmonic Drive
Reduction Unit Spur Gears, Spur Gears,
Bevel Gears Bevel Gears
Cycloidal Cycloidal
Rota-Vector Reduction Unit, Reduction Unit,
JT6 Harmonic Drive Harmonic Drive
Reduction Unit Bevel Gears, Bevel Gears,
Spur Gears Spur Gears
May 22, 2001 1-21

SAFETY
2.0 SAFETY ........................................................................................................... 2-2

2.1 Introduction....................................................................................................... 2-2
2.2 Safety Conventions and Symbology ................................................................. 2-3
2.2.1 Warning/Caution Symbols ................................................................................ 2-3
2.3 Safety Categories ............................................................................................. 2-4
2.3.1 Personal Safety ................................................................................................ 2-4
2.3.2 Safety During Operation ................................................................................... 2-6
2.3.3 Safety During Programming ............................................................................. 2-7
2.3.4 Safety During Inspection and Maintenance ...................................................... 2-8
2.4 Safety Features ................................................................................................ 2-9
2.5 Work Envelope Drawings ............................................................................... 2-10
2.5.1 FC06N/FS06N/FW06N/FS10C....................................................................... 2-10
2.5.2 FP20N ............................................................................................................ 2-11
2.5.3 FS02N/FS03N ................................................................................................ 2-12
2.5.4 FS06L ............................................................................................................. 2-13
2.5.5 FS10E ............................................................................................................ 2-14
2.5.6 FS10L ............................................................................................................. 2-15
2.5.7 FS10N ............................................................................................................ 2-16
2.5.8 FS20C ............................................................................................................ 2-17
2.5.9 FS20N ............................................................................................................ 2-18
2.5.10 FS30L ............................................................................................................. 2-19
2.5.11 FS30N/FS45C ................................................................................................ 2-20
2.5.12 FS45N ............................................................................................................ 2-21
2.5.13 UB150 ............................................................................................................ 2-22
2.5.14 UT100/150/200 ............................................................................................... 2-23
2.5.15 UX70 .............................................................................................................. 2-24
2.5.16 UX100/120/150 .............................................................................................. 2-25
2.5.17 UX200 ............................................................................................................ 2-26
2.5.18 UX300 ............................................................................................................ 2-27
2.5.19 UZ100/120/150 ............................................................................................... 2-28
2.5.20 ZD 130 ............................................................................................................ 2-29
2.5.21 ZT165 ............................................................................................................. 2-30
2.5.22 ZX130L ........................................................................................................... 2-31
2.5.23 ZX130U .......................................................................................................... 2-32
2.5.24 ZX165U .......................................................................................................... 2-33
2.5.25 ZX200S .......................................................................................................... 2-34
2.5.26 ZX200U .......................................................................................................... 2-35
2.5.27 ZX300S .......................................................................................................... 2-36
August 2, 2000 2-1

SAFETY
2.0 SAFETY
2.1 INTRODUCTION
Safety is an important consideration in the use of automated and robotic equipment in

the industrial environment. All operators, maintenance personnel, and programmers
must be aware of all automated equipment, peripheral and robotic equipment that
occupies the work cell, and their associated operational and maintenance procedures.
For this reason it is recommended that all personnel who operate, maintain, and
program Kawasaki robots, attend a Kawasaki approved training course that would be
pertinent to each employee’s specific job responsibilities.
The following safety sections in this text are designed to support and augment existing
safety guidelines that may be in use in your plant, and/or are provided by municipal,
state, or federal governments, but are NOT designed to supplant or supersede any
existing rules, regulations, or guidelines that may be in use. Because safety is the
primary responsibility of the user, owner, and/or employer, Kawasaki recommends that
specific safety guidelines and recommendations be adopted from groups or individuals
that are professionals in safety design and implementation.
Two recommended sources for national and federal safety laws and regulations are:
1. OCCUPATIONAL SAFETY AND HEALTH STANDARDS, available from:

U.S. Department of Labor
Occupational Safety & Health Administration
Office of Public Affairs - Room N3647
200 Constitution Avenue
Washington, DC 20210
http://www.osha-slc.gov/SLTC/robotics/index.html
2. AMERICAN NATIONAL STANDARD FOR INDUSTRIAL ROBOTS AND ROBOT

SYSTEMS-SAFETY REQUIREMENTS (ANSI/RIA R15.06-1992), available from:
American National Standards Institute
11 West 42nd Street
New York, NY 10036
http://www.ansi.org/
All safety related issues and descriptions, either presented in written or oral form from
any representative of Kawasaki Robotics (USA), Inc., are intended to provide general
safety precautions and procedures and, therefore, are not intended to provide all safety
measures necessary for the protection of all personnel in the work environment.
2-2 August 2, 2000

SAFETY
Kawasaki robots are considered safe for use in industrial environments when all safety
guidelines are adhered to. Adherence to the safety guidelines for safe robot operation
and the protection of personnel and equipment is the responsibility of the end user.
2.2 SAFETY CONVENTIONS AND SYMBOLOGY
2.2.1 WARNING/CAUTION SYMBOLS
The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines, as set forth in the text, are designed to provide
pertinent information for the protection of personnel:
! WARNING
This warning symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
serious injury or death to personnel.
The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines as set forth, are designed to provide pertinent
information for the protection of robotic related equipment:
! CAUTION
This caution symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
damage to robotic or peripheral equipment.
August 2, 2000 2-3

SAFETY
2.3 SAFETY CATEGORIES
Personnel safety can be described in one of four categories:
• Personal safety
• Safety during operation
• Safety during programming
• Safety during inspection and maintenance
A description of each follows in this section.
2.3.1 PERSONAL SAFETY
Safety procedures must be an integral part of operational procedures for the operator,
programmer, and maintenance person. These procedures must be followed explicitly
and on a regular basis. Safety procedures are followed on a daily basis, they should
become a regular part of everyday operational procedures, which are designed to
protect the user. Some guidelines are presented in brief in the following section:
• Before operating or maintaining the robot or robot controller, be sure to fully

understand and comprehend ALL maintenance, operating, and programming
procedures, and ensure that ALL safety related precautions are taken and complied
with before these procedures are attempted.
• AVOID wearing loose clothing, scarves, wrist watches, rings, and jewelry when
working on the controller and robot. It is also recommended that if ties must be
worn in your shop environment that they be the clip-on variety rather than tied ties.
• ALWAYS wear safety glasses or goggles and approved safety shoes for your shop
conditions. Follow all applicable OSHA, NIOSHA, MSHA, local, state, federal, and
plant safety specifications and procedures.
• Know the ENTIRE work cell or area that the robot occupies.
• Be aware of the ENTIRE work envelope of the robot and any peripheral devices.
• Locate ALL emergency stop buttons or switches.
• AVOID trap points in which personnel could become trapped between a moving
device and any stationary devices.
2-4 August 2, 2000

SAFETY
• Personnel should NEVER enter the work envelope during automatic operations.
• Ensure that ALL personnel are clear of the work envelope before initiating any
motion commands for the robot.
• Before initiating any motion commands, KNOW beforehand how the robot will
perform when that command is given.
• Be sure that the ENTIRE work area is free of any debris, tools, fixturing, lubricants,
and cleaning equipment before operation of the robot is attempted.
• If any personnel observe unsafe working conditions, report them IMMEDIATELY to

your supervisor or plant safety coordinator.
• ALL personnel should identify by name and function ALL switches, indicators, and
control signals that could initiate robot motion.
• NEVER defeat, render useless, jumper out, or bypass any safety related device,
whether mechanical or electrical in design.
• ALL safety devices approved for use in your plant must be properly installed and
maintained to ensure personnel safety.
• NEVER attempt to stop or brake the robot during operation with your body or per-
son.
• ONLY utilize E-stops to stop robot motion in emergency situations.
August 2, 2000 2-5

SAFETY
2.3.2 SAFETY DURING OPERATION
• During operation of the robot, identify the maximum reach of the robot in ALL
directions, which is referred to as the work envelope.
• ALWAYS keep your work area clean and free of any debris which includes, but
is not limited to, oil, water, tool, fixturing, electronic test equipment, etc.
• During operations that involve the teach pendant, the ONLY person allowed in
the work envelope is the teacher, or the person operating the teach pendant.
The teach pendant has provisions to protect the operator. These safety
provisions include an E-stop, trigger switch, and deadman switch.
• NEVER block the operator’s path of retreat.
• During the teach operation of the robot ALWAYS have a path of retreat planned.
• AVOID pinch points.
2-6 August 2, 2000

SAFETY
2.3.3 SAFETY DURING PROGRAMMING
• During operation of the robot, be sure you are able to identify the maximum
reach of the robot in ALL directions, which is referred to as the work envelope.
• During teach operations the ONLY person allowed in the work envelope is the
teacher, or the person operating the teach pendant. The teach pendant has
provisions to protect the operator including E-stop, trigger switch, and deadman
switch.
• AVOID pinch points.
• During point-to-point playback operations, be aware that the robot is ONLY

cognizant of its present location and the next point it is requested to move to.
It executes this move with total disregard to what may lie in its path when
the move is executed.
• Playback accuracy and speed can affect the geometry of the path coordinates.
Therefore, when changing accuracy or speed, ALWAYS test run the program at
a slow speed or point-to-point mode before attempting the continuous path
operation in the repeat mode.
• ALWAYS test run a new path program at a reduced speed or in point-to-point

mode prior to attempting a high-speed playback operation in the repeat mode.
August 2, 2000 2-7

SAFETY
2.3.4 SAFETY DURING INSPECTION AND MAINTENANCE
Before entering the work envelope to perform either inspection or maintenance

procedures, turn off 3-phase power on the disconnect and tag and lockout the
disconnect switch.
! WARNING
The input side (top) of the controller disconnect may still
be live when the controller disconnect is turned OFF. If
work is to be performed at the controller disconnect
switch, turn OFF the 3-phase power at the source, and
tag and lockout the source disconnect.
• When removing an axis motor, be aware that the axis WILL fall if left unsupported.
The brake assembly is in the servo drive motor, therefore, the axis of the robot is
unsupported if removed.
• When using the axis brake release switches in the controller, be aware that the axis
MAY fall if left unsupported.
• Before working on pneumatic or high pressure water supplies, turn off supply
pressure and purge ALL lines to remove any residual pressure.
• Assign ONLY qualified personnel to perform all maintenance procedures.
• Consult ALL available documentation before attempting any repair or service

procedures.
• Use ONLY replacement parts approved by Kawasaki Robotics (USA), Inc.
• BEFORE attempting to adjust or repair a device in the robot controller that may
have yellow interlock control circuit wires attached, locate the source of the power
and remove it by disconnecting the appropriate disconnect at its source.
• During inspection and maintenance procedures, if your installation is equipped

with safety fences and safety plugs, REMOVE and HOLD the safety plug while
performing these operations. In addition, the safety procedures outlined above
should be adhered to.
2-8 August 2, 2000

SAFETY
2.4 SAFETY FEATURES
To safeguard the user, the Kawasaki robot system is equipped with many safety
features. These safety items include:
• All E-stops are hard-wired.
• The multi function panel, small teach pendant, and operation panel are equipped
with red mushroom-type detented E-stop push buttons. If an optional interface
panel is installed, the E-stop from the operation panel is relocated to the optional
interface panel.
• All robot axes are monitored by the robot controller for velocity and deviation errors.
• Robot velocities are constantly monitored by software. If an over-velocity condition

is detected, the robot faults in a velocity error condition.
• Teach velocities and check mode velocities are limited to a maximum of 250
mm/sec (9.843 in/sec).
• All robot axes have software limits.
• JT1 is equipped with overtravel limit switches (JT2 and JT3 are optional).
• All F- and U-series mechanical units have overtravel hardstops on the JT1, JT2,
JT3, and JT5 axes.
• All robot axes are equipped with 24 VDC electromechanical brakes. Should the
robot lose line power, the robot arm does not drop because the brakes are engaged
when power is OFF at the robot controller.
August 2, 2000 2-9

SAFETY
2.5 WORK ENVELOPE DRAWINGS
2.5.1 FC06N/FS06N/FW06N/FS10C
Figure 2-1 FC06N/FS06N/FW06N/FS10C Work Envelope
2-10 August 2, 2000
C SERIES CONTROLLER
SAFETY
2.5.2 FP20N
Figure 2-2 FP20N Work Envelope
August 2, 2000 2-11

SAFETY
2.5.3 FS02N/FS03N
Figure 2-3 FS02N/FS03N Work Envelope
2-12 August 2, 2000

SAFETY
2.5.4 FS06L
Figure 2-4 FS06L Work Envelope
August 2, 2000 2-13
SAFETY
2.5.5 FS10E
Figure 2-5 FS10E Work Envelope
2-14 August 2, 2000
SAFETY
2.5.6 FS10L
August 2, 2000 2-15
SAFETY
2.5.7 FS10N
Figure 2-7 FS10N Work Envelope
2-16 August 2, 2000
SAFETY
2.5.8 FS20C
Figure 2-8 FS20C Work Envelope
August 2, 2000 2-17
SAFETY
2.5.9 FS20N
2-18 August 2, 2000
SAFETY
2.5.10 FS30L
August 2, 2000 2-19
SAFETY
2.5.11 FS30N/FS45C
Figure 2-11 FS30N/FS45C Work Envelope
2-20 August 2, 2000
SAFETY
2.5.12 FS45N
August 2, 2000 2-21
SAFETY
2.5.13 UB150
Figure 2-13 UB150 Work Envelope
2-22 August 2, 2000

SAFETY
2.5.14 UT100/150/200
Figure 2-14 UT100/120/150 Work Envelope
August 2, 2000 2-23
SAFETY
2.5.15 UX70
Figure 2-15 UX70 Work Envelope
2-24 August 2, 2000
SAFETY
2.5.16 UX100/120/150
Figure 2-16 UX100/120/150 Work Envelope
August 2, 2000 2-25
SAFETY
2.5.17 UX200
2-26 August 2, 2000
SAFETY
2.5.18 UX300
August 2, 2000 2-27
SAFETY
2.5.19 UZ100/120/150
Figure 2-19 UZ100/120/150 Work Envelope
2-28 August 2, 2000
SAFETY
2.5.20 ZD 130
Figure 2-20 ZD130 Work Envelope
August 2, 2000 2-29
C SERIES CONTROLLER
SAFETY
2.5.21 ZT165
Figure 2-21 ZT165 Work Envelope
2-30 August 2, 2000

SAFETY
2.5.22 ZX130L
Figure 2-22 ZX130L Work Envelope
August 2, 2000 2-31
SAFETY
2.5.23 ZX130U
Figure 2-23 ZX130U Work Envelope
2-32 August 2, 2000
SAFETY
2.5.24 ZX165U
August 2, 2000 2-33
SAFETY
2.5.25 ZX200S
Figure 2-25 ZX200S Work Envelope
2-34 August 2, 2000
SAFETY
2.5.26 ZX200U
August 2, 2000 2-35
SAFETY
2.5.27 ZX300S
Figure 2-27 ZX300S Work Envelope
2-36 August 2, 2000
OPERATION PANEL
3.0 OPERATION PANEL ........................................................................................... 3-2
May 22, 2001 3-1

OPERATION PANEL
3.0 OPERATION PANEL
This unit provides information about the switches, indicators and connectors located on
the door and the main body of the controller.
The numbered call outs in figure 3-1 correspond with table 3-1 to identify the functions
of the components.
Multi Function Panel

(Shown) or
Type 2 Teach Pendant
Operation Panel
9
Disconnect Switch 3
8
4
7
5
6
I/F Switch Panel RS-232C Connector
AC Outlet
Multi Function Panel or

1 Type 2 Teach Pendant
2 Connector (X1)
Door Lock
3-2 May 22, 2001

OPERATION PANEL
Table 3-1 Operation Panel Switches
No. Switch Function
CONTROL POWER
The white CONTROL POWER lamp indicates that
1.
the controller power supply is turned ON.
The HOUR METER indicates the total servo motor

2. 0 1 9 9 6 9 power ON time.
ERROR
The red ERROR lamp indicates that an error has
3.
occured.
ERROR RESET The yellow ERROR RESET switch resets the system
4. and the error lamp is turned off. This switch does
not clear the error if the error is continuous.
HOLD RUN The RUN position allows program execution and

5. robot motion; the HOLD position places the robot
into a temporary stop condition.
The TEACH REPEAT switch selects the teach or

6.
repeat mode of operation.
CYCLE START The green CYCLE START switch initiates execution

7. of the selected program. The lamp remains ON
during program execution.
MOTOR POWER The orange MOTOR POWER switch turns servo

8. motor power ON. The lamp remains ON while motor
power is ON.
EMERGENCY STOP The red EMERGENCY STOP switch turns the servo
motor power OFF, the brakes are applied, and the
9.
robot stops. The motor power lamp and cycle star t
lamp are turned OFF at this time.
May 22, 2001 3-3

POWER ON/OFF PROCEDURES
4.0 POWER ON/OFF PROCEDURES ..................................................................... 4-2

4.1 Controller Power On/Off Procedures .................................................................. 4-2
4.1.1 Controller Power On Procedures ....................................................................... 4-2
4.1.2 Controller Power Off Procedures ....................................................................... 4-2
4.2 Servo Motor Power-On Procedures ................................................................... 4-5
4.2.1 Servo Motor Power-On in the Repeat Mode ...................................................... 4-5
4.2.2 Servo Motor Power-On in the Teach Mode......................................................... 4-5
4.3 Methods for Stopping the Robot ........................................................................ 4-6
4.3.1 EMERGENCY STOP Switch .............................................................................. 4-6
4.3.2 Hold/Run Switch................................................................................................. 4-6
4.3.3 Teach/Repeat Switch ......................................................................................... 4-6
May 22, 2001 4-1

4.0 POWER ON/OFF PROCEDURES
This unit provides the power ON/OFF procedures for the robot controller and servo
motors. Refer to figures 4-1 through 4-4 during these procedures.
4.1 CONTROLLER POWER ON/OFF PROCEDURES
4.1.1 CONTROLLER POWER ON PROCEDURES
1. Ensure that all personal are clear of the work cell, and that all safety devices are in
place and operational.
2. Turn the HOLD/RUN switch to the HOLD position.
3. Place the controller main disconnect switch in the ON position. At this time the
CONTROL POWER indicator lamp illuminates.
4.1.2 CONTROLLER POWER OFF PROCEDURES
1. Turn the HOLD/RUN switch to the HOLD position; the robot decelerates to a stop,
and the MOTOR POWER lamp turns off.
2. Press the EMERGENCY STOP switch. At this time the CYCLE START lamp is
turned off.
3. Place the controller main disconnect switch in the OFF position.
4-2 July 7, 1999

May 22, 2001 4-3

EMERGENCY STOP
ERROR MOTOR POWER
ERROR RESET CYCLE START
TEACH REPEAT HOLD RUN
Figure 4-2 North American C Controller Operation Panel
1 4
X Rx
2 5
Y Ry
3 6
Z
Three-Position
Rz
Three-Position
4-4 May 22, 2001

4.2 SERVO MOTOR POWER-ON PROCEDURES
4.2.1 SERVO MOTOR POWER-ON IN THE REPEAT MODE
1. Place the TEACH/REPEAT switch in the REPEAT position.
2. Place the TEACH LOCK switch in the OFF position.
3. Press the MOTOR POWER push button. The MOTOR POWER lamp illuminates.
4. Place the HOLD/RUN switch in the RUN position.
5. The robot is now ready to execute a program.
4.2.2 SERVO MOTOR POWER-ON IN THE TEACH MODE
1. Place the TEACH/REPEAT switch in the TEACH position.
2. Place the TEACH LOCK switch the ON position.
3. Set the HOLD/RUN switch to RUN.
4. At the BLOCK TEACHING screen, press and hold one of the enabling devices and
press the MOTOR POWER switch. At this time the MOTOR POWER lamp illumi-
nates.
Emergency Stop
Teach Lock
ON OFF
TEACH LOCK
Two-Position
Enabling Devices
May 22, 2001 4-5

4.3 METHODS FOR STOPPING THE ROBOT
Three methods can be used to stop robot motion. Each of these methods is described
in the following sections.
4.3.1 EMERGENCY STOP SWITCH
When the EMERGENCY STOP switch is pressed, motor power is turned off and the
brakes are applied stopping the robot immediately. This places very high loads upon the
robot and is only recommended for emergency situations. To stop the robot during non-
emergency situations refer to section 4.3.2, HOLD/RUN SWITCH.
4.3.2 HOLD/RUN SWITCH
When the HOLD/RUN switch is turned to the HOLD position the robot decelerates
smoothly to a stop and the brakes are applied. This places the robot into a temporary
stop condition. The motor power lamp turns OFF and the CYCLE START lamp remains
ON. When the HOLD/RUN switch is again turned to the RUN position the robot contin-
ues the motion it had been executing prior to HOLD. To create a permanent stop condi-
tion, press the EMERGENCY STOP switch or turn the TEACH/REPEAT switch to the
TEACH position (the CYCLE START and MOTOR POWER indicator lamps turn off in
either case).
4.3.3 TEACH/REPEAT SWITCH
When the TEACH/REPEAT switch is turned to the TEACH position motor power is
turned off and the brakes are applied stopping the robot immediately. This places very
high loads upon the robot and is only recommended for emergency situations. To stop
the robot during non-emergency situations refer to section 4.3.2, HOLD/RUN SWITCH.
4-6 May 22, 2001

BASIC OPERATIONS
5.0 MULTI FUNCTION PANEL/ TYPE 2 TEACH PENDANT .............................. 5-2

5.1 Multi Function Panel Description ................................................................... 5-2
5.1.1 Type 2 Teach Pendant Description ................................................................ 5-4
5.2 General Multi Function Panel and Type 2 Teach Pendant Keys .................... 5-6
5.2.1 Program and Step Selection Keys ................................................................ 5-6
5.2.1.1 Program Selection......................................................................................... 5-7
5.2.1.2 Step Selection, Multi Function Panel ............................................................ 5-9
5.2.1.3 Step Selection, Type 2 Teach Pendant ........................................................ 5-10
5.2.2 Cursor Movement Keys ............................................................................... 5-11
5.2.2.1 Figure Input and Cursor Selection .............................................................. 5-12
5.3 Screen Selection Keys ................................................................................ 5-13
5.3.1 Teaching Key ............................................................................................... 5-14
5.3.1.1 Block Teaching Screen, Multi Function Panel ............................................. 5-15
5.3.1.2 Block Teaching Screen, Type 2 Teach Pendant ........................................... 5-17
5.3.1.3 Auxiliary Program Data Selection Keys ....................................................... 5-18
5.3.1.4 Clamp and Signal Selection Keys ............................................................... 5-20
5.3.1.5 OX (Output External) and WX (Wait External) Selection Keys .................... 5-22
5.3.1.6 Record and Teach New Keys ...................................................................... 5-24
5.3.1.7 Aux Set and Disp. Key ................................................................................. 5-25
5.3.1.8 S Key ........................................................................................................... 5-25
5.3.1.9 Check Mode Keys ....................................................................................... 5-25
5.3.1.10 Robot Manual Operation Keys, Multi Function Panel .................................. 5-27
5.3.1.11 Robot Manual Operation Keys, Type 2 Teach Pendant ............................... 5-29
5.3.1.12 Program Edit ............................................................................................... 5-31
5.3.1.13 AS Teaching ................................................................................................ 5-32
5.3.1.14 AS Location ................................................................................................. 5-33
5.3.1.15 Check Mode ................................................................................................ 5-34
5.3.2 Status Key ................................................................................................... 5-36
5.3.2.1 Status Screen ............................................................................................. 5-36
5.3.2.2 Program List Screens ................................................................................. 5-38
5.3.2.3 Monitor Screen ............................................................................................ 5-40
5.3.2.4 Current Position Screen .............................................................................. 5-41
5.3.3 Menu Key .................................................................................................... 5-41
5.3.3.1 Function Screen .......................................................................................... 5-42
5.3.3.2 Keyboard ..................................................................................................... 5-43
5.4 Character Input ........................................................................................... 5-46
May 22, 2001 5-1

BASIC OPERATIONS
5.0 MULTI FUNCTION PANEL/ TYPE 2 TEACH PENDANT
5.1 MULTI FUNCTION PANEL DESCRIPTION
The multi function panel (MFP), shown in figure 5-1, is equipped with an 18 cm (7.2 in)
color liquid crystal display (LCD) touch panel, a pen to operate the touch panel keys,
and a PC card slot. Hard switches include; EMERGENCY STOP, TEACH LOCK, and
two two-position enabling devices. The function of these components is described in
table 5-1.
If the MFP display is not touched for ten minutes, the display automatically goes to a
dark energy saving mode. Touching any area of the display screen reactivates the
display.
Emergency Stop Teach Lock
ON OFF
TEACH LOCK
Two-Position Two-Position
Touch Panel Pen
PC Card Slot Brightness Control
NOTE
If the LCD display screen of the MFP is exposed to high

levels of static electricity, the display may go blank for a
short period. The display shows the opening screen
when the static electricity has dissipated. This condition
does not cause an error message.
5-2 May 22, 2001

BASIC OPERATIONS
Table 5-1 Multi Function Panel
No. Switch Function
EMERGENCY STOP The red EMERGENCY STOP switch sets the servo motor
power to OFF, the brakes are applied, and the robot
1.
stops. The motor power and cycle star t lamps are set to
OFF.
Teach lock ON - cycle star t (program execution) is
disabled; teaching, jogging, and check mode operations
ON OFF
can be performed.
2.
TEACH LOCK
Teach lock OFF - cycle star t is enabled; teaching, jogging,
and check mode operations cannot be performed.
One of the two enabling devices must be pressed to

3. Enabling Device
enable motor power in the teach mode and check mode.
Provides touch keys for teaching, editing, check mode

Liquid crystal operations, and configuring and monitoring the robot
4.
display system. Also provides display areas for system status,
error messages, program data, system data, etc.
Opening to inser t a PC card for backing-up or restoring

5. PC card slot
data in the controller memory.
Brightness
6. Adjusts the brightness of the LCD backlight.
control
7. Touch panel pen Pen used for operation of the keys on the touch screen.
May 22, 2001 5-3

BASIC OPERATIONS
5.1.1 TYPE 2 TEACH PENDANT DESCRIPTION
The type 2 teach pendant (TP) shown in figure 5-2, is equipped with an 18 cm (7.2 in)
color liquid crystal display (LCD) touch panel, touch panel keys, soft keys, and, a PC
card slot. Hard switches include; EMERGENCY STOP, TEACH LOCK, and two three-
position enabling devices. The function of these components is described in table 5-2.
If the type 2 TP display is not touched for ten minutes, the display automatically goes to
a dark energy saving mode. Touching any area of the display screen reactivates the
display.
Brightness Control
PC Card Slot
1 4
X Rx
2 5
Y Ry
3 6
Three-Position
Z Rz
Three-Position
NOTE
If the LCD display screen of the type 2 TP is exposed to

high levels of static electricity, the display may go blank
for a short period. The display shows the opening
screen when the static electricity has dissipated. This
condition does not cause an error message.
5-4 May 22, 2001

BASIC OPERATIONS
Table 5-2 Type 2 Teach Pendant
No. Switch Function
EMERGENCY STOP The red EMERGENCY STOP switch turns the servo
motor power OFF, the brakes are applied, and the robot
1.
stops. The motor power lamp and cycle star t lamp are
turned OFF at this time.
Teach lock ON - cycle star t (program execution) is
disabled; teaching, jogging, and check mode operations
ON OFF can be performed.
2.
TEACH LOCK
Teach lock OFF - cycle star t is enabled; teaching, jogging,
and check mode operations cannot be performed.
One of the two enabling devices must be pressed to

3. Enabling Device
enable motor power in the teach mode and check mode.
Provides touch keys for teaching, editing, check mode

Liquid crystal operations, and configuring and monitoring the robot
4.
display system. Also provides display areas for system status,
error messages, program data, system data, etc.
Opening to inser t a PC card for backing-up or restoring

5. PC card slot
data in the controller memory.
Brightness
6. Adjusts the brightness of the LCD backlight.
control
May 22, 2001 5-5

BASIC OPERATIONS
5.2 GENERAL MULTI FUNCTION PANEL AND TYPE 2 TEACH PENDANT KEYS
The keys displayed on the multi function panel and type 2 teach pendant screens are
detailed in the following sections.
5.2.1 PROGRAM AND STEP SELECTION KEYS
PROGRAM STEP PC
pg1 1
The keys shown above are used to select robot programs, program steps, and to display
the selected program name, step number and process control (PC) program(s). The
function of these keys is described in table 5-3.
Table 5-3 Function of Program and Step Selection Keys
Key Function
PROGRAM
The PROGRAM key displays the currently selected program. When
pg1
this key is pressed, the program select screen is displayed and
another program can be selected.
STEP
The STEP key displays the currently selected program step. When
1
this key is pressed, the step selection screen is displayed and
another program step can be selected.
PC The PC key displays the currently selected process control (PC)

program(s).
5-6 May 22, 2001

BASIC OPERATIONS
5.2.1.1 PROGRAM SELECTION
The PROGRAM key is used to select programs for playback, editing, deletion, create
new program names (teach mode only), and display the selected program name. Use
the cursor keys to select the desired program from the list and press RETURN. Figure
5-3 illustrates the use of the PROGRAM key for program selection.
PROGRAM
ò
8 9
PROGRAM SELECT
pg?? 6 7
pg10 pg1
work1 pg2
test pg8
4 5 DELETE EXIT
2 3 BS
PROGRAM
LIST
CHARACTER
0 1
RETURN
ò
RETURN
Figure 5-3 Program Selection Methods
May 22, 2001 5-7

BASIC OPERATIONS
To delete a program, select the program name with the cursor keys and press the DE-
LETE key. Press ENTER to continue or EXIT to abort the process.
The example in figure 5-4 deletes program pg10.
ò
DELETE
ò
pg??
pg1 pg10
pg2 pg8
test work1
OK to delete the program? (ENTER/EXIT)

pg10
ò
ENTER
ò
pg??
pg1 pg2
pg8 test
work1
pg
Figure 5-4 Program Delete Function
5-8 May 22, 2001

BASIC OPERATIONS
5.2.1.2 STEP SELECTION, MULTI FUNCTION PANEL
The STEP key is used to select steps for program playback or editing.
Four methods of step selection are available: FIRST STEP, BACKWARD, FORWARD,
and STEP SELECT.
• The FIRST STEP key selects step one of the program. Pressing the S key changes
the FIRST STEP key to LAST STEP. The LAST STEP key selects the last step of
the program.
• The BACKWARD and FORWARD keys decrement and increment the steps respec-
tively.
• The STEP SELECT key allows selection of a specific step. When a step number
greater than the number of steps in a program is entered, the last step is selected in
the REPEAT mode and one step beyond the last step is selected in the TEACH
mode.
Press the EXIT key to return to the previous mode.
Figure 5-5 illustrates the use of the STEP SELECT key.
STEP
ò
PROGRAM STEP PC
pg1 1
ò
ò
STEP
3 3
STEP 3 is Displayed
RETURN
Figure 5-5 Step Selection, Multi Function Panel
May 22, 2001 5-9

BASIC OPERATIONS
5.2.1.3 STEP SELECTION, TYPE 2 TEACH PENDANT
The STEP key is used to select steps for program playback or editing.
Four methods of step selection are available: FIRST/LAST, BACKWARD, FORWARD,

and STEP SELECT.
• The FIRST/LAST key selects the first or the last step of the program. Pressing the
FIRST/LAST key and the BACKWARD key selects the first step of the program.
Pressing the FIRST/LAST key and the FORWARD key selects the last step of the
program.
• The BACKWARD and FORWARD keys decrement and increment the steps respec-
tively.
• The STEP SELECT key allows selection of a specific step. When a step number
greater than the number of steps in a program is entered, the last step is selected in
the REPEAT mode and one step beyond the last step is selected in the TEACH
mode.
Press the EXIT key to return to the previous mode.
Figure 5-6 illustrates the use of the STEP SELECT key.
STEP
ò
PROGRAM STEP PC
pg1 1
FIRST
LAST
ò
ò
STEP
3 3
STEP 3 is Displayed
RETURN
Figure 5-6 Step Selection, Type 2 Teach Pendant
5-10 May 22, 2001

BASIC OPERATIONS
5.2.2 CURSOR MOVEMENT KEYS
The cursor movement keys are used to select items or data entry fields.
Figure 5-7 illustrates the use of the cursor keys for program selection.
PROGRAM SELECT PROGRAM SELECT
ð ð
Pg?? Pg??
pg10 pg1 pg10 pg1
work1 pg2 work1 pg2
work2 work3 work2 work3
ñ
ò
ò ñ
PROGRAM SELECT PROGRAM SELECT
ð ð
Pg?? Pg??
pg10 pg1 pg10 pg1
work1 pg2 work1 pg2
work2 work3 work2 work3
Figure 5-7 Cursor Movement Keys
May 22, 2001 5-11

BASIC OPERATIONS
5.2.2.1 FIGURE INPUT AND CURSOR SELECTION
Many screens allow selection by figure input or cursor keys. Program selection, editing,
and the AUX menu allow selection by either method.
Figure 5-8 illustrates AUX menu selection using both methods.
AUX
2 LOCATION & SPEED DISPLAY
3 DATA TRANSFER
5 KILL PROGRAM
6 MIRROR CONVERSION
9 DATA CONVERSION
10 MEMORY PC CARD
11 PC CARD MEMORY
12 FILE DIRECTORY (FDIRECTORY)
14 PC CARD AUX. FUNCTION
41 ZEROING
F1 F2 F3 F4
PREV. PG NEXT PG
ò
1 4
ò
AUX AUX
2 LOCATION & SPEED DISPLAY 2 LOCATION & SPEED DISPLAY
3 DATA TRANSFER 3 DATA TRANSFER
5 KILL PROGRAM 5 KILL PROGRAM
6 MIRROR CONVERSION 6 MIRROR CONVERSION
9 DATA CONVERSION 9 DATA CONVERSION
10 MEMORY PC CARD 10 MEMORY PC CARD
11 PC CARD MEMORY 11 PC CARD MEMORY
12 FILE DIRECTORY (FDIRECTORY) 12 FILE DIRECTORY (FDIRECTORY)
14 PC CARD AUX. FUNCTION 14 PC CARD AUX. FUNCTION
41 ZEROING 41 ZEROING
F1 F2 F3 F4 F1 F2 F3 F4
PREV. PG NEXT PG PREV. PG NEXT PG
ò
RETURN
Figure 5-8 Figure Input or Cursor Key Selection
5-12 May 22, 2001

BASIC OPERATIONS
5.3 SCREEN SELECTION KEYS
TEACHING STATUS MENU
The keys shown above are used to select drop down menus for teaching screens, robot
status screens, auxiliary menus, and the keyboard screen.
The drop menu for each key is shown in figure 5-9.
BLOCK
STATUS
TEACHING
STATUS
E-STOP
PROGRAM PROGRAM
EDIT LIST
FUNCTION
AS
TEACHING
MONITOR I/F
I/F
AS CURRENT
LOCATION POSITION
KEYBOARD
CHECK
MODE
Figure 5-9 Drop Down Menus
May 22, 2001 5-13

BASIC OPERATIONS
5.3.1 TEACHING KEY
TEACHING
ð TEACHING
BLOCK
TEACHING
PROGRAM
EDIT
AS
TEACHING
AS
LOCATION
CHECK
MODE
Pressing the TEACHING key displays a drop down menu with up to five selections
depending on settings in AUX 96 ENVIRONMENT DATA OF PANEL.
The five selections are BLOCK TEACHING, PROGRAM EDIT, AS TEACHING, AS

LOCATION and CHECK MODE. The STATUS and FUNCTION menus are accessible
from all TEACHING screens.
5-14 May 22, 2001

BASIC OPERATIONS
5.3.1.1 BLOCK TEACHING SCREEN, MULTI FUNCTION PANEL
The BLOCK TEACHING screen displays the input keys and information windows shown
in figure 5-10. The display areas are described below.
• System message area - reserved for robot system errors, operational errors, and
operational messages.
• Title area - displays the title of the selected screen or menu item, for example,
TEACHING, STATUS, AUX.
• Auxiliary data area - displays the auxiliary data used for block step programming.
• STATUS area - displays conditions of the robot system shown in figure 5-11. The
conditions are: motor power ON/OFF (M-ON/M-OFF), hold/run, repeat/teach
modes, slow repeat and wait, and spray ON/spray inhibit (paint application only).
Figure 5-10 Block Teaching Screen, Multi Function Panel
May 22, 2001 5-15

BASIC OPERATIONS
¡M-OFF ¡ M-ON ¡ M-ON ¡ M-ON

¡HOLD ¡ RUN ¡ RUN ¡ RUN
¡TEACH ¡ WAIT ¡ REPEAT ¡ SLOW REP (SLOW REPEAT)
¡ ¡ ¡ SPRAY ON ¡ SPRAY IN (SPRAY INHIBIT)
Figure 5-11 Robot System Conditions
5-16 May 22, 2001

BASIC OPERATIONS
5.3.1.2 BLOCK TEACHING SCREEN, TYPE 2 TEACH PENDANT
The BLOCK TEACHING screen displays the input keys and information windows shown
in figure 5-12. The display areas are described below.
• System message area - reserved for robot system errors, operational errors, and
operational messages.
• Title area - displays the title of the selected screen or menu item, for example,
TEACHING, STATUS, AUX.
• Auxiliary data area - displays the auxiliary data used for block step programming.
• STATUS area - displays conditions of the robot system shown in figure 5-11. The
conditions are: motor power ON/OFF (M-ON/M-OFF), hold/run, repeat/teach
modes, slow repeat and wait, and spray ON/spray inhibit (paint application only).
• Record data - displays the current selected teach data recorded when the ENA +
RECORD keys are pressed.
• Program step data - displays the program step data of the currently selected pro-
gram step.
Status Area Record Data Program Step Data
PROGRAM STEP PC CURRENT MEMORY

INTERPJOINT JOINT
SPEED 8 9
ACCU 1 1
TEACHING STATUS NEXT MENU TIMER 0 0
M-OFF TOOL 1 1
System Messages HOLD WORK 0 0
TEACH CL1 OFF OFF
Title Area TEACHING(BLOCK TEACHING) T1 0,0,0 0,0,0
CL2 OFF OFF
INTERP SPEED ACCU TIMER TOOL 0,0,0 0,0,0
JOINT 8 1 0 JE JUMP
1
MAN.SPEED OX 1 1
2
CL1 3
Auxiliary Data WORK J/E COMMENT
WSO CL2
Area 0 CCO CCO
INCHING
O
TEACH CLAMP OX TEACH

RECORD WX 1
DATA SIGNAL WX NEW 2
3
CHECK AUX COORDINATE

CHECK CHECK ONCE SET&DISP S JOINT
BACKWARD FORWARD
Figure 5-12 Block Teaching Screen, Type 2 Teach Pendant
May 22, 2001 5-17

BASIC OPERATIONS
5.3.1.3 AUXILIARY PROGRAM DATA SELECTION KEYS
INTERP SPEED ACCU TIMER TOOL

JOINT 9 1 0 1
WORK J/E COMMENT CL2

0 CCO
TEACH
DATA
The keys shown above are used to select the auxiliary program data used for block step
teaching and editing.
The function of each key is described in table 5-4.
Table 5-4 Function of Auxiliary Program Data Selection Keys
Key Function
TEACH
DATA The TEACH DATA key provides access to the program auxiliary data keys.
The INTERP (interpolation) key selects and displays the type of path the
INTERP robot uses during program playback. This key is used to select joint, linear,
JOINT
and optional; circular 1 (CIR1), circular 2 (CIR2) FLIN, FCIR1, FCIR2
interpolation.
SPEED The SPEED key selects and displays the speed (0 through 9) the robot
9
uses during program playback.
ACCU The ACCU (accuracy) key selects and displays the accuracy (1 through 4)
1
the robot uses during program playback.
TIMER The TIMER key selects and displays the timer (0 through 9) used during
0
program playback. Timer 0 indicates a timer is not selected.
5-18 May 22, 2001

BASIC OPERATIONS
Table 5-4 Function of Auxiliary Program Data Selection Keys (Continued)
Key Function
TOOL The TOOL key selects and displays the tool (1 through 9) used during
1
teaching and program playback.
The WORK key selects and displays the work coordinate system (0 through 9)
WORK
0
used during program teaching. Work 0 indicates that no work coordinate
system is selected.
The J/E (jump/end) key is used in conjunction with the random program
J/E selection (RPS) function and jump function to determine at what step within a
program that a program changeover (call) occurs. This key is used to select
jump, end, or blank (no program changeover).
The COMMENT key is used to bring up the keyboard screen, where a

COMMENT
comment of up to eight characters is entered. The comment is displayed on
the key.
CL1
WSO The CL1/CL2 clamp application type specifies the type of output signal used
CCO
O for a clamp. A spot weld application type specifies a momentary output signal
and a handling type specifies a sustained output signal. If sealing software is
CL2
CCO downloaded into the controller, the output is sustained.
May 22, 2001 5-19

BASIC OPERATIONS
5.3.1.4 CLAMP AND SIGNAL SELECTION KEYS
CL1 WS CC O/C
OFF 0 0 O
CL2 WS CC O/C
OFF 0 0 O
CLAMP
SIGNAL
SIG1 SIG2 SIG3 SIG4

SIG5
SIG5 SIG6 SIG7 SIG8
CLAMP
SIGNAL
The keys shown above are used to select the weld schedules, clamp conditions and
output signals. Weld schedules, clamp conditions, and output signals can be forced on
and off manually. The function of each key is described in table 5-5.
5-20 May 22, 2001

BASIC OPERATIONS
Table 5-5 Function of Clamp and Signal Selection Keys
Switch Function
CLAMP The CLAMP SIGNAL key toggles between the clamp selection
SIGNAL
keys and signal selection keys.
CL1 CL2 The CLAMP ON/OFF keys select and display the clamps that turn
OFF OFF
ON or OFF during program playback.
The WS (weld schedule) key selects and displays the weld

schedule number that is sent to the weld controller during
WS
0
program playback. This key is used to select weld schedule 0
through 31. Weld schedule 0 indicates that a weld schedule is not
selected.
The CC (clamp condition) key selects and displays the clamp

CC condition used during program playback. This key is used to
0
select clamp condition 0 through 9. Clamp condition 0 indicates
that a clamp condition is not selected.
CC The O/C (open/close) key displays the opening and closing of a

O
retractable gun during program playback.
The SIG1~8 keys are used to force outputs on or off. An ON state

SIG1 SIG8 is indicated by the LED in the upper left corner of the key. A key
…
with a dark border indicates the signal is dedicated to a specific
condition and cannot be forced on or off.
The up/down cursor keys select the next and previous screens.
May 22, 2001 5-21

BASIC OPERATIONS
5.3.1.5 OX (OUTPUT EXTERNAL) AND WX (WAIT EXTERNAL) SELECTION KEYS
OX1 OX2 OX3 SIG5

OX4
ON OFF OFF OFF
OX5 OX5 OX7 OX8

OFF OFF OFF OFF
OX
WX
WX1 WX2 WX3 SIG5

WX4
ON OFF OFF OFF
WX5 WX5 WX7 WX8

OFF OFF OFF OFF
OX
WX
The keys shown above are used to select output signals (OX) and input/wait signals
(WX) for program steps.
5-22 May 22, 2001

BASIC OPERATIONS
Table 5-6 Function of OX and WX Selection Keys
Key Function
OX The OX/WX key toggles between the output signal and input signal
WX
selection keys.
The OX keys select the output signals sent during program

playback. These keys toggle on and off. A key that is dark blue
OX1 OX8
indicates the signal is dedicated to a specific condition, and cannot
…
ON OFF be selected for program use. The number of available outputs
depends on total system I/O. Signals 1~64 are available for use in
block step programs.
The WX keys select the input signals the robot waits for during
program playback. These keys toggle ON and OFF. A key that is
WX1 WX8
dark blue indicates the signal is dedicated to a specific condition
…
ON OFF and cannot be selected for program use. The number of available
outputs depends on total system I/O. Signals 1~64 are available
for use in block step programs.
The up/down cursor keys select the next and previous screens.
May 22, 2001 5-23

BASIC OPERATIONS
5.3.1.6 RECORD AND TEACH NEW KEYS
TEACH
RECORD
NEW
OVERWRITE DELETE INSERT POS. REWRT AUX. REWRT

/NEW
The keys shown above are used to record and edit program steps. The function of each
key is described in table 5-7.
Table 5-7 Function of Record and Teach New Keys
Key Function
The RECORD key is used to record program data. When this key
RECORD is pressed, new program data is recorded and existing steps are
modified.
With the type 2 teach pendant press and hold the ENA (enable)
+ RECORD
key and press the RECORD key.
The TEACH NEW key records new steps in a program. When

TEACH modifying an existing program, the key displays a drop down menu
NEW
with OVERWRITE/NEW, DELETE, INSERT, POS.REWRT (position
rewrite) and AUX.REWRT (auxiliary rewrite) keys.
5-24 May 22, 2001

BASIC OPERATIONS
5.3.1.7 AUX SET AND DISP. KEY
AUX
SET&DISP
The AUX SET & DISP (DISPLAY) key shown above is used to setup or change the
auxiliary data used for teaching block step programs. Pressing and holding the key and
then pressing an AUX key moves to the designated auxiliary function screen.
5.3.1.8 S KEY
The S (shift) key shown above is used with the auxiliary data keys (TOOL, TIMER,
ACCU, SPEED, WORK) to allow auxiliary data selections in ascending or descending
order.
The S (shift) key is used to access alternate key functions like the FIRST STEP/LAST
STEP key in the step select drop down menu.
5.3.1.9 CHECK MODE KEYS
CHECK
CHECK CHECK
BACKWARD FORWARD ONCE
The touch keys shown above are used to check a program prior to playback in the
repeat mode with the multi function panel or type 2 teach pendant.
The soft keys shown above provide an alternate method of checking a program with the
type 2 teach pendant.
May 22, 2001 5-25

BASIC OPERATIONS
Table 5-8 Function of Check Mode Keys
Key Function
The CHECK ONCE or the CNT (type 2 TP) keys toggle between
ONCE and CONT (CONTINUE), and selects the method for step
execution in the check mode. ONCE causes the robot to stop at
CHECK
ONCE total coincidence of each taught point. CONT causes the robot to
continue moving until the CHECK FORWARD or CHECK
BACKWARD and CHECK + or CHECK - (type 2 TP) keys are
released.
When the CHECK BACKWARD or CHECK - (type 2 TP) key is

CHECK
BACKWARD
pressed and held, the robot moves to the previous step in the
program. When the key is released, the robot stops moving.
When the CHECK FORWARD or CHECK + (type 2 TP) key is

CHECK
FORWARD
pressed and held, the robot moves to the next step in the program.
When the key is released the robot stops moving.
5-26 May 22, 2001

BASIC OPERATIONS
5.3.1.10 ROBOT MANUAL OPERATION KEYS, MULTI FUNCTION PANEL
1
_ +
2
_ +
3
_ +
MAN.SPEED
4
_ +
INCHING
EXT.AXIS
5
_ +
OFF
6
COORDINATE _ +
JOINT
The keys shown above are used to jog the robot in the teach mode.
May 22, 2001 5-27

BASIC OPERATIONS
Table 5-9 Function of Robot Jogging Keys with Multi Function Panel
Key Function
The MAN.SPEED key selects and displays the speeds for jogging
and check mode operation. This key selects from three available
speeds. The selected speed is indicated by the number of
MAN.SPEED
highlighted ver tical LEDs, i.e., one LED = speed 1, two LEDs =
speed 2, three LEDs = speed 3. The red LED in the upper left
corner lights when the key is pressed to indicate this is the active
mode. When the key is inactive, the LED is blue.
The INCHING key selects and displays the distance for inching
increment. This key selects from three available distances.
Selected distance is indicated by the number of highlighted ver tical
LEDs, i.e., one LED = distance 1, two LEDs = distance 2, three
INCHING
LEDs = distance 3. The red LED in the upper left corner lights
when the key is pressed to indicate this is the active mode. When
the key is inactive, the LED is blue.
The EXT.AXIS/ROBOT key is used to select additional axes in the
robot system for jogging. The appearance of this key varies
depending on system configuration. If the robot system is
EXT.AXIS ROBOT configured for 7-axes the key toggles between EXT.AXIS OFF and
OFF or 1 EXT.AXES ON. If the robot system is configured for two arm
control the key selects from ROBOT1, ROBOT2, or
COOPERATION. This key is not displayed on a 6-axes robot
system multi function panel or type 2 teach pendant.
The COORDINATE key selects and displays the coordinate system

COORDINATE
JOINT used for jogging the robot. This key selects from JOINT, BASE, or
TOOL coordinate systems.
The AXIS keys select robot axes or directions of movement. The

1
labeling of each key changes depending on the coordinate system
_ + selected for jogging. If joint coordinates are selected, the keys are
labeled 1~6 and operate joints individually. If base coordinates are
selected, the keys are labeled X, Y, Z, RX, RY, RZ and operate in
6
_ + the base coordinate system. If tool coordinates are selected, the
keys are labeled x, y, z, rx, ry, and rz and operate in the tool
coordinate system.
5-28 May 22, 2001

BASIC OPERATIONS
5.3.1.11 ROBOT MANUAL OPERATION KEYS, TYPE 2 TEACH PENDANT
MAN.SPEED
INCHING
EXT.AXIS
OFF
COORDINATE
JOINT
1 4
X Rx
2 5
Y Ry
3 6
Z Rz
The keys shown above are used to jog the robot in the teach mode.
May 22, 2001 5-29

BASIC OPERATIONS
Table 5-10 Function of Robot Jogging Keys with Type 2 Teach Pendant
Key Function
The MAN.SPEED key selects and displays the speeds for jogging
and check mode operation. This key selects from three available
MAN.SPEED
speeds. The selected speed is indicated by the number of
highlighted ver tical LEDs, i.e., one LED = speed 1, two LEDs =
speed 2, three LEDs = speed 3. The red LED in the upper left
corner lights when the key is pressed to indicate this is the active
mode. When the key is not active, the LED is blue. The speed key
increases the MAN SPEED setting, one step at a time.
The INCHING key selects and displays the distance for inching
increment. This key selects from three available distances.
Selected distance is indicated by the number of highlighted ver tical
LEDs, i.e., one LED = distance 1, two LEDs = distance 2, three
INCHING
LEDs = distance 3. The red LED in the upper left corner lights
when the key is pressed to indicate this is the active mode. When
the key is not active, the LED is blue.
The SHIFT key is used to select additional axes in the robot

system for jogging. If the robot system is configured for 7-axes the
shift key toggles the 1/X axis keys to operate the seventh axis.
If the robot system is configured for two arm control the key selects
ROBOT
1
ROBOT1, ROBOT2, or COOPERATION. This key does not appear
on a single robot operation controller touch panel.
The COORDINATE keys select and display the coordinate system

COORDINATE
JOINT used for jogging the robot. This key selects JOINT, BASE, or
TOOL coordinate system.
The AXIS keys select robot axes and directions of movement. The
labeling of each key corresponds to the joint of the robot or
1
X
4
Rx
coordinate system the key operates during jogging. If joint
2
Y
5
Ry coordinate is selected, the keys operate JT 1~6. If base coordinate
3
Z
6
Rz is selected, the keys operate the robot in the base coordinate
mode. If tool coordinate is selected, the keys operate the robot in
the tool coordinate mode.
5-30 May 22, 2001

BASIC OPERATIONS
5.3.1.12 PROGRAM EDIT
The PROGRAM EDIT screen provides editing of a program without jogging the robot
(Figure 5-13). Steps can be copied and pasted within a program or to/from other pro-
grams. Input and output signals can also be programmed.
PROGRAM EDIT is available (ON/OFF) through AUX function 96.
When ON (Enabled), PROGRAM EDIT is accessible by pressing the TEACHING key

and the PROGRAM EDIT key on the touch panel.
PROGRAM STEP PC
pgsrt01 1
M-ON
HOLD
TEACH
PROGRAM EDIT(TEACH DATA)
INTERP SPEED ACCU TIMER TOOL DELETE CANCEL

JOINT 9 1 0 1
WORK COMMENT
J/E CUT PASTE
0
TEACH CLAMP OX LOCATION MODE

DATA SIGNAL WX DATA COPY INSERT
AUX PARTS
SET&DISP S COPY
ENTER
Figure 5-13 Program Edit Screen
May 22, 2001 5-31

BASIC OPERATIONS
5.3.1.13 AS TEACHING
Each step of a program can be edited in the AS Language editor using the optional AS
TEACHING screen (Figure 5-14). Steps can be inserted, edited or deleted. The vari-
ables, instructions and comments can be programmed beforehand as an AS Language
character string. For additional information see Aux. function 133 in unit 11.
PROGRAM STEP PC SPEED 10% '97-03-18

17:30
pgsrt01 1 REPT. CONT RPS ON

TEACHING STATUS MENU STEP CONT DRYRUN OFF
M-OFF
HOLD
TEACH
AS INSTRUCTION TEACHING
CHARACTER
JMOVE LMOVE #pick place - PROGRAM

INPUT
5 6 7 8 9 , . TEACH
NEW
0 1 2 3 4 SPACE SHIFT RECORD
Figure 5-14 AS Teaching Screen
5-32 May 22, 2001

BASIC OPERATIONS
5.3.1.14 AS LOCATION
The AS LOCATION screen is set up to perform program editing and teaching functions
while viewing numeric positional data for each robot joint (Figure 5-15 and 5-16). Signal
data can also be programmed from this screen
Figure 5-15 AS Location Screen Multi Function Panel

INTERPJOINT JOINT
SPEED 8 9
pgsrt01 1 ACCU 1 1
TEACHING STATUS MENU TIMER 0 0
M-OFF TOOL 1 1
HOLD WORK 0 0
TEACH CL1 OFF OFF
AS INSTRUCTION POSITION TEACHING(TEACH DATA) T1 0,0,0 0,0,0
? JMOVE CL2 OFF OFF
CUR.POS.: JT1: 0.000 X: 388.499 0,0,0 0,0,0
JE JUMP
JT2: 0.000 Y: 1864.760 MAN.SPEED OX 1 1
JT3: 0.000 Z: 1870.000 2
JT4: 0.000 O: 80.000 3
JT5: 0.000 A -90.000
JT6: 0.000 T: 0.000 INCHING
JT7: 0.000
INTERP TEACH CLAMP TEACH EXT.AXIS WX

RECORD 1
DATA SIGNAL NEW OFF
JMOVE 2
3
CHECK VAR.NAME COORDINATE

CHECK CHECK ONCE INPUT S JOINT
BACKWARD FORWARD
Figure 5-16 AS Location Screen Type 2 Teach Pendant
May 22, 2001 5-33

BASIC OPERATIONS
5.3.1.15 CHECK MODE
From the CHECK MODE screen more options are available for program checking than
from the BLOCK TEACHING screen. The CHECK MODE screen displays ten steps of
the program as shown in figures 5-17 and 5-18.
The function of each key is described in table 5-11
CHECK MODE
INTERP SPD ACCU TIMER TOOL WORK J/E OX WX
1 HOME
2 LINEAR 9 1 0 1 1 JUMP[10,20,30,40][1,3,5,7]
3 JOINT 9 1 1 1 1 [ ][ ]
4 LINEAR 8 2 0 2 0 [ ][ ]
5 LINEAR 8 1 2 2 0 [10,15 ][1,10 ]
6 LINEAR 9 1 1 1 0 [ ][ ]
7 LINEAR 8 2 0 2 0 [ ][ ]
8 LINEAR 8 1 2 2 0 [10,15 ][1,10 ]
9 LINEAR 9 1 1 1 0 [ ][ ]
10 HOME
BACKWARD FORWARD NEXT DISP CHECK NEXT

ONCE STEP CHECK CHECK
BACKWARD FORWARD
SPEED
Figure 5-17 Check Mode Screen MFP
CHECK MODE
1 HOME
2 LINEAR 9 1 0 1 1 JUMP[10,20,30,40][1,3,5,7]
3 JOINT 9 1 1 1 1 [ ][ ]
4 LINEAR 8 2 0 2 0 [ ][ ]
5 LINEAR 8 1 2 2 0 [10,15 ][1,10 ]
6 LINEAR 9 1 1 1 0 [ ][ ]
7 LINEAR 8 2 0 2 0 [ ][ ]
8 LINEAR 8 1 2 2 0 [10,15 ][1,10 ]
9 LINEAR 9 1 1 1 0 [ ][ ]
10 HOME
SCROLL SCROLL
NEXT DISP CHECK
Page Down Page Up ONCE
SPEED
Figure 5-18 Check Mode Screen Type 2 TP
5-34 May 22, 2001

BASIC OPERATIONS
Table 5-11 Function of Check Mode Keys
Key Function
BACKWARD FORWARD
The BACKWARD/Page Down and FORWARD/Page UP keys allow
the user to scroll through the display if the program contains more
SCROLL SCROLL
than ten steps.
Page Down Page Up
The NEXT DISP key allows the user to monitor CLAMP DATA, WX
and OX signal data during program checking.
The CHECK ONCE key toggles between ONCE and CONT

(CONTINUE), and selects the method for step selection in the
check mode. ONCE causes the robot to stop at total coincidence
of each taught point. CONT causes the robot to continue moving
until the CHECK FORWARD or CHECK BACKWARD keys are
released.
The SPEED key selects and displays the speeds for check mode
operation. This key selects from three available speeds. Selected
speed is indicated by the number of highlighted ver tical LEDs i.e.,
one LED = speed 1, two LEDs = speed 2, three LEDs = speed 3.
The NEXT STEP key is used to advance to the next step of the
program in check once mode, if step continuous is set to
NEXT
STEP INEFFECT in AUX 99 CHECK SPECIFICATIONS. To advance to
the next step press and hold the NEXT STEP key while pressing
the CHECK FORWARD or CHECK BACKWARD key.
When the CHECK BACKWARD/CHECK - key is pressed, the robot

CHECK
BACKWARD
moves to the previous step in the program. When the key is
released, the robot stops moving.
When the CHECK FORWARD/CHECK + key is pressed, the robot

CHECK
FORWARD
moves to the next step in the program. When the key is released
the robot stops moving.
May 22, 2001 5-35

BASIC OPERATIONS
5.3.2 STATUS KEY
Pressing the status key reveals a pull down menu with the following screen selection
keys; STATUS, PROGRAM LIST, MONITOR, and CURRENT POSITION. The TEACH-
ING and MENU keys can be accessed from the STATUS screens.
5.3.2.1 STATUS SCREEN
The STATUS screen, shown in figure 5-19, provides basic system information including
the current program and step/repeat conditions, time and date, switch status, and robot
position. Refer to table 5-12 for more information about the STATUS screen.
PROGRAM STEP PC SPEED 10% ‘97-03-18 ‘97-03-18
JOINT
pg99 5 REPT. CONTINUE
17:30
RPS ON
3 T. SPD3
17:30
RPS ON 3a
STEP CONTINUE DRYRUN OFF CHK. ONCE DRYRUN OFF
M-ON
RUN
WAITING
STATUS
ERROR HOLD TEACH CYCLE MOTOR E-STOP NORMAL RELEASE
START POWER EXT. HOLD
4
REPEAT REPEAT STEP RECORD

1 10% CONDITION FORWARD ACCEPT 5
4 JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF, 15, 1, C)
5 LINEAR SPEED8 ACCU3 TIMER1 TOOL1 WORK0 CLAMP1 (OFF, 15, 1, C)
2 6 JMOVE 1c1
7 JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF, 15, 1, C)
JT1 JT2 JT3 JT4 JT5 JT6 JT7

-26.248 -5.518 -37.812 -75.092 11.449 5.315
X Y Z
71102
O A T 6
532.690 656.487 1022.774 -154.463 113.890 46.616
Figure 5-19 Status Screen
5-36 May 22, 2001

BASIC OPERATIONS
Table 5-12 Status Screen Explanation
No. Item Description
The REPEAT key selects and displays the current monitor

speed. Adjustments to speed are made in 10% increments.
The REPEAT CONDITION key selects the step execution

method (STEP CONT/ONCE), program execution method
1.
(REPEAT CONT/ONCE), DRYRUN mode, and RPS
(Random Program Select) mode.
The STEP FORWARD key appears when STEP ONCE has
been selected with the REPEAT CONDITION key, and is
used to execute the next step of a program.
Program Display Displays the steps of the currently selected program. The
2.
Area step that is being executed is displayed in reverse video.
SPEED 10% ‘97-03-18

17:30 Displays the settings of the repeat conditions and monitor
3. REPT. CONTINUE RPS ON
STEP CONTINUE DRYRUN OFF
speed as well as the date and time.
With the type 2 teach pendant this area displays repeat

‘97-03-18 conditions in repeat mode and teach/check mode conditions
JOINT 17:30
3a. T. SPD3 RPS ON in teach mode. Repeat conditions are as described in item
CHK. ONCE DRYRUN OFF
No. 3. above. Teach conditions include interpolation, teach
speed, and check mode condition once or continuous.
Displays the current setting of the switches located on the
interface panel. Push button switches change color to
4. Switch Status
indicate an ON/OFF change, rotary switches turn to indicate
the switch position.
Displays the setting of the AUX 71 function to prohibit or

5.
allow the teaching or editing of programs.
Displays the current position of the robot as joint angles

6. Position Display
and Car tesian coordinates with OAT angles.
May 22, 2001 5-37

BASIC OPERATIONS
5.3.2.2 PROGRAM LIST SCREENS
The PROGRAM LIST screens, shown in figure 5-20, for multi function panel, and figure
5-21, for type 2 teach pendant, display the instructions within each step of the current
program. Screen 1 of 2 (1/2) displays AS Language instructions and block step auxiliary
data (interpolation, speed, accuracy, timer, tool, work, jump/end, and OX and WX signal
numbers). Screen 2 of 2 (2/2) displays the clamp data for block step programs. Press
the NEXT PG and PREV. PG keys to select screens. The BACKWARD/SCROLL Page
Down and FORWARD/Scroll Page Up keys allow the operator to scroll through the
program display. The step that is being executed is displayed in reverse video. If more
than four clamps are defined, a third program list screen is available.
PROGRAM LIST (1/2)

1 LINEAR 9 1 0 1 1 JUMP[10,20,30,40][1,3,5,7]
2 JOINT 9 1 1 1 1 [ ][ ]
3 LINEAR 8 2 0 2 0 [ ][ ]
4 LINEAR 8 1 2 2 0 [10,15 ][1,10 ]
5 LINEAR 9 1 1 1 0 [ ][ ]
NEXT PG BACKWARD FORWARD
PREV.PG NEXT PG
PROGRAM LIST (2/2)
CLAMP DATA
1 1( ON, 15, 1, C) 2(OFF, 0, 1, O) 3( ON, 0, 0, O) 4( ON, 9, 9, C)
2 1(OFF, 15, 1, C) 2(OFF, 0, 1, O) 3(OFF, 0, 0, O) 4(OFF, 9, 9, C)
3 1(OFF, 15, 1, C) 2(ON, 0, 1, O) 3(OFF, 0, 0, O) 4(OFF, 9, 9, C)
5 1(OFF, 15, 1, C) 2(OFF, 0, 1, O) 3(OFF, 0, 0, O) 4( ON, 9, 9, C)
PREV.PG BACKWARD FORWARD
Figure 5-20 Program List Screens, Multi Function Panel
5-38 May 22, 2001

BASIC OPERATIONS
PROGRAM LIST (1/2)

1 LINEAR 9 1 0 1 1 JUMP[10,20,30,40][1,3,5,7]
2 JOINT 9 1 1 1 1 [ ][ ]
3 LINEAR 8 2 0 2 0 [ ][ ]
4 LINEAR 8 1 2 2 0 [10,15 ][1,10 ]
5 LINEAR 9 1 1 1 0 [ ][ ]
SCROLL SCROLL
NEXT PG
Page Down Page Up
PREV.PG NEXT PG
PROGRAM LIST (2/2)
CLAMP DATA
1 1( ON, 15, 1, C) 2(OFF, 0, 1, O) 3( ON, 0, 0, O) 4( ON, 9, 9, C)
SCROLL SCROLL
PREV.PG
Page Down Page Up
Figure 5-21 Program List Screens, Type 2 Teach Pendant
May 22, 2001 5-39

BASIC OPERATIONS
5.3.2.3 MONITOR SCREEN
The MONITOR screens, shown in figure 5-22, display the input, output, and internal
signal on/off status. Press the INPUT, OUTPUT, and INTERNAL keys at the bottom of
the screen to select the type of signal to monitor. Press the NEXT PG and PREV.PG
keys to view the next or previous page of signals. Signals that are in an ON state are
displayed in reverse video. Press the GRAPH key (an optional function which must be
enabled, refer to unit 11) to view the selected signals (1~64 only) on a time based
graph.
Figure 5-22 Monitor Screen 1
5-40 May 22, 2001

BASIC OPERATIONS
5.3.2.4 CURRENT POSITION SCREEN
The CURRENT POSITION screen, shown in figure 5-23, displays the current position of
the robot in terms of joint angles and Cartesian coordinates. Joint angles represent the
degrees of rotation for each joint from the zeroed position. Cartesian coordinates repre-
sent the location and orientation of the tool center point relative to the origin of the base
coordinate system.
Figure 5-23 Current Position Screen
5.3.3 MENU KEY
ð
MENU MENU
STATUS
E-STOP
FUNCTION
I/F
I/F
KEYBOARD
Pressing the MENU key reveals a drop down menu with four screen selection buttons;
STATUS (section 5.5), FUNCTION (section 5.6), Interface Panel (I/F) (section 11.25),
and KEYBOARD (section 5.7).
The TEACHING screens can be accessed from the STATUS or FUNCTION screens.
May 22, 2001 5-41

BASIC OPERATIONS
5.3.3.1 FUNCTION SCREEN
Auxiliary functions of the robot can be programmed from the FUNCTION screen (Figure
5-24). Auxiliary functions such as welding schedules, teach speeds, system initialization
and the optional interface panel can all be programmed from these screens. See unit 9,
Auxiliary Functions, for more details.

17:30
TEACH
TEACHING FUNCTION MENU
8 9
AUX
2 LOCATION & SPEED DISPLAY

3 DATA TRANSFER 6 7
5 KILL PROGRAM
6 MIRROR CONVERSION
9 DATA CONVERSION
10 MEMORYPC CARD(SAVE) 4 5 - EXIT
11 PC CARDMEMORY(LOAD)
12 FILE DIRECTORY(FDIRECTORY)
14 PC CARD AUX. FUNCTION
2 3 . BS
F1 F2 F3 F4
NEXT PG 0 1 CLEAR
RETURN
Figure 5-24 Function Screen
5-42 May 22, 2001

BASIC OPERATIONS
5.3.3.2 KEYBOARD
The multi function panel keyboard, shown in figure 5-25, and type 2 teach pendant
keyboard, shown in figure 5-26, are used to enter AS Language commands into the
robot system.
The functions of the labeled keys are explained in table 5-13.
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
] “EXIT”
A S D F G H J K L EXIT Key
: “ ~ =
Z X C V B N M ; ‘ _ + BS “BS”
Key
CTRL+N ® < > ?

® , . / _ “Enter”
Shift Next PG CTRL+L Space Enter Key
“Shift” “Next PG” “CTRL+N “Space”

Key Key CTRL+L” Key
Key
Figure 5-25 Keyboard, Multi Function Panel
May 22, 2001 5-43

BASIC OPERATIONS
MODE:JOINT T.SPEED:2 CHECK:ONCE

! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
] “EXIT”
A S D F G H J K L EXIT Key
: “ ~ =
Z X C V B N M ; ‘ _ + BS “BS”
Key
CTRL+N ® < > ?

® , . / _ “Enter”
Shift Next PG CTRL+L Space Enter Key
“Shift” “Next PG” “CTRL+N “Space”

Key Key CTRL+L” Key
Key
Figure 5-26 Keyboard, Type 2 Teach Pendant
5-44 May 22, 2001

BASIC OPERATIONS
Table 5-13 Function of Keyboard Keys
Switch Function
BS The BS (back space) key is used to delete characters one at a time.
EXIT The EXIT key is used to exit back to the status screen from the
keyboard screen.
Enter The ENTER key is used to enter AS Language commands for

execution.
The SHIFT key selects the upper character of dual character keys
Shift i.e., pressing the 1 key after the shift key inputs the (!) character.
The shifted keys are displayed yellow.
CTRL+N The CTL+L/CTL+N key brings up the last 10 lines that were entered.
CTRL+L When the SHIFT key is pressed, CTL+L changes to CTL+N. The
CTL+N key takes you to the next line in the program.
SPACE Key The SPACE key inputs a blank space into a character string.
The CURSOR key is used to cursor left (normal) and right (shifted)
in a step of a program for editing. To use the cursor key, enter "o"
(for overwrite) in the AS Language editor mode.
May 22, 2001 5-45

BASIC OPERATIONS
5.4 CHARACTER INPUT
Screens that contain the CHARACTER key allow character input through the keyboard.
Screens that use AS Language commands or the CHARACTER key, utilize the key-
board. Use the touch panel pen at the bottom of the multi function panel to type charac-
ters from the keyboard. Press the BS (back space) key to delete characters that have
been typed. After the information is typed press the ENTER key. Press the EXIT key to
exit the character input mode.
Character entry is the same for the multifunction panel and the type 2 teach pendant.
Figure 5-27 illustrates the use of the character input keyboard.
CHARACTER
ò
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
A S D F G H J K L ] EXIT
: “ ~ =
Z X C V B N M ; ‘ _ + BS
CTRL+N ® < > ?

® , . / _
Shift Next PG CTRL+L Space Enter
ò
... ...
A Z 1 0
Enter
Figure 5-27 Character Input
5-46 May 22, 2001

JOGGING OPERATION
6.0 JOGGING OPERATION .................................................................................... 6-2

6.1 Keys Used for Jogging Operation....................................................................... 6-2
6.2 Jogging Operation Procedures .......................................................................... 6-4
6.3 Optional Axes Operation .................................................................................... 6-7
6.3.1 Optional Axes Operation, Multi Function Panel .................................................. 6-7
6.3.2 Optional Axes Operation, Type 2 Teach Pendant ............................................... 6-8
6.4 Coordinate Systems ........................................................................................... 6-9
6.4.1 Joint Coordinates ............................................................................................... 6-9
6.4.2 Base Coordinates............................................................................................. 6-12
6.4.3 Tool Coordinates .............................................................................................. 6-15
6.4.4 Linear Movement Errors ................................................................................... 6-17
May 22, 2001 6-1

JOGGING OPERATION
6.0 JOGGING OPERATION
This unit provides information for manual robot operation or jogging. Information pro-
vided includes the keys required for manual robot operation, movement modes, and an
explanation of the coordinate systems.
6.1 KEYS USED FOR JOGGING OPERATION
The keys used for jogging the robot are shown in figure 6-1, for the multi function panel
and in figure 6-2, for the type 2 teach pendant.
Two-Position Enabling Device Two-Position Enabling Device
ON OFF
TEACH LOCK
1
TEACHING
BLOCK
2
TEACHING
PROGRAM 3
EDIT
MAN.SPEED
AS 4
TEACHING
INCHING
AS EXT.AXIS 5
LOCATION
OFF
CHECK 6
MODE COORDINATE
JOINT
Kawasak
AXIS Keys
AS LOCATION Key COORDINATE Key
BLOCK TEACHING Key EXT.AXIS/ROBOT Key
TEACHING Key INCHING Key
MAN. SPEED Key
Figure 6-1 Jogging Operation Keys, Multi Function Panel
6-2 May 22, 2001

JOGGING OPERATION

INTERPJOINT JOINT
TEACHING Key TEACHING STATUS NEXT MENU
SPEED 8
ACCU 1
9
1
M-OFF TIMER 0 0
BLOCK TEACHING Key BLOCK

TEACHING
HOLD TOOL
TEACH WORK 0
CL1
1 1
0
OFF OFF
TEACHING(BLOCK TEACHING) T1 0,0,0 0,0,0
CL2 OFF OFF
INTERP SPEED ACCU TIMER TOOL
JOINT 8 1
PROGRAM
0
EDIT 1
MAN.SPEED JE JUMP
OX 1
0,0,0 0,0,0
1
MAN. SPEED Key
CL1 2
WORK
0
J/E COMMENT
WSO
AS
TEACHING
CCO
O
CL2
CCO
INCHING
3
INCHING Key
CLAMP OX
AS LOCATION Key TEACH
DATA SIGNAL WX
AS
RECORD
LOCATION
TEACH
NEW
ROBOT WX
1
1
2 ROBOT key
3
CHECK AUX
COORDINATE Keys
CHECK COORDINATE
CHECK CHECK ONCE SET&DISP
MODE S JOINT
BACKWARD FORWARD
MAN. SPEED Key

EXT. AXIS Keys
1 4
X Rx
AXIS Keys 2
Y
5
Ry
3 6
Z Rz
Three-Position Three-Position
Figure 6-2 Jogging Operation Keys, Type 2 Teach Pendant
May 22, 2001 6-3

JOGGING OPERATION
The keys used for jogging the robot include the following:
• TEACHING KEY - for teach mode screen selection
• Axis keys for joint or directional movement
• COORDINATE key for coordinate system selection
• MAN.SPEED key for speed selection
• INCHING key for distance selection
• EXT.AXIS or ROBOT key for optional axes selection
• Enabling devices to enable motor power in the TEACH mode
6.2 JOGGING OPERATION PROCEDURES
HOLD RUN CONTROL POWER TEACH REPEAT ON OFF HOLD RUN MOTOR POWER
BLOCK AS
TEACHING LOCATION
TEACH LOCK TEACHING
1. Ensure all personal are clear of the work cell, and all safety devices are in place and
operational.
2. Turn the HOLD/RUN switch in the HOLD position.
3. Place the controller main disconnect switch in the ON position. At this time the
CONTROL POWER indicator lamp illuminates.
4. Turn the TEACH/REPEAT switch to the TEACH position.
5. Turn the TEACH LOCK to the ON position.
6. Press the TEACHING key and from the drop down menu select BLOCK TEACHING
or AS LOCATION.
7. Turn the HOLD/RUN switch to the RUN position.
8. Press one of the enabling devices and the motor power key is displayed on the
touch panel. Press the MOTOR POWER key on the touch panel or the motor power
switch on the control panel. At this time the MOTOR POWER lamp illuminates.
6-4 May 22, 2001

JOGGING OPERATION
9. Select a coordinate system by pressing the COORDINATE key. This key toggles
between the JOINT, BASE, and TOOL coordinate systems and changes the opera-
tion of the axis keys as shown in figure 6-3 for multi function panel or figure 6-4 for
type 2 teach pendant.
COORDINATE COORDINATE COORDINATE

JOINT BASE TOOL
1 X x
_ + _ + _ +
2 Y y
_ + _ + _ +
3 Z z
_ + _ + _ +
4 RX rx
_ + _ + _ +
5 RY ry
_ + _ + _ +
6 RZ rz
_ + _ + _ +
Figure 6-3 Axis Keys, Multi Function Panel
May 22, 2001 6-5

JOGGING OPERATION

JOINT BASE TOOL
or

JOINT BASE TOOL
1 2 3
1 4
X Rx
2 5
Y Ry
3 6
Z Rz
Figure 6-4 Axis Keys, Type 2 Teach Pendant
10. Press the MAN.SPEED or INCHING key to select continuous or incremental robot
motion. Each key toggles between three selections. The selected speed or inching
increment is shown by the number of LEDs that are lit (see figure 6-5). With the
type 2 teach pendant the soft SPEED key (Figure 6-2) increases the MAN.SPEED
setting one step at a time.
Slow Fast
MAN.SPEED
INCHING
Figure 6-5 Speed and Inching Selection
When MAN.SPEED is selected, the robot moves continuously while an AXIS key is
pressed. When INCHING is selected, the robot moves only the selected distance
when an axis key is pressed.
11. Press one or more of the axis keys to select the joint or direction the robot moves.
6-6 May 22, 2001

JOGGING OPERATION
6.3 OPTIONAL AXES OPERATION
6.3.1 OPTIONAL AXES OPERATION, MULTI FUNCTION PANEL
EXT.AXIS ROBOT
OFF 1
Robot systems that utilize traversing tables, servo guns, or a second manipulator, have
an EXT.AXIS or ROBOT key on the multi function panel.
The EXT.AXIS/ROBOT key is used to select the additional axes for manual operation.
The appearance of this key varies depending upon system configuration.
If the robot system is configured for additional axes (traversing tables, etc.) the key
toggles between EXT.AXIS OFF and EXT.AXES ON.
If the robot system is configured for two arm control the key toggles between ROBOT1,
ROBOT2, and COOPERATION.
The axis keys display changes when the EXT.AXIS key is pressed, as shown in figure 6-
6. Axes keys are displayed for installed axes.
These keys are not displayed on the multi function panel of a 6-axes robot system.
EXT.AXIS
ON
7
_ +
Figure 6-6 External Axis Keys, Multi Function Panel
May 22, 2001 6-7

JOGGING OPERATION
6.3.2 OPTIONAL AXES OPERATION, TYPE 2 TEACH PENDANT
ROBOT
1
Robot systems that utilize a second manipulator, have a ROBOT key on the type 2
teach pendant touch panel.
If the robot system is configured for two arm control the key toggles between ROBOT1,
ROBOT2, and COOPERATION.
The SHIFT key on the soft key panel is used to select additional axes for manual opera-
tion. The red LED on the SHIFT key is illuminated when the external axes are available.
If the robot system is configured for additional axes (traversing tables, etc.) the shift key
toggles the 1/X, 2/Y, and 3/Z keys between operating JT1/X, JT2/Y, and JT3/Z and
operating JT7, JT8, and JT9.
To operate the seventh axis, press the SHIFT key, the LED illuminates and the 1/X axes
keys control the seventh axis (Figure 6-7).
When the SHIFT key is pressed again, the LED is extinguished and the 1/X axes keys
operate JT1 or move the robot in the X coordinate.
Figure 6-7 External Axis Keys, Type 2 Teach pendant
6-8 May 22, 2001

JOGGING OPERATION
6.4 COORDINATE SYSTEMS
The robot is equipped with three coordinate systems that are used during program
playback and teaching/editing operations. The coordinate systems - Joint, Base, and
Tool, provide the means for linear and nonlinear motion control and program location
modification.
6.4.1 JOINT COORDINATES
The joint coordinate system, allows the robot axes to be driven without regard to tool
orientation and other coordinate systems.
COORDINATE
JOINT
In the TEACH mode, when the COORDINATE JOINT button is selected, the robot axes
can be jogged individually to acquire any arm position or orientation. Figures 6-8
through 6-10 illustrate the robot joint coordinate mode and the positive and negative
directions of movement.
Figure 6-8 Robot Joint Coordinate Mode
May 22, 2001 6-9

JOGGING OPERATION
1 4
_ + _ +
2 5
_ + _ +
3 6
_ + _ +
Figure 6-9 F-Series Robot Joint Movement
6-10 May 22, 2001

JOGGING OPERATION
1 4
_ + _ +
2 5
_ + _ +
3 6
_ + _ +
Figure 6-10 U-Series Robot Joint Movement
May 22, 2001 6-11

JOGGING OPERATION
6.4.2 BASE COORDINATES
COORDINATE
BASE
The base coordinate mode provides a means for jogging the tool center point (TCP) in a
straight line, at a constant velocity, while maintaining tool orientation. The base coordi-
nate system origin is initially located in the robot base with an orientation defined by the
left-hand rule (see figure 6-12). The origin and the orientation of the base coordinate
system can be modified using AUX 47 or the BASE command. In the teach mode, the
TCP can be driven in X, Y, or Z directions or rotated about the X, Y, and Z axes using the
RX, RY, and RZ keys (see figure 6-13).
Figure 6-11 Base Coordinate System Mode
6-12 May 22, 2001

JOGGING OPERATION
An easy way to determine the orientation and direction of the base coordinate system is
illustrated by the “left-hand rule”, shown in figure 6-12. When using the left-hand rule,
orient your left hand so that your arm represents the cables entering the base of the
robot. From this orientation the middle finger, held 90 degrees from the arm points in
the positive X direction. The extended index finger points in the positive Y direction and
the extended thumb points in the positive Z direction.
+Z
-Z
-Y +Y
-X
+X
Figure 6-12 Left-Hand Rule
May 22, 2001 6-13

JOGGING OPERATION
X RX
_ + _ +
Y RY
_ + _ +
Z RZ
_ + _ +
Figure 6-13 Base Coordinate System Movement
6-14 May 22, 2001

JOGGING OPERATION
6.4.3 TOOL COORDINATES
The tool coordinate mode provides another means for jogging the TCP in a straight line,
at a constant velocity, while maintaining tool orientation. The tool coordinate system
origin is the TCP, and is initially located and oriented at the center of the tool mounting
flange as shown in figure 6-14. When tool dimensions are entered into the robot system
using AUX 48 or the TOOL command, the tool coordinate system origin and orientation
change accordingly. The orientation of the tool coordinate system is typically set so that
its positive Z axis points in the direction of the tool. During jogging operation the tool
coordinate system maintains this orientation, but changes the directionality of the coor-
dinate axes when changes are made to the robot position (see figure 6-14). In addition
to moving in the tool coordinate X, Y, or Z directions, the TCP can also be rotated about
the X, Y, and Z axes using the rx, ry, and rz keys (see figure 6-15).
Figure 6-14 Tool Coordinate System
May 22, 2001 6-15

JOGGING OPERATION
x rx
_ + _ +
y ry
_ + _ +
z rz
_ + _ +
Figure 6-15 Tool Coordinate System Movement
6-16 May 22, 2001

JOGGING OPERATION
6.4.4 LINEAR MOVEMENT ERRORS
When moving the robot in either base coordinate or tool coordinate mode, certain arm or
wrist positions do not allow linear movement (see figure 6-16). For example, when JT2
and JT3 align to a straight position, insufficient reach or velocity errors can occur. An-
other condition known as singularity occurs when JT5 moves to a 0° (straight) position
during linear movement. If any of these conditions occur during linear movement, the
robot shuts down, displaying an error related to arm configuration or speed. To avoid
this condition, reteach the affected locations with a different arm configuration or use the
joint mode.
To avoid a singularity condition in repeat mode where a linear move is required select
linear 2 interpolation. Linear 2 interpolation allows a hybrid interpolated move that is
able to work through most singularity conditions. In instances where a linear 2 move
does not work, reteach the positions with a different robot configuration or select joint
interpolation.
Figure 6-16 Linear Movement Errors
May 22, 2001 6-17

RECORDING AND EDITING PROGRAMS
7.0 RECORDING AND EDITING PROGRAMS ................................................... 7-2

7.1 Preparation for Teaching ................................................................................. 7-2
7.2 Program Names .............................................................................................. 7-3
7.3 Creating a Program ........................................................................................ 7-6
7.3.1 Recording Program Steps .............................................................................. 7-6
7.3.2 Direct Speed Function .................................................................................. 7-11
7.4 Checking Program Operation ....................................................................... 7-12
7.5 Editing Program Data ................................................................................... 7-13
7.5.1 Overwriting Steps ......................................................................................... 7-13
7.5.2 Deletion of Steps .......................................................................................... 7-14
7.5.3 Insertion of Steps .......................................................................................... 7-15
7.5.5 Auxiliary Rewrite ........................................................................................... 7-16
7.5.4 Position Rewrite ............................................................................................ 7-16
7.5.6 Cut/Copy/Paste or Delete for Individual Steps .............................................. 7-17
7.5.6.1 How to Cut and Paste Steps within a Program ............................................. 7-17
7.5.6.2 How to Copy and Paste Steps within a Program .......................................... 7-19
7.5.6.3 How to Copy and Paste Steps to another Program ...................................... 7-21
7.5.6.4 How to Delete Steps within a Program ......................................................... 7-23
7.5.6.5 How to Copy Auxiliary Data .......................................................................... 7-25
7.6 Program Confirmation ................................................................................... 7-26
May 22 2001 7-1

7.0 RECORDING AND EDITING PROGRAMS
This unit covers teaching/recording program locations and auxiliary program data,
program verification with the check step procedure, and program editing.
7.1 PREPARATION FOR TEACHING
The appendix section of this manual contains sample program sheets for spot welding
and material handling applications. These program sheets are helpful when planning
new programs. The program sheets are filled out prior to programming the robot and
provide the operator with a plan of the elements needed in the program.
The program sheets also identify peripheral components that interact with the program
such as input and output signal numbers, type(s) of clamps to use and auxiliary function
settings.
When the program sheet is filled out and the elements of the program are identified, the
actual recording of the program steps can begin.
7-2 May 22, 2001

7.2 PROGRAM NAMES
PROGRAM
pg1
The selection of a new program name is at the discretion of the programmer. Program
names should be consistent with company practices and the names of other programs
that are in system memory. The multi function panel or type 2 teach pendant must be in
the teaching display to name a new program, reference unit 5 of this manual for menu
screen locations.
To name a new program, press the PROGRAM key to display the PROGRAM SELECT
screen shown in figure 7-1.
Figure 7-1 Program Select Screen
From the PROGRAM SELECT screen, the operator has two options for naming pro-
grams. If the program is to have a numeric name, up to thirteen digits can be entered at
this screen when pg?? is highlighted.
It is important to note that while up to thirteen digits can be entered for program names,
only six digits are displayed to identify the selected program. Numeric program names
must be preceded by the pg prefix.
After the desired number for the program name is selected, the enter key is pressed to
record the name of the new program. To confirm the new program number is in system
memory, press the PROGRAM key to display a list of programs.
May 22 2001 7-3

If the new program is to have an alpha or alphanumeric name, press the CHARACTER
key to display the screen shown in figure 7-2, for the multi function panel and figure 7-3,
for the type 2 teach pendant.
pg
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
: “ ~ =
Z X C V B N M ; ‘ _ + BS
CTRL+N ® < > ?

® , . / _
Figure 7-2 Character Set, Multi Function Panel
7-4 May 22, 2001

pg
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
: “ ~ =
Z X C V B N M ; ‘ _ + BS
CTRL+N ® < > ?

® , . / _
Figure 7-3 Character Set, Type 2 teach Pendant
If the pg prefix is not desired, the BS (back space) key must be used to remove these
characters. Programs named using the character set, not having the pg prefix, must
have an alpha character as the first character. The remaining characters can be a mix
of alpha and numeric.
If the pg prefix is maintained, the characters can be an alphanumeric mix. Spaces

cannot be used in program names and the only special characters that can be used in
program names are the “.” and “_” characters. Up to fifteen alphanumeric characters can
be selected for program names, provided that the pg prefix was removed, however, only
eight characters are shown as part of the display to identify the selected program.
After the desired characters for the program name are selected, press the ENTER key
to record the new program name.
To confirm that the new program name is in system memory, press the PROGRAM key
to display the list of programs.
May 22 2001 7-5

7.3 CREATING A PROGRAM
The recording of program steps includes two elements; positional and auxiliary data.
The positional element is the location of the robot that is repeated each time a particular
step is executed.
When the record key is pressed, the axis joint angles of the current robot position are
stored in the system memory as part of the program step data. In addition to the posi-
tional data recorded with each step, a set of auxiliary data is also recorded.
The auxiliary data includes how the robot travels to the taught location (interpolation),
the speed of travel to the location, the type of tool installed, output signals generated
when it reaches the point, input signals to wait for at the point, etc..
7.3.1 RECORDING PROGRAM STEPS
TEACH TEACH
NEW
RECORD
+ or + RECORD
NEW
Using the jogging methods covered in unit 6 of this manual, position the robot tool in the
location to record a position. The method used to jog the robot into position for record-
ing a point is not part of the program, the auxiliary interpolation data controls the play-
back path.
When the RECORD key is pressed (ENA + REC type 2 teach pendant), the location is
entered into memory, the step display of the teaching display is incremented by one, and
the system message area of the screen displays the message “position recorded”.
The key to the right of the RECORD key displays “TEACH NEW” to identify the step
indicated is not entered into memory. The robot can now be jogged to the next location
and the process repeated.
Figure 7-4, multi function panel and figure 7-5, type 2 teach pendant, shows the
TEACHING screen and the keys used to record program steps.
7-6 May 22, 2001

Figure 7-4 Teaching Screen, Multi Function Panel
Status Area Record Data Program Step Data

INTERPJOINT JOINT
SPEED 8 9
ACCU 1 1
TEACHING STATUS NEXT MENU TIMER 0 0
M-OFF TOOL 1 1
System Messages HOLD WORK 0 0
TEACH CL1 OFF OFF
Title Area TEACHING(BLOCK TEACHING) T1 0,0,0 0,0,0
CL2 OFF OFF
INTERP SPEED ACCU TIMER TOOL 0,0,0 0,0,0
JOINT 8 1 0 JE JUMP
1
MAN.SPEED OX 1 1
2
CL1 3
Auxiliary Data WORK J/E COMMENT
WSO CL2
Area 0 CCO CCO
INCHING
O
TEACH CLAMP OX TEACH

RECORD WX 1
DATA SIGNAL WX NEW 2
3
CHECK AUX COORDINATE

CHECK CHECK ONCE SET&DISP S JOINT
BACKWARD FORWARD
Figure 7-5 Teaching Screen, Type 2 Teach Pendant
May 22 2001 7-7

NOTE
The recording of positional data is only one element of a

block step program and must be done in conjunction
with the recording of the desired auxiliary data that is
part of the program step.
In addition to positional data, each step of a block step program contains auxiliary data.
The auxiliary data is set from the TEACHING screen shown in figure 7-4, for the multi
function panel and figure 7-5, for the type 2 teach pendant and is detailed in table 7-1.
When new positions are recorded, the auxiliary data from the previous step is carried
forward to the next step recorded; if this auxiliary data is different for the new step it
must be changed before the record key is pressed.
After the last step of the program is recorded, it is not necessary to identify the end of
the program. The controller recognizes the last taught step as the end of the program
and automatically adds an .END statement after the last step.
Table 7-1 shows the auxiliary data that is recorded for each block step of a program.
Table 7-1 Auxiliary Data
AUXILIARY DATA
KEY FUNCTION AND SETTINGS
ELEMENT
Sets the motion path of the robot to reach a taught position. In JOINT
interpolation, all joints move to reach total coincidence simultaneously to
achive the recorded robot posture. The TCP moves in an arcing motion.
INTERP In LINEAR interpolation, joint movement is coordinated to drive the TCP
Interpolation
JOINT in a linear motion and maintain tool orientation. CIR1 and CIR2 move
the TCP in a circular path based on at least three points along and arc
(option).
JOINTLINEARCIR1CIR2
Selects the speed of the step as a percent of maximum possible
machine speed. Maximum possible machine speed is in
SPEED degrees/second. This applies only to joint moves. Linear moves are
Speed 9 slower than joint moves and are in units of mm/second. Ten settings are
available (set in auxiliary function 54).
SPEED 0SPEED 1SPEED 2…SPEED 9
7-8 May 22, 2001

Table 7-1 Auxiliary Data (continued)
AUXILARY DATA
KEY FUNCTION AND SETTINGS
ELEMENT
Selects a wait timer that star ts timing when the robot reaches the
ACCU accuracy range of the taught position. 0 is used when no timer is
Accuracy 1 selected, nine settings are available (set in auxiliary function 58).
TIMER 0TIMER 1TIMER 2…TIMER 9
Selects a wait timer that star ts timing when the robot reaches the
TIMER accuracy range of the taught position. 0 is used when no timer is
Timer
0 selected, nine settings are available (set in auxiliary function 58).
TIMER 0TIMER 1TIMER 2…TIMER 9
Allows the user to select a predefined alternative coordinate system. 0
WORK is used for the standard base coordinate system. Nine work coordinate
Work 0 systems are available (defined in auxiliary function 49).
WORK 0WORK 1WORK2…WORK 9
When JUMP or END are used in a program, input signals are evaluated
J/E to determine program selection. Jump/End returns to blank after
JUMP/END RECORD is pressed. The Jump/End program command is used in
conjunction with dedicated signals set in auxiliary function 111.
BLANKJUMPEND
Pressing the OX/WX key changes the display to show available signals
and signal state for the programmed step, see figure 7-6. Pressing the
signal keys toggle the signals ON and OFF. The down and up arrow
Output Signals
OX keys are used to display the next group of signals. The OX and WX
OX and Input
WX screens are used in the same manner. The TEACH DATA key is
Signals WX
pressed to return to the auxiliary data screen. OX signals remain ON
during the steps in which they are programmed. WX signals cause the
robot to wait until the signals are ON or wait override is used.
When the COMMENT key is pressed, the character set (see figure 7-2
for multi function panel or figure 7-3 for type 2 teach pendant) is
COMMENT
Comment displayed allowing the user to enter a comment (up to eight characters).
After the characters are selected, press the ENTER key. The comment
is displayed on the comment key during step execution.
CLAMP
Pressing the CLAMP SIGNAL key changes the display to show clamp
Clamp Signal SIGNAL settings, see figure 7-7. The clamp operating signals, weld schedules,
and clamp condition codes selected are set in auxiliary function 114.
The CL1/CL2 clamp application type keys display the signal type, the
weld schedule, and clamp condition code selected in auxiliary function
114. A spot welding application specifies a momentary output signal, a
Clamp 1 and
weld schedule, and a clamp condition code. A handling or sealing
Clamp 2
C L2 application specifies a sustained output signal, and a clamp condition
CCO code. An O (open) or a C (close) indicates if the clamp is opened or
closed when in the ON state.
May 22 2001 7-9

OX1 OX2 OX3 SIG5

OX4
ON OFF OFF OFF
OX5 OX5 OX7 OX8 TEACH

OFF OFF OFF OFF DATA
OX
WX
Figure 7-6 OX Signal Key Display
CL1 WS CC O/C
OFF 0 0 O
TEACH
CL2 WS CC O/C
DATA
OFF 0 0 O
CLAMP
SIGNAL
Figure 7-7 Clamp Settings
Pressing the TEACH DATA key, from a SIGNAL DISPLAY or CLAMP SETTINGS screen,
returns the screen to the TEACHING screen shown in figure 7-4, for the multi function
panel or figure 7-5, for the type 2 teach pendant.
7-10 May 22, 2001

7.3.2 DIRECT SPEED FUNCTION
The optional Direct Speed function allows the operator to select the absolute speed for
joint or linear moves in seconds or millimeters per second respectively.
The function is accessible to the operator during the teach mode of operation for the
current program. Use the following procedure to set direct speed.
1. Select the interpolation for the current step of the program from the block teaching
screen (Figure 7-4 or 7-5).
2. Select speed 10 from the teach data speed key. Press the teach data speed and
the AUX SET and DISP keys simultaneously (Figure 7-4 or 7-5). The Direct Speed
screen is displayed as shown in figure 7-8.
8 9
DIRECT SPEED
INTERP. SPEED 6 7
4 5 _ EXIT
2 3 BS
0 1
RETURN
Figure 7-8 Direct Speed Display
3. The INTERP. and SPEED keys in the upper left corner display the interpolation
selected from the block teaching screen and the speed selected by the operator
from the numeric keypad.
4. Press the RETURN key to complete the procedure and return to the block teaching
screen.
May 22 2001 7-11

7.4 CHECKING PROGRAM OPERATION
CHECK CHECK
CONT CHECK CHECK
ONCE FORWARD BACKWARD
After the program is completed and the controller is in the TEACH mode, the program
check feature can be used to confirm the program playback.
To use this feature, CHECK MODE must be enabled, refer to unit 9, AUX 96.
The CHECK key switches between CHECK CONT and CHECK ONCE each time it is
pressed.
With CHECK ONCE selected, an enabling device held, and motor power ON, press and
hold the CHECK FORWARD or CHECK + key to move the robot to the step displayed.
When CHECK FORWARD or CHECK + is released and pressed again, the robot moves
to the next step of the program.
With CHECK CONT selected, an enabling device held, and MOTOR POWER ON,
press and hold the CHECK FORWARD or CHECK + key to move the robot through the
program at the selected check speed.
The robot stops at the last step of the program and the step select key must be used to
select the first step of the program to continue the process.
With CHECK CONT or CHECK ONCE selected, an enabling device held, and MOTOR
POWER ON, press and hold the CHECK BACKWARD or CHECK – key to move the
robot through the program backwards to the previous step. The CHECK BACKWARD or
CHECK – key must be released and pressed and held again before the robot moves to
the previous step.
For additional information, refer to section 9.36.
7-12 May 22, 2001

7.5 EDITING PROGRAM DATA
OVERWRITE DELETE INSERT POS. REWRT AUX. REWRT

/NEW
Once a program is written there are a number of ways that it can be modified: steps can
be added or deleted, locations changed, and auxiliary data modified.
Program editing must be done in the teach mode.
From the teaching screen, when a taught step is shown, the key to the right of the
record key displays TEACH OVERWRITE. When TEACH OVERWRITE is selected, a
row of selectable editing keys on the bottom of the display becomes available to the
operator.
These keys are: OVERWRITE/NEW, DELETE, INSERT, POS. REWRT, and AUX.
REWRT.
7.5.1 OVERWRITING STEPS
When the TEACH OVERWRITE key is displayed, pressing the RECORD key overwrites
the displayed step with the current position and auxiliary data. The previous location
and auxiliary data are replaced with the new data. The message display area of the
multi function panel or type 2 teach pendant shows a message that the step was re-
corded and the step number is incremented to the next step.
May 22 2001 7-13

7.5.2 DELETION OF STEPS
To delete steps within a program, use the step select process (reference unit 5, Basic
Operations, for a description of the step select process), to select the step to delete. If a
number of steps are to be deleted, start with the highest number first, this eliminates the
need to figure out the new numbering sequence.
With the step to delete selected and TEACH DELETE displayed, press the RECORD
key to delete the step.
Figure 7-9 shows the renumbering process that takes place when steps are deleted.
Figure 7-9 Deleting Program Steps
7-14 May 22, 2001

7.5.3 INSERTION OF STEPS
The TEACH INSERT key allows the operator to enter new steps into a program. New
steps are inserted into current positions and existing steps are incremented by one in
the program.
Figure 7-10 shows the renumbering sequence.
To insert a new step with TEACH INSERT, select the step at the insertion point. Jog the
robot to the new position and set all auxiliary data. Press the RECORD key and this
becomes the selected step and the previous taught position moves to the next step.
The multi function panel or type 2 teach pendant remains in the teach insert mode,
ready to accept additional steps for insertion.
Figure 7-10 Inserting Program Steps
May 22 2001 7-15

7.5.4 POSITION REWRITE
To change the location of a taught position, the position rewrite process can be used.
To change the position of a taught point, jog the robot to the desired position, ensure the
multi function panel or type 2 teach pendant is displaying the TEACH POS. REWRT key
and the correct step number for the new position.
Press the RECORD key to enter the new position while maintaining the original auxiliary
data.
The multi function panel or type 2 teach pendant displays a message that the step is
recorded and increments to the next step while still in the pos. rewrt mode.
7.5.5 AUXILIARY REWRITE
To change the auxiliary data for a program step, the auxiliary rewrite process can be
used.
To change the auxiliary data for a taught point, set the auxiliary data keys to the desired
information, ensure the multi function panel or type 2 teach pendant is displaying the
TEACH AUX. REWRT key and the correct step number for the new auxiliary data.
Press the RECORD key to enter the new auxiliary data while maintaining the original
position data.
The multi function panel or type 2 teach pendant displays a message that the step is
recorded and increments to the next step number remaining in the AUX. REWRT mode.
7-16 May 22, 2001

7.5.6 CUT/COPY/PASTE OR DELETE FOR INDIVIDUAL STEPS
7.5.6.1 HOW TO CUT AND PASTE STEPS WITHIN A PROGRAM
NOTE
This procedure is used to cut and paste individual pro-

gram steps by omitting steps 12-13 below.
PROGRAM STEP PC
4
M-OFF
FIRST STEP HOLD
EXIT TEACH
STEP SELECT

JOINT 9 1 0 1
CL1
WORK COMMENT WSO
CL2
0 J/E CCO CUT PASTE
CCO

COPY INSERT /
DATA SIGNAL WX DATA OVERWRITE
AUX PARTS
SET&DISP 5 COPY
RETURN
Figure 7-11 Step Editing
1. Set the TEACH LOCK switch to ON.
2. Set the TEACH/REPEAT switch to TEACH.
3. Select AUX 96 to enable the PROGRAM EDIT function.
4. Press the EXIT key twice.
5. Press the TEACHING key.
6. Press the PROGRAM EDIT key from the drop down TEACHING menu.
May 22 2001 7-17

7. Press the PROGRAM key, and select the program to edit.
8. Press the STEP key.
9. Press the BACKWARD or FORWARD key to scroll to the first step to cut.
10. Press the CUT key.
11. Press the STEP key (the auxiliary data keys change from yellow to magenta).
12. Press the FORWARD key to scroll to the last step to cut (10 steps maximum;
the auxiliary data keys change from magenta to yellow).
14. Press the EXIT key.
15. Press the RETURN key (the auxiliary data keys change from magenta to yellow).
17. Press the BACKWARD or FORWARD key to select the insertion point.
19. (Optional) Press the INSERT/OVERWRITE key to select the type of insertion.
20. Press the PASTE key (the auxiliary data keys change from yellow to magenta).
21. Press the RETURN key (the auxiliary data keys change from magenta to yellow;
the copied steps are inserted before the program step selected in step 19 above).
22. (Optional) Repeat steps 8-21 above to cut and paste up to 10 more program
steps.
23. Exit the PROGRAM EDIT function.
7-18 May 22, 2001

7.5.6.2 HOW TO COPY AND PASTE STEPS WITHIN A PROGRAM
NOTE
This procedure is used to copy and paste individual pro-

gram steps by omitting steps 12-13 below
PROGRAM STEP PC
4
M-OFF
FIRST STEP HOLD
EXIT TEACH
STEP SELECT

JOINT 9 1 0 1
CL1
WORK COMMENT WSO
CL2
0 J/E CCO CUT PASTE
CCO

COPY INSERT /
AUX PARTS
SET&DISP 5 COPY
RETURN
May 22 2001 7-19

10. Press the COPY key.
12. Press the FORWARD key to scroll to the last step to copy (10 steps maximum;
20. Press the PASTE key (the auxiliary data keys change from yellow to magenta).
the copied steps are inserted before the program step selected in step 19 above)
22. (Optional) Repeat steps 8-21 above to copy and paste up to 10 more program
steps.
7-20 May 22, 2001

7.5.6.3 HOW TO COPY AND PASTE STEPS TO ANOTHER PROGRAM
NOTE
This procedure is used to copy and paste individual pro-

gram steps by omitting steps 12-13 below
PROGRAM STEP PC
4
M-OFF
FIRST STEP HOLD
EXIT TEACH
STEP SELECT

JOINT 9 1 0 1
CL1
WORK COMMENT WSO
CL2
0 J/E CCO CUT PASTE
CCO

COPY INSERT /
AUX PARTS
SET&DISP 5 COPY
RETURN
7. Press the PROGRAM key, and select the program to copy lines from.
May 22 2001 7-21

10. Press the COPY key.
12. Press the FORWARD key to scroll to the last step to copy (10 steps maximum;
16. Press the PROGRAM key, and select the destination program.
21. Press the PASTE key (the auxiliary data keys change from yellow to magenta)
the copied steps are inserted before the program step selected in step 18 above)
23. (Optional) Repeat steps 7-22 above to copy and paste up to 10 more program
steps.
7-22 May 22, 2001

7.5.6.4 HOW TO DELETE STEPS WITHIN A PROGRAM
NOTE
This procedure is used to delete individual program

steps by omitting steps 12-13 below
PROGRAM STEP PC
4
M-OFF
FIRST STEP HOLD
EXIT TEACH
STEP SELECT

JOINT 9 1 0 1
CL1
WORK COMMENT WSO
CL2
0 J/E CCO CUT PASTE
CCO

COPY INSERT /
AUX PARTS
SET&DISP 5 COPY
RETURN
May 22 2001 7-23

10. Press the DELETE key.
12. Press the FORWARD key to scroll to the last step to delete (10 steps maximum;
16. (Optional) Repeat steps 8-15 above to delete up to 10 more program steps.
7-24 May 22, 2001

7.5.6.5 HOW TO COPY AUXILIARY DATA
1. Follow steps 1 through 8 of “CUT / COPY / PASTE OR DELETE FOR INDIVIDUAL

STEPS”.
2. Once at the desired step, press the MODE INSERT/OVERWRITE key to display
MODE OVERWRITE.
3. Press the PARTS COPY key.
4. Select the auxiliary data to be copied (the auxiliary data key (s) change color from
yellow to magenta).
5. Press the RETURN key.
6. Use the BACKWARD or FORWARD key to select a new position for the copied data
or select a desired program using the PROGRAM key.
7. Press the PASTE key.
8. Press the RETURN key; the copy steps have now been placed.
9. To exit the PROGRAM EDIT function, exit the step select screen and select another
function.
May 22 2001 7-25

7.6 PROGRAM CONFIRMATION
REPEAT STEP STEP

CONT ONCE FORWARD
STATUS
Operation of new programs can be confirmed in the repeat mode by selecting the STEP
ONCE key (this key toggles between STEP CONT and STEP ONCE) and pressing
STEP FORWARD key to execute one step of the program at a time. In this mode, the
program executes program steps at their repeat condition speed.
It is recommended the speed is reduced the first time the “step through” process is
executed.
7-26 May 22, 2001

C SERIES CONTROLLER
PROGRAM EXECUTION
PROGRAM EXECUTION
8.0 PROGRAM EXECUTION .................................................................................. 8-2
8.1 Program Selection .............................................................................................. 8-2
8.2 Repeat Condition ............................................................................................... 8-4
8.2.1 Repeat Condition Display ................................................................................... 8-4
8.2.2 Repeat Speed .................................................................................................... 8-5
8.2.3 Repeat Cont/Once ............................................................................................. 8-5
8.2.4 Step Cont/Once ................................................................................................. 8-5
8.2.5 RPS Enable/Disable ........................................................................................... 8-5
8.2.6 Dry Run Off/On .................................................................................................. 8-6
8.3 Running a Program ............................................................................................ 8-6
8.4 Monitoring the Program ...................................................................................... 8-7
8.4.1 Program List Screens ......................................................................................... 8-8
8.4.2 Monitor Screens ................................................................................................. 8-9
8.4.3 Current Position Screen ................................................................................... 8-10
8.5 Stopping a Running Program ........................................................................... 8-11
8.6 Slow Repeat Mode ........................................................................................... 8-11
8.7 Wait Override ................................................................................................... 8-12
May 22, 2001 8-1

C SERIES CONTROLLER
PROGRAM EXECUTION
8.0 PROGRAM EXECUTION
This unit provides information on how to select, run, monitor, and stop programs. Set-
ting repeat conditions and slow repeat speed, and how to override wait signals are also
covered.
! WARNING
Before program execution, ensure that all personnel are
outside the safety fencing system and clear of robot op-
erations. Ensure that the robot work space is properly
configured to execute the program selected.
8.1 PROGRAM SELECTION

PROGRAM
pg1
To select a program, ensure control power is ON, the HOLD/RUN switch is in the HOLD
position, and the controller is in the REPEAT mode of operation, reference unit 4, Power
On/Off Procedures.
Pressing the PROGRAM key on the upper left portion of the multi function panel or type
2 teach pendant brings up the display shown in figure 8-1. The program select screen
displays the names of all the programs in the controller memory. The cursor keys are
used to highlight the desired program and the return key is pressed to select the pro-
gram. The newly selected program name is shown on the program key (pg1 in the
example above), confirming it is properly selected.
8-2 May 22, 2001

C SERIES CONTROLLER
PROGRAM EXECUTION
PROGRAM SELECT
pg??
pg10 pg1
work1 pg2
test pg8
PROGRAM
CHARACTER
LIST
Figure 8-1 Program Select
NOTE
Many operators utilize a “mainline” program to select all

robot control programs. Mainline programs are routinely
named pg00. If your robot is integrated into a system
that is designed to operate with a mainline program, it is
important that the mainline program is selected to start
production. If an individual program is selected and run
independent of the mainline program, the required op-
erations of the mainline program are not processed.
May 22, 2001 8-3

C SERIES CONTROLLER
PROGRAM EXECUTION
8.2 REPEAT CONDITION
The repeat conditions are accessed from the multi function panel or type 2 teach pen-
dant STATUS screen. Pressing the REPEAT CONDITION key displays four additional
repeat condition keys (REPEAT CONT/ONCE, STEP CONT/ONCE, RPS ENABLE/
DISABLE, and DRY RUN ON/OFF). All of the repeat condition keys and the display are
shown in figure 8-2. The REPEAT (speed), REPEAT CONT/ONCE and STEP CONT/
ONCE keys are all available to the operator while a program is executing.
SPEED 10% ‘97-03-18

17:30
REPEAT REPEAT REPT. CONT RPS ON
10% CONDITION
REPEAT STEP RPS DRYRUN

CONT CONT ENABLE OFF
Figure 8-2 Repeat Condition Keys and Display
8.2.1 REPEAT CONDITION DISPLAY
The repeat condition display is shown in figure 8-3. This display is in the upper right
portion of the multi function panel or type 2 teach pendant and shows the status of the
repeat condition items. The repeat speed is shown as a percentage and on a bar graph.
Figure 8-3 Repeat Conditions Display
8-4 May 22, 2001

C SERIES CONTROLLER
PROGRAM EXECUTION
8.2.2 REPEAT SPEED
Pressing the REPEAT (speed) key displays the 10% up and 10% down keys. The over-
all playback speed of the program can be adjusted in 10% increments by pressing these
additional keys. When the speed has been changed, the new speed is displayed on the
REPEAT (speed) key and the REPEAT CONDITION display.
8.2.3 REPEAT CONT/ONCE
Pressing the REPEAT CONT key toggles the key to REPEAT ONCE. Selecting the
CONT option allows the program to run continuously. Selecting ONCE allows the pro-
gram to run one time.
8.2.4 STEP CONT/ONCE
Pressing the STEP CONT key toggles the key to STEP ONCE. Selecting the CONT
option allows the program to run continuously. Selecting ONCE allows the program to
run only one step at a time. When ONCE is selected for this key, an additional STEP
FORWARD key is displayed directly above it. Pressing the STEP FORWARD key allows
the operator to execute the program one step at a time.
8.2.5 RPS ENABLE/DISABLE
RPS
ENABLE
The RPS (random program selection) key is used to select programs from a remote
source. Pressing the RPS key changes the display from ENABLE to DISABLE. If EN-
ABLE is selected, an input signal to the controller selects the program to run. If DIS-
ABLE is selected, programs are selected by the operator as described in section 8.1.
For more information on RPS see section 11.35.
May 22, 2001 8-5

C SERIES CONTROLLER
PROGRAM EXECUTION
8.2.6 DRY RUN OFF/ON
The DRY RUN key allows the operator to execute programs without any robot motion.
Signals are output and program logic is executed, but there is no movement of the robot
when dry run is ON. When dry run is OFF, programs run with full robot motion.
8.3 RUNNING A PROGRAM
! WARNING
It is important to realize that when CYCLE START is
pressed, the robot begins the program from its present
position and travels to the next taught position. The ro-
bot makes this move with total disregard for anything
that may be in its path.
When a program is selected and the repeat conditions set, program execution can
begin. Turn RUN/HOLD to HOLD, then press MOTOR POWER and CYCLE START.
Turn RUN/HOLD to RUN to start execution. This avoids unexpected external cycle start.
Pressing the CYCLE START switch starts the program at whatever step is displayed on
the multi function panel or type 2 teach pendant and the robot moves to the next step in
the program sequence. If the program is required to start from a different step than the
one currently displayed, the step select function can be used to place the program at the
desired step.
8-6 May 22, 2001

C SERIES CONTROLLER
PROGRAM EXECUTION
8.4 MONITORING THE PROGRAM
The status screens display updated information about the condition of the robot when a
program is running. Information about the speed, location, signal status, and program
progress are all displayed.
Figure 8-4 shows the initial status screen and the information it provides for program
monitoring.
PROGRAM STEP PC SPEED 10% ‘97-03-18

17:30 REPEAT CONDITION STATUS
pg99 5 REPT. CONTINUE RPS ON AND DATE/TIME
ROBOT SYSTEM
CURRENT STEP CONDITIONS
OF PROGRAM STATUS
ERROR HOLD TEACH CYCLE MOTOR E-STOP NORMAL RELEASE
START POWER EXT. HOLD
SWITCH STATUS
RECORD
THE STEP FORWARD KEY
REPEAT REPEAT STEP
REPEAT CONDITIONS 10% CONDITION FORWARD ACCEPT ONLY APPEARS WHEN SINGLE
STEPPING THROUGH A PROGRAM
PROGRAM LIST WITH 4 JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF, 15, 1, C)
5 LINEAR SPEED8 ACCU3 TIMER1 TOOL1 WORK0 CLAMP1 (OFF, 15, 1, C)
CURRENT STEP OF 6 JMOVE 1c1
PROGRAM HIGHLIGHTED 7 JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF, 15, 1, C)
JT1 JT2 JT3 JT4 JT5 JT6 JT7

-26.248 -5.518 -37.812 0.000 -75.092 11.449 5.315 CURRENT POSITION OF ROBOT
X Y Z O A T
532.690 656.487 1022.774 63.245 113.890 46.616
Figure 8-4 Current Conditions
May 22, 2001 8-7

C SERIES CONTROLLER
PROGRAM EXECUTION
8.4.1 PROGRAM LIST SCREENS
Pressing the PROGRAM LIST key from the STATUS drop down menu displays the
screen shown in figure 8-5. If more than four clamps are defined, there are three pages
in the program list.
IDENTIFIES NUMBER OF
SCREENS AVAILABLE
PROGRAM LIST (1/2)

1 LINEAR 9 1 0 1 1 JUMP[10,20,30,40][1,3,5,7]
2 JOINT 9 1 1 1 1 [ ][ ]
3 LINEAR 8 2 0 2 0 [ ][ ]
CURRENT STEP OF PROGRAM 4 LINEAR 8 1 2 2 0 [10,15 ][1,10 ]
AND INSTRUCTIONS ARE 5 LINEAR 9 1 1 1 0 [ ][ ]
HIGHLIGHTED
BACKWARD AND FORWARD KEYS
ALLOW THE USER TO SCROLL
NEXT PG BACKWARD FORWARD THROUGH THE STEPS OF THE
PROGRAM
PRESSING THIS KEY

WILL DISPLAY CLAMP
INFORMATION
PROGRAM LIST (2/2)
CLAMP DATA
1 1( ON, 15, 1, C) 2(OFF, 0, 1, O) 3( ON, 0, 0, O) 4( ON, 9, 9, C)
6 1( ON, 15, 1, C) 2(OFF, 0, 1, O) 3(OFF, 0, 0, O) 4(OFF, 9, 9, C) CURRENT STEP OF PROGRAM
AND CLAMP INFORMATION
IS HIGHLIGHTED
PREV.PG BACKWARD FORWARD
PRESSING THIS KEY WILL RETURN

TO THE PREVIOUS SCREEN
Figure 8-5 Program List Screens
8-8 July 7, 1999

C SERIES CONTROLLER
PROGRAM EXECUTION
8.4.2 MONITOR SCREENS
Pressing the MONITOR key from the STATUS drop down menu reveals the MONITOR
screens shown in figure 8-6.
MONITOR (OUTPUT SIGNAL)
SIGNALS THAT 1 OX1 9 OX9 17 WC1-WS1 25 OX25

ARE ON ARE 2 OX2 10 OX10 18 WC1-WS2 26 OX26
HIGHLIGHTED 3 OX3 11 OX11 19 WC1-WS4 27 HOME
4 OX4 12 OX12 20 WC1-WS8 28 TEACH_MODE
5 OX5 12 OX13 21 OX21~ 29 CYCLE_START
6 OX6 13 OX13 22 CLAMP1_ON 30 AUTOMATIC
7 OX7 14 OX14 23 OX23 31 ERROR
8 OX8 15 OX15 24 CLAMP2_ON 32 MOTOR_ON
DEDICATED SIGNALS
INPUT INTERNAL NEXT PG AND SIGNALS
ASSIGNED THROUGH
AUXILIARY FUNCTIONS
PRESSING THIS
KEY WILL DISPLAY
THE NEXT GROUP
33 OX33 41 OX41 49 OX49 57 OX57

34 OX34 42 OX42 50 OX50 58 OX58
35 OX35 43 OX43 51 OX51 59 OX59
36 OX36 44 OX44 52 OX52 60 OX60
37 OX37 45 OX45 53 OX53 61 OX61
38 OX38 46 OX46 54 OX54 62 OX62
39 OX39 47 OX47 55 OX55 63 OX63
40 OX40 48 OX48 56 OX56 64 OX64
INPUT INTERNAL PREV.PG

THE INPUT KEY
CHANGES THE
DISPLAY TO
SHOW ROBOT PRESSING THIS
INPUTS KEY DISPLAYS THE
THE INTERNAL KEY PREVIOUS GROUP
CHANGES THE DISPLAY
TO SHOW INTERNAL
SIGNALS
Figure 8-6 Monitor Screens
July 7, 1999 8-9

C SERIES CONTROLLER
PROGRAM EXECUTION
8.4.3 CURRENT POSITION SCREEN
Pressing the CURRENT POSITION key from the STATUS drop down menu displays the
CURRENT POSITION screen shown in figure 8-7. On the CURRENT POSITION
screen, data is continuously updated as the robot moves.
The joint angle position of each joint is represented in degrees from a zero reference
point.
The XYZ section of the screen shows the coordinate location of the tool center point in
millimeters from the origin of the base coordinate system. The orientation angle of the
tool is represented by OAT and is expressed in degrees.
For more information on OAT and tool dimensions see section A.1.
Figure 8-7 Current Position
8-10 May 22, 2001

C SERIES CONTROLLER
PROGRAM EXECUTION
8.5 STOPPING A RUNNING PROGRAM
HOLD RUN EMERGENCY STOP MOTOR POWER CYCLE START
The EMERGENCY STOP switch (located on the multi function panel or type 2 teach
pendant and controller cabinet) should be pressed anytime an operator needs to stop
robot motion immediately. However, it is recommended that the emergency stop switch
is not used as a routine method of stopping robot motion. When the emergency stop
switch is pressed, power to the motors is immediately turned off and the brakes applied.
Because normal deceleration of the robot does not occur in an emergency stop, the
mechanical unit may be subjected to severe dynamic shock loads.
If the running program is to be stopped and motor power is to be turned off, the following
procedure can be followed:
1. Turn the HOLD/RUN switch to the HOLD position, deceleration of robot motion
begins at the point that the switch is turned to HOLD, the robot comes to a complete
stop after deceleration. The CYCLE START lamp remains ON.
2. Pressing the EMERGENCY STOP switch turns OFF the CYCLE START lamp,
removes motor power from the servo motors and applies the mechanical brakes.
3. Control power can now be turned OFF.
To restart a program from the point where it was stopped, turn the HOLD/RUN switch
from the HOLD to the RUN position while the CYCLE START lamp is ON. This resumes
the program execution, from the point where it was stopped, when the HOLD/RUN
switch is turned to RUN.
8.6 SLOW REPEAT MODE
The slow repeat mode speed is set between 1 and 25% from auxiliary function 55,
reference unit 9, section 9.20. A dedicated input signal is assigned to the slow repeat
function, reference unit 9, section 9.20.
When the slow repeat signal is ON, the program runs at the slow repeat speed. When
the slow repeat signal is OFF, the program runs at the speeds set in the program and
the repeat speed set from the repeat conditions.
When the state of the slow repeat signal changes, the program momentarily stops
before it resumes at the new speed.
May 22, 2001 8-11

C SERIES CONTROLLER
PROGRAM EXECUTION
8.7 WAIT OVERRIDE
M-ON
RUN WAIT
WAITING SCREEN
The wait override procedure is a method of bypassing an expected input signal when a
program is running and a WX (input) signal is not received.
When a wait condition occurs, with any teaching or status screen displayed, the status
display changes to “WAIT SCREEN”. The operator can access the wait override screen
(see figure 8-8) by pressing the WAIT SCREEN key. From this screen the operator can
press the individual WX signal number(s) to select the signal(s) to override, or select
ALL to override all WX signals that are not received.
The WAIT SCREEN key changes to “RETURN TO LAST” key when the wait override
screen is displayed. Pressing the RETURN TO LAST key returns the screen displayed
before the wait override screen is accessed.
RETURN
TO LAST
WX WX WX WX ALL
1 2 3 4
CONDITION WAIT
OVERRIDE
5 LINEAR SPEED8 ACCU3 TIMER1 TOOL1 WORK0 CLAMP1
Figure 8-8 Wait Override Screen
8-12 July 7, 1999

C SERIES CONTROLLER
PROGRAM EXECUTION
SPEED 50% 99-07-12

19:43
WAITING
MENU
Figure 8-9 Repeat Condition Wait Display
When a wait condition occurs with a function or interface panel screen displayed, the
repeat condition area indicates a wait condition (see figure 8-9). The operator can
access the wait override screen by exiting the function, or interface panel screen, and
pressing the WAIT SCREEN key.
When a wait condition occurs with the keyboard screen displayed, a wait condition is not
indicated. The operator can access the wait override screen by exiting the keyboard
screen and pressing the WAIT SCREEN key.
July 7, 1999 8-13

AUXILIARY FUNCTIONS
9.0 AUXILIARY FUNCTIONS .............................................................................. 9-3

9.1 Auxiliary Function List .................................................................................... 9-4
9.2 Location & Speed Display, Aux 2 ................................................................... 9-8
9.3 Data Transfer, Aux 3 ..................................................................................... 9-10
9.4 Kill Program, Aux 5 ...................................................................................... 9-11
9.5 Memory®PC Card (Save), Aux 10 ............................................................... 9-12
9.6 PC Card®Memory (Load), Aux 11 ............................................................... 9-14
9.7 File Directory, Aux 12 ................................................................................... 9-15
9.8 PC Card Aux. Function, Aux 14 ................................................................... 9-16
9.9 Manual Weld, Aux 35 ................................................................................... 9-17
9.10 Zeroing, Aux 41 ............................................................................................ 9-18
9.11 Pos. Error Range at E-Stop, Aux 42 ............................................................. 9-20
9.12 Encoder Error Range, Aux 43 ...................................................................... 9-21
9.13 Zeroing Data Set/Display, Aux 44 ................................................................ 9-22
9.14 Installation Type, Aux 46 .............................................................................. 9-23
9.15 Base Coordinate, Aux 47 ............................................................................. 9-24
9.16 Tool Dimensions, Aux 48.............................................................................. 9-25
9.17 Software Limit, Aux 51 ................................................................................. 9-26
9.17.1 Overtravel Error Recovery ........................................................................... 9-27
9.18 Accuracy, Aux 53 ......................................................................................... 9-28
9.19 Speed, Aux 54 ............................................................................................. 9-31
9.20 Slow Repeat Mode, Aux 55.......................................................................... 9-32
9.21 Check Speed, Aux 56 .................................................................................. 9-33
9.22 Teach Speed, Aux 57 ................................................................................... 9-34
9.23 Timer, Aux 58 ............................................................................................... 9-35
9.24 Memory Available, Aux 70............................................................................ 9-35
9.25 Record Data (PRG CHG) Inhibit, Aux 71 ..................................................... 9-36
9.26 Spray On/Off, Aux 73 ................................................................................... 9-37
9.27 System Switch, Aux 75 ................................................................................ 9-38
9.27.1 Check.Hold Switch ....................................................................................... 9-40
9.27.2 CP (Continuous Path) Switch....................................................................... 9-40
9.27.3 CYCLE.STOP Switch ................................................................................... 9-41
9.27.4 OX.Preout Switch ......................................................................................... 9-42
9.27.5 Prefetch.Sigins Switch ................................................................................. 9-43
9.27.6 QTool Switch ................................................................................................ 9-43
9.27.7 REP_ONCE (Repeat Once) Switch ............................................................. 9-43
9.27.8 RPS (Random Program Selection) Switch .................................................. 9-43
9.27.9 STP_ONCE (Step Once) Switch.................................................................. 9-44
9.27.10 AFTER.WAIT.TIMER Switch ........................................................................ 9-44
9.27.11 SPOT_OP .................................................................................................... 9-44
9.27.12 Messages Switch ......................................................................................... 9-44
9.27.13 Screen Switch .............................................................................................. 9-44
9.27.14 AUTOSTART.PC Switches ........................................................................... 9-45
9.27.15 ERRSTART.PC Switch ................................................................................. 9-45
May 22, 2001 9-1

AUXILIARY FUNCTIONS
9.27.16 DISPIO_01 Switch ...................................................................................... 9-45

9.27.17 HOLD.STEP ................................................................................................ 9-45
9.27.18 WS_COMPOFF .......................................................................................... 9-46
9.27.19 WS.ZERO ................................................................................................... 9-46
9.27.20 PLC.CHECK................................................................................................ 9-46
9.27.21 Flowrate ...................................................................................................... 9-46
9.28 Home Position, Aux 76 ................................................................................ 9-47
9.29 Clear Check Sum Error, Aux 78 .................................................................. 9-48
9.30 Program Parameter/Comment, Aux 87 ....................................................... 9-49
9.31 Change Program Name, Aux 88 ................................................................. 9-50
9.32 Software Version Display, Aux 90 ................................................................ 9-52
9.33 Environment Data, Aux 91 .......................................................................... 9-53
9.34 Environment Data2, Aux 95 ........................................................................ 9-54
9.35 Environment Data of Panel, Aux 96 ............................................................ 9-55
9.35.1 Environment Data of Panel, Aux 96, Multi Function Panel .......................... 9-55
9.35.2 Environment Data of Panel, Aux 96, Type 2 Teach Pendant ....................... 9-56
9.36 CHECK SPEC. (Check Specification), Aux 99 ............................................ 9-57
9.37 System Init. (System Initialization), Aux 100 ............................................... 9-58
9.38 Battery Error Check, Aux 101 ..................................................................... 9-59
9.39 Touch Panel Short Circuit Check, Aux 103 ................................................. 9-60
9.40 Time, Aux 110 ............................................................................................. 9-61
9.41 Dedicated Input Signal, Aux 111 ................................................................. 9-62
9.42 Dedicated Output Signal, Aux 112 .............................................................. 9-63
9.43 Dedicated Signal Display, Aux 113 ............................................................. 9-64
9.44 Clamp Specification, Aux 114 ..................................................................... 9-65
9.45.1 Clamp Application ....................................................................................... 9-68
9.45.2 Clamp Condition ......................................................................................... 9-69
9.45.3 Spot Weld Clamp Definition ........................................................................ 9-70
9.45.4 Spot Weld Control ....................................................................................... 9-71
9.45.5 Spot Weld Gun Weld Definition ................................................................... 9-73
9.45.6 Handling and Clamp Data ........................................................................... 9-74
9.46 Error Logging, Aux 120 ............................................................................... 9-75
9.47 Operation Logging, Aux 122 ....................................................................... 9-76
9.48 Encoder Rot. Counter Reset, Aux 140 ........................................................ 9-77
9.49 Z-Series Robot Functions ........................................................................... 9-78
9.49.1 Arm ID Board Functions .............................................................................. 9-78
9.49.1.1 Maintenance Log, Aux 123 ......................................................................... 9-79
9.49.1.2 Maintenance Log Set .................................................................................. 9-79
9.49.1.3 Maintenance Log Display ............................................................................ 9-82
9.49.1.4 Maintenance Log Delete ............................................................................. 9-83
9.49.1.5 Setting Signal Allocation ............................................................................. 9-84
9.49.1.6 Arm ID Board AS Language Commands .................................................... 9-85
9.49.1.7 Arm ID Board Errors and Error Codes ........................................................ 9-87
9-2 May 22, 2001

AUXILIARY FUNCTIONS
9.0 AUXILIARY FUNCTIONS
The auxiliary functions are accessed with the multi function panel or type 2 teach pen-
dant and provide the operator the ability to view and change numerous settings that
affect robot operation. The auxiliary function screens are accessed by pressing the
MENU key and selecting the FUNCTION key from the drop down menu.
Figure 9-1 shows the first auxiliary screen, additional screens are accessed by pressing
the F3 key.
Figure 9-1 Auxiliary Function Screen
NOTE
Some auxiliary functions are optional and must be pur-

chased separately. The optional auxiliary functions are
covered in unit 11 of this manual.
May 22, 2001 9-3

AUXILIARY FUNCTIONS
9.1 AUXILIARY FUNCTION LIST
All of the auxiliary function numbers, the function names and a brief description of each
are identified below in the Auxiliary Function List. A detailed explanation of each func-
tion and its use follows the Auxiliary Function List.
Auxiliary Function List
No. Function Name Function Description
2 LOCATION & SPEED Displays present position information.

DISPLAY
3 DATA TRANSFER Used to transfer all, or part of, one program to

another.
5 KILL PROGRAM Removes the selected program from the stack,

does not delete the program.
10 MEMORY→PC CARD Saves data from the system memory to a flash

RAM or SRAM PC card.
11 PC CARD→MEMORY Loads file data from a flash RAM or SRAM PC

card to system memory.
12 FILE DIRECTORY Displays a list of files currently on the PC card.
14 PC CARD AUX. FUNCTION Used to format flash RAM or SRAM PC cards and
delete files stored on flash RAM or SRAM PC
cards.
35 MANUAL CONDUCTION Sets weld schedules and clamp conditions for weld
operations.
41 ZEROING Used to set zeroing data for encoders with a loca-

tion reference to ensure proper motion of the
robot.
42 POSITION ERROR RANGE Displays a deviation range error message after an

AT EMERGENCY STOP E-stop.
43 ENCODER ERROR RANGE Displays a deviation range error message at con-

troller power-up.
9-4 May 22, 2001

AUXILIARY FUNCTIONS
Auxiliary Function List (continued)
44 ZEROING DATA SET Allows the operator to set zeroing data.

AND DISPLAY
46 INSTALLATION TYPE Used to determine mechanical unit mounting

configuration.
47 BASE COORDINATES Allows the operator to set the base coordinate

system at a position other than zero.
48 TOOL DIMENSIONS Used to set tool dimensions.
51 SOFTWARE LIMIT Sets the upper and lower ranges for robot motion.
53 ACCURACY Used to set the distances of the four accuracies

used in block step programming.
54 SPEED Sets the ten speeds used in block step program-

ming.
55 SLOW REPEAT MODE Used in conjunction with an input signal to slow

down the program execution speed.
56 CHECK SPEED Sets the robot speeds used in check mode.
57 TEACH SPEED Used to set the three teach speeds and the three
inching distances.
58 TIMER Sets the timer values for the nine timers available
for use in block step programming.
70 MEMORY AVAILABLE Displays the system memory status.
71 RECORD DATA /INHIBIT Prevents recording data if set to inhibit.
73 SPRAY ON/OFF Identifies robot application type.
May 22, 2001 9-5

AUXILIARY FUNCTIONS
75 SYSTEM SWITCH Used to set system software switches.
76 HOME POSITION Used to set and display robot home positions.
78 CLEAR CHECK SUM ERROR Used to clear check sum errors.
87 PROGRAM PARAMETER/ Allows a comment after the program name.

COMMENT
88 CHANGE PROGRAM NAME Used to change the name of an existing program.
90 SOFTWARE VERSION Displays the version numbers of the installed

DISPLAY system software.
91 ENVIRONMENT DATA Sets a timer to turn off servo motors and identify
installed equipment.
95 ENVIRONMENT DATA2 Used to identify installed hardware.
96 ENVIRONMENT DATA OF Used to identify type of operator interface con-

PANEL nected.
99 CHECK SPECIFICATION Enables or disables selected program instructions

in check mode.
100 SYSTEM INITIALIZATION Program data is deleted and system is reset to

default settings.
101 BATTERY ERROR CHECK Enables or disables RAM low battery error check-
ing at power up.
103 TOUCH PANEL SHORT When used, detects if a short circuit is present
CIRCUIT CHECK in the multi function panel/type 2 teach pendant
touch screen.
9-6 May 22, 2001

AUXILIARY FUNCTIONS
110 TIME Used to set the date and time for the controller
processor.
111 DEDICATED INPUT SIGNAL Used to set dedicated input signals.
112 DEDICATED OUTPUT Used to set dedicated output signals.

SIGNAL
113 DEDICATED SIGNAL Displays dedicated input and output signals.

DISPLAY
114 CLAMP SPECIFICATION Used to identify clamp data and specifications.
120 ERROR LOGGING Displays a history of error messages.
122 OPERATION LOGGING Displays the history of operation activity.
140 ENCODER ROTATION Used to reset the encoder values as part of the
COUNTER RESET zeroing process.
March 31, 2000 9-7

AUXILIARY FUNCTIONS
9.2 LOCATION & SPEED DISPLAY, AUX 2
The LOCATION & SPEED DISPLAY includes six display modes for positional data and
robot movement.
Function keys F1 to F6 are used to select the type of positional data displayed.
Figure 9-2 shows the initial joint angle display when auxiliary function 2 is selected.
For information on the optional EXTENDED LOCATION & SPEED DISPLAY see unit 11.
ENTER KEY
Figure 9-2 Location and Speed Display
9-8 May 22, 2001

AUXILIARY FUNCTIONS
The data in the LOCATION & SPEED DISPLAY screens is continuously updated and
scrolls from the bottom of the screen. When the ENTER key is pressed the screen
stops scrolling. When the ENTER key is pressed again the screen resumes scrolling.
Pressing the EXIT key returns the display to the AUX function screen.
Table 9-1 provides information about the six different screens accessed from the loca-
tion and speed display.
Table 9-1 Location and Speed Display
Function Key Description Unit

F1 JOINT ANGLE The present angle of each joint. Degrees
The TCP position in the base coordinate
F2 XYZOAT Millimeters/Degrees
system (XYZ), and angle (OAT).
F3 JOINT COMMAND The present commanded position for each joint. Degrees
The deviation between the commanded position
F4 JOINT OFFSET Degrees
and the actual position.
F5 ENCODER The encoder count for each joint. Bits
F6 JOINT SPEED The speed of each joint in degrees per second. Degrees/Second
May 22, 2001 9-9

AUXILIARY FUNCTIONS
9.3 DATA TRANSFER, AUX 3
The DATA TRANSFER function allows the operator to copy and paste program steps
from one program to a different program or a different location within the same program.
Figure 9-3 shows the DATA TRANSFER screen.
AUX 3 DATA TRANSFER

SOURCE PROGRAM Pgtest
SOURCE STEP 5
NUMBER OF STEPS 21
DESTINATION PROGRAM Pgtest2
DESTINATION STEP 4
(0:APPEND AT THE LAST STEP)
F1 F2 F3 F4
PROGRAM
INPUT
Figure 9-3 Data Transfer
The use of the DATA TRANSFER function is outlined in the following procedure:
1. Press the F1 PROGRAM INPUT key to select a source program containing the
steps to be copied. A screen showing a list of available programs in the system
memory is displayed. Use the cursor keys to select the program containing the
steps to copy, and press the ENTER key.
2. Use the numeric key pad to enter the first step and the number of steps to copy.
3. Press the F1 PROGRAM INPUT key to select the program to paste the copied
steps into. A screen showing a list of available programs in the system memory is
displayed. Use the cursor keys to select the program to paste the copied steps into
and press the ENTER key.
4. Use the numeric key pad to enter the step number, in the destination program, to
paste the copied steps before. When 0 is entered the steps are inserted after the
last step of the destination program. When program steps are inserted into a pro-
gram the existing steps are renumbered.
9-10 May 22, 2001

AUXILIARY FUNCTIONS
9.4 KILL PROGRAM, AUX 5
The KILL PROGRAM function is used to remove the selected program from active
status. The KILL PROGRAM function does not delete the program from system
memory.
Figure 9-4 shows the KILL PROGRAM screen.
AUX 5 KILL PROGRAM
Are you sure?
F1 F2 F3 F4
YES NO
Figure 9-4 Kill Program
Press the F1 (YES) key to confirm the KILL PROGRAM operation.
If the KILL PROGRAM selection is made in error, press the F2 (NO) key to return to the
AUX function screen.
May 22, 2001 9-11

AUXILIARY FUNCTIONS
→PC CARD (SAVE), AUX 10

9.5 MEMORY→
This function is used to save data in the controller’s memory to a PC card. The PC card
is inserted into the PC card slot in the back of the multi function panel or type 2 teach
pendant.
Figure 9-5 shows the screen display when the save function is selected.
AUX 10 MEMORY -> PC CARD (SAVE) AUX 10 MEMORY -> PC CARD (SAVE)
1 ALL DATA
2 PROGRAM
3 AUXILIARY DATA
4 ALL DATA (selected program only)
10 ROBOT DATA
11 ERROR LOGGING
FILE0
FUNCTION NUMBER:
F1 F2 F3 F4 F1 F2 F3 F4
CHARACTER
Figure 9-5 Memory→PC Card (Save)
The MEMORY→ →PC CARD (SAVE) screen has six selections available for storing differ-
ent types of data. Data is saved on the PC card as ASCII text files. Use the cursor keys
or the numeric keypad to select the desired option and press the enter key.
Use the numeric keypad to enter a numeric file name and press RETURN.
If a alphanumeric file name is desired press the F4 (CHARACTER) key. Select the
desired characters for the file name and press the ENTER key. When the file name
screen is displayed press the RETURN key to complete the procedure.
• File names are limited to fifteen characters.
• Alphanumeric file names must start with an alpha character.
• File names cannot contain spaces.
• An under score or period is used as a delimiter.
The options for saving data on a PC card are shown in table 9-2.
9-12 May 22, 2001

AUXILIARY FUNCTIONS
Table 9-2 Memory to PC Save
Option Extension Description

Includes all robot, system, auxiliary, program,
1 ALL DATA .AS
variable and program data.
Saves program data only. System data and
variables are not saved. If the saved program
2 PROGRAM .PG
calls other programs (subroutines), the called
programs are also saved.
3 AUXILIARY Includes auxiliary data such as accuracy, timer
.AU
DATA and teach speed settings, HOME positions, etc.
4 ALL DATA Saves all data for up to five selected programs.
(SELECTED This option saves variables, system data and
.AS
PROGRAM auxiliary data. If subroutines are called they are
ONLY) not saved unless they are identified individually.
10 ROBOT Includes robot type, number of axes and specific
.RB
DATA software settings.
Saves the data from the error log up to the last
11 ERROR
.EL 1,000 entries, including the date and time of the
LOGGING
entry.
When data is stored onto a PC card a file number or name must be specified. The
display prompts the operator to enter a number for the file identification. The file exten-
sion is added to the file name based on the option of the file type selected.
If a file is identified with the same file number, or name, as an existing file, a backup file
is automatically created. A “B” is added to the extension of the original file name indicat-
ing a backup file (i.e. .BAS). Only one backup file is created, if additional files of the
same name are saved the backup file is overwritten.
May 22, 2001 9-13

AUXILIARY FUNCTIONS
→MEMORY (LOAD), AUX 11

9.6 PC CARD→
This function is used to load data to the controller’s memory from a PC card. The PC
card is inserted into the PC card slot in the back of the multi function panel or type 2
teach pendant.
Figure 9-6 shows the screen displayed when the load function is selected.
Figure 9-6 PC Card→Memory (Load)
Use the cursor keys or the numeric keypad to select the option number for the data to
load from the PC card file into the controller memory.
If option one is selected, the display prompts the operator to load, or not to load, the
robot data. After the response to loading robot data is entered, the remainder of the
data in the selected file is loaded.
If option two is selected, the operator is prompted whether or not each category of data
in the PC card file is to be loaded.
If a program is loaded from the PC card with the same program name as a program in
controller memory, the program in the controller memory is overwritten.
9-14 May 22, 2001

AUXILIARY FUNCTIONS
9.7 FILE DIRECTORY, AUX 12
This function allows the operator to view the names of all the files contained on the PC
card. The file extensions identify the type of file, see table 9-2 for a description of file
extensions.
Figure 9-7 shows an example of the FILE DIRECTORY screen.
Figure 9-7 File Directory
May 22, 2001 9-15

AUXILIARY FUNCTIONS
9.8 PC CARD AUX. FUNCTION, AUX 14
This function allows the operator to format a PC card or delete files from a PC card.
When a PC card is formatted, any data on the PC card is deleted. When the PC card
formatting option is selected, the display prompts the operator to confirm the action. If
the file delete option is selected, the display prompts the operator to select files to delete
from a list of files on the PC card. Once a file is deleted from the PC card it is not recov-
erable.
Figure 9-8 shows the PC CARD AUX. FUNCTION screen.
Figure 9-8 PC Card Aux. Function
9-16 May 22, 2001

AUXILIARY FUNCTIONS
9.9 MANUAL WELD, AUX 35
This function allows the operator to perform a manual weld operation from the multi
function panel or type 2 teach pendant. When this function is selected, the operator
must specify the clamp conditions and weld schedule to be performed. After the clamp
conditions and weld schedule are specified, the clamp to perform the weld operation is
selected. When the clamp key is pressed the weld operation is performed.
! WARNING
When the clamp key is pressed, the weld process oc-
curs. Safety precautions must be observed to avoid
personal injury. Personnel must be knowledgeable re-
garding the welding process they are initiating.
Figure 9-9 shows the multi function panel or type 2 teach pendant screen when auxiliary
function 35, MANUAL WELD, is selected. From this screen, the weld schedules, clamp
conditions, and the clamp number that is actuated are selected.
AUX 35 MANUAL WELD T0
CL1 WS CC O/C
OFF 0 0 O MAN.SPEED
CL2 CC
OFF 0 INCHING
EXT.AXIS
OFF
S COORDINATE
JOINT
Figure 9-9 Manual Weld
May 22, 2001 9-17

AUXILIARY FUNCTIONS
9.10 ZEROING, AUX 41
Auxiliary function 41, ZEROING, is used to set the value of the encoder count to a zero
degree reference position. From this screen, the operator can choose to zero a single
joint or zero all joints.
The zeroing data set from function 41 is entered in conjunction with data recorded in
auxiliary function 140 to accomplish zeroing of the mechanical unit.
Figure 9-10 shows the display screen when function 41 is selected.
! CAUTION
Operators must be aware of the effect changes made in
this function have on the position of programmed loca-
tions. Changing this data without following the complete
zeroing process may move programmed locations to po-
sitions that cause damage to the robot, fixtures, or work.
9-18 May 22, 2001

AUXILIARY FUNCTIONS
The procedure for simple zeroing is as follows:
1. Jog all axes to zero, to algin the zeroing scribe marks.
2. Select auxiliary function 140, ENCODER ROT. COUNTER RESET, and enter the
joint number to zero. To zero all joints, “0” is entered for the joint number.
3. Set the zero position value from the auxiliary function 41, ZEROING screen, by
entering the joint number to zero. To zero all joints, “0” is entered for the joint num-
ber.
4. Confirm the new zero position by operating the robot in the check mode on a previ-
ously taught program to verify the playback accuracy of locations.
For further information about the zeroing process, reference the C Series Controller
Electrical Maintenance Manual, unit 8, Zeroing.
AUX 41 ZEROING
SETTING CURRENT
JT1 268422562 268422562
JT2 268437254 268437254
JT3 268421269 268421269
JT4 268433264 268433264
JT5 268427274 268427274
JT6 268428465 268428465
JOINT NO. = 0
(0 = all joint)
F1 F2 F3 F4
PRE DATA
Figure 9-10 Zeroing
May 22, 2001 9-19

AUXILIARY FUNCTIONS
9.11 POS. ERROR RANGE AT E-STOP, AUX 42
The POS. ERROR RANGE AT E-STOP function is used to set a comparison range for
checking the robot’s commanded position when an emergency stop is applied with the
position when motor power is reapplied.
If the difference between the robot’s position when motor power is reapplied and when
the emergency stop was pressed is greater than the set value, a position offset error is
displayed.
The position offset error generated from this function cannot be reset and motor power
cannot be applied. The error range must be reset to a value that does not cause an
error.
The purpose of this function is to prevent interference with fixtures, jigs, or work pieces
when the robot is restarted after an emergency stop condition.
The acceptable range of data for the position error range at emergency stop is from 0.1
degree to 10.0 degrees for axes one to six and from 0.1 mm to 100 mm for a seventh
axis. If 0 is entered the error check is not performed. The default setting for this function
is 0.
The POS. ERROR RANGE AT E-STOP function screen is shown in figure 9-11.
Figure 9-11 Position Error Range at E-Stop
9-20 May 22, 2001

AUXILIARY FUNCTIONS
9.12 ENCODER ERROR RANGE, AUX 43
This function sets the range of encoder deviation allowed before an error is displayed
upon applying power to the controller. The encoder value when control power is turned
off is compared to the encoder value when control power is turned on.
If the difference is larger than the range set, a JT encoder abnormality error is displayed.
The range of acceptable data for this function is from 0.1 degree to 10.0 degrees for
axes one to six and from 0.1 mm to 100 mm for a seventh axis. The default setting for
the ENCODER ERROR RANGE function is 2.0 degrees.
Operators should be aware that if this range is set too low, error messages may be
displayed when the system is performing within design performance specifications.
The display screen to set the values for the ENCODER ERROR RANGE function is
shown in figure 9-12.
The F1, PREV.DATA, key is used to restore the settings if the enter key has not been
pressed.
AUX 43 ENCODER ERROR RANGE
JT1 2.0deg
JT2 2.0deg
JT3 2.0deg
JT4 2.0deg
JT5 2.0deg
JT6 2.0deg
RANGE :Rotation 0.1deg -10.0deg

Linear 0.1mm - 100.0mm
F1 F2 F3 F4
PRE DATA
Figure 9-12 Encoder Error Range
May 22, 2001 9-21

AUXILIARY FUNCTIONS
9.13 ZEROING DATA SET/DISPLAY, AUX 44
The ZEROING DATA SET/DISPLAY function allows the operator to set encoder counts
and encoder offsets.
Figure 9-13 shows the ZEROING DATA SET/DISPLAY.
The first screen shows the current encoder reading and setting.
The second screen shows the offset of the encoders.
AUX 44 ZEROING DATA SET/DISPLAY AUX 44 ZEROING DATA SET/DISPLAY

SETTING CURRENT OFFSET
JT1 268427264 267427264 JT1 1

JT2 268427264 267427264 JT2 65539
JT3 268427264 267427264 JT3 63
JT4 268427264 267427264 JT4 31
JT5 268427264 267427264 JT5 65532
JT6 268427264 267427264 JT6 115
F1 F2 F3 F4 F1 F2 F3 F4
PRE DATA NEXT PG PRE DATA PRE PG
Figure 9-13 Zeroing Data Set/Display
9-22 May 22, 2001

AUXILIARY FUNCTIONS
9.14 INSTALLATION TYPE, AUX 46
This function allows the operator to define the mechanical unit’s configuration, such as
floor, wall, or ceiling installation as shown in figure 9-14.
AUX 46 INSTALLATION TYPE
INSTALLATION POSTURE 0
(0:FLOOR 1: CEILING 2: WALL 3: WALL2)
F1 F2 F3 F4
PRE DATA
Figure 9-14 Installation Type
May 22, 2001 9-23

AUXILIARY FUNCTIONS
9.15 BASE COORDINATE, AUX 47
This function allows the operator to redefine the base reference frame by effectively
shifting the base transformation values XYZ and OAT.
When the machine is first initialized the transformation values of the base coordinate
system are all set to a null or zero position. A null base has the transformation values
0,0,0,0,0,0.
The BASE COORDINATE function is used to change the base reference location.
Programmers must be aware of the impact shifting the base coordinate origin has on
program playback. Shifting the base coordinate origin results in the equivalent shift
occurring for all transformation locations stored in the controller memory.
Locations recorded as precision points are played back based on the joint angles of the
robot’s six axes and are not affected by a base coordinate shift.
The acceptable range for the base coordinate shift function is from -9999.9 mm to 1000
mm in the XYZ directions and from -180° to 180° for angles OAT.
The BASE COORDINATE function screen is shown in figure 9-15.
AUX 47 BASE COORDINATE
BASE COORDINATE SHIFT VALUE
X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg
F1 Rotation
RANG: F20.0deg - F3
10.0deg F4
Traverse 0.0mm - 100.0mm
PRE DATA
Figure 9-15 Base Coordinate
9-24 May 22, 2001

AUXILIARY FUNCTIONS
9.16 TOOL DIMENSIONS, AUX 48
This function allows the operator to record the unique tool dimensions and orientation.
Up to nine separate tools can be defined with this function. Tool dimensions specified
from this function are associated with the nine tools identified in block step programs.
Tool dimensions are expressed in XYZ tool coordinates in 0.1 mm increments and 0.1
degree increments for the OAT rotation axes.
Nine separate screens are available for this function, pressing the F3 key displays the
next available screen and the F2 key returns to the previous screen.
The weight of the tool and the load it carries can also be entered from the tool dimen-
sions screens. The F1 key can be used to restore previous tool dimensions and weight
information, if the enter key has not been pressed to record the new data.
Figure 9-16 shows the TOOL DIMENSIONS display screen for TOOL 1.
Figure 9-16 Tool Dimensions
May 22, 2001 9-25

AUXILIARY FUNCTIONS
9.17 SOFTWARE LIMIT, AUX 51
This function allows the operator to set the upper and lower limits of robot travel as
expressed in degrees of axes rotation. The robot cannot travel to locations that are
outside of these limits.
During jogging operations, an audible beep indicates the robot is approaching a soft-
ware limit. The frequency of the audible beep increases as the robot moves closer to
the limit. When the limit is reached, the robot stops moving in that direction and the
audible tone is constant, no error message is generated.
The robot can be jogged away from software limits by simply changing direction. If the
robot is moved with the brake release to a location beyond the software limits or the
software limits are changed, placing the robot outside the software limits, the operator
can jog back into the software limits envelope.
If the overtravel limit switch is engaged (JT1), the overtravel error recovery procedure
(see 9.17.1) must be used.
The SOFTWARE LIMIT display is shown in figure 9-17.
The allowable maximum and minimum settings are displayed along with the current
settings. Use the cursor keys and numeric keypad to change the settings. If data is
entered that is beyond the allowable settings, an out of range error occurs. The first
screen displayed shows the upper limits, the lower limits are displayed by pressing the
F3 NEXT PG key.
The operator must be aware that the minus sign for the lower limit settings is not as-
sumed and must be included when data for the lower limits is set.
AUX 51 SOFTWARE LIMIT AUX 51 SOFTWARE LIMIT

UPPER LOWER
F3
ð
SET ABLE UPPER SETTING SET ABLE LOWER SETTING
JT1 180.000deg 45.000deg NEXT PG

ð JT1 -180.000deg -45.000deg
JT2 70.000deg 70.000deg JT2 -65.000deg -65.000deg
F1 F2 F3 F4 F1 F2 F3 F4
PRE DATA NEXT PG PRE DATA PREV. PG
Figure 9-17 Software Limit
9-26 May 22, 2001

AUXILIARY FUNCTIONS
9.17.1 OVERTRAVEL ERROR RECOVERY
To recover from an overtravel error, the operator must press and hold the red override
switch located on the 1HP board and reset the error by pressing the ERROR RESET
switch on the operation panel or multi function panel or type 2 teach pendant.
With the override switch held, apply servo power and jog the robot off the limit switch.
An alternate method is to use the brake release switch for JT1 and manually move the
robot.
May 22, 2001 9-27

AUXILIARY FUNCTIONS
9.18 ACCURACY, AUX 53
When auxiliary function 53, ACCURACY, is selected from the auxiliary function menu,
the screen shown in figure 9-18 is displayed. From this screen, the operator sets the
four accuracies used in block step programming. The acceptable accuracy range for F-
series is from 0.1 mm to 5000 mm, for UT/UX-series from 0.5 mm to 5000 mm, for UZ/Z-
series from 0.3 mm to 5000 mm.
When the robot is in the repeat mode of operation, the playback accuracy is affected by:
• Distance between the taught points
• Speed
• Accel and decel parameters
• CP switch setting
• Timers and wait conditions
Default accuracy settings are shown in figure 9-18.
AUX 53 ACCURACY
ACCURACY1 1.0mm
ACCURACY2 10.0mm
ACCURACY3 50.0mm
ACCURACY4 100.0mm
F1 F2 F3 F4
PRE DATA
Figure 9-18 Accuracy
9-28 May 22, 2001

AUXILIARY FUNCTIONS
The auxiliary function incorporates Motion Type 1 (MT1) and Motion Type 2 (MT2) path
planning systems. Both of these systems blend two robot path segments to achieve
continuous path motion.
When a fine accuracy is used to reach a target point, maximum deceleration and accel-
eration are used to reach that point.
When a large accuracy is used, a continuous path motion is produced. The deceleration
of the current step and the acceleration of the next step creates a smooth transition from
one point to the next.
The MT1 path planning system determines the blending of multiple linear or joint inter-
polated segments based on the acceleration, deceleration, and the length of the
blended segments. Joint interpolated paths are planned using MT1.
MT2 was developed for the C controller to improve the repeat mode path accuracy and
repeatability. This is accomplished by blending two linear or circular segments based on
accuracy (Figure 9-19). MT2 path planning is valid only for Linear and Circular Interpo-
lation motions, generated by AS/Block instructions, i.e., LINEAR, C1MOVE, C2MOVE,
FLIN and HMOVE.
ACCURACY RANGE
100 mm
50 mm
25 mm
A
B
Figure 9-19 Motion Type 2 Path
May 22, 2001 9-29

AUXILIARY FUNCTIONS
Refer to figure 9-19 during the following explanation.
For Motion Type 2 the maximum allowable accuracy is determined by:
Maximum allowable accuracy, Amax = MIN (½ AB, ½ BC)
Where:
½ AB = Half the distance between point A and point B
½ BC = Half the distance between point B and point C
MIN = the minimum value of 2 real numbers
example : MIN(2, 3) = 2, MIN(8,5) = 5
Accuracy used is determined by:
Accuracy defined in the program = Aoperator and accuracy used by the software = Aused
IF Aoperator < Amax, THEN Aused = Aoperator

IF Aoperator > Amax THEN Aused = Amax
If a WAIT, SWAIT, TWAIT, TOOL or WORK instruction follows a motion instruction, MT2
is invalid and MT1 is used.
Example:
ACCURACY 25
LMOVE B
SWAIT 1001 ;The SWAIT instruction causes the software to ignore the 25 mm
;accuracy and decelerate to point B then resume motion to point C.
9-30 May 22, 2001

AUXILIARY FUNCTIONS
9.19 SPEED, AUX 54
When function 54, SPEED, is selected from the auxiliary function menu, the screen
shown in figure 9-19 is displayed. From this screen, the operator can set the ten speeds
that are used in block step programming. The acceptable speed range is from 0.1 to
100%.
For joint interpolated moves, the playback percentage speed is determined by the need
for all joints to reach total coincidence simultaneously.
For linear and circular interpolated moves, the playback percentage speed is deter-
mined by the maximum linear interpolation speed.
When the robot is in the repeat mode of operation the playback speed is a function of
both the step speed and the repeat condition speed. Refer to unit 11 for a description of
the optional DIRECT SPEED function.
Default speed settings are shown in figure 9-20.
Figure 9-20 Speed
May 22, 2001 9-31

AUXILIARY FUNCTIONS
9.20 SLOW REPEAT MODE, AUX 55
When function 55, SLOW REPEAT MODE, is selected from the auxiliary function menu,
the screen shown in figure 9-21 is displayed.
This function allows the operator to set the slow repeat mode speed of the robot from 1
to 25% of maximum speed.
A dedicated input signal must be assigned for the slow repeat mode function. When this
signal is ON, the SLOW REPEAT MODE of operation is activated.
Figure 9-21 Slow Repeat Mode
9-32 May 22, 2001

AUXILIARY FUNCTIONS
9.21 CHECK SPEED, AUX 56
The check speed function sets the three speeds available for single step program play-
back using the check forward and check backward keys in teach mode.
The check speed corresponds to the , , , indicators, representing speeds one,

two, and three and is set in millimeters per second.
The default check speed settings are shown in figure 9-22.
Figure 9-22 Check Speed
May 22, 2001 9-33

AUXILIARY FUNCTIONS
9.22 TEACH SPEED, AUX 57
The AUX 57 TEACH SPEED display screen is shown in figure 9-23.
The three jogging speeds and inching distances are set, from this screen.
The teach speed set from this function corresponds to the speed selected on the multi
function panel or type 2 teach pendant displayed by , , or , representing speeds
one, two and three. The teach speed function can be set up to a maximum of 250.0
mm/sec.
The maximum allowable teach speed is defined by ANSI/RIA standards.
The inching distances set from this function correspond to the inching selection on the
multi function panel or type 2 teach pendant, displayed by , , or representing
distances one, two, and three.
The maximum inching distance allowable is 1.000 mm.
AUX 57 TEACH SPEED
MANU.SP INCHING
SPEED. 1 10.0mm/s 0.016mm

SPEED. 2 80.0mm/s 0.500mm
SPEED 3 250.0mm/s 1.000mm
F1 F2 F3 F4
PRE DATA
Figure 9-23 Teach Speed
9-34 May 22, 2001

AUXILIARY FUNCTIONS
9.23 TIMER, AUX 58
The TIMER function allows the operator to set nine timers for use in block step program-
ming. The timers can range from 0.1 second to 99.9 seconds. Timers begin timing out
when the robot reaches the accuracy range of the taught point.
Figure 9-24 shows the TIMER function screen and default settings.
Figure 9-24 Timer Settings
9.24 MEMORY AVAILABLE, AUX 70
This function is used to display the amount of memory available for programming. The
available memory is displayed in both bytes and percentage of usable memory.
Figure 9-25 shows the MEMORY AVAILABLE display.
Figure 9-25 Memory Available
May 22, 2001 9-35

AUXILIARY FUNCTIONS
9.25 RECORD DATA (PRG CHG) INHIBIT, AUX 71
The RECORD DATA function allows the operator to prevent the recording of block step
program data by selecting INHIBIT for record.
AS Language programs cannot be edited if the PRG CHANGE is set to INHIBIT.
If an attempt to change data is made, an error message is displayed. The error mes-
sage instructs the programmer to set the respective switch to the ACCEPT status.
The RECORD DATA (PRG CHG) INHIBIT display screen is shown in figure 9-26.
Figure 9-26 Record Data Inhibit
9-36 May 22, 2001

AUXILIARY FUNCTIONS
9.26 SPRAY ON/OFF, AUX 73
This function enables, or disables, trigger signals for a painting or sealing operation.
The operator has the option to select spray on or spray off, depending on the robot
application.
Figure 9-27 shows the display screen for function 73, SPRAY ON/OFF.
Figure 9-27 Spray On/Off
May 22, 2001 9-37

AUXILIARY FUNCTIONS
9.27 SYSTEM SWITCH, AUX 75
The SYSTEM SWITCH function allows the operator to turn software switches on and off
to alter functions of the robot system. It is important to realize that any changes made
to the status of these switches are global and affect all programs in the system memory.
The type 2 teach pendant includes an EXPLAIN key. When the EXPLAIN key is
pressed, a description of the selected system switch is displayed at the bottom of the
screen.
The AUX 75 SYSTEM SWITCH display screens are shown in figure 9-28.
The F3 NEXT PG key is used to display the remaining switches.
Figure 9-28 System Switches
9-38 May 22, 2001

AUXILIARY FUNCTIONS
Table 9-3 shows the default settings for the system switches. When the system is initial-
ized, all switches are reset as shown in table 9-3.
Table 9-3 System Switches Default Settings
Switch Setting
CHECK.HOLD OFF
CP ON
CYCLE.STOP OFF
OX.PREOUT ON
PREFETCH.SIGINS OFF
QTOOL ON
REP_ONCE OFF
RPS OFF
STP_ONCE OFF
AFTER.WAIT.TIMER OFF
SPOT_OP OFF
MESSSAGES ON
SCREEN ON
AUTOSTART.PC OFF
AUTOSTART2.PC OFF
AUTOSTART3.PC OFF
ERRSTART.PC OFF
DISPIO_01 OFF
HOLD.STEP OFF
WS_COMP OFF OFF
WS.ZERO OFF
PLC.CHECK OFF
FLOWRATE OFF
May 22, 2001 9-39

AUXILIARY FUNCTIONS
9.27.1 CHECK.HOLD SWITCH
This function affects the AS Language commands EXECUTE, DO, STEP MSTEP and
CONTINUE. When the CHECK.HOLD switch is ON these commands are available only
if the HOLD/RUN switch is in the HOLD position.
The controller accepts these commands with the HOLD/RUN switch in the HOLD posi-
tion, but robot motion is not initiated until the switch is manually placed in the RUN
position.
The default setting for this switch is OFF.
9.27.2 CP (CONTINUOUS PATH) SWITCH
The CP switch activates the continuous path function. When the CP switch is ON and
the accuracy ranges are large enough, the robot makes smooth transitions from
point-to-point, as indicated in figure 9-29.
When the switch is OFF, the robot decelerates and stops at each recorded point regard-
less of the accuracy of those points.
The default setting for this switch is ON.
Robot path with CP ON

Robot path with CP OFF
TAUGHT POSITION
ACCURACY RANGE
Figure 9-29 CP Switch
9-40 May 22, 2001

AUXILIARY FUNCTIONS
9.27.3 CYCLE.STOP SWITCH
The CYCLE.STOP switch is used in conjunction with an external input signal used to
stop the motion of the robot.
With the switch ON, when the input signal is received the robot stops and the CYCLE
START light turns off. When the program is started again it starts at the beginning. If
the program was called from another program, the program restarts at the beginning of
the main program.
With the switch OFF, when the input signal is received the robot stops and the CYCLE
START light remains ON. The robot is in a hold condition and, when the program is
restarted, it continues at the point in the cycle where it stopped.
May 22, 2001 9-41

AUXILIARY FUNCTIONS
9.27.4 OX.PREOUT SWITCH
The OX.PREOUT switch affects the timing of output signal generation in block step
programs.
When the switch is ON, an output programmed for a given point is turned on as soon as
the robot begins motion to that point.
With the OX.PREOUT switch OFF, an output programmed for a given point is turned on
at the accuracy range of the point.
Figure 9-30 shows the different effects the OX.PREOUT switch has on signal timing.
Clamp signals are not affected by the setting of the switch.
Figure 9-30 OX.PREOUT Switch
9-42 May 22, 2001

AUXILIARY FUNCTIONS
9.27.5 PREFETCH.SIGINS SWITCH
The PREFETCH.SIGINS switch is used in conjunction with AS Language instructions

and has the same affect on signal timing that the OX.PREOUT switch has with block
step instructions.
9.27.6 QTOOL SWITCH
This switch allows the operator to identify tools to use in block step or AS Language
programming.
When the QTOOL switch is ON, the programmer has up to nine tools available to use for
programming and jogging. The unique tool dimensions are recorded and assigned a
tool number using auxiliary function number 48.
When the QTOOL switch is ON, the selected tool dimensions are in effect for jogging
and linear playback of block step programs.
When the QTOOL switch is OFF, the tool identified with AS Language instructions is
utilized.
9.27.7 REP_ONCE (REPEAT ONCE) SWITCH
When the REP_ONCE switch is ON, programs run one time.
With the switch OFF, programs run continuously.
9.27.8 RPS (RANDOM PROGRAM SELECTION) SWITCH
This switch enables the processor to scan for a binary input from peripheral devices and
select which program is executed.
The AS Language instructions EXTCALL, JUMP and END combined with the input
signal and RPS function determine which program runs.
The default setting for this switch OFF.
May 22, 2001 9-43

AUXILIARY FUNCTIONS
9.27.9 STP_ONCE (STEP ONCE) SWITCH
When the STP_ONCE switch is ON, the repeat condition function of progressing
through a program one step at a time becomes active.
The step forward key must be used to progress through a program. When the switch is
OFF, programs run continuously.
9.27.10 AFTER.WAIT.TIMER SWITCH
When the AFTER.WAIT.TIMER switch is in the ON position, timers begin their timing at
a specified step when all wait conditions are satisfied.
With the switch in the OFF position, timers begin timing when the robot reaches coinci-
dence of the taught point.
9.27.11 SPOT_OP
This switch allows the robot controller to monitor the time between weld initiate and weld
tip closed and adjust the weld initiate signal timing to optimize the program.
9.27.12 MESSAGES SWITCH
The MESSAGES switch allows PRINT and TYPE information, which is part of programs,
to be displayed for operator viewing. If the MESSAGES switch is OFF this information is
not displayed.
9.27.13 SCREEN SWITCH
This switch enables or disables the scrolling of the screen when the amount of informa-
tion being sent by the processor is larger than the screen can display.
With this switch ON, information is scrolled on the screen using the NEXT PG (next
page) and PRE PG (previous page) keys.
The default setting for this switch is ON
9-44 May 22, 2001

AUXILIARY FUNCTIONS
9.27.14 AUTOSTART.PC SWITCHES
The AUTOSTART.PC, AUTOSTART2.PC, AND AUTOSTART3.PC switches automati-

cally start the associated PC program when control power is applied. For information on
PC programs see the C Series Controller AS Language Reference Manual.
The default setting for these switches is OFF.
9.27.15 ERRSTART.PC SWITCH
When operator specified errors occur a PC program can be started if the

ERRSTART.PC switch is in the ON position.
The default setting for this switch OFF.
9.27.16 DISPIO_01 SWITCH
This switch allows the operator to select the type of display used to view the status of
input and output signals.
If the switch is ON, 1s and 0s are displayed to identify the signal state of individual
signals. A 1 represents a signal that is on, and a 0 represents a signal that is off.
If the switch is OFF, xs and os are used to represent the signal states. An o represents
a signal that is ON, and an x represents a signal that is OFF.
The X and O display also identifies if a signal number has a dedicated function. Dedi-
cated signals are represented by uppercase Xs and Os.
9.27.17 HOLD.STEP
When this switch is ON and the HOLD/RUN switch is placed in the HOLD position, the
current logic or motion step is displayed.
When the switch is OFF and the HOLD/RUN switch is placed in the HOLD position, the
last motion step executed is displayed.
May 22, 2001 9-45

AUXILIARY FUNCTIONS
9.27.18 WS_COMPOFF
When this switch is ON, the WS bits are set low after they are sent rather than when the
robot is at the next step of the program.
9.27.19 WS.ZERO
When this switch is ON and weld schedule 0 is selected, the controller waits for the weld
complete signal before continuing robot motion.
When this switch is OFF and weld schedule 0 is selected the controller does not wait for
the weld complete signal.
9.27.20 PLC.CHECK
This function enables the 1GA board’s CPU and the Sharp Sequencer Board CPU
watchdog communication. Watchdog communication is an error checking function.
9.27.21 FLOWRATE
This switch is available with sealing software only.
With sealing software installed and the FLOWRATE switch ON, data in AUX 65 is used
to control sealer dispensing.
With this switch OFF, data defined using the AS Language command SETOUTSPEED
is used.
9-46 May 22, 2001

AUXILIARY FUNCTIONS
9.28 HOME POSITION, AUX 76
The HOME POSITION function allows the operator to set two home positions for the
robot. These home positions can be set to any location within the work envelope.
Home positions have two unique characteristics. A dedicated output signal can be
assigned to each of the home positions so that whenever the robot is within the range
set for that position the signal is generated.
Home positions are also recognized in a unique way in AS Language commands, the
only code needed to send the robot to the home position is the statement “HOME”.
When this instruction is encountered, the robot performs a joint move to the home
position. A second home position is identified by the designation HOME2 and is set
from the second screen of function 76.
Figure 9-31 shows the screen to set HOME POSITION 1. From this screen the operator
can choose to enter the desired home position as expressed in joint angles or the cur-
rent position of the robot.
To enter a HOME position other than the current position, use the cursor keys to high-
light KEY-IN and move to the desired joint number. Enter the desired number of de-
grees for each joint and press ENTER when completed.
The range for the home position is also set from this screen. When the robot reaches a
point within the specified range, the output signal is generated.
The recommended minimum setting for the home position range is between 5 mm and
10 mm to ensure the home position output is generated.
Figure 9-31 Home Position
May 22, 2001 9-47

AUXILIARY FUNCTIONS
9.29 CLEAR CHECK SUM ERROR, AUX 78
The CLEAR CHECK SUM ERROR function allows the operator to clear error 1019,
abnormal check sum.
An abnormal check sum error is generated when the processor calculates a difference
between data when the controller is powered up compared to data in memory.
When this error occurs select AUX 78, and change the setting to “EFFECT” as shown
figure 9-32.
When control power is cycled, the error may be cleared and the setting returned to
“INEFFECT”.
If the clear check sum error does not clear with the cycling of control power, the second
screen shown in figure 9-32 is displayed identifying additional troubleshooting paths.
Figure 9-32 Clear Check Sum Error
9-48 May 22, 2001

AUXILIARY FUNCTIONS
9.30 PROGRAM PARAMETER/COMMENT, AUX 87
The PROGRAM PARAMETER/COMMENT function is activated in AUX 96 ENVIRON-

MENT DATA OF PANEL and allows the operator to add a comment to a program name.
When the parameter/comment function is activated in AUX 96, it is displayed in the
auxiliary function menu.
To use the PROGRAM PARAMETER/COMMENT function, follow the procedure below.
1. Select auxiliary function 87 from the auxiliary function menu.
2. Use the cursor keys to select the desired program and press the RETURN key. The
character set keyboard is displayed.
3. At the character set keyboard enter a semicolon followed by the desired comment
(up to nineteen characters) and press ENTER.
4. Repeat steps 2 and 3 to add comments to another program name or press EXIT to
return to the auxiliary function screen.
Figure 9-33 shows the PROGRAM PARAMETER/COMMENT display screen after a

comment is entered.
AUX 87 PROGRAM ARGUMENT / COMMENT

pg??
test [Accuracy test prog.]
test
F1 F2 F3 F4
Figure 9-33 Program Parameter/Comment
May 22, 2001 9-49

AUXILIARY FUNCTIONS
9.31 CHANGE PROGRAM NAME, AUX 88
AUX 88, CHANGE PROGRAM NAME, allows the operator to change the names of
existing programs. To change the name of a program, select AUX 88 from the function
screen. The CHANGE PROGRAM NAME screen is displayed as shown in figure 9-34.
Use the following procedure to change the name of a program.
1. Press the F1 PROGRAM INPUT key and the PROGRAM SELECT screen is dis-
played
2. Scroll to the program name to change and press ENTER.
3. The CHANGE PROGRAM NAME screen is displayed with the name of the program
selected.
4. Use the down cursor key to select the new program name line.
5. Press the F1 PROGRAM INPUT key and the PROGRAM SELECT screen is dis-
played with “pg” at the bottom of the window.
6. Press the F4 CHARACTER key.
7. Enter the new program name and press ENTER.
8. The PROGRAM SELECT screen is displayed with the new name at the bottom of
the window.
9. Press ENTER. The CHANGE PROGRAM NAME screen is displayed with the old
and the new name.
10. Press ENTER again and the prompt “Are you sure?” is displayed.
11. Press the YES key to complete the procedure.
9-50 May 22, 2001

AUXILIARY FUNCTIONS
AUX 88 CHANGE PROGRAM NAME PROGRAM SELECT

pg??
Old program name pg00 test
pg02 pg01
F1
ï ï pg04
pg08
pg07
ï ï
PROGRAM
New program name INPUT
F1 F2 F3 F4 F1 F2 F3 F4
PROGRAM PROGRAM NEXT CHARACTER
INPUT INPUT PG
AUX 88 CHANGE PROGRAM NAME

PROGRAM SELECT
pg??
Old program name test pg00 test
pg02 pg01
F1 F4
ï ï pg04
pg08
pg07 ï ï
PROGRAM CHARACTER
New program name
INPUT
F1 F2 F3 F4 test
F1 F2 F3 F4
PROGRAM
INPUT PROGRAM NEXT CHARACTER
INPUT PG
Figure 9-34 Change Program Name
May 22, 2001 9-51

AUXILIARY FUNCTIONS
9.32 SOFTWARE VERSION DISPLAY, AUX 90
This function displays the version of software that is operating in the controller and multi
function panel or type 2 teach pendant.
Figure 9-35 shows the screen displayed when auxiliary function 90 is selected.
AUX 90 SOFTWARE VERSION DISPLAY
AS
Robot Name : Js005-E001 Num of AXES 6 Serial Num. 1
Software Version : version 000006106...97/05/15 14:05
Servo : SAOAON-UX120-07 1997.01.27
Number of signals : input=32 output=32 internal=256
Clamp number : 2
TP
Software version : version T00006106...97/05/20 03:43
F1 F2 F3 F4 F5 F6
EXIT
Figure 9-35 Software Version Display
9-52 May 22, 2001

AUXILIARY FUNCTIONS
9.33 ENVIRONMENT DATA, AUX 91
The ENVIRONMENT DATA function is used to set an auto servo timer and identify if the
controller is operating with a teach pendant or multi function panel installed.
The AUTO SERVO OFF TIMER sets a time period that motor power remains ON if no
movement of the robot has occurred. The auto servo off timer function is designed to
save energy by allowing the brakes to maintain robot position as opposed to using
electrical power and servo motors.
When the robot has not moved and the auto servo off timer has reached its set value,
the brakes are applied and power is removed from the servo motors. The motor power
light remains ON and the robot begins motion under the same conditions as if the auto
off servo timer did not remove power from the motors.
The ENVIRONMENT DATA function also allows the operator to identify if a teach pen-
dant is installed. The enabling devices and the emergency stop button are hard-wired
and a jumper (or a different operator interface) must be installed if the teach pendant is
removed.
Figure 9-36 shows the screen that is displayed when auxiliary function 91 is selected.
AUX 91 ENVIRONMENT DATA
AUTO SERVO OFF TIMER 0 sec

(0: Not servo off)
TEACH PENDANT CONN./DISCONN.
F1 F2 F3 F4
PREV.DATA
Figure 9-36 Environment Data
May 22, 2001 9-53

AUXILIARY FUNCTIONS
9.34 ENVIRONMENT DATA2, AUX 95
The ENVIRONMENT DATA2 function allows the operator to identify if a multi function
panel or terminal is installed. The deadman buttons and the emergency stop buttons of
the multi function panel are hard-wired and a jumper (or a different operator interface)
must be installed if the multi function panel is removed.
Figure 9-37 shows the ENVIRONMENT DATA2 screen.
AUX 95 ENVIRONMENT DATA2
PANEL CONN./DISCONN.
TERMINAL CONN./DISCONN.
F1 F2 F3 F4
PREV.DATA
Figure 9-37 Environment Data 2
9-54 May 22, 2001

AUXILIARY FUNCTIONS
9.35 ENVIRONMENT DATA OF PANEL, AUX 96
9.35.1 ENVIRONMENT DATA OF PANEL, AUX 96, MULTI FUNCTION PANEL
The AS INSTRUCTION POS. TEACHING, KEYBOARD, PROGRAM EDIT, AS IN-

STRUCTION TEACHING, CHECK MODE, and 2 PUSH RECORD MODE menu items
from this function affect the menus available from the teaching screens of the multi
function panel (see section 9.35.2 for the type 2 teach pendant).
If “ON” is selected for these items, they are available when the teaching key is pressed.
If “OFF” is selected, pressing the teaching key does not display the associated function
and screen.
In the 2 PUSH RECORD MODE, the RECORD key only records a step if the (S) SHIFT
key is held down simultaneously with the RECORD key.
If the TEACH NEW/OVERWRITE key is pressed and a different mode is selected from
the drop down menu (AUX REWRITE, POS REWRITE, INSERT, DELETE, or OVER-
WRITE/NEW) the 2 PUSH RECORD must be used if enabled.
Figure 9-38 shows the ENVIRONMENT DATA OF PANEL screen for the multi function
panel (see figure 9-39 for the type 2 teach pendant).
Figure 9-38 Environment Data of Panel, Multi Function Panel
May 22, 2001 9-55

AUXILIARY FUNCTIONS
9.35.2 ENVIRONMENT DATA OF PANEL, AUX 96, TYPE 2 TEACH PENDANT
The BLOCK TEACHING, AS INSTRUCTION POS. TEACHING, KEYBOARD, PRO-

GRAM EDIT, AS INSTRUCTION TEACHING, CHECK MODE, PROGRAM COMMENT,
and 2 PUSH RECORD MODE menu items from this function affect the menus available
from the teaching screens of the type 2 teach pendant.
If “ON” is selected for these items, they are available when the teaching key is pressed.
If “OFF” is selected, pressing the teaching key does not display the associated function
and screen.
Program comment activates auxiliary function 87 when ON is selected (see section

9.30).
In the 2 PUSH RECORD MODE, the RECORD key only records a step if the ENA
(enable) key is held down simultaneously with the RECORD key.
If the TEACH NEW/OVERWRITE key is pressed and a different mode is selected from
the drop down menu (AUX REWRITE, POS REWRITE, INSERT, DELETE, or OVER-
WRITE/NEW) the 2 PUSH RECORD must be used if enabled.
The type 2 teach pendant includes a function for 2 PUSH RECORD MODE for the
record key below the touch panel (Aux 96 page 2). This 2 PUSH RECORD MODE
operates in the same manor as the touch screen RECORD key.
Figure 9-39 shows the ENVIRONMENT DATA OF PANEL screens for the type 2 teach
pendant.
AUX 96 ENVIRONMENT DATA OF PANEL AUX 96 ENVIRONMENT DATA OF PANEL
AS INSTRUCTION POS. TEACHING ON/OFF PROGRAM COMMENT ON/OFF

KEYBOARD ON/OFF 2 PUSH RECORD MODE ON/OFF
PROGRAM EDIT ON.OFF (HARD KEY)
AS INSTRUCTION TEACHING ON/OFF
CHECK MODE ON/OFF
2 PUSH RECORD MODE ON/OFF
(TOUCH PANEL)
BLOCK TEACHING ON/OFF
F1 F2 F3 F4 F1 F2 F3 F4
Page 1 Page 2
Figure 9-39 Environment Data of Panel, Type 2 Teach Pendant
9-56 May 22, 2001

AUXILIARY FUNCTIONS
9.36 CHECK SPEC. (CHECK SPECIFICATION), AUX 99
The CHECK SPEC. function is used to select certain AS Language instructions used
when programs are run in the check mode. The following commands are set as EF-
FECT (on), or INEFFECT (off), during check mode operation: CALL, TIMER, JUMP/
END, OX, WX and CLAMP. If INEFFECT is selected for any of these commands, when
a program is executed using the check mode, the command is not processed as a
program instruction and is bypassed.
During check mode operation in reverse program order, only the CLAMP and OX in-
structions are dependent on the settings of auxiliary function 91. The AS Language
instructions CALL, TIMER, JUMP/END, and WX are not processed during reverse order
check mode operation.
Figure 9-40 shows the auxiliary function 99, CHECK SPEC. screen.
Figure 9-40 Check Spec. Screen
May 22, 2001 9-57

AUXILIARY FUNCTIONS
9.37 SYSTEM INIT. (SYSTEM INITIALIZATION), AUX 100
The SYSTEM INIT. function is used to clear everything from the system memory and
reset all default settings. When the system is initialized, all programs, variable data,
system switches, and system settings are deleted or returned to default settings. The
only data not affected by the initialization process is the error and operation logs.
Figure 9-41 shows the screen displayed when function 100, SYSTEM INIT. is selected.
! CAUTION
Initializing the system erases all program and variable
data and reset system data to default settings. If a PC
is connected to the controller and the initialization func-
tion is selected, care must be taken not to initialize the
hard drive of the PC.
ENTER is selected to activate initialization of the system from this screen. If the system
is not to be initialized, EXIT is selected returning the screen to the first auxiliary function
screen.
AUX 100 SYSTEM INIT.

**************
* WARNING *
**************
If this function is performed, all

data in memory will be deleted.
And all system switches will be
reset to default setttings.
OK to initialize? (ENTER/EXIT)
F1 F2 F3 F4
Figure 9-41 System Initialization
9-58 May 22, 2001

AUXILIARY FUNCTIONS
9.38 BATTERY ERROR CHECK, AUX 101
If EFFECT is selected from this function, when control power is applied, the batteries
that maintain RAM memory are checked for low voltage. If a low voltage is detected, an
error message is displayed. If INEFFECT is selected from this function, the batteries
are not checked when control power is applied.
Figure 9-42 shows the screen for the battery error check.
Figure 9-42 Battery Error Check
May 22, 2001 9-59

AUXILIARY FUNCTIONS
9.39 TOUCH PANEL SHORT CIRCUIT CHECK, AUX 103
If EFFECT is selected from this function, at controller power-up, an error is generated if

there is a short circuit (closed contact) on the multi function panel or type 2 teach pen-
dant touch screen. The same error occurs if the operator presses any area of the multi
function panel or type 2 teach pendant touch screen during controller power-up.
Figure 9-43 shows the TOUCH PANEL SHORT CKT. CHECK function screen.
Figure 9-43 Touch Panel Short Circuit Check
9-60 May 22, 2001

AUXILIARY FUNCTIONS
9.40 TIME, AUX 110
The TIME function is used to set the current year, month, day, and time. The controller
automatically displays the day of the week based on the date information. The cursor
keys are used to select the data field to be modified.
Error and operations logs are date and time stamped based on the information from this
function.
Figure 9-44 shows the TIME function screen.
AUX 110 TIME
DATE : 97-5-20 (TUE)
TIME : 10:59:46
F1 F2 F3 F4
Figure 9-44 Time
May 22, 2001 9-61

AUXILIARY FUNCTIONS
9.41 DEDICATED INPUT SIGNAL, AUX 111
The DEDICATED INPUT SIGNAL function allows the operator to identify signal numbers
that are assigned specific functions and cannot be used for other purposes.
Figure 9-45 shows the screens used to set dedicated input signals.
Figure 9-45 Dedicated Input Signal
9-62 May 22, 2001

AUXILIARY FUNCTIONS
9.42 DEDICATED OUTPUT SIGNAL, AUX 112
The DEDICATED OUTPUT SIGNAL function allows the operator to identify signal num-
bers that are assigned specific functions and cannot be used for other purposes.
Figure 9-46 shows the screens used to set dedicated output signals.
AUX 112 DEDICATED OUTPUT SIGNAL AUX 112 DEDICATED OUTPUT SIGNAL
MOTOR_ON SET/RESET
SIGNAL NUMBER: 32 TEACH_MODE SET/RESET
ERROR SET/RESET SIGNAL NUMBER: 0
SIGNAL NUMBER: 31
F3 HOME1 SET/RESET
AUTOMATIC SET/RESET
ï ï SIGNAL NUMBER: 0
SIGNAL NUMBER: 30 NEXT PG HOME2 SET/RESET
Run in panel switch SET/RESET SIGNAL NUMBER: 0
EXT_IT not set to hold SET/RESET POWER_ON SET/RESET
Repeat in panel switch SET/RESET SIGNAL NUMBER: 0
Repeat continuous SET/RESET RGSO SET/RESET
SIGNAL NUMBER: 0
Ext. Program select (RPS) enabled
F2
ï ï SET/RESET
SIGNAL NUMBER: 0
PREV.PG
F1 F2 F3 F4 F1 F2 F3 F4
PREV.DATA NEXT PG PREV.DATA PREV.PG
Figure 9-46 Dedicated Output Signal
May 22, 2001 9-63

AUXILIARY FUNCTIONS
9.43 DEDICATED SIGNAL DISPLAY, AUX 113
The DEDICATED SIGNAL DISPLAY, function 113, is a screen where the settings of
both dedicated input and output signals can be viewed. This function is used to review
the status of the dedicated signals and cannot be used to set or release dedicated
signals.
Figure 9-47 shows the auxiliary function 113 display screens.
AUX 113 DEDICATED SIGNAL DISPLAY
Dedicated signal set at present

EXT. MOTOR ON=1032
EXT. ERROR RESET=1031
EXT. CYCLE START=1030
MOTOR ON=32
ERROR=31
AUTOMATIC=30
Condition: Run in panel switch.
Condition: Repeat in panel switch.
Condition: Repeat continuous.
Condition: Step continuous.
F1 F2 F3 F4 F5 F6
NEXT PG EXIT
ï
F3
ï
NEXT PG
F2
PREV.PG
ï
ï
AUX 113 DEDICATED SIGNAL DISPLAY
CYCLE_START=29
TEACH_MODE=28
HOME1=27
F1 F2 F3 F4 F5 F6
PREV.PG
EXIT
Figure 9-47 Dedicated Signal Display
9-64 May 22, 2001

AUXILIARY FUNCTIONS
9.44 CLAMP SPECIFICATION, AUX 114
Auxiliary function 114, CLAMP SPECIFICATION, displays a menu screen where infor-
mation for up to eight available clamps is entered. From this screen additional menu
screens can be accessed to define specific types of clamps, clamp conditions, and
clamp definitions.
Figure 9-48 shows the first screen of auxiliary function 114.
AUX 114 CLAMP SPECIFICATION
1 CLAMP APPLICATION
2 CLAMP CONDITION
10 SPOT WELD CLAMP DEFINITION
11 SPOT WELD CONTROL DEFINE
12 SPOT WELD GUN DEFINITION
20 HANDLING CLAMP DEFINITION
FUNCTION NUMBER:
F1 F2 F3 F4
Figure 9-48 Clamp Specification
The flow chart on the following page illustrates the process of setting up a spot welding
clamp or material handling clamp.
May 22, 2001 9-65

AUXILIARY FUNCTIONS
START
114-1 CLAMP APPLICATION

TYPE
114-2 CLAMP CONDITION(CC)

DEFINITION
For spot welding For material handling
Modify if application application
necessary
114-10 SPOT WELD

CLAMP DEFINITION
.
114-11 SPOT WELD

CONTROL DEFINITION
114-12 SPOT WELD GUN

DEFINITION 114-20 HANDLING
CLAMP DEFINITION
Teach program
Check content of
program
Production operation
End
Figure 9-49 Clamp Setting Flowchart
9-66 May 22, 2001

AUXILIARY FUNCTIONS
The following diagram shows the input and output signals associated with the welding
process. These signals are identified in the sub menus of auxiliary function 114,
CLAMP SPECIFICATION.
Weld schedule
(six bits or less)
Weld initiate
Weld
Weld completed
Controller
Weld fault
Reset weld fault

Robot
Controller
Weld gun clamp
Stroke change.
(Single solenoid/double solenoid)
Retractable gun retract detection
Retractable gun extend detection
Figure 9-50 Weld Process I/O
May 22, 2001 9-67

AUXILIARY FUNCTIONS
9.44.1 CLAMP APPLICATION
When option one is selected from the CLAMP SPECIFICATION menu, the CLAMP
APPLICATION screen shown in figure 9-51 is displayed. From this screen, up to eight
clamps are identified as spot welding or material handling. For each of the eight clamps
a number 1 is used to define a spot welding application, a 2 is used to define a material
handling application, and a 0 is entered if the clamp is not used.

1 CLAMP APPLICATION
APPLICATION
CLAMP1 1
CLAMP2 2
CLAMP3 0
CLAMP4 0
CLAMP5 0
CLAMP6 0
CLAMP7 0
CLAMP8 0
0 : Not used, 1 : Spot weld, 2 : Handling

F1 F2 F3 F4
PRE DATA
Figure 9-51 Clamp Application
If a spot welding clamp is identified, additional specifications must be defined from

selections 2, 10, 11, and 12 from the first function 114 menu screen. Figure 9-52 shows
the CLAMP SPECIFICATIONS screen. If a handling clamp is identified, additional
specifications must be defined from selection 20 in the AUX 114 menu screen.
1 CLAMP APPLICATION
2 CLAMP CONDITION
10 SPOT WELD CLAMP DEFINITION
11 SPOT WELD CONTROL DEFINE
20 HANDLING CLAMP DEFINITION
FUNCTION NUMBER:
F1 F2 F3 F4
Figure 9-52 Clamp Specification
9-68 May 22, 2001

AUXILIARY FUNCTIONS
9.44.2 CLAMP CONDITION
Figure 9-53 shows the CLAMP CONDITION screen that is displayed when number 2 is
selected from the CLAMP SPECIFICATION menu. Pressing the F3 key displays the
same screen for clamp conditions 2 through 9. Pressing the F2 key returns the display
to the previous clamp conditions number.

2 CLAMP CONDITION
CODE 1
ANTICIPATION OF CLAMP 0.00s
MOTION START DELAY AFTER WELD 0.30s
GUN NO. 1
(0:Controlled by clamp subroutine)
CLAMP SUBROUTINE number pg.90
(Valid only when gun No.=0)
GUN CLOSING TIME 0.00S
GUN CLAMP COMPLETE DELAY 0.00S
WELD DELAY TIME 0.00S
F1 F2 F3 F4
PRE DATA NEXT PG
Figure 9-53 Clamp Condition
• ANTICIPATION OF CLAMP specifies when clamping pressurization begins before

the clamp reaches coincidence with the taught location. The default setting for the
anticipation of clamp is 0.00 seconds. The acceptable range for the anticipation of
clamp is between 0.00 and 0.99 seconds.
• MOTION START DELAY AFTER WELD specifies how long the weld clamp remains
in position after the weld complete signal is received. The default setting for the
motion start delay after weld is 0.30 seconds. The acceptable range for the motion
start delay after weld setting is from 0.00 to 0.99 seconds.
• GUN NO. (NUMBER) specifies the weld parameters that are used when a specific
gun is used. When 0 is entered for the gun number, the weld parameters are con-
trolled by a clamp subroutine. When a number between 1 and 8 is entered, the
welding parameters identified in auxiliary function 114, menu selection number 12,
are used.
If 0 is entered for the gun number, a clamp subroutine must be specified. The clamp
subroutine is an individual AS Language program that sets the parameters for the spot
welding process. The clamp subroutine begins executing the weld control process after
the signal to pressurize the clamp is generated. The acceptable range for clamp sub-
routine numbers is from 00 to 99. Only programs with numerical program names in this
range are acceptable as clamp subroutines.
May 22, 2001 9-69

AUXILIARY FUNCTIONS
9.44.3 SPOT WELD CLAMP DEFINITION
Figure 9-54 shows the screen that is displayed when number 10 is selected from the
CLAMP SPECIFICATION menu. Pressing the F3 key displays the same screen for
setting the clamp definitions for clamps 2 through 8. Pressing the F2 key returns the
display to the previous clamp number.
Figure 9-54 Spot Weld Clamp Definition
• WELD CONTROL NUMBER is used to identify one of eight possible weld control-
lers to control the weld process. The acceptable entries for this function are from
one to eight. The data set in auxiliary function 114, menu selection 11, spot weld
control defines how each weld controller interfaces with the controller to perform the
weld process.
• GUN CLAMP COMMAND OUTPUT identifies the signal number that is output when
a weld clamp command has been completed. When 0 is entered the clamp com-
mand output is processed as not used.
• EXTEND OUTPUT SIGNAL is used in conjunction with retractable weld clamps.

The signal number set in this function is an output that extends the clamp. When 0
is entered, the extend output signal is not used.
• RETRACT OUTPUT SIGNAL is used in conjunction with retractable weld clamps.

The signal number set in this function is an output that retracts the clamp. When 0
is entered, the retract output signal is not used.
9-70 May 22, 2001

AUXILIARY FUNCTIONS
• RETRACT POS. INPUT SIGNAL is used in conjunction with retractable weld

clamps. The RETRACT POS. INPUT SIGNAL is generated when the retractable
gun is returned to the retracted position. When 0 is entered, the retract position
input signal is not used.
• EXTEND POS. INPUT SIGNAL is used in conjunction with retractable weld clamps.
The EXTEND POS. INPUT SIGNAL is generated when the retractable gun has
returned to the extended position. When 0 is entered, the extend position input
signal is not used.
9.44.4 SPOT WELD CONTROL
Figure 9-55 shows the SPOT WELD CONTROL screen that is displayed when number
11 is selected from the CLAMP SPECIFICATION menu (auxiliary function 114). Press-
ing the F3 key displays the same screen for setting the spot weld control specifications
for weld controllers 2 through 8. Pressing the F2 key returns the display to the previous
weld controller number.
11 SPOT WELD CONTROL WELD CONT1

WELD INITIATE OUTPUT 23
OUTPUT TIME 0.00s
LEVEL(enter 0)/PULSE(enterTIME)
WELD SCHEDULE OUTPUT TOP SIGNAL 17
NUMBER OF SIGNAL TO USE 4
OUTPUT FORMAT (0:Binary 1:Discrete) 0
Following are set to 0 when not in use.
WELD COMP. INPUT SIGNAL 1029
WELD COMP. INPUT MONITOR 3s
WELD FAULT INPUT SIGNAL 0
WELD FAULT RESET OUTPUT 0
F1 F2 F3 F4
PRE DATA NEXT PG
Figure 9-55 Spot Weld Control
• WELD INITIATE OUTPUT SIGNAL is a robot output signal that is used to initiate
the weld process. A signal number of 0 is not acceptable data.
• The OUTPUT TIME LEVEL/PULSE entry is used to set the type of output signal
from the robot to the weld controller. If 0.00 is entered, the output signal remains in
effect until the welding sequence is completed. If a TIME is set, when the weld
initiate signal is generated, the output timer begins. The acceptable range for set-
ting the OUTPUT TIME LEVEL/PULSE is from 0.00 to 99.99 seconds.
May 22, 2001 9-71

AUXILIARY FUNCTIONS
• WELD SCHEDULE OUTPUT TOP SIGNAL identifies the first signal number that is
used as an output to the weld controller(s). The WELD SCHEDULE OUTPUT TOP
SIGNAL is used in conjunction with the next item on the menu, NUMBER OF SIG-
NAL TO USE. After the first signal number is identified, the number of signals to
use is entered. For example, if output signal 17 is identified as the WELD SCHED-
ULE OUTPUT TOP SIGNAL and 4 was entered as the number of signals to use,
signals 17, 18, 19, and 20 are used to select weld sequences. Up to six signals can
be used for the NUMBER OF SIGNAL TO USE entry.
• OUTPUT FORMAT entry identifies how the output signals used to select weld
sequences are evaluated. If 0 is entered, the signals are evaluated based on their
binary state and value, with the first signal (WELD SCHEDULE OUTPUT TOP
SIGNAL) being the least significant bit in the sequence. If 1 is entered, the indi-
vidual signal numbers are utilized to select weld sequences. Selecting the binary
format does not require as many signals as the individual format. Using the binary
format with four signals, there are 15 combinations possible. The individual format
would require 15 signals for 15 combinations.
• The WELD COMP. (complete) INPUT SIGNAL is a signal transmitted from the weld
controller and must be received and recognized by the robot controller before the
robot continues to the next step in the program. The signal number for this function
is entered after the WELD COMP. INPUT SIGNAL section of the SPOT WELD
CONTROL menu. An error message is generated if the WELD COMP. INPUT
SIGNAL is not received by the controller.
• WELD COMP. (complete) INPUT MONITOR is a timing delay that causes the pro-
gram to wait for a specified time before an error is generated when a WELD COMP.
INPUT SIGNAL is not received. A standard setting for this function is 3 seconds.
The acceptable data range for the WELD COMP. INPUT MONITOR is from 0 to 9
seconds.
• The WELD FAULT INPUT SIGNAL is a signal from the weld controller that gener-
ates an incomplete weld sequence error message. The signal number for this
function is entered after the WELD FAULT INPUT SIGNAL section of the SPOT
WELD CONTROL menu.
• The WELD FAULT RESET OUTPUT signal is a signal from the robot controller used
to reset the weld fault error signal from the weld controller. The reset switch on the
controller cabinet is used to generate this signal. When a 0 is entered for this func-
tion, a WELD FAULT RESET OUTPUT signal is not generated.
9-72 May 22, 2001

AUXILIARY FUNCTIONS
9.44.5 SPOT WELD GUN WELD DEFINITION
Figure 9-56 shows the spot weld gun definition screen that is displayed when number 12
is selected from the CLAMP SPECIFICATION menu (auxiliary function 114). The SPOT
WELD GUN definition assigns whether retractable or non-retractable guns are being
used. Retractable C and X gun types are also assigned. To define additional guns,
pressing the F3 key displays the same screen for setting weld guns 2 through 8. Press-
ing the F2 key returns the display to the previous gun number.

GUN1
GUN TYPE (1:Non ret) 1
(2:C-ret, 3:X-ret)
Following are valid only retract gun.
WELD DELAY ON RETRACT EXTEND 0.5s
MOTION DELAY EXTEND RETRACT 1.0s
RETRACT MONITOR (0:not, 1:monitor) 0
EXTEND MONITOR (0:not, 1:monitor) 0
EXTEND SIGNAL OUTPUT DELAY 0.5s
RETRACT SIGNAL OUTPUT DELAY 0.2s
F1 F2 F3 F4
PRE DATA NEXT PG
Figure 9-56 Spot Weld Gun Definition
The information entered on the SPOT WELD GUN definition screen corresponds with
the clamp conditions specified in auxiliary function 114, menu selection 2. The first
information entered is the weld GUN TYPE. There are three types of weld guns that can
be identified: 1 assigns a single stroke non-retractable gun, 2 assigns a two stroke C
type gun, 3 assigns a two stroke X type gun. No other numbers are acceptable data for
this field.
• WELD DELAY ON RETRACT→EXTEND is used to set the time delay for the initia-
tion of the weld process of a retractable gun after it is retracted. The standard value
for the weld delay on retract - extend is 0.5 seconds. The acceptable range for this
function is from 0.0 to 9.9 seconds.
• MOTION DELAY EXTEND→RETRACT is used to set the time delay for the start of
robot motion for a retractable gun after the gun has completed a weld and moves to
the extended position. The standard value for the motion delay on extend - retract is
1.0 seconds. The acceptable range for this function is from 0.0 to 9.9 seconds.
May 22, 2001 9-73

AUXILIARY FUNCTIONS
• RETRACT MONITOR is set to monitor an input signal from the weld gun when it is
in the retracted position. If the RETRACT MONITOR is utilized, a 1 is entered on
the menu. If the RETRACT MONITOR function is not utilized, a 0 is entered on the
menu.
• EXTEND MONITOR is set to monitor an input signal from the weld gun when it is in
the extended position. If the EXTEND MONITOR is utilized, a 1 is entered on the
menu. If the EXTEND MONITOR function is not utilized, a 0 is entered on the
menu.
• EXTEND SIGNAL OUTPUT DELAY sets a delay in the time the output to extend the
gun is generated. The standard setting for this delay function is 0.5 seconds. The
acceptable range of data for the EXTEND SIGNAL OUTPUT DELAY is from 0.0 to
9.9 seconds.
• RETRACT SIGNAL OUTPUT DELAY sets a delay in the time the output to retract
the gun is generated. The standard setting for this delay function is 0.2 seconds.
The acceptable range of data for the RETRACT SIGNAL OUTPUT DELAY is from
0.0 to 9.9 seconds.
9.44.6 HANDLING AND CLAMP DATA
Figure 9-57 shows the HANDLING AND CLAMP DATA screen displayed when number
20 is selected from the CLAMP SPECIFICATION menu (auxiliary function 114). This
data is for material handling applications and allows the operator to specify the output
signal numbers that turn the clamp(s) on and off. For clamps that have a single solenoid
valve, only one signal is specified.

20 HANDLING AND CLAMP DATA
CLAMP “ON” SIG CLAMP “OFF” SIG
SIG
CLAMP1 10 9
CLAMP2 0 11
CLAMP3 0 0
CLAMP4 0 0
CLAMP5 0 0
CLAMP6 0 0
CLAMP7 0 0
CLAMP8 0 0
For single solenoid valve, specify one

of these signals
F1 F2 F3 F4
PRE DATA
Figure 9-57 Handling Clamp Data
9-74 May 22, 2001

AUXILIARY FUNCTIONS
9.45 ERROR LOGGING, AUX 120
The ERROR LOGGING function allows the operator to view a history of the errors that
have occurred on an individual controller.
Up to 1,000 errors are recorded by this function. The errors are listed in chronological
order with the most recent entry first. The date, time, error number, and a description of
the error are all listed. Error messages cannot be deleted or edited and remain in
memory even after the controller has been initialized.
Figure 9-58 shows an example of the error logging function screen. Pressing the F3 key
displays the next group of errors in the log.
Figure 9-58 Error Logging
May 22, 2001 9-75

AUXILIARY FUNCTIONS
9.46 OPERATION LOGGING, AUX 122
The OPERATION LOGGING function allows the operator to view a history of the opera-
tions that have occurred on an individual controller.
Up to 100 previously performed operations are recorded by this function. The opera-
tions are listed in chronological order with the most recent entry first. The operation
logging function also displays the name of the operator interface the operation was
performed on, the date, time, and a description of the operation performed.
Operation log entries cannot be deleted or edited and remain in memory even after the
controller is initialized.
Figure 9-59 shows an example of the operations logging function screen. Pressing the
F3 key moves the display to the next group of operations in the log.
AUX 122 OPERATION LOGGING

1-(TP), [97/02/25 16:28:21 WHERE 1:6 3,1]
2-(TP), [97/02/25 16:25:14 SAVE FILE3]
3-(TP), [97/02/25 16:27:03 list/r]
4-(TP), [97/02/25 16:11:51 dir]
5-(TP), [97/02/25 16:01:36 list/r]
6-(TP), [97/02/25 15:59:41 dir]
7-(TP), [97/02/25 14:58:08 list/r]
8-(TP), [97/02/25 13:50:12 edit]
9-(TP), [97/02/25 09:31:21 WHERE]
10-(TP), [97/02/25 09:29:17 SAVE FILE2]
11-(TP), [97/02/25 09:09:35 SAVE FILE1]
F1 F2 F3 F4 F5 F6
NEXT PG
EXIT
Figure 9-59 Operation Logging
9-76 May 22, 2001

AUXILIARY FUNCTIONS
9.47 ENCODER ROT. COUNTER RESET, AUX 140
The ENCODER ROT. (rotation) COUNTER RESET function is used in conjunction with
auxiliary function 41, ZEROING and auxiliary function 44, ZEROING DATA SET DIS-
PLAY, as part of the zeroing process. When maintenance is performed that mechani-
cally changes the position of the robot in relation to the encoders or a servo motor is
replaced, zeroing is required.
! CAUTION
Operators must be aware of the effect changes made in
this function have on the position of programmed loca-
tions. Changing this data without following the complete
zeroing process may move programmed locations to po-
sitions that cause damage to the robot, fixtures or work.
Auxiliary function 140 provides the operator with the option of selecting a single joint or
all joints to the reset encoder rotation count. If a single joint is selected, a set degree
angle for that axis may also be entered. When the data for this function is entered, the
offset is stored by the 1GA board to provide accurate robot motion.
Figure 9-60 shows the ENCODER ROT. COUNTER RESET screen.
AUX 140 ENCODER ROT.COUNTER RESET

SETTING CURRENT
JT1 268427264 268427264
JT2 268427264 268427264
JT3 268427264 268427264
JT4 268427264 268427264
JT5 268427264 268427264
JT6 268427264 268427264
JOINT number = 0
(0=RESET ALL JOINT)
SET DEGREE = 0deg
F1 F2 F3 F4
PRE DATA
Figure 9-60 Encoder Rot. Counter Reset
May 22, 2001 9-77

AUXILIARY FUNCTIONS
9.48 Z-SERIES ROBOT FUNCTIONS
9.48.1 ARM ID BOARD FUNCTIONS
The arm ID board is installed in the robot arm ID board box (Figure 9-61). The arm ID
board stores model information, maintenance log information, and I/O signal settings.
Functions and settings of the arm ID board are accessed from the controller.
The functions and settings of the arm ID board include:
• entries to the maintenance log

• display of the maintenance log
• deletion of maintenance log entries
• settings for I/O signals to the robot arm
Figure 9-61 Robot Arm ID Board Location
9-78 May 22, 2001

AUXILIARY FUNCTIONS
9.48.1.1 MAINTENANCE LOG, AUX 123
The maintenance log is accessed through AUX 123 MAINTENANCE LOG (Figure 9-62).
Select functions by cursor keys or function number and press RETURN.
1. MNT LOG SET — input person in charge and maintenance log entries
2. MNT LOG DISPLAY — display maintenance log
3. MNT LOG DELETE — delete maintenance log entries
Figure 9-62 Maintenance Log
9.48.1.2 MAINTENANCE LOG SET
Input the name of the person in charge, using the character key (F4) (Figure 9-63). The
character key displays the keyboard screen to allow the operator to enter data. When
the data is entered on the keyboard screen, press the ENTER key. The display returns
to AUX 123, and the name entered on the keyboard screen replaces NO_NAME. Press
the RETURN key to complete the entry.
When the name of the person in charge is entered the display changes to NON OF
ABNORMALITY (Figure 9-63). The operator uses the CHARACTER key to input the
maintenance record memo in the same manor used to enter the name of the person in
charge.
May 22, 2001 9-79

AUXILIARY FUNCTIONS
Figure 9-63 Maintenance Log Set
If data is not entered for the maintenance record memo, the message “NON OF AB-
NORMALITY“ is displayed (Figure 9-63).
9-80 May 22, 2001

AUXILIARY FUNCTIONS
Figure 9-64 Maintenance Log Set Entry Confirmation Screen
When the operator enters the data, the confirmation screen displays the option to ac-
cept the data (YES) or to cancel the entry (NO) (Figure 9-64). When the operator
presses F1 (YES), “Now processing” is displayed. When the data is processed “Nor-
mally completed” is displayed at the top of the screen.
NOTE
Do not turn controller power off while the “Now process-

ing” message is displayed or the entry is not accepted.
May 22, 2001 9-81

AUXILIARY FUNCTIONS
9.48.1.3 MAINTENANCE LOG DISPLAY
Figure 9-65 Maintenance Log Display
Use NEXT PG (F3) and PRE PG (F2) to view data in the maintenance log (Figure 9-65).
9-82 May 22, 2001

AUXILIARY FUNCTIONS
9.48.1.4 MAINTENANCE LOG DELETE
Figure 9-66 Maintenance Log Delete
Select the maintenance log entry to delete with cursor keys and press the RETURN key
(Figure 9-66). Use the NEXT PG key to display more entries. When the RETURN key is
pressed “Are you sure?” is displayed. Pres F1 (YES) to delete data, or F4 (NO) to
cancel deletion.
NOTE
Do not turn controller power off while “Delete executing”

is displayed or the entry is not accepted.
May 22, 2001 9-83

AUXILIARY FUNCTIONS
9.48.1.5 SETTING SIGNAL ALLOCATION
To set the allocation of parallel I/O signals for the arm ID board, access AUX 175 SIG-
NAL OF BUILT-IN ARM BOARD (Figure 9-67).
Figure 9-67 Setting Arm ID Board I/O Signals
Use the cursor and numeric keys to input data. TOP SIGNAL is the first signal number
in the sequence. See table 9-4 for proper data.
Table 9-4 Arm ID Board Signal Allocation
Inputs Outputs
Standard (1GV Board) 2 0
Optional (1GV + 1JD Board) 24 8
Conditions:
• Consecutive output signals up to number 64 are used.

• Consecutive input signals up to number 1064 are used.
• Do not duplicate signal numbers when two or more robots are used.
9-84 May 22, 2001

AUXILIARY FUNCTIONS
9.48.1.6 ARM ID BOARD AS LANGUAGE COMMANDS
The AS Language commands used with the arm ID board are:
• MNTREC – maintenance log record

• MNTLOG – maintenance log display
• ARMIOSET – arm ID board I/O set
$MNTREC robot_number
The MNTREC command is used to register maintenance log entries. If the robot num-
ber is omitted, 1 is assumed. The maintenance log stores the last 100 entries. When
over 100 entries are made the oldest entry is deleted.
EXAMPLE:
$MNTREC <ENTER>
Person in charge of record (input)? Joe Supervisor <ENTER>
Non of abnormality : 0 Memo input : 1? 1<ENTER>

(Memo input) : JT1 motor replaced <ENTER>
content of registration
Person in charge : Joe Supervisor

Memo : JT1 motor replaced
Are you sure? (Yes:1, No:0) 1 <ENTER>

arm ID board is busy.
Writing ended.
$
NOTE
Do not turn controller power off until “Writing ended” is

displayed, or entry is not accepted.
May 22, 2001 9-85

AUXILIARY FUNCTIONS
$MTLOG robot_number
The MNTLOG command is used to display the contents of the maintenance log. If the
robot number is omitted, 1 is assumed. The maintenance log displays the last 100
entries, starting with the most recent. Press ENTER to stop the listing.
EXAMPLE:
$MNTLOG <ENTER>
1-[00/06/24 12:03:00 Joe Supervisor]
[REPLACE JT1 HARNESS]
2-[00/04/12 14:20:32 Kawasaki]
[REPLACE JT2 MOTOR]
$ARMIOSET robot_number,output_signal_No.,number_of_output_signals,
input_signal_No.,number_of_input_signals
The ARMIOSET command is used to allocate arm board parallel I/O signals. If the
robot number is omitted 1 is assumed. Top signal range for output is 1 - 64. Number of
output signals is 1 - 8. Top signal range for input is 1001 - 1064. Number of input sig-
nals is 1 - 24.
EXAMPLE:
$ARMIOSET <ENTER>
TOP SIGNAL, SIGNAL NUMBER
OUTPUT SIGNAL 1 0
Change? (If not, Press RETURN only.)
6,8 <ENTER>

OUTPUT SIGNAL 6 8
<ENTER>

INPUT SIGNAL 1001 0
1012,24 <ENTER>

INPUT SIGNAL 1012 24
<ENTER>
$
9-86 May 22, 2001

AUXILIARY FUNCTIONS
9.48.1.7 ARM ID BOARD ERRORS AND ERROR CODES
When the controller is powered up and robot data in the controller memory is different
than the robot data in the arm ID board, the message “Robot 1 type is not correspond-
ing” or “Zeroing data of robot 1 is not corresponding” is displayed (Figure 9-68).
Figure 9-68 Arm ID Board Start-up Messages
May 22, 2001 9-87

AUXILIARY FUNCTIONS
The messages in figure 9-68 are displayed when the:
• controller or controller CPU board is replaced.

• system is initialized.
• robot is replaced.
• arm ID board is replaced with arm ID board with different robot data stored.
When 1 is entered, the controller uses robot and zeroing data from the arm ID board
and data on the controller CPU board is overwritten.
When 2 is entered, the controller uses robot and zeroing data from the controller CPU
board and data on the arm ID board is overwritten.
9-88 May 22, 2001

AUXILIARY FUNCTIONS
When the controller is powered up and there is no data in the arm ID board (new board)
or a check sum error occurs in the arm ID board, the message “There is no data in the
arm ID board” or “Flash memory check sum error in the arm ID board” is displayed
(Figure 9-69).
Figure 9-69 Arm ID Board Error Messages
May 22, 2001 9-89

AUXILIARY FUNCTIONS
Error code messages appear as shown in figure 9-70. Refer to table 9-5 for error code
descriptions.
Figure 9-70 Error Codes
9-90 May 22, 2001

AUXILIARY FUNCTIONS
Error Codes (see table 9-5)
(-1220) No response from the arm ID board.

Possible damaged arm ID board or power sequence board.
(-1221) Arm ID board error (code xxx).

Possible damaged arm ID board or power sequence board.
(-1222) Power sequence board error (code xxx).

Possible damaged power sequence board.
Table 9-5 Arm ID Board Error Codes
Code Discription -1220 -1221 -1222

NA No response from the arm ID board x
4AH Arm ID board data is not normal or corrupt x
4FH Writing error to arm ID board memory1 x
C1H Communication check sum error2 x x
C5H Communication protocol error2 x x
C6H Communication response time-out error2 x
C7H Communication character string time-out error2 x
F1H ROM check sum error (at board star t-up)3 x
F2H Abnormal RAM (at board star t-up)3 x
F4H Abnormal SRAM (at board star t-up)3 x
F5H Abnormal DRAM (at board star t-up)3 x
FFH Other errors x x
1
Cannot write to arm ID board memory. Replace arm ID board.
2
Damaged or disconnected communication cable.
3
Cycle controller power ON and OFF. If error does not clear further diagnosis is needed
(possible damaged arm ID board or power sequence board).
May 22, 2001 9-91

ERROR CODES/TROUBLESHOOTING
10.0 ERROR CODES/TROUBLESHOOTING .......................................................... 10-2

10.1 Error Recovery .................................................................................................. 10-2
10.2 Error Codes ....................................................................................................... 10-5
May 22, 2001 10-1

10.0 ERROR CODES/TROUBLESHOOTING
This unit provides error recovery flowcharts, error code information, and error code
troubleshooting flow charts. In addition, typical causes and remedies for the errors are
also provided.
10.1 ERROR RECOVERY
Figure 10-1 shows troubleshooting processes that may be helpful if the controller be-
comes unresponsive to commands or an error code has been encountered that cannot
be cleared. Troubleshooting should begin with confirmation of basic integrity of the
system: ensure that the power supply is on and meeting supply requirements, all cables
are correctly attached, all circuit boards are properly installed and fully seated, all pe-
ripheral equipment is wired correctly, software is properly configured, etc.
10-2 March 31, 2000

Locate error in the error code

Source of error known Troubleshoot
table and determine the Run program
characteristics and possible and correct and continue
causes of the error source of to monitor
error
Source of error unknown
Error cleared and robot Run program

Press the yellow
runs normally and continue
reset button on the
controller panel to monitor
Error will not clear or

machine is in a “locked” mode
Have any changes been

made to system? New Error clears and robot
Ensure the robot Run program
internal parts, interface Yes runs normally
system data and and continue
components added or programs are to monitor
removed, signal interface compatible
agrees with program, etc.
No
Error or “locked” Run program

Cycle the
condition cleared and continue
controller power
off and on to monitor
Error still present
With control Error or “locked” Run program

power on, press the condition cleared and continue
red reset button on the
to monitor
1GA board
Continued on next page
Figure 10-1 Trouble Shooting Process
March 31, 2000 10-3

Continued from previous pg
Create Error or “locked” Reset Run program

backup information condition cleared system settings not and continue
files and initialize the set to defaults after to monitor
system initialization
Error still present
Remove the
1GA board from the
rack and allow RAM
memory to deplete
Reinstall Error clears and robot

1GA board, Run program
runs normally
initialize the and continue
system, zero to monitor
Begin electrical
troubleshooting and repair if
qualified; call service
technician for further
assistance
Figure 10-2 Trouble Shooting Process (cont’d)
10-4 March 31, 2000

10.2 ERROR CODES

This unit provides information about the error codes that are displayed on the multi
function panel or other user interfaces that provide display screen information. The error
codes are listed in numerical order by code number with the message that is displayed
with the associated code. An expanded explanation of the message is provided along
with possible methods to clear or prevent the specific error. Troubleshooting information
is preceded by a ⇒ symbol.
ERROR CODE -50 Warning! Cannot move along straight line in this
configuration.
Joint speed may exceed maximum, joints 4 and 6 aligned.
⇒ Change angle of joint 5, slow the speed, change to joint mode.

_____________________________________________________________________
ERROR CODE -57 Set low speed because of exceeding joint max. speed in
check.
When joint speed is checked with commanded speed, the difference exceeds accept-
able range.
⇒ Slow the speed.

_____________________________________________________________________
ERROR CODE -100 Matrix Calculation Error.
The vector element of the matrix cannot be operated because of 0.
⇒ Change and recalculate value.

_____________________________________________________________________
ERROR CODE -101 Turn off motor power.
Motor power cannot turn on according to command and instruction.
⇒ Turn motor power OFF and execute command and instruction.

_____________________________________________________________________
March 31, 2000 10-5

ERROR CODE -102 Application is changed. Turn OFF & ON the control power.
The robot configuration was changed from spot welding/material handling to a paint/
sealant application using AUX function 907.
⇒ Turn controller power OFF then ON.

_____________________________________________________________________
ERROR CODE -103 There is no external axis.
External axis equipment is not installed and cannot operate.
⇒ Enable option or contact customer service to install desired option.

_____________________________________________________________________
ERROR CODE -104 Illegal positioner type.
Equipment is not installed and cannot operate.

_____________________________________________________________________
ERROR CODE -105 Cannot change data because user data exist.
Data cannot be overwritten.
⇒ Delete current data and replace with new data.

_____________________________________________________________________
ERROR CODE -106 Graphic area error.
Unable to display data in designated display area.
⇒ Select different display area.

_____________________________________________________________________
ERROR CODE -107 Option is OFF.
Selected option is OFF or is not installed.

_____________________________________________________________________
10-6 May 22, 2001

ERROR CODE -200 Cannot execute a program because motor power is OFF.
Program will not start because motor power is not on.
⇒ Turn motor power ON.

_____________________________________________________________________
ERROR CODE -201 Cannot execute a program in TEACH mode.
Programs cannot run when in the teach mode of operation.
⇒ Ensure that the controller is in the REPEAT mode of operation.

_____________________________________________________________________
ERROR CODE -202 Cannot execute a program because teach lock is ON.
Programs cannot be run with the teach lock in the ON position.
⇒ Turn the TEACH LOCK switch to OFF and execute the program again in repeat
mode.
_____________________________________________________________________
ERROR CODE -207 Turn to HOLD at HOLD/RUN sw.
Occurs when an attempt to perform DO, STEP, MSTEP, CONTINUE, or EXECUTE

commands is made with the RUN/HOLD switch in the RUN position. Only applies if the
CHECK HOLD system switch is ON.
⇒ Turn the RUN/HOLD switch to HOLD position.

_____________________________________________________________________
ERROR CODE -208 Teach pendant is not connected.
Hardwired switches for teach pendant and multi function panel must be jumpered and
equipment configuration identified in environmental data functions.
⇒ Install teach pendant or configure system accordingly.

_____________________________________________________________________
May 22, 2001 10-7

ERROR CODE -211 Cannot edit a program because the TEACH LOCK switch
is ON.
Programs cannot be edited if the TEACH LOCK switch is ON.
⇒ Turn TEACH LOCK switch OFF.

_____________________________________________________________________
ERROR CODE -212 Cannot execute because executed by other device.
Occurs when the operator attempts to execute the same command from the KCWIN
terminal and the multi function panel or type 2 teach pendant at the same time.
⇒ Cannot execute commands from two devices at the same time.

_____________________________________________________________________
ERROR CODE -213 Cannot execute a program because of EXT-IT.
External hold signal and or external hold reset signal not received.
⇒ Check dedicated input signals in Aux 111 match signals programed from the PLC in
the Slogic program.
⇒ If the external hold signal is not needed, change the signal setting in Aux111 from set
to reset.
_____________________________________________________________________
ERROR CODE -300 Program is already running.
Occurs when an attempt is made to edit or execute a program that is currently running.
⇒ Stop the robot control program prior to editing or checking.

_____________________________________________________________________
ERROR CODE -301 Robot control program is already running.
Occurs when an attempt is made to execute a DO, TOOL, or BASE command when a
robot control program is running.
⇒ Wait for the robot control program to complete execution.

⇒ Stop the robot control program.
_____________________________________________________________________
10-8 May 22, 2001

ERROR CODE -302 Can’t continue. Use EXEC.
The CONTINUE command is not permitted because of program selection status.
⇒ Use the EXECUTE command to start program.

_____________________________________________________________________
ERROR CODE -303 Robot is moving now.
Displayed if any of the following commands are entered while a program is running:
EXECUTE, CONTINUE, TOOL, BASE, DO. SYSINIT or CYCLE START.
⇒ Stop the program or confirm the operation to be performed.

_____________________________________________________________________
ERROR CODE -304 Cannot execute because in error now. Reset error.
Occurs when attempt is made to start robot motion if an error has not been cleared.
⇒ Clear any errors and re-enter the command.

_____________________________________________________________________
ERROR CODE -306 Cannot execute with DO command.
Displayed when the DO command is entered with an instruction that is not of acceptable
format.
⇒ Execute the instruction from within a program or use acceptable instruction format for
DO command.
_____________________________________________________________________
ERROR CODE -308 PC program is running.
Occurs when a PC program is running and instructions are entered that are not allowed.
⇒ Stop the PC program and enter the command.

_____________________________________________________________________
May 22, 2001 10-9

ERROR CODE -314 Cannot execute because the program is already used.
Occurs when a program being edited is selected to run by a CALL, ON, ONI or PC
program instruction.
⇒ Stop editing the program or stop the program that is calling the program being edited.
_____________________________________________________________________
ERROR CODE -316 Waiting weld completion.
Displayed when a command to change the step is entered while a welding sequence is
in progress.
⇒ Wait until after the weld sequence is completed or force a weld complete condition.
_____________________________________________________________________
ERROR CODE -317 Position offset error at last E-stop JTxx.
The error message is generated when an E-stop is applied and the position of the robot
is not within a range of the commanded position. The error deviation range is specified
in auxiliary function 42.
⇒ Before the error is reset, operators must be aware of the robot’s position within the
work envelope.
_____________________________________________________________________
ERROR CODE -318 Waiting retract or extend pos. input signal.
One of the following operations were attempted when the robot was processing a spot
weld sequence (waiting for the Retract/Extend signal after the weld complete signal had
been received).
1. Cycle start (including EXECUTE, CONTINUE command).
2. Program selection or step change.
3. Record.
⇒ Input the Retract/Extend detection signal to the robot or press the WX key and wait
override key on the multi function panel.
_____________________________________________________________________
10-10 May 22, 2001

ERROR CODE -319 Spot sequence is running.
Step change, program change, or program execution were attempted while the spot
weld sequence was executing (after Retract/Extend input signal and weld complete
signal have been received). For example, the robot is executing move delay time after
weld complete.
⇒ Perform step change, program registration or program execution after the spot weld-
ing sequence.
_____________________________________________________________________
ERROR CODE -320 Cannot operate because teach pendant in operation.
You cannot perform functions on the personal computer while the multi function panel is
in use.
⇒ Perform functions on the PC after the multi function panel has completed operation.
_____________________________________________________________________
ERROR CODE -324 Cannot execute with MC instruction.
MC instruction could not be carried out.
⇒ Use instruction which can be executed by MC instruction.

_____________________________________________________________________
ERROR CODE -325 Cannot execute the instruction in robot program.
Command and instruction cannot be used or executed.
⇒ Rewrite the command or instruction.

_____________________________________________________________________
ERROR CODE -326 Cannot delete because used by another command.
Cannot COPY, DELETE or XFER command because current step is being executed.
⇒ Perform DELETE commands after execution ends.

_____________________________________________________________________
May 22, 2001 10-11

ERROR CODE -327 Used in programs.
The variable used with the program was deleted.
⇒ Confirm the deleted variable.

_____________________________________________________________________
ERROR CODE -328 Used in editor.
When the program was used in the editor, the program was deleted.
_____________________________________________________________________
ERROR CODE -329 KILL or PCKILL to delete program.
Occurs when an attempt to delete a program is made and that program is still on the
stack (selected).
⇒ Select another program or KILL/PC KILL the program, then delete.

_____________________________________________________________________
ERROR CODE -330 Cannot paste.
Occurs when the operator is executing the paste function and no data is stored in the
paste buffer or the step(s) cannot be overwritten.
⇒ Check paste operation and the destination steps.

_____________________________________________________________________
ERROR CODE -350 Illegal input data.
Input data from AS Language monitor command is improper for the instruction.
⇒ Enter data that is within acceptable range.

_____________________________________________________________________
ERROR CODE -351 Too many arguments.
Input data from AS Language editor commands exceeds the number of user specified
items allowed by the format.
⇒ Verify input data and format of command.

_____________________________________________________________________
10-12 May 22, 2001

ERROR CODE -353 Input data is too big.
Data entered for the POINT or HERE commands exceeds the allowable range.

_____________________________________________________________________
ERROR CODE -360 Illegal WHERE parameter.
Occurs if data entered with the WHERE command is not an integer between 1 and 6.
⇒ Ensure that data is within acceptable range.

_____________________________________________________________________
ERROR CODE -361 Illegal PC number.
Unused
_____________________________________________________________________
ERROR CODE -365 Illegal robot number.
Unused
_____________________________________________________________________
ERROR CODE -367 Illegal priority.
Priority level designation is wrong.
⇒ Input a correct priority level.

_____________________________________________________________________
ERROR CODE -368 Invalid coordinate value.
Upper limit value is less than value of lower limit.
⇒ Input the correct upper limit coordinates.

_____________________________________________________________________
May 22, 2001 10-13

ERROR CODE -371 External axis type and gun data mismatch.
The servo gun setting does not correspond to the type of external axis (set in AUX 160)
and type of gun (set in AUX 114). This error is detected when motion begins for a step
with a clamp signal set.
⇒ Confirm that the external axis and gun type data settings are correct.
ERROR CODE -400 Syntax error.
Occurs when an AS Language command is entered that does not follow the correct
format or contains typing or spelling errors.
⇒ Correct format or spelling of command/instruction.

_____________________________________________________________________
ERROR CODE -401 Invalid statement.
Occurs when an AS Language command is entered that has typing errors, incorrect
spelling or is in the wrong format.
⇒ Correct the input data spelling or format.

_____________________________________________________________________
ERROR CODE -402 Ambiguous statement.
Displayed when an abbreviation is entered incorrectly or has missing letters.
⇒ Enter the correct abbreviation or entire command.

_____________________________________________________________________
ERROR CODE -403 Cannot use this command or instruction here.
Displayed because a program or monitor command was entered that could not be
executed while a program is running.
⇒ Stop program execution or wait for completion.

_____________________________________________________________________
10-14 May 22, 2001

ERROR CODE -404 Cannot execute with DO command.
A program instruction that is not acceptable to use with the DO command was entered.
⇒ Place the desired instruction within a program or choose an acceptable instruction for
use with a DO command at the monitor prompt.
_____________________________________________________________________
ERROR CODE -405 Statement cannot be executed.
Occurs when the AS Language instruction entered was not acceptable for the mode of
operation. For example: a monitor command was entered in the editor mode.
⇒ Use instructions and commands that are compatible with the input mode.
_____________________________________________________________________
ERROR CODE -406 Not a program instruction.
An instruction was entered into a program that is not a valid program instruction, i.e., a
monitor command, editor command, etc.
⇒ Refer to the AS Language Manual for proper use of AS Language commands.

_____________________________________________________________________
ERROR CODE -407 Too many arguments.
Input data from AS Language editor commands exceeds the number of user specified
items allowed by the format.
⇒ Verify input data and format of command.

_____________________________________________________________________
ERROR CODE -408 Missing argument.
Displayed when a DO command is not followed by an acceptable program instruction.
⇒ Correct the input and re-enter.

_____________________________________________________________________
May 22, 2001 10-15

ERROR CODE -410 Illegal expression.
A real number expression must be present for processing DECOMPOSE command(s).

Also displayed when incorrect numerical information is entered with arguments.
⇒ Ensure correct format and numerical expressions are entered.

_____________________________________________________________________
ERROR CODE -411 Illegal function.
Occurs when functions are used to assign values to variables but the data is incompat-
ible. For example: assigning XYZ coordinate data to precision points.
⇒ Ensure function is compatible with variables.

_____________________________________________________________________
ERROR CODE -412 Illegal argument of function.
Occurs when function and argument are not in correct format.
⇒ Use correct format for functions and arguments.

_____________________________________________________________________
ERROR CODE -413 Invalid variable (or program) name.
Displayed when illegal variable or program name is entered from the editor or monitor
modes. For example: JM ##a (to many precision symbols) or CALL #a (not an accept-
able program name).
⇒ Define program names and variables correctly.

_____________________________________________________________________
ERROR CODE -414 Illegal variable type.
Displayed when illegal variable is entered from editor or monitor modes.

For example: b = #a + b (combining location and real variables using an arithmetic
operator).
⇒ Use compatible variable type for commands or instructions.

_____________________________________________________________________
10-16 May 22, 2001

ERROR CODE -415 Illegal array index.
Displayed when an attempt is made to use a variable that has previously been defined
as an array. May also occur if the order of an array is reversed when editing or entering
monitor commands.
⇒ Enter the correct array variable information.

_____________________________________________________________________
ERROR CODE-416 Missing parenthesis.
Occurs when parentheses are not entered as a pair, containing both a left and right
parenthesis.
⇒ Enter parentheses in left and right pairs.

_____________________________________________________________________
ERROR CODE -417 Expected to be a binary operator.
A non-binary operator has been entered where a command expected a binary operator.
⇒ Input a binary operator.

_____________________________________________________________________
ERROR CODE -418 Illegal constant.
A variable, or a non constant is used where a constant or integer should be used in a

monitor command.
Example: WHERE a (Should be WHERE 1 … WHERE 6)
⇒ Use the proper constant or integer with the command. See the C Series Controller
AS Language Reference Manual for more information.
_____________________________________________________________________
ERROR CODE -419 Illegal qualifier.
Displayed when monitor commands are followed by unexpected qualifiers. For example:
LIST W (expected characters would include P, L, and R for program, location, and real
variables; “W” causes error).
⇒ Use only acceptable qualifiers.

_____________________________________________________________________
May 22, 2001 10-17

ERROR CODE -420 Invalid label.
Occurs in the editor mode when a GOTO instruction is combined with a reserved char-
acter. For example: GOTO #a (“#” is a reserved character).
⇒ Do not use reserved characters in label identification.

_____________________________________________________________________
ERROR CODE -421 Invalid name.
Displayed when an unidentified program, file, variable, etc., is used in a command.
⇒ Use only names that have been defined.

_____________________________________________________________________
ERROR CODE -422 Missing expected character.
Occurs when commands or instructions are entered with an incorrect format. For ex-
ample: TOOL a=b (TOOL a would be correct, “=b” causes error).
⇒ Use correct format for commands and instructions.

_____________________________________________________________________
ERROR CODE -423 Illegal switch name.
Displayed when a system switch is incorrectly identified. For example: SWITCH light
(there is no system switch named “light”).
⇒ Use only available switch names.

_____________________________________________________________________
ERROR CODE -424 Ambiguous switch name.
Displayed when a switch name has been entered that is not available for the software
version that is operating in the controller.
⇒ Use only system switches that are compatible with the software version that is operat-
ing.
_____________________________________________________________________
10-18 May 22, 2001

ERROR CODE -425 Illegal format qualifier.
Occurs when the TYPE or PRINT command is not used with an acceptable format
portion of the instruction.
⇒ Use only specified format instructions with TYPE and PRINT commands.
_____________________________________________________________________
ERROR CODE -426 Duplicate statement label.
A specific program label name can only be used once per program. Error is displayed if
the same label name is entered a second time in the same program.
⇒ Use label names only once per program.

_____________________________________________________________________
ERROR CODE -430 Cannot define as array.
A non-array variable with the same name as the array variable that was attempted to be
created, already exists.
⇒ Use a different name for the new variable. Refer to the AS Language Manual for
proper use of AS Language commands.
_____________________________________________________________________
ERROR CODE -431 Dimension exceeds 3.
Attempted to create an array variable with more than 3 dimensions.

_____________________________________________________________________
ERROR CODE -432 Different dimensional array exist.
An array variable with same name but a different number of dimensions already exists.
⇒ Change the name of the new variable or provide the same number of dimensions as
the existing variable. Refer to the AS Language Manual for proper use of AS Lan-
guage commands.
_____________________________________________________________________
May 22, 2001 10-19

ERROR CODE -433 Array variable exist.
Attempted to create a non-array variable with the same name as an existing array vari-
able.
⇒ Confirm array variable exists. Select new name for non-array variable or select array
variable.
_____________________________________________________________________
ERROR CODE -434 Non array variable exist.
Attempted to create an array variable with the same name as an existing non-array
variable.
⇒ Confirm non-array variable exists. Select new name for array variable or select non-
array variable.
_____________________________________________________________________
ERROR CODE -435 Array variable expected.
A non-array variable exists with the same name as the array variable that was specified
for the decompose instruction.
⇒ Select a new name for the array variable that was specified for the decompose in-
struction.
_____________________________________________________________________
ERROR CODE -440 Local variable expected.
A subroutine call to a program with a local variable found a program with the same
name but without a local variable.

_____________________________________________________________________
ERROR CODE -441 Unexpected suffix.
No data was provided in the brackets of an array variable.

_____________________________________________________________________
10-20 May 22, 2001

ERROR CODE -442 Mismatch of arguments at subroutine call.
The order of the local variable in the called program and the order of the local variable in
the actual program are different.
⇒ Check the order of the local variable in the actual program and modify the subroutine
call accordingly. Refer to the AS Language Manual for proper use of AS Language
commands.
_____________________________________________________________________
ERROR CODE -443 Mismatch of argument type at subroutine call.
The type of argument, i.e. location variable, real variable, is different than the argument
in the origin program.
⇒ Correct the type of the argument in the called program or origin program.
_____________________________________________________________________
ERROR CODE -450 Control structure error.
Displayed when an illegal program control flow structure is evaluated.
⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________
ERROR CODE -451 Step:xxx Wrong END statement.
Occurs when an illegal END statement is entered during editing.

_____________________________________________________________________
ERROR CODE -452 Step:xxx Extra END statement.
Occurs when an extra END statement is present and there is no corresponding struc-
ture.
⇒ Use correct syntax and components in control flow structures, check structure of
END statements.
_____________________________________________________________________
May 22, 2001 10-21

ERROR CODE -453 Step:xxx Cannot terminate DO with END.
This error is displayed when the control flow structure DO….UNTIL is entered with an
END statement .

_____________________________________________________________________
ERROR CODE -454 Step:xxx No VALUE statement after CASE.
Occurs when the control flow structure CASE OF….END is entered without a value to
evaluate.

_____________________________________________________________________
ERROR CODE -455 Step:xxx Preceding IF missing.
Displayed when control flow structure does not contain the correct structure for
IF…THEN… ELSE…END commands.

_____________________________________________________________________
ERROR CODE -456 Step:xxx Preceding CASE missing.
CASE…of… VALUE…ANY…END commands.

_____________________________________________________________________
ERROR CODE -457 Step:xxx Preceding DO missing.
DO…UNTIL.

_____________________________________________________________________
10-22 May 22, 2001

ERROR CODE -458 Step:xxx Can’t find END of xxx.
Occurs when control flow structure that requires an END statement does not contain the
necessary END.

_____________________________________________________________________
ERROR CODE -459 Step:xxx Too many control structures.
Occurs when 11 layers of control flow structure are exceeded.
⇒ Limit control flow structure to 11 layers.

_____________________________________________________________________
ERROR CODE -460 Variable (or program) already exists.
Displayed when a variable is entered that is already part of the system memory. For
example: a location named “weld1” is entered when a program named “weld1” is already
in the memory.
⇒ Do not use variable names for more than one item.

_____________________________________________________________________
ERROR CODE -461 Variable of different type already exists.
Displayed when a variable is entered that is already part of the system memory. For
example: a location named “weld1” is entered when a program named “weld1” is already
in the memory.
⇒ Do not use variable names for more than one item.

_____________________________________________________________________
ERROR CODE -464 Internal buffer over.
Attempted to solve a complex mathematical equation in a program.
⇒ Rewrite to reduce the complexity of the operations required to solve the equation.
_____________________________________________________________________
May 22, 2001 10-23

ERROR CODE -465 Undefined Variable (or program).
Attempt call a subroutine or process a variable that does not exist.
⇒ Verify the variable or program exists.

_____________________________________________________________________
ERROR CODE -466 Illegal clock value.
Time or date was entered in the wrong format.
⇒ Re-enter the values correctly; time - military, date - yy/mm/dd.

_____________________________________________________________________
ERROR CODE -470 Expect “=”.
The argument is missing the necessary “=”.
⇒ Check the argument and correct it.

_____________________________________________________________________
ERROR CODE -471 Expect “)”.
The argument is missing the necessary “)”.

_____________________________________________________________________
ERROR CODE -472 Expect “]”.
The argument is missing the necessary “]”.

_____________________________________________________________________
ERROR CODE -473 “Expect “TO”.
The argument is missing the necessary “TO”.

_____________________________________________________________________
10-24 May 22, 2001

ERROR CODE -474 “Expect “BY”.
The argument is missing the necessary “BY”.

_____________________________________________________________________
ERROR CODE -475 Expect “:”.
The argument is missing the necessary “:”.

_____________________________________________________________________
ERROR CODE -476 “Expect ”ON/OFF”.
An instruction other than ON/OFF was used with a SYSTEM SWITCH.
⇒ Check the ON/OFF status SYSTEM SWITCH and input it correctly.

_____________________________________________________________________
ERROR CODE -490 Program name not specified.
Displayed when no program is on the stack and the EDIT command is entered without
specifying a program name.
⇒ Identify the name of the program to be edited.

_____________________________________________________________________
ERROR CODE -494 Program is interlocked by another procedure.
Attempt to edit a running program was made.
⇒ Stop program execution before editing the program.

_____________________________________________________________________
ERROR CODE -499 Invalid statement.
Occurs when the program is executed and instructions are encountered that cannot be
processed as AS Language commands.
⇒ Use correct syntax and components for AS Language commands.

_____________________________________________________________________
May 22, 2001 10-25

ERROR CODE -507 Communication error.
When a vision system is incorporated and the transmission of data is interrupted (trans-
mission line problem or stoppage of the program) this error will be displayed.
_____________________________________________________________________
ERROR CODE -514 Device is not ready.
Unused
_____________________________________________________________________
ERROR CODE -523 Illegal file name.
Unused
_____________________________________________________________________
ERROR CODE -525 File already exists.
Occurs when the operator executes the rename command and the designated file name
already exists.
⇒ Change file name or delete existing file.

_____________________________________________________________________
ERROR CODE -543 Data read error.
Unused
_____________________________________________________________________
ERROR CODE -545 Record inhibited. Set ”record accept” and operate again.
Displayed when an attempt is made to enter data, but RECORD INHIBIT in auxiliary
function 71 is set to inhibit.
⇒ Change the setting of the RECORD INHIBIT in auxiliary function 71.

_____________________________________________________________________
10-26 May 22, 2001

ERROR CODE -548 Program change inhibited. Set ”program change accept”
and operate again.
Displayed when an attempt is made to enter data, but PROGRAM CHANGE INHIBIT in
auxiliary function 71 is set to inhibit.
⇒ Change the setting of the PROGRAM CHANGE INHIBIT in auxiliary function 71.
_____________________________________________________________________
ERROR CODE -551 Cannot open the file.
Unused
_____________________________________________________________________
ERROR CODE -565 RI/O board is not installed.
1FS board is not installed.
⇒ Ensure the 1FS board is properly installed and operational.

_____________________________________________________________________
ERROR CODE -580 Retry error.
Occurs when there is a problem with the communication link between the controller and
a host communication PC.
⇒ Check the integrity of the controller and host PC link.

_____________________________________________________________________
ERROR CODE -581 Stop of process.
(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________
ERROR CODE -583 Receive not data after receive request.

_____________________________________________________________________
May 22, 2001 10-27

ERROR CODE -584 Too long receive data (MAX=255 character).

_____________________________________________________________________
ERROR CODE -585 Abnormal data (EOT) received in communicating.

_____________________________________________________________________
ERROR CODE -586 Time out.

_____________________________________________________________________
ERROR CODE -591 Illegal device number.
Two types of selections are possible for the serial port. This error occurs when port
numbers other than the sensor port are specified.

_____________________________________________________________________
ERROR CODE -596 Cannot attach terminal.
The prompt instruction was executed by two or more programs at the same time.
⇒ Do not execute the prompt instruction from two or more programs at the same time.
_____________________________________________________________________
ERROR CODE -597 Cannot attach communication port.
The RECEIVE instruction and the SEND instruction were executed by two or more
programs at the same time.
⇒ Do not execute these instructions from two or more programs at the same time.
_____________________________________________________________________
10-28 May 22, 2001

ERROR CODE -598 Cannot execute on this terminal.
Attempt was made to execute a command that cannot be used at that terminal. Some
commands can only be used at the multi function panel and some only at the PC.
⇒ Use the above command from the proper terminal.

_____________________________________________________________________
ERROR CODE -599 Waiting input data for PROMPT. Connect input device.
The input device specified by the prompt command, i.e., PC or MFP, was not connected.
⇒ Verify that the specified device is connected.

_____________________________________________________________________
ERROR CODE -600 Motor power OFF. Displayed whenever an emergency

stop is encountered.
⇒ Reset emergency stop button and reapply motor power.

_____________________________________________________________________
ERROR CODE -605 PLC communication error.
Allen-Bradley (RI/O) PLC communication error between the 1FS board node adapter
chip (NAC) and the Allen-Bradley PLC.
Occurs when the PLC is not in run mode, the NAC configuration is incorrect, or connec-
tion is lost with the PLC.
⇒ Ensure the PLC is in run mode.

⇒ Ensure the NAC configuration is correct.
⇒ Ensure the PLC connection is established.
_____________________________________________________________________
ERROR CODE -606 Weld controller #%d not connected.
Occurs when the 1FS board RI/O function is not able to communicate normally with a
welder. When the START sequence is executed there is no response from the welder.
⇒ Ensure the welder connection is established.

⇒ Ensure the welder is operational.
_____________________________________________________________________
May 22, 2001 10-29

ERROR CODE -607 Weld controller #%d no response.
welder. When the NORMAL sequence is executed there is no response from the
welder.

⇒ Ensure the welder and related peripherals are operational.
_____________________________________________________________________
ERROR CODE -608 Weld controller #%d response error.
welder. The data received form the welder or the protocol is incorrect.

⇒ Ensure the welder communication protocol is correct.
⇒ Ensure the welder and related peripherals are operational.
_____________________________________________________________________
ERROR CODE -610 Weld completion time over.
Occurs when a weld complete signal is not received in a specified time period.
⇒ Override the wait condition, ensure that weld complete signal specifications are
correctly identified, check the operation of the weld gun or controller.
_____________________________________________________________________
ERROR CODE -611 Illegal extend (retract) output signal.
Occurs when the output signals for the extend and retract operation of a spot welding
application are not properly set.
⇒ Check the setting in auxiliary function 114.

_____________________________________________________________________
ERROR CODE -612 Weld fault input.
Displayed when the controller receives a weld fault signal.
⇒ Check operation of welding equipment, ensure signal numbers are correctly set.
_____________________________________________________________________
10-30 May 22, 2001

ERROR CODE -613 Retract pos. monitor error.
Occurs when the input signal for the retract operation of a spot welding application is not
received.
⇒ Check the operation of welding equipment, check the signal number setting in auxil-
iary function 114-10.
_____________________________________________________________________
ERROR CODE -614 Extend pos. monitor error.
Occurs when the input signal for the extend operation of a spot welding application is
not received.
⇒ Check the operation of welding equipment, check the signal number setting in auxil-
iary function 114-10.
_____________________________________________________________________
ERROR CODE -615 Weld completion signal is already inputted.
Displayed when the weld complete signal has been received before the weld initiate
output has not been issued.
⇒ Check operation of welding equipment, check the signal number setting in auxiliary
function 114-11.
_____________________________________________________________________
ERROR CODE -616 Gun retract position mismatch.
In the check mode, retractable gun output signals are monitored and compared to open/
close data for a specific step. If the data does not compare, an error is displayed.
⇒ Check settings in clamp conditions, check operation of gun with clamp key.
_____________________________________________________________________
May 22, 2001 10-31

ERROR CODE -631 Cannot achieve desired pressure.
The gun does not obtain the set closing pressure within 5 seconds after the gun starts
closing.
1. Tip wear measurement is not executed.

2. Incorrect taught point (closing pressure is not defined for the recorded position).
3. Closing pressure is set too high.
⇒ Perform the tip wear measurement.

⇒ Reteach the point.
⇒ Decrease the closing pressure.
_____________________________________________________________________
ERROR CODE -632 Gun chip[tip] stick.
Indicates that the tips are stuck. More power is required to open the gun, following a
weld, than the stuck detection value, set in AUX 114-41, WELDING DETECTION(0:NO
CHK) [kgf].
If the stuck detection value is set below the power level required for normal operation,
the gun cannot operate properly and the error is set.
⇒ If the gun is stuck, release it manually.

⇒ If the gun is not stuck, verify that the stuck detection value (AUX 114-41, WELDING
DETECTION(0:NO CHK) [kgf]) is set correctly. This setting may need to be in-
creased.
_____________________________________________________________________
ERROR CODE -633 Copper plate abrasion over the limit. step=*.
The copper backing plate wear exceeds the copper plate wear limit (AUX 114-12). The
error is detected when the gun executes a weld.
⇒ Replace the copper backing plate.

_____________________________________________________________________
ERROR CODE -634 Not dedicated encoder and brake power off signal.
The gun separation accept signal is not received during a gun change.
⇒ From AUX 111 Dedicated Input Signal, set the gun separation accept signal number
(encoder brake power supply OFF control signal).
_____________________________________________________________________
10-32 May 22, 2001

ERROR CODE -641 Now servo gun is disconnected or a different gun.
The robot executes a step when a gun is not attached to the tool changer or the gun
number in the tool changer is different than the gun number for the program step.
⇒ Execute the step in manual mode or manually install the correct gun. In the teach or
check mode, verify connection of the gun by pressing the connect/separate button.
⇒ If the correct gun is attached to the tool changer, confirm that the gun signal number
(AUX 114-41, GUN CONNECTION SIGNAL) is correct. From the MONITOR (INPUT
SIGNAL) screen, confirm that the signal number is received.
⇒ Inspect the connectivity from the gun to the 1FG board.
⇒ Temporarily set the gun connect signal number (AUX 114-41, GUN CONNECTION
SIGNAL) to 0 (when the gun connect number is set to 0, the error is not detected);
ensure that the correct gun is in the tool changer. Repair the gun connection and set
the gun connect signal number as soon as possible.
_____________________________________________________________________
ERROR CODE -642 Calibration is not completed.
The controller terminates the calibration operation after a gun change.
⇒ Reset the error and perform a manual gun change.

_____________________________________________________________________
ERROR CODE -643 Measure of chip abrasion (stage 1) was not executed.
When the tip wear measurement program stage 2 (reference plate) is attempted, without
first performing stage 1.
⇒ Execute tip wear measurement program stage 1 prior to executing stage 2.

_____________________________________________________________________
ERROR CODE -644 Work sensing signal (gun_chip[tip] touch sig) is not estab-
lished.
A workpiece thickness measurement is attempted, when the gun tip touch signal (set in
AUX 114-41) has not been received.
⇒ Set the gun tip touch signal number (AUX 114-41).

_____________________________________________________________________
May 22, 2001 10-33

ERROR CODE -645 Cannot weld because of abnormal thickness.
The thickness of the workpiece is out of tolerance.
Probable causes:
1. Defective workpiece.
2. Incorrect positioning of the workpiece
3. A gap between the two panels being welded.
4. Current tip wear (AUX 114-41) and actual tip wear are different.
⇒ Inspect the workpiece. Measure the thickness and positioning; replace workpiece
and/or correct abnormal positioning.
⇒ Execute the tip wear measurement program. Manually measure the tip wear; com-
pare these measurements to the current tip wear data (AUX 114-41).
_____________________________________________________________________
ERROR CODE -646 Servo welding gun mechanical parameter is not estab-
lished.
When connecting a new gun, the mechanical parameters are not defined.
⇒ Define the parameters in AUX 114-12 SPOT WELD GUN DEFINITION and AUX114-
42 SERVO WELDING MECHANICAL PARA.
_____________________________________________________________________
ERROR CODE -653 Illegal DOUBLE OX output.
When Double type signals are used, if either output in the pair is turned ON, the other
turns OFF. An instruction to turn both outputs ON or turn both outputs OFF (OX=+1,2 or
OX=-1,2) causes this error.
⇒ Modify using the teaching screen.

_____________________________________________________________________
10-34 May 22, 2001

ERROR CODE -654 Cannot use DOUBLE OX.
When Double type signals are used, if either output in the pair is turned ON, the other
turns OFF. An instruction (BITS, PULSE, DELSIG, etc.) to change the state of either
output causes this error to occur.
⇒ Modify using the teaching screen.

_____________________________________________________________________
ERROR CODE -660 Gun chip abrasion over the limit.
The maximum tip wear limit (AUX 114-41 MAX ABRASION MOVING/FIXED[mm]) is
exceeded.
⇒ Replace the tips.

_____________________________________________________________________
ERROR CODE -662 Start point position error for circle.
The robot was stopped after it began executing a circular motion and moved 4 mm or
more away from its calculated path (jogging or brake slippage, etc.). Attempting to
continue execution of the path from this position will result in this error.
⇒ Move the robot closer to the calculated path or restart the program a step prior to the
circular path.
_____________________________________________________________________
ERROR CODE -671 Cannot execute in check back mode.
The program reached an instruction which cannot be executed in check back mode.
⇒ Execute after selecting a step that can be checked backward. If possible, check
forward.
_____________________________________________________________________
ERROR CODE -672 Cannot execute in ONE program.
The instructions specified in the ONE program area not valid for this type of program.
⇒ Refer to the AS Language manual for proper use of the AS Language commands.
_____________________________________________________________________
May 22, 2001 10-35

ERROR CODE -673 Angle between JT2 and JT3 is out of range at start loca-
tion.
Movement from the current position to the start location position would cause JT2 and
JT3 to move beyond their limits.
⇒ Modify the position of the start location of the program.

_____________________________________________________________________
ERROR CODE -674 Angle between JT2 and JT3 is out of range at end loca-
tion.
Movement from the current position to the end location position would cause JT2 and
JT3 to move beyond their limits.
⇒ Modify the position of the end location of the program.

_____________________________________________________________________
ERROR CODE -675 Terminal is not connected.
A PRINT, TYPE, or PROMPT command is specified for display on a PC that is not

connected.
⇒ Verify the PC connections or modify the commands for display on the MFP.
_____________________________________________________________________
ERROR CODE -676 Cannot input /output to multi function panel.
A PRINT, TYPE, or PROMPT command is specified for display on the MFP, although no
MFP connection is present.
⇒ Verify the MFP connections or modify the commands for display on the PC.
_____________________________________________________________________
ERROR CODE -691 Cannot change two or more guns at the same step.
The operator attempts to execute a step with more than one gun change.
⇒ Edit the program so that there is only one gun change per step.
_____________________________________________________________________
10-36 May 22, 2001

ERROR CODE -692 Gun is connected other.
The tool changer attempts to connect to a gun that is already connected to another tool
changer or is missing.
⇒ Select a different gun or disconnect the gun from the other tool changer.
NOTE
The following are conventional robot errors; however,

when they occur for the servo gun axis, the following ad-
ditional causes are possible.
_____________________________________________________________________
ERROR CODE -700 No free memory.
No free memory is available to teach or edit programs.
⇒ Delete unused programs and variables, or, expand system memory to maintain the
required capacity.
_____________________________________________________________________
ERROR CODE -800 Program does not exist.
No program is on the stack at the time of cycle start or execution command (without a
program being specified).
⇒ Identify program to be executed.

_____________________________________________________________________
ERROR CODE -801 No program step. The step specified for execution does
not exist.
⇒ Select valid step numbers for execution.

_____________________________________________________________________
ERROR CODE -802 Nonexistent label.
Occurs when executing the GOTO command and the destination label is not defined.
⇒ Ensure valid labels are used within the program.

_____________________________________________________________________
May 22, 2001 10-37

ERROR CODE -803 Undefined variable. Variable data for a specific argument
in a command is not defined.
⇒ Ensure variables are properly defined.

_____________________________________________________________________
ERROR CODE -804 Undefined location data.
The location variable for the BASE, TOOL or POINT command is not specified. Also, a
named position in a program is not defined in system memory.
⇒ Define all locations identified in programs.

_____________________________________________________________________
ERROR CODE -805 Undefined string variable. String variables that are evalu-
ated by ASC and LEN functions are not defined.
⇒ Define the string variables to be evaluated or correct the name of the string variable
used for evaluation.
_____________________________________________________________________
ERROR CODE -807 Undefined program or label.
The program name or label associated with an ON or ONI command does not exist.
⇒ Define the program or label used with the ON or ONI command.

_____________________________________________________________________
ERROR CODE -808 Illegal value. The numeric value entered exceeds the
upper or lower limits of the acceptable range.

_____________________________________________________________________
ERROR CODE -809 Undefined array suffix.
Attempt to process an array variable with undefined suffixes, i.e., attempting to process
A=B[C,D,E], but C, D, E have no values.
⇒ Rewrite the program to define the array suffix before attempting to process the array.
_____________________________________________________________________
10-38 May 22, 2001

ERROR CODE -810 Divided by zero.
Occurs when the system encounters a mathematical evaluation that involves division by
“0”. Typically associated with the FRAME function and circular interpolation.
⇒ Check data source for calculations.

_____________________________________________________________________
ERROR CODE -811 Floating point overflow.
Occurs when the system encounters a numeric floating point overflow in using arith-
metic (+, -, *, /)or logical (AND, OR, etc.) operators. This also occurs when converting a
numeric argument to an integer value.
⇒ Correct the program. Integer values with full precision ranges are from -16,777,216
to 16,777,216. For more information refer to the C Series Controller AS Language
Reference Manual.
_____________________________________________________________________
ERROR CODE -812 Character string is too long.
Character strings associated with arithmetic or comparative operators or the LEN func-
tion are too long.
⇒ Correct the program.

_____________________________________________________________________
ERROR CODE -813 Illegal exponential operation.
Numeric values that have exponents must be positive in value.
⇒ Correct equations in program.

_____________________________________________________________________
ERROR CODE -814 Expression too complicated.
A numeric calculation too complex to be evaluated was encountered.
⇒ Simplify mathematical equations.

_____________________________________________________________________
May 22, 2001 10-39

ERROR CODE -815 No expressions to evaluate.
The type of data in an argument is incompatible with the operation being performed.
⇒ Correct the program to evaluate compatible expressions.

_____________________________________________________________________
ERROR CODE -816 Unexpected error while evaluating expression.
Occurs when the system is evaluating the argument in an expression and the data of
the argument is found to be incompatible or missing.
⇒ Correct the program so that data is compatible with arguments and expressions.
_____________________________________________________________________
ERROR CODE -817 SQRT parameter is negative.
In the argument of a SQRT function, a negative number was entered for evaluation.
⇒ Do not enter negative numbers for evaluation by the SQRT function.

_____________________________________________________________________
ERROR CODE -820 Illegal array index.
Occurs when the array subscript number exceeds the acceptable range from 0 to 9999.
⇒ Ensure the range of array subscripts is acceptable.

_____________________________________________________________________
ERROR CODE -821 Illegal argument value.
Displayed when the parameter specified for an command or instruction is illegal. For
example: TOOL 2112 (after the TOOL command a defined transformation location or null
is expected, 2112 causes error).
⇒ Use correct argument values.

_____________________________________________________________________
ERROR CODE -822 Illegal joint number.
The joint numbered entered does not exist or is in the wrong format.
⇒ Retype the command using the correct format.

_____________________________________________________________________
10-40 May 22, 2001

ERROR CODE -823 Illegal signal number.
This is displayed when the SIG or BITS command is used and the specified signal
number is beyond the range permitted by the system configuration.
⇒ Use acceptable signal numbers for system configuration.

_____________________________________________________________________
ERROR CODE -824 Illegal timer number.
Displayed when a timer was specified that was not within the acceptable range of be-
tween 1 and 10.
⇒ Specify timers in the range between 1 and 10.

_____________________________________________________________________
When the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT commands are used with a
signal number that exceeds the range permitted by system configuration, this error is
displayed.
⇒ Check signal number specified in instruction and ensure it is within system configura-
tion.
_____________________________________________________________________
ERROR CODE -826 Illegal clamp number.
Displayed when the clamp number entered exceeds the maximum permitted by system
configuration.
⇒ Use only clamp numbers that are supported by system configuration.

_____________________________________________________________________
ERROR CODE -827 Illegal time value.
Displayed when a negative number is entered as part of a DELAY or TIMER command.
⇒ Correct the time setting to a positive number.

_____________________________________________________________________
May 22, 2001 10-41

ERROR CODE -828 No value set.
Occurs when an instruction like the BITS command is evaluated and there is no corre-
sponding value set.
⇒ Correct program code to evaluate existing values.

_____________________________________________________________________
This error is displayed when the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT com-
mands are used with a signal number that exceeds the range permitted by system
configuration.
⇒ Check signal number specified in the instruction and ensure it is within system con-
figuration.
_____________________________________________________________________
ERROR CODE -832 Illegal time input data.
Occurs when erroneous data has been entered in the setting of the TIME and DATE
function. For example: a date of Feb. 30.
⇒ Input time and date information correctly, mm/dd/yy.

_____________________________________________________________________
ERROR CODE -834 Program name already exists.
When using the RENAME command a new program name must be specified. If an
existing name is used to rename a program this error will be displayed.
⇒ Specify unused program names when renaming programs.

_____________________________________________________________________
ERROR CODE -835 Can’t KILL because the program is running.
Displayed when an attempt was made to KILL a program that was in the process of
executing.
⇒ Stop program execution with HOLD or ABORT commands before program is re-
moved from the stack with a KILL command.
_____________________________________________________________________
10-42 May 22, 2001

ERROR CODE -837 Cannot use dedicated signal.
Occurs when a previously dedicated signal was used as a general purpose signal.
⇒ Use signals that have not been dedicated for general functions.
_____________________________________________________________________
ERROR CODE -838 Not RPS mode.
Occurs when the required input signals are not dedicated at the time an attempt to run
an externally selected program is made.
⇒ If RPS is to be used the necessary signals must be dedicated.

_____________________________________________________________________
ERROR CODE -839 Cannot use negative number. Displayed when a negative
number has been used in conjunction with the PULSE or
ACCURACY commands.
⇒ Use only positive numbers in the acceptable range for the PULSE and ACCURACY
commands.
_____________________________________________________________________
ERROR CODE -840 Too many subroutines.
Occurs when more than 20 subroutines are nested with EXTCALL or CALL instructions.
⇒ Do not exceed 20 nested subroutines.

_____________________________________________________________________
ERROR CODE -842 Nonexistent subroutine. Displayed when the program

identified by a CALL, ON, or ONI does not exist.
⇒ Select only existing programs to be run as subroutines.

_____________________________________________________________________
ERROR CODE -846 No program exist.
Pertinent program does not exist in DIRECTORY and LIST commands.
⇒ Correct program or make program.

_____________________________________________________________________
May 22, 2001 10-43

ERROR CODE -850 Out of absolute lower limit.
Displayed when an attempt has been made to set the software lower limits of robot
travel to a value that is too low.
⇒ Set lower software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -851 Out of absolute upper limit.
Displayed when an attempt has been made to set the software upper limits of robot
travel to a value that is too high.
⇒ Set upper software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -852 Out of user lower limit.
Displayed when an attempt has been made to set the software lower limits of robot
travel to a value that is too low.
⇒ Set lower software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -853 Out of user upper limit.
Displayed when an attempt has been made to set the software upper limits of robot
travel to a value that is too high.
⇒ Set upper software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -854 Current position of jt* is out of range.
This error can occur when two guns are used. When a program is taught with one gun,
and a second gun is used to perform the program, the second gun may not be able to
execute a program step. This may be due to differences in the physical size or mechani-
cal characteristics of the two guns.
⇒ Reteach the point(s), using a configuration which allows the robot to reach the de-
sired position with both guns.
_____________________________________________________________________
10-44 May 22, 2001

ERROR CODE -855 Motion start location of jt-x is out of range.
Prior to beginning a program or motion to a step, the software has calculated the loca-
tion to be outside of the allowable upper or lower software limits.
⇒ Correct location to within working envelope or expand software limits to accept loca-
tion.
_____________________________________________________________________
ERROR CODE -856 Motion and location of jt-x is out of range.
While executing a motion to a step, the software has calculated the location destination
of the specific joint number to be outside of the allowable upper or lower software limits.
tion.
_____________________________________________________________________
ERROR CODE -857 Destination is out of range.
While executing a motion to a step, the software has calculated the location destination
of all joints to be outside of the allowable upper or lower software limits.
tion.
_____________________________________________________________________
ERROR CODE -858 Illegal configuration for linear motion.
System software has determined that the start and end points of a linear move will
cause the robot to exceed the acceptable motion parameters.
⇒ Change motion interpolation to a joint move; move location to avoid configuration.

_____________________________________________________________________
ERROR CODE -871 Illegal joint number.
Occurs when the DRIVE command is used and specifies a joint number that is not part
of the robot configuration.
⇒ Confirm robot configuration before using the DRIVE command.

_____________________________________________________________________
May 22, 2001 10-45

ERROR CODE -872 Cannot execute motion instruction in PC program.
A PC program cannot contain instructions that initiate robot motion. If a motion instruc-
tion is encountered in a PC program this error will be displayed.
⇒ Correct the PC program by removing motion instructions.

_____________________________________________________________________
ERROR CODE -873 Illegal auxiliary data number.
The value selected for auxiliary data (speed, timer, tool etc.) exceeds allowable range.
⇒ Correct the value of auxiliary data.

_____________________________________________________________________
ERROR CODE -874 No circular location.
Program circular motion instructions must have C1 moves followed by either a C1 or C2

move.
⇒ Correct program instructions.

_____________________________________________________________________
ERROR CODE -875 No C1MOVE(CIR1) ins.
Program circular motion instructions must have C2 moves preceded by a C1 move.

_____________________________________________________________________
ERROR CODE -876 Cannot create circle.
Circular interpolation moves cannot be processed because the points identified are too
narrow or are on a straight path.

_____________________________________________________________________
10-46 May 22, 2001

ERROR CODE -877 Cannot execute, because of sealing type.
Occurs when a command for a sealing application is evaluated by a controller that is not
configured for sealing applications.
⇒ Correct program instructions to match software configuration.

_____________________________________________________________________
ERROR CODE -879 Cannot execute, because of not sealing type.
Occurs when a GUNON, GUNOFF, GUNONTIME or GUNOFFTIME command for a

sealing application is evaluated by a controller that is not configured for sealing applica-
tions.
⇒ Correct program instructions to match software configuration.

_____________________________________________________________________
ERROR CODE -896 Option is not set up, can’t execute.
⇒ Contact customer service for option specifications after confirming the purchase
specification.
_____________________________________________________________________
ERROR CODE -900 Arc failure.
The signal (current detection: WCR) that indicates the robot is executing the weld did not
return from the welder for 1 sec. or more after welding started.
⇒ Check for insulating debris that prevents welding.

⇒ Confirm that adequate supply of wire is available.
⇒ Confirm that wire is not stuck to the welding tip.
_____________________________________________________________________
ERROR CODE -901 Wire stuck.
The wire is stuck to the base metal at the weld end.
⇒ Cut the wire.

⇒ Change weld conditions if problem occurs frequently.
_____________________________________________________________________
May 22, 2001 10-47

ERROR CODE -902 Electric pole stuck.
⇒ Contact KRI Customer Service.

_____________________________________________________________________
ERROR CODE -909 Watch-Dog Error RS485 Special Communication Board.

_____________________________________________________________________
ERROR CODE -910 Work not detected (Touch sensing)

_____________________________________________________________________
ERROR CODE -911 Undefined sensing direction. (Touch sensing)

_____________________________________________________________________
ERROR CODE -912 Insufficient sensing points. (Touch sensing)

_____________________________________________________________________
ERROR CODE -913 Mother or daughter work does not exist. (Touch sensing)

_____________________________________________________________________
ERROR CODE -914 Number of sensing points exceeded. (Touch sensing)

_____________________________________________________________________
ERROR CODE -915 Illegal work appointment. (Touch sensing)

_____________________________________________________________________
ERROR CODE -916 Illegal sensing points appointment. (Touch sensing)

_____________________________________________________________________
10-48 May 22, 2001

ERROR CODE -917 Wire check failed. (Touch sensing)

_____________________________________________________________________
ERROR CODE -919 No RS485 Special Communication board.

_____________________________________________________________________
ERROR CODE -920 Illegal welding condition number.

_____________________________________________________________________
ERROR CODE -921 Weld data not set up.

_____________________________________________________________________
ERROR CODE -922 Weld data out of range.

_____________________________________________________________________
ERROR CODE -934 No weld data base.

_____________________________________________________________________
ERROR CODE -935 Cannot change condition.

_____________________________________________________________________
ERROR CODE -951 No RTPM board. (RTPM)

_____________________________________________________________________
ERROR CODE -960 To many taught points for RTPM. (RTPM)

_____________________________________________________________________
May 22, 2001 10-49

ERROR CODE -961 RTPM arc sensor error. (RTPM)

_____________________________________________________________________
ERROR CODE -962 Out of RTPM tracking value. (RTPM)

_____________________________________________________________________
ERROR CODE -963 Out of RTPM tracking capacity. (RTPM) Þ Contact KRI
Customer Service.
_____________________________________________________________________
ERROR CODE -964 RTPM current deviation error. (RTPM)

_____________________________________________________________________
ERROR CODE -990 No welding interface board.
The welding interface board was not detected at control power on.
⇒ Turn control power off and confirm that the weld interface board is mounted.
⇒ Confirm that the weld interface board is not loose. Insert the board firmly.
_____________________________________________________________________
ERROR CODE -999 No welding interface board.
The welding interface board was not detected at control power on.
⇒ Turn control power off and confirm that the weld interface board is mounted.
⇒ Confirm that the weld interface board is not loose. Insert the board firmly.
_____________________________________________________________________
10-50 May 22, 2001

ERROR CODE -1003 Data base error.
The program storage area of the system memory has been damaged and is not linking
data correctly.
⇒ Turn on the 1GA board switch SW2-8 to initialize the memory, do not use AUX100 or
SYSINIT command. Reload the teach data.
⇒ Check that system is properly isolated from electrical noise.
⇒ Check the memory backup battery. Replace if necessary.
⇒ Replace the 1GA board if the error re-occurs.
_____________________________________________________________________
ERROR CODE -1012 Command position of jt-x has suddenly changed.
Spot welding and material handling

In the repeat mode, the commanded position of the joint identified has exceeded 1.3
times the maximum arm speed. In the check mode, the commanded position of the joint
identified has exceeded 200 mm/sec.
⇒ Check for singularity condition during robot motion and reteach to correct.
⇒ Check for loose or defective servo system encoders, harnesses, and circuit boards.
Servo welding gun

Occurs when corrections for deflection cause movement of the robot to exceed the
range of motion of one or more axes. This condition is not limited to the gun axis; any
axis, including the gun axis, can cause this error.
⇒ Change the posture of the robot.

⇒ Decrease the speed in the step.
⇒ Reduce the amount of the deflection correction in the step by using AS Language
SGREFLEX command.
⇒ Reteach the point and change the configuration of the posture of the robot if needed.
_____________________________________________________________________
May 22, 2001 10-51

ERROR CODE -1014 Commanded position of jt-x is out range.

The commanded position for the joint identified has exceeded the software limits. Con-
dition is monitored in both the check and repeat modes.
⇒ Correct taught positions to avoid the software limits.

⇒ Adjust the software limits to provide the necessary work envelope.
Servo welding gun

If a taught point is near a servo gun or arm axis range of motion limit, the combination of
tip wear and deflection correction can prevent the robot from reaching the taught point.
⇒ Do not teach points that are near axes range of motion limits.
_____________________________________________________________________
ERROR CODE -1017 Angle between JT2 and JT3 is out of range.
The commanded position for JT2 and JT3 cannot be reached due to the nature of the
mechanical links that exist between these points for the U-series, EH, and ES robots.
This error does not apply to JS-series robots. The main cause of this error is that the
taught positions, including positions through which the robot moves, are bad.
⇒ Change the taught positions.

_____________________________________________________________________
ERROR CODE -1019 Check sum error of system data.
The check sum of the system data of the AS software was changed when the system
information such as model number, number of axis, and option setting, was downloaded.
When the error occurs in situations other than downloading, the error is caused by
defective memory back-up, defective 1GA board, or memory error from noise.
⇒ Use Aux 78 CLEAR CHECK SUM ERROR or CHSUM command to reset the data.
When the error cannot be reset using the check sum commands, the command with
the abnormality is shown. Rewrite the command and use CHSUM or Aux 78 to clear
the error.
⇒ Check the memory backup battery. Replace if necessary.
⇒ Replace the 1GA board if the error re-occurs.
_____________________________________________________________________
ERROR CODE -1022 RAM battery low voltage <board name>.
10-52 May 22, 2001

When control power is applied or motor power is turned on, a voltage check is per-
formed on the batteries that maintain SRAM memory when power is off. This message
is displayed when a voltage of 2.5 VDC or less is detected (normal is 3.6 VDC).
⇒ Back up system and program data, check and replace batteries as required.
⇒ Check batteries for defective connections. Repair the defective connection.
⇒ Defective battery voltage monitoring circuit. Replace the circuit board.
_____________________________________________________________________
ERROR CODE -1025 AS Flash memory sum check error.
A check sum error of AS system data in flash memory on 1GA board occurred when the
power was turned on. The check sum data is created when the FCHK command is
executed and is recorded in flash memory during download. Main causes of the error
are:
1. When the AS system was downloaded, the FCHK command was not executed.
2. The addressing of the FCHK command was wrong.
3. The flash memory and 1GA board are defective.
4. The system data in the flash memory is damaged.
⇒ Confirm the content of the command as_load.cmd file in the IC card if error occurs
immediately after downloading the AS system. Download system again. If error
continues after download, exchange the 1GA board.
_____________________________________________________________________
ERROR CODE -1026 Servo Flash memory sum check error.
A check sum error of the servo system in flash memory on 1GA board occurred when
the power was turned on. The check sum data is created when the FCHK command is
executed and is recorded in flash memory during download. Main causes of the error
are:
1. When the servo system was downloaded, the FCHK command was not executed.
2. The addressing of the FCHK command was wrong.
3. The flash memory and 1GA board are defective.
4. The system data in flash memory is damaged.
⇒ If the error occurs immediately after download, confirm the content of as_load.cmd in
the PC card and download again. If the error persists, change the 1GA board.
_____________________________________________________________________
ERROR CODE -1051 Cannot execute in this robot arm.
May 22, 2001 10-53

Unused
_____________________________________________________________________
ERROR CODE -1100 CPU Error (Code = ****).
The 1GA board CPU has stopped (detected with the AS software). This error is caused
by defective AS or servo software, defective hardware, or noise related malfunction.
⇒ With a PC connected enter “$save/flt filename” to save the fault data, and send to
KHI.
⇒ Confirm which board the error occurred on by referring to the message that appears
on the PC. This error does not appear on the multi function panel or the small teach
pendant.
I/O BUS ERROR: error in the address of the 1FR or 1GW board.
PSB BUS ERROR: error with the 1FP or 1HP power sequence board.
VME BUS ERROR: error in the address of the boards that use the VME bus.
⇒ If the initialization prompt appears, answer “no”, then reload software. If the error
returns, initialize the system and reload software. If the multi function panel or PC are
not functional, system initialization cannot be performed.
⇒ If this error occurs during certain specific operations it may indicate a defect in the AS
system.
⇒ Replace the 1GA board if the error cannot be reproduced or cleared.
_____________________________________________________________________
ERROR CODE -1101 Main CPU BUS error.
10-54 May 22, 2001

On the 1GA board, a bus error (in the VME bus line, data processing was not able to be
done normally) has occurred (detected with the AS software). This error is caused by
defective AS or servo software, defective 1GA board, or noise related malfunction.
⇒ With PC connected enter “$save/flt filename” to save the fault data, and send to KHI.
pendant.
system.
_____________________________________________________________________
ERROR CODE -1102 VME BUS error.
This error occurs when the CPU does not receive a response from one of the I/O bus
devices within a specific time. This error is caused by defective AS or servo software,
defective 1GA board, or noise related malfunction.
⇒ With a PC connected enter “$save/flt filename” to save the fault data, and send to
KHI.
pendant.
system.
_____________________________________________________________________
ERROR CODE -1200 Encoder board is not installed.
May 22, 2001 10-55

Unused
_____________________________________________________________________
ERROR CODE -1201 Power sequence board is not installed.
The first address of the No.1 power sequence board (1FP/1HP board) cannot be read
when control power is turned ON. Main causes for this error include:
1. The power sequence board (1FP/1HP board) is not installed in the correct card slot.
2. Jumper or dip switch settings of the power sequence board are incorrect.
3. Defect in the power sequence board.
⇒ Ensure the 1FP/1HP board DSW1 setting is configured as power sequence board
No. 1 and is installed in the 1FP/1HP card rack slot. Check and replace the board if
necessary.
_____________________________________________________________________
ERROR CODE -1202 No2 power sequence board is not installed.
The first address of the No.2 power sequence board (1FP/1HP board) cannot be read
when the control power is turned ON. Main causes for this error include:
1. The power sequence board (1FP/1HP board) is not installed in the correct card slot.
2. Jumper or dip switch settings of the power sequence board are incorrect.
⇒ Ensure the 1FP/1HP board DSW1 setting is configured as power sequence board
No. 2 and is installed in the 1FP/1HP card rack slot. Check and replace the board if
necessary.
_____________________________________________________________________
ERROR CODE -1203 No x-M I/O board is not installed.
10-56 May 22, 2001

Cannot read the first addresses of I/O boards (1FR/1GW board, etc.) based on the
number of signals that have been set with DO (output point), or DI (input point) of the
ZSIGSPEC command, when the control power supply is turned on. This error is not
used when a 1FS board is installed. Main causes include:
1. Incorrect value set with the ZSIGSPEC command.
2. Error in board address of I/O board (1FR/1GW board, etc.).
3. Defect of I/O board (1FR/1GW board, etc.).
⇒ Set the correct number of signals with the ZSIGSPEC command. I/O cards are
typically mounted in the card rack from right to left in ascending order. Because of
VME buss communication, this is not critical. The robot can run without I/O boards.
The maximum number of signals in the software set with the ZIGSPEC command is
DO, DI=256, INT=512, but DO and DI are restricted by hardware and other options.
⇒ Set board address jumpers correctly.
⇒ Replace the 1FR/1GW board.
_____________________________________________________________________
ERROR CODE -1204 Option SIO port is not installed.
The 1GA board sets more than seven axes at control power ON, but the IC (SIO) for
serial communications for command line 3 and 4CH communication with the servo
board is not installed. This error typically does not occur because SIO is installed on
standard 1GA boards but may not be on the prototype boards. Main causes of this error
include more than seven axes set with a prototype board with SIO not mounted or a
defect in the 1GA board.
⇒ Replace the 1GA board.

_____________________________________________________________________
ERROR CODE -1205 Power sequence board any error.
May 22, 2001 10-57

An error signal, not classified through the error summary, is generated by the 1FP/1HP
board and not recognized by the AS software. Main causes include:
1. The error detection function of the power sequence board does not correspond to
the error processing function of the AS software.
3. Defect in the 1GB board.
4. Defect in the wiring between the 1FP/1HP board and the 1GB board.
(XGB-CN1 ↔ XHZ-CN4)
⇒ Replace the power sequence board.

⇒ Repair/Replace the 1FP/1HP board to the 1GB board wiring harness.
⇒ Install the correct version of the AS software.
_____________________________________________________________________
ERROR CODE -1206 Built-in sequence board is not installed.
Installation of the built-in sequencer board is checked when the control power supply is
turned ON. This error occurs when the built-in sequencer board is not installed.
⇒ Install the built-in sequencer board.

_____________________________________________________________________
ERROR CODE -1208 RI/O board is not installed.
This error occurs when the control power supply is turned on and the first address of the
RI/O board is not read (1GW, 1FS etc.).
1. The RI/O board is not installed.
2. Defect in the RI/O board.
⇒ Ensure the RI/O board installed.

⇒ Replace the RI/O board.
_____________________________________________________________________
ERROR CODE -1209 RI/O board initialize error.
10-58 May 22, 2001

This error occurs when the control power supply is turned on and the RI/O board does
not successfully initialize (1FS board).
1. Incorrect dip switch settings on the RI/O.
2. Defect in the RI/O board software.
⇒ Set dip switch correctly on RI/O board.

⇒ Reinstall the RI/O board software.
_____________________________________________________________________
ERROR CODE -1247 Axis setting data incorrect.
The command channel line for the external axis was incorrectly set using AUX 901,
External Axis Set.
⇒ Input the correct value.

_____________________________________________________________________
ERROR CODE -1248 Number of Axis Changed! SYSINI.
The number of axis assigned to the robot has changed.
⇒ Change the number of axes and initialize the system.

_____________________________________________________________________
ERROR CODE -1249 Servo parameter Changed! Control power turn OFF & ON.
Servo parameters in system data changed during LOAD.
⇒ Turn control power supply OFF and ON.

_____________________________________________________________________
ERROR CODE -1250 Servo board (X) Initialize error.
May 22, 2001 10-59

The servo software was not successfully loaded from the FLASH memory on the 1GA
board to the servo board when control power was turned ON. The contents of (X) is an
alphanumeric code as indicated below:
A 0 7
7: Servo program download error

6: Servo parameter download error
4: Trap error (Servo software initialization error)
CPU channel of servo board
Main causes include:

1. Defect in the 1GB servo board.
2. Defect of the harness between power sequence board and servo board.
3. Error in mother board jumper setting.
4. The servo software is not in the flash memory on the 1GA board.
(XGB-CN1↔XHZ-CN4)
5. Malfunction caused by noise, etc.
6. Servo software and AS software versions incompatible.
7. Versions of ROM in servo software and servo board not compatible.
⇒ Replace the 1GA, servo board, and each harness.

⇒ Confirm the servo software and the servo board monitor ROM version and install the
corresponding servo software again. Confirmation of the version can be confirmed by
AUX 90, Software Version Display, or ID command.
_____________________________________________________________________
ERROR CODE -1251 Servo board (X) communication error.
10-60 May 22, 2001

Communications in the command line of each CPU of the servo board (1GB board)
failed twice consecutively. The command line always communicates every 4 msec.
When each CPU of the servo board stops, this error might be detected. Main causes
include:
Relay to Power Sequence

CH To Communication
Board (1FP/1HP PC Board)
A First 1GB PC Board A Unit Master
B First 1GB PC Board B Unit Master
First 1GB PC Board C Unit
or
C Second 1GB P Board A Unit Slave
or
One Axis Amplifier
Second 1GB P Board B Unit
D or Slave
One Axis Amplifier
1. Defect in the 1GA board.

3. Defect in each communication harness.
4. Encoder defect if JT3 (A) or JT4 (B) are displayed.
5. Noise malfunction.
6. Mismatch of AS and servo software
7. Improper setting of AUX 928; servo type 2.
⇒ Ensure software versions are correct.

⇒ Ensure AUX 928 setting is correct.
⇒ Replace the 1GA, servo board, and each harness.
_____________________________________________________________________
ERROR CODE -1252(A), -1253(B), -1254(C), -1255(D)
May 22, 2001 10-61

Servo board (x) hardware error code = xxxx.
A hardware error was detected by the 1GB board with no corresponding error in the AS
software. The internal error code number that the AS software detected is displayed in
xxxx. The unit name of the servo board displayed at x in the error message corresponds
to the CH column in the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
Main causes of this problem include the following abnormalities:

1. Defect in the servo software.
3. Defect in the harness between servo board and power sequence board.
4. Defect of the servo board.
5. Versions of servo and AS software incompatible.
6. Malfunction in the servo or AS software.
⇒ Install upgraded versions of servo and AS software.

⇒ Replace the 1GA board, the servo board, and each harness.
⇒ When this error occurs, contact KRI to report the details.
_____________________________________________________________________
ERROR CODE -1256(A), -1257(B), -1258(C), -1259(D)
10-62 May 22, 2001

Servo board (x) software error code = xxxx.
A hardware error was detected by the 1GB board with no corresponding error in the AS
software. The internal error code number that the AS software detected is displayed in
xxxx. The unit name of the servo board displayed at x in the error message corresponds
to the CH column in the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
Main causes of this problem include the following abnormalities:

1. Defect in the servo software.
4. Defect of the servo board.
⇒ Install upgraded versions of servo and AS software.

⇒ When this error occurs, contact KRI to report the details.
_____________________________________________________________________
ERROR CODE -1260 Option changed! SYSINI.
May 22, 2001 10-63

Unused
_____________________________________________________________________
ERROR CODE -1261 Servo board (x) parameter setting error.
After a setting was changed with AUX 976 servo parameter, the data sent to the servo
board was different than the data received two or more times. The unit name of the
servo board displayed at x in the error message corresponds to the CH column in the
table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
Main causes of this error include:

1. Defect in the 1GA board.
2. Defect in the servo board.
3. Defect of each communication harness.
5. Malfunction by noise.
⇒ Replace the 1GA board, the servo board and each harness.
⇒ Install correct versions of AS and servo software.
⇒ If error cannot be reset, reset data with AUX 976.
⇒ If error cannot be reset, cycle control power.
_____________________________________________________________________
ERROR CODE -1262 EXT AXIS cutting error.
10-64 May 22, 2001

Occurs when a gun disconnect is not normally completed.
⇒ Check for errors on the 1HP and 1GB boards.

⇒ Check the wiring harness between the 1HP and 1GB boards.
ERROR CODE -1263 EXT AXIS connecting error (CODE ).
Occurs when the gun axis connection is not normally completed.
Code 0: No answer from the servo welding gun.

Code 11: Terminated normally.
Code 80: Channel No. is erroneous or erroneous code.
Code 81: Inexecutable due to RGSO is unkown.
Code 101: Pressure applying force limit value is not yet selected in negative section.
Code 102: Pressure applying force limit value is not yet selected in positive section.
Code 103: Pressure applying force limit value is not yet selected in both sections.
Code 200: Scope of movement restoration after calibration is not terminated.
According to the code number displayed following the error message, perform the
following:
Code 0:This error occurs when the servo software does not respond. It may be caused
by failure of the 1HP or 1GB board or the harness between the boards.
Code 200: After connecting the gun, if the gun cannot be operated within a specified
time this error is displayed.
If the gun fully opens once and the error is generated:
⇒ Verify that the servo gun’s upper and lower limits are correctly set.
⇒ Use the gun brake release switch, release the gun’s brake. Manually move the gun
to check for mechanical binding.
If the gun cannot be moved and the error is generated:
⇒ The pressure setting may not be enough to move the gun.

From the Spot service : Servo welding gun pressure adjustment function, calibrate
the clamping pressure.
⇒ Check the gun for proper mechanical functioning. Check the brake.
ERROR CODE -1300 Servo CPU-(x) watch dog error.
May 22, 2001 10-65

The watch dog circuit on the 1GB board has detected a software problem. This is
caused by a defective servo board or a problem with the servo software. The unit name
of the servo board displayed at x in the error message corresponds to the CH column in
the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
⇒ Replace the servo board.

_____________________________________________________________________
ERROR CODE -1306 Servo board command error.
Servo software has returned the error code to the AS software. Main causes include:
4. Defect of the servo board or the 1GA board.
⇒ Install correct versions of servo and AS software.

_____________________________________________________________________
ERROR CODE -1308 Motor power off.
10-66 May 22, 2001

Occurs when software turns motor power on (K1 or K2 contactors on) but there is no
signal feedback (MCON) indicating motor power is on. Main causes include:
1. Defect in the power sequence board (1FP/1HP board).
2. Defect in the relay board (1FY/1HY board).
3. Malfunction in the error detection circuit and error processing of each board.
4. Auxiliary contact of magnet contactor (K1, K2) for motor power is defective.
5. Malfunction with the servo software or the AS software.
6. Defect in the harnesses between XHY-CN3 and KI/K2.
⇒ Replace the power sequence board.

⇒ Replace the relay board.
⇒ Replace the magnetic contactor.
⇒ Repair or replace the harnesses between XHY-CN3 and K1/K2.
_____________________________________________________________________
ERROR CODE -1333 Monitor ID of servo board mismatch!
The monitor ROM software version of each unit on the 1GB board is different, caused by
a defect of the 1GB board.
⇒ Replace the 1GB board.

_____________________________________________________________________
ERROR CODE -1334 Servo control line error.
Brake open command is not returned within 2 seconds when the servo control on
(SVCN) signal is sent from the AS software to the servo board (1GB) through the EPLD
register of the power sequence board (1FP/1HP). Main causes include:
1. Defect in the 1FP/1HP power sequence board.
3. Incorrect 1GB board dip switch settings.
4. Defect in the harness between the two boards. (XGB-CN1↔XHZ-CN4)
5. Defect in the harness between the 1GC/1GD power block and K3 contactor.
(X1SA↔MS, X1-SA↔XGC/XGD-CN10/CN12)
6. Defect in the harness between the 1GB servo board and the 1GC power block.
(XGB-CN12↔XGC/XGD-CN8, XGB-CN13↔XGC/XGD-CN9)
7. Defect in the 1GC/1GD power block.
⇒ Repair or Replace harnesses as needed.

⇒ Exchange the power sequence board and the servo board, etc.
⇒ Check 1GB board dip switch settings.
_____________________________________________________________________
ERROR CODE -1336 Safety gate circuit open.
May 22, 2001 10-67

The safety gate branch of the safety circuit is open due to a missing safety plug or
defective circuit.
⇒ Reinsert the safety plug.

⇒ Repair open circuit.
⇒ Replace the power sequence board (1FP/1HP).
_____________________________________________________________________
ERROR CODE -1337 Two MC lines are not consistent.
A problem has been detected with the MC lines controlling the K1/K2 contactors, due to
an open safety circuit, loose connectors or defects of the 1HP, 1HY, or 1HZ boards.
⇒ Check the safety circuit.

⇒ Check connections to the 1HP, 1HY, and 1HZ boards.
⇒ Replace the 1HP, 1HY, or 1HZ boards as necessary.
_____________________________________________________________________
ERROR CODE -1338 K1 and/or K2 works wrong.
Feedback from the auxiliary contacts of the K1/K2 contactors was not received within a
fixed time, when the contactor was energized. Main causes are safety circuit failures,
K1/K2 auxiliary contact fault (welded, etc.), loose connectors or defects of the 1HP, 1HY,
or 1HZ boards.
(XHP-CN3↔XHY-CN4↔1HY↔XHY-CN3↔K1/K2)
⇒ Check the safety circuit.

⇒ Check connections to the 1HP, 1HY, and 1HZ boards.
⇒ Replace the 1HP, 1HY, or 1HZ boards as necessary.
_____________________________________________________________________
ERROR CODE -1401 Amp over current jt x-M.
10-68 May 22, 2001

The feedback current from a current sensor in the power block exceeded 144% of the
maximum instantaneous motor current rating. This error can be caused by the following
abnormalities:
1. Short in the U, V, W from the power block to motor and ground wire.
(power block↔X4/X5↔robot)
2. Defect in the motor.
3. Defect in the power block.
4. Defect in the servo board (1GB board, etc.)
⇒ Check the connection for the U, V, W and ground line to the power block. Replace the
separation harness if necessary.
⇒ Replace the motor, 1GB board, or power block.
_____________________________________________________________________
ERROR CODE -1407 AMP power unit error.
General servo system error. This error indicates that a servo system error has occurred.
Main causes include a defect in the connection of the harness between the power
sequence board and the servo board.
⇒ Check the servo error codes that follow this error for additional information. Check
the harness connections between the 1HP board and 1GB board. Replace the 1HP
board.
_____________________________________________________________________
ERROR CODE -1413 Regenerative resistor overheat or disconnect.
Unused
_____________________________________________________________________
ERROR CODE -1420 Current detector type (x) mismatch!
May 22, 2001 10-69

When the control power supply is turned ON, the ID code data of the 1GM board and
the AS software installed on the 1GB board do not correspond. The unit name of the
servo board displayed at x in the error message corresponds to the CH column in the
table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier

1. 1GM board is not suitable for the AS software (robot model).
2. The AS software does not correspond to the 1GM board.
⇒ Install the 1GB board equipped with 1GM board.

⇒ Load the robot system data when this error occurs immediately after initializing.
⇒ Re-initialize and reload the robot/system data if this error occurred immediately after
loading the data.
_____________________________________________________________________
ERROR CODE -1500 Motor overload jt-x.
10-70 May 22, 2001


The current feedback from the power block exceeded maximum continuous ratings
longer than the time allowed. Main causes include:
Mechanical -
1. The robot arm has contacted an external item hindering movement.
2. The harness is caught in the robot arm.
3. The decelerator, the gear, or the bearing are damaged.
4. Gear decelerator backlash is too narrow.
5. Payload weight exceeds robot specifications for capacity.
6. Robot motion pattern exceeds ratings of the motor.
7. Motor brake is not released.
Electrical-
1. Motor power line U, V, and W phase are disconnected.
(1GC↔power block↔X4/X5↔robot)
2. The brake line is disconnected or brake drive circuit is damaged.
(T1↔TB1↔V1↔XHY-CN1↔1HY↔XHY-CN2↔XGB-CN14↔1GB↔
XGB-CN6↔X5↔robot)
3. The power block is damaged.
4. Defect in the 1HY board.
6. Malfunction of the motor.
⇒ Check the decelerator, etc. for mechanical failure. Replace as necessary.

⇒ Re-teach the robot motion as necessary.
⇒ Check the harness and servo unit for electrical malfunctions and replace if necessary.
Servo welding gun

1. Clamping pressure time is excessive.
2. Distance between weld points is short; the motor does not have time to cool suffi-
ciently between welds.
3. Clamping pressure setting exceeds the servo gun motor power capacity.
⇒ If the weld points are close to each other, set a time delay. This provides a cool-down
period for the servo gun motor.
⇒ Set the clamping force lower (see servo gun manufacturer’s specifications).
_____________________________________________________________________
ERROR CODE -1501 Overheat or motor harness is disconnected (x).
May 22, 2001 10-71

Motor thermal circuit is open due to motor overheat or harness problem. Not all robot
models utilize thermal switches in the motors. The unit name of the servo board dis-
played at x in the error message corresponds to the CH column in the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier

1. Disconnected thermal line.
(1GB↔XGB-CN6↔XTH↔X4↔robot)
2. Defective connection in the separation harness.
4. When the thermal is built-in:
The robot rated weight capacity is exceeded.
The ambient temperature exceeds limits for use.
Constant execution of abrupt high speed direction changes.
Defect robot cooling fan or cooling air purge system.
Servo system holding the robot arm in high load position for extended periods.
Defect in the thermal switch.
⇒ When the thermal switch opens, error cannot be reset until cooling is complete.
⇒ Confirm continuity of thermal line.
⇒ Replace the harness or servo board as necessary.
⇒ Use the auto servo off function, AUX 91, to prevent the servo system holding a high
load arm position for extended periods.
_____________________________________________________________________
ERROR CODE -1503 Speed error jt-x.
10-72 May 22, 2001

Joint speed (motor speed) calculated using encoder values exceeds a regulated value.
In the Repeat mode: the regulated value is joint speed (motor speed) multiplied by 1.2.
In the Teach/Check modes: the regulated value is 250 mm/sec. multiplied 1.5, at the
equivalent radius position for a rotating joint or actual command value speed for joints
during a linear move.
This error is caused by the following abnormalities:

1. Disconnected motor power line U, V, and/or W phase, or defective power block.
2. Wiring error in motor power line and/or encoder line.
3. Disconnected encoder signal line, short circuit in encoder or encoder wiring, and/or
defective main body of the encoder.
4. Robot motion program causes a singularity.
5. Defect in the 1GB servo board and/or 1GB power block.
6. Moment of inertia exceeded the motor torque.
⇒ Check for disconnection, short circuit, and proper wiring. Replace the harness and
encoder if necessary.
⇒ Replace the servo unit.
⇒ Rewrite program teach data such as speed and position in the case of singularity
motion.
_____________________________________________________________________
ERROR CODE -1504 Position envelope error jt-x.
May 22, 2001 10-73


The difference between the current value from the encoder and the command value in
the AS software exceeded a regulated value which varies by robot model. Main causes
include singularity motion or the following abnormalities:
Mechanical -
1. The robot arm has contacted an external item hindering movement.
2. The harness is caught in the robot arm.
3. The decelerator, the gear, or the bearing are damaged.
4. Gear decelerator backlash is too narrow.
5. Payload weight exceeds robot specifications for capacity.
6. Robot motion pattern exceeds ratings of the motor.
7. Motor brake is not released.
Electrical-
1. Motor power line U, V, and W phase are disconnected.
(1GC↔power block↔X4/X5↔robot)
2. The brake line is disconnected or brake drive circuit is damaged.
(T1↔TB1↔V1↔XHY-CN1↔1HY↔XHY-CN2↔XGB-CN14↔1GB↔
XGB-CN6↔X5↔robot)
3. The power block is damaged.
5. Malfunction of the motor.
⇒ Check the decelerator, etc. for mechanical failure. Replace as necessary.

⇒ Re-teach robot motion as necessary.
⇒ Check the harness and servo unit for electrical malfunctions and replace if neces-
sary.
⇒ Correct the teach data in case of singularity motion.
Servo welding gun

The thickness of the workpiece at the weld point is greater than the thickness when the
point was taught. The thickness difference needed to set this error is approximately
10mm, depending on the gun type.
⇒ Inspect the workpiece; replace it if necessary.

_____________________________________________________________________
ERROR CODE -1505 Velocity envelope error jt-x.
The robot’s current velocity is unable to keep up with the velocity command signal.
⇒ Refer to Error Code -1504: Position envelope error jt-x

_____________________________________________________________________
ERROR CODE -1506 Commanded speed error jt-x.
10-74 May 22, 2001

Unused.
_____________________________________________________________________
ERROR CODE -1507 Commanded acceleration error jt-x.
Unused.
_____________________________________________________________________
ERROR CODE -1510 Encoder harness broken jt-x.
The encoder signal is lost.

1. The machine signal or separate signal harness is damaged.
2. The +12 VDC or +5 VDC supply is not present at the 1FG board.
3. Defective 1GB or 1FG board
⇒ Replace damaged machine signal or separate signal harness.

⇒ Repair cause of +12 VDC or +5 VDC supply not present at the 1FG board.
⇒ Replace defective 1GB or 1FG board.
_____________________________________________________________________
ERROR CODE -1511 Encoder battery voltage low [Servo (A)].
Voltage of the encoder back up battery on the 1FG board decreased to 3.2 volts, or the
encoder battery alarm signal (BAL_AL) was disconnected. This error is only detected at
control power on or motor power on. This is caused by the following:
1. Discharged batteries.
2. Defective encoder battery board (1FG board).
3. Defective encoder.
4. Short in the harness from the encoder battery backup board to the encoder.
5. Battery discharge.
6. Defective servo board (1GB board).
This error is reported by servo board unit A.
⇒ Exchange the battery. There is a possibility that internal encoder data may be lost.
Check the robot zeroing.
⇒ Check each harness for short circuit.
⇒ Replace the encoder, the servo board, or the encoder battery backup board, if neces-
sary.
_____________________________________________________________________
ERROR CODE -1513 Encoder rotation data abnormal jt-x.
May 22, 2001 10-75

Occurs when there is a difference between the rotation data in the serial encoder data
and the calculated rotation data by incremental technique.
⇒ Check connections at encoder, 1FG board, and separation harness.

⇒ Check for noise and shield integrity.
⇒ Check connections, jumpers, and switches on 1GB board.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Replace 1FG board.
⇒ Replace the 1GB board.
⇒ Replace the encoder.
_____________________________________________________________________
ERROR CODE -1516 Encoder data abnormal jt-x.
When control power is switched ON, the current encoder value is compared to the
stored encoder value when the power was turned OFF. If the difference is more than the
value set by AUX 43, Encoder Error Range, or the ENCCHK_DATA command, this error
occurs. Normal occurrence is due to the following:
1. Back up battery failure due to disconnection or discharged battery.
2. Control power was turned off during robot motion by an abnormal power supply, etc.,
causing the robot to stop in a position other than the last position memorized by the
AS software.
3. Motor replacement/encoder replacement.
4. Robot arm or motor operated by force when control power was off.
5. Robot was initialized.
⇒ Data may have been lost due to backup battery. See error -1511. Exchange the
battery. There is a possibility that internal encoder data may be lost. Check the robot
zeroing.
⇒ Check each harness for short circuit.
⇒ Replace the encoder, the servo board or the encoder battery backup board if neces-
sary.
_____________________________________________________________________
ERROR CODE -1517 Cannot read initial data encoder jt-x.
10-76 May 22, 2001


Immediately after control power on, steady encoder data was not able to be read. This
error is caused by a disconnected encoder signal line or a short circuit, or a defect in the
main body of the encoder.
⇒ Check for disconnection or short circuit for encoder signal line.

⇒ Replace the encoder.
⇒ Replace the servo board (1GB board).
Servo welding gun

The gun is disconnected from the tool changer, without performing a software discon-
nect.
⇒ Connect the gun manually and cycle the controller power (OFF/ON).
_____________________________________________________________________
ERROR CODE -1518 Miscount of encoder data jt*.
The servo gun or tool changer harness is defective.
⇒ Inspect the servo gun and tool changer harnesses; replace if necessary.
_____________________________________________________________________
ERROR CODE -1521 Mismatch ABS and INC encoder of jt-x.
Occurs when there is a large difference between the value in the serial encoder data
and the data calculated by incremental technique.
⇒ Replace encoder, replace 1GB board.

_____________________________________________________________________
ERROR CODE -1524 Encoder line error of jt-x.
Not used.
_____________________________________________________________________
ERROR CODE -1550 Encoder initialize error jt-x.
May 22, 2001 10-77

The encoder is not able to fix the absolute position at control power on. The scanning of
absolute data is begun immediately after a shift from the state of non-operation or back-
up operation to normal encoder operation. BUSY=1 is output until the absolute position
has been determined.
⇒ In the case of a conveyor encoder, ensure power-up speed is below 300 RPM.
⇒ Check connections at encoder, 1FG board, jumpers, and switches on 1GB board. ⇒
Replace encoder, replace 1GB board, replace 1FG board.
_____________________________________________________________________
ERROR CODE -1553 Encoder response error jt-x.

Occurs when the encoder does not respond to data request signal from the 1GB board.

⇒ Check for noise malfunction and shield integrity.
Servo welding gun

The servo gun or tool changer harness is defective.
⇒ Inspect the servo gun and tool changer harnesses; replace if necessary.
_____________________________________________________________________
ERROR CODE -1554 Encoder communication error jt-x.
Occurs when the encoder serial data is not correctly transmitted according to communi-
cation protocol.

_____________________________________________________________________
ERROR CODE -1555 Encoder data conversion error jt-x.
10-78 May 22, 2001

Occurs when the M-code data from the encoder has an error pattern.

⇒ Check connections, jumpers and switches on 1GB board.
_____________________________________________________________________
ERROR CODE -1556 Encoder ABS-track error jt-x.
The absolute data and the incremental data in the encoder are different. ABSALM=1 is
output from the encoder when this error occurs.
⇒ Defective encoder.
⇒ Defective 1GB or 1FG boards.
⇒ Open or short-circuited encoder harness.
_____________________________________________________________________
ERROR CODE -1557 Encoder INC-pulse error jt-x.
Occurs when the encoder A and B incremental pulses are abnormal. The encoder
INALM bit sent with the serial data=1.

_____________________________________________________________________
ERROR CODE -1558 Encoder MR-sensor error jt-x.
The state of the MR sensor in the encoder does not match with JT ENCODER in one
rotation.
⇒ Replace the encoder harness.

_____________________________________________________________________
ERROR CODE -1559 Power module error jt-x.
May 22, 2001 10-79

An error signal from the IPM module in the power block was detected. This error may be
caused by:
1. Defect in the power block.
3. Short-circuit of the motor power line U, V, and W phase.
4. Defective cooling fan in the servo unit.
5. Defect in the harness between the servo board and the power blocks.
(XGB-CN12↔XGC/XGD-CN8, XGB-CN13↔XGC/XGD-CN9)
⇒ Replace the servo unit.

⇒ Check for short circuit in the motor harness and replace if necessary.
_____________________________________________________________________
ERROR CODE -1561 Current sensor disconnect [Servo (x)].
The current sensor cable between the servo board and the power blocks is not con-
nected. The x indicates the servo board unit reporting the error. Check the following
harnesses as indicated below.
Unit A - 1GB-CN9↔power block CN1, CN2 CN3.

Unit B - 1GB-CN10↔power block CN4, CN5, CN6.
Unit C - 1GB-CN11↔power block CN7.
This error may be caused by a defect in the 1GB board.
⇒ Check connection and continuity in the current sensor cable between the 1GB board
and the power block. (XGB-CN9↔XGB-CN10)
⇒ Replace the 1GB board if necessary.
_____________________________________________________________________
ERROR CODE -1563 Servo unit 12V DC error [Servo (A)].
The +/-12V supply to the 1GB board is below specified limits of +10.75V and -10.4V.
This error may be caused by a defect in the harness between the 1GB board (XGB-
CN8), the mother board (XHZ-CN2) and the AVR, or a defect in the 1GB board. This
error is reported by servo board unit A.
⇒ Check the voltage and replace the 1GB board and the AVR as necessary.
_____________________________________________________________________
ERROR CODE -1567 Regenerative resistor error [Servo (A)].
10-80 May 22, 2001

Current was sent to regenerative resistors for six or more consecutive seconds. Main
causes include:
1. Abrupt direction changes at high speed.
2. Burned out resistors or defective power block.
3. Defect in the servo board (1GB board).
4. Defective connection or harness between the servo board and the power block
(1GB-CN13 ⇔ power block CN9).
5. Defect in the optional second regenerative resistance unit (when used).
⇒ Avoid abrupt high speed direction changes. Change accuracy, speed, add points.
⇒ Install optional second regenerative resistance unit.
_____________________________________________________________________
ERROR CODE -1568 Servo unit P-N low voltage [Servo (A)].
The voltage between P-N supplied to the power block is 60VDC or less at servo on.
1. Defect of K1, K2, K3.
2. Defect in the relay board (1FY/1HY board).
3. Defect in the power sequence board (1FP/1HP board).
4. Defect in the power unit.
6. Defect in the motor power circuit (diode bridge, K3, etc).
7. Defect in Circuit breaker F2 or F2 is in the OFF position.
8. Defect in the harness between the operation unit and the servo units or the connec-
tions.
⇒ Check the motor power circuit and the equipment, replace as necessary.
⇒ Check the power sequence board, the relay board ,and the servo unit, and replace as
necessary.
_____________________________________________________________________
ERROR CODE -1569 Servo unit P-N- high voltage [Servo (A)].
May 22, 2001 10-81

The voltage between P-N supplied to the power block exceeded 410 VDC. This error is
caused by:
1. Defect in regenerative resistance control circuit, overheat failure of regenerative
resistance unit, defect in the voltage monitoring circuit, or defect in the power block.
2. Defect of servo board (1GB board)
3. Defect in the regenerative resistance unit.
4. Defect in the servo board (1GB board).
5. High inertia loads due to tool weight or program data.
⇒ Reteach program steps to eliminate sudden high speed direction changes (dynamic
shock).
⇒ Replace the servo unit and the regenerative unit.
⇒ Add the second regenerative resistor unit.
_____________________________________________________________________
ERROR CODE -1570 Regenerative resistor over-heat [Servo (A)] or controller

hot.
The thermal switch for the power block regenerative resistor unit, or the optional regen-
erative resistor unit reached 140° C (284°F), or the heat sink thermal switch reached
90°C (194°F), or the controller cabinet thermal switch reached 70° C (158° F). This
error is reported by servo board unit A.
⇒ Defective cooling fans.

⇒ Insufficient clearance for air circulation.
⇒ Power block connecter X5-SA disconnected, or defect in the wiring harness to the
controller cabinet thermal switch, or to the optional regenerative resistor unit.
⇒ High inertia loads.
⇒ High ambient controller temperature.
⇒ Defective power block.
⇒ Defective regenerating resistor unit.
⇒ Defective 1GB board.
⇒ Defect in the following harnesses: 1GB-CN13↔power block CN9,
1GC-CN21↔optional regenerative resistor unit.
_____________________________________________________________________
ERROR CODE -1600 Uncoincidence error jt-x.
10-82 May 22, 2001

During the execution of a program, all joints must reach total coincidence within a given
accuracy and time (approx. 5 seconds) This error occurs if the difference between the
designated value and current value exceeds the established accuracy. Typical causes
are listed below.
Mechanical-
1. Damaged bearings.
2. Insufficient gear backlash.
3. Motor brake not released.
4. Arm movement restricted by harnesses or peripheral devices.
Electrical-
1. Defective servo board (1GB board).
2. Defective power block.
3. Disconnected motor power or brake lines.
4. Defective encoder or encoder harness.
Program data-
1. Wrist positions at the beginning and end of a path that utilize the same XYZ coordi-
nate.
⇒ Repair mechanical or electrical failures.

⇒ Check interference from external devices.
⇒ Modify taught wrist positions as required.
_____________________________________________________________________
ERROR CODE -1601 Limit switch of joint-x is ON.
This error occurs when the software can specify the axis that has caused the over travel
condition. If the joint number cannot be specified, ERROR CODE 1602 Limit switch is
broken, is displayed. Main causes include:
1. Software limits are set incorrectly.
2. Axis was moved using the manual brake release and the limit switch was turned ON.
3. The limit switch was turned ON by overshoot from inertia.
⇒ Check and exchange the harness and the limit switch.

⇒ Set the software limits to an appropriate value.
⇒ Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒ Replace the power sequence board if necessary.
_____________________________________________________________________
ERROR CODE -1602 Limit switch signal line is broken.
May 22, 2001 10-83

This error occurs when the software cannot specify the axis that has caused the over
travel condition. If the joint number can be identified, the “ERROR CODE 1601 Limit
switch of jt-x is ON.”
⇒ Set the software limits to an appropriate value.

⇒ Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒ Check harness and limit switch and replace as necessary.
⇒ Check the power sequence board and replace if necessary.
_____________________________________________________________________
ERROR CODE -1610 Torch is interfered.
The limit switch for torch interference detection has been tripped.
⇒ Move the robot away from the interference to close the limit switch. Inspect the torch
for damage.
⇒ Determine the cause of the interference before continuing operation.
_____________________________________________________________________
ERROR CODE -1735 GROUP is not primed.
The GROUP instruction is not programmed before a motion instruction, with external
axis system.
⇒ This error occurs if the program is interrupted after a GROUP instruction and before
the motion commands pertaining to the GROUP instruction are complete. When
restarting the program prime the program before the GROUP instruction.
⇒ In check mode, if the GROUP instruction is used, start checking before the GROUP
instruction.
_____________________________________________________________________
ERROR CODE -1800 AC primary power off.
10-84 May 22, 2001

This error occurs when there is an instantaneous decrease in the primary power to the
AVR for control power supply (AC130-145V or less for 20-30 msec from 0 phase). The
main causes for this error are:
1. NFB for the control power supply was turned OFF.
2. AC200/220V supplied to AVR for the control power supply caused the instantaneous
decrease.
3. Defective AVR for control power supply.
4. Defective NFB for control power supply or NFB tripped.
5. Defect in the primary power supply.
6. Defective power sequence board.
7. Defect in the relay board.
⇒ It is normal for this error to occur when NFB for control power supply is turned OFF.
⇒ Check power supply circuit in AVR for the control power supply and NFB.
⇒ Confirm that primary power is supplied according to specifications.
_____________________________________________________________________
ERROR CODE -1801 24VDC power source is low.
24VDC to the power sequence board has dropped below 21.6V. Main causes include
the following abnormalities:
1. Defect in the AVR for control power supply.
3. Defect in the relay board.
4. Short circuit in the motor power on circuitry, the EMERGENCY STOP switch and axis
restriction limit switch circuits.
5. Short in machine valve and sensor circuits.
⇒ Check the power supply, machine valve, and the sensor circuits for short circuits.
⇒ Check the AVR, the power sequence board, and the relay board and replace as
necessary.
_____________________________________________________________________
ERROR CODE -1802 Primary power source is high.
May 22, 2001 10-85

Voltage level of the AVR for the control power supply was too high (AC2667-277V or
more for 1-2 sec.). The main causes of this error include a defect in the AVR, the power
sequence board, the relay board or the power supply circuit.
⇒ Verify the power supply to the controller are within ratings.

⇒ Check power supply circuit to the AVR.
⇒ Confirm the supply power is within specifications.
⇒ Confirm transformer tap settings are correct.
_____________________________________________________________________
ERROR CODE -1803 Primary power source is low.
Voltage level of the AVR for the control power supply was too low (AC150-158V or less
for 1-2 sec.). The main causes of this error include an instantaneous drop in the power
supply; a defect in the AVR or NFB, the power sequence board, the relay board or the
power supply circuit.
⇒ Verify the power supply to the controller is within ratings.

⇒ Check the AVR and NFB.
⇒ Confirm supply power is within specifications.
⇒ Confirm transformer tap settings are correct.
_____________________________________________________________________
ERROR CODE -1804 5 VDC or ± 12 VDC is abnormal.
10-86 May 22, 2001

5 VDC or +/-12 VDC supplied to the 1GA board is out of specifications.

+5 VDC: less than +4.85 VDC - more than +5.45 VDC
+12 VDC: +10.75 VDC or less
-12 VDC: -10.4 VDC or more
1. Defective DC power supply.
2. Defective 1GA board.
3. Power supply contacts in the mother board are bad.
4. Defective MFP, small teach pendant, or harness.
5. Defective servo board or power block.
6. Defective 1FG board.
7. Short in the harness between the servo unit and the 1FG board.
8. Short in the optional circuit boards, i.e., vision, etc.
9. Insufficient DC power supply capacity to support optional boards.
⇒ Replace the AVR and each board for the control power supply.
⇒ Check for short circuits in the MFP, the operation panel, and separation harness and
replace as necessary.
_____________________________________________________________________
ERROR CODE -1805 Memory is locked because of AC_FAIL.
The memory was accessed during the controller shut down due to a power supply
abnormality (ACFAIL).
⇒ Cycle the controller power OFF and ON.

_____________________________________________________________________
May 22, 2001 10-87

10.3 TROUBLESHOOTING FLOWCHARTS
The following flowcharts are arranged in the numerical order of the error code. Refer
also to the corresponding error code information in section 9.2 during troubleshooting
procedures.
10-88 March 31, 2000

Error 1513
Does this
error occur just Follow
Yes troubleshooting
after resetting error
1553, 1554, or flowchart for each
1555? error
No
Replace encoder
Yes
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes
Check connections at the

encoder connector
Check connections on the

1FG board
Check connections in the

separation harness
Check connections, jumpers, and

switches on the 1GB board
Figure 10-3 Error 1513 Flowchart (1)
May 22, 2001 10-89

Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
10-90 May 22, 2001

Error 1521
Does this
error occur just Follow
Yes troubleshooting
after resetting error
1553, 1554, or flowchart for each
1555? error
No
No
Replace encoder END
Yes
Does
problem still
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes

encoder connector

1FG board

separation harness

May 22, 2001 10-91

Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
10-92 May 22, 2001

Error 1550
Does the
Reduce conveyor
encoder revolve over
Yes encoder revolution
300 RPM?
speed under 300
(Case of conveyor
RPM at power-up
encoder)
No END
encoder connector

1FG board

separation harness

Does No
problem still END
exist?
Yes
Replace encoder
Does No
problem still END
exist?
Yes
May 22, 2001 10-93

Replace 1GB board
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Check machine
harness and
separation harness
Does No
problem still END
exist?
Yes
Service call
10-94 May 22, 2001

Error 1553
Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully
No
Check connections at the Yes Does the error

encoder connector reoccur?
No
1FG board
END

separation harness

Does No
problem still END
exist?
Yes
Replace encoder
Does No
problem still END
exist?
Yes
May 22, 2001 10-95

Replace 1GB board
Does No
problem still END
exist?
Yes
Check machine
harness and
separation harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
10-96 May 22, 2001

Error 1554
Retry robot
operation carefully
No
Check connections at the Yes Does the error

encoder connector reoccur?
No
1FG board
END

separation harness

Does No
problem still END
exist?
Yes
Replace encoder
Does No
problem still END
exist?
Yes
May 22, 2001 10-97

Replace 1GB board
Does No
problem still END
exist?
Yes
Check machine
harness and
separation harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
10-98 May 22, 2001

Error 1555
Retry robot
operation carefully
No
Replace encoder Yes Does the error

reoccur?
Yes
No
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes

encoder connector

1FG board

separation harness

May 22, 2001 10-99

Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
10-100 May 22, 2001

Error 1556
Replace encoder
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes
encoder connector

1FG board

separation harness

Does
No
problem still END
exist?
Yes
May 22, 2001 10-101

Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
10-102 May 22, 2001

Error 1557
Replace encoder
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes
encoder connector

1FG board

separation harness

Does
No
problem still END
exist?
Yes
March 31, 2000 10-103

Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
10-104 March 31, 2000

OPTIONAL FUNCTIONS
11.0 OPTIONAL FUNCTIONS ........................................................................ 11-4

11.1 Optional Function List .............................................................................. 11-4
11.2 Extended Location and Speed Display, AUX 2 ........................................ 11-7
11.3 Mirror Conversion, AUX 6 ........................................................................ 11-8
11.4 Data Conversion, AUX 9 ........................................................................ 11-10
11.5 Floppy Disk Drive (FD_SAVE), AUX 20 ................................................. 11-11
11.6 Floppy Disk Drive (FD_LOAD), AUX 21 ................................................. 11-13
11.7 File Directory (FD_FDIR), AUX 22 ......................................................... 11-13
11.8 FDD AUX Function, AUX 23 .................................................................. 11-14
11.9 Auto Tool Set, AUX 40 ........................................................................... 11-15
11.9.1 Setting Tool Center Point ....................................................................... 11-16
11.9.2 Tool Center Point and OAT Angles ........................................................ 11-17
11.9.3 Automatic Tool Calibration Function....................................................... 11-18
11.9.3.1 Automatic Tool Calibration Preparation .................................................. 11-19
11.9.3.2 Automatic Tool Calibration Procedure .................................................... 11-20
11.10 Circular Interpolation ............................................................................. 11-26
11.11 Hybrid Interpolation ............................................................................... 11-28
11.12 Fixed Tool Dimensions, AUX 45 ............................................................. 11-28
11.13 Work Dimensions, AUX 49 .................................................................... 11-30
11.13.1 Work Dimensions Definition Procedure ................................................. 11-31
11.14 Flowrate Control, AUX 64 ...................................................................... 11-33
11.15 Speed Output, AUX 65 .......................................................................... 11-34
11.16 System Switch, AUX 75 ......................................................................... 11-40
11.17 Work Space Output, AUX 77 ................................................................. 11-43
11.18 XYZ Shift, AUX 80 ................................................................................. 11-45
11.19 Joint Shift, AUX 81 ................................................................................. 11-46
11.20 Tool Shift, AUX 82 .................................................................................. 11-47
11.21 Work Shift, AUX 83 ................................................................................ 11-48
11.22 Inverse Copy Program, AUX 89 ............................................................. 11-49
11.23 OX Specification, AUX 117 .................................................................... 11-50
11.24 PC Program Run/Stop, AUX 130 ........................................................... 11-52
11.25 Interface Panel, AUX 131 ...................................................................... 11-54
11.25.1 Programming Interface Panel Switches/Lamps ..................................... 11-54
11.25.2 Programming Interface Panel Switches/Lamps Procedure .................... 11-56
11.25.3 Push Button Switch Setting ................................................................... 11-58
11.25.4 Push Button with Lamp .......................................................................... 11-59
11.25.5 Two Notch Selector Switch .................................................................... 11-59
11.25.6 Three Notch Selector Switch ................................................................. 11-60
11.25.7 Pilot Lamp .............................................................................................. 11-60
11.25.8 Digital Switch ......................................................................................... 11-61
11.25.9 Digital Display ........................................................................................ 11-62
11.25.10 Text Window ........................................................................................... 11-63
11.25.10.1 Text Window Procedure ......................................................................... 11-63
11.25.11 Software Dedicated Signal .................................................................... 11-64
May 22, 2001 11-1

OPTIONAL FUNCTIONS
11.25.12 I/F Panel Programmed by PC ............................................................... 11-65

11.26 AS Instruction Definition, AUX 133 ....................................................... 11-66
11.27 Online Edit, AUX 135 ............................................................................ 11-67
11.28 SLOGIC ................................................................................................ 11-73
11.29 Remote I/O and Slogic Specifications .................................................. 11-76
11.30 RI/O Monitor, AUX 180 ......................................................................... 11-79
11.30.1 Signal Status......................................................................................... 11-80
11.30.2 Timer and Counter Status ..................................................................... 11-81
11.30.3 Slogic Monitor ....................................................................................... 11-82
11.30.4 Last Weld Data ..................................................................................... 11-83
11.30.5 Slogic Status ......................................................................................... 11-84
11.31 RI/O PLC (NAC) Setting, AUX 181 ....................................................... 11-84
11.32 RI/O Weld Control, AUX 182 ................................................................. 11-85
11.33 RI/O Slogic Control, AUX 183 ............................................................... 11-86
11.34 RI/O Slogic Forced Output, AUX 184.................................................... 11-87
11.35 Random Program Selection (RPS) ....................................................... 11-88
11.35.1 RPS Commands ................................................................................... 11-88
11.35.2 RPS Signals.......................................................................................... 11-88
11.35.3 RPS Procedure ..................................................................................... 11-89
11.35.4 RPS Operation ...................................................................................... 11-91
11.36 Password Set, AUX 197 ........................................................................ 11-93
11.37 Auxiliary Function Select, AUX 198 ...................................................... 11-94
11.38 Direct Speed ......................................................................................... 11-95
11.39 Monitor Screen Graph .......................................................................... 11-96
11.40 Z-Series Options ................................................................................... 11-98
11.40.1 Failure Prediction Function, AUX 124 ................................................... 11-98
11.40.1.1 Failure Prediction Function Setup Procedure ....................................... 11-98
11.40.1.2 Motor Current Information Error .......................................................... 11-102
11.40.1.3 Motor Torque Information, Peak Current ............................................. 11-104
11.40.1.4 Motor Torque Information, Duty........................................................... 11-105
11.40.2 Operation Information, AUX 127 ......................................................... 11-106
11.40.3 Data Storage Function, AUX 147 ........................................................ 11-108
11.40.3.1 Graph Display Screens ....................................................................... 11-109
11.40.3.2 Trigger Set Screen .............................................................................. 11-113
11.40.3.3 Set Dimension Screen ........................................................................ 11-116
11.40.3.4 Navigating Graph Display Screens ..................................................... 11-118
11.40.3.5 Data Save Screens ............................................................................. 11-120
11.40.3.6 I/O Display Screens ............................................................................ 11-123
11.40.3.7 Navigating I/O Display Screens .......................................................... 11-125
11.40.3.8 I/O Data Display Screen ..................................................................... 11-127
11.40.3.9 Signal Select Screen .......................................................................... 11-128
11.40.3.10 Data Display Screens ......................................................................... 11-129
11.40.3.11 Navigating Data Display Screens ....................................................... 11-132
11.40.4 Collision Detection Function ............................................................... 11-134
11-2 May 22, 2001

OPTIONAL FUNCTIONS
11.40.4.1 Setting Tool Weight Data Using AUX 149 .............................................. 11-134
11.40.4.2 Detection Level Threshold Setting ......................................................... 11-136
11.40.4.3 Threshold for Teach Mode ..................................................................... 11-137
11.40.4.4 Threshold for Repeat Mode ................................................................... 11-138
11.40.4.5 Auto Calibration ..................................................................................... 11-139
11.40.4.6 Collision Detection Error ........................................................................ 11-140
11.40.4.7 Troubleshooting ..................................................................................... 11-140
May 22, 2001 11-3

OPTIONAL FUNCTIONS
11.0 OPTIONAL FUNCTIONS
This unit covers information pertaining to the optional functions of the C controller. To
install or enable optional functions contact Kawasaki customer service.
11.1 OPTIONAL FUNCTION LIST
All of the optional function numbers, the function names and a brief description of each
are identified below in the Auxiliary Function List. A detailed explanation of each func-
tion and its use follows the auxiliary function list.
Optional Function List
2 EXTENDED LOCATION AND Provides four different positional information

SPEED DISPLAY menus.
6 MIRROR CONVERSION Converts programmed locations into locations with

mirror symmetry with the Y and Z planes of the
base coordinate system.
9 DATA CONVERSION Provides the ability for off-line data to be con-

verted into data for use in an on-line machine.
20 FLOPPY DISK DRIVE Used to save program data from RAM to an

(FD_SAVE) optional floppy disk drive unit.
21 FLOPPY DISK DRIVE Used to transfer data from the disk to the
(FD_LOAD) controller’s RAM memory.
22 FILE DIRECTORY Displays all files currently in the Floppy Disc Drive
(FD_FDIR) directory.
23 FDD AUX FUNCTION Allows four auxiliary functions to be used.
40 AUTO TOOL SET Used to automatically dimension tools.
45 FIXED TOOL DIMENSIONS Used to set tool center point coordinates relative
to a fixed point.
49 WORK DIMENSIONS Sets a reference frame for the robot other than the
base coordinate system.
11-4 August 2, 2000

OPTIONAL FUNCTIONS
Optional Function List (continued)
64 FLOWRATE CONTROL Allows the scaling of output voltage from the

analog port of the 1GW board.
65 SPEED OUTPUT Allows the operator to input a voltage and flowrate

based on the specific application to linearize the
flow of sealant.
75 SYSTEM SWITCH Used to set the flowrate switch.
77 WORK SPACE OUTPUT The top and the bottom position of the work space
are set from this function.
80 XYZ SHIFT Used to shift programmed locations in the base

coordinate system.
81 JOINT SHIFT Used to change the joint values for selected pro-
grammed points.
82 TOOL SHIFT Used to shift programmed locations in the tool

coordinate system.
83 WORK SHIFT Used to shift programmed locations in a work

coordinate system.
89 INVERSE COPY PROGRAM Allows the operator to transfer program steps from
one program to a different program, or a different
location within the same program, in reverse order.
117 OX SPECIFICATION Sets output signal characteristics.
124 MOTOR TORQUE Monitors motor current to detect possible failures.

INFORMATION
127 OPERATION INFORMATION Stores and displays system operation information.
130 PC PROGRAM RUN/STOP Allows the operator to control PC programs, and

monitor the status of the PC programs.
March 31, 2000 11-5

OPTIONAL FUNCTIONS
Optional Function List (continued)
131 INTERFACE PANEL Allows the operator to program switches and

lamps to control and monitor robot operation and
peripherals.
133 AS INSTRUCTION Allows the operator to assign program instructions

DEFINITION to keys for repeated use during AS programming.
135 ONLINE EDIT Used to edit block step programs.
147 DATA STORAGE FUNCTION Allows the operator to store one page of any of the
graph screens.
148 COLLISION DETECTION Monitors motor current to detect a possible

FUNCTION collision.
149 TOOL REGISTRATION Determines weight and position of load on arm.
180 RI/O MONITOR Allows the operator to enable various remote I/O
functions.
181 RI/O PLC (NAC) SETTING Allows the operator to view and set information
about the PLC Node Adapter Chip (NAC) settings.
182 RI/O WELD CONTROL Allows the operator to view information about the
weld control settings.
183 RI/O SLOGIC CONTROL Allows the operator to control the Slogic program
or function.
184 RI/O SLOGIC FORCED Allows the operator to force outputs that are used
OUTPUT by the RI/O system.
197 PASSWORD SET Sets a password level for AUX functions.
198 AUXILIARY FUNCTION Allows the operator to set the AUX functions to
SELECT display or hide.
11-6 March 31, 2000

OPTIONAL FUNCTIONS
11.2 EXTENDED LOCATION AND SPEED DISPLAY, AUX 2
There are four different positional information menus available (see figure 11-1) which
are accessed by pressing the F6 (Menu Select) key three separate times. Each time the
menu key is pressed the function keys F1 through F5 change allowing access to differ-
ent functions. The F6 key remains the menu key.
Each of the four menu screens display specific function keys for accessing graphs. The
first menu screen allows graph access for the F1 (Joint Angle), F2 (XYZOAT), and F3
(Joint Command) keys. Press the function keys twice to access the graphs.
The second menu screen displays the F1 (Joint) and F5 (Motor Current) keys to access
graphs when pressed twice.
The third menu screen displays the F1 (Motor Speed) and F4 (Motor Current Command)
screens for accessing graphs when pressed twice.
The fourth menu screen displays the F1 (TCP) key for accessing a graph when pressed
twice. When a graph is accessed from any of the four menu screens, the F6 (Menu) key
becomes a (Graph Exit) key allowing the operator to return to the previous menu.
Figure 11-1 Extended Location and Speed Display
March 31, 2000 11-7

OPTIONAL FUNCTIONS
11.3 MIRROR CONVERSION, AUX 6
F1
PROGRAM
INPUT
This function allows the operator to perform mirror imaging of taught location points.
This function mirrors data taught in the X-axis of the base coordinate system about the
YZ plane.
Another application for the MIRROR CONVERSION function is when two robots are
directly opposite each other on a line and are performing the same motion. In this case,
one program is recorded, transferred, mirrored, and used as a basis for the robot pro-
gram on the opposite side of the line.
Figure 11-2 shows an application of the mirror conversion function.
Figure 11-3 shows the MIRROR CONVERSION function screen.
Figure 11-2 Mirror Conversion
11-8 March 31, 2000

OPTIONAL FUNCTIONS
AUX 6 MIRROR CONVERSION
PROGRAM NAME
START STEP 0
END STEP(O:START STEP ONLY) 0
F1 F2 F3 F4
PROGRAM
INPUT
Figure 11-3 Mirror Conversion Screen
1. To enter the name of the program that contains the points to mirror, press the F1
PROGRAM INPUT key to display the PROGRAM SELECT screen.
2. From the PROGRAM SELECT screen, select the program that contains the points
to mirror and press the RETURN key.
3. Enter the step number of the first step to mirror as the START STEP. If a 0 is en-
tered for the START STEP, the first step mirrored is step 1.
4. Enter the last step to mirror as the END STEP. If a 0 is entered for the END STEP,
the START STEP is the only step mirrored.
March 31, 2000 11-9

OPTIONAL FUNCTIONS
11.4 DATA CONVERSION, AUX 9
The DATA CONVERSION function allows the operator to utilize off-line programming
processes to load program data.
One advantage of this process is a robot that is in a production operation does not need
to be taken off-line for teaching new programs.
Programmers can work off-line with computer simulation models to develop and test
program scenarios while keeping on-line machines in production.
The DATA CONVERSION function screen is shown in figure 11-4.
Figure 11-4 Data Conversion
11-10 March 31, 2000

OPTIONAL FUNCTIONS
11.5 FLOPPY DISK DRIVE (FD_SAVE), AUX 20
The FLOPPY DISK DRIVE (FD_SAVE) function allows the operator to save program
data from RAM to an optional floppy disc drive unit.
The six save options are:
Option 1: ALL DATA-includes robot data, system data, auxiliary data, program data,
and variable data.
Option 2: PROGRAM-includes up to five selected programs.
Option 3: AUX DATA-includes data settings from the Data Set menus.
Option 4: ALL DATA (SELECTED PROGRAM ONLY)-includes robot data, system

data, auxiliary data, selected program data, and variable data associated
with selected programs.
Option 10: ROBOT DATA-includes the robot type, number of axes, robot specific
software settings.
Option 11: ERROR LOGGING-includes error data from the error log.
To access this function press the MENU key on the top tool bar, then press the FUNC-
TION key from the drop down menu. Use the arrow keys to navigate through the auxil-
iary functions until AUX 20 is reached and highlighted, or type in the AUX function
number, and press the ENTER key.
Figure 11-5 shows the AUX 20 display screen.
AUX 20 MEMORY ->FDD (FD_SAVE)
1 ALL DATA
2 PROGRAM
3 AUX DATA
4 ALL DATA (SELECTED PROGRAM ONLY)
10 ROBOT DATA
11 ERROR LOGGING
F1 F2 F3 F4
Figure 11-5 AUX 20, FDD (FD_SAVE)
August 2, 2000 11-11

OPTIONAL FUNCTIONS
Save options 2 and 4, in AUX 20, have “next page” displays to allow the operator to save
specific programs.
With the save option 2 screen displayed press the F3 NEXT PG key. At the second
page use the F1 PROGRAM INPUT key to select up to five programs (see figure 11-6).
Figure 11-6 shows the save option 2 “next page” display.
F3
ï
NEXT PG
F2
ï ï
PREV.PG
Figure 11-6 AUX 20, Save Option 2 “Next Page” Display
11-12 August 2, 2000

OPTIONAL FUNCTIONS
11.6 FLOPPY DISK DRIVE (FD_LOAD), AUX 21
Loading data is accomplished through AUX 21: (FD_LOAD). The data on the disk is
loaded to the controller’s RAM.
The two options are:
Option 1: ALL DATA
Option 2: SELECTED DATA
AUX 21 FDD ->MEMORY (FD_LOAD)
1 ALL DATA
2 SELECTED DATA
F1 F2 F3 F4
Figure 11-7 AUX 21, FDD (FD_LOAD)
11.7 FILE DIRECTORY (FD_FDIR), AUX 22
This function displays all files currently in the floppy disk drive directory.
August 2, 2000 11-13

OPTIONAL FUNCTIONS
11.8 FDD AUX FUNCTION, AUX 23
The FDD AUX FUNCTION consists of four options.
The four options are:
Option 1: FDD FORMATTING (FD_FORMAT) - used to format the floppy disk to 1.44
MB or 1.25 MB.
Option 2: FILE DELETE (FD_FDEL) - used to delete files from the directory.
Option 3: FILE RENAME (FD_RENAME) - used to rename files.
Option 4: FDD CONFIG. - used to configure the optional floppy disk drive unit con-
nection and disconnection.
AUX 23 FDD AUX.FUNCTION
1 FDD FORMATTING (FD_FORMAT)

2 FILE DELETE (FD_FDEL)
3 FILE RENAME (FD_RENAME)
4 FDD CONFIG.
F1 F2 F3 F4
Figure 11-8 AUX 23, FDD AUX Function
11-14 August 2, 2000

OPTIONAL FUNCTIONS
11.9 AUTO TOOL SET, AUX 40
The AUTO TOOL SET function is used to determine tool dimensions and orientation for
tools 1 through 9. Tool dimensions and orientation are referred to as tool coordinates.
Correct tool coordinates are important during jogging, in base and tool mode, and dur-
ing linear moves, in repeat mode, to maintain proper tool orientation.
A tool name is entered and the type of conversion (0:XYZ, 1:XYZOAT) is selected. Type
0 sets only the tool center point (TCP), while type 1 sets the TCP and the OAT angles.
Refer to sections 11.9.1 and 11.9.2 respectively, for additional information about setting
the TCP and OAT angles.
Figure 11-9 shows the AUTO TOOL SET screens.
Figure 11-9 Auto Tool Set
May 22, 2001 11-15

OPTIONAL FUNCTIONS
11.9.1 SETTING TOOL CENTER POINT
QTOOL switch must be set to on prior to setting tool dimensions (refer to AUX 75 SYS-
TEM SWITCHES in unit 9). For more information about tool dimensions refer to AUX 48
in unit 9.
To set the tool center point:
1. Enter the tool name (no.) and the tool type as shown in figure 11-9 and press the
RETURN key, NEXT PG appears in the F3 key position.
2. Press the F3 key to access the next screen. The keys on the multi function panel
change to show the jogging keys.
3. Points A1 through A4 are displayed at this time. Record the individual tool positions
as shown in (Figure 11-9).
The joint angles recorded for each point are used by the controller’s CPU to calculate
the tool center point. Use the scroll keys to select a position to record. Figure 11-10
shows the tool position relative to points A1 through A4. The tool center point must
touch the stationary reference point at each position as shown in figure 11-10. The Z-
axis of the tool should be 90 degrees from the Z-axis of the fixed pointer for positions
A1, A3, and A4. For position A2, the Z-axis of the tool should be parallel to the Z-axis of
the stationary reference point as shown in figure 11-10.
4. Once the robot position is at an “A” point, press the RECORD key.
5. Jog the tool to the next “A” point to record and repeat the procedure until all four “A”
points are recorded, refer to figure 11-10.
6. Once all points are recorded, press the ENTER key. The new tool points are now
recorded and “normally completed” appears in the message window.
7. Press the NEXT PG. key and then the YES key to complete the recording
procedure.
8. Press the EXIT key to access the AUX function menu and select AUX 48 TOOL
DIMENSIONS. At this screen press the ENTER key to apply the new tool dimen-
sions (the new dimensions are displayed but are not applied until the ENTER key is
pressed).
11-16 March 31, 2000

OPTIONAL FUNCTIONS
Z+
A2
A3
A1
45-90 Y-
X+
45-90
45-90
A4
Y+
X-
Stationary Reference
Point
Figure 11-10 Teaching Tool Dimensions
11.9.2 TOOL CENTER POINT AND OAT ANGLES
To set the tool center point and OAT angles, select 1 (XYZOAT) as the type from the AUX
40 screen. Use the procedure from section 11.9.1 to set points A1 through A4. Once
these points have been established, the OAT angles are set using points B and C as
1. Jog the tool center point to the position recorded as point A4. See figure 11-10.
2. Jog the tool away (100 mm min.) from point A4 in the base interpolation mode along
the X-axis as shown in figure 11-11. Select point B and press REC. This sets the
tool X-axis.
3. Return the tool to the position recorded as point A3 shown in figure 11-10.
4. Jog the tool away (100 mm min.) from point A3 in the base interpolation mode along
the Y-axis as shown in figure 11-11. Select point C and press REC. This sets the
tool Y-axis.
5. When all points are recorded, press the ENTER key.
The new tool points are now recorded, and “normally completed” displays in the mes-
sage window. Press the NEXT PG. key and the YES key to complete the recording
procedure.
Press the EXIT key to access the AUX function menu and select AUX 48 TOOL DIMEN-
SIONS. At this screen press the ENTER key to apply the new tool dimensions (the new
dimensions are displayed but are not applied until the ENTER key is pressed).
May 22, 2001 11-17

OPTIONAL FUNCTIONS
Point C
Z+
45-90
Y-
45-90
100mm min.
Point B
100
mm
min
.
Stationary Reference X-
Point
Figure 11-11 Tool XYZ
11.9.3 AUTOMATIC TOOL CALIBRATION FUNCTION
The AUTO TOOL SET function with the AUTOMATIC TOOL CALIBRATION option (U-
series and Z-series model robots) allows the operator to automatically set the load mass
and the center of gravity of the load attached to the tool mounting flange (Figure 11-12).
Figure 11-12 AUTO TOOL CALIBRATION FUNCTION
11-18 May 22, 2001

OPTIONAL FUNCTIONS
11.9.3.1 AUTOMATIC TOOL CALIBRATION PREPARATION
To obtain accurate tool calibration data, the robot configuration must be set as shown in
figure 11-13, for a floor mounted robot, or 11-14, for a shelf mounted robot.
Figure 11-13 Robot Configuration for a Floor Mounted Robot
Figure 11-14 Robot Configuration for a Shelf Mounted Robot
May 22, 2001 11-19

OPTIONAL FUNCTIONS
11.9.3.2 AUTOMATIC TOOL CALIBRATION PROCEDURE
1. Install the tooling on the tool mounting flange.
2. Use teach mode to configure the robot as shown in figure 11-13 or 11-14 (for infor-
mation on jogging procedures refer to unit 6).
With the robot in the proper configuration select repeat mode (for information on
repeat mode refer to unit 8).
3. From the auxiliary function screen, select AUX 40 AUTO TOOL SET and 2 AUTO
TOOL CALIBRATION FUNCTION and press RETURN (Figure 11-12).
4. Enter the tool number (1-9) at the tool number registration screen and press
RETURN (Figure 11-15).
Figure 11-15 Tool Number Registration Screen
11-20 May 22, 2001

OPTIONAL FUNCTIONS
5. When the tool number is accepted “Normally completed” is displayed at the top of
the screen and “NEXT PG” is displayed on the F3 key (Figure 11-16).
Figure 11-16 Tool Number Registration Screen, Tool Number Entered
6. Press F3 to display the MOTION RANGE REGISTRATION screen (Figure 11-17).

Set the data within a safe motion range for the robot and all peripherals in the work
cell.
May 22, 2001 11-21

OPTIONAL FUNCTIONS
Figure 11-17 MOTION RANGE REGISTRATION Screen
7. When the data is entered press RETURN. If the data is accepted “Normally com-
pleted” is displayed at the top of the screen and “NEXT PG” is displayed on the F3
key.
8. Press F3 NEXT PG, to display the CONFIRM THE MOTION screen (Figure 11-18).
Figure 11-18 CONFIRM THE MOTION Screen
11-22 May 22, 2001

OPTIONAL FUNCTIONS
9. Press RETURN to select the motion check program zn_8_n_4 (Figure 11-19).
Press the MOTOR POWER button and the CYCLE START button (with repeat
mode selected) to check the robot tool calibration motion at low speed.
Figure 11-19 Motion Check Program
10. If the motion check program is completed normally (“Normally completed” dis-
played) without safety concerns, press F3 NEXT PG to proceed (Figure 11-20).
If not, stop the robot and press F2 PRE PG and repeat steps 6 and 7, to set the
motion range within safe values.
With the new values set repeat step 9.
May 22, 2001 11-23

OPTIONAL FUNCTIONS
Figure 11-20 START MEASURING Screen
11. With the START MEASURING screen displayed, press the RETURN key, MOTOR
POWER, and CYCLE START switches to run the calibrating motion program at
normal speed.
When the tool calibration is successfully completed, “Normally completed” is dis-

played at the top of the screen and “NEXT PG” is displayed on the F3 key.
Press F3 NEXT PG key to display the results of the automatic tool calibration func-
tion (Figure 11-21).
11-24 May 22, 2001

OPTIONAL FUNCTIONS
Figure 11-21 Auto Tool Calibration Results
The RESULTS screen displays the calculated weight and the position of the load.
The moment of inertia around the X, Y, and Z axes is entered from the tool specification
sheet provided by the tool manufacturer.
From this screen the operator can manually adjust the tool calibration data.
With data adjustments (if needed) and the moment of inertia data entered, press
RETURN to register the data.
May 22, 2001 11-25

OPTIONAL FUNCTIONS
11.10 CIRCULAR INTERPOLATION
Circular interpolation allows the operator to program a path in an arcing motion. The
controller computes the circular path based on a minimum of three taught points. The
first, or starting move, may be any type of move except CIR1 (JOINT, LINEAR or CIR2).
The second point must be a CIR1 move. The last point must be a CIR2 move. Figure
11-22 and 11-23 show examples of circular move programing. Multiple CIR1 moves
may be used between the starting move and the CIR2 ending move.
Figure 11-22 Circular Interpolation Program Example
11-26 May 22, 2001

OPTIONAL FUNCTIONS
Figure 11-23 Circular Interpolation Program Examples
May 22, 2001 11-27

OPTIONAL FUNCTIONS
11.11 HYBRID INTERPOLATION
The optional linear 2 interpolation provides for hybrid interpolated movement. Hybrid
interpolation allows the operator to avoid singularity on axes when linear moves are
necessary. The robot maintains the tool center point in a linear move, but adjust tool
orientation to drive through the singularity. An error results if the limits are exceeded.
11.12 FIXED TOOL DIMENSIONS, AUX 45
The FIXED TOOL DIMENSIONS function allows the operator to program moves that are
relative to an external fixed point in the work envelope. This type of interpolation is
called fixed linear interpolation (FLIN). In a FLIN move the robot path is calculated to
maintain a set relationship to a fixed point.
Applications for FLIN moves include moving a part around a fixed sealing dispenser or a
fixed stud welding gun. The FLIN path enables the programmer to reduce the number of
programmed points needed to maintain a fixed distance from the sealing dispenser.
Figure 11-24 shows the auxiliary function screen used to enter the dimensions for a
fixed tool used with FLIN moves.
Figure 11-25 shows how the path of a windshield moved by a robot is differs with linear
and FLIN interpolation.
FIXED TOOL1
X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg
Figure 11-24 Fixed Tool Dimensions
11-28 May 22, 2001

OPTIONAL FUNCTIONS
Figure 11-25 Fixed Tool Dimensions and FLIN
May 22, 2001 11-29

OPTIONAL FUNCTIONS
11.13 WORK DIMENSIONS, AUX 49
The WORK DIMENSIONS function is active in the teach mode and allows the operator
to jog the robot relative to an alternative coordinate system.
Figure 11-26 shows the display used to set WORK DIMENSIONS 1-9.
AUX 49 WORK DIMENSIONS
WORK 1
X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg
F1 F2 F3 F4
RANG: Rotation 0.0deg - 10.0deg
PREV.DATA
Traverse 0.0mmNEXT PG
- 100.0mm
Figure 11-26 Work Dimensions
The WORK DIMENSIONS are determined using the AS Language FRAME and POINT
commands to define a coordinate system based on the orientation of the work where
points are taught. Reference the KRI AS Language Manual for information on the
FRAME function and the commands needed to enter WORK DIMENSIONS.
Figure 11-27 shows how the orientation of the work dimensions is different from the
base coordinate orientation.
11-30 May 22, 2001

OPTIONAL FUNCTIONS
X
Z
NS
SIO
EN
IM
KD
X
R
Z
WO
Figure 11-27 Work Dimensions Orientation
11.13.1 WORK DIMENSIONS DEFINITION PROCEDURE
1. Jog the robot to the X, Y, and Z coordinates (Figure 11-27) for the new work dimen-
sion frame location.
Use the AS Location teaching screen or the keyboard with the HERE command to
record the three locations.
The X location is recorded as lc3, the Y location is recorded as lc4, and the Z loca-
tion is recorded as lc2.
2. At the keyboard enter the AS Language POINT command shown below.
POINT lc1 = FRAME(lc2,lc3,lc4,lc2)
When this command is entered, the location values for lc1 are displayed as shown
below.
X[mm] Y[mm] Z[mm] O[deg] A[deg] T[deg]

-977.125 955.250 667.542 -31.747 180.00 -7.240
3. Round the values to one decimal place and enter the values in AUX 49 as the work
dimensions for the desired WORK DIMENSION, screen 1 through 9, as shown in
figure 11-28.
May 22, 2001 11-31

OPTIONAL FUNCTIONS
Figure 11-28 (A) shows the robot base coordinate system as X, Y, and Z and the desired
new base coordinate system as X1 and Y1.
Figure 11-28 (B) shows the three points to record (lc2, lc3, and lc4) to establish the new
coordinate system.
The line POINT lc1= FRAME(lc2,lc3,lc4.lc2) is entered at the keyboard screen (Figure
11-28B), to associate point lc1 to the frame. When this line is entered the resulting
component values of lc1 are displayed. The resulting values are rounded to one deci-
mal place and entered as work dimensions in AUX 49 (Figure 11-26).
(See note on the following page)
Figure 11-28 Work Dimension Component Values
11-32 May 22, 2001

OPTIONAL FUNCTIONS
NOTE
Work 0 remains as the original base coordinate system.
When Work 1- 9 dimensions are used to jog the robot

and teach locations, there is no affect on block step pro-
gram motion in repeat mode.
If AS Language program steps are executed after work

1-9 are used in a block step program, the AS Language
steps may be affected.
11.14 FLOWRATE CONTROL, AUX 64
The FLOWRATE CONTROL function allows the scaling of output voltage (tool tip speed
and bead width) from the analog port of the 1GW board. The FLOWGAIN COMMAND
range is from 50% to 150%.
AUX AUX 64 FLOWRATE CONTROL

64 FLOWRATE CONTROL FLOWGAIN COMMAND 100.0%
65 SPEED OUTPUT
70 MEMORY AVAILABLE
71 RECORD DATA (PRG CHG) INHIBIT
75 SYSTEM SWITCH
76 HOME POSITION
77 WORK SPACE OUTPUT
78 CLEAR CHECK SUM ERROR
80 XYZ SHIFT
81 JOINT SHIFT
FUNCTION NUMBER:
F1 F2 F3 F4 F1 F2 F3 F4
PRE PG NEXT PG PRE DATA
Figure 11-29 Flowrate Control
May 22, 2001 11-33

OPTIONAL FUNCTIONS
11.15 SPEED OUTPUT, AUX 65
The SPEED OUTPUT function starts an analog output voltage according to data the
linerization table in AUX 65 SPEEDOUTPUT. This voltage is based on the scale voltage
of Flowrate (tool tip speed and bead width) from the analog port of the 1GW board. The
screen shown below allows the operator to input a voltage and flowrate based on the
specific application to linearize the flow of sealant.
The flowrate is entered as mm3/sec and the range of the voltage depends on the dis-
pensing equipment.
Figure 11-30 Speed Output
To access flowrate data for flowrate Nos. eight to twenty one use NEXT PG. key.
11-34 May 22, 2001

OPTIONAL FUNCTIONS
In addition to the OUTPUT SPEED settings, the operator must program the AS Lan-
guage instructions described below.
1. SETOUTSPEED time, maxspeed, maxvolt, minvolt
time Analog output anticipation time. Unit is 0.01 second.

Range 0 ~ 10 seconds. Default = 0.
maxspeed Tool tip speed at maximum voltage

Range 0 ~ 10,000 mm/sec. Default = 2000
(Only effective when FLOWRATE switch is OFF)
maxvolt Voltage is based on the setting of sw1 or sw2 on the 1GW

board.
Maximum voltage = +10 if 0 ~ 10 or ±10 is selected
Maximum voltage = +15 if 0 ~ 15 is selected.
minvolt Voltage is based on the setting of sw1 or sw2 on the 1GW

board.
Minimum voltage = 0 if 0 ~ 10 or 0 ~ 15 is selected.
Minimum voltage = -10 if ±10 is selected.
2. SETOUTSIG lsb, bits, logic
lsb Least significant bit of the analog card. 3000 for 1GW board
analog channel 1 or 3001 for 1GW board analog channel 2.
bits 8 bits
logic If 0 ~ 10 or 0 ~ 15 is selected, Negative Theory 0.

If ±10 is selected, Positive Theory 1.
The 1GW board is equipped with a D/A converter with 8 bit

signals. The least significant bit (lsb) is 3000 for channel 1
and 3001 for channel 2.
0 volt = 255 and 10 volts = 0 if 0 ~ 10 volts is selected.
0 volt = 255 and 15 volts = 0 if 0 ~ 15 volts is selected.
-10 volts = 0 and +10 volts = 255 if ±10 volts is selected.
3. OUTSPEED Starts analog output dependent on the scaled voltage of the

tool tip speed from the analog port of the 1GW board.
4. OUTSPEED 0 Stops the analog output signal.
May 22, 2001 11-35

OPTIONAL FUNCTIONS
5. OUTSPEED(time) Return the tool tip speed after the designated time.
Unit is mm/second.
Real value: time: seconds >=0
Programing example
vel = OUTSPEED(0.3)
if VEL >2000 THEN
vel = 2000
END
output = 255*vel/2000
BITS 33,8 = 255 - output
6. OUTLOC(time) Return the transformation after the designated time.

Real value: time: seconds >=0
Programing example
TIMER 1 = 0
POINT last = OUTLOC(0)
10 IF TIMER(1) <0.1 GOTO 10
period = TIMER(1)
TIMER 1 = 0
POINT new = OUTLOC
dist = DISTANCE (new, last)
POINT last = new
vel = dist/period
IF vel >2000 THEN
vel = 2000
END
output = 255*vel/2000
BITS 33,8 = 255 - output
GOTO 10
7. BEAD Diameter (Default 6)
dia Bead diameter width. Unit is 0.1 mm. Range is 0 ~ 50 mm

FLOWRATE is calculated from this bead size and tool tip
speed.
8. QBEAD Volume (default 5000)

Determines the volume of sealer dispensed. Unit is 1 mm3/
sec. Range is 0 ~ 200000
11-36 May 22, 2001

OPTIONAL FUNCTIONS
9. FLOWGAIN % (Default 100)
% Adjusts the bead width diameter.

Range 0 ~ 150%.
10. FLOWRATE ON/OFF
ON ON = FLOWRATE mode
OFF OFF = OUTSPEED mode
11. GUNPURGE Volt (Default -15)
volt Constant voltage output for purging. Unit is 0.1 volt.

Range is -15 ~ +15 volts.
12. ACCFLOW Gain (Default 0)
gain Increases the output voltage according to the difference of

TCP speed.
13. MBREAK Causes a break in the program until the current motion
command is complete.
Programming Example
ACCURACY 1000 ALWAYS

LMOVE #A
LMOVE #B
LMOVE #C
MBREAK
SIGNAL 2
LMOVE #D
This program causes signal 2 output at #C and remains on until #D is reached.
14. Conversion of Flow Rate
The following is the conversion formula from inch-pound units to metric units.
Wn [lbs.]: Actual weight of material during “ t ” sec flow from the nozzle at the
“n” volt analog output (n = 0 ~ 10 volts).
D [lbs./in3]: Specific gravity (Density)
Flow Rate [mm3/sec.] = 25.43 * (Wn / t) / D = 16387 * Wn / t * D
May 22, 2001 11-37

OPTIONAL FUNCTIONS
To get the flow rate by cc/sec. (cubic centimeter), use the following formula to
convert for the OUTSPEED linearize table data in AUX 65.
Flow Rate [mm3/sec.] = 1000 * [cc/sec.]
15. Bead Width as Auxiliary Data
Set up the bead width matrix from AUX 114-2 CLAMP CONDITION (CC) CODE,
BEAD. The available range is from 0 to 50 mm. A 0 indicates to use previous data,
or the bead remains the same width. Use the F3 NEXT PG key to access codes
1~9.
AUX AUX 114 GUN SPECIFICATIONS
1 GUN APPLICATION
100 SYSTEM INITIALIZE 2 GUN CONDITION
101 BATTERY ERROR CHECK 13 CLEAR SPOT OPTIMIZE DATA
103 TOUCH PANEL SHORT CIRCUIT CHECK 14 SPOT GUN PRESS ADJUST
110 TIME 20 HANDLING CLAMP DEFINITION
111 DEDICATED INPUT SIGNALS 30 PAINTING/SEALING GUN DEFINITION
112 DEDICATED OUTPUT SIGNALS
113 DEDICATED SIGNALS DISPLAY
114 GUN SPECIFICATIONS
120 ERROR LOGGING
122 OPERATION LOGGING
FUNCTION NUMBER: FUNCTION NUMBER:

F1 F2 F3 F4 F1 F2 F3 F4
PRE PG NEXT PG
AUX 114 GUN SPECIFICATIONS

2 GUN CONDITION
CODE1
GUN SUBROUTINE 1
(0 : Effect, 1: Ineffect)
GUN SUBROUTINE NO. pg 90
(Valid only when enabled)
BEAD (0:Unchanged) 50.0
FLOWGAIN 100.0 %
OUTSPEED (1:Effect, 0:Ineffect) 0
F1 F2 F3 F4
PRE DATA NEXT PG
Figure 11-31 Bead Width as Auxiliary Data
11-38 May 22, 2001

OPTIONAL FUNCTIONS
16. Analog output timing is controlled by the AS Language command SETOUTSPEED

or AUX 65-2 ENVIRONMENT SET.
Figure 11-32 AUX 65-2 Environment Set
May 22, 2001 11-39

OPTIONAL FUNCTIONS
11.16 SYSTEM SWITCH, AUX 75
Function 75 shown below has a flowrate switch. When this switch is ON, the SPEED
OUTPUT AUX 65 table is used. When this switch is OFF, a proportional analog output
voltage is calculated based on the tool tip speed and the SPEED OUTPUT AUX 65
table is not used.
AUX 75 SYSTEM SWITCH
ERRSTART.PC OFF
DISPIO_01 OFF
HOLD.STEP OFF
WS_COMP OFF ON
WS.ZERO OFF
PLC.CHECK OFF
FLOWRATE OFF
F1 F2 F3 F4
PREV.DATA NEXT PG ON/OFF
Figure 11-33 System Switch
Sample mainline and block step programs for sealing applications are provided on the
following pages.
11-40 May 22, 2001

OPTIONAL FUNCTIONS
Sample Mainline Program
.PROGRAM pg00()
FLOWRATE ON
SETOUTSPEED 0,500,13,0
SETOUTSIG 33,8,0
FLOWGAIN 100
OUTSPEED
;
100 RESET
HOME
SIGNAL 1,2,3 ; Clear to xfer and to clamp
WAIT BITS(1021,4) ; Wait for program selection
pg = Bits(1021,4) ; Load program code (4 bits) into “pg”
CASE pg OF
VALUE 11:
CALL pg11 ; Manual purge program
VALUE 10:
CALL pg 10: ; Auto purge program
END
IF NOT SIG(1001) GOTO 100
SIGNAL -1,-2,-3
pg = BITS(1021,4)
CASE pg OF
VALUE 1:
CALL pg01 ; Sealing operation program 1
VALUE 2:
VALUE 3:
.END
May 22, 2001 11-41

OPTIONAL FUNCTIONS
Sample Program including Bead Width
.PROGRAM pg01()
JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0
CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O)
WX= OX=
LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0

WX= OX=
BEAD 3.5

WX= OX=10

WX= OX=10

WX= OX=

WX= OX=
BEAD 2.5

WX= OX=10

WX= OX=10

WX= OX=
.END
11-42 May 22, 2001

OPTIONAL FUNCTIONS
11.17 WORK SPACE OUTPUT, AUX 77
When the TCP is within the space defined by the WORK SPACE OUTPUT function, the
assigned signal is on.
Jog the robot to the UPPER and LOWER locations and record the X, Y, and Z positional
information for input into AUX 77.
Whenever the TCP is within the three dimensional space defined by the WORK SPACE
OUTPUT function an output signal is on. The work space output signal is set in AUX
112 dedicated outputs.
Figure 11-34 shows the display to set the UPPER and LOWER X, Y, and Z dimensions.
Figure 11-35 shows an example of how the dimensions are determined.
AUX 77 WORK SPACE OUTPUT

WORK SPACE 1
UPPER X DIRECTION 0mm
Y DIRECTION 0mm
Z DIRECTION 0mm
LOWER X DIRECTION 0mm
Y DIRECTION 0mm
Z DIRECTION 0mm
OUTPUT SIGNAL 16
F1 F2 F3 F4
PREV.DATA NEXT PG
Figure 11-34 Work Space Output
May 22, 2001 11-43

OPTIONAL FUNCTIONS
UPPER XYZ
Z
LOCATION
NS UT
SIO OUTP
X
DIM PACE
EN
S
RK
WO
LOWER XYZ
LOCATION
Figure 11-35 Work Space Output Dimensions
11-44 May 22, 2001

OPTIONAL FUNCTIONS
11.18 XYZ SHIFT, AUX 80
The XYZ SHIFT function is used in conjunction with block step programs and shifts
programmed locations in the base coordinate system.
The display screen used to set the shift information is shown in figure 11-36.
Figure 11-36 XYZ Shift
The use of the XYZ SHIFT function is outlined in the following steps:
1. Press the F1 PROGRAM INPUT key to select the name of the program that con-
tains the points to shift. The PROGRAM SELECT screen is displayed. Select the
program name that contains the locations to shift.
2. Enter the number of the first step to shift as the START STEP. If a 0 is entered for
the START STEP the first step shifted is step 1.
3. The END STEP is the last step shifted in the program. If a 0 is entered for the END
STEP only the START STEP is shifted.
The distance and direction of shifting in the base coordinate system is entered in the
X,Y,Z section of the screen. The value of the shift in each coordinate direction is en-
tered in mm. In the TEACH mode of operation the shift value is in the range of ±500mm;
in the REPEAT mode of operation the shift value is in the range of ±10mm.
May 22, 2001 11-45

OPTIONAL FUNCTIONS
11.19 JOINT SHIFT, AUX 81
The JOINT SHIFT function is used in conjunction with block step programs and shifts
programmed locations based on joint angle information.
The display screen used to set the information is shown in figure 11-37.
Figure 11-37 Joint Shift
The use of the JOINT SHIFT function is outlined in the following steps:
4. Enter the distance (in degrees) and joint to shift in the JT1 to JT6 sections of the
screen.
In the TEACH mode the shift value is in the range of ±10°, in the REPEAT mode the
shift value is in the range of ±1°
11-46 May 22, 2001

OPTIONAL FUNCTIONS
11.20 TOOL SHIFT, AUX 82
The TOOL SHIFT function is used in conjunction with block step programs and shifts
programmed locations in the tool coordinate system.
The display screen used to set the tool shift information is shown in figure 11-38.
Figure 11-38 Tool Shift
The use of the TOOL SHIFT function is outlined in the following steps:
Enter the distance and direction of shift in the tool coordinate system in the X,Y,Z sec-
tion of the screen. Enter the value of the shift in each tool coordinate direction in mm.
In the TEACH mode of operation the shift value is in the range of ±500mm, in the RE-
PEAT mode of operation the shift value is in the range of ±10mm.
May 22, 2001 11-47

OPTIONAL FUNCTIONS
11.21 WORK SHIFT, AUX 83
The WORK SHIFT function is used in conjunction with block step programs and shifts
programmed locations in the coordinate system defined as “work”.
The display screen used to set the information is shown in figure 11-39.
Figure 11-39 Work Shift
The use of the WORK SHIFT function is outlined in the following steps:
Enter the distance and direction of shift in the work coordinate system in the X,Y,Z
section of the screen. Enter the value of the shift in each work coordinate direction in
mm. In the TEACH mode of operation the shift value is in the range of ±500mm, in the
REPEAT mode of operation the shift value is in the range of ±10mm.
11-48 May 22, 2001

OPTIONAL FUNCTIONS
11.22 INVERSE COPY PROGRAM, AUX 89
The INVERSE COPY PROGRAM function is used to copy and paste program steps
from one program to a different program or a different location within the same program
in reverse order. The INVERSE COPY PROGRAM function works in the same manner
as DATA TRANSFER AUX 3, except program steps are copied in reverse order.
Figure 11-40 shows the INVERSE COPY PROGRAM screen.
AUX 89 INVERSE COPY PROGRAM

SOURCE PROGRAM Pgtest
SOURCE STEP 5
NUMBER OF STEPS 21
DESTINATION PROGRAM Pgtest1
DESTINATION STEP 4
(0:APPEND AT THE LAST STEP)
F1 F2 F3 F4
PROGRAM
INPUT
Figure 11-40 Inverse Copy Program
The use of the INVERSE COPY PROGRAM function is outlined in the following steps:
1. Press the F1 PROGRAM INPUT key to select a source program for steps to copy.
A screen showing a list of programs available in the system memory is displayed.
Use the cursor keys to select the program containing the steps to copy and press
the ENTER key.
2. Use the numeric key pad to enter the first step and the number of steps to copy.
3. Press the F1 PROGRAM INPUT key and a screen showing a list of programs avail-
able in the system memory is displayed. Use the cursor keys to select the program
to paste the copied steps into and press the ENTER key.
4. Use the numeric key pad to enter the first step of the destination program to paste
the copied steps into. When 0 is entered the data is inserted after the last step of
the destination program. When steps are inserted into a program the existing steps
are renumbered.
May 22, 2001 11-49

OPTIONAL FUNCTIONS
11.23 OX SPECIFICATION, AUX 117
The OX specification function allows the operator to set the characteristics of output
signals. Four types of signals can be specified, they include the STEP, KEEP, DOUBLE,
and PULSE types. The settings of the OX PREOUT and AFTER.WAIT.TMR switches
affect signal timing; unit 9 of this manual covers the function of these switches.
• The STEP type signal is the standard type of signal that is output without the op-
tional OX specification function. The STEP type signal is turned on at each step of
the block step program that identifies the signal number. When the robot moves to
a location that does not include the signal number in the auxiliary data, the signal is
turned off. A 0 is entered to specify a STEP type of signal from the OX specification
table.
• The KEEP type of signal remains on until it is turned off at a specific step. A “1” is
entered to specify a KEEP type of signal from the OX specification table.
• The DOUBLE type of signal turns one signal on and one off; DOUBLE type signals
must be entered in pairs. A 2 is entered to specify DOUBLE types of signals from
the OX specification table.
• The PULSE type of signal remains on for the specified length of the pulse width, in
seconds. A “3” is entered to specify a PULSE type of signal from the OX specifica-
tion table. The length of the pulse is also entered from this screen.
Figure 11-41 shows the OX specification screen used to set the signal characteristics
and figure 11-42 is a graph showing the affect of each type of signal on signal timing.
8 9
AUX 117 OX SPECIFICATION SET
OX No. 1 2 3 4 5 6 7 8
TYPE 0 0 0 0 0 0 0 0 6 7
PULSE 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
WIDTH [sec]
OX No. 9 10 11 12 13 14 15 16
TYPE 0 0 0 0 0 0 0 0 4 5 EXIT
PULSE 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
WIDTH [sec]
TYPE(0:STEP, 1:KEEP BS
2:DOUBLE, 3:PULSE
2 3
F1 F2 F3 F4
PREV.DATA NEXT PG
0 1 CLEAR
RETURN
Figure 11-41 OX Specification
11-50 May 22, 2001

OPTIONAL FUNCTIONS
Figure 11-42 Output Timing
May 22, 2001 11-51

OPTIONAL FUNCTIONS
11.24 PC PROGRAM RUN/STOP, AUX 130
Auxiliary function 130 enables the operator to control the PC program, as well as deter-
mine the status of the program. The process control (PC) program allows the operator
to coordinate the robot controller with assembly line or process control.
The PC program runs in the background and can monitor I/O, set internal signals, and
perform mathematical computations. The PC program can execute I/O commands,
perform logic operations and mathematical computations, but cannot execute motion
instructions.
Figure 11-43 shows the PC PROGRAM RUN/STOP display screen.
Refer to Table 11-1 for PC program run/stop Commands
AUX 130 PC PROGRAM RUN/STOP
1 START (PCEXECUTE)
2 ABORT (PCABORT)
3 STOP (PCEND)
4 CONTINUE (PCONTINUE)
5 KILL (PCKILL)
6 STATUS (PCSTATUS)
FUNCTION NUMBER:
F1 F2 F3 F4
Figure 11-43 PC Program Run/Stop
11-52 May 22, 2001

OPTIONAL FUNCTIONS
Table 11-1 PC Program Run/Stop Commands
AS LANGUAGE
ITEM EXPLANATION
COMMAND
Executes the designated PC program. The

START number of execution cycles and the star t step PCEXECUTE
can also be defined.
ABORT Interrupts the currently executing PC program. PCABORT
Stops the PC program at the next robot

STOP program STOP command, or after the last step PCEND
of a robot program is executed.
Star ts PC program execution, after interruption

CONTINUE PCCONTINUE
by a PCABORT or a PCEND command.
KILL Cancels the currently selected PC program. PCKILL
Displays the status of the currently executing

STATUS PCSTATUS
PC program.
May 22, 2001 11-53

OPTIONAL FUNCTIONS
11.25 INTERFACE PANEL, AUX 131
On the C-series controller, the operation (interface) panel, with the switches to operate
the robot and peripherals and lamps to monitor the robot and peripherals, can be pro-
gramed on the multi function panel or type 2 teach pendant.
Auxiliary function 131 allows the operator to program the same switches and lamps for
display and use on the software interface panel (I/F).
Figure 11-44 shows an example of the interface panel.
The numbered locations (Figure 11-45) correspond to the locations on the first I/F panel
(1/2) shown in grey numbers (Figure 11-44).
To toggle between the first (1/2) and the second (2/2) I/F panel screen press the I/F key
at the top of the screen (Figure 11-44).
For the type 2 teach pendant the operator can access the interface panel using the
MENU key and select the I/F key from the drop down menu or use the soft interface
panel key located to the left of the REC (record) key. The interface panel key is also
used to toggle between interface panel screens one and two.
11.25.1 PROGRAMMING INTERFACE PANEL SWITCHES/LAMPS
Auxiliary function 131 allows the operator to program specified switches, lamps and text
boxes to display on one of two I/F panel screens. There are 32 locations available on
each screen.
The characteristics of each interface panel function are set by pressing the PARAM-
ETER SET key. Pressing this key displays the PARAMETER SET window for each
function.
When programming each of the interface panel functions, the operator specifies the
following items: label, color, signal number and operate inhibit. See figure 11-46, Push
Button Parameters.
Switches and lamps may have up to four lines available for labels. Each line may con-
tain up to 10 character spaces. To enter text for a line, use the F4 CHARACTER key to
access the character set keyboard.
Scrolling to the color specification line, the number keypad keys display colors for input.
When RETURN is pressed, the message NORMALLY COMPLETED is displayed.
Specify signal numbers according to desired output signals.
11-54 May 22, 2001

OPTIONAL FUNCTIONS
PROGRAM STEP PC SPEED 10% ‘97-03-18
I/F 17:30
pg99 5 REPT. CONTINUE RPS ON
TEACHING I/F NEXT MENU
INTERFACE PANEL (1/2)

AUTO MANU OFF LINE ENABLE
OFF AUTO
HOME PALLET
REMOVE 6 7 8
MODE MODE
13 14 15 16
MANUAL
9 10
OFF
AUTO OFF-LINE
AUTO
17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
Figure 11-44 Interface Panel
PROGRAM STEP PC SPEED 30% 1-01-23

22:17
Test 1 TEACH
Normally completed.
Normally completed. 8 9
AUX 131 INTERFACE PANEL
POSITION (UPPER) SPEC (LOWER)

1 2 3 4 5 6 7 8
6 7
Screen Locations
[ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0]
9 10 11 12 13 14 15 16
[ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0]
4 5 EXIT
17 18 19 20 21 22 23 24
[ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0]
25 26 27 28 29 30 31 32 BS
Switch or Lamp Type [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] 2 3
F1 F2 F3 F4
CLEAR
PRE DATA NEXT PG PARAMETER 0 1
SET RETURN
Figure 11-45 AUX 131, Interface Panel
May 22, 2001 11-55

OPTIONAL FUNCTIONS
11.25.2 PROGRAMMING INTERFACE PANEL SWITCHES/LAMPS PROCEDURE
1. From the auxiliary function menu select AUX 131 INTERFACE PANEL.
2. Use the cursor keys to select the location for display of the switch/lamp (Figure 11-
44). Use the F3 NEXT PG key to select locations 33-64 (interface panel 2/2).
3. Use the cursor keys to select the switch/lamp type below the location number. The
types of switches/lamps are displayed on the number keypad keys (Figure 11-46).
4. Use the cursor keys to select the desired type of switch/lamp and press RETURN.
5. Press the F4 PARAMETER SET key. The screen displayed depends on the type of
switch/lamp selected (figures 11-47 through 11-54).
As an example procedure the push-button with lamp is used (Figure 11-49).
6. Use the cursor keys to select a line (1-4) for labeling the bush button with lamp.
With the desired label line selected press the F4 CHARACTER key, to display the
character set keyboard.
At the character set keyboard enter the desired label and press the ENTER key.
Repeat this step for lines 1-4 if desired.
7. Use the cursor keys to select COLOR (ON)/(OFF). When COLOR (ON)/(OFF) is
selected the available colors are displayed on number keypad keys 0 through 8
(Figure 11-47). Press the desired color key and press RETURN.
8. Use the cursor keys to select the SIGNAL NUMBER (SWITCH). Use the number
keypad to select the desired 1GA board output signal number (figure 11-63 Robot
Signal Numbers). Ensure the signal number selected is not used as a dedicated
output signal in auxiliary function 112 (unless the button is used to actuate the
function) or used in a program. Press RETURN and normally completed is dis-
played in the message area.
9. Use the cursor keys to select the SIGNAL NUMBER (LAMP). Use the number
keypad to select the desired 1GA board input signal number (figure 11-63 Robot
Signal Numbers). Ensure the signal number selected is not used as a dedicated
input signal in auxiliary function 111 (unless the lamp is used to indicate the func-
tion) or used in a program. Press RETURN and normally completed is displayed in
the message area.
10. Edit the Slogic program to assign the signals used above as needed (refer to sec-
tion 11.28).
11-56 May 22, 2001

OPTIONAL FUNCTIONS

22:17
Test 1 TEACH
Normally completed. TEXT
WINDOW
6 7
POSITION (UPPER) SPEC (LOWER) DIGITAL DIGITAL
1 2 3 4 5 6 7 8 SWITCH DISPLAY
[ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0]
9 10 11 12 13 14 15 16 4 5
[ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] S-NOTCH LAMP EXIT
SELECTOR
17 18 19 20 21 22 23 24
[ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0]
25 26 27 28 29 30 31 32 2 3
PUSHBUTTON 2-NOTCH BS
[ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] WITH LAMP SELECTOR
F1 F2 F3 F4
0 1 CLEAR
NOT USED PUSH
PRE DATA NEXT PG PARAMETER BUTTON
SET RETURN
Figure 11-46 Switch/Lamp Type Select Screen

28:46
Test 1 TEACH
PINK BISQUE

6 7
POSITION 1 PUSH BUTTON WITH LAMP
YELLOW WHITE
LABEL 1
2
3
4
4 5
COLOR (ON) 0 GREEN LIGHT BLUE EXIT
(OFF) 0
SIGNAL NUMBER (SWITCH) 0
(LAMP) 0 2 3
BS
RED ORANGE
F1 F2 F3 F4
0 1 CLEAR
PRE DATA CHARACTER GRAY BLUE
RETURN
Figure 11-47 Switch Lamp Color Select Screen
May 22, 2001 11-57

OPTIONAL FUNCTIONS
11.25.3 PUSH BUTTON SWITCH SETTING
Push button switches are set to activate signals. The switch is labeled with up to four
lines of characters. Specify the desired color for signal status on and off. Assign the
desired output signal to the switch in the SIGNAL NUMBER field. When the push button
is pressed on the multi function panel or type 2 teach pendant, the specified signal is
generated.
Figure 11-48 shows an example of a push button switch.
POSITION 1 PUSH BUTTON

LABEL 1
2 HOME
3
4
HOME COLOR (ON) 2
(OFF) 1
SIGNAL NUMBER(SWITCH) 10
F1 F2 F3 F4
PREV.DATA CHARACTER
Figure 11-48 Push Button Parameters
11-58 May 22, 2001

OPTIONAL FUNCTIONS
11.25.4 PUSH BUTTON WITH LAMP
A push button with a lamp is set similarly to a push button. Different signals are speci-
fied for the lamp and the switch.
Figure 11-49 shows the parameters for a pallet remove switch.
POSITION 2 PUSH BUTTON WITH LAMP

LABEL 1
2 PALLET
3 REMOVE
4
PALLET COLOR (ON) 2
REMOVE (OFF) 1
SIGNAL NUMBER(SWITCH) 11
(LAMP) 1002
F1 F2 F3 F4
PREV.DATA CHARACTER
Figure 11-49 Push Button with Lamp
11.25.5 TWO NOTCH SELECTOR SWITCH
Auxiliary function 131 provides set for a two notch selector switch. Colors are specified
for each position of the switch. Enter the appropriate signals numbers for each.
Figure 11-50 shows the set up of an AUTO/MAN switch.

POSITION 32-NOTCH SELECTOR SWITCH
LABEL 1 MANU AUTO
2
3
4
MODE
COLOR (LEFT) (UP) 6 AUTO MANU
MANUAL
(RIGHT) (DOWN) 2
AUTO
SIGNAL No. (LEFT) (UP) 11
(RIGHT) (DOWN) 12
DISPLAY TYPE UP DOWN/ ROTARY
F1 F2 F3 F4
PREV.DATA CHARACTER
Figure 11-50 Two Notch Selector Switch
May 22, 2001 11-59

OPTIONAL FUNCTIONS
11.25.6 THREE NOTCH SELECTOR SWITCH
Switches with three notches are set up similar to two notch switches. Colors and signals
are set for all three positions. The three notch switch can also be set as a rotary switch,
or a linear up and down switch.
Figure 11-51 shows the set up for a mode selector switch.

POSITION 43-NOTCH SELECTOR SWITCH
LABEL 1 OFF LINE
2 OFF AUTO
3
4
COLOR (LEFT) (UP) 6
MODE
(MIDDLE) 2 OFF LINE
OFF AUTO
OFF
OFF-LINE
(RIGHT)(DOWN) 1
AUTO SIGNAL No. (LEFT) (UP) 11
(MIDDLE) 12
(RIGHT)(DOWN) 13
DISPLAY TYPE UP DOWN/ ROTARY
F1 F2 F3 F4
PREV.DATA CHARACTER
Figure 11-51 Three Notch Switch
11.25.7 PILOT LAMP
Pilot lamps are set up to display the status of a specific signal. The color specified for
ON indicates the activation of the signal specified.
Figure 11-52 shows the set up for a pilot lamp.
POSITION 5 PILOT LAMP

LABEL 1 ENABLE
2
3
ENABLE 4
COLOR (ON) 6
(OFF) 1
SIGNAL NUMBER(LAMP) 1002
F1 F2 F3 F4
PREV.DATA CHARACTER
Figure 11-52 Pilot Lamp
11-60 May 22, 2001

OPTIONAL FUNCTIONS
11.25.8 DIGITAL SWITCH
A digital switch can be created to generate digital output signals. The outputs are based
on the number displayed on the switch. The programmer can dictate the outputs by
setting the number on the switch. The signals from the switch can be set as binary or
decimal.
Table 11-2 shows the parameters used to set a digital switch.
Figure 11-53 shows the digital switch display screen.
Table 11-2 Digital Switch Input
Digital Switch Parameter

Figures Specifies the number of digits displayed
This digital signal indicates which outputs are on or off. Digital input
data can be directly entered with the numeric keys or the value
Input Data
increased by one each time the switch is pressed, it returns to the
minimum value when the maximum value is exceeded.
Limit Data The range of the input data can be limited (YES) or not limited (NO).
Specifies first number of the signal defined for a digital switch
Top Signal No.
(Internal signal number or output signal number).
Number of
Specifies the channel numbers of signals used as a digital switch.
Signals to Use
Outputs correspond to either a binary or decimal number.
Signal Type BCD: Decimal number
BINARY: Binary Number
Upper Limit
Specify the maximum/minimum value which can be set.
Lower Limit
May 22, 2001 11-61

OPTIONAL FUNCTIONS

POSITION 7 DIGITAL SWITCH
LABEL 1 WORK
2 KIND
FIGURES(1 4) 4
INPUT DATA TEN KEYS/PUSH SWITCH
LIMIT DATA YES/NO
WORK TOP SIGNAL NO. 8
KIND
NUMBER OF SIGNALS TO USE 16
0022 SIGNAL TYPE BCD/BINARY
UPPER LIMIT 9999
LOWER LIMIT 0
F1 F2 F3 F4
PREV.DATA CHARACTER
Figure 11-53 Digital Switch
11.25.9 DIGITAL DISPLAY
Set up of a digital display is similar to the digital switch in the previous section.

POSITION 8 DIGITAL DISPAY
LABEL 1 PROGRAM
2 NUMBER
FIGURES(1 4) 4
TOP SIGNAL NO. 1008
PROGRAM NUMBER OF SIGNALS TO USE 6
No. SIGNAL TYPE BCD/BINARY
0022
F1 F2 F3 F4
PREV.DATA CHARACTER
Figure 11-54 Digital Display
11-62 May 22, 2001

OPTIONAL FUNCTIONS
11.25.10 TEXT WINDOW
A TEXT WINDOW is used in conjunction with an AS Language command to print a

message in a designated area of the interface panel. Four text windows are available.
POSITION 1 TEXT WINDOW

Window Number 1
Window Size 4
Default Back Ground Color 6
F1 F2 F3 F4
PREV.DATA
Figure 11-55 Text Window Parameters
11.25.10.1 TEXT WINDOW PROCEDURE
1. Enter a number from 1-4 in the Window Number field. The window number corre-
sponds to one of the four windows specified.
2. Enter a number, 1-4, in the Window Size field according to the desired size of the
window. The window size corresponds to the size of the display area for the mes-
sage. An area up to 4 times the sizes of a standard I/F display area can be speci-
fied.
3. Select the background color of the text window display. When this field is selected a
color palette is displayed to specify the desired color.
4. Enter the AS Language command IFPWPRINT in the program to display the text
window message in the TEXT WINDOW.
The format for the IFPWPRINT command is:
IFPWPRINT window number (1 to 4), line number to display message (1 to 4),

number of spaces from the left of the TEXT WINDOW the first character is dis-
played, the background color of the TEXT WINDOW = “the message”.
Example: IFPWPRINT 1,1,2,6 = “Part is not in place.”
May 22, 2001 11-63

OPTIONAL FUNCTIONS
11.25.11 SOFTWARE DEDICATED SIGNAL
The interface panel can be automatically displayed by using external input signals.
External input signals can be set by DEFSIG INPUT command or “Auxiliary 111”.
• I/F panel, One page selection.

• I/F panel, Two page selection.
There are two software dedicated signals. The interface panel changes to the pertinent
page when the signal changes from OFF to ON at software dedicated signal.
11-64 May 22, 2001

OPTIONAL FUNCTIONS
11.25.12 I/F PANEL PROGRAMMED BY PC
The interface panel can also be programed from a personal computer.
Specify switch type and position as follows when the file is loaded or is saved (xxxxxx is
file name).
LOAD xxxxxx. if when file with the data is loaded in memory.
SAVE/if xxxxxx when saving to disk file.
The following example shows set up of the interface panel using a personal computer.
.INTER_PANEL
1,1, “ “,”HOME”,” “,” “,1,2,1,0
2,2, “PALLET”,”REMOVE”,” “,” “,2,3,2,2,0
3,3, “AUTOMANU”,” “,” “,” “,3,4,3,4,0,-1
4,4, “ OFFLINE”,”OFF AUTO”,” “,” “,4,5,6,5,6,7,0,0
5,5, “ ENABLE”,” “,” “,” “,5,6,1
7,6, “ WORK”,” KIND”,4,-1,0,8,8,0,999,0,0
8,7, “ PROGRAM”,” No.”,4,8,8,0
11,3,” MODE”,” MANUAL”,” AUTO”,” “,3,4,3,4,-1,-1
12,4,” MODO”,” OFF”,” OFFLINE”,” AUTO”,”4,5,6,5,6,7,-1,0
15,6,” “,” “,3,-1,0,8,8,0,999,0,0
16,7,” “,” “,3,8,8,0
23,6,” “,” “,2,-1,0,8,8,0,999,0,0
24,7,” “,” “,2,8,8,0
31,6,” “,” “,1,-1,0,8,8,0,999,0,0
32,7,” “,” “,1,8,8,0
.END
* Specify the data in the following order.
The parameter of display position (1-64), type code (0-7), the detailed data (the same
order as setting screen), and the selection item shows that the following is selected.
0 : The right side.
-1 : The left side.
May 22, 2001 11-65

OPTIONAL FUNCTIONS
11.26 AS INSTRUCTION DEFINITION, AUX 133
Auxiliary function 133 allows the operator to assign program instructions to keys for
repeated use during AS programming. The operator may define up to 32 variables,
instructions, or commands and assign them to corresponding buttons (Figure 11-56).
AUX 133 AS INSTRUCTION DEFINITION
1 JMOVE 9
2 LMOVE 10
3 #pick 11
4 place 12
5 13
6 14
7 15
8 16
F1 F2 F3 F4
PRE DATA NEXT PG CHARACTER

17:30
pg01 1 REPT. CONT RPS ON

TEACHING STATUS MENU STEP CONT DRYRUN OFF
M-OFF
HOLD
TEACH
AS INSTRUCTION TEACHING
DEFINED ?JMOVE
INSTRUCTION ? CHARACTER
BUTTONS
{ JMOVE LMOVE #pick place - PROGRAM

INPUT
5 6 7 8 9 , . TEACH
NEW
0 1 2 3 4 SPACE SHIFT RECORD
Figure 11-56 AS Instruction Definition
Instructions 17 through 32 are accessed by pressing the “NEXT PG” (F3) key.
Character strings are defined with up to 8 characters. The character string is defined
only when “Record Accept” is set by AUX 71 RECORD (PRGCHG) INHIBIT.” Press the
F4 CHARACTER key to access the keyboard for definition string input or editing.
11-66 May 22, 2001

OPTIONAL FUNCTIONS
Once the instructions are defined, pressing the corresponding key inserts the instruction
into the AS program as shown in the lower screen of figure 11-56.
11.27 ONLINE EDIT, AUX 135
Block step programs can be edited using the multi function panel or type 2 teach pen-
dant in the teach and repeat modes. Online program data includes auxiliary data
(SPEED, ACCURACY, TIMER, TOOL, WORK, J/E, and COMMENT), clamps, guns and
OX/WX signals. This online data can be edited using AUX 135 Online Edit.
Figures 11-57 and 11-58 show the AUX 135 ONLINE EDIT display screens.
AUX 135 ONLINE EDIT
PROGRAM NAME test
STEP NUMBER 10
(0 : FIRST STEP)
F1 F2 F3 F4
PROGRAM
INPUT
Figure 11-57 Online Edit
May 22, 2001 11-67

OPTIONAL FUNCTIONS
A U X .13 5 O N LIN E E D IT p g1
1 JOINT 9( 100.0%) 1( 1.0) 0(0.0) 1 0 ;START
2 LINEAR 4( 50.0%) 2( 10.0) 0(0.0) 1 0
3 CIR1 4( 50.0%) 3( 100.0) 0(0.0) 1 0
4 CIR2 4( 50.0%) 3( 100.0) 0(0.0) 1 0
5 FLIN 9( 100.0%) 1( 1.0) 1(0.1) 2 0
6 FCIR1 9( 100.0%) 1( 1.0) 2(0.2) 2 0 JUMP
. -
5 6 7 8 9 (S E T +) (S E T -) BS
0 1 2 3 4 S EX IT
R E TU R N
S S
PRE PG NEXT PG SCREEN SCREEN
A U X .1 35 O N L IN E E D IT pg 1
STEP
5 6 7 8 9 CHARACTER P R E D ATA
S E LE C T
0 1 2 ! 4 S E X IT
RETURN
Figure 11-58 Online Edit Screen, AUX 135
11-68 May 22, 2001

OPTIONAL FUNCTIONS
With the S key activated, the operator can scroll to the next and previous pages as well
as CLAMP DATA, OX/WX and other function screens. Select the desired screen, deacti-
vate the S key and use the arrow keys to move the cursor to the item to change. Use
the SET + and SET - keys to change the data.
PRE PG NEXT PG SCREEN SCREEN
The screen display the PRE PG and NEXT PG buttons for programs that have more
than seven steps. Use PRE PG and NEXT PG to scroll up and down the steps. The
SCREEN buttons select the next screen containing data for other functions.
Pressing the SCREEN key takes you to the following screens:
The clamp data (gun data) screen allows the operator to edit clamp signals for each
individual step. Figure 11-59 shows a spot welding/handling application and a painting/
sealing application.
Figure 11-59 Clamp Data Screens
May 22, 2001 11-69

OPTIONAL FUNCTIONS
Use SET+ and SET- to program OX and WX signals on or off for various steps.
The OX signals are edited from the next screen (Figure 11-60). From this screen each
OX signal is programmed on or off at each individual step of the program. Scrolling to
the next screen reveals OX signals 32 and higher.
A U X .13 5 O N LIN E E D IT pg 1
OX 01 05 10 15 20 25 30 ★:O N
1 ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
2 M★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
3 M M★M M M M M★M M M M M M M M M M M M M M M M M M M M M M M
4 M M M★M M M M M M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M
6 M M M M M★M M M M M M M M M M M M M M M M M M M M M M M M M M
7 M M M M M M★M M M M M M M M M M M M M M M M M M M M M M M M M
ñ ò
SCREEN SCREEN
Use the SCREEN keys
to show more signals.
ñ ò
A U X .13 5 O N LIN E E D IT pg1

O X 35 40 45 50 55 60 ★:O N
2 M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
3 M M★M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M
4 M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M★ M M M M M M M M M M M M M M M M M M M M M M M M M M M
6 M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M
7 M M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M
Figure 11-60 OX Edit Screen
Use the SCREEN keys to scroll to the WX Edit Screen (Figure 11-61). WX signals are
edited the same as OX signals shown above. SET+ and SET- are used to change
signal status from on to off.
11-70 May 22, 2001

OPTIONAL FUNCTIONS
A U X .13 5 O N LIN E E D IT p g 1
W X 01 05 10 15 20 25 30 ★:O N
3 M M ★M M M M M ★ M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M
ñ ò
SCREEN SCREEN
Use the SCREEN keys
to show more signals.
ñ ò
A U X .13 5 O N LIN E E D IT pg1

W X 35 40 45 50 55 60 ★:O N
3 M M★M M M M M★M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M★ M M ★ M M M M M M M M M M M M M M M M M M M M M M M M
Figure 11-61 WX Edit Screen
May 22, 2001 11-71

OPTIONAL FUNCTIONS
The robot location can be edited and configured from the location edit screen. Use the
SCREEN keys to scroll to the screen. This screen allows the operator to change the
numeric joint angle value for each individual joint at each step (Figure 11-62).
Use the arrow keys to scroll to the joint position to change and enter the desired nu-
meric value with the number keys. Joint angle data cannot be changed if the online edit
program is executing.
Figure 11-62 Joint Location Edit Screen
11-72 May 22, 2001

OPTIONAL FUNCTIONS
11.28 SLOGIC
Relay circuitry for the robot interface is reduced by replacing it with the Slogic software
function. Slogic is similar to ladder logic, used with programmable controllers (table 11-
3). Making signal assignments using Slogic is much easier than making changes on
hard-wired systems. For hard-wired systems, changes are made by physically making
connections. Using Slogic, changes are made by simply making changes to programs.
Slogic program instructions are used to specify outputs, timers, and counters. Slogic
program instructions are edited on the 1GA board (main CPU) via the multi function
panel or type 2 teach pendant and then transferred to the 1FS (R I/O) board, which
executes the Slogic program.
The remote input/output (R I/O) function is performed by the optional 1FS board. The
RI/O system provides Allen-Bradley (A-B) programmable logic controller (PLC) serial
communication, weld control serial communication, and Slogic execution.
The R I/O function provides the status of all signals, including A-B PLC and weld control
serial signals. Internal Slogic signals can be displayed via the multi function panel.
The R I/O system performs the following functions:
• A-B PLC serial communication is performed by the A-B node adapter chip (NAC).
Robot controllers are daisy chained through the NAC, enabling communication with
the line PLC system. A maximum of 128 I/O channels are available.
• Weld control serial communication is performed by the 1FS board serial I/O func-
tion, which is capable of controlling a maximum of four weld controllers. A maxi-
mum of 16 I/O channels are available for each weld controller.
• The Slogic function is similar to a PLC instruction which uses Slogic instructions for
outputs, timers, and counters. The Slogic instructions are edited on the robot
controller through the 1GA board (main CPU), and then transferred to the 1FS
board for execution of Slogic programs.
May 22, 2001 11-73

OPTIONAL FUNCTIONS
Table 11-3 Slogic
11-74 May 22, 2001

OPTIONAL FUNCTIONS
The following is an example of the process used to edit the Slogic programs using the
keyboard screen.
Keyboard Screen
$SS “SLOGIC Stop”
$SU “S Upload” - Upload Slogic from the 1FS board to the 1GA board to edit
the program SPG.
$EDI SPG Program SPG can now be edited.
1 SOUT 301 = 101

1?
2 SOUT 302 = 101 and 102
2?
3 SOUT 303 = 101 or 102
3?
4 SOUT 304 = (-101 and -102) or -103
4?
5 SOUT 305 = (101 or 103) and (102 or -104)
5?
6 STIM 2601 = 101, 5.0
6?
7 SOUT 306 = 2601
7?
8 SCNT 2701 = 101, 110, 102, 10
8?
9 SOUT 307 = 2701
9?
10?E Exit
$SD “S Download” - Download the program from the 1GA board to the 1FS
board to execute the program.
Password 4989 (same for all controllers)
$$SR SLOGIC Run
Editing SLOGIC
S STEP# The step number to be edited

I Insert lines before the current step.
D Delete the program step.
O Places the cursor on the current step for editing (overwrite)
E Exits from the editor to the monitor mode.
Note: Output may be used only once.
May 22, 2001 11-75

OPTIONAL FUNCTIONS
11.29 REMOTE I/O AND SLOGIC SPECIFICATIONS
The following are specifications for remote I/O and Slogic functions:
Control method: Stored program (Slogic)
Program size: Approximately 1,500 steps (max. 72,000 characters)
Note: 1. The following example Slogic instruction is considered two steps:
SOUT XXXX=YYYY + 80 comment characters = 96 total characters
2. The following example Slogic instruction is considered three steps:
SOUT XXXX=YYYY AND ZZZZ + 119 comment characters = 144 total characters
Execution cycle time: 1-300 steps 5ms

301-900 steps 10ms
901-1500 steps 15ms
Number of parallel signals:
Standard signals (one 1GW board): 32 I/O channels

24 VDC, 100mA
Optional signals: 64 I/O channels (one additional 1GW board)

96 I/O channels (two additional 1GW boards)
128 I/O channels (three additional 1GW boards)
Number of internal signals:
Non-retentive relay 128

Retentive relay 16
Timer 16 (range: 0.1 to 999.9 seconds)
Counter 16 (range: 1 to 9999 counts)
Message display 64
Slogic status 16
11-76 May 22, 2001

OPTIONAL FUNCTIONS
Robot CPU (1GA)

Robot Output 1 ~ 256 OX signals = Robot Output signals 1-64
Robot Input 1001 ~ 1256 WX signals = Robot Input signals 1001-1064
Robot Internal 2001 ~ 2256
1001 ~ 1256 1 ~ 256

PLC Weld
Serial Serial
Input Input
1501 ~ 1564 1601 ~ 1632
1FS Board
Allen-Bradley Weld
PLC *SLOGIC Functions Controllers
(Internal Signals) (maximum 8)
501 ~ 564 601 ~ 632

PLC Weld
Serial Serial
Output 1301~1428 301~428 Output
I/O Boards
(1GW, maximum 4,
optional)
*SLOGIC Functions (Internal Signals)
Relays: Non-Retentive 2301 ~ 2428

Relays: Retentive 2501 ~ 2516 An additional magnetic
Relays: Timers 2601 ~ 2616 relay output "SRUN" signal
Relays: Counters 2701 ~ 2716 is available. This signal
SLOGIC Status Signals 2801 ~ 2816 indicates that SLOGIC is
W/C #1 Not Connected 2801 running. It does not have
W/C #2 Communication Error 2802 a signal number.
NAC Communication Error 2803
Battery Error 2804
W/C #2 Not Connected 2805
W/C #2 Communication Error 2806
Spare 2807 ~ 2816
Message Display 2901 ~ 2964
SLOGIC messages must be named $w2901 ~ $w2964.

Refer to AS Language manual for steps to create
string variables (e.g., $w2901 = "message").
Signal for Last Weld Current 2965
Figure 11-63 Robot Signal Numbers (1FS board)
May 22, 2001 11-77

OPTIONAL FUNCTIONS
Robot CPU (1GA)

Robot Output 1 ~ 256 OX signals = Robot Output signals 1-64
Robot Input 1001 ~ 1256 WX signals = Robot Input signals 1001-1064
Robot Internal 2001 ~ 2256
1001 ~ 1256 1 ~ 256

PLC Weld
Serial Serial
Input Input
1501 ~ 1596 1601 ~ 1664
1701 ~ 1732
1HS Board
Mitsubishi Weld
PLC *SLOGIC Functions Controllers
With CC Link (Internal Signals) (maximum 4)
501 ~ 596 601 ~ 664

PLC 701 ~ 732 Weld
Serial Serial
Output 1301~1428 301~428 Output
I/O Boards
(1GW, maximum 4,
optional)
*SLOGIC Functions (Internal Signals)
Relays: Non-Retentive 2301 ~ 2428

Relays: Retentive 2501 ~ 2516 An additional magnetic
Relays: Timers 2601 ~ 2616 relay output "SRUN" signal
Relays: Counters 2701 ~ 2716 is available. This signal
SLOGIC Status Signals 2801 ~ 2816 indicates that SLOGIC is
W/C #1 Not Connected 2801 running. It does not have
W/C #2 Communication Error 2802 a signal number.
NAC Communication Error 2803
Battery Error 2804
W/C #2 Not Connected 2805
W/C #2 Communication Error 2806
Spare 2807 ~ 2816
Message Display 2901 ~ 2964
SLOGIC messages must be named $w2901 ~ $w2964.

Refer to AS Language manual for steps to create
string variables (e.g., $w2901 = "message").
Signal for Last Weld Current 2965
Figure 11-64 Robot Signal Numbers (1HS Board)
11-78 May 22, 2001

OPTIONAL FUNCTIONS
11.30 RI/O MONITOR, AUX 180
This optional function allows the operator to access functions regarding the remote I/O
functions (Figure 11-65).
Figure 11-65 RI/O Monitor
May 22, 2001 11-79

OPTIONAL FUNCTIONS
11.30.1 SIGNAL STATUS
The signal status screens, shown in figure 11-66, allows the operator to view the status
of all remote I/O and robot signals. Figure 11-66 shows two of five signal status
screens. Use the NEXT PG keys to scroll to the remaining screens
Figure 11-66 RI/O Signal Status Screens
11-80 May 22, 2001

OPTIONAL FUNCTIONS
11.30.2 TIMER AND COUNTER STATUS
The TIMER AND COUNTER STATUS function allows the operator to view the timer or
counter values (Figure 11-67). The elapsed time or number of counts is also displayed.
The first screen shows the status of timers and the second screen shows the status of
counters. Navigate between the screens using the PRE PG and NEXT PG keys.
Figure 11-67 Timer and Counter Status Screens
May 22, 2001 11-81

OPTIONAL FUNCTIONS
11.30.3 SLOGIC MONITOR
The SLOGIC MONITOR screen (Figure 11-68) allows the operator to monitor output
signals used by the Slogic program. It also displays the status of the signal. When this
function is accessed, key in the desired output signal at the prompt and press the EN-
TER key on the multi function panel.
Figure 11-68 Slogic Monitor Screen
11-82 May 22, 2001

OPTIONAL FUNCTIONS
11.30.4 LAST WELD DATA
The LAST WELD DATA screen displays the weld sequence parameters. Use the NEXT
PG and PRE PG keys to scroll between the three available screens. Figure 11-69
shows two of the three available screens.
Figure 11-69 Last Weld Data Screens
May 22, 2001 11-83

OPTIONAL FUNCTIONS
11.30.5 SLOGIC STATUS
The SLOGIC STATUS screen allows the operator to view the status of the Slogic pro-
gram (Figure 11-70). It displays the status of Slogic programs as active (RUN) or inac-
tive (STOP). It also indicates how many steps are used in the Slogic program, the
number of bytes free in the memory, and the date and time the Slogic program was
downloaded.
Figure 11-70 Slogic Status Screen
11.31 RI/O PLC (NAC) SETTING, AUX 181
Auxiliary function 181 allows the operator to view and set parameters for the PLC Node
Adapter Chip (NAC) settings (Figure 11-71).
Figure 11-71 RI/O PLC(NAC) Setting
11-84 May 22, 2001

OPTIONAL FUNCTIONS
11.32 RI/O WELD CONTROL, AUX 182
Auxiliary function 182 allows the operator to view information about the weld control
settings. The operator can select the number of weld controllers that are used for the
application. Changes to other options cannot be made, it is used only for displaying the
current settings.
Figure 11-72 RI/O Weld Control Setting
May 22, 2001 11-85

OPTIONAL FUNCTIONS
11.33 RI/O SLOGIC CONTROL, AUX 183
The RI/O Slogic Control screen allows the operator to control the Slogic program or
function. The operator can activate (run) or deactivate (stop) the Slogic program by
selecting SLOGIC RUN or SLOGIC STOP respectively.
To edit the Slogic program:
• Select SLOGIC STOP to deactivate the Slogic program.
• Load the Slogic program into the 1GA board memory by selecting SLOGIC
UPLOAD.
• Edit the Slogic program as needed using the keyboard screen (see section 11.28).
• Select SLOGIC DOWNLOAD to load the edited Slogic program to the 1FS board
memory. Enter the password when prompted (see section 11.28).
• Select SLOGIC RUN to activate the Slogic program.
Slogic programs can also be started and stopped from the keyboard screen using AS
Language commands (see section 11.28).
Figure 11-73 shows the Slogic control display screen.
AUX.183 RI/O SLOGIC CONTROL
1 SLOGIC RUN (SRUN)

2 SLOGIC STOP (SSTOP)
3 SLOGIC DOWNLOAD (SDOWNLOAD)
4 SLOGIC UPLOAD (SUPLOAD)
FUNCTION NUMBER:
F1 F2 F3 F4
Figure 11-73 Slogic Control
11-86 May 22, 2001

OPTIONAL FUNCTIONS
11.34 RI/O SLOGIC FORCED OUTPUT, AUX 184
Function 184 allows the operator to force outputs that are used by the RI/O system.
This function cannot be used when Slogic is in the active (run) state.
AUX.184 RI/O SLOGIC FORCED OUTPUT
SIGNAL NUMBER 0
F1 F2 F3 F4
Figure 11-74 Slogic Forced Output
May 22, 2001 11-87

OPTIONAL FUNCTIONS
11.35 RANDOM PROGRAM SELECTION (RPS)
Random program selection allows the operator to select robot motion programs through
a programmable logic controller (PLC). The following commands, signals, and proce-
dures are used to set up and operate the RPS function.
11.35.1 RPS COMMANDS
JUMP Is used to “jump” to another program and return to the step following
the jump command based on RPS signal states.
END Is used to call another program, at the end of a program, based on

RPS signal states. If the RPS signals are not changed, the same
program repeats.
11.35.2 RPS SIGNALS
RPS_ON Is used to activate the RPS function by a PLC output signal.
RPS_ST Is used by the PLC to monitor the RPS function status by a robot
controller output signal.
JUMP_ON Is used to allow a “jump” to another program and return to the step
following the jump command after the “jump” program is completed.
JUMP ON is a PLC output signal.
The RPS function must be active and the jump signal in the ON
state. The “jump” program is determined by the state of the RPS
program selection signals.
JUMP_OFF Is used to disable the “jump” function.
The END command is executed independent of JUMP ON/OFF

signals.
JUMP OFF is a PLC output signal.
JUMP_ST Is used by the PLC to monitor the JUMP function status by a robot
controller output signal.
RPS code Is a binary or binary coded decimal signal used by the controller to
determine program selection.
The RPS code signals are PLC output signals.
11-88 May 22, 2001

OPTIONAL FUNCTIONS
11.35.3 RPS PROCEDURE
1. Programs are named pg0 – pgxx and must contain END commands as the last
step. JUMP commands are optional.
2. I/O signals are set in auxiliary function 111. See figure 11-75 for example of signal
settings.
Figure 11-75 AUX 111 RPS Signals Example
3. Signals selected in auxiliary function 111 must be hard wired with a 1GW board
(discrete I/O) or programed through the Slogic program with a 1FS board. An
example Slogic program, to use the signals selected above, is shown in figure 11-
76.
1 SOUT 1010 = 1307

1?
2 SOUT 1011 = 1308
2?
3 SOUT 1012 = 1301
3?
4 SOUT 1013 = 1302
4?
5 SOUT 1014 = 1303
5?
6 SOUT 1015 = 1304
6?
7 SOUT 1016 = 1305
7?
8 SOUT 301 = 15
8?
9 SOUT 302 = 16
9?
Figure 11-76 RPS Slogic Program Example
May 22, 2001 11-89

OPTIONAL FUNCTIONS
4. Set the RPS system switch in AUX 75 to ON and press RETURN (Figure 11-77).
For the RPS switch to remain ON, RPS signals in AUX 111 must be entered and
accepted.
Figure 11-77 RPS System Switch
5. From the STATUS screen select REPEAT CONDITION and RPS ENABLE (Figure
11-78).
Figure 11-78 RPS Enable
11-90 May 22, 2001

OPTIONAL FUNCTIONS
11.35.4 RPS OPERATION
For more information on the RPS function refer to the C Series Controller I/O Interface
Manual.
RPS program names are assigned binary values using a maximum of sixteen bits
(Tables 11-4 and 11-5).
Table 11-4 RPS Codes Table
MSB RPS CODE SIGNALS LSB
RPS64 RPS32 RPS16 RPS8 RPS4 RPS2 RPS1

PROGRAM (1019) (1018) (1017) (1016) (1015) (1014) (1013)
pg0 OFF OFF OFF OFF OFF OFF OFF
pg1 OFF OFF OFF OFF OFF OFF ON
pg2 OFF OFF OFF OFF OFF ON OFF
pg3 OFF OFF OFF OFF OFF ON ON

.
.
.
.
pg15 OFF OFF OFF ON ON ON ON
pg16 OFF OFF ON OFF OFF OFF OFF

.
.
.
.
pg99 ON ON OFF OFF OFF ON ON
7-Bit Binary RPS Code Examples
May 22, 2001 11-91

OPTIONAL FUNCTIONS
Table 11-5 RPS Binary Coded Decimal (BCD) Codes Table
MSB RPS CODE SIGNALS LSB
RPS8 RPS4 RPS2 RPS1 RPS8 RPS4 RPS2 RPS1

PROGRAM (1020) (1019) (1018) (1017) (1016) (1015) (1014) (1013)
pg0 OFF OFF OFF OFF OFF OFF OFF OFF
pg1 OFF OFF OFF OFF OFF OFF OFF ON
pg2 OFF OFF OFF OFF OFF OFF ON OFF
pg3 OFF OFF OFF OFF OFF OFF ON ON

.
.
.
.
pg15 OFF OFF OFF ON OFF ON OFF ON
pg16 OFF OFF OFF ON OFF ON ON OFF

.
.
.
.
pg99 ON OFF OFF ON ON OFF OFF ON
8-Bit Binary Coded Decimal RPS Code Examples
If BCD is selected, four bits allows up to nine programs, five bits allows up to nineteen
programs, and six bits allows up to thirty nine programs (sixteen bits maximum).
If no RPS signals are present and RPS is enabled, the controller is in a wait condition
until RPS signals are received.
If JUMP ON and JUMP OFF signals are received at the same time an error occurs.
11-92 May 22, 2001

OPTIONAL FUNCTIONS
11.36 PASSWORD SET, AUX 197
AUX 197 is used to set a password level for AUX functions. The password corresponds
to the level entered for each auxiliary function in AUX 198. The password level entered
corresponds to which auxiliary functions are displayed in the function screen. Functions
assigned to levels 2 and 3 do not appear in the function screen when a password level
1 is entered.
Figure 11-79 Password Level
May 22, 2001 11-93

OPTIONAL FUNCTIONS
11.37 AUXILIARY FUNCTION SELECT, AUX 198
Auxiliary functions can be set to display or be hidden from the auxiliary function menu.
By setting password levels for functions, functions are only displayed in the menu when
the password level is set to the corresponding level or higher. Auxiliary functions as-
signed levels 2 and 3 are not displayed in the menu when the password level is 1.
Figure 11-80 Auxiliary Function Select
11-94 May 22, 2001

OPTIONAL FUNCTIONS
11.38 DIRECT SPEED
The optional Direct Speed function allows the operator to select the absolute speed for
joint or linear moves in seconds or millimeters per second respectively.
The function is accessible to the operator during the teach mode of operation for the
current program. Use the following procedure to set direct speed.
1. Select the interpolation for the current step of the program from the block teaching
screen.
2. Select speed 10 from the teach data speed key. Press the teach data speed and
the AUX SET and DISP keys simultaneously. The Direct Speed screen is displayed
as shown in figure 11-81.
8 9
DIRECT SPEED
INTERP. SPEED 6 7
4 5 _ EXIT
2 3 BS
0 1
RETURN
Figure 11-81 Direct Speed Display
3. The INTERP. and SPEED keys, in the upper left corner of the screen, display the
interpolation selected from the block teaching screen and the speed selected by the
operator from the numeric keypad.
4. Press the RETURN key to complete the procedure and return to the block teaching
screen.
May 22, 2001 11-95

OPTIONAL FUNCTIONS
11.39 MONITOR SCREEN GRAPH
The monitor screen graph for input, output, and internal signals is an optional function
that, when enabled, allows the operator to view a graph of the selected signal type. The
accessibility of this function is shown in figure 11-82 and 11-83. Figure 11-83 specifi-
cally shows the enabled graph screen.
Figure 11-82 Monitor Screen
11-96 May 22, 2001

OPTIONAL FUNCTIONS
Pressing the graph button displays the first 16 signals of the current signal screen. To
view the next 16 signals of the selected 32, press the GRAPH button again. To stop and
restart the graph update, press GRAPH STOP/GRAPH START. A vertical line is placed
at the point where the graph starts. GRAPH EXIT returns to the previous monitor dis-
play.
1 OX1 9 OX9 17 WC1-WS1 25 OX25

2 OX2 10 OX10 18 WC1-WS2 26 OX26
3 OX3 11 OX11 19 WC1-WS4 27 HOME
4 OX4 12 OX12 20 WC1-WS8 28 TEACH_MODE
5 OX5 12 OX13 21 OX21~ 29 CYCLE_START
6 OX6 13 OX13 22 CLAMP1_ON 30 AUTOMATIC
7 OX7 14 OX14 23 OX23 31 ERROR
8 OX8 15 OX15 24 CLAMP2_ON 32 MOTOR_ON
INPUT INTERNAL NEXT PG GRAPH
GRAPH GRAPH
EXIT

OX 1
OX 2
OX 3
OX 4
OX 5
OX 6
OX 7
OX 8
OX 9
OX 10
OX 11
OX 12
OX 13
OX 14
OX 15
OX 16
INPUT INTERNAL PREV.PG GRAPH GRAPH GRAPH

STOP EXIT
GRAPH
START
Figure 11-83 Monitor Screen and Graph
May 22, 2001 11-97

OPTIONAL FUNCTIONS
11.40 Z-SERIES OPTIONS
11.40.1 FAILURE PREDICTION FUNCTION, AUX 124
This function establishes average current levels of motors during normal program opera-
tion and monitors motor current.
Reduction gear failure is gradual and motor current increases in small increments as the
reduction gear approaches failure.
If the current levels exceed the established normal level, a warning message is dis-
played and an alarm signal is pulsed for one second.
If a program has varying operating conditions, that affect motor current, such as pay-
loads of different weights, this function cannot be used.
Program teaching and verification must be completed before using this function. If
changes are made to the program, average current levels must be revised.
11.40.1.1 FAILURE PREDICTION FUNCTION SETUP PROCEDURE
The AS Language command I2PG is used in programs to monitor motor torque (cur-
rent). Each program must use the I2PG START pg (pg = program number) command at
the point in the program current monitoring begins. The I2PG END command is used to
end current monitoring. For usage of the I2PG command see the example below.
11-98 May 22, 2001

OPTIONAL FUNCTIONS
To begin using the failure prediction function, set AUX 124-20 INSPECTION FORE-
CAST SETTING to EFFECT (Figure 11-84).
Figure 11-84 AUX 124-20 Inspection Forecast Setting
May 22, 2001 11-99

OPTIONAL FUNCTIONS
With the inspection forecast setting set to EFFECT, the base data is automatically set.
To establish average motor current for each program, the mean value of I2 is monitored
through the program five times. These values are displayed in AUX 124-21. Figure 11-
85A shows the display during base data measurement. Figure 11-85B shows the re-
sults after base data is measured.
Figure 11-85 AUX 124-21 Inspection Base Data
11-100 May 22, 2001

OPTIONAL FUNCTIONS
If monitor speed is changed several times or teach mode is used, during base data
measurements, the base data measurements are repeated.
Use the NEXT PG key to display data for other programs (Figure 11-85). The mean
value of I2 (for each motor) is monitored during program operation and the display is
updated each time it is accessed.
The base data for 20 programs can be stored. This data is stored in the memory of the
central processing unit (CPU) board (1HA). If the 1HA board is replaced the data is lost
and must be reset.
If programs are modified the base data must be reset. To repeat the base data mea-
surements, display the program in AUX 124-21 (Figure 11-85B) and press the F6 BASE
MEASUR key. When the program completes five cycles the new base data is stored.
May 22, 2001 11-101

OPTIONAL FUNCTIONS
11.40.1.2 MOTOR CURRENT INFORMATION ERROR
If the current exceeds the 107% threshold an error is set and a warning is displayed as
Figure 11-86 Motor Current Information Error Display
If the keyboard screen is displayed during a motor current error or a PC is interfaced

with the controller the warning appears as:
WARNING! (-61) Needs inspection. possibility of failure. JT6 program number 11 step
3 6.3[Arms] 109.1[%]
When the error message is displayed an entry is made to the warning log (20 max) in
AUX 124-1 (Figure 11-87).
When the warning is displayed the robot does not stop.
To clear the warning press the CLOSE key (Figure 11-86).
11-102 May 22, 2001

OPTIONAL FUNCTIONS
Figure 11-87 AUX 124-1 Warning Log
If the “Mechanical Warning” dedicated output signal in AUX 112 is set, the designated
signal number is pulsed for one second. This signal is sent to a warning lamp, PLC, or
other outside device.
The warning log is saved to a text file with a .CVS extension using the AS Language
SAVE command, as shown in the example below.
SAVE/MWLOG file_name
May 22, 2001 11-103

OPTIONAL FUNCTIONS
11.40.1.3 MOTOR TORQUE INFORMATION, PEAK CURRENT
Motor torque information is a torque monitor function. Maximum motor torque informa-
tion (motor current) is shown for JT1 - JT6. The program, step number of the program,
the maximum current value (Arms), the percentage of mechanical current limit, and the
date and time of occurrence is displayed for each axes (Figure 11-88).
To clear the data and restart the monitor function press F6 CLEAR. The “SINCE” date
and time at the top of the display is set to the current date and time. As programs are
executed, the data for each axis is updated in the PEAK CURRENT display.
Figure 11-88 AUX 124-10 Peak Current
11-104 May 22, 2001

OPTIONAL FUNCTIONS
11.40.1.4 MOTOR TORQUE INFORMATION, DUTY
AUX 124-11 (Figure 11-89) displays the duty of the motor for each axes as a percent-
age.
The left column PROGRAM displays the mean value of I2 of the last program executed.
The mean value of I2 is the average motor current calculated form the I2PG START
command to the I2PG END command in the program. If the I2PG command is not used
“0” is displayed.
The right column AVERAGE displays the mean value of I2 over the last ten seconds.
The AVERAGE column does not require the use of the I2PG command to display data.
The values in both columns should be similar.
Figure 11-89 AUX 124-11 Duty
May 22, 2001 11-105

OPTIONAL FUNCTIONS
11.40.2 OPERATION INFORMATION, AUX 127
AUX 127 (Figure 11-90) displays information about robot operation.
The information monitored is:
• controller power ON time (control power ON)
• servo ON time
• frequency of motor ON
• frequency of servo ON
• frequency of E-stop with robot moving
• total time in move, JT1 - JT6
• total displacement, JT1- JT6
The F3 NEXT PG and F2 PRE PG keys are used to display the information.
11-106 May 22, 2001

OPTIONAL FUNCTIONS

17:30
*pg3 44 COINCIDE
AUX 127 OPERATION INFORMATION

Operation information (00/2/7 19:07:45 - )
Time of control power ON 35676.6 [H]

Time of servo ON 11764.6 [H]
Frequency of motor ON 5714
Frequency of servo ON 15
Frequency of E-STOP (moving) 57
F1 F2 F3 F4 F5 F6
RENEW NEXT PG
EXIT

17:30
*pg3 44 COINCIDE
AUX 127 OPERATION INFORMATION

JT1
Total time in move 9867.0 [H]
Total displacement 178148.685 [x1000 DEG, mm]
JT2
JT3
F1 F2 F3 F4 F5 F6
RENEW PRE PG NEXT PG EXIT
Figure 11-90 Operation Information
May 22, 2001 11-107

OPTIONAL FUNCTIONS
11.40.3 DATA STORAGE FUNCTION, AUX 147
The data storage function allows the operator to save one page of any of the graph
screens available. The graph screens available are:
• JOINT
• XYZOAT
• JOINT COMMAND
• JOINT OFFSET
• JOINT SPEED
• MOTOR CURRENT
• MOTOR CURRENT COMMAND
• TOP SPEED
• I/O DISPLAY
The save function is activated with the following triggers:
• when an error occurs

• at motor power off
• by a specified signal at controller start-up
• by a specified signal at controller shutdown
The data storage function is accessed through AUX 147 DATA STORAGE FUNCTION
(Figure 11-91).
Figure 11-91 AUX 147 Data Storage Function
11-108 May 22, 2001

OPTIONAL FUNCTIONS
11.40.3.1 GRAPH DISPLAY SCREENS
When the operator selects “1” from the AUX 149 menu screen, the joint angles for robot
joints JT1 - JT6 are displayed in degrees (Figure 11-92).
The graph display screen functions consist of :
• F1 expands the graph display

• F2 compresses the graph display
• F5 displays the trigger set screen
• F6 starts recording data (F6 START, changes to F6 STOP)
• RETURN restarts the display
• EXIT returns to the data storage function menu screen
Figure 11-92 Graph Display Screen
May 22, 2001 11-109

OPTIONAL FUNCTIONS
Figure 11-93 Graph Display Screen During Recording
The graph display screen during recording functions consists of:
• F6 STOP changes the display to the graph display screen (Figure 11-92)
• EXIT stops the recording of data and F6 STOP changes to F6 START
• F6 STOP and EXIT are the only functions available in the recording mode
11-110 May 22, 2001

OPTIONAL FUNCTIONS
The graph data display screen loads saved data from memory, a PC card or a floppy
disk. The data loading process is displayed as a percentage and no functions are avail-
able (Figure 11-94).
Figure 11-94 Graph Data Display Screen (Loading Data)
May 22, 2001 11-111

OPTIONAL FUNCTIONS
When data loading is complete the following functions become available (Figure 11-95).
• F1 changes the display to the SET DIMENSION screen

• F5 deletes data and the displays returns to the GRAPH DISPLAY screen
• RETURN restarts the display
• EXIT returns to the graph display screen
Figure 11-95 Graph Data Display Screen (Displaying Data)
11-112 May 22, 2001

OPTIONAL FUNCTIONS
11.40.3.2 TRIGGER SET SCREEN
The trigger function screen allows the operator to select the conditions used to activate
the data storage function (Figure 11-96).
Figure 11-96 Trigger Set Screen
The trigger conditions consist of:
• IN MOTOR POWER OFF

Detects motor power off
• IN ERROR
Detects an error condition
• START-UP
Detects specified signal transition from OFF to On at start-up
• START-DOWN
Detects specified signal transition from ON to OFF at start-down (shut-down)
May 22, 2001 11-113

OPTIONAL FUNCTIONS
Figure 11-97 Trigger Position
The trigger position determines the timing of data storage, based on the trigger condi-
tion set. Trigger position that is set. The trigger Position, in seconds, determines the
time prior to the trigger condition, that data storage begins (Figure 11-97).
11-114 May 22, 2001

OPTIONAL FUNCTIONS
The operator selects the desired trigger and position to activate the data storage func-
tion. Signal numbers are selected for start-up and start-down triggers. The operator
must press the RETURN key to complete the entry of data.
EXIT returns the display to the previous graph display or I/O display screen (Figure 11-
98).
The word “trigger” is displayed in the upper right of the screen when a trigger is set
(Figure 11-98).
Figure 11-98 Display Screens with Trigger Set
May 22, 2001 11-115

OPTIONAL FUNCTIONS
11.40.3.3 SET DIMENSION SCREEN
The set dimension screen allows the operator to set parameters for the Y axis and the X
axis of the graph display (Figure 11-99). The Y axis represents movement of the robot
joints. The X axis represents time elapsed during the movement.
Figure 11-99 Set Dimension Screen
When the operator selects magnification of 2 or 4 in the set dimension screen and the
data displayed exceeds one screen, F3 and F4 are used to move to the last or next
screen (Figure 11-100).
11-116 May 22, 2001

OPTIONAL FUNCTIONS
Figure 11-100 Data Display Next and Last Keys
May 22, 2001 11-117

OPTIONAL FUNCTIONS
11.40.3.4 NAVIGATING GRAPH DISPLAY SCREENS
The following navigation chart is used as a quick reference for navigating the graph
display screens.
AUX 147 DATA STORAGE FUNCTION
1. JOINT
2. XYZOAT
3. JOINT COMMAND
4. JOINT OFFSET
5. JOINT SPEED
6. MOTOR CURRENT
7. MOTOR CURRENT COMMAND
8. TCP SPEED
9. I/O SIGNAL
99. DATA DISPLAY
FUNCTION NUMBER:
F1 F2 F3 F4

EXIT 1 - 8 RETURN

17:30
1 REPT. CONTINUE RPS ON

pgtest STEP CONTINUE DRYRUN OFF
AUX 147 DATA STORAGE TRIGGER SETTING
1. TRIGGER CONDITION
AUX 147 DATA STORAGE FUNCTION GRAPH DISPLAY IN MOTOR POWER OFF EFFECT/INEFFECT
IN ERROR EFFECT/INEFFECT
JT 1 START-UP SIG EFFECT/INEFFECT
JT 2

F5 SIGNAL NUMBER 0
JT 3 TRIGGER
START-DOWN SIG EFFECT/INEFFECT
JT 4 SET SIGNAL NUMBER 0
JT 5
JT 6 2. TRIGGER POS.(1-7) 0s
EXIT
MAX: MAX F1 F2 F3 F4
F1 F2 F3 F4 F5 F6 PRE DATA
TRIGGER EXIT
SET START
F6
START

EXIT
F6
STOP

(Continued on next page)
11-118 May 22, 2001

OPTIONAL FUNCTIONS
(Continued from previous page)
F5
DATA
DELETE

17:30

AUX 147 DATA STORAGE FUNCTION GRAPH DISPLAY

JT 1
JT 2
JT 3
JT 4
JT 5
JT 6

MAX: MAX
F1 F1 F2 F3 F4 F5 F6 F6
EXIT DIM
SET TRIGGER EXIT EXIT DATA
SAVE
SET START

AUX 147 DATA STORAGE FUNC DIM. SETTING AUX 147 DATA STORAGE FUNCTION DATA SAVE
1. PC CARD
1. Y AXIS UPPER 62 2. FD DRIVE
LOWER -62
2. X (TIME) AXIS 1/2/4 TIME
FUNCTION NUMBER:
F1 F2 F3 F4 F1 F2 F3 F4
May 22, 2001 11-119

OPTIONAL FUNCTIONS
11.40.3.5 DATA SAVE SCREENS
The data save screen allows the operator to save graph display and I/O display screen
data to a PC card or floppy disk (Figure 11-101).
A B
Figure 11-101 Data Save screens
Select the device to save data to (Figure 11-101A) using the cursor keys and press the
RETURN key. When the device is selected, the screen changes to PC CARD (Figure
11-101B) or FD DRIVE screen and the operator uses the character key (F4) to access
the keyboard screen (see figure 11-102, for the multi function panel or figure 11-103,
type 2 teach pendant) screen to input the file name. With the file name entered on the
keyboard screen, the operator presses ENTER to start the data save process.
The data is saved to the selected device and the file extension .CSV is added.
11-120 May 22, 2001

OPTIONAL FUNCTIONS
$
FILE1
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
: “ ~ =
Z X C V B N M ; ‘ _ + BS
CTRL+N < > ?

, . / _
Figure 11-102 Keyboard Screen, Multi Function Panel
May 22, 2001 11-121

OPTIONAL FUNCTIONS
$
file1
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
: “ ~ =
Z X C V B N M ; ‘ _ + BS
CTRL+N < > ?

, . / _
Figure 11-103 Keyboard Screen, Type 2 Teach Pendant
11-122 May 22, 2001

OPTIONAL FUNCTIONS
11.40.3.6 I/O DISPLAY SCREENS
The I/O screen (Figure 11-104) functions include:
• the F4 key changes the display to the SIGNAL SET screen.

• the F5 key changes the display to the TRIGGER SET screen.
• the F6 key starts the DATA SAVE function and F6 START changes to F6 STOP.
• the RETURN key restarts the display.
• the EXIT key returns the display to the MENU key.
Figure 11-104 I/O Display Screen (Displaying Data)
May 22, 2001 11-123

OPTIONAL FUNCTIONS
Figure 11-105 I/O Display Screen (Recording Data)
The I/O display screen functions during recording (Figure 11-105) include:
• F6 stops the recording of data and changes the display to the I/O data display
screen.
• EXIT stops recording data and F6 STOP changes to F6 START.
• F4 SIGNAL SET, F5 TRIGGER SET and the RETURN key are not functional in the
recording mode.
11-124 May 22, 2001

OPTIONAL FUNCTIONS
11.40.3.7 NAVIGATING I/O DISPLAY SCREENS
The following navigation chart is used as a quick reference for navigating the I/O display
screens.

17:30

AUX 147 DATA STORAGE FUNCTION pgtest STEP CONTINUE DRYRUN OFF
1. JOINT
2. XYZOAT
3. JOINT COMMAND
4. JOINT OFFSET AUX 147 DATA STORAGE FUNCTION I/O DISPLAY
5. JOINT SPEED WX 1
6. MOTOR CURRENT WX 2
7. MOTOR CURRENT COMMAND WX 3

8. TCP SPEED WX 4
WX 5
9. I/O SIGNAL 9 WX 6
99. DATA DISPLAY RETURN

WX 7
FUNCTION NUMBER: WX 8
OX 1

F1 F2 F3 F4 EXIT
OX 2
OX 3
OX 4
OX 5
OX 6
OX 7
OX 8
F1 F2 F3 F4 F5 F6
SIGNAL TRIGGER EXIT
SET SET START
F4
F5
F6

EXIT SIGNAL TRIGGER EXIT EXIT
SET SET START
F6
STOP

AUX 147 DATA STORAGE SIGNAL SELECT AUX 147 DATA STORAGE TRIGGER SETTING
1. TRIGGER CONDITION
CH1 1001 CH9 1
IN MOTOR POWER OFF EFFECT/INEFFECT
CH2 1002 CH10 2
IN ERROR EFFECT/INEFFECT
CH3 1003 CH11 3
START-UP SIG EFFECT/INEFFECT
CH4 1004 CH12 4
SIGNAL NUMBER 0
CH5 1005 CH13 5
START-DOWN SIG EFFECT/INEFFECT
CH6 1006 CH14 6
SIGNAL NUMBER 0
CH7 1007 CH15 7
CH8 1008 CH16 8
2. TRIGGER POS.(1-7) 0s
F1 F2 F3 F4 F1 F2 F3 F4
PRE DATA PRE DATA
May 22, 2001 11-125

OPTIONAL FUNCTIONS

17:30

AUX 147 DATA STORAGE FUNCTION I/O DISPLAY

WX 1
WX 2
WX 3
WX 4
WX 5
WX 6
WX 7
WX 8
OX 1
OX 2
OX 3
OX 4
OX 5
OX 6
OX 7
OX 8
F1 F2 F3 F4 F5 F6
DATA DATA EXIT
DELETE SAVE
F5
F6

EXIT DATA DATA EXIT
DELETE SAVE


17:30

TEACHING FUNCTION MENU AUX 147 DATA STORAGE FUNCTION DATA SAVE
1. PC CARD
2. FD DRIVE
AUX 147 DATA STORAGE FUNCTION I/O DISPLAY

WX 1
WX 2
WX 3
WX 4
WX 5
WX 6
WX 7
WX 8
OX 1
OX 2 FUNCTION NUMBER:
OX 3
OX 4 F1 F2 F3 F4
OX 5
OX 6
OX 7
OX 8
F1 F2 F3 F4 F5 F6
SIGNAL TRIGGER EXIT
SET SET START
11-126 May 22, 2001

OPTIONAL FUNCTIONS
11.40.3.8 I/O DATA DISPLAY SCREEN
The I/O data display screen (Figure 11-106) functions include:
• F5 deletes data and the display returns to the I/O DISPLAY screen.
• F6 returns the display to the DATA SAVE screen.
• RETURN key restarts the display.
• EXIT returns the display to the I/O DISPLAY screen.
Figure 11-106 I/O Data Display Screen
May 22, 2001 11-127

OPTIONAL FUNCTIONS
11.40.3.9 SIGNAL SELECT SCREEN
The signal select screen (Figure 11-107) allows the operator to set the signal numbers
for CH1 to CH16 to monitor. Signal numbers represent 1HA board outputs 1-256 and
1FS board outputs 1001-1256.
Figure 11-107 Signal Select Screen
• F1 changes current data to previous data

• EXIT returns the display to the I/O DISPLAY screen
11-128 May 22, 2001

OPTIONAL FUNCTIONS
11.40.3.10 DATA DISPLAY SCREENS
The data display screen allows the operator to display stored data from operator
memory, a PC card, or a floppy disk (Figure 11-108). 99. DATA DISPLAY is accessible
in TEACH MODE only.

99. DATA DISPLAY
1. USER MEMORY
2. PC CARD
3. FD DRIVE
FUNCTION NUMBER:
F1 F2 F3 F4
Figure 11-108 Data Display Screen
When the operator selects PC CARD or FD DRIVE as the data source, the file selection
screen is displayed (Figure 11-109).
May 22, 2001 11-129

OPTIONAL FUNCTIONS
Figure 11-109 File Selection Screen
• The file selection screen (Figure 11-109) displays all files with the .csv extension.
• Use the cursor keys to select the desired file and press the RETURN key to load
the data.
• Data is loaded to USER MEMORY.
• Return to 99 DATA DISPLAY and select USER MEMORY (Figure 11-108) to

display selected file data.
• Additional files are listed using the F3 NEXT PG key.
11-130 May 22, 2001

OPTIONAL FUNCTIONS
Figure 11-110 Loading Data to File Memory
Figure 11-110 shows the display screen during file load. When file load is finished “File
load complete” is displayed.
May 22, 2001 11-131

OPTIONAL FUNCTIONS
11.40.3.11 NAVIGATING DATA DISPLAY SCREENS
The following navigation chart is used as a quick reference for navigating the data dis-
play screens. 99 DATA DISPLAY, is accessible in TEACH MODE only.
AUX 147 DATA STORAGE FUNCTION AUX 147 DATA STORAGE FUNCTION
99. DATA DISPLAY
1. JOINT 1. USER MEMORY
2. XYZOAT 2. PC CARD
3. JOINT COMMAND 3. FD DRIVE
4. JOINT OFFSET
5. JOINT SPEED
6. MOTOR CURRENT EXIT
7. MOTOR CURRENT COMMAND
8. TCP SPEED
9. I/O SIGNAL
99. DATA DISPLAY
FUNCTION NUMBER:
9 9 RETURN
FUNCTION NUMBER:
F1 F2 F3 F4 F1 F2 F3 F4

EXIT 1 RETURN
EXIT 2 OR 3
RETURN


1 ALL DATA
FILE1 CSV Feb 8 14:35 85658
FILE2 CSV Feb 8 14:34 16772
FILE3 CSV Feb 8 14:16 1024
FILE4 CSV Feb 8 14:08 11093
FILE5 CSV Feb 8 14:00 18101
FILE6 CSV Feb 8 13:56 1024
FILE7 CSV Feb 8 13:55 78
FILE8 CSV Feb 8 13:43 5010
FILE9 CSV Feb 8 13:28 23294
FILE10 CSV Feb 8 13:26 1024
F1 F2 F3 F4
Select File

RETURN

11-132 May 22, 2001

OPTIONAL FUNCTIONS

17:30

Loading... (FILE1.CVS)
STORAGE DATA
File load complete. (0 errors)
F1 F2 F3 F4 F5 F6
0 1 2 3 9 EXIT

EXIT

99. DATA DISPLAY
1. USER MEMORY
2. PC CARD
3. FD DRIVE
FUNCTION NUMBER:
F1 F2 F3 F4
May 22, 2001 11-133

OPTIONAL FUNCTIONS
11.40.4 COLLISION DETECTION FUNCTION
The collision detection function is used to minimize damage to tooling and robotic equip-
ment.
To activate the collision detection function, several parameters are set, using function
screens or AS Language commands. Settings using function screens are covered in
sections 11.40.4.1 - 11.40.4.7. Settings using AS Language commands are covered in
the C Series Controller AS Language Reference Manual, MRPCCONTO118E.
11.40.4.1 SETTING TOOL WEIGHT DATA USING AUX 149
The mass (weight), center of gravity location, and the inertia moment of the tool (Figure
11-111) are registered in AUX 149 TOOL REGISTRATION. Nine tools are available.
Use NEXT PG and PRE PG keys to access tool 1 - 9 (Figure 11-112). Data in AUX 149
is linked to the data in AUX 48 TOOL DIMENSIONS. If data is changed in one function
it is automatically changed in the other.
Use the cursor keys to select the data field and the numeric keys to make changes. To
complete data entry press the return key. If data is accepted “Normally completed” is
displayed. If data is not accepted “Illegal input data” is displayed.
The range of values are:
• load mass 0 - load mass

• center of gravity location -9999.9 - 10000.0
• inertia moment 0 - 999.99
Figure 11-111 Tool Data
11-134 May 22, 2001

OPTIONAL FUNCTIONS
Data entered in AUX 149, is obtained from the tool specification sheet supplied by the
manufacturer of the tooling or contact the tooling manufacturer.
8 9
AUX 149 TOOL REGISTRATION
TOOL 1
6 7
WEIGHT OF LOAD 10.0 kg
X POSITION OF LOAD 0.0 mm

Y POSITION OF LOAD 74.4 kg 4 5 EXIT
Z POSITION OF LOAD 4.5 mm
INERTIA AROUND X AXIS 5.10 kgm^2

BS
INERTIA AROUND Y AXIS 0.21 kgm^2 2 3
INERTIA AROUND Z AXIS 0.52 kgm^2
F1 F2 F3 F4
CLEAR
PREV DATA NEXT PG 0 1
RETURN
⇑ ⇓
F2 F3
PRE PG NEXT PG
⇑ ⇓
8 9
AUX 149 TOOL REGISTRATION
TOOL 2
6 7
WEIGHT OF LOAD 7.0 kg
X POSITION OF LOAD 45.0 mm

Y POSITION OF LOAD 0.0 kg 4 5 EXIT
Z POSITION OF LOAD 100.0 mm
INERTIA AROUND X AXIS 2.13 kgm^2

2 BS
INERTIA AROUND Y AXIS 0.32 kgm^2 3
INERTIA AROUND Z AXIS 0.75 kgm^2
F1 F2 F3 F4
CLEAR
PREV DATA PRE PG NEXT PG 0 1
RETURN
Figure 11-112 AUX 147 Tool Registration
May 22, 2001 11-135

OPTIONAL FUNCTIONS
11.40.4.2 DETECTION LEVEL THRESHOLD SETTING
The two types of thresholds are collision detection and shock detection.
Each threshold is set for motion in teach mode and in repeat mode.
These thresholds are set using AUX 148 on the multi function panel or type 2 teach
pendant (Figure 11-113), AS Language monitor commands and program instructions
(Table 11-6), or by automatic calibration (AUX 148-3).
For information on AS Language commands used for collision detection refer to the C
Series Controller AS Language Reference Manual, MRPCCONTO118E.
Table 11-6 Collision Detection Function Settings
AUX 148 COLLISION DETECTION FUNCTION

Threshold and Function Setting AS Language Command/Instruction Range
Set Threshold for Collision Detection COLT 0 - 500
Teach Mode Collision detection COLTON/COLTOFF EFFECT/INEFFECT

(Check Mode) Set Threshold for Shock Detection COLTJ 0 - 200
Shock Detection COLTJON/COLTJOFF EFFECT/INEFFECT
Set threshold for Collision Detection COLR 0 - 500
Collision Detection COLRON/COLROFF EFFECT/INEFFECT
Repeat Mode
Set Thredhold for Shock Detection COLRJ 0 - 200
Shock Detection COLRJON/COLRJOFF EFFECT/INEFFECT
Auto Calibration COLCALON/COLCALOFF EFFECT/INEFFECT
11-136 May 22, 2001

OPTIONAL FUNCTIONS
AUX 148 COLLISION DETECTION FUNCTION
1 SET THRESHOLD FOR TEACH MODE

2 SET THRESHOLD FOR REPEAT MODE
3 AUTO CALIBRATION
FUNCTION NUMBER:
F1 F2 F3 F4
Figure 11-113 Collision Detection Function Screen, AUX 148
11.40.4.3 THRESHOLD FOR TEACH MODE
To set the collision detection and shock detection for teach mode use AUX 148-1 (Figure
11-114).
AUX 148 COLLISION DETECTION FUNCTION AUX 148 COLLISION DETECTION FUNCTION
1 SET THRESHOLD FOR TEACH MODE 1 SET THRESHOLD FOR TEACH MODE
SET THRESHOLD FOR COLLISION DETECTION F3 SET THRESHOLD FOR SHOCK DETECTION
JT1 15%
⇒ NEXT PG
⇒ JT1 5%/msec
JT2 35% JT2 6%/msec
JT3 42% JT3 4%/msec
JT4 120% JT4 15%/msec
JT5 110% JT5 44%/mesc
JT6 160% F2 JT6 23%/msec
⇐ ⇐
PRE PG
COLLISION DETECTION EFFECT/INEFFECT SHOCK DETECTION EFFECT/INEFFECT
F1 F2 F3 F4 F1 F2 F3 F4
Figure 11-114 Set Collision Function for Teach Mode Screen
May 22, 2001 11-137

OPTIONAL FUNCTIONS
11.40.4.4 THRESHOLD FOR REPEAT MODE
To set the collision detection and shock detection for repeat mode use AUX 148-2 (Fig-
ure 11-115).
AUX 148 COLLISION DETECTION FUNCTION AUX 148 COLLISION DETECTION FUNCTION
2 SET THRESHOLD FOR REPEAT MODE 2 SET THRESHOLD FOR REPEAT MODE
SET THRESHOLD FOR COLLISION DETECTION F3 SET THRESHOLD FOR SHOCK DETECTION
JT1 45%
⇒ NEXT PG
⇒ JT1 3%/msec
JT2 60% JT2 5%/msec
JT3 75% JT3 5%/msec
JT4 235% JT4 11%/msec
JT5 305% JT5 11%/mesc
JT6 225% F2 JT6 15%/msec
⇐ ⇐
PRE PG
COLLISION DETECTION EFFECT/INEFFECT SHOCK DETECTION EFFECT/INEFFECT
F1 F2 F3 F4 F1 F2 F3 F4
Figure 11-115 Set Collision Function for Repeat Mode Screen
Use NEXT PG and PRE PG keys to access collision detection and shock detection data
for teach mode (Figure 11-114) and repeat mode (Figure 11-115). If 0 is selected for an
axis, collision detection is not effective for the axis. Select collision detection and shock
detection effect (used) or ineffect (not used) for teach mode (Figure 11-114) and repeat
mode (Figure 11-115).
Use the cursor keys to select the data field and the numeric keys to make changes. See
table 11-4 for setting range of data for AUX 148. To complete data entry, press the
return key. If data is accepted, “Normally completed” is displayed. If data is not ac-
cepted, “Illegal input data” is displayed.
The recommended procedure for setting threshold data is to use AUX 148-3 AUTO
CALIBRATION.
11-138 May 22, 2001

OPTIONAL FUNCTIONS
11.40.4.5 AUTO CALIBRATION
To prepare the robot system for auto calibration:
• Ensure accurate tool information is entered in AUX 149.
• Set up actual operating conditions (as close as possible).
• In a welding or assembly process, have workpiece in place.
• In a material handling process, have part or material in clamp or other tooling.
To use auto calibration to set threshold values, enter function 3 from AUX 148. Select
start and press return. The next screen displays the prompt to execute auto calibration
(yes) or exit auto calibration (no).
To activate auto calibration, in AUX 148 set threshold for motion mode desired (TEACH/
CHECK or REPEAT) to EFFECT (Figure 11-116).
For TEACH/CHECK mode, use check mode to step through the program several times
to ensure accurate threshold values. For REPEAT mode, set the system to operate in
repeat mode and run the program several times to ensure accurate threshold values.
Return to AUX 148-3 and select exit to deactivate the auto calibration mode.
Figure 11-116 Auto Calibration Screen
May 22, 2001 11-139

OPTIONAL FUNCTIONS
Collision detection is in effect for auto calibration, and it is possible for a false collision
detection to occur during auto calibration.
If a false collision detection occurs, multiply threshold setting by 1.2 and manually reset
the factory threshold settings to the new values.
Repeat the auto calibration procedure.
11.40.4.6 COLLISION DETECTION ERROR
Error code -1902 JT* collision or abnormal disturb is detected. Occurs when current
exceeds the range set by the JT1-JT6 thresholds.
If a collision occurred, move the robot away from the obstacle.
If a collision did not occur:
• confirm settings in AUX 149 TOOL REGISTRATION.

• multiply threshold setting by 1.2 and reset the thresholds to the new values.
11.40.4.7 TROUBLESHOOTING
Repeated mis-detection:

• preform auto calibration again.
• multiply threshold setting by 1.2 and reset thresholds to the new values.
Detection is slow:

• perform auto calibration again.
Collision is not detected:
• ensure collision detection is set to effect in AUX 148.

• ensure threshold data is not set to 0. If threshold data is set to 0, collision detection
is not effective for the axis.
11-140 May 22, 2001

OPTIONAL FUNCTIONS
NOTE
Collision detection is not effective during a gun motion

which includes a spot weld.
May 22, 2001 11-141

APPENDIX
A.0 APPENDIX .......................................................................................................... A-2

A.1 Setting of Tool Dimensions .................................................................................. A-2
A.2 Programming Sheets ........................................................................................... A-5
May 22, 2001 A-1

APPENDIX
A.0 APPENDIX
A.1 SETTING OF TOOL DIMENSIONS
AUX Function 48 - Tool Dimensions, shown in figure A-1, allows the operator to set and
store tool dimensions and coordinate system orientation parameters, for one to nine
different end effectors.
Changes in the X, Y, and Z directions are measured in millimeters. The range is from
–10,000 mm to +10,000 mm, and is measured in tenths of a millimeter (0.1 mm).
Changes in the O, A, and T tool coordinate rotation angles are measured in degrees.
The range is from –180° to +180°, and is measured in tenths of a degree (0.1°).
AUX 48 TOOL DIMENSIONS

TOOL 1
X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg
WEIGHT OF LOAD 120.0kg
X POSITION OF LOAD 0.0mm
Y POSITION OF LOAD 0.0mm
Z POSITION OF LOAD 0.0mm
F1 F2 F3 F4
PRE DATA NEXT PG
Figure A-1 AUX Function 48 - Tool Dimensions
A-2 May 22, 2001

APPENDIX
The base and tool coordinate systems shown in figure A-2 show the standard
orientation and origin of each coordinate system.
The tool coordinate system has been rotated, through system software, from the base
coordinate orientation by using the O, A, and T angles of +90°, +90°, and –90°
respectively. For this reason, the robot location is shown as having O, A, and T angles
of +90°, +90°, and –90° when the wrist is in a straight, or zero position, and the tool
dimension is set with O, A, and T angles of 0°, 0°, and 0°.
The tool coordinate system can be rotated into other orientations by defining the proper
O, A, and T angles. Typically this is done so that the "Z" tool coordinate axis is aligned
in the direction of the tool.
X
Y
Tool Coordinate System
X, Y, Z, O, A, T = 0, 0, 0, 0, 0, 0
Y
Base Coordinate System
X, Y, Z, O, A, T = 0, 0, 0, 0, 0, 0
Figure A-2 Robot Coordinate Systems
May 22, 2001 A-3

APPENDIX
Figure A-3 shows the rotation of the tool coordinate system in its standard orientation
from the base coordinate system orientation, with the values O = +90°, A = +90°, and
T = –90°. This standard orientation is displayed as O = 0°, A = 0°, and T = 0° on the tool
dimension setup screens (AUX function 48). To properly specify the OAT angles, the
tool coordinate system axes must be rotated in the correct order, beginning with the O
angle, then the A angle, and finally the T angle.
O — Turning angle around the Z-axis

A — Turning angle around the Y-axis after O has been specified
T — Turning angle around the Z-axis after O and A have been specified
1 Defining O=90 2 Defining A=90 3 Defining T=-90
Z Z
Y Y
+ -
+
+
-
Y X Z
-
X
X
O - Defined A - Defined T - Defined

Z
Y Y
X Z Z
X
X Y
Figure A-3 Orientation of XYZ and OAT
A-4 May 22, 2001

APPENDIX
A.2 PROGRAMMING SHEETS
The following pages contain examples of block step programming sheets. Programming
sheets are aids used when programs are written and to track changes to production
programs. They are particularly helpful in tracking input and output signal numbers and
their assigned functions.
May 22, 2001 A-5

APPENDIX
Line No./Station
olation
Interp-
A-6 December 18, 1998
APPENDIX
Line No./Station :
olation
Interp-
December 18, 1998 A-7
GLOSSARY
GLOSSARY ................................................................................................................ G-2
May 22, 2001 G-1

GLOSSARY
This glossary contains definitions of terms used by operators, programmers, and main-
tenance personnel who work with Kawasaki robots. The definitions are listed in alpha-
betical order.
A
• ACCELERATE
To speed up a process.
• ACCURACY
A measure of the difference between the commanded robot arm position and the
actual position. Also identifies how well an indicated value conforms to a true value
(i.e., an actual or accepted standard value).
• ACRONYM
A word formed from the initial letters of words in a name or phrase. For example,
ASCII is an acronym for American Standard Code for Information Interchange.
• ADDRESS
A number that identifies a specific location in the computer’s or processor’s memory.
Means of identifying a location or data in a control system.
• ADDRESSING
Computer operations store data in specific memory locations or addresses. The
largest memory location determines the amount of data that can be stored. The
larger the number, the larger the possible program.
• AIR CUT
Moving a weld gun into position but without generating an arc.
• ALGORITHM
A finite set of well-defined rules or procedures for solving a problem step-by-step.
• ALPHANUMERIC
Pertaining to a set of symbols that contain both letters and numbers, either individu-
ally or in combination.
• AMBIENT TEMPERATURE
The temperature of air or liquid that surrounds a device.
• AMPERE (AMP)
A unit of electrical current flow that is equivalent to one (1) coulomb per second.
One (1) volt across one (1) ohm of resistance causes a current flow that is equiva-
lent to one (1) amp.
G-2 May 22, 2001

GLOSSARY
• ANALOG
A continuously changing electrical voltage signal. In robot systems, the magnitude
or value of the signal represents commanded robot axis motion.
• ANALOG DATA
Information that is represented by a characteristic of the value or magnitude of an
electrical signal, such as the amplitude, phase, or frequency of the voltage, the
amplitude or duration of a pulse, the angular position of a shaft, or the pressure of a
fluid number.
• ANTI-FRICTION BEARING
A rolling element which is used to support a rotating shaft.
• ARC SENSOR
A sensor that detects weld lines utilizing arc characteristics.
• ARGUMENT
A value applied to a procedure; data used by a function or other command. For
instance, in the AS command JMOVE flange, 2. The variable, flange, and the clamp
number 2 are the arguments of the function JMOVE.
• ARRAY
An ordered set of addresses or their values. Elements of an array can be refer-
enced individually or collectively. Array elements all have the same type of data, for
instance, integer or character, and are usually presented in rows and columns.
• ARTICULATED
To join together permanently or semi-permanently by means of a pivot connection
for operating separate segments as a unit.
• ARTICULATED ROBOT
A robot arm which contains at least two consecutive revolute joints, acting around
parallel axes, resembling human arm motion. The work envelope is formed by
partial cylinders or spheres. The two basic types of articulated robots, vertical and
horizontal, are sometimes called anthropomorphic because of the resemblance to
the motions of the human arm.
• ASCII
An acronym for American Standard Code for Information Interchange. This stan-
dard 8-bit code is used by many devices, such as keyboards and printers.
• AS LANGUAGE
Kawasaki robot language used to communicate commands and instructions from a
keyboard to the CPU.
May 22, 2001 G-3

GLOSSARY
• ASSIGNMENT
An instruction used to express a sequence of operations, or used to assign oper-
ands to specified variables, or symbols, or both.
• ASYNCHRONOUS
A means of data communication where the data is sent a character at a time pre-
ceded by a start bit and followed by a stop bit. No direct timing signal links the
transmitter and receiver.
• AUXILIARY DATA
Information about a point, other than the positional data, such as speed, accuracy,
weld schedule and clamp condition.
• AXIS
A straight line about which sections of the mechanical unit rotate (e.g., joints JT1,
JT2, JT3 etc.).
B
• BACKLASH
The clearance, slack, or play between adjacent gears, or the jar or reaction often
caused by such clearance when the parts are suddenly put in action or are in ir-
regular action.
• BASE COORDINATE
A fixed coordinate system having an origin at the intersection of the X, Y, and Z
axes.
• BAUD RATE
Determines the number of bits per second (bps) or characters transmitted between
devices.
• BCD
An abbreviation for binary coded decimal. The BCD 8-4-2-1 code expresses each
decimal digit by its own 4-bit binary equivalent. The 8-4-2-1 code is identical to
binary through the decimal number 9. Above the decimal number 9 each decimal
digit is represented by its own 4-bit binary equivalent. For example, using the 8-4-2-
1 binary-coded system, the number 10 is interpreted as 0001 0000.
• BINARY CODE
A system in which characters are represented by a group of binary digits, that have
the value of either 0 or 1, true or false, on or off.
G-4 May 22, 2001

GLOSSARY
• BIT
Acronym for binary digit, having one of two values: 0 or 1.
• BOOT
The method by which computers are brought from a non-operating to an operating
state. During this sequence, the computer memory is usually reset. This is often
performed to restart the computer after a crash, to bring it on-line.
• BUFFER
A temporary memory storage area in a computer or electronic device.
• BUG
A problem in a software or hardware element of a system.
• BUS
The primary communication path in the controller along which internal signals are
sent among processors and memories.
C
• CABLE CARRIER
A device which carries cables and hoses (including power sources) from a station-
ary location to a linear moving device.
• CARTESIAN COORDINATE
A location in space defined by three axes at right angles to each other, commonly
labeled X, Y, Z.
• cc
Abbreviation for cubic centimeter.
• CELL
A manufacturing unit consisting of two or more work stations or machines, and the
material transport mechanisms and storage buffers that interconnect them.
• CENTER OF GRAVITY
The point at which the entire weight of a body may be considered as concentrated,
so that if supported at this point the body would remain in equilibrium in any posi-
tion.
• CHARACTER
A term that describes all numbers, letters, and other symbols typically found on a
computer keyboard.
May 22, 2001 G-5

GLOSSARY
• CHECK MODE
A procedure that allows the user to check positional data and auxiliary data while in
the teach mode with the Kawasaki robot . This procedure is in many ways analo-
gous to reverse point and forward point operations in other robot models.
• CHECKSUM
A method by which the contents of data or a transmission are verified to be accu-
rate. This method ‘sums’ all the characters and translates them into a number which
is appended to the data.
• CHEMICAL ANCHOR
A threaded rod installed in a structure (e.g., a concrete floor) and secured by epoxy,
for the purpose of securing hardware.
• CIRCULAR INTERPOLATION
A path taken by the robot that connects at least three points with an arching motion.
The CPU will calculate a path that places the taught points on a section of a circle.
• CLOSED-LOOP SYSTEM
A system in which a command value is output and a feedback value is returned.
The resulting error, the difference between the command and the feedback, is used
to correct the signal. In a robot system, the command signal is output by the con-
troller, causing the robot arm to move, and the feedback signal is produced by the
encoder, which reads the current position of the arm.
• CODE
A set of rules for expressing information in a language that is understood and pro-
cessed by a control system.
Also, a term for instructions in a computer program. Code performs a process, and
data is the information that is processed.
• COMMAND
An analog signal, or group of signals or pulses, which cause a specified function to
be performed. An instruction or request in a computer program that performs a
particular action. Commands that are needed to run the operating system are
called a command language.
• COMMENT
Optional, non-executing remarks added to a program to explain various aspects of
the program.
G-6 May 22, 2001

GLOSSARY
• COMPILER
A system task that translates a program written in source code, into binary code
that can be understood by the processor.
• COMPOUND TRANSFORMATION
A location in the Cartesian coordinate system that is defined relative to another
Cartesian coordinate location.
• CONTIGUOUS FILE
A file that is stored in continuously adjacent areas of memory, in contrast to a file
which is scattered to make more efficient use of disk space.
• CONTINUOUS PATH CONTROL

A type of robot control in which the robot moves according to a replay of closely
spaced points programmed on a constant time base during teaching.
• CONTROL ERROR CODE

A code which identifies system problems whenever an alarm condition occurs.
• CONTROLLED AXIS
A robot axis that is operated by electrical or hydraulic power.
• CONTROLLER
An electronic device, with processing capabilities and software, which controls the
robot actions and functions.
• CONVEYER TRACKING
Used to make the robot follow a part on a conveyor, without the use of a traverse
axis.
• COORDINATE
A set of numbers that locate a point in space.
• CPU
Abbreviation for central processing unit. A collection of hardware in a computer
which performs all calculations, handles I/O, and executes programmed tasks.
• CRASH
A situation where the computer fails to operate, due to a software or hardware
problem.
• CRT
Abbreviation for cathode ray tube. A CRT is a charge storage tube in which the
information is written by means of the cathode ray beam.
May 22, 2001 G-7

GLOSSARY
• CURRENT LOOP
A circuit in which a portion of the output is returned to modify the control circuit
output. This circuit may be used as a limiting device, for safety protection.
• CURSOR
A pointer or indicator on a computer screen, that identifies the current position on
the screen.
• CYCLE
A complete path of projectory performed by the robot for a specific application.
• CYCLOIDAL DRIVE
A mechanical gear reduction unit that reduces the speed of the input and increases
the torque capacity. The cycloidal unit consists of an internal arrangement of discs
and pins that are driven by an eccentric drive cam. This type of gear reduction
offers low gear train backlash and the capability to achieve high reduction ratios
from a single contained unit.
D
• DATA
A term given to information, instructions, words or symbols that are usually transmit-
ted, processed, or stored as a group.
• DETENT
A part of a mechanism that locks or unlocks a movement.
• DISCONNECT
A switch that isolates a circuit or one or more pieces of electrical apparatus after the
current has been interrupted by other means.
• DEVIATION ERROR
In all mechanical devices, the actual position of the mechanical unit will lag behind
the electrical command of the controller. An allowable limit is assigned for this
difference. However, if the controller detects a condition where the difference be-
tween this mechanical value and the desired electrical position is larger than the
established value limit, the robot controller will generate a deviation error. This error
is sometimes referred to as a FOLLOWING ERROR in the robot industry.
• DEBUG
The process by which an operator’s program is checked for mistakes and then
corrected.
G-8 May 22, 2001

GLOSSARY
• DECIMAL NUMBER
Numbers in the base-10 numbering system, which uses the numerals 0 - 9.
• DEDICATED
A term used to describe a system resource, such as an I/O device or terminal,
which is used for only one purpose, or assigned a single function.
• DEDICATED SIGNAL
A term used to describe a signal which is used for only one purpose, or assigned a
single function. Both inputs and outputs can be dedicated.
• DEFAULT
A value or operation that is automatically entered by the system, if the operator
does not specify one. Typically, the default is the standard or expected response.
• DELETE
A command which will eliminate unwanted data.
• DELIMITER
A character which separates a group of items or a character string, from other
groups, or which terminates a task.
• DEVICE
Any peripheral hardware connected to the processor and capable of receiving,
sorting, or transmitting data.
• DIAGNOSTICS
Function performed by the processor to identify and check for error conditions in the
robot arm and peripheral devices.
• DIP SWITCH
DIP is an acronym for dual in-line package. A set of small switches on circuit
boards that can be set for different configurations.
• DIRECTORY
A logical structure that organizes a group of similar files.
• DISK
A high-speed, random-access memory device.
• DISK-BASED SYSTEM
System in which programs and files are stored on the hard disk and are read into
memory when requested by the user.
May 22, 2001 G-9

GLOSSARY
• DISK PACK
A device which is used to store additional data in a computer system, and is usually
removable.
E
• ECHO
Process in which characters that are typed on a keyboard are also displayed on the
screen or are sent to the printer.
• EDITOR
An aid for entering information into the computer system and modifying existing text.
• EMERGENCY STOP (E-Stop)

An immediate stop of robot motion, selected by the operator with a switch.
• ENCODER
An electromechanical device that is connected to a shaft to produce a series of
pulses that indicate the position of the shaft.
• EPROM
Acronym for erasable programmable read-only memory. The contents of this
memory (computer chip) are retained, even when power to the system is turned off.
Usually stores executive programs and critical system variables.
• ERROR LOG
A report which contains a sequential list of system error messages.
• ERROR MESSAGE
Messages displayed on the plasma screen of the robot controller, when the action
requested by the operator could not be completed. Error messages can occur
when components malfunction or if an incorrect command is typed by the operator.
• EXPRESSION
A combination of real-valued variables and functions, and mathematical and logical
operators. When evaluated, this combination yields a numeric value.
F
• FEEDBACK
The transmission of a signal from a measuring device (e.g., encoder, transducer) to
the device which issued the command signal within a closed-loop system. See
CLOSED-LOOP SYSTEM.
• FIELD SIGNALS
G-10 May 22, 2001
GLOSSARY
All electrical signals that exit or enter an electrical panel.
• FILE
A set of related records or data elements, which are stored using one name and are
arranged in a structure that can be used by a program.
• FILESPEC
Includes the name, creation date and size of the specified file.
• FIXED DISK
An electromagnetic mass storage device which is not removable. Hard disks have
much higher storage capacity than floppy disks.
• FLOPPY DISK
An electromagnetic mass storage device which can be removed and exchanged.
• FORM FEED
Process which causes a printer to advance the paper to the top of the next page.
• FUNCTION
A formula or routine for evaluating an expression.
G
• GAIN
A proportional increase in power or signal value relative to a control signal. The
ratios of voltage, power, or current as related to a reference or control signal input.
• GLOBAL
Refers to a function or process that affects the entire system or file.
• GRAY CODE
A positional binary number notation in which any two numbers whose difference is
one are represented by expressions that are the same except in one place or col-
umn and differ by only one unit in that place or column.
H
• HALF-DUPLEX COMMUNICATION
Data transmission between two devices, where the signal is sent in only one direc-
tion at a time.
• HANDSHAKING PROTOCOL
May 22, 2001 G-11

GLOSSARY
Communication rules used for data transmissions between devices. Each device
must recognize the same protocol in order to communicate.
• HANG
A term which refers to the state of a computer system that seems to be inoperative
when processing should be taking place.
• HARDSTOP
A mechanical constraint or limit on motion.
• HARDWARE
Physical equipment and devices such as computer hard disk, cables, printer, etc.
• HAZARDOUS SIDE
The unsafe side of a component or panel, such as the inside of the control panel
when power is applied and functions are being performed.
• HOLD
When an external or an internal input is available for a hold condition, the robot will
stop its motion and servo drive power will be removed from the robot. When an
external hold reset is performed, the servo drive power will be energized.
• HOME POSITION
Refers to the starting or resting position of the robot.
• HYBRID ENCODER
On the Kawasaki robot a hybrid encoder is used to generate positional data, and is
composed of an incremental encoder that generates incremental pulses, and an
absolute encoder that generates gray code binary data.
I
• ID
Abbreviation for Identification.
• INCHING
A value that is used during the jogging process that allows the user to position the
robot in small minute increments.
• INCREMENTAL CODE
G-12 May 22, 2001

GLOSSARY
A digital closed loop feedback code that provides digital feedback pulses to the
robot controller for the purpose of providing positional information. These incremen-
tal pulses are generated by an encoder through the use of an optical disk with
alternating opaque and transparent bars or lines around the periphery of the disk.
On one side of the disk a light source is mounted, and on the opposite side a
phototransistor When the disk rotates, the phototransistor is alternately forced into
saturation and cutoff, producing the digital signal.
• INPUT
Transmission of an external signal into a control system.
• INTEGRATED CIRCUIT (IC)

A combination of interconnected circuit elements which are within a continuous
substrate.
• INTERACTIVE SYSTEM
System where the user and the operating system communicate directly; the user
through the keyboard, and the operating system via the display screen.
• INTERLOCK
An arrangement whereby the operation of one part or mechanism automatically
brings about or prevents the operation of another.
• INTERPRETER
A program that changes English-like commands into machine language. An inter-
preter translates and executes one command at a time.
• INSTRUCTIONS
Discrete steps in a computer program that are commands or statements that tell a
computer to do something or identify data.
• INTEGER
A whole number, a number without a fractional part such as 7, -318, or 19.
• INTERFACE
The circuitry that fits between a system and a peripheral device to provide compat-
ible coupling between the two pieces of equipment.
• INTERPOLATION
The mathematical process that the CPU utilizes to plot a path for the robot to travel
from one position to another. A mathematical process that evaluates a number of
dependent and independent variables for the purpose of comparison and prediction.
• INTERRUPT
An external signal that halts program execution so that the computer can service
May 22, 2001 G-13

GLOSSARY
the needs of some peripheral device or subsystem.
• INTRINSIC SAFETY BARRIER (ISB)

An electronic device used in robot controllers to restrict current and voltage to a
safe level.
• INVERTER
A circuit which switches a positive signal to a negative signal, and vice versa.
• I/O
Abbreviation for Input/Output. The interconnections through which the computer
and its peripheral devices communicate.
• IPM
Abbreviation for Intelligent Power Module
J
• JOG
A term used to describe the process in which the user moves the mechanical unit
through interaction with the robot controller and the teach pendant. Sometimes
referred to as slewing.
• JOINT
1. A term used to describe the individual axes of a robot.
2. A term used to describe the jogging process in which the robot is jogged one
axis at a time.
• JOINT MOVE
A mode of operation in which the robot moves from one point to the next with an
arching path. All axes motors (required for the move) begin and end their rotation at
the same time. The tool center point does not follow a linear path to reach the
taught position.
L
• LABEL
An identifier for a program command line. To identify an instruction, memory loca-
tion, or part of a program.
• LAN
An acronym for local area network. A group of computer terminals interconnected
G-14 May 22, 2001

GLOSSARY
by cables, allowing communication of information via the network.
• LCD
Abbreviation for liquid crystal display. This type of display is made of material
whose reflectance or transmittance of light changes when an electric field is ap-
plied.
• LIMIT SWITCH
An electrical switch positioned to be switched when a motion limit occurs, thereby
deactivating the actuator that caused the motion.
• LINEAR MOVE
An operation where the rate and direction of relative movement of the robot arm are
continuously under computer control.
• LINE PRINTER
A high-speed output device that prints a line at a time.
• LINE TURN-AROUND
Changing the source of transmission in half-duplex communications.
• LOGICAL OPERATION
Any of several operations that manipulate information according to the rules of logic
(e.g., AND, OR, NOT, and exclusive OR).
• LM
Abbreviation for linear motion.
• LOAD
The weight applied to the end of the robot arm.
• LOCKOUT
Serving to prevent operation of a device or part of it.
• LSB
Abbreviation for least significant bit.
May 22, 2001 G-15

GLOSSARY
• MANIPULATOR
Another term for the mechanical portion of the robot system.
• MACHINE LANGUAGE
A low-level computer language, usually written in binary code.
• MASS-STORAGE DEVICE
An input/output device that retains data input to it. Examples include: hard disk
drives, magnetic tapes, floppy diskettes, and disk packs.
• MECHANICAL UNIT
robot (excluding controller)
• MEMORY
An area of the computer which stores data, either permanently or temporarily.
When a program is requested, it is first loaded into memory so it can be accessed
quickly by the processor.
• MHz
Abbreviation for megahertz. One million cycles per second.
• MIRROR IMAGE
A process which converts the positive and negative values of a taught path from a
right-handed robot to a left-handed robot, or vice versa. The actions of the oppos-
ing robots are then coordinated and synchronized.
• mm
Abbreviation for millimeter.
• MNEMONIC
A term used to help the operator remember a large string of words or commands.
• MODEM
A signal conversion device that modulates and demodulates data into an audio
signal for transmission.
• MOMENT OF INERTIA
Used to calculate end of arm tooling and handling weights. The sum of the prod-
ucts formed by multiplying the mass of the load by the square of the distance from
the tool mounting flange.
• MONITOR PROGRAM
An administrative computer program that oversees operation of a system. The AS
G-16 May 22, 2001

GLOSSARY
monitor accepts user input and initiates the appropriate response, follows instruc-
tions from user programs to direct the robot, and performs the computations neces-
sary to control the robot.
• MSB
Abbreviation for most significant bit.
• MSEC
Abbreviation for millisecond (0.001 seconds).
N
• NOISE
Any unwanted disturbance within a dynamic, mechanical, or electrical system.
• NULLED
An electrical zero state.
O
• OCTAL NUMBER
A numeral in the base-8 numbering system, which uses the numerals 0 - 7.
• OFF LINE
A state in which communications between two devices cannot occur (e.g., between
a printer and a computer, if the printer is off line).
• ON LINE
A state in which communication between two devices can occur.
• OPERATING SYSTEM
A set of system tasks and commands that are entered by the operator and inter-
preted and performed by the system.
• OPEN LOOP
A control which does not use feedback to determine its output.
• OPERATOR
Any mathematical action or function. The arithmetic operators are: add, subtract,
May 22, 2001 G-17

GLOSSARY
multiply, divide, modulo, and exponentiate. The relational operators are: greater
than, less than, equal to, and their combinations. The logical operators are: AND,
OR, exclusive OR, negate. The binary logical operators are AND, OR, exclusive
OR, ones complement.
• OPTO
An optical isolator or level converter.
• OVERFLOW
When a value or buffer exceeds a predefined limit.
• OVERTRAVEL
An error condition that exists when the robot exceeds its normal software limit
values, and then actuates an overtravel limit switch.
• OVERVELOCITY
When an axis exceeds a preset value for velocity.
• OX (OUTPUT EXTERNAL)
Information transferred from the robot controller through output modules to control
output devices.
P
• PARITY
Method by which errors are detected. In this method the combined binary values of
a byte are flagged as 1 or 0.
• PARSE
To break a command string into individual elements, so it can be interpreted.
• PASSWORD
A code, entered by the user, to permit access to protected information.
• PAYLOAD
The maximum weight that a robot can handle satisfactorily during its normal opera-
tions and extensions.
• PC PROGRAM
PC is an abbreviation for process control. A PC program cannot contain any step
that causes robot motion. PC programs are used to evaluate logic and variables
and execute program CALL and GOTO commands
• PERIPHERAL DEVICE
Hardware equipment which is external to the CPU, but that transmits and/or re-
G-18 May 22, 2001
GLOSSARY
ceives I/O from the processor. Examples include: printer, CRT screen, or disk.
• PHASE
The angular relationship between current and voltage in alternating current circuits.
In a waveform or period function, the fraction of the period that has elapsed, as
measured from a reference point. Phase angle is determined by multiplying the
phase by 360 degrees.
• PINCH POINT
Any point where it is possible for a part of the body to be injured between the mov-
ing or stationary parts of a robot and the moving or stationary parts of associated
equipment, or between the material and moving parts of the robot or associated
equipment.
• PLA
Abbreviation for programmable logic array. Used in many servo drive circuits.
• PLAYBACK
An operation where a taught path is run for evaluation purposes.
• PLC
Abbreviation for programmable logic controller. Usually referred to as the cell mod-
ule controller.
• POINT-TO-POINT
A robot motion control in which the robot can be programmed by a user to move
from one position to the next. The intermediate paths between these points cannot
be specified.
• POLARITY KEYS
These teach pendant or multi function panel keys allow the user to jog or slew the
robot in the Joint, Base (XYZ), or Tool coordinates system.
• PORT
The connection point of an opening or passage that is usually located outside the
housing of a device.
• POSITIONAL DATA
The location in space of the robot manipulator.
• POUNCE POSITION
A positional location at a point near the workpiece, clear of the transfer mechanism
May 22, 2001 G-19

GLOSSARY
and part, from which the robot is ready to begin production.
• PRINTED CIRCUIT
An assembly of electronic elements that provide a complete path of electrical cur-
rent through conductive material deposited between terminals on an insulated
surface.
• PRECISION POINT
The play back of robot location based on the angular position of the six axes, joint
angles
• PRINTING
A process in which characters are stamped on a surface, usually paper.
• PROGRAM
A predefined, step-by-step set of instructions that are entered into a computer so a
specific process can be performed repeatedly without reentering all the steps.
Robot paths are stored and run as part of programs.
• PROGRAM EDIT
Modification of an existing program.
• PROCESSOR
Generally, any hardware or software system for carrying out programs and acting on
data.
• PULSE WIDTH MODULATION (PWM)

A modulation process in which the instantaneous sampling of the modulating wave
is caused to modulate the duration of the pulse. This type of modulation is also
referred to as pulse duration modulation (PDM), or pulse length modulation (PLM).
R
• RAM
Acronym for random access memory. An area used by the CPU for processing and
temporarily loading programs so they can be accessed quickly. The contents of
RAM are lost when the computer is powered down, unless battery backup is pro-
vided.
• REAL NUMBER
A number with a fractional part, such as 1.75, -31.89, .5, -4.00, etc.
• REAL-TIME
The actual time during which the computer analyzes and processes data: informa-
G-20 May 22, 2001

GLOSSARY
tion is usually processed as it is received.
• REAL VARIABLE
AS language term for a variable that has had a real value assigned to it.
• REPEAT MODE
A mode of operation that allows the user to check positional and auxiliary informa-
tion at a selected speed value, in a continuous or a step by step type of movement
of the mechanical unit.
• REPEATABILITY
The measurement of the closeness of agreement among repeated measurements
of the same variable under the same conditions.
• REWRITE MODE
A mode of operation which allows the user to rewrite positional, or auxiliary data,
and to insert or delete step address locations.
• RISC
Acronym for reduced instruction set computer.
• ROM (read-only memory)
A memory device which is programmed at the factory and whose contents thereaf-
ter cannot be altered.
• RS-232C
An ASCII specification for connections and communication between serial devices.
• RUN
A mode of operation that allows the user to select servo motor power to provide
drive energy to the robot, allowing it to perform such modes of operation as teach,
check, repeat, and rewrite.
S
• SAFETY PLUG
A device used with safety fencing to interlock the opening of the fence with the
removal of power to the robot.
• SCROLL
When more information exists than can be displayed on one screen, the operator
May 22, 2001 G-21

GLOSSARY
can move up and down through the data to view it. When data is scrolled to the
screen, the information previously viewed moves up off the screen, and new infor-
mation enters the screen from the bottom.
• SENSOR
A device used to detect various conditions: proximity, heat, pressure, etc. An electri-
cal signal from the sensor can be used to communicate information to a robot
program.
• SERIAL
A method of transmitting data by which only one bit is sent or received at any one
point in time.
• SEQUENTIAL ACCESS
A method used by many computers whereby data is read in the order in which it is
physically stored.
• SINGULARITY POSITION
When the robot is processing a linear or circular move and two or more joints are in
alignment. The CPU can not process the ambiguity of a singularity configuration
and an error is generated.
• SOFTWARE LIMITS
Programmed values that are included in a program at the point before a mechanical
device hits an overtravel limit switch or a hard limit.
• SOFTWARE
A set of written programs and instructions that are executed by a computer system.
• SOURCE CODE
A program that contains the actual software instructions entered by the user, in
contrast to object code which is source code that has been translated into a lan-
guage which can be interpreted by the computer.
• STRING
A series of characters that have been entered in a distinct sequence that can be
interpreted as a valid statement or command.
• STROKE
The movement in either direction of a mechanical part having a reciprocating mo-
tion. The entire distance passed through in such a movement.
• SUBSCRIPT
A set of numbers that identifies an element of an array.
G-22 May 22, 2001

GLOSSARY
• SUBROUTINE
A set of instructions that is run by another routine.
• SYMBOL
A character or design that has a distinct meaning and/or is associated with some-
thing.
• SYNTAX
The proper way in which commands and phrases should be typed in order to be
understood by the control system. If the operator incorrectly types a command (i.e.,
misspelled or invalid characters), a syntax error message will be displayed.
• SYSTEM DATA
Data that is specific to a individual robot. Zeroing data, upper and lower software
limits, and software switch settings are all examples of system data.
• SYSTEM SWITCH
Software switches that are set to determine various configurations and characteris-
tics of the robot system performance.
T
• TEACH MODE
A mode selected on the operator panel, during which robot arm axes positions can
be taught by the operator and are recorded by the robot.
• TEACH PENDANT
A hand-held, portable device used by the operator during teach and jogging opera-
tions.
• TOOL COORDINATES
A Cartesian coordinate system in which the origin point is at the face plate of the
robot and the orientation of the tool can be expressed in terms of a 3-dimensional
space representation of X, Y, and Z projections.
• TOOL MODE
A mode of operation in which all motions are calculated to maintain the orientation
of the tool in space.
• TORQUE
Something which produces or tends to produce rotation or torsion and whose effec-
May 22, 2001 G-23

GLOSSARY
tiveness is measured by the product of the force and the perpendicular distance
from the line of action of the force to the axis of rotation.
• TRANSFORMER
A device to convert the current of a primary circuit into variations of voltage and
current used in secondary circuits.
• TRANSFORMATION
A mathematical description of a location that defines the position and orientation of
the location without regard for the configuration of the robot when it is at that loca-
tion.
• TRAP POINT
See PINCH POINT.
• TTL
Abbreviation for transistor-transistor logic.
• TWO’S COMPLEMENT
A means of representing a negative number as one more than the binary comple-
ment of the absolute value of the number.
• TRIANGULAR WAVEFORM
A waveform that has the shape of a triangle and is used in determining sampling
values for servo drive circuits that utilize pulse width modulation.
U
• UHF
Abbreviation for ultra-high frequency.
V
• VARIABLE
The name of a memory location or stored value. A variable can refer to a scalar or
an array.
• VELOCITY COMMAND
This analog signal is directly proportional to motor speed, and provides the initial
signal that is processed by the servo drive system to drive a servo motor.
• VELOCITY ERROR
When the robot controller detects an axis that has exceeded a preset value for
G-24 May 22, 2001

GLOSSARY
velocity, the robot controller will E-stop the robot.
• VOLT
A unit of electrical potential difference and electromotive force. One volt is equiva-
lent to the force required to produce one amp of current through one ohm of resis-
tance.
W
• WORK ENVELOPE
The effective range or reach of a robot’s axes.
• WORLD COORDINATES
A Cartesian coordinate system in which the origin point is near the base of the
robot, and robot movement can be expressed in terms of a 3-dimensional space
representation of X, Y, and Z projections.
• WRITE
In computer systems, a process in which information is output to and stored by a
device or area in memory.
• WS (WELD SCHEDULE)
Data that is stored in the weld controller and provides the specific current, clamp
pressures, etc. for spot welding applications.
• WX (WAIT EXTERNAL)
The wait external signal is one of many inputs that are processed by the robot
controller. When the robot encounters a wait external condition, the robot will cease
motion and the servo power will be removed.
Z
• ZEROING
This procedure provides the robot controller with encoder data that is referenced
from a known mechanical position (zeroing witness marks, in simple zeroing, or
inclinometer values in precision zeroing) and then establishes an encoder value for
this known position. Two methods can be used, simple and precision zeroing.
Some robot manufacturers call this procedure mastering or calibration.
May 22, 2001 G-25

INDEX
INDEX .........................................................................................................................IN-2
May 22, 2001 IN-1

INDEX
Symbols
1 and 0 Display, 9-45
1FS Board, 1-17, 11-73, 11-77
1GA Board, 1-16, 11-73
1GB Board, 1-16, 1-19
1GC Board, 1-16
1GD Board, 1-16
1GM Board, 1-16
1GW Board, 1-17
1HP Board, 1-17
1HS Board, I-12, 11-78
3 Notch Selector Switch, 11-60
A
Abnormal Check Sum, 9-48
ACCFLOW, 11-37
Accuracy, I-11, 2-7, 9-28
After Wait Timer Switch, 9-44
Allen-Bradley, 11-73
Alpha Program Name, 7-4
Amplifier, 1-19
ANSI/RIA, 2-2
ANSI/RIA Standards, 9-34
Anticipation of Clamp, 9-69
Arm ID Board, 9-78
Arm ID Board AS Language Commands, 9-85
Arm ID Board Error Codes, 9-91
Arm ID Board Errors, 9-87
Arm ID Board Signal Allocation, 9-84
AS Instruction Definition, 11-66
AS Location, 5-33
AS Teaching, 5-32
Auto Calibration, 11-139
Auto Servo Timer, 9-53
Auto Tool Set, 11-15
Automatic Tool Calibration Function, 11-18
Automatic Tool Calibration Preparation, 11-19
Automatic Tool Calibration Procedure, 11-20
Autostart.PC Switches, 9-45
Aux 123 Maintenance Log, 9-79
Aux 149, 11-134
Aux 181, 11-84
Aux 198, 11-94
AUX 48 Tool Dimensions, A-2
Aux 64, 11-33
Aux 65, 11-34
Aux Set & Display Key, 5-25
Auxiliary Axis, I-2
Auxiliary Data, 7-8, 7-13, 7-16
Auxiliary Data Area, 5-15, 5-17
Auxiliary Function List, 9-4, 11-4
Auxiliary Function Screens, 9-3
IN-2 May 22, 2001

INDEX
Auxiliary Function Select, 11-94

Auxiliary Program Data Selection Keys, 5-18
Axis Keys, 6-5
B
B-Axis, I-2
Backup File, 9-13
Base (World) Coordinates, I-3
Base Coordinate, 9-24
Base Coordinate Shift, 9-24
Base Coordinate System, A-3
Base Data, 11-100
Battery Error Check, 9-59
BEAD, 11-36
Bead Width, 11-38, 11-42
Block Teaching Screen, Multi Function Panel, 5-15
Block Teaching Screen, Type 2 Teach Pendant, 5-17
Brake Release Switches, 2-8
Brakes, 2-5, 2-8, 2-9
C
C and X Gun Types, 9-73
Center of Gravity, 11-18
Central Processing Unit, 1-16
Character Input, 5-46
Check Backward, 7-12
Check Mode, 5-34
Check Mode Keys, 5-25, 5-26, 5-35
Check Specification, 9-57
Check Speed, 9-33
Check Sum Error, 9-48
Circular Interpolation, 11-26
Clamp and Signal Selection Keys, 5-20
Clamp Application, 9-68
Clamp Conditions, 9-4, 9-17, 9-65, 9-69, 9-73
Clamp Specifications, 9-65
Clamp Subroutine, 9-69
Clear Check Sum Error, 9-48
CMOS RAM, I-11
Collision Detection Error, 11-140
Collision Detection Function, 11-134
Collision DetectionTroubleshooting, 11-140
Computer Simulation Models, 11-10
Constant Velocity, 6-12, 6-15
Controller Design Specifications, I-11
Conversion of Flow Rate, 11-37
Coordinate Key, 6-5
Coordinate Systems, I-3
BASE, A-3
TOOL, A-3
CP Switch, 9-40
Current Detect Modules, 1-19
May 22, 2001 IN-3

INDEX
Current Position Screen, 5-41, 8-10
D
D-Axis, I-2
Data Conversion, 11-10
Data Display Next and Last Keys, 11-117
Data Display Screens, 11-129, 11-132
Data Editing, I-11
Data Save Screens, 11-120
Data Storage Function, 11-108
Data Transfer, 9-10
Dedicated Input Signals, 9-62
Dedicated Output Signals, 9-63
Dedicated Signal Display, 9-64
Dedicated Signals
Inputs, I-13
Outputs, I-13
Default Settings, 9-28, 9-31
Delete, 7-14
Detection Level Setting, 11-136
Digital Command Signal, 1-19
Digital Display, 11-62
Digital Switch, 11-61
Dimensions, I-14
Direct Speed, 7-11, 11-95
Display Inputs/Outputs, 9-45
Double Type Output Signal, 11-50
Dry Run, 8-6
E
Emergency Stop, 2-5, 2-6, 2-7, 2-9
Encoder Abnormality Error, 9-21
Encoder Deviation, 9-21
Encoder Rotation Counter Reset, 9-77
END Command, 11-88
End of Program, 7-8
Environmental Data, 9-53
Environmental Data2, 9-54
Error Codes/Troubleshooting, 10-2
Error Logging, 9-75
Error Messages, I-13
Error Recovery, 10-2
Error Start.PC Switch, 9-45
Ext.Axis/Robot key, 6-7, 6-8
Extend Monitor, 9-74
Extend Output Signal, 9-70
Extend Position Input, 9-71
Extend Signal Output Delay, 9-74
External Fixed Point, 11-28
F
Failure Prediction Function, 11-98
IN-4 May 22, 2001

INDEX
Failure Prediction Function Setup Procedure, 11-98

FC06N/FS06N/FW06N/FS10C, Work Envelope, 2-10
Features, 1-2
Figure Input and Cursor Selection, 5-12
File Extension, 9-13, 9-15
Fixed Linear Interpolation (FLIN), 11-28
Fixed Tool Dimensions, 11-28
FLASH Memory, 1-16
Floppy Disk Drive, I-14
Flowgain, 11-37
Flowrate Control, 11-33
Flowrate Switch, 11-40
FP20N Work Envelope, 2-11
FS02N/FS03N, Work Envelope, 2-12
FS06L, Work Envelope, 2-13
FS10E, Work Envelope, 2-14
FS10N, Work Envelope, 2-16
FS20C, Work Envelope, 2-17
FS30N/FS45C, Work Envelope, 2-20
Function Screen, 5-42
G
Global Changes, 9-38
Graph Access, 11-7
Graph Display Screens, 11-109, 11-118
Graph Screens, 11-97
Gun Number, 9-69
H
Handling Clamp Data Screen, 9-74
Home Position, 9-47
Hybrid Encoder, 1-19, 1-20
Hybrid Interpolation, 11-28
I
I/O Channels, 11-73, 11-76
I/O Data Display Screen, 11-127
I/O Display Screens, 11-123, 11-125
I/O Signals, I-12
I2PG Command, 11-98
Inching, 9-34
Inching Key, 6-6
Initialization, 9-58
Inspection Forecast Setting, 11-99
Intelligent Power Modules, 1-16
Interface Devices, 1-7
Interface Panels, 1-13
IPM, 1-17
May 22, 2001 IN-5

INDEX
J
Jogging Operation Keys, Multi Function Panel, 6-2
Jogging Operation Keys, Type 2 Teach Pendant, 6-3
Joint Shift, 11-46
JUMP Command, 11-88
JUMP_OFF, 11-88
JUMP_ON, 11-88
JUMP_ST, 11-88
K
Keep Type Output Signal, 11-50
Keyboard, 5-43
Keyboard Keys, 5-45
Keyboard, Multi Function Panel, 5-43
Keyboard, Type 2 Teach Pendant, 5-44
Kill Program, 9-11
L
Ladder Logic, 11-73
Last Weld Data, 11-83
Left-Hand Rule, 6-12
Limit Switches, 2-9
Lithium Batteries, 1-16
Load Mass, 11-18
Loading Data to File Memory, 11-131
Location Display, 9-9
Lower Limits, 9-26
M
Main CPU, 1-16
Maintenance Log, 9-78
Maintenance Log Delete, 9-83
Maintenance Log Display, 9-82
Maintenance Log Entries, 9-79
Major Axes, I-2
Major Components, 1-4
Man. Speed Key, 6-6
Manual Weld Operation, 9-17
Material Handling, 9-68
MBREAK, 11-37
Mechanical Unit, 1-21
Memory Available, 9-35
Memory Capacity, I-11
Memory Load, 9-14
Memory Saving, 9-12
Menu Key, 5-41
Messages Switch, 9-44
Minor Axes, I-2
Monitor Screens, 5-40
Motion Delay Extend - Retract, 9-73
Motion Start Delay, 9-69
IN-6 May 22, 2001

INDEX
Motor Current Information Error, 11-102

Motor Torque Information, Duty, 11-105
Motor Torque Information, Peak Current, 11-104
MSHA, 2-4
Multi Function Panel, I-10, I-14, 1-8, 2-9
Multi Function Panel Display Areas, 5-6, 5-15, 5-17
Multi Function Panel/Type 2 Teach Pendant, 5-2, 11-73
N
New Program, 7-3
NIOSHA, 2-4
Node Adapter Chip (NAC), 11-73
Null, 9-24
Numeric Program Name, 7-3
O
O-Axis, I-2
OAT Angles, A-4
Off Line Programming, 11-10
Online Edit, 11-67
Operation Information, 11-106
Operation Logging, 9-76
Operation Panel, 1-12
Operation Panel Switches, 3-3
Optional Functions, 11-4
OSHA, 2-2, 2-4
OUTLOC, 11-36
Output Format Entry, 9-72
Output Time Level/Pulse, 9-71
OUTSPEED, 11-35
Overtravel Error Recovery, 9-27
OX and WX Selection Keys, 5-23
OX Preout Switch, 9-42
OX Specification Function, 11-50
P
Parallel I/O, 1-17
Password Level, 11-93
PC Card, 1-10
PC Flash RAM Memory Card, I-14
Peak Current, 11-104
Personal Computer, I-14, 1-13
Pg Prefix, 7-5
Playback Accuracy, 9-28
Playback Speed, 9-31
PLC, 1-17
PLC(NAC), 11-84
Position Error Range, 9-20
Position Rewrite, 7-16
Power Block, 1-16, 1-19
Power Requirements, I-14
Power Unit, 1-19
May 22, 2001 IN-7

INDEX
Power Up Sequence, 1-17

Program Check Feature, 7-12
Program Confirmation, 7-26
Program Delete Function, 5-8
Program Edit, 5-31
Program Editing, 7-13
Program Execution, 8-6
Program List Screen, 5-38
Program List Screens, Multi Function Panel, 5-38
Program List Screens, Type 2 Teach Pendant, 5-39
Program Name, 7-3
Program Parameter/Comment, Aux 87, 9-49
Program Select Screen, 8-2
Program Selection, 8-2
Program Sheets, 7-2
Programmable Logic Controller (PLC), 11-73
Programming Sheets, A-5
Pulse Type Output Signal, 11-50
Pulse Width Modulation, 1-16
PWM, 1-19
Q
QBEAD, 11-36
QTOOL Switch, 9-43
R
R-Axis, I-2
Random Program Selection, 9-43
Record a Position, 7-6
Record and Teach New Keys, 5-24
Remote I/O, 11-76
Repeat Condition Speed, 9-31
Repeat Conditions, 8-4
Repeat Once, 8-5
Repeat Once Switch, 9-43
Retract Monitor, 9-74
Retract Output Signal, 9-70
Retract Position Input Signal, 9-71
Retractable Weld Clamps, 9-70
RI/O PLC (NAC) Setting,, 11-84
RI/O Signal Status, 11-80
RI/O Version, 1-17
RISC CPU, I-11
Robot Jogging Keys with Multi Function Pane, 5-28
Robot Jogging Keys with Type 2 Teach Pendant, 5-30
Robot Manual Operation Keys, Multi Function Panel, 5-27
Robot Manual Operation Keys, Type 2 Teach Pendant, 5-29
Robot Specifications, I-4, I-5, I-6, I-7, I-8, I-9
RPS Code, 11-88
RPS Codes, 11-91
RPS Enable, 11-90
RPS Operation, 11-91
IN-8 May 22, 2001

INDEX
RPS Procedure, 11-89

RPS Random Program Selection, 8-5
RPS Slogic Program Example, 11-89
RPS System Switch, 11-90
RPS_ON, 11-88
RPS_ST, 11-88
S
S Key, 5-25
S-Axis, I-2
Safety Features, 2-9
Sample Mainline Program, 11-41
Save Screen, 9-12
Screen Selection Keys, 5-13
Screen Switch, 9-44
Serial Communication, 1-17, 11-73
Servo CPU, 1-16
Servo Motor, 1-19
Servo Software, 1-19
Set Dimension Screen, 11-116
SETOUTSIG, 11-35
SETOUTSPEED, 11-35
Setting Tool Weight Data, 11-134
Signal Select Screen, 11-128
Signal Timing, 9-42
Single Stroke Non Retractable Gun, 9-73
Singularity, 6-17, 11-28
Slogic, 11-73, 11-75, 11-76
Slogic Editing, 11-75
Slogic Forced Output, 11-87
Slogic Program, 11-75
Slogic Status Screen, 11-84
Slow Repeat, 8-11
Slow Repeat Mode, 9-32
Small Teach Pendant, I-10, 1-11, 2-6, 2-7, 2-9
Software Features, I-12
Software Interface, 1-14
Software Switches, 9-38
Software Version, 9-52
Special Features, I-13
Speed, I-11, 9-31
Speed Display, 9-9
Speed Output, 11-34
Spot Weld Clamp Definition, 9-70
Spot Weld Control Screen, 9-71
Spot Weld Gun Definition, 9-73
Spot Welding, 9-68
Spray On/Off, 9-37
Status Area, 5-15, 5-17
Status Key, 5-36
Status Screen, 5-36, 5-37
Step Once, 8-5
May 22, 2001 IN-9

INDEX
Step Once Switch, 9-44

Step Selection, Multi Function Panel, 5-9
Step Selection, Type 2 Teach Pendant, 5-10
Step Speed, 9-31
Step Type Signal, 11-50
Stopping Robot Motion, 8-11
System Initialization, 9-58
System Message Area, 5-15, 5-17
System Switch, 9-38
T
T-Axis, I-2
TCP, 6-12
Teach Overwrite, 7-13
Teach Pendant, I-14
Teaching Key, 5-14
Text Window, 11-63
Threshold for Repeat Mode, 11-138
Threshold for Teach Mode, 11-137
Time Function, 9-61
Timer and Counter Status Screens, 11-81
Timer Function, 9-35
Title Area, 5-15, 5-17
Tool Center Point, 6-12
Tool Coordinate System, A-3
Tool Coordinates, I-3, 6-15
Tool Dimensions, 6-15, 9-25, 9-43
AUX 48, A-2
Tool Shift, 11-47
Trap Points, 2-4
Trigger Keys, 2-6, 2-7
Trigger Set Screen, 11-113
Troubleshooting Flowcharts, 10-88
Two Stroke C Type Gun, 9-73
Two Stroke X Type Gun, 9-73
Type 2 Teach Pendant, I-10, I-14, 1-9
Type 2 Teach Pendant Display Areas, 5-17
Type 2 Teach Pendant Keys, 5-6
U
UB150 Work Envelope, 2-22
Upper Limits, 9-26
User Interface, 1-7
User Memory, 11-130
UT100/150/200, Work Envelope, 2-23
UX100/120/150, Work Envelope, 2-25
UX200, Work Envelope, 2-26
UZ100/120/150, Work Envelope, 2-28
IN-10 May 22, 2001

INDEX
V
V-Axis, I-2
W
Weight, I-14
Weld Complete Signal, 9-69
Weld Completed Input Monitor, 9-72
Weld Completed Input Signal, 9-72
Weld Control, 11-73
Weld Control Number, 9-70
Weld Control Setting, 11-85
Weld Fault Input Signal, 9-72
Weld Fault Reset Output Signal, 9-72
Weld Initiate Output Signal, 9-71
Weld Parameters, 9-69
Weld Schedule, 9-4, 9-17, 9-72
Work Cell, 2-2, 2-4
Work Envelope, 2-4, 2-5, 2-6, 2-7, 2-8, 8-12
Work Envelope Drawings, 2-10
Work Shift, 11-48
X
X and O Display, 9-45
XYZ Shift, 11-45
Z
Z-Series Options, 11-98
ZD 130 Work Envelope, 2-29
Zeroing, 9-4, 9-5, 9-7, 9-19, 9-22, 9-77
Zeroing Data, 9-77
Zeroing Data Set Display, 9-22
ZT165 Work Envelope, 2-30
ZX130L Work Envelope, 2-31
ZX130U Work Envelope, 2-32
ZX200S Work Envelope, 2-34
ZX300S Work Envelope, 2-36
May 22, 2001 IN-11

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Copyright © 2001, Kawasaki Robotics (USA), Inc.

KAWASAKI ROBOTICS (USA), INC. TRAINING

Training courses covering operation, programming, electrical maintenance, and me-

For additional information contact:

Kawasaki Robotics (USA), Inc.

-0 6/3/99 Initial PDF release, based on rev. 4 of print copy KR

-1 4/24/00 Revision based on rev. 6 of print copy KR

-2 9/19/00 Revision based on rev. 7 of print copy CB

-3 7/23/01 Revision based on rev. 8 of print copy CB

I.0 INTRODUCTION.................................................................................................. I-2

March 10, 1999 I-1

I.1 MECHANICAL UNIT

The major axes are:

• JT1 (R-axis) rotary; rotation of the base

The minor axes are:

• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

The auxiliary axis, if so equipped is:

• JT7 (V-axis) traverse; linear positioning of the mechanical unit

I-2 May 22, 2001

• Base (World) coordinates

I.1.1 MECHANICAL UNIT DESIGN SPECIFICATIONS

March 31, 2000 I-3

Table I-1 Robot Specifications

ROBOT MODEL FS02N FS03N FC06N FS06L FS06N FW06N FS10C

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 250°/sec 240°/sec 240°/sec 200°/sec 240°/sec 240°/sec 200°/sec

JT2 180°/sec 100°/sec 200°/sec 140°/sec 200°/sec 200°/sec 140°/sec

JT3 180°/sec 140°/sec 250°/sec 200°/sec 250°/sec 250°/sec 200°/sec

JT6 600°/sec 360°/sec 720°/sec 600°/sec 720°/sec 720°/sec 600°/sec

JT2 +60°/-150° +60°/-150° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°

JT3 +210°/-270° +210°/-270° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

I-4 May 22, 2001

Table I-1 Robot Specifications (Continued)

ROBOT MODEL FS10E FS10L FS20C FS20N FS30L FS30N FS45C

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 200°/sec 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec

JT2 140°/sec 140°/sec 140°/sec 140°/sec 140°/sec 140°/sec 140°/sec

JT3 200°/sec 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec

JT6 600°/sec 500°/sec 500°/sec 500°/sec 340°/sec 340°/sec 340°/sec

JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°

JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

August 2, 2000 I-5

Table I-1 Robot Specifications (Continued)

ROBOT MODEL FS45N UT100 UT120 UT150 UX70 UX100 UX120

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 160°/sec 120°/sec 120°/sec 100°/sec 120°/sec 120°/sec 120°/sec

JT2 140°/sec 100°/sec 100°/sec 90°/sec 120°/sec 120°/sec 120°/sec

JT3 160°/sec 120°/sec 120°/sec 100°/sec 120°/sec 120°/sec 120°/sec

JT6 340°/sec 240°/sec 240°/sec 200°/sec 200°/sec 240°/sec 240°/sec

JT2 +140°/-105° +55°/-80° +55°/-80° +55°/-80° +70°/-65° +70°/-65° +70°/-65°

JT3 +295°/-225° +95°/-105° +95°/-105° +95°/-105° +90°/-119° +90°/-119° +90°/-119°

JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

I-6 August 2, 2000

Table I-1 Robot Specifications (Continued)

ROBOT MODEL UX150 UX200 UX300 UZ100 UZ120 UZ150 ZT130S

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 100°/sec 100°/sec 100°/sec 120°/sec 120°/sec 100°/sec 130°/sec

JT2 100°/sec 90°/sec 80°/sec 100°/sec 100°/sec 100°/sec 130°/sec

JT3 100°/sec 90°/sec 68°/sec 110°/sec 110°/sec 100°/sec 130°/sec