XRC Basic

XRC Robot Controller
XRC Basic Programming

Training Manual
Revised 7/12/00
NOT FOR RESALE
April 1, 1999
MOTOMAN
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200 FAX: (937) 847-6277
24-HOUR SERVICE HOTLINE: (937) 847-3200
WWW.MOTOMAN.COM
The information contained within this document is the proprietary property of Motoman, Inc., and may
not be copied, reproduced or transmitted to other parties without the expressed written authorization of
Motoman, Inc.
©1999 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications
without notice. YASNAC and MOTOMAN are registered trademarks of YASKAWA Electric
Manufacturing.
PREFACE
PURPOSE OF THIS MANUAL
This XRC Basic Training manual is to be used in conjunction with MOTOMAN’s
XRC Basic Programming Class and is not intended for use as a training tool in
itself. This manual is not for resale and will not be sold separately.
WHO SHOULD USE THIS MANUAL

This manual should be used by attendees of MOTOMAN’s XRC Basic
Programming Class. Do not use this manual as a reference tool unless you have
attended the XRC Basic Class and have received certification through
MOTOMAN.
HOW TO USE THIS MANUAL

This manual has been written according to MOTOMAN’s XRC Basic
Programming Class daily course structure. It is designed to assist students in
understanding basic XRC functions for a MOTOMAN robot. Use this manual
as a step-by-step guide through the XRC Programming Basic Class.
DISCLAIMER
Information in this manual is based on the assumption that the XRC controller is
using the Edit Security Level and the Standard language with Learn off, etc. Be
aware that keystrokes described in this manual may vary with other settings,
software versions, etc.
NOTE: All MOTOMAN Technical Education Center Training Manuals are copy-
righted. Do not copy any portion of these manuals.
Table of Contents
TABLE OF CONTENTS
Section Page
1.0 XRC START-UP AND SHUTDOWN
1.1 POWERING UP THE XRC ............................................................................ 1-1
1.2 TURNING OFF POWER TO THE XRC ........................................................ 1-2
2.0 PLAYBACK PANEL
2.1 PANEL OPERATION BUTTONS .................................................................. 2-1
2.1.1 E-Stop ................................................................................................ 2-1
2.1.2 Start ................................................................................................... 2-2
2.1.3 Hold ................................................................................................... 2-2
2.1.4 Servo On Ready ................................................................................. 2-2
2.2 PANEL MODE BUTTONS............................................................................. 2-2
2.2.1 Play Mode .......................................................................................... 2-2
2.2.2 Teach Mode ........................................................................................ 2-3
2.2.3 Remote Mode ..................................................................................... 2-3
2.3 ALARM/ERROR INDICATOR LIGHT........................................................... 2-3
2.4 EDIT LOCK KEY SWITCH ........................................................................... 2-3
3.0 PROGRAMMING PENDANT
3.1 DISPLAY SCREEN ........................................................................................ 3-1
3.1.1 Display Areas ..................................................................................... 3-2
3.1.2 General Purpose Display Area .......................................................... 3-3
3.1.3 Menu Area.......................................................................................... 3-3
3.1.4 Status Display Area ........................................................................... 3-3
3.1.5 Human Interface Area ....................................................................... 3-4
3.1.6 Message Line ..................................................................................... 3-4
3.1.7 Input Buffer Line ................................................................................ 3-4
3.1.8 Input Line .......................................................................................... 3-4
3.2 TOP MENU, AREA, CURSOR, AND SELECT KEYS ................................... 3-5
3.2.1 Top Menu Key .................................................................................... 3-6
3.2.1.1 Job ..................................................................................................... 3-6
3.2.1.2 Arc Welding, General, Handling, and Spot Welding .......................... 3-6
3.2.1.3 Variable .............................................................................................. 3-6
3.2.1.4 In/Out ................................................................................................. 3-6
3.2.1.5 Robot .................................................................................................. 3-7
3.2.1.6 System Info ......................................................................................... 3-7
XRC Basic Prograamming Manual Table of Contents-1 © MOTOMAN

Table of Contents
3.2.2 Area Key ............................................................................................. 3-7
3.2.3 Cursor Key ......................................................................................... 3-7
3.2.4 Select Key ........................................................................................... 3-7
3.3 TEACH LOCK ............................................................................................... 3-8
3.4 ENABLE SWITCH ......................................................................................... 3-8
3.5 E-STOP .......................................................................................................... 3-9
3.5.1 E-Stop ................................................................................................ 3-9
3.5.2 Releasing the E-Stop .......................................................................... 3-9
3.6 EDITING KEYS ........................................................................................... 3-10
3.6.1 Programming Pendant Keypad ........................................................ 3-10
3.6.2 Enter ................................................................................................ 3-10
3.6.3 Cancel .............................................................................................. 3-10
3.6.4 Insert ................................................................................................ 3-11
3.6.5 Modify .............................................................................................. 3-11
3.6.6 Delete ............................................................................................... 3-11
3.7 SHIFT KEYS ................................................................................................ 3-11
3.8 INTERLOCK KEY ....................................................................................... 3-12
3.9 EIA 232D (RS-232C) SERIAL PORT .......................................................... 3-12
4.0 COORDINATES/AXES
4.1 JOINT COORDINATES ( ) ........................................................................ 4-2
4.2 WORLD ( ), CYLINDRICAL ( ), TOOL ( ), OR USER ( ) .................. 4-2
4.2.1 COORD Key ...................................................................................... 4-6
4.2.2 MANUAL SPEED Keys ...................................................................... 4-6
4.2.3 HIGH SPD Key .................................................................................. 4-6
4.2.4 ROBOT Key ........................................................................................ 4-7
4.2.5 EX. AXIS Key ..................................................................................... 4-7
4.3 DISPLAYING CURRENT POSITION ........................................................... 4-7
4.4 DISPLAYING COMMAND POSITION ......................................................... 4-7
4.5 OPERATION ORIGIN ................................................................................... 4-8
5.0 ALARMS AND ERRORS
5.1 ERROR MESSAGES ...................................................................................... 5-1
5.2 MINOR ALARMS ........................................................................................... 5-1
5.3 MAJOR ALARMS........................................................................................... 5-1
5.4 USER ALARMS .............................................................................................. 5-2
5.5 DISPLAYING MAJOR AND MINOR ALARM HISTORY ............................ 5-2

Table of Contents
6.0 SPECIFIED POINT (SECOND HOME POSITION)
7.0 CREATING A JOB
7.1 CREATE NEW JOB ....................................................................................... 7-1
7.2 SELECTING A JOB ....................................................................................... 7-2
7.3 MASTER JOB ................................................................................................ 7-2
7.3.1 Registration of the Master Job ........................................................... 7-3
7.3.2 Calling Master Job to the Screen ...................................................... 7-3
7.4 DISPLAYING THE CONTENT OF THE ACTIVE JOB ................................ 7-3
8.0 PATH CREATION
8.1 MOTION TYPES THAT REQUIRE ONE POSITION STEP.......................... 8-2
8.1.1 Joint Motion Type .............................................................................. 8-2
8.1.2 Linear ................................................................................................ 8-2
8.2 PLAY SPEED ................................................................................................. 8-2
8.3 TEACHING POSITIONS AS PROGRAM STEPS .......................................... 8-3
8.4 OVERLAPPING FIRST AND LAST STEPS .................................................. 8-4
8.5 PATH CONFIRMATION................................................................................ 8-6
8.5.1 METHOD 1: FWD and BWD keys ................................................... 8-6
8.5.2 METHOD 2: INTERLOCK/TEST START ........................................ 8-6
8.6 CYCLE SELECTION ..................................................................................... 8-7
8.7 PLAYING A JOB ............................................................................................ 8-8
8.8 MOTION TYPES REQUIRING THREE OR MORE POSITION STEPS ....... 8-8
8.8.1 Circular Motion Type......................................................................... 8-8
8.8.2 Spline Motion Type ............................................................................ 8-9
9.0 COPY, DELETE, & RENAME JOB
9.1 COPY JOB ..................................................................................................... 9-1
9.2 DELETE JOB ................................................................................................ 9-2
9.3 RENAME JOB ............................................................................................... 9-2
9.4 NAME/DATE JOB LISTS ............................................................................... 9-3
9.4.1 Setting JOB LIST organization by NAME or DATE. ......................... 9-3
9.4.2 Detail Display ................................................................................... 9-4
9.4.3 Job Header......................................................................................... 9-4
9.5 CAPACITY ..................................................................................................... 9-5

Table of Contents
10.0 JOB EDITING
10.1 PATH CORRECTION .................................................................................. 10-2
10.1.1 Inserting a Step ................................................................................ 10-2
10.1.2 Modifying a Step Position ................................................................ 10-3
10.1.3 Deleting a Step................................................................................. 10-3
10.1.4 Changing Motion Type .................................................................... 10-4
10.1.5 Summary of Insert, Modify, Delete and Cursor Locations .............. 10-4
10.2 POSITION LEVEL SPECIFICATION ......................................................... 10-4
10.2.1 Selecting a Position Level During Initial Programming ................. 10-5
10.2.2 Adding a Position Level to an Existing Step .................................... 10-6
10.2.3 Deleting a Position Level from an Existing Step ............................. 10-6
10.3 COPY, CUT, PASTE, & REVERSE PASTE .................................................. 10-7
10.3.1 Copy ................................................................................................. 10-7
10.3.2 Cut ................................................................................................... 10-8
10.3.3 Paste................................................................................................. 10-8
10.3.4 Reverse Paste ................................................................................... 10-9
10.4 GENERAL LINE EDITING ......................................................................... 10-9
10.5 DETAIL EDIT ............................................................................................ 10-10
11.0 SPEED CORRECTION/ADJUSTMENT
11.1 PLAY SPD (GENERAL LINE EDITING) .................................................... 11-1
11.2 ENTERING SPECIFIC PLAY SPD DATA (DETAIL EDIT) ....................... 11-2
11.3 CHANGE SPEED ........................................................................................ 11-3
11.3.1 Relative Speed Change .................................................................... 11-3
11.3.2 Absolute Units Speed Change.......................................................... 11-4
11.4 TRAVERSE RUN TIME ................................................................................ 11-5
11.5 CYCLE TIME DISPLAY .............................................................................. 11-6
11.6 SPEED OVERRIDE ..................................................................................... 11-7
12.0 SPECIAL PLAYBACK MODES
12.1 LOW SPEED START .................................................................................... 12-1
12.2 SPEED LIMIT.............................................................................................. 12-2
12.3 DRY-RUN SPEED ........................................................................................ 12-2
12.4 CHECK-RUN ............................................................................................... 12-3
12.5 MACHINE LOCK ........................................................................................ 12-4
12.6 TURNING OFF ALL SPECIAL PLAYBACK MODES ................................ 12-4

Table of Contents
13.0 INFORM LIST
13.1 Opening the INFORM List .......................................................................... 13-1
14.0 CONTROL INSTRUCTIONS
14.1 CALL............................................................................................................ 14-1
14.1.1 Linking Jobs ..................................................................................... 14-1
14.1.2 Nesting Jobs ..................................................................................... 14-2
14.2 RET (RETURN) ........................................................................................... 14-3
14.3 DIRECT OPEN ............................................................................................ 14-5
14.4 JUMP ........................................................................................................... 14-6
14.4.1 Executing a Jump instruction to a Label in the job ........................ 14-6
14.5 LABEL ......................................................................................................... 14-7
14.6 COMMENTING ........................................................................................... 14-8
14.7 TIMER ......................................................................................................... 14-9
14.8 PAUSE.......................................................................................................... 14-9
15.0 ARITHMETIC VARIABLES AND INSTRUCTIONS
15.1 ARITHMETIC VARIABLES ......................................................................... 15-1
15.1.1 Displaying Variables ........................................................................ 15-1
15.1.2 Editing Variables ............................................................................. 15-2
15.2 Arithmetic Instructions ...................................................................................... 15-2
15.2.1 INC (INCREMENT) ......................................................................... 15-3
15.2.2 DEC (DECREMENT) ...................................................................... 15-4
15.2.3 SET .................................................................................................. 15-5
15.2.4 CLEAR ............................................................................................. 15-6
16.0 CONDITIONAL “IF” CONSTRUCT
16.1 PROGRAMMING THE “IF” CONSTRUCT ............................................... 16-2
16.2 ADDING AN “IF” CONSTRUCT ............................................................... 16-2
17.0 I/O INSTRUCTIONS
17.1 DOUT (DIGITAL OUTPUT) ....................................................................... 17-1
17.2 PULSE (DIGITAL OUTPUT) ...................................................................... 17-2
17.3 MONITORING UNIVERSAL OUTPUTS .................................................... 17-3
17.4 AOUT (ANALOG OUTPUT) ....................................................................... 17-4
17.5 MONITORING ANALOG OUTPUTS .......................................................... 17-5
17.6 WAIT (DIGITAL INPUT) ............................................................................. 17-5
17.7 MONITORING UNIVERSAL INPUTS ........................................................ 17-6
17.8 PROGRAMMING “IF” CONSTRUCT BASED ON INPUT STATUS ......... 17-7
17.9 DIN (DIGITAL INPUT) ............................................................................... 17-7
17.10 DOUT (DIGITAL OUTPUT) to Groups ...................................................... 17-9
Table of Contents
18.0 USER FRAMES
18.1 CREATING USER FRAMES ....................................................................... 18-2
18.2 ACCESSING USER FRAMES ..................................................................... 18-3
19.0 EDIT PROTECTION
19.1 EDIT LOCK KEY SWITCH ......................................................................... 19-1
19.2 SOFTWARE EDIT PROTECTION .............................................................. 19-1
19.2.2 Software Edit Protection Levels....................................................... 19-2
20.0 TOOL CENTER POINT DEFINITION
20.1 MANUAL TCP DEFINITION ...................................................................... 20-1
20.2 AUTOMATIC TCP DEFINITION ................................................................ 20-3

Table of Contents
LIST OF FIGURES
Figure Page
Figure 1-1 Main Power Switch or Circuit Breaker (ON) ............................... 1-1
Figure 1-2 Main Power Switch (OFF) ........................................................... 1-2
Figure 2-1 Playback Panel .............................................................................. 2-1
Figure 3-1 Programming Pendant .................................................................. 3-1
Figure 3-2 Display Areas ............................................................................... 3-2
Figure 3-3 Screen Title ................................................................................... 3-2
Figure 3-4 Human Interface Display Area ..................................................... 3-4
Figure 3-5 Top Menu, Area, Cursor, and Select Keys ................................... 3-5
Figure 3-6 Teach Lock Key............................................................................ 3-8
Figure 3-7 Enable Switch ............................................................................... 3-9
Figure 3-8 Programming Pendant E-STOP Button ........................................ 3-9
Figure 3-9 Editing Keys ............................................................................... 3-10
Figure 3-10 EIA 232D (RS232C) Serial Port ................................................ 3-12
Figure 4-1 Programming Pendant Coordinates Key & Display ..................... 4-1
Figure 4-2 Axis Keys and Joint (S,L,U,R,B,T) Coordinate Operation .......... 4-2
Figure 4-3 Path of X-Axis Movement in World ............................................ 4-3
Figure 4-4 Path of Y-Axis Movement in World ............................................ 4-3
Figure 4-5 Path of Z-Axis Movement in World ............................................. 4-3
Figure 4-6 Path of X-Axis Movement in Cylindrical..................................... 4-4
Figure 4-7 Path of Y-Axis Movement in Cylindrical..................................... 4-4
Figure 4-8 Path of Z-Axis Movement in Cylindrical ..................................... 4-4
Figure 4-9 Teach Condition Display CYL/RECT Selection .......................... 4-5
Figure 4-10 Axis Keys to Change Tool’s Angle of Orientation ...................... 4-5
Figure 4-11 Manual Speed Keys ...................................................................... 4-6

Table of Contents
Figure 6-1 Specified Point (Second Home) Position Display ........................ 6-1
Figure 8-1 Programming Path and Velocity................................................... 8-1
Figure 8-2 Motion Type Display .................................................................... 8-4
Figure 8-3 Job Path with Linear Motion ........................................................ 8-5
Figure 8-4 Path Confirmation ........................................................................ 8-6
Figure 8-5 Cycle Selection ............................................................................. 8-7
Figure 8-6 Job Path with Circular Motion ..................................................... 8-9
Figure 8-7 Spline Example ............................................................................. 8-9
Figure 8-8 Job Path with Spline Motion ...................................................... 8-10
Figure 10-1 The Two Sections of the Job Screen .......................................... 10-1
Figure 10-2 The INSERT, MODIFY, and DELETE Keys ............................ 10-2
Figure 10-3 Position Levels ........................................................................... 10-5
Figure 10-4 Detail Edit screen for MOV instruction ..................................... 10-5
Figure 13-1 Inform List Key .......................................................................... 13-1
Figure 13-2 Inform List Grouping.................................................................. 13-1
Figure 13-3 Inform List Specific Instructions ................................................ 13-1
Figure 14-1 Linking jobs using Call .............................................................. 14-1
Figure 14-2 Nesting jobs using Call ............................................................... 14-2
Figure 14-3 Return instruction in a child job ................................................. 14-4
Figure 14-4 DIRECT OPEN Key ................................................................... 14-5
Figure 14-5 Displaying a Job Using DIRECT OPEN .................................... 14-5
Figure 14-6 Jump to a Label........................................................................... 14-6
Figure 15-1 Job Example Using INC ............................................................. 15-3
Figure 15-2 Job Example Using DEC ............................................................ 15-4
Figure 15-3 Job Example Using SET ............................................................. 15-5
Figure 15-4 Job Example Using CLEAR ....................................................... 15-6
Figure 16-1 Job Sample with “IF” construct .................................................. 16-1

Table of Contents
Figure 17-1 Example DOUT Instruction........................................................ 17-1
Figure 17-2 Job Example with PULSE and TIMER Instructions .................. 17-2
Figure 17-3 Job Example with AOUT Instruction ......................................... 17-4
Figure 17-4 Job Examples using the Wait Instruction ................................... 17-5
Figure 17-5 Job Example using DIN .............................................................. 17-8
Figure 17-6 Job Example using Byte Variables ............................................. 17-8
Figure 17-7 Job Example Using DOUT to Groups ........................................ 17-9
Figure 18-1 User Frame Points ...................................................................... 18-1
Figure 19-1 Job Header Screen ...................................................................... 19-2
Figure 19-2 Teach Condition Screen.............................................................. 19-2
Figure 20-1 Entering Tool Dimensions .......................................................... 20-2
Figure 20-2 Pointer ......................................................................................... 20-4
LIST OF TABLES
Table Page
Table 15-1 Arithmetic Variable Table ........................................................... 15-1
Table 15-2 Arithmetic Instruction Table ...................................................... 15-2
Table 17-1 8-Bit Place Values in Binary ...................................................... 17-8

Table of Contents
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XRC Start-up and Shutdown
1.0 XRC START-UP AND SHUTDOWN
1.1 POWERING UP THE XRC

The main power switch or circuit breaker is on the front door of the XRC cabinet.
Turning the switch to the ON position supplies power to the controller and initializes
the XRC diagnostic function. The controller goes through a series of diagnostic
tests which check the robot’s internal circuitry for faults, RAM errors, and incorrect
connections.
Main Power Switch
Playback Panel
Program Pendant
Figure 1-1 Main Power Switch or Circuit Breaker (ON)
If a failure occurs, an error message is displayed on the LCD screen of the

Programming Pendant, or if an alarm condition occurs, an alarm screen is displayed.
If there are no failures or alarm conditions, a TOP MENU with icons appear on the
LCD screen.
XRC Basic Programming Manual Page 1-1 © MOTOMAN

XRC Start-up and Shutdown
1.2 TURNING OFF POWER TO THE XRC
Turning the main power switch OFF removes all external power to the controller.
Before turning off controller power, servo power should be removed by pressing
any Emergency Stop (E-Stop) button, or place the system in the TEACH mode.
Main Power Switch
Playback Panel EMERGENCY

STOPS
Program Pendant
Figure 1-2 Main Power Switch (OFF)

Playback Panel
2.0 PLAYBACK PANEL
The Playback Panel is located on the front of the controller door and provides
access to the E-STOP switch, buttons for PLAY, TEACH, & REMOTE Mode
selection, EDIT LOCK key switch, SERVO ON READY, HOLD, START control
buttons, and an indicator for ALARMS & ERRORS.
Figure 2-1 Playback Panel
2.1 PANEL OPERATION BUTTONS
2.1.1 E-Stop
Pressing the E-STOP (Emergency Stop) removes servo motor power and applies
all brakes. The pendant message “!Robot is stoppped by P. PANEL emergency
stop” is displayed, and the SERVO ON READY indicator lights turn off. Twist the
E-Stop knob clockwise to release it. All of the E-Stops function the same in
Teach, Play, or Remote mode.

Playback Panel
2.1.2 Start
In Play mode with servo power ON, pressing the START button will begin
execution of a job from the line the cursor is on in the program. The START button
light remains lit the entire time the controller is running the program. Also, the
START button’s indicator light will be ON whenever a TEST START is performed
in TEACH mode.
2.1.3 Hold
Pressing the HOLD button stops execution of a job in the PLAY mode. Servo
power remains on, and the brakes are not applied. The START light goes off when
job execution ceases. The HOLD button light is on only as long as the HOLD
button is pressed. To resume program execution, press the START button.
2.1.4 Servo On Ready
In PLAY mode, fully depressing the SERVO ON READY button initiates a

sequence that sends power to the servo motors and releases all brakes. The green
“SERVO ON” lights will turn on at the Playback Panel and the Programming
Pendant. Playback of any job (with or without motion steps) is not possible unless
servo power is applied.
In TEACH mode, pressing the SERVO ON READY button will only cause both
“SERVO ON” lights to blink. The Programming Pendant’s TEACH LOCK must
be ON before servo power can be applied by properly activating the enable switch
located on the back left side of the pendant.
2.2 PANEL MODE BUTTONS

Three mode buttons determine control of the robot system. These buttons are
PLAY, TEACH, and REMOTE. Each button has an indicator light which is lit
when the mode is selected.
2.2.1 Play Mode
In PLAY mode, the START button becomes functional and the XRC has control of
job execution. Special playback menu choices become available.

Playback Panel
2.2.2 Teach Mode
In TEACH mode, the operator has control for jogging the robot, programming,
editing, customizing, and other menu choices.
NOTE: Changing modes from PLAY to TEACH, during playback, will cause the
program to cease execution (similar to an E-Stop); to resume, push
PLAY, SERVO ON READY, and START.
2.2.3 Remote Mode
The REMOTE mode allows control from an optional external device such as a
remote operator station or a host computer.
2.3 ALARM/ERROR INDICATOR LIGHT
If an error or alarm occurs, the ALARM/ERROR indicator light illuminates and

remains on until the condition is cleared. (See Section 5.0 for clearing errors and
alarms).
2.4 EDIT LOCK KEY SWITCH
Turning the Edit Lock Key Switch to the ON position prevents any data in the
controller from being changed. This includes jobs, files, parameters, and condition
lists. This key cannot be removed while in the OFF position, but should be removed
when Edit Lock is turned ON.

Playback Panel
NOTES

Programming Pendant
3.0 PROGRAMMING PENDANT
Figure 3-1 Programming Pendant
3.1 DISPLAY SCREEN
The display is a 5.7 inch, 12-line, 40-character LCD. It is divided into specific areas,
allowing the operator to monitor and edit programs, display files, etc.
NOTE: The Programming Pendant LCD screen automatically dims after a few
minutes of inactivity. Press any key on the pendant to restore the screen.

Programming Pendant
3.1.1 Display Areas
The screen is divided into four areas, as shown in Figure 3-2.
MENU AREA
STATUS AREA
GENERAL DISPLAY AREA
HUMAN INTERFACE AREA
Figure 3-2 Display Areas
Each screen has a title that is displayed in the upper left corner of the General
Purpose display area.
Screen Title
Figure 3-3 Screen Title
The example shown in Figure 3-3 above is displaying a Job Content. This is the
body of the job and contains all the normal job structure, including all line numbers
and all related instructions.
NOTE: The active job name is displayed under the Screen Title as “J: (job name).”

Programming Pendant
3.1.2 General Purpose Display Area
The General Purpose Display area is where the content of the currently selected
menu choice is displayed.
3.1.3 Menu Area
The Menu Area, at the top of the screen, changes according to the active General
Display on the screen. The default start-up menu is CYCLE and SECURITY. If
the controller is in PLAY mode, the desired cycle setting can easily be accessed, or
if in TEACH mode, the desired security level can quickly be set. The example in
the top line of Figure 3-3 (JOB, EDIT, DISPLAY, and UTILITY) shows the Menu
Area for a job content screen.
3.1.4 Status Display Area
The Status Display Area, below the Menu Area, shows the data related to the
controller’s current condition. Items displayed are as follows:
The active Robot, Station Axis, or Base Axis (R1, R2, or R3; or S1, S2, etc.; or
B1, B2, etc.)
Coordinate System
Joint, World, Cylindrical, Tool, or User Frame
Manual Speed Setting
Inching, Low, Medium, or High
Cycle Mode
Step, 1-Cycle, or A Auto
System Status
E-Stop, Stop, Running/Start, Hold, or Alarm
The symbol for additional pages when applicable.

Programming Pendant
3.1.5 Human Interface Area
This area, shown in Figure 3-4, displays the data for User interface and always
consists of at least one line, the Message Line. Additional lines may be displayed.
Input Buffer Line =>TIMER T=1.00

Input Line >Timer=1.00
Message Line !Enter value
Figure 3-4 Human Interface Display Area
3.1.6 Message Line
Error messages and editing/programming prompts are displayed on this line. An

Error message takes precedence over other messages and must be cleared by
pressing CANCEL. If any message is too long to display on a single line, the
screen automatically scrolls to the left, repeatedly displaying the full message.
NOTE: The message “!Memory battery weak” will appear on the Message Line
of the Programming Pendant display when the battery needs to be
replaced. DO NOT TURN OFF THE CONTROLLER UNTIL THE
BATTERY HAS BEEN REPLACED.
3.1.7 Input Buffer Line
This line may appear when a job is being edited and is used for temporary display
of instructions and/or data from the Input Line prior to insertion into the job being
edited.
3.1.8 Input Line
This line also appears when a job is being edited and when data input is required
from the Programming Pendant keypad.

Programming Pendant
3.2 TOP MENU, AREA, CURSOR, AND SELECT

KEYS
All the various menus for each of the sections of the screen (Menu, General, and the
Human Interface) can be accessed by using the TOP MENU key, the AREA key,
the 8-way Cursor Key, and the SELECT key, or combinations of these keys. Each
section’s respective choices depend on the set SECURITY Level of Operation.
There are three levels of SECURITY:
• OPERATING (no password required)

• EDITING (4 to 8-digit password USER ID number required)
• MANAGEMENT (4 to 8-digit password USER ID number
required).
NOTE: This training manual is based on the EDITING security level.
CURSOR KEY
TOP MENU KEY AREA KEY SELECT KEY
Figure 3-5 Top Menu, Area, Cursor, and Select Keys

Programming Pendant
3.2.1 Top Menu Key
The TOP MENU key, shown in Figure 3-5, returns the pendant display to the top
level with the cursor on the JOB icon. Also, the Menu Area display defaults to
CYCLE and SECURITY. The Cursor key and SELECT key may then be used to
choose the desired function from the following menu icons:
• JOB
• ARC WELDING or GENERAL or HANDLING or SPOT WELDING
• VARIABLE
• IN/OUT
• ROBOT
• SYSTEM INFO
• FD/PC CARD
• SETUP
3.2.1.1 Job
The JOB icon accesses menu bars to allow selection of the currently selected JOB,
the MASTER JOB, or to SELECT JOB from the entire list, as well as view the
JOB CAPACITY. In TEACH mode and EDITING level only, the CREATE NEW
JOB selection becomes available.
3.2.1.2 Arc Welding, General, Handling, and Spot Welding

This icon will be labeled with one of the four applications for which the XRC can be
initialized. The corresponding menu will be items pertinent only to that application.
3.2.1.3 Variable
The VARIABLE icon allows the display and editing of four kinds of arithmetic
variables used for number storage and the display of the position variable file used
for position and shift data storage.
3.2.1.4 In/Out
The IN/OUT icon offers DETAIL and SIMPLE displays of all the controller’s
types of input and output signals. The DETAIL display shows the name for each
input/output in groups of eight. The SIMPLE display shows only the status of the
I/O as 1 (ON) or 0 (OFF), but several groups at a time may be viewed. In the
Teach mode the Universal Outputs can be forced ON/OFF.

Programming Pendant
3.2.1.5 Robot
The ROBOT selection allows the display of the robot’s CURR. POS, POWER
ON/OFF POS, COMMAND POS for a step in a job, the SECOND HOME
POS, and the (operation) OPE ORIGIN POS. Also, the function for setting
TOOL data and USER COORDINATE data is accessed through this menu.
3.2.1.6 System Info

The SYSTEM INFO selection provides VERSION information on the robot’s
hardware and software, an ALARM HISTORY, and MONITORING TIME for
power on, servo on, job play, robot travel time, and device/tool operating time.
3.2.2 Area Key

The AREA key, shown in Figure 3-5, moves the cursor to the different areas of the
display screen. As programming requires the use of selections in the different areas,
the cursor must be moved to the appropriate area. The AREA key will cycle
through the 3 areas; Menu Area, General Display Area, and the Human Interface
Area. If there are more than one message displayed on the message line, the AREA
key will cycle through it as well. Hold the SHIFT key and CURSOR right to scroll
through the available messages.
3.2.3 Cursor Key

The CURSOR key, shown in Figure 3-5, is an 8-way, directional key that moves
the cursor up, down, right or left based on the arrows marked accordingly. Also,
the cursor can move diagonally, where applicable, based on the dash markings
between the arrows. The cursor key must be used to move-about within a job
content screen, a list, etc., or to highlight a desired menu item which can then be
chosen by using the SELECT key.
3.2.4 Select Key

The SELECT key, shown in Figure 3-5, is used to choose the item currently
highlighted by the cursor. It is also used in conjunction with the INTERLOCK key
for forcing Universal Outputs ON/OFF.

Programming Pendant
3.3 TEACH LOCK
The TEACH LOCK key activates an important and necessary safety feature. With
TEACH LOCK on, control of the robot rests solely at the Programming Pendant;
operation is not possible from the Playback Panel. The TEACH LOCK key must
be toggled ON in order to apply Servo Power with the ENABLE switch located on
the back left side of the pendant.
NOTE: The message “!TEACH-LOCK set” appears.
Teach Lock Key
Figure 3-6 Teach Lock Key
Once operation from the Programming Pendant is complete, press the TEACH
LOCK key again to toggle the LED lamp to OFF to allow use of the PLAY mode
button at the Playback Panel.
NOTE: The message “!Caution! TEACH-LOCK mode released” appears.

Failure to disable TEACH LOCK before setting to PLAY mode will
result in an Error Message. Also, TEACH-LOCK is canceled if the
controller is turned OFF.
3.4 ENABLE SWITCH
Servo Power is required in order to manipulate the robot, modify job positions, or
program new steps in a job. In order to turn on servo power in the Teach mode,the
SERVO ON READY button must be pressed, then the Programming Pendant’s
TEACH LOCK must be pressed, and the ENABLE switch must be pressed to its
middle position. The ENABLE switch located at the back left side of the
Programming Pendant is a three position switch. Fully released or fully
compressed causes the servos to shut OFF when operating from the Programming
Pendant.

Programming Pendant
Figure 3-7 Enable Switch
3.5 E-STOP
Figure 3-8 Program Pendant E-Stop Button
3.5.1 E-Stop
Pressing this E-STOP (Emergency Stop) removes servo motor power and causes
the brakes to be applied. The pendant message “!Robot is stopped by P. P.
emergency stop” is displayed, and each SERVO ON READY button’s light turns
off.
3.5.2 Releasing the E-Stop
Twist the E-Stop knob clockwise to release it. All of the E-Stops function the same
in Teach, Play, or Remote mode.

Programming Pendant
3.6 EDITING KEYS
Figure 3-9 Editing Keys
3.6.1 Programming Pendant Keypad

The Programming Pendant keypad is used primarily for entering numeric values.
A negative or decimal number may be entered where applicable. These keys are
also labeled with device operating instructions specific to the application for which
the controller has been initialized.
3.6.2 Enter
The ENTER key stores selected data into the controller. The ENTER key must be
pressed after each completed data entry from the keypad. When programming/
editing a motion step or an instruction, carefully check the completed input buffer
line before pressing ENTER to record the information in the job.
3.6.3 Cancel
The CANCEL key is used to clear error messages. Also, pressing CANCEL will
clear the input line to allow new data to be entered or to completely abort the
instruction.

Programming Pendant
3.6.4 Insert
The INSERT key must be selected before pressing ENTER in order to add
additional instructions between existing lines in a job. The new line is always
inserted below the cursor.
3.6.5 Modify
The MODIFY key must be selected before pressing ENTER in order to change the
existing position of a step in a job, or to replace an existing instruction line with an
entirely different instruction line.
3.6.6 Delete
The DELETE key must be selected before pressing ENTER in order to remove an
existing line in job. To DELETE a motion step, the robot must be at the step’s
command position.
3.7 SHIFT KEYS
There are two SHIFT keys on the Programming Pendant so that either hand can
comfortably use a SHIFT key in conjunction with the following keys:
• TOP MENU key (to go back to previous menu for that icon)
• PAGE KEY key (to go to previous page)
• CURSOR key (to previous/next page when job or list fills more
than one screen or scroll left/right when instruction side of job
exceeds width of screen)
• COORD key (for TOOL No. and User Frame selection)
• RESERVE DISPLAY key (to register/reserve one display for easy
access)
NOTE: The description for use of the SHIFT key with each of the above
functions is described in detail in the sections of the manual that require
its use.

Programming Pendant
3.8 INTERLOCK KEY
The INTERLOCK key is used in conjunction with the following keys:
• SELECT key (for manually “forcing” Universal Outputs ON/OFF)

• TEST START key (for path confirmation simulating playback)
NOTE: The description for use of the INTERLOCK key with each of the above
functions is described in detail in the sections of the manual that require
its use.
3.9 EIA 232D (RS-232C) SERIAL PORT
This 9-pin serial port is used for data communication between the XRC and a
floppy disk controller (FC1 or FC2), or the XRC and a host computer with FDE
(Floppy Disk Emulator) software or other form of communication.
EIA 232D (RS232C) port
Figure 3-10 RS-232C Serial Port

Coordinates / Axes
4.0 COORDINATES/AXES
Coordinates are used for “jogging” the Robot. Four Coordinate systems are
available to allow the operator/programmer convenient ways to move the Robot.
Figure 4-1 Programming Pendant COORD Key & Display
The Programming Pendant has six sets of axis keys with “+” and “-” for each axis,
making a total of twelve keys. Each key is multifunction and is labeled as shown in
Figure 4-2. The applicable label is determined by the coordinate system selected.
The coordinate system is selected by pressing the COORD (coordinate) key and is
indicated by the icon in the Status Display Area.

Coordinates / Axes
Figure 4-2 Axis Keys and JOINT (S,L,U,R,B,T) Coordinate Operation
4.1 JOINT COORDINATES ( )
When in Joint coordinates, the letters S, L, U, R, B, T on the six pair of axis keys
are applicable, allowing the operator to move the robot one axis (one motor) at a
time in a positive or negative direction. Each axis is independent of the others. This
is the default coordinate system upon power up or job selection.
4.2 WORLD ( ), CYLINDRICAL ( ), TOOL ( ),

OR USER ( )
In these coordinate systems, the TCP (Tool Control or Center Point) is controlled
by the axis keys, rather than the individual axis motors. The XYZ labels are
applicable, as they define the direction for jogging the TCP. The keys will,
however, move the robot differently in each coordinate system. World, Tool, and
User coordinates are based on the X-Y-Z rectangular coordinate system. In
World, the TCP (Tool Control or Center Point) moves in a straight line path, as
shown in Figures 4-3, 4-4, and 4-5. Figures 4-6, 4-7, and 4-8 show TCP
movement in Cylindrical. Tool coordinates are based on the X-Y-Z coordinates as
related to tool orientation. User coordinates are based on a user-defined plane in
space.

Coordinates / Axes
Figure 4-3 Path of X-Axis Movement in World
Figure 4-4 Path of Y-Axis Movement in World
Figure 4-5 Path of Z-Axis Movement in World

Coordinates / Axes
Figure 4-6 Path of X-Axis Movement in Cylindrical
Figure 4-7 Path of Y-Axis Movement in Cylindrical
Figure 4-8 Path of Z-Axis Movement in Cylindrical

Coordinates / Axes
To set the AXIS KEYS to operate in the World ( ) or the Cylindrical ( )

coordinate system, perform the following steps in TEACH mode:
1. Press the TOP MENU key.

2. Cursor to the SET-UP icon (down twice, right once) and press SELECT.
3. Cursor to TEACHING COND and press SELECT.
4. Cursor to the RECT/CYLINDRICAL indicator.
5. Pressing the SELECT button toggles between select “CYL” and “RECT.”
6. Press TOP MENU to return to the initial menu screen.
DATA EDIT DISPLAY UTILITY

L
TEACHING CONDITION R1 C S
RECT/CYLINDRICAL RECT
LANGUAGE LEVEL SUBSET
MOVE INSTRUCTION SET LINE
STEP ONLY CHANGING PROHIBIT
Figure 4-9 Teach Condition Display CYL / RECT Selection
When using WLD/CYL, TOOL or USER Coordinates, pressing a “rotate-about”

rx, ry, rz axis key (the six keys in Figure 4-10) will change the tool’s angle of
orientation, but the TCP should remain at its present position. This can also be used
to verify that the TOOL DATA for the Tool No. currently in use is accurate.
Figure 4-10 Axis Keys to Change Tool’s Angle of Orientation

Coordinates / Axes
4.2.1 COORD Key

The Programming Pendant defaults to JOINT coordinates after a power-up
sequence. If a different coordinate system is desired, the COORD (coordinate)
key must be used.
4.2.2 MANUAL SPEED Keys

The Manual Speed determines the velocity at which the axis keys or the FWD &
BWD keys will operate the ROBOT or EX. AXIS. The four speed settings as
listed below are changed by using the MAN. SPEED keys FST or SLW. The icon
changes in the Status Display Area accordingly.
High
M
Medium
L
Low
I
Inching
Figure 4-11 Manual Speed Keys
When INCHING has been selected, each press of an axis key will move the robot
one pulse count in Joint coordinates. In all other coordinate systems the default
setting for INCHING will move the robot’s TCP 0.30 mm/0.30 degrees with each
press of the axis key.
NOTE: The Programming Pendant defaults to LOW manual speed upon

power-up.
4.2.3 HIGH SPD Key

While using only a single axis key or only the FWD key, pressing and holding the
HIGH SPD key will momentarily override the L, M, or H manual speed setting
with a preset faster speed. Releasing the key defaults back to the selected manual
speed. The HIGH SPD key will not override I (Inching), and it is not functional
with the BWD key.

Coordinates / Axes
4.2.4 ROBOT Key

In a system setup with only robots R1, R2, or R3 (no external station axes or base
track axes) the ROBOT key’s LED will automatically be ON whenever the servos
are in use. Pressing the ROBOT key chooses the desired robot R1, R2, or R3 and
the selection is displayed in the Status Area. However, in a system with servos
controlling axes other than a robot, the operator would have to turn on the desired
control group key, either ROBOT or EX. AXIS.
4.2.5 EX. AXIS Key

Pressing this key configures the axis keys to move external servo motors for station
axes or base track axes.
4.3 DISPLAYING CURRENT POSITION
To display the current position in PULSE (S,L,U,R,B,T) or XYZ coordinates for

BASE, ROBOT or USER, perform the following:

2. Cursor to the ROBOT icon and press SELECT.
3. Cursor to CURRENT POS and press SELECT. The CUR POS screen will
be displayed as last chosen. If a different form is desired, continue with
step 4 and also 5 if USER is desired.
4. Press SELECT and cursor to PULSE, BASE, ROBOT, or USER and
press SELECT again.
5. If USER is selected, then enter the frame number on the data input line
(>User_coord_no.= ) and press ENTER.
4.4 DISPLAYING COMMAND POSITION
To display the COMMAND position of a cursored step in a job content screen,

perform the following:

3. Cursor to COMMAND POS and press SELECT.
The left column displays the command position [CMD] for that step, and the right
column displays the current position [CURR] of the robot’s.

Coordinates / Axes
4.5 OPERATION ORIGIN
The Operation Origin Position (OPE ORIGIN POS) can be used to move the
robot to a frequently desired position and is tied into interference cubes
(cube 24 - R1). The default setting is all axes at zero, but it can be modified.
To modify the OPE ORIGIN POS, perform the following:
1. In TEACH, with Servo Power ON, jog the robot to the desired position.
3. Cursor to the ROBOT icon; press SELECT.
4. Cursor to OPE ORIGIN POS; press SELECT. The message line will read
“!Available to move to or modify OPE ORIGIN POS.”
5. Press the MODIFY key.
6. Press ENTER.
To move to the OPE ORIGIN POS, perform the following:
1. In TEACH, with Servo Power ON, press the TOP MENU key.
2. Cursor to the ROBOT icon; press SELECT.
3. Cursor to OPE ORIGIN POS; press SELECT. The message line will read
“!Available to move to or modify OPE ORIGIN POS.”
4. Set the jogging coordinates to JOINT, choose a manual speed, then press
the FWD key until the robot stops at the OPE ORIGIN POS.

Alarms and Errors
5.0 ALARMS AND ERRORS

Alarm or error codes cause the program to stop execution. There are three levels
of alarms and errors: Error Messages, Minor Alarms, Major Alarms, User Alarms
and Off-Line Alarms.
5.1 ERROR MESSAGES

Error Messages occur when simple mistakes have been made, such as pressing the
START button while robot is not in Play mode. A four-digit error code and a
message appear at the bottom of the display. These errors are cleared by pressing
the CANCEL button on the Programming Pendant.
NOTE: Errors are not registered in the pendant’s ALARM HISTORY display.
5.2 MINOR ALARMS

Minor Alarms usually indicate simple programming errors that request the controller
to perform tasks it is not capable of performing. The four-digit alarm codes for
Minor Alarms normally begin with “4”. The alarm code and message appear in the
General Display area. Job execution is stopped, but Servo Power remains ON.
These alarms are cleared by pressing the SELECT key to choose the RESET
ICON. The cause of the minor alarm should be fixed immediately to avoid
reoccurrence.
5.3 MAJOR ALARMS

Major Alarms may occur because of equipment failure or what the controller
considers a potential failure situation. Major Alarms are often associated with
crashes. The four-digit alarm codes for major alarms normally begin with “ 1, 2, or
3”. The alarm code and a message appear in the General Display area. Servo
power turns off. Major alarms may be cleared by cycling controller power OFF/
ON. True hardware failures will require repair/replacement of the affected
components.
NOTE: Write down the alarm number and message before powering down.

Alarms and Errors
5.4 USER ALARMS
These alarms are user defined alarms. These alarms are designed specifically for
the system application and the user’s workcell environment, etc. The four-digit
alarm code begins with the digit 9. If the system is running, a SYSTEM/USER
Alarm will stop job execution similar to a Minor Alarm; the cause must be remedied
before pressing the SELECT key to RESET the User Alarm.
5.5 OFF-LINE ALARMS
These alarms are found during system diagnostics. The 4 digit alarm code begins
with a “0”. Off-line alarms may be cleared by cycling controller power OFF/ON.
True hardware failures will require repair/replacement of the affected components.
NOTE: Write down the alarm number and message before powering down.
5.6 DISPLAYING MAJOR AND MINOR ALARM

HISTORY
The Programming Pendant keeps a log of the last 20 each of Major Alarms, Minor
Alarms, User Alarms (System), User Alarms (User), and Off-Line Alarms.
To display the history of these alarms, perform the following steps:

2. Cursor to SYSTEM INFO and press SELECT.
3. Cursor to ALARM HISTORY and press SELECT.
4. Press the PAGE key to select the alarm category.
5. Move the cursor to choose a specific alarm; details for this alarm will appear at
the bottom of the screen display.

Specified Point (Second Home Position)
6.0 SPECIFIED POINT

(SECOND HOME POSITION)
If the controller determines there is a change in encoder data (pulse) between
power off and power on, it will generate the “ALARM 4107 OUT OF RANGE
(ABSO DATA)”. After resetting the alarm and turning the servo power ON, the
controller will prompt with the message “!Check Position.” Checking position
involves jogging the robot to a known position (that is, a specified point) and then
ensuring the robot is at the proper position. The default position is the “Home
Position”, where the alignment arrows and keyways for each axis are alined.
To check the Specified Point, perform the following steps:
1. Press SELECT on the Programming Pendant to RESET alarm.

2. Press TEACH on the Playback Panel.
3. Press the TOP MENU key on the Programming Pendant.
5. Cursor to SECOND HOME POS and press SELECT. The displays a data
screen with columns as shown in Figure 6-1.
DATA EDIT DISPLAY UTILITY

L
SPECIFIED POINT R1 C S
SPECIFIED CURRENT DIFFERENCE
R1:S 0 0 0
L 0 0 0
U 0 0 0
R 0 0 0
B 0 0 0
T 0 0 0
!Available to move to any modify specified point
Figure 6-1 Specified Point, Second Home Position Display

Specified Point (Second Home Position)
6. Press the SERVO ON READY button at the Playback Panel.

7. Press the TEACH LOCK key on the Programming Pendant. The display
reads “!Available to move to and modify Specified Point.”
8. Turn Servos ON with the ENABLE switch.
9. Ensure the pendant is in JOINT coordinates and increase manual speed to
Medium.
CAUTION! An error in the pulse generator (PG) system can cause an alarm. If PG
failure is suspected, then do not FWD until checking each suspected
axis separately by jogging + and - in JOINT coordinates to confirm valid
operation.
CAUTION! The operation below may cause a crash when the FWD key is pressed
if there are obstacles between the robot’s present position and the
Specified Point position; use extreme care during this procedure.
10. Press and hold the FWD key to move the robot to the Specified Point.
The data display changes to all zeros in the DIFFERENCE column.
NOTE: Steps 11 - 13 are necessary in the event of an actual ALARM:4107.
11. Press the AREA key to move the cursor to the Menu Area.
12. Cursor to Data and press SELECT.
13. Cursor to CONFIRM POSITION; press SELECT. The message line will
display “!Home position checked”.
14. Press the TOP MENU key to return to the initial start-up menu.

Creating a Job
7.0 CREATING A JOB

NOTE The controller must be set for the EDITING security level in order to
access CREATE NEW JOB in the JOB menu.
To create a new job, the job must first be named. A job can be named in several
ways: numerically, alphabetically, or symbolically or in any combination using up to
eight characters with no spaces.
7.1 CREATE NEW JOB
To create a new job name, complete the following steps:
1. If not already in Teach mode, press TEACH on the Playback Panel.

2. Press the TOP MENU key on the Programming Pendant and press
SELECT to choose the JOB icon.
3. Cursor to CREATE NEW JOB and press SELECT.
4. Cursor to JOB NAME:******** and press SELECT.
5a. Enter the job name using either the numeric keypad.
or
5b. Cursor to the first desired alphabet/symbol character and press
SELECT. Move the cursor to the next desired character and press
SELECT again. Continue until the name is complete, selecting up to
eight characters
NOTE: Pressing the AREA key moves the cursor to the name input line.
Pressing the cursor right and left can be used to move-about within the
name; characters will insert to the left of the cursor. The down cursor
will delete the character to the left of the cursor. Pressing CANCEL will
clear the input line.
6. Press ENTER to accept the JOB NAME input line.

7a. Press ENTER again to create the job.
or
7b. Cursor to “EXECUTE” aand press SELECT.
The JOB CONTENT screen for the newly created job will appear with two
instructions: 0000 NOP (NO OPERATION, top of program) and 0001 END.
Creating a Job
NOTE: Jobs may also be created from an existing JOB CONTENT screen.
Press the AREA key to move the cursor to the Menu Line. With the
cursor on JOB, press SELECT. Cursor to CREATE NEW JOB and
press SELECT. Continue as above in steps 4-7.
NOTE: Pressing SELECT while on the “COMM” line of the CREATE NEW JOB
screen will allow a comment to be entered that will appear in the JOB
HEADER.
7.2 SELECTING A JOB
To bring an existing job to the screen in Teach or Play modes:
1. Press TOP MENU.

2. Press SELECT to choose the JOB icon.
3. Cursor to SELECT JOB and press SELECT.
4. Cursor to the name of the desired job and press SELECT.
NOTE: Other jobs cannot be selected during program execution (when the
START light is on) in Play mode.
7.3 MASTER JOB
It is useful to register (store) a frequently played job as the Master Job, because
this allows easy access to this job. Only one job can be registered as the Master
Job in a standard system configuration.

Creating a Job
7.3.1 Registration of the Master Job
To register a Master Job name, complete the following:

2. Press TOP MENU.
3. Cursor to the JOB icon and press SELECT.
4. Cursor to MASTER JOB and press SELECT.
5. Press SELECT.
6. Cursor to SETTING MASTER JOB and press SELECT.
7. Cursor to the desired job name and press SELECT.
The chosen Master Job name will be registered and the Job Content screen will
appear.
7.3.2 Calling Master Job to the Screen
To call the Master Job to the screen in Teach or Play modes, perform the following:
1. Press TOP MENU; press SELECT.

2. Cursor to MASTER JOB; press SELECT.
3. Press SELECT (to choose CALL MASTER JOB).
4. Press SELECT (to display job content on screen).
NOTE: The Master Job cannot be “called” when the START light is on during
program execution in Play mode.
7.4 DISPLAYING THE CONTENT OF THE ACTIVE

JOB
To return to the active (most recently selected job) Job Content screen from
another display, perform the following steps:
1. Press TOP MENU.

2. Cursor to the JOB icon and press SELECT.
3. Cursor to JOB and press SELECT.

Creating a Job
NOTES

Path Creation
8.0 PATH CREATION

Using the axis keys, MOTION TYPE key, and PLAY SPD selections on the
Programming Pendant, the path and the velocity that the robot takes when moving
to a taught position can be programmed. After creating the robot path, the FWD
and BWD keys and the TEST START method must be used to verify the path.
Figure 8-1 Programming Path and Velocity
The MOTION TYPE key, shown in Figure 8-1, selects what type of path the robot
will take to a programmed step. The four motion types in order are Joint, Linear,
Circular, and Spline. Each time the MOTION TYPE key is pressed, a different
motion type is displayed. These are sequenced in the order above.
NOTE: While in the job content screen in the EDIT security level, the currently
selected motion type and play speed are displayed on the Input Buffer
line.
The first two motion types, Joint and Linear, require only one position step and are
described in Sections 8.1.1 and 8.1.2. The other two types, Circular and Spline,
require at least three consecutive position steps and are described in Section 8.8.

Path Creation
8.1 MOTION TYPES THAT REQUIRE

ONE POSITION STEP
8.1.1 Joint Motion Type

Choosing Joint motion for a step has the controller move the robot in the easiest
path to the taught point. This path will not be straight, because the controller does
not calculate a path. This motion type is used primarily for approaches to and
departures from the workpiece. Joint motions are sometimes called “air cuts.” The
first and last steps of a job are normally programmed in Joint motion. Joint motions
appear in the program as MOVJ.
8.1.2 Linear
Choosing Linear motion for a step has the controller move the robot TCP (Tool
Center Point or Tool Control Point) in a straight path to the taught point. Linear is
an interpolated motion type. This means the TCP will move in a straight line even if
there is a change of tool angle through the path. Linear motions appear in the
program as MOVL.
8.2 PLAY SPEED

When Joint motion has been selected, the PLAY SPD is configured for VJ=Joint
speed (VJ) in percentages of maximum velocity. The default PLAY SPD selections
include 8 speeds from 0.78% to 100.00%.
When linear motion has been selected, the PLAY SPD is configured for actual
speed of the TCP. This speed is indicated as “V” and is units of cm/min, mm/sec,
in/min, or mm/min. The default PLAY SPD selection also has eight settings from 66
to 9000 cm/min; 11.0 to 1500.0 mm/sec; 26 to 3543 in/min; or 660 to 90,0000
mm/min.
The PLAY SPD selection allows the programmer to select the velocity the robot
will take to the taught position. Select the appropriate motion type before selecting
the play speed.

Path Creation
To select one of the eight available play speeds, perform the following steps:
1. With the cursor on the desired address line, press SELECT to move the cursor
to the input line.
2. Cursor right to the speed digits.
3. While holding the SHIFT key, use the up or down cursor to choose the
desired speed.
NOTE: The requested play speed may not be fully attained during playback,
depending on activation of special playback modes, distance to travel,
and/or acceleration/deceleration parameters.
8.3 TEACHING POSITIONS AS PROGRAM STEPS
To program a step in a job, perform the following steps:
1. Press TEACH and SERVO ON READY on the Playback Panel.

2. Display the job on the Programming Pendant screen.
3. Move the cursor on the Address side (left side) to the line immediately above
where the move instruction is to be programmed. (For the first point in the
job, this will be the NOP line.)
4. Choose any desired COORD for jogging.
5. Turn TEACH LOCK on, then turn servo power on with the ENABLE switch
and jog the robot to the desired position.
6. Note the motion type displayed on the input line (see Figure 8-2). To change
the motion type, press the MOTION TYPE key.

Path Creation
JOB EDIT DISPLAY UTILITY

L
JOB CONTENT R1 C S
J: TEST S: 000 R1 TOOL: ¬
0 0 0 0 NOP
0001 END
=> MOVJ VJ=0.78

!
Figure 8-2 Motion Type Display
7. Select an appropriate speed on the Input Line.
8. Press ENTER. All information regarding position data, motion type, and
speed is recorded in the job and the Tool No. for that position is displayed on
the right side of the job content screen.
8.4 OVERLAPPING FIRST AND LAST STEPS

When possible, the first and last steps of a job should be taught at the same
location. This overlapping keeps the robot from ending and starting the same job at
different locations or taking an indeterminate path from the end of one job to the
beginning of the next.

Path Creation
1,6
2 5
3 4
LINE INSTRUCTION
0000 NOP
0001 MOVJ VJ=0.78
0002 MOVJ VJ=100.00
0003 MOVJ VJ=25.00
0004 MOVL V=138
0005 MOVJ VJ=50.00
0006 MOVJ VJ=100.00
0007 END
Figure 8-3 Job Path with Linear Motion
To program the last step at the same location as the first, complete the
following:
1. Move the cursor to the first step (Step 001) on the Address side.
2. Ensure a clear path, then press and hold the FWD key until the robot comes to
a stop at Step 001. The cursor will stop flashing when the robot reaches the
Command Position.
3. Move the cursor to your last recorded step (Step 005 in the example above).
4. Choose a motion type. This is normally a Joint motion type.
5. Choose an appropriate play speed.
6. Press ENTER.
The last step (Step 006 in the example) is now programmed at the same location as
the first step (Step 001).

Path Creation
8.5 PATH CONFIRMATION

The Programming Pendant has two path confirmation functions that check the
programmed path using the keys shown in Figure 8-4.
Figure 8-4 Path Confirmation
8.5.1 METHOD 1: FWD and BWD keys

Begin with the cursor on the first step in the job and verify that there is a clear path
to this command position from where the robot is currently positioned. Whenever
the current robot position does not match the cursored command position, the
information under the cursor of that step will blink. Choose a desired manual speed
setting. To have the controller move the robot to the cursored step command
position, press and hold the FWD key. The robot will move to the step and cease
motion; the cursor will no longer flash. To move the robot through each successive
step, release and press the FWD key. This will allow the programmer/operator to
sequence through the job and take the robot through the calculated path. Pressing
the BWD key will move the robot to the previous step. Robot motion will be
executed only while the FWD or BWD keys are pressed; releasing the key will stop
robot motion. The HIGH SPD key is functional with FWD, but not BWD.
8.5.2 METHOD 2: INTERLOCK/TEST START

This method allows the robot to act as if it were in the playback mode. All
instructions (other than tool instructions) are executed as programmed. Motions
recorded at speeds greater than 20% of the robot’s maximum speed will be
executed at 20% of the maximum capability; all others will be executed at program
speed. The cycle selection will affect the TEST START program execution;
therefore, the 1-cycle setting is recommended. Also, verify that there is a clear path
from where the robot is currently positioned to the first step in the job.
Begin with the cursor on NOP, while pressing the INTERLOCK key, press and
hold the TEST START key. The START button on the Playback Panel will light
and the robot will go through all steps of the programmed path. The Interlock key
may be released once the robot is in motion. To interrupt/stop program execution,
just release the TEST START key.
NOTE: The programmer/operator should always verify that there is a clear path
from where the robot is currently positioned to the first step command
position.

Path Creation
8.6 CYCLE SELECTION

Three cycle selections determine how the controller runs the selected job when the
START button is pressed in the Play mode. They also affect TEST START
operation of the Programming Pendant . These selections are STEP, 1-CYCLE,
and AUTO; the selected cycle is indicated in the pendant Status Line.
STEP
The controller will execute only the one line on which the cursor is
located, in the selected job, each time the START button is pressed.
Tool/Device instructions are NOT executed when in the STEP cycle.
1-CYCLE
The controller will execute the selected job one time, from the
cursor location to the END statement of that job when the START
button is pressed.
AUTO
The controller will execute the selected job repetitively from the
cursor location when the START button is pressed.
To select the desired cycle:
1. Press TOP MENU.

2. Press the AREA key to move the cursor to the Menu Line.
3. Move the cursor to highlight CYCLE.
4. Press SELECT; a drop-down menu screen appears with the three cycles
shown.
5. Cursor to the desired cycle setting, then press SELECT. The screen symbol in
the Status Display Area will change accordingly.
Figure 8-5 Cycle Selection

Path Creation
8.7 PLAYING A JOB
To play a job after verifying with both the above methods, perform the following
steps:
1. Select a job and verify where the cursor will begin execution of the job
(normally at NOP).
2. Verify the Programming Pendant TEACH LOCK key LED is OFF.
3. Press the PLAY mode button on the Playback Panel.
4. Press the SERVO ON READY button.
5. Choose the desired cycle (AUTO, 1-CYCLE, or STEP) as described in
Section 8.6.
6. Press the START button on the Playback Panel to initiate job execution.
8.8 MOTION TYPES REQUIRING THREE OR

MORE POSITION STEPS
In addition to the Joint and Linear motion types the XRC supports two other motion
types: Circular and Spline.
8.8.1 Circular Motion Type

Choosing Circular motion type for a series of steps has the controller move the
robot TCP (Tool Center Point or Tool Control Point) through a circular path
defined by at least three (3) consecutive taught points. Circular is an interpolated
motion type. To define a full circle, five points may be necessary for the best
interpolation.
To program circular points, press the MOTION TYPE key until MOVC appears
on the input line. When circular motion has been selected, the Play Speed is
configured for “V” speed units of cm/min, mm/sec, in/min or mm/min, just as with
linear motion. Set an appropriate speed from the Play Speed selection.

Path Creation
NOTE: The robot will move in a linear path to the first circular step in the
sequence.
3 4 6 7
0003 MOVJ VJ=25.00

0004 MOVC V=558
0005 MOVC V=558
0006 MOVC V=558
0007 MOVL V=558
Figure 8-6 Job Path with Circular Motion
8.8.2 Spline Motion Type
Choosing Spline motion type for a series of steps has the controller move the
robot TCP (Tool Center Point or Tool Control Point) through a parabolic, or
free curve, path defined by three (3) consecutive taught points. Spline is an
interpolated path.
1 3
Figure 8-7 Spline Example

Path Creation
To program spline points, press the MOTION TYPE key until SPLINE is indicated
on the Programming Pendant. Spline points appear in the program as MOVS.
When spline motion has been selected, the PLAY SPD list is configured for “V”
speed units of cm/min, mm/sec, in/min., or mm/min., just as with linear and circular
motion. Point 2 must be programmed on the line perpendicular to the line between
Point 1 and Point 3 as shown in Figure 8-7.
NOTE: The robot will move in a linear path to the first spline point in the
sequence.
2 6
3 5
0002 MOVJ VJ=100.00

0003 MOVS V=2250
0004 MOVS V=276
0005 MOVS V=276
0006 MOVJ VJ=50.00
Figure 8-8 Job Path with Spline Motion

Copy, Delete, & Rename Job
9.0 COPY, DELETE, & RENAME JOB
Most system housekeeping is performed from the JOB LIST, which displays all the
registered job names. COPY, DELETE, and RENAME are considered
housekeeping functions. One way to perform these tasks is from the JOB LIST.
9.1 COPY JOB
The COPY JOB function allows you to make an identical copy of a job where only
the job name is different. Use this function to create jobs whenever a cell has
multiple jobs with minor differences. Use COPY JOB also whenever you plan to
edit a job heavily. It is best to make a copy of the job and work in the copy. In
case the editing does not go well, the original production job is not corrupted.
To copy a job, perform the following steps:

2. Press TOP MENU on the Programming Pendant.
3. SELECT the JOB icon.
5. Move the cursor to the job to be copied.
6. Press the AREA key to move the cursor to the MENU Area.
8. Cursor to COPY JOB and press SELECT. The job name appears on the
name input line. The existing name can either be modified, or press CANCEL
and create a new job name.
NOTE: See Section 7.0 for additional information on naming jobs.
9. After renaming the job copy in the Input Line, press ENTER.
10. Cursor to [YES] on the “Copy?” screen and press SELECT.
NOTE: COPY JOB may also be performed from the JOB CONTENT screen.
Use steps 6 through 10 only.

9.2 DELETE JOB
The DELETE JOB function will allow the operator to delete unused, obsolete, or
unwanted jobs from the controller.
To delete a job, perform the following steps:

5. Move the cursor to the job to be deleted.
NOTE: The pull-down menu may contain more commands than are visible. As
the cursor is moved down, they will appear.
8. Cursor down until DELETE JOB is visible to highlight it and press SELECT.
9. Cursor to [YES] on the “Delete?” screen and press SELECT.
NOTE: DELETE JOB may also be performed from the JOB CONTENT screen.
Use steps 6 through 10 only.
9.3 RENAME JOB
The RENAME JOB function allows you to change a job name. Renaming is
necessary if a job with the same name is to be loaded into the system from the
floppy drive. The floppy drive software will not allow a file to be overwritten, so
the job in the controller must be renamed.
To rename a job from the job list display, perform the following steps:


5. Move the cursor to the job to be renamed.

8. Cursor to RENAME JOB; press SELECT. The job name appears on the
name input line. The existing name can either be modified or press CANCEL
and create a new job name.
NOTE: See Section 7.0 for additional information on naming jobs.
9. After renaming the job Copy, Press ENTER.

10. Cursor to [YES] on the “Rename?” screen and press SELECT.
NOTE: RENAME JOB may also be performed from the JOB CONTENT
screen. Use steps 6 through 10 only.
9.4 NAME/DATE JOB LISTS
The JOB LIST can be set to display the names of the jobs in alphabetical order
(NAME), or in order of date of creation (DATE).
9.4.1 Setting JOB LIST organization by NAME or DATE.
To set the JOB LIST organization by NAME or DATE, complete the following
steps:

5. Cursor to DISPLAY and press SELECT.
6. Cursor to NAME or DATE and press SELECT. (Only one can be selected at
a time.)

9.4.2 Detail Display
Details of a job may be displayed while in the Job List through the use of the
DETAILS selection. Information about the cursored job is displayed on the lower
portion of the General Display Area.
To enable or disable the DETAIL display, complete the following steps:

6. Cursor to DETAIL and press SELECT.
NOTE: The DETAIL display for the cursored job name will always show when
the SELECT JOB list is on the screen until the DETAIL selection is
disabled.
9.4.3 Job Header
The Job Header is like the title page of the job. It displays additional detailed
information about the job currently selected. The Job Header shows the job name,
comment, the date and time it was last edited, if edit protect has been set, and if the
job has been saved.
To display a job’s HEADER complete the following from the JOB CONTENT
screen:
3. With the cursor on JOB HEADER press SELECT.
To return to the Job Content screen, complete the following from the JOB
HEADER screen:
3. With the cursor on JOB CONTENT press SELECT.

9.5 CAPACITY
This display shows the number of jobs, bytes used and remaining, and the number
of steps used and remaining for ROBOT, BASE, or STATION AXES.
To check memory capacity, complete the following steps:
1. Press TOP MENU and SELECT the JOB icon.

2. Cursor to JOB CAPACITY; press SELECT.

NOTES

Job Editing
10.0 JOB EDITING

There are several ways to edit job instructions or the path of the robot. This section
includes: Path Correction, Position Level Specification, and Cut, Copy, Paste, and
Reverse (Paste).
The Job Content screen is divided in two sections, as shown in Figure 10-1.
The left side of the screen is the “address” area of the screen, which contains line
numbers. Each line of a job has a line number. Each line that includes a robot
motion, such as MOVJ, also has a “step” number that is indicated in the upper part
of the Job Content screen next to the Job Name. The cursor must be on the
address side for initial programming and to insert, modify, or delete steps and
instructions.
The right side of the screen is the “instruction” (and information) area of the
screen. The cursor must be on the right side of the screen for line editing and
motion type changes.
Step Number
Address Instruction
Side Side
Figure 10-1 The Two Sections of the Job Screen

Job Editing
10.1 PATH CORRECTION
Use the following methods to modify a programmed path. Figure 10-2 shows the
INSERT, MODIFY, and DELETE keys.
10.1.1 Inserting a Step
To insert a step between existing program lines/steps in a job, perform the

following steps:

2. Select the job to be edited.
3. Move the cursor on the address side to the line above the step to be inserted.
The new step will be inserted below the cursor.
4. Enable servos and jog the robot to the desired point.
5. Choose the desired MOTION TYPE.
6. To choose play speed, press SELECT, then cursor to the speed data on the
input buffer line. Hold the SHIFT key and cursor up/down to select desired
choice.
7. Press INSERT.
Note: The INSERT key may be turned ON any time after step 2 above, but
last opportunity is just before pressing ENTER.
8. Press ENTER.
Figure 10-2 The INSERT, MODIFY, and DELETE Keys

Job Editing
10.1.2 Modifying a Step Position
To modify the position of a step in a job, perform the following steps:

3. Move the cursor, on the address side, to the step that you want to modify.
4. Enable servos and jog the robot to the desired position.
5. Press MODIFY.
NOTE: The MODIFY key may be turned ON any time after step 2 above, but
last opportunity is just before pressing ENTER.
6. Press ENTER.
10.1.3 Deleting a Step
To delete a step in a job, perform the following steps:

3. Move the cursor, on the address side, to the step that you want to delete.
NOTE: To delete a step, the robot must be positioned at the step to be deleted.
When the robot is not at the Command Position, the cursored step
number will blink.
4. To move the robot to the exact programmed point, assure a clear path and
then press FWD until the cursor is not blinking.
5. Press DELETE.
NOTE: The DELETE key may be turned ON any time after step 2 above, but
last opportunity is just before pressing ENTER.)
6. Press ENTER.

Job Editing
10.1.4 Changing Motion Type

To change the motion type of a programmed step, perform the following
steps:

2. Select the job content to be edited.
3. Move the cursor to the desired step on instruction side of the screen and press
SELECT. The cursor will then be highlighting the =>MOV on the input
buffer line.
4. Hold the SHIFT key and cursor up/down to choose the desired motion type.
5. Press ENTER.
NOTE: Changing the motion type of a step will alter the programmed path.
Always perform Path Confirmation (Section 8.5) to verify/confirm the
path.
10.1.5 Summary of Insert, Modify, Delete and Cursor Locations
The cursor must be on the address side of the job to use the DELETE, INSERT, &
MODIFY keys. The DELETE key is used to remove an instruction line or a
motion step. The INSERT key must be used when adding a line/step between
existing program lines/steps. The cursor must be on the instruction side for
changing motion type.
10.2 POSITION LEVEL SPECIFICATION

At higher velocities, the robot’s TCP will not reach a taught position if it is at a
corner. The robot will turn the corner short in order to maintain the program speed
as its priority.
If high velocity and high precision are needed, a Position Level can be used. The
controller has five Position levels: PL=0 (exact), PL=1, PL=2, PL=3, and PL=4.
These Position Levels force the robot’s TCP to come within the set distance of the
target point before going directly to the next destination point.

Job Editing
Positioning level 0
P2 P3
Positioning level 1
Positioning level 2
Positioning level 3
Positioning level 4
P1
Figure 10-3 Position Levels
A position level is an option on every position step.
10.2.1 Selecting a Position Level During Initial Programming
To select a Position Level during initial step programming, perform the following
steps after jogging the robot to the desired position and choosing the MOTION
TYPE and play speed on the input buffer line:
1. With the cursor on the =>MOV portion of the Input Buffer Line, press
SELECT. (The DETAIL EDIT screen appears as in Figure 10-4.)
Figure 10-4 Detail Edit screen for MOV instruction
2. Cursor to the POS LEVEL “UNUSED” and press SELECT.

3. Cursor to “PL=” and press SELECT.
4. Cursor to the default setting “0” and press SELECT.
5. Enter the value (0, 1, 2, 3, or 4) on the data input line “>Positioning_level=”
and press ENTER.
6. Press ENTER to display the JOB CONTENT screen with the input buffer line.
7. The position, motion type, play speed, and selected Position Level are
registered on the step by pressing ENTER again. (Servo power must be on.)

Job Editing
10.2.2 Adding a Position Level to an Existing Step
To add a Position Level to an existing step, perform the following steps:

2. Select the desired JOB CONTENT.
3. Move the cursor on the instruction side to the step where the Position Level
needs to be defined and press SELECT.
SELECT. (The DETAIL EDIT screen appears.)
5. Cursor to the POS LEVEL “UNUSED” and press SELECT.
6. Cursor to “PL=” and press SELECT.
7. Cursor to the default setting “0” and press SELECT.
8. Enter the value (0, 1, 2, 3, or 4) on the data input line “>Positioning_level=”
and press ENTER.
10. Press ENTER again to add the PL tag to the step in the job.
10.2.3 Deleting a Position Level from an Existing Step
To delete a POS LEVEL, perform the following steps:

2. Select the desired JOB CONTENT.
3. Move the cursor, on the instruction side, to the line where the Position Level
needs to be deleted and press SELECT.
SELECT. (The DETAIL EDIT screen appears.)
5. Cursor to the POS LEVEL “PL=” and press SELECT.
6. Cursor to “UNUSED” and press SELECT.
8. Press ENTER again to place the modified step in the job.

Job Editing
10.3 COPY, CUT, PASTE, & REVERSE PASTE
The Cut, Copy, Paste & Reverse Paste functions edit jobs using a memory buffer
area as follows:
COPY—Copies a specified range of lines/steps to a memory buffer.
CUT—Cuts a specified range of lines/steps from a job and copies it to a memory

buffer.
PASTE—Inserts the memory buffer contents into a job below the cursor.
REVERSE—Reverses the order of the memory buffer contents and inserts them
into a job below the cursor.
COPY and CUT data can be pasted in any job of the same type, using the PASTE
and REVERSE functions. Data that has been copied or cut remains in the buffer
until cleared, replaced by new copied or cut data, or controller is turned OFF.
10.3.1 Copy
To copy a specified range of lines/steps to the buffer, perform the following steps:

2. Select the job content that contains the lines to be copied.
3. Move the cursor on the instruction side to the starting line of the range to be
copied. Hold the SHIFT key and press SELECT.
4. If more than one line is to be copied, move the cursor to the ending line of the
desired range. The selected line numbers will be highlighted.
5. Press the AREA key until cursor is on the Menu Area.
6. Cursor to EDIT and press SELECT.
7. Cursor to COPY and press SELECT.

Job Editing
10.3.2 Cut
To cut (remove) a specified range of lines/steps from a job to the buffer, perform the
following steps:

2. Select the job content that contains the lines to be cut.
3. Move the cursor on the instruction side to the starting line of the range to be
cut, hold the SHIFT key and press SELECT.
4. If more then one line is to be cut, move the cursor to the ending line of the
desired range. The selected line numbers will be highlighted.
5. Press the AREA key.
7. Cursor to CUT and press SELECT.
8. Cursor to [YES] on the “Delete?” screen and press SELECT.
10.3.3 Paste
To paste a specified range of lines/steps from the buffer, perform the following steps:

2. Select a destination job.
3. Move the cursor to the instruction side. Information will be pasted below the
cursor.
6. Cursor down to PASTE and press SELECT.
7. If the content is correct, cursor to [YES] on the “Paste?” screen and press
SELECT.

Job Editing
10.3.4 Reverse Paste
To paste a specified range of lines/steps and have the steps reversed when pasted,
perform the following steps:

2. Select a destination job.
3. Move the cursor, on the instruction side. Information will be pasted below the
cursor in the reverse order.
6. Cursor down to REVERSE PASTE and press SELECT.
7. If the content is correct, cursor to [YES] on the “Paste?” screen and press
SELECT.
10.4 GENERAL LINE EDITING
General line editing is used to modify existing data in any line as well as changing the
motion type of a step. This type of editing is all performed within the Input Buffer
Line; the JOB CONTENT screen remains in view.
To perform a general line edit on the Input Buffer Line, complete the following:

2. Move the cursor to the line to be edited on instruction side of the screen and
press SELECT.
3. Cursor left or right until the portion of the line to be modified is highlighted by
the cursor in the input buffer line.
4. Hold the SHIFT key and cursor up/down to choose from the menu to make
the desired changes on the input buffer line.
5. Repeat steps 3 and 4 until all desired changes appear on the input buffer line.
6. Press ENTER.

Job Editing
10.5 DETAIL EDIT
The DETAIL EDIT screen must be accessed in order add conditions and/or tags
such as “PL=” or to make changes in the type of data, as well as changing the data
values.
To perform a DETAIL EDIT, complete the following:

press SELECT.
3. With the cursor highlighting the initial instruction, press SELECT. The
DETAIL EDIT screen appears.
4. Using the cursor and SELECT keys, make all the desired detail changes from
the available menu selections.
5. Press ENTER to accept the Input Buffer Line and return to the JOB
CONTENT screen.
6. Press ENTER to place the changes into the job.
NOTE: DETAIL EDIT is the only way to access the menu for using a
VR=Angle_speed (Velocity of Rotation) to replace a
V=Control_point_speed on a MOVL, MOVC, or MOVS motion step. A
velocity in units of 1-360 degrees per second for rate-of-angle-change
should be used on a step where the TCP is not traveling, but it is
pivoting its orientation about a point. This gives more control over how
fast the wrist adapts to the position. Typically, after a MOVL with the
V=Control_point_speed to travel to a “corner,” an additional step using
MOVL with VR=Angle_speed is inserted to set-up the tool angle for the
next travel path.

Speed Correction / Adjustment
11.0 SPEED CORRECTION/ADJUSTMENT
There are four methods to change programmed speeds in TEACH mode on the
XRC controller:
• PLAY SPD list (general line editing)

• Custom PLAY SPD value (DETAIL EDIT)
• CHANGE SPEED (RELATIVE or ABSOLUTE)
• TRAVERSE RUN TIME (TRT)
11.1 PLAY SPD (GENERAL LINE EDITING)
To modify a programmed speed to any one of the eight preset speeds in the speed
list, perform the following steps:

2. Move the cursor to the instruction side of the screen on the step that
requires changing and press SELECT. The cursor appears on the Input
Buffer Line highlighting the MOV_.
3. Cursor right to highlight the speed data to be changed.
4. Hold the SHIFT key while pressing the cursor (as many times as necesary) up
to increase the speed or down to decrease the speed.
5. Press ENTER to place the data on the Input Line into the job.
NOTE: This speed correction function only allows you to change the speed to
one of the eight preset velocities. If you want a speed different from one
of these eight preset velocities, use the method in Section 11.2.
XRC Programming Basic Manual Page 11-1 © MOTOMAN

To modify a programmed speed to one other than the eight preset speeds, perform
the following steps:

2. Move the cursor to the instruction side of the screen on the step that
requires changing and press SELECT. The cursor appears on the Input
Buffer Line highlighting the MOV_.
3. Cursor right to highlight the speed data to be changed.
4. Press SELECT, the Input Data Line will appear. Enter a speed value within the
appropriate range.
5. Press ENTER to place the value from the Input Data Line to the Input Line.
11.2 ENTERING SPECIFIC PLAY SPD DATA (DETAIL EDIT)
The DETAIL EDIT screen allows the programmed speed to be changed to any
value within the programmed motion type’s range. DETAIL EDIT also permits a
change to the type of Velocity from “V=” to “VR=”.
To change velocities with DETAIL EDIT, perform the following steps:

press SELECT, the cursor will move to the Input Buffer Line.
3. With the cursor highlighting the initial =>MOV_ instruction, press SELECT.
The DETAIL EDIT screen appears.
NOTE: There are two different speed data types for a MOVL , MOVC, and
MOVS (V= or VR=), to change to VR=, cursor to the “V=” and press
SELECT.
4. Cursor to the speed data to be changed; press SELECT.

5. Enter the desired speed data on the numeric key pad and press ENTER.

• VJ =Joint_speed for MOVJ. [0.01-100.00%]

• V=Control_point_speed for MOVL, MOVC, and MOVS [1-9000 cm/
min; 0.1-1500.0 mm/sec, 1-3543 in/min, or 1-90000 mm/min.]
• VR =Angle_speed for MOVL, MOVC, MOVS. [1-360 deg/sec]
• VE=Ex.Axis_speed used for changing speed of an external station
axis. [0.01-100.00%]
6. Press ENTER to accept the Input Buffer Line and return to the JOB
CONTENT screen.
11.3 CHANGE SPEED
There are two basic methods to use the CHANGE SPEED feature:
• Relative
• Absolute
With both methods it is important to understand the difference between the

CONFIRM and NO CONFIRM selections under the category of
MODIFICATION TYPE.
NO CONFIRM - If NO CONFIRM is chosen, then upon selecting EXEC, all

steps will be changed simultaneously.
CONFIRM - If CONFIRM is chosen, then upon selecting EXEC, each step must
be changed individually using the ENTER key.
Note: The CHANGE SPEED screen will default to NO CONFIRM; VJ 25%

each time it is displayed.
11.3.1 Relative Speed Change

Choosing RELATIVE in the CHANGE SPEED menu allows a percentage
decrease (1-99%) or increase (101-200%) of all the SPEED KINDs existing
programmed speeds in a job. The change will be done instantly upon EXEC when
NO CONFIRM is set. However, if only certain steps are desired, then choose
CONFIRM. The cursor will sequence to each appropriate step and the speed will
be changed by pressing ENTER.

To CHANGE SPEED with the RELATIVE specification, perform the following

steps:
1. If not already in TEACH mode, press TEACH.

2. Select the desired JOB CONTENT with the cursor on the instruction side.
3. Press the AREA key until the cursor is on the MENU LINE.
5. Cursor down to CHANGE SPEED and press SELECT.
6. Cursor to SPEED KIND and press SELECT.
7. Cursor to RELATIVE and press SELECT.
8. Cursor to SPEED and press SELECT.
9. Enter the desired speed change on the numeric keypad (1-200%) and press
ENTER.
10. If desired to do each step individually, cursor to the MODIFICATION
TYPE: NO CONFIRM and press SELECT to change it to CONFIRM.
11. Cursor down to EXEC and press SELECT.
NOTE: When NO CONFIRM has been selected, all speeds in the job will be
changed at once.
11.3.2 Absolute Units Speed Change
The CHANGE SPEED menu also allows the type of velocity to be selected (VJ=,
V=, VR=, and VE=) and specific data entered in the appropriate units.
To CHANGE SPEED with specific velocity type and data, perform the following
steps:
1. If not already in TEACH mode, press TEACH.

2. Select the desired JOB CONTENT with the cursor on the instruction side.
4. Cursor to EDIT; press SELECT.
5. Cursor down to CHANGE SPEED; press SELECT.
6. Cursor to SPEED KIND; Press SELECT.
7. Cursor to the type of velocity desired (VJ=, V=, VR=, or VE=) and press
SELECT.
8. Cursor to SPEED and press SELECT.

9. Cursor to the default data and enter the desired data on the numeric keypad;
press ENTER.
10. If desired to do each step individually, cursor to the MODIFICATION
TYPE: NO CONFIRM and press SELECT to change it to CONFIRM.
11. Cursor down to EXEC; press SELECT.
NOTE: When CONFIRMING, the cursor stops on selected SPEED KIND steps.
12. Pressing ENTER applies the speed change, pressing the down cursor
maintains the steps speed and places the cursor on the next matching SPEED
KIND step.
11.4 TRAVERSE RUN TIME
Traverse Run Time (TRT) allows you to have the robot perform a task in a specified
amount of time. With speed correction by TRT, the length of time the entire motion
in the program or a portion of the program should take to run may be entered. The
TRT function calculates and rewrites the speeds to achieve the desired cycle time.
The selected job must be executed to establish the existing MOVING TIME in
order to make a judgment on the requested SETTING TIME.
To use TRT, perform the following steps:

2. Move the cursor to the first line of the measured range on the instruction side
of the screen.
3. Hold SHIFT and press SELECT.
4. Cursor down to highlight all the desired address lines to be measured.
NOTE: CALL and JUMP instructions are not allowed in the measured range.

7. Cursor down to TRT and press SELECT.
8. Cursor to SETTING TIME and press SELECT.
9. Enter the desired SETTING TIME in seconds on the numeric keypad and
press ENTER.
10. Cursor to EXEC and press SELECT. The MOVING TIME display will
change accordingly.

NOTE: If the desired TRT is not achieved on the first EXEC, press SELECT
again, until the desired results are achieved.
11. When finished with TRT, cursor to CANCEL and press SELECT to return to
the JOB CONTENT screen.
NOTE: If some of the speeds within the measured range go to maximum or

minimum value, a message “!Limited to maximum speed” or “!Limited
to minimum speed” appears.
11.5 CYCLE TIME DISPLAY
The CYCLE TIME screen displays the PLAYBACK TIME (the amount of time
since the START button was last pressed), and the robot’s MOVING TIME for all
position steps executed since the last START.
To access the cycle time display, perform the following steps:
1. If not already in Play mode, press PLAY.

4. Cursor to CYCLE TIME and press SELECT. A “✓” (check mark) appears
beside it indicating that this screen will now be displayed when in PLAY mode.
To remove the CYCLE TIME display, repeat Steps 1 through 4.
NOTE: If the job is run in AUTO cycle, the Cycle Time display will show
cumulative time data. To determine the time for just one cycle, play the
job from NOP to END in 1-Cycle mode.

11.6 SPEED OVERRIDE
This function allows speeds in a job, including related jobs using JUMP and CALL
(“GLOBAL”), to be changed by a percentage (50 - 150%) in the PLAY mode. A
change of 100% = no speed change. The SPEED OVERRIDE function cannot be
used during job PLAYBACK.
To change speeds using SPEED OVERRIDE, complete the following steps:
1. Press PLAY on the Playback Panel.

2. Press the AREA key to access the Main Menu Area.
3. Cursor to UTILITY and press SELECT.
4. Cursor to SPEED OVERRIDE and press SELECT.
5. Cursor to MODIFY [ON / OF] and press SELECT.
NOTE: Selecting “OF” will not change any speeds when START is pressed.
6. Cursor to [100%] and press SELECT.

7. Enter the range value of change desired (50%-150%).
8. Press ENTER.
9. Press START to execute the speed change desired AND to play the job(s).

NOTES

Special Playback Modes
12.0 SPECIAL PLAYBACK MODES

The special playback modes, which are listed below, allow programs to be run at
lower speeds, with and without tool instructions being executed, and with and
without robot motion:
• Low Speed Start

• Speed Limit
• Dry-Run Speed
• Check-Run
• Machine Lock
12.1 LOW SPEED START
The Low Speed Start moves the robot at a constant velocity of 10% of maximum
speed (regardless of programmed speed), without execution of tool instructions, to
the step on which the cursor rests, and then stops. To continue the job as
programmed, you must press the START button again. This mode may be used for
E-Stop recovery.
NOTE: The Programming Pendant displays “!SLOW SPEED mode” in the

message line area while in Low Speed Start mode.
To turn Low Speed Start ON or OFF from the Job Content screen, perform the
following steps:

4. Cursor to SETUP SPECIAL RUN and press SELECT.
5. Cursor to LOW SPEED START and press SELECT. The screen entry for
that item will change to VALID.
6. Cursor to COMPLETE and press SELECT to return to the JOB CONTENT
with the selected mode enabled.
NOTE: After the robot reaches the cursored step and stops, press START
again to continue normal playback. LOW SPEED START is
automatically reset to OFF.

12.2 SPEED LIMIT
The Speed Limit mode limits robot travel speed to no more than 25% of maximum
speed, tool instructions are executed. This mode may be used, for example, to test
new jobs so that “aircuts” programmed at 100%, etc., will be executed at a safer
25%. The Speed Limit mode is not recommended for testing jobs where the tool
instructions involve program speeds exceeding 25% because of the affects on the
process (poor results and possible hazards).
To turn Speed Limit ON or OFF from the Job Content screen, perform the
following steps:

5. Cursor to SPEED LIMIT and press SELECT. The screen entry for that item
will change to VALID.
NOTE: The Programming Pendant displays “!Speed Limit mode” in the

message line area while in Safety Speed mode.
12.3 DRY-RUN SPEED

Dry-run mode runs the robot through all program steps at a constant velocity of
10% of maximum speed, tool instructions are not executed. This mode may be
useful for verifying motion type for path and command position points.
To turn Dry-run speed ON or OFF from the Job Content screen, perform the
following steps:


5. Cursor to DRY-RUN and press SELECT. The screen entry for that item will
change to VALID.
NOTE: The Programming Pendant displays “!Dry-Run mode” in the message

line area while in Dry-Run mode.
12.4 CHECK-RUN
Check-Run mode has the controller run the job at programmed speeds with no tool
instructions being executed. It is used primarily to check the path of the program at
programmed speeds without executing the tool instructions. It is frequently used in
conjunction with the Speed Limit Mode.
To turn check speed ON or OFF from the Job Content screen, perform the
following steps:

3. Cursor to UTILITY; press SELECT.
4. Cursor to SETUP SPECIAL RUN; press SELECT.
5. Cursor to CHECK; press SELECT. The screen entry for that item will change
to VALID.
6. Cursor to COMPLETE; press SELECT to return to the JOB CONTENT
NOTE: The Programming Pendant displays “!Check mode” in the message line
area while in check mode.

12.5 MACHINE LOCK

Machine Lock mode allows the controller to execute a job at programmed speeds,
no tool instructions are executed and the robot does not move. Machine
Lock is typically used to check communication between the controller and external
devices.
To turn machine lock ON or OFF, perform the following steps:

5. Cursor to MACHINE LOCK and press SELECT. The screen entry for that
item will change to VALID.
NOTE: The Programming Pendant displays “!Machine lock mode” in the

message line area while in Machine Lock mode.
12.6 TURNING OFF ALL SPECIAL PLAYBACK

MODES
All five modes are toggle-type selections (that is, SELECT to turn ON;
SELECT again to turn OFF). If two or more of these special modes are on at the
same time, the controller uses the slowest speed and no tools.
NOTE: All special playback modes default to an OFF status when the
controller is turned off, then on.
To release all special modes, perform the following steps:

5. Cursor to the mode to be disabled and press SELECT. The screen entry for
that item will change to INVALID.
with the selected mode disabled.

INFORM List
13.0 INFORM LIST

The XRC INFORM List contains all of the non-motion instructions. These
instructions perform tasks related to controlling sequencing, performing
Arithmetic functions, performing Input and Output tasks, and controlling the
end-of-arm tooling.
13.1 Opening the INFORM List

The INFORM List is selected by pressing the INFORM LIST Key.
INFORM
LIST
Figure 13-1 Inform List Key
This will open a “window” that allows selections of the groupings indicated
below.
IN/OUT
CONTROL
DEVICE
MOTION
ARITH
SHIFT
Figure 13-2 Inform List Grouping
Cursor to the group and press SELECT. This opens the group and allows
access to the specific instructions.
..
DOUT
DIN
WAIT
PULSE
AOUT
Figure 13-3 Inform List Specific Instructions
To return to the “main” INFORM List, cursor to the “..” and press SELECT.
To leave the INFORM List, press the INFORM LIST key.
XRC Basic Programming Manual Page 13-1 MOTOMAN

INFORM List
NOTES
XRC Basic Programming Manual Page 13-2 MOTOMAN

Control Instructions
14.0 CONTROL INSTRUCTIONS
14.1 CALL
The CALL instruction allows one job to open another as a subroutine. The job
doing the calling is referred to as the parent job. The job being called is referred to
as a child job.
14.1.1 Linking Jobs
Jobs can be linked together consecutively simply by creating a parent job with a
CALL instruction for each desired child job in the order they should be executed.
The following job samples illustrate child jobs linked together consecutively in the
parent job:
1.
-1
0000 NOP
0000 NOP
0001 MOVJ VJ=.78
0001 CALL JOB: TEST-1
0002 MOVJ VJ=100.00
0003 MOVL V=138
0003 END
2. 0004 MOVJ VJ=50.00
0005 MOVJ VJ=100.00
0006 END
3.
-2
0000 NOP
4. 0001 MOVJ VJ=.78
0002 MOVJ VJ=100.00
0003 MOVL V=558
0004 MOVJ VJ=50.00
0005 MOVJ VJ=100.00
0006 END
Figure 14-1 Linking jobs using Call
NOTE: The XRC controller will automatically return to the next line of
execution of the parent job after the END of the child job.
NOTE: If the called job is also a motion job, great care should be taken to
ensure a clear path to and from the child job.
NOTE: FWD and BWD keys do not execute Call instructions. These can only
be executed in the TEACH Mode using the Interlock/Test Start path
confirmation technique while in Step cycle or using the Direct Open
function (section 14.3).

14.1.2 Nesting Jobs

The CALL instruction can be used within a child job to “nest” jobs inside one
another. Up to eight levels of nested jobs can be used with the original parent as
level one.
The following job samples illustrate child jobs nested from the original parent job:
1.
-1
0000 NOP
0000 NOP
0001 MOVJ VJ=.78
0002 MOVJ VJ=100.00
0002 END
4. 0003 CALL JOB: TEST-2
0004 MOVJ VJ=50.00 3.
0005 MOVJ VJ=100.00
0006 END
2.
-2
0000 NOP
0001 MOVJ VJ=.78
0002 MOVJ VJ=100.00
0003 MOVL V=558
0004 MOVJ VJ=50.00
0005 MOVJ VJ=100.00
0006 END
Figure 14-2 Nesting jobs using Call
NOTE: At the END of each child job the controller automatically returns to the
next line of instruction in the parent job that called it.
NOTE: ALARM 4443 STACK MORE THAN 8 (JOB CALL) occurs if more than
8 levels of nested calls are attempted. To display the JOB STACK in
PLAY mode, press the AREA key to move the cursor to the Menu Line,
cursor to DISPLAY, press SELECT, cursor to <JOB STACK> and press
SELECT. A “3” appears beside it indicating that this screen will now
always be displayed when in PLAY mode. (To remove the STACK
display, repeat the steps.)

To program a CALL instruction in a parent job, perform the following steps:

2. Move the cursor to the address side of the screen on the line above where the
call is to be entered.
3. Press the INFORM LIST key.
The INFORM LIST of program instructions will appear in a column along the right-
hand side of this area whenever the key is activated in the EDITING mode.
4. Cursor to CONTROL on the list; press SELECT.

5. Cursor to CALL on the list; press SELECT.
6. “CALL JOB:” appears on the input buffer line; cursor right to the job name
and press SELECT.
7. Cursor to the job to be called from the job list; press SELECT. The input
buffer line will display the instruction.
NOTE: When inserting any instruction between existing lines (not just before
the END instruction), the INSERT key must be ON before pressing the
final ENTER to put the buffer line content into the job. To completely
replace an existing line with the Input Buffer Line, MODIFY must be on.
8. Press (INSERT?/MODIFY?) ENTER to insert the instruction in the job.
14.2 RET (RETURN)
The RET (Return) instruction is used to have the controller “close” the Child job
and return to the Parent Job. This RET (Return) gives the programmer the option
to use part of the Child Job.

PARENT CHILD
JOB:ABC JOB:123
LINE INSTRUCTION LINE INSTRUCTION
0000 NOP 0000 NOP
0001 MOVJ VJ=50.00 0001 MOVL V=276
0002 MOVJ VJ=6.25 0002 MOVL V=276
0003 CALL JOB:123 0003 RET
0004 MOVJ VJ=25.00 0004 MOVL V=276
0005 MOVJ VJ=100.00 0005 MOVL V=276
0006 END 0006 END
Figure 14-3 Return instruction in a child job
NOTE: Remember, great care should be taken to ensure a clear path to and
from the child job.
To program a RET (return) instruction in a child job, perform the following

steps:

2. Move the cursor to the address side of the screen.
4. Cursor to CONTROL on the list and press SELECT.
5. Cursor to RET on the list and press SELECT.
6. Press (INSERT?/MODIFY?) ENTER.
NOTE: If a child job is executed “independently” (without being called by a

parent job) and it attempts to execute a RET instruction, then ALARM:
4440 UNDEFINED RETURN JOB will occur.

14.3 DIRECT OPEN

The DIRECT OPEN function allows viewing of information related to certain
instructions. Pressing the DIRECT OPEN key while the cursor is on a CALL
instruction will open the specified Child Job. Pressing the DIRECT OPEN key
while the cursor is on a motion step will display the Command Position Screen.
Figure 14-4 shows the location of the DIRECT OPEN key. This function will only
display one level below the original level. When the Direct Open key LED is on,
the function cannot be used for further displays.
Direct Open Key
Figure 14-4 Direct Open Key
To use the DIRECT OPEN function for CALL jobs, perform the following steps:

2. In the parent job, move the cursor to either the address or instruction side of
the CALL of the child job that you want to “open” (display), as shown in
Figure 14-5.
Parent Job
0000 NOP
0003 END -1
0000 NOP
0001 MOVJ VJ=.78
0002 MOVJ VJ=100.00
0003 MOVL V=138
0004 MOVJ VJ=50.00
0005 MOVJ VJ=100.00
0006 END
Child Job
Figure 14-5 Displaying a Job Using Direct Open

3. Press the DIRECT OPEN key. The key light illuminates, and the job contents
of the child job are displayed.
4. To edit the directly opened job, use the same techniques discussed in
Section 11.
5. To return to the parent job, press the DIRECT OPEN key again. The key
LED turns off and the contents of the parent job are displayed again.
14.4 JUMP
The JUMP instruction is a “Go-To” instruction. This can instruct the controller to
go to other locations in the same job (through the use of the below described
Label). It can also instruct the controller to go to another job, though this is not
considered “normal” programming in a basic programming situation. The controller
will not return to the original job when Jump to a job is used.
14.4.1 Executing a Jump instruction to a Label in the job
The JUMP instruction may be used to go forward or backward to a specified label

within a job. Upon execution of a JUMP instruction to a label, the cursor moves to
the matching label in the job.
In the job sample below, the controller will execute the program from L:0004 to
L:0008 without executing lines 5,6, and 7.
0003 MOVJ VJ=25.00

0004 JUMP *1
0005 MOVC V=150
0006 MOVC V=150
0007 MOVC V=150
0008 *1
0009 MOVL V=150
0010 MOVJ VJ=25.00
Figure 14-6 Jump to a Label
NOTE: Remember that a clear path is necessary if the program is jumping

motions! In the example above, a clear path is necessary not only from
L:0003 to L:0005 and from L:0007 to L:0009 as defined in the original
program, but a clear path is also required from L:0003 to L:0009.

To program a JUMP instruction, complete the following steps:

JUMP command is to be inserted.
5. Cursor to JUMP on the list and press SELECT.
6. “JUMP” appears on the input buffer line. Cursor right to the LABEL and
press SELECT.
NOTE: The label definition will automatically be preceded by an asterisk (*).

Labels can contain up to 8 characters and can be defined with upper or
lowercase letters, numbers, symbols, or any combination of these. Use
the underscore “_” for a space, if needed.
7. Press CANCEL to clear the input buffer line, then SELECT each desired
character. When complete, press ENTER.
8. Press (INSERT?/MODIFY?) ENTER to insert the instruction into the job.
14.5 LABEL
After the Jump instruction to a Label is entered, a Label must be defined in the
program. The Label is the indicator within the job where the controller is to take
the cursor. When programmed, an asterisk automatically precedes the Label (*).
The Label must be exactly the same as the Label specified in the Jump instruction.
To program a Label into a job, perform the following steps:

4. Cursor to CONTROL on the list; press SELECT.
5. Cursor to LABEL on the list; press SELECT.
6. An asterisk (∗ ) appears on the input buffer line. Cursor right to highlight
LABEL and press SELECT.

NOTE: The label definition will automatically be preceded by an asterisk (*).

Labels can contain up to 8 characters and can be defined with upper or
lowercase letters, numbers, symbols, or any combination of these.
Although a space (SP) is available, it is not recommended that spaces
be used in labels. Use the “-” (minus sign on keypad) if a space is
needed.
8. Press (INSERT?/MODIFY?) ENTER to place the Label into the job.
14.6 COMMENTING
Comments are notes to the Programmer/ Operator. They are not recognized as part
of the job by the controller, and therefore do not affect the operation of the job.
Comments are preceded by an apostrophe (’) and are limited to 32 characters per
line.
To program a comment into a job, perform the following steps:

2. Move the cursor to the address side of the screen on the line above where you
want the comment.
5. Cursor to COMMENT on the list and press SELECT.
6. An apostrophe ( ’ ) appears on the input buffer line. Cursor right to higlight
COMMENT and press SELECT.
NOTE: Up to 32 characters can be defined with upper or lower case letters,

numbers, symbols, or any combination. A space (SP) is available for
use. Pressing the AREA key moves the cursor to the name input line.
The cursor right and left can be used to move-about within the name;
characters will insert to the left of the cursor. The down cursor will
delete the character to the left of the cursor. Pressing CANCEL will
clear the input line.
8. Press (INSERT?/MODIFY?) ENTER to insert the Comment into the job.

14.7 TIMER
This instruction causes the entire system (the robot as well as inputs and outputs,
and tool instructions) to remain at present status until the designated time expires.
The cursor remains on this instruction line while the program executes the TIMER.
The TIMER function is typically used when the robot needs to remain at a certain
position for some length of time, such as during arc establish, gripping, nozzle
cleaning, etc. The TIMER function’s range is 0.01 to 655.35 seconds.
To program a TIMER instruction, complete the following steps:

TIMER instruction is to be inserted.
5. Cursor to TIMER on the list and press SELECT.
6. Cursor to the data and press SELECT.
7. Enter the amount of time required and press ENTER.
8. Press (INSERT?/MODIFY?) ENTER to insert the TIMER into the job.
14.8 PAUSE
This function causes the robot to cease execution of the job. The start lamp turns
OFF, and the robot maintains its position. Pause instructions are used whenever a
programmed HOLD is required. To continue the job, press the START button.
To program a PAUSE instruction, complete the following steps:

PAUSE instruction is to be inserted.
5. Cursor to PAUSE on the list and press SELECT.
6. Press (INSERT?/MODIFY?) ENTER to insert the PAUSE into the job.

NOTE

Arithmetic Variables and Instructions
15.0 ARITHMETIC VARIABLES AND INSTRUCTIONS

The INFORM LIST language supports several different types of variables. The
four arithmetic variable types are Integer, Double Precision Integer, Real, and Byte.
Table 15-1 describes the attributes and uses of each variable type.
15.1 ARITHMETIC VARIABLES
Type Addresses Range Application

Integer I000-I099 -32768 to +32767 Counting
Double
D000-D099 -2147483648 to +2147483647 Distance (Microns)
Precision
±3.400000 E+38
Higher Arithmetic Calculations
(minimum/maximum)
Real R000-R099 (DIV, SQRT, SIN, COS, ATAN,
±9.999999 E-38
etc.)
(values between -1 and +1)
Byte B000-B099 0-255 I/O Communication
Table 15-1 Arithmetic Variable Table
15.1.1 Displaying Variables

To view the content value in any variable address, regardless of TEACH or PLAY
mode, perform the following steps:
1. Press TOP MENU, cursor to the VARIABLE icon and press SELECT.
2. Cursor to the variable type (INTEGER, DOUBLE PRECISION, REAL,
or BYTE) and press SELECT.
3. Use cursor to locate the appropriate variable address.
or
with the cursor on variable number, press SELECT, enter number from the
keypad, and press SELECT.

or
perform search as follows:
a. Press the AREA key, cursor right to EDIT; press SELECT.
b. Cursor to SEARCH; press SELECT.
c. Enter the desired variable address; press ENTER.
15.1.2 Editing Variables
All variable values may be modified manually as follows:
1. Display the desired variable address as described in Section 15.1.1 steps 1-3 .
2. Cursor right to VALUE (contents of variable address) and press SELECT.
3. Enter the desired amount on the numeric keypad and press ENTER.
15.2 Arithmetic Instructions
Function Format Example Result

Adds one to the contentsINC B<address> INC B023 If contents = 6,
INC of specified address. INC I<address> INC I023 it increments to 7.
INC D<address> INC D023
Subtracts one from the DEC B<address> DEC B023 If contents = 6,
DEC contents of specified DEC I<address> DEC I023 it decrements to 5.
address. DEC D<address> DEC D023
Sets (makes) Data 1 equal SET <Data 1><Data 2> SET I012 3 Data 1 (I012) becomes a
SET
to Data 2. constant of 3.
Clears range from address CLEAR <address> CLEAR I007 4 Clears I007, 8, 9, 10
CLEAR
to specified value. CLEAR <address> CLEAR I007 ALL Clears from I007 on (I007-I099)
Table 15-2 Arithmetic Instruction Table
NOTE: All ARITHMETIC instructions are accessed through the INFORM LIST.

15.2.1 INC (INCREMENT)
The INC instruction INCREASES the value stored in a variable by one (1). For
example, if I013 has a value of six (6), upon execution of the instruction INC I013,
it will have a value of seven (7).
The INC instruction is used primarily for counting. An INC instruction can be used
if it is necessary to count the number of times a certain job has been run or to count
the total number of parts run by a workcell. For most accurate results, change the
count in a job only after the job has been completed. Enter the INC instruction at
the bottom of the job, as shown below:
0003 MOVJ VJ=25.00

0004 MOVJ VJ=100.00
0005 INC I012
0006 END
Figure 15-1 Job Example Using INC
The INC Arithmetic instruction can only be used with B, I, & D variables. If the
INC command will cause the stored value to exceed the maximum of that
variable’s range, ALARM: 4446 OVER VARIABLE LIMIT will occur, stopping
execution of the job on that instruction line. To continue, press SELECT (to
RESET the Alarm) and make necessary changes to prevent future alarms.
To program the INC instruction in a job, perform the following steps:

4. Cursor to ARITHMETIC on the list and press SELECT.
5. Cursor to INC on the list and press SELECT.
6. With the cursor highlighting INC on the input buffer line, press SELECT.
7. Cursor right at RESULT (TOKEN) to [ ] and press SELECT.
»
8. Cursor to the appropriate variable type B, I , or D; press SELECT.

9. Left cursor to the address and press SELECT, then enter the address (0 to 99)
using the numeric keypad and press ENTER.
10. Press ENTER to insert the instruction into the job.

15.2.2 DEC (DECREMENT)
The DEC instruction DECREASES the value stored in a variable by one (1). For
example, if I022 has a value of 11, upon execution of the instruction DEC I022, it
will have a value of 10.
This instruction can be used in applications that must reach a production goal. A
variable is chosen to store the required number of parts that must be run. The
variable would be decremented (DEC) each time a part is completed. For best
results, change the count only after the job has been completed. Enter the DEC
instruction at the bottom of the job, as shown below:
0003 MOVJ VJ=25.00

0004 MOVJ VJ=100.00
0005 DEC I022
0006 END
Figure 15-2 Job Example Using DEC
The DEC instruction can only be used with B, I, & D variables. If the DEC
instruction will cause the stored value to exceed the minimum or maximum of that
variable’s range, ALARM: 4446 OVER VARIABLE LIMIT will occur, stopping
execution of the job on that instruction line. To continue, press SELECT (to
RESET the Alarm) and make necessary changes to prevent future alarms.
To program the DEC instruction in a job, perform the following steps:

5. Cursor to DEC on the list and press SELECT.
6. With the cursor highlighting DEC on the input buffer line, press SELECT.
7. Cursor right at RESULT (TOKEN) to [ ] and press SELECT.
»


15.2.3 SET
The SET instruction places a specific value in a specific variable address. This
provides the ability to automatically put a value (SET) in a variable file.
In LINE 0006 of the job below, SET is used to reset the contents of variable I015
to zero.
0004 MOVJ VJ=25.00

0005 MOVJ VJ=50.00
0006 SET I015 0
0007 END
Figure 15-3 Job Example Using SET
To program a SET instruction in a job, perform the following steps:

4. Cursor to ARITHMETIC on the list; press SELECT.
5. Cursor to SET on the list; press SELECT.
6. With the cursor highlighting SET on the input buffer line, press SELECT. The
DETAIL EDIT screen appears.
7. Cursor right at DESTINATION to [ ] and press SELECT.
»

10. Cursor to SOURCE and press SELECT, then enter the constant value on the
numeric keypad and press ENTER.
11. Press ENTER to store the value onto the input buffer line and return to the
JOB CONTENT.
NOTE: Since all the Arithmetic Variable addresses are “global” (seen by all
jobs), using the SET command is important to ensure that each job
uses the appropriate initial value.

15.2.4 CLEAR
The CLEAR instruction allows variable files to be cleared of data. This instruction
will clear data from single files or groups of files. With the CLEAR instruction, the
starting address and a constant number to define the range of addresses must be
specified. In the example below, CLEAR I007 4 clears data from the addresses
I007, I008, I009, and I010 (four addresses beginning with I007). ALL may be
selected instead of a constant number, clearing (zeroing) all addresses through the
end of the variables. For example, CLEAR I007 ALL clears data from addresses
I007 through I099.
0004 MOVJ VJ=25.00

0005 MOVJ VJ=50.00
0006 CLEAR I007 4
0007 END
Figure 15-4 Job Example Using CLEAR
To program a CLEAR instruction in a job, perform the following steps:

5. Cursor to CLEAR on the list and press SELECT.
6. With the cursor highlighting CLEAR on the input buffer line, press SELECT.
7. Cursor on the TARGET line to [ ] and press SELECT.
»
8. Cursor to the desired variable type and press SELECT.

9. Cursor left to the address and press SELECT, then enter the address and
press ENTER.
Choose step 10a or 10b below.
10a. To enter a number to define a range of addresses starting at the specified

address, perform the following steps:
1) Cursor to CLEAR NUM. and press SELECT.
2) Enter the number of addresses to be cleared and press ENTER.
3) Press ENTER to insert the instruction into the job.

OR
10b. To clear from the specified address to 099, perform the following steps:
1) Cursor to CLEAR NUM. and press SELECT.
2) Cursor right to [ ] and press SELECT.
»
3) Cursor to ALL; press SELECT.
4) Press ENTER to insert the instruction into the job.

NOTES

Conditional “If” Statement
16.0 CONDITIONAL “IF” CONSTRUCT
The IF statement is a conditional construct that instructs the controller to execute the
instruction only if certain conditions have been met. For example, CALL a tool
cleaning job if a Variable has reached a certain value or JUMP a sequence of steps
if a Variable has reached a certain value.
By adding the IF construct, you can make the following CONTROL instructions
conditional:
• JUMP
• CALL
• RETURN
• PAUSE
These instructions are identified as the “root” instruction. Any instruction that is the
first in the line (eg. MOVL, CALL, INC) is the “root” instruction.
CONDITIONAL OPTIONS:
The conditional options available for use with the IF statement are as follows:
Var - compare value of a variable

IN# - check status of an input
IG# - check binary value for status of an input group
0000 NOP
0001 SET I039 0
0002 MOVJ VJ=25.00
0003 MOVJ VJ=100.00
0004 MOVJ VJ=12.50
0005 *Line5
0006 MOVC V=558
0007 MOVC V=558
0008 MOVC V=558
0009 MOVL V=558
0010 INC I039
0011 JUMP *Line5 IF I039<3
0012 END
Figure 16-1 Job Sample with “IF” construct

16.1 PROGRAMMING THE “IF” CONSTRUCT
To program an IF statement on a CALL, RET, JUMP, or PAUSE

instruction, perform the following steps:
1. Enter instruction as usual without pressing the final ENTER keystroke.

2. Cursor to the root instruction and press SELECT.
3. Cursor down to CONDITION “UNUSED” and press SELECT.
4. Cursor up to “IF” and press SELECT.
5. Cursor to TARGET and press SELECT.
6. Choose one of the following variable types: B, I, D, or R. (Inputs and Input
Groups are covered in Section 17)
7. Cursor to the variable address displayed and press SELECT.
8. Using the numeric keypad, enter the variable address, press ENTER.
9. Cursor down to CONDITION “=” and press SELECT.
10. Cursor to the appropriate symbol of equality/inequality and press SELECT.
11. Cursor down to CONDITION [ 0 ] (value) and press SELECT.
12. Using the keypad, enter a value.
13. Press ENTER to place the information onto the input buffer line.
16.2 ADDING AN “IF” CONSTRUCT TO AN EXISTING

CONTROL INSTRUCTION
To add an IF statement to an existing CALL, RET, JUMP, or PAUSE

instruction, perform the following steps:

2. Move the cursor to the instruction side of the screen on the line to be edited.
3. Press SELECT twice.
4. Cursor to CONDITION “UNUSED” and press SELECT.

6. Choose one of the following variable types: B, I, D, or R. (Inputs and Input

Groups are covered in Section 17).
7. Cursor to the variable address displayed and press SELECT.

8. Using the numeric keypad, enter the variable address, press ENTER.
9. Cursor down to CONDITION “=” and press SELECT.
10. Cursor to the appropriate symbol of equality/inequality and press SELECT.
11. Cursor down to CONDITION [ 0 ] (value) and press SELECT.
12. SELECT a constant.
13. Using the keypad, enter a value.

NOTES

I/O Instructions
17.0 I/O INSTRUCTIONS

A robot very rarely works without having to interact with other devices. In nearly
all instances, the controller has to communicate with external equipment, such as
welding power sources, positioners, fixturing, and sensors. This communication is
accomplished through the use of Inputs and Outputs (I/O). The INFORM II
language supports a number of I/O instructions, which are described below.
17.1 DOUT (DIGITAL OUTPUT)
This instruction is used any time a device, such as a light or gripper, is to be turned
ON or OFF. This instruction is a digital output instruction. The following is an
example of the DOUT instruction used with a single Universal Output:
0003 DOUT OT#(3) ON
Figure 17-1 Example DOUT Instruction
To program a DOUT instruction in a job, perform the following steps:

4. Cursor to IN/OUT and press SELECT.
5. Cursor to DOUT and press SELECT.
6. Press SELECT to access the DETAIL EDIT screen.
7. Cursor to the OUTPUT TO line, press SELECT, cursor to OT and press
SELECT. Enter the number of the OT#( ) and press ENTER.
8. Cursor to DATA value, press SELECT to choose ON/OFF.
9. Press ENTER to accept and return to the JOB CONTENT screen.
NOTE: Once an output has been turned ON it will remain ON until a DOUT
“OFF” command is executed by the job or manually turned off as in
Section 17.3.

I/O Instructions
17.2 PULSE (DIGITAL OUTPUT)
This digital output instruction acts as a momentary contact switch for a single
Universal Output. PULSE is used when a device is to be turned ON and
maintained for some length of time. Examples of pulsed devices include wire
cutters, sealing gun and gas line purges, and PLC communication. The controller
continues execution of the job while the output is pulsing.
NOTE: To delay execution of the program during pulse time, insert a Control
menu TIMER greater than or equal to the pulse time (depending on
application) directly beneath the Pulse instruction. Adding this timer
will interrupt the cycle execution until the timer “times out.” The job
example below contains both a PULSE instruction and a Control
TIMER.
0003 MOVJ VJ = 12.50 PL=0

0004 PULSE OT#(1) T=0.50
0005 TIMER T=0.55
0006 MOVJ VJ = 6.25
Figure 17-2 Job Example with PULSE and TIMER Instructions
To program a PULSE instruction in a job, perform the following steps:

5. Cursor to PULSE and press SELECT.
7. Cursor to the output number on the OUTPUT NO. line, press SELECT, then
enter the output number OT#( ) and press ENTER.
NOTE: If no time is specified/desired, pulse default time is ≅ 0.3 seconds.

Continue keystrokes with step 9.

I/O Instructions
To specify a PULSE time,

8. Cursor to TIME [UNUSED] and press SELECT. Cursor to “T=” and press
SELECT. Cursor to the value area, press SELECT. Enter the time in seconds
(0.01 - 655.35) and press ENTER.
17.3 MONITORING UNIVERSAL OUTPUTS
It is possible to monitor the status and/or determine the name description of

Universal Outputs whether in TEACH mode or PLAY mode.
To display the names and monitor/operate Universal Outputs, perform the

following steps to access the DETAIL display screen:
1. Press TOP MENU, cursor to the IN/OUT icon and press SELECT.
2. Cursor to UNIVERSAL OUTPUT and press SELECT.
NOTE: This screen offers two different displays. SIMPLE shows only
groupings of outputs with Bit indicators for each individual output.
DETAIL shows individual outputs with names and status. If the Detail
display appears, omit steps 3 and 4.
3. Press the AREA key to move the cursor to the Menu Line, cursor to
DISPLAY and press SELECT.
4. Cursor to DETAIL and press SELECT.
To search for a specific output number:

1. Cursor to EDIT, press SELECT, then cursor to SEARCH SIGNAL NO. and
press SELECT. Enter the output number; press ENTER.
or
put the cursor on any OT#( ), press SELECT, enter the desired number and
press ENTER.
With the DETAIL output screen displayed, Universal Outputs can be turned ON/
OFF.

I/O Instructions
To force individual outputs ON/Off, performing the following steps in

TEACH mode:
1. Cursor to the status symbol [❍] for the Output to be changed.

2. Hold the INTERLOCK key and press SELECT to toggle the Output status
between [●] ON and [❍] OFF.
17.4 AOUT (ANALOG OUTPUT)
Sometimes with welding or dispensing applications, you need to turn a device ON

and set a level. For example, a device, such as a sealing gun, is not just turned ON,
but is set to a flow level of 200 cfm output. To accomplish this, an AOUT
instruction is used with an analog voltage output signal. Standard welding and
dispensing XRC systems have three analog output channels. The channels are rated
for ± 14 volts. AOUT is an analog output instruction.
0004 AOUT AO#(1) 7.00
Figure 17-3 Job Example with AOUT Instruction
To program an AOUT instruction in a job, perform the following steps:

3. Press INFORM LIST, cursor to IN/OUT and press SELECT.
4. Cursor to AOUT and press SELECT.
5. Press SELECT again to access the DETAIL screen.
6. Cursor right to [ ] and press SELECT. Choose constant or variable for the
Output channel.
7. Cursor left to “1” and press SELECT.
8. Enter the channel number from the keypad and press ENTER.
9. Cursor down to ANALOG DATA “0.00” and press SELECT.
10. Set level 0 to ± 14.0 volts and press ENTER.

I/O Instructions
17.5 MONITORING ANALOG OUTPUTS
It is possible to monitor the status of analog outputs in TEACH mode or PLAY

mode.
To monitor the analog outputs, perform the following steps:
1. Press TOP MENU, cursor down to the IN/OUT icon and press SELECT.
2. Cursor down to ANALOG OUTPUT and press SELECT.
17.6 WAIT (DIGITAL INPUT)

The WAIT instruction is a digital input instruction often used when a robot program
is dependent on a signal from a sensor, such as a limit switch or proximity sensor.
The following are examples of the WAIT instruction using a UNIV IN with/without
a timer:
0011 WAIT IN#(3)=ON [waits indefinitely for input 3 to be ON]
0052 WAIT IN#(5)=OFF T=3.25 [waits either for IN#5 to be OFF or for
3.25 seconds,then resumes]
Figure 17-4 Job Examples Using the Wait Iinstruction
NOTE: If the condition status is already “true” when the controller gets to the
WAIT instruction in the job then there will be no waiting.
To program a WAIT instruction in a job for a UNIV IN, perform the

following steps:

3. Press INFORM LIST.
5. Cursor to WAIT and press SELECT.

I/O Instructions
6. Press SELECT to view the DETAIL EDIT screen.

7. Cursor to the WAIT TARGET line and press SELECT.
8. Cursor to IN#( ) and press SELECT.
9. Right cursor to “1” and press SELECT.
10. Enter the desired IN#( ) from the keypad and press ENTER.
11. If OFF desired, cursor right to CONDITION ON and press SELECT to
toggle ON and OFF.
12. If needed, cursor to TIME UNUSED; press SELECT cursor to T= and press
SELECT. Cursor to the time value and press SELECT. Enter the seconds to
specify an expiration time for the WAIT instruction and press ENTER.
14. Press (INSERT?/MODIFY?) ENTER to insert the instruction into a job.
17.7 MONITORING UNIVERSAL INPUTS
It is possible to monitor the status and/or determine the name description of

Universal Inputs whether in TEACH mode or PLAY mode.
To display the names and monitor Universal Inputs, perform the following
steps to access the DETAIL display screen:
1. Press TOP MENU, cursor to the IN/OUT icon and press SELECT.
2. Cursor to UNIVERSAL INPUT and press SELECT.
NOTE: This screen offers two different displays. SIMPLE shows only
groupings of inputs with Bit indicators for each individual input. DETAIL
shows individual inputs with names and status. If the Detail display
appears, omit steps 3 and 4.
3. Press the AREA key, cursor to DISPLAY and press SELECT.
4. Cursor to DETAIL; press SELECT.
To search for a specific input number:

1. Cursor to EDIT, press SELECT, then cursor to SEARCH SIGNAL NO. and
press SELECT. Enter the input number and press ENTER.
OR
put the cursor on any IN#( ), press SELECT, enter the desired number and
press ENTER.

I/O Instructions
17.8 PROGRAMMING CONTROL INSTRUCTIONSWITH

“IF”CONSTRUCT BASED ON INPUT STATUS
Frequently, Control instructions are performed conditionally (IF) based on input

signals. This allows the use of selector switches to CALL jobs or perform other
Control Functions. Per Chapter 16, the only Control instructions that can be
performed conditionally are CALL, RET, JUMP, or PAUSE.
To program an IF statement on a CALL, RET, JUMP, or PAUSE instruction

based on Universal Inputs, perform the following steps:
1. Enter the instruction as usual without pressing the final ENTER keystroke.
2. Cursor to the root instruction and press SELECT.
3. Cursor down to CONDITION “UNUSED” and press SELECT.
6. Cursor to IN# and press SELECT.
7. Cursor to the IN# value and press SELECT.
8. Using the numeric keypad, enter the desired input number and press ENTER.
9. Cursor down to CONDITION “ON”. Press SELECT to toggle between ON
and OFF.
NOTE: To add information to an existing Control Instruction, perform the same

keystrokes but start with the cursor on the Instruction Side.
17.9 DIN (DIGITAL INPUT)
The DIN instruction is used to store I/O status in a Byte variable. This I/O
information may be received by the controller from a PLC, thumbwheel, or other
multiple-point input device. This information to be “stored” frequently comes into
the controller as a “grouping” of signals. These groups are based on eight (8) inputs
or outputs. Groups can be displayed when viewing the Universal Inputs or
Universal Outputs Detail Display under ther IN/OUT icon. This will indicate the
“Input Group” or “Output Group” number at the top of the screen.

I/O Instructions
The value of the Decimal quantity is based on a Binary system. Each Input or
Output is assigned a Binary position, with the On or Off status read as a (1) or (0).
The 8-bit place values in Binary are the same for each Group and are shown in
Table 17-1 for Input and Output Group #(1).
IN#/OT# (8) (7) (6) (5) (4) (3) (2) (1)

Binary place value 27 26 25 24 23 22 21 20
Decimal value 128 64 32 16 8 4 2 1
Sample ON/OFF 1 0 0 1 0 0 0 0 = 144
Table 17-1 8-Bit Place Values in Binary
When the DIN instruction is performed, the controller will “look at” the information
and store it in the designated Byte variable, both as Decimal and Binary values.
0001 DIN B012 IG#(1)
Figure 17-5 Job Example Using DIN
Using the information in Table 17-1, the instruction in Figure 17-5 would store in
B012 a decimal value of 144 and a binary value of 10010000. This could be
viewed by displaying the BYTE Variable files. The value in B012 can now be used
as any other variable information.
0004 CALL JOB:PART1 IF B012=144

0005 JUMP *1 IF B012 <>144
Figure 17-6 Job Example Using Byte Variables

I/O Instructions
To program a DIN instruction in a job, perform the following steps:

3. Press Inform List key.
5. Cursor to DIN and press SELECT.
7. Cursor to the INPUT TO line, press SELECT, enter the byte address, press
ENTER.
8. Cursor to the INPUT FROM line, press SELECT, cursor to IG#( ) from the
list, and press SELECT.
9. Cursor to “1” and press SELECT. Enter the group number from the keypad
and press ENTER.
11. Press (INSERT?/MODIFY?) ENTER to record the information into the job.
17.10 DOUT (DIGITAL OUTPUT) to Groups

Digital Output instructions can be made to groups, as well as individual outputs.
This concept uses the values as indicated in Table 17-1. With these instructions
multiple outputs can be turned On or Off at the same time.
0004 DOUT OG#(1) 17

0005 TIMER T=1.00
0006 DOUT OG#(1) 0
Figure 17-7 Job Example Using DOUT to Groups

I/O Instructions
To program a DOUT instruction to an Output Group, perform the following

steps:

5. Cursor to DOUT and press SELECT.
7. Cursor to the OUTPUT TO line, press SELECT, cursor to OG# and press
SELECT.
8. Cursor to value of Group, press SELECT.
9. Enter the number of the OG#( ) and press ENTER.
10. Cursor to DATA [ ], press SELECT.
11. Cursor to CONSTANT and press SELECT.
12. Cursor to the value and press SELECT.
13. Enter the value of the selection on the keypad and press ENTER.

Users Frames
18.0 USER FRAMES

The World Coordinate system is inconvenient when working on rotated or inclined
planes. As a teaching aid, it is useful to define a coordinate system that resides on
the plane in which the work will actually be taught. The XRC supports 24 user-
definable coordinate systems, referred to as User Frames (UF#1-24).
A User Frame is defined by three points:
• ORG The origin is the zero position for User Coordinate Frame in XYZ.
• XX A point on the positive direction of the X-axis.
• XY A point on the positive Y side of the plane.
XY XX
ORG
Figure 18-1 User Frame Points
As a convention, the origin (ORG) is chosen to be the right-hand corner of the

fixture closest to the robot, XX straight forward from the ORG point in the desired
X+ direction for jogging on the fixture, and the XY point is fixed to the left of the
line created by ORG and XX so that the Z+ axis key will jog up away from the
fixture when actually using the created User Frame coordinate system.

Users Frames
18.1 CREATING USER FRAMES
Creating User Frames is a function available under the ROBOT icon.
To define a User Frame, complete the following steps:

2. Press TOP MENU, cursor to the ROBOT icon and press SELECT.
3. Cursor to USER COORDINATE and press SELECT.
4. Cursor up/down to find the desired User Frame number and press SELECT.
5. Ensure that the cursor is set to “SET POS: ORG.”
6. With SERVO READY ON, press TEACH LOCK and enable Servo Power.
7. Choose any jogging COORD other than USER and jog the robot TCP to the
desired origin point.
8. Press MODIFY, ENTER. The bullet for ORG will be set (l).
9. Press SELECT, cursor to XX and SELECT it.
10. Jog the robot TCP to the desired XX point.
11. Press MODIFY, ENTER. The bullet for XX will be set (l).
12. Press SELECT, cursor to XY and SELECT it.
13. Jog the robot TCP to the desired XY point.
14. Press MODIFY, ENTER. The bullet for XY will be set (l).
15. When all three points have been correctly taught, cursor down to
COMPLETE and press SELECT.
16. To name the User Frame, cursor right to [ name area ] and press SELECT.
Cursor and SELECT up to 16 characters from the alphanumeric screen, then
press ENTER.
NOTE: To view/verify the set position of ORG, XX, or XY, choose the desired
“SET POS:” (as in steps 5, 9, or 12 above), then press the FWD key
until the highlighted “SET POS:” for ORG, XX, or XY stops flashing.
NOTE: Previously defined frames will indicate the bullet as set (l). These
frames may be modified using the above keystrokes.

Users Frames
18.2 ACCESSING USER FRAMES
Once a frame has been defined, it can be accessed from the user frame list at
anytime for jogging purposes.
To access a user coordinate frame, perform the following steps:
1. Press COORD until the User coordinate is shown in the Status Display Area.
2. Press and hold the SHIFT key, then press COORD. The user frame list is
displayed.
3. Cursor to the desired user coordinate frame. This frame number is now set.
4. Return to the Job Content screen or any other through the Top Menu Screen.
NOTE: Once selected, the robot will move on this coordinate frame when in
User until another frame is selected.

Users Frames
NOTES

Edit Protection
19.0 EDIT PROTECTION

The XRC supports two types of edit protection: 1) A hardware key switch for
protection of all RAM information for user interface, and 2) software protection for
individual jobs.
19.1 EDIT LOCK KEY SWITCH
The Edit Lock key switch, located on the Playback Panel, is a hardware protection
of all jobs, files, parameters, and condition lists. Turning the Edit Lock key to the
ON position prevents use of function/editing menus. The display of all files, variables
and icons is available, but no changes can be made. The Edit Lock key should be
removed when in the ON position. To allow editing and full menu selections, insert
the key and turn it to the OFF position.
19.2 SOFTWARE EDIT PROTECTION
The software edit protection function is for jobs only. EDIT LOCK is turned
ON/OFF from each job’s HEADER. The level at which jobs are protected is set in
the TEACHING COND list(see section 19.2.2).
To display a job’s HEADER to edit protect the job, complete the following:
1. If not already in Teach mode, press TEACH.

2. Press TOP MENU, cursor to the JOB icon and press SELECT.
3. Cursor to the name of the job to be protected; press SELECT.
4. Press the Area key to move the cursor to the Menu Line, cursor to DISPLAY
and press SELECT.
5. Cursor to JOB HEADER and press SELECT.
NOTE: The job header is like the title page of the job. It displays the total
memory used, the number of steps and lines in the job, the date and
time of the last modification to the job, and whether or not the current
revision is backed up on a disk. It also displays the edit protection
status.
6. To change the edit protection status, cursor down to EDIT LOCK and press
SELECT to toggle ON/OFF.

Edit Protection
Figure 19-1 Job Header Screen
Setting EDIT LOCK [ON] protects only the selected job at one of two selected
levels (see Section 19.2.2 below). Child or CALL jobs are not automatically
protected. They must be individually selected and edit protected. Setting EDIT
LOCK [OFF] makes the selected job unprotected.
19.2.2 Software Edit Protection Levels
There are two levels of the EDIT LOCK [ON] status for all protected jobs. One
item in the TEACHING CONDITION list (under the SETUP icon) determines the
level of ED LOCK [ON] protection. Setting this condition to PROHIBIT protects
jobs from deletion, name change, or any editing of steps/instructions with INSERT,
MODIFY, or DELETE. Setting this condition to PERMIT allows the operator to
MODIFY existing step positions only, but prevents all other editing.
To set the TEACHING CONDITION list, complete the following steps:
1. If not already in Teach mode, press TEACH.

2. Press TOP MENU, cursor to the SETUP icon and press SELECT.
3. Cursor to TEACHING COND and press SELECT.
4. Cursor to STEP ONLY CHANGING.
5. Press SELECT to toggle to PERMIT to allow position modifications or
PROHIBIT for full edit protection.
FIgure 19-2 Teach Condition Screen

Tool Center Point Definition
20.0 TOOL CENTER POINT DEFINITION

A well-defined Tool Center Point or Tool Control Point (TCP) is necessary for
most applications, especially process work such as welding, sealing, and cutting . A
well-defined TCP is a must for the axis keys (particularly the Rx, Ry, and Rz keys)
to operate appropriately in WLD/CYL, TOOL, or USER Coordinates when
jogging the robot. Another primary reason for accurate Tool Data is for precise
Linear, Circular, and Spline motion interpolation and V (Control Point Speed)
program velocities.
The XRC is capable of storing up to 24 different TCP data files:
• The first TCP is called the Standard Tool, or Tool 00. Robots with one tool
are typically concerned only with the Standard Tool.
• The remaining 23 TCP data files are called Universal Tools or Tool No. 01-
23 and are only available when activated by parameter setting. Robots with
multiple tools will require TOOL data defined for each TCP and may use the
Standard Tool No. 00 and Universal Tools No. 01-23.
There are two methods for defining the TCP data: Manual TCP definition and
Automatic TCP definition.
20.1 MANUAL TCP DEFINITION
Manual TCP definition is typically used for entering/modifying the Rx, Ry, and Rz in
degrees after using the Automatic Method of determining the Tool Data for X, Y, &
Z in millimeters. However, manual definition of the X, Y, Z may also be used when
the values are already known or have been accurately measured.
To define or manually enter TOOL data, complete the following steps in

Teach mode:
1. TOP MENU, cursor to the ROBOT icon and press SELECT.

2. Cursor to TOOL and press SELECT.
3. Move the cursor to the first tool dimension that requires modification and press
SELECT.
4. Using the numeric keypad, enter the dimension/angle of the tool, relative to the
wrist flange (see Figure 20-1).

5. Press ENTER.
6. Repeat Steps 3 through 5 for each tool dimension to be entered.
The TCP is now defined. To ensure accuracy of the TOOL data, use the “rotate-
about” keys Rx, Ry, and Rz in WLD or TOOL Coordinates to rotate the tool’s
orientation about the TCP. The TCP should not move off of the point location when
rotated. Also check the X, Y & Z directions of operation in TOOL Coordinates;
the Z+ should operate in the direction of the application. For example, rather than
the default Z+ direction off the Wrist Flange, for a welding torch’s wire-feed, the
data Ry = -45 degrees has been entered (see Flange Coordinate of TOOL B in
Figure 20-1).
Flange Coordinates
Z+ in Tool
Case of Tool A Case of Tool B
X 0.000 mm Rx 0.00 deg. X 0.000 mm Rx 0.00 deg.

Y 0.000 mm Ry 0.00 deg. Y 145.000 mm Ry -45.00 deg.
Z 260.000 mm Rz 0.00 deg. Z 260.000 mm Rz 0.00 deg.
Case of Tool C
X 0.000 mm Rx 0.00 deg.

Y 145.000 mm Ry 0.00 deg.
Z 260.000 mm Rz 90.00 deg.
Figure 20-1 Entering Tool Dimensions

20.2 AUTOMATIC TCP DEFINITION

Automatic TCP definition calibrates the X, Y, and Z dimensions (offsets, in
millimeters, from the wrist flange of the T-axis ) for the Tool Data. The desired
orientation in degrees for Rx, Ry, and Rz must be entered manually (see Section
20.1). Usually the Z+ direction of operation in TOOL Coordinates should be the
same as the application direction, such as wire feed, dispensing, water jet, or laser
direction.
To define a TCP automatically, follow these steps:
1. Put a pointer (with the sharp end up) on the fixture. Ensure that the pointer is
placed so that it will not move.
2. Press the TEACH mode button on the Playback Panel.
3. Press TOP MENU, cursor to the ROBOT icon and press SELECT.
4. Cursor to TOOL and press SELECT.
5. Press the AREA key to move the cursor to the Menu Line, cursor to
UTILITY and press SELECT.
6. Cursor to CALIBRATION and press SELECT.
NOTE: To clear existing data, press the AREA key to highlight DATA, press
SELECT. With cursor on CLEAR DATA, press SELECT. Cursor to
[YES] on the “Clear data?” screen and press SELECT.
7. Press TEACH LOCK and turn Servos On. Choose any COORD except
TOOL.
8. If TC1 is not highlighted, press SELECT. Cursor to TC1 and press SELECT.
9. Jog the robot to the pointer until the desired tool control point is located at the
tip of the pointer (see Figure 20-2); press MODIFY and ENTER.
The first point, TC1, is now accepted and the bullet is set ●.

Figure 20-2 Pointer
10. Repeat Steps 8 and 9 four more times, selecting TC2 through TC5.
NOTE: Obtain as much variance as possible when changing the robot’s

orientation between the five TC points.
NOTE: If necessary to view the position where a TC point was set, use the
FWD key to move to the desired TC point. When the highlighted TC
number stops flashing, the robot is at that TC point set location.
11. After all five TC points have been entered, cursor down to COMPLETE and
press SELECT.
Once calculations are completed, the tool display screen, which shows the newly
calculated XYZ dimensions of the tool, appears.
12. If desired, move the cursor to the right side of the screen to input tool angle
dimensions manually as in Section 20.1.
The TCP is now defined. To ensure accuracy of the TOOL data, use the “rotate-
about” keys Rx, Ry, and Rz in WLD or TOOL Coordinates to rotate the tool’s
orientation about the TCP. The TCP should not move off of the point location when
rotated. Also check the X, Y & Z directions of operation in TOOL Coordinates;
the Z+ should operate in the direction of the application such a welding torch’s
direction of wire-feed, the direction of a gripper’s handling process, the direction of
dispensing sealant, etc., or the direction of cutting with water jet, laser, or plasma.

Index
INDEX
A
ACCESSING USER FRAMES, 18-3
ADDING A POSITION LEVEL, 10-5, 10-6
ADDING AN “IF” CONSTRUCT, 16-2
ALARM HISTORY, 5-2
ALARM/ERROR INDICATOR LIGHT, 2-3
ALARMS AND ERRORS, 5-1
AOUT (ANALOG OUTPUT), 17-4
AREA KEY, 3-7
ARITHMETIC VARIABLES AND INSTRUCTIONS, 15-1
AUTO CYCLE, 8-7
AUTOMATIC TCP DEFINITION, 20-3
AXIS KEYS/COORDINATE SYSTEMS, 4-1
B
BATTERY STRENGTH, 3-4
BWD KEY, 8-6
BYTE VARIABLE, 15-1
C
CALL, 14-1
CALLING MASTER JOB TO SCREEN, 7-3
CANCEL, 3-10
CAPACITY, 9-5
CARTESIAN ((USER) COORDINATE SYSTEM, 18-1
CARTESIAN COORDINATE SYSTEM, 4-2
CHANGE SPEED, 11-3
CHANGING MOTION TYPES, 10-4
CHECK-RUN, 12-3
CIRCULAR, 8-8
CLEAR, 15-6
COMMAND POSITION, 4-7
COMMENTING, 14-8
CONDITIONAL “IF” CONSTRUCT, 16-1
CONTROL INSTRUCTIONS, 14-1
CONTROL POWER ON/OFF SWITCH, 1-1
COORD KEY, 4-6
COORDINATES/AXES, 4-1
COPY (JOB), 9-1
COPY/PASTE, 10-7
CREATING A JOB, 7-1
CREATING USER FRAMES, 18-1
CURSOR KEY, 3-7
CURSOR LOCATIONS, SUMMARY OF, 10-3
CURSOR UP/DOWN WITH SHIFT, 3-11
CUT & PASTE, 10-7
CYCLE SELECTION, 8-7
CYCLE TIME DISPLAY, 11-6
XRC Basic Programming Manual Page INDEX-1 MOTOMAN

Index
D
DEC (DECREMENT), 15-4
DELETE A STEP 10-3
DELETE JOB, 9-2
DELETE KEY, 3-11
DELETING A POSITION LEVEL FROM A STEP, 10-6
DELETING A STEP, 10-6
DETAIL EDIT, 10-10
DIN (DIGITAL INPUT), 17-7
DIRECT OPEN, 14-5
DISPLAY AREAS, 3-2
DISPLAY DETAIL/SIMPLE, 17-3
DISPLAY SCREEN, 3-1
DISPLAY, 3-1
DISPLAYING COMMAND/CURRENT POSITION, 4-7
DISPLAYING CYCLE TIME, 11-6
DISPLAYING MAJOR AND MINOR ALARM LISTS, 5-2
DISPLAYING POSITION (PULSE/XYZ), 4-7
DISPLAYING THE CONTENT OF THE ACTIVE JOB, 7-2
DISPLAYING THE CONTENT OF THE ACTIVE JOB, 7-3
DISPLAYING ARITHMETIC VARIABLES, 15-1
DOUT (DIGITAL OUTPUT), 17-1
DOWN CURSOR, 3-7
DRY-RUN SPEED, 12-2
E
EDIT (DETAIL SCREEN), 10-7
EDIT (GENERAL LINE EDITING), 10-6
EDIT LOCK KEY SWITCH, 2-3, 19-1
EDIT PROTECTION, 19-1
EDITING SECURITY LEVEL, 3-5
EDITING FROM JOB LIST, 9-1
EDITING KEYS, 3-10
EDITING VARIABLES, 15-2
ENABLE/DISABLE, 3-8
ENTER, 3-10
ERROR MESSAGES, 5-1
E-STOP, 2-1, 3-9
EXTERNAL AXIS KEY, 4-7
F
FWD KEY, 8-6
G
GENERAL LINE EDITING, 10-9
GENERAL DISPLAY AREA, 3-2

Index
H
HIGH SPD KEY, 4-6
HOLD, 2-2
HUMAN INTERFACE DISPLAY AREA, 3-4
I
IF CONSTRUCT, 16-1, 17-7
IG# - DIN, 17-7
IN# - MONITOR UNIVERSAL INPUT, 17-6
I/O INSTRUCTIONS, 17-1
IN/OUT (ICON, TOP MENU), 3-6
INC (INCREMENT), 15-3
INPUT BUFFER LINE, 3-4
INPUT LINE, 3-4
INSERT KEY, 3-11
INSERTING A STEP, 10-2
INTERLOCK KEY, 3-12
INTERLOCK/SELECT (OUTPUTS), 17-4
INTERLOCK/TEST START, 8-6
J
JOB, DISPLAY ACTIVE, 7-3
JOB , SELECT, 7-2
JOB, COPY, 9-1
JOB, DELETE, 9-2
JOB LISTS, 9-3
JOB, CREATE NEW, 7-1
JOB, RENAME, 9-2
JOINT COORD (SLURBT), 4-2
JUMP, 14-6
K
KEYPAD, 3-10
L
LABEL, 14-7
LINE EDIT, DETAIL, 10-10
LINE EDIT, GENERAL, 10-9
LINEAR, 8-2
LINKING JOBS WITH CALL, 14-1
LISTS, JOB, 9-3
LOW SPEED START, 12-1

Index
M
MACHINE LOCK, 12-4
MAJOR ALARMS, 5-1
MAN SPD KEYS, 4-6
MANAGEMENT SECURITY LEVEL, 3-5
MANUAL TCP DEFINITION, 20-1
MASTER JOB, 7-2
MENU AREA, 3-3
MESSAGE LINE, 3-4
MINOR ALARMS, 5-1
MODE BUTTONS, 2-2
MODIFY KEY, 3-11
MODIFYING A STEP POSITION, 10-3
MONITORING ANALOG OUTPUTS, 17-4
MONITORING UNIVERSAL INPUTS, 17-6
MONITORING UNIVERSAL OUTPUTS, 17-3
MOTION TYPE KEY, 8-1, 8-3
MOTION TYPE, 8-1
MOTION TYPES PROGRAMMED AS ONE POSITION STEP, 8-2
MOTION TYPES REQUIRING THREE OR MORE MOTION STEPS, 8-8
MOTION TYPES, 8-1
N
NAMING A JOB ALPHANUMERICALLY, 7-1
NESTING JOBS WITH CALL, 14-2
O
OT# ( ) MONITOR UNIVERSAL OUTPUTS, 17-3
OG# ( ) DOUT TO GROUPS, 17-9
OPERATING SECURITY LEVEL, 3-5
OPERATION CYCLE, 8-7
OPERATION MODE, 2-2
OPERATION ORIGIN, 4-8
OVERLAPPING FIRST AND LAST STEPS, 8-4
P
PANEL MODE BUTTONS, 2-2
PANEL OPERATION BUTTONS, 2-1
PASTE, 10-8
PATH CONFIRMATION, 8-6
PATH CORRECTION, 10-2
PATH CREATION, 8-1
PATH EDITING, 10-1
PAUSE, 14-9
PLAY MODE, 2-2
PLAY SPEED, 8-2
PLAYBACK PANEL, 2-1
PLAYING A JOB, 8-8
POSITION, DISPLAYING, 4-7
POSITION LEVEL SPECIFICATION, 10-4

Index
POWERING UP THE XRC, 1-1
PROGRAMMING “IF” CONSTRUCT, 16-2
PROGRAMMING PENDANT, 3-1
PROTECTION, EDIT, 19-1
PULSE (DIGITAL OUTPUT), 17-2
R
REGISTRATION OF MASTER JOB, 7-3
REMOTE MODE, 2-3
ROBOT KEY, 4-7
RENAME JOB, 9-2
RET (RETURN), 14-3
REVERSE PASTE, 10-9
RS-232C 9 PIN SERIAL PORT (EIA-232D), 3-9
S
SECURITY LEVELS, 3-5
(SLURBT) - JOINT COORDINATE , 4-2
SECOND HOME POSITION (SPECIFIED POINT), 6-1
SELECT KEY, 3-7
SELECTING A JOB, 7-2
SELECTING A POSITION LEVEL DURING INITIAL
SERVO ON READY, 2-2, 3-8
SET, 15-5
SHIFT KEYS, 3-11
SOFTWARE EDIT PROTECTION, 19-1
SOFTWARE EDIT PROTECTION LEVELS, 19-2
SPECIAL PLAYBACK MODES, 12-1
SPECIFIED POINT (SECOND HOME POS.), 6-1
SPEED CORRECTION/ADJUSTMENT, 11-1
SPEED LIMIT, 12-2
SPEED CHANGE, 11-3
SPLINE, 8-9
START BUTTON, 2-1
STATUS DISPLAY AREA, 3-3
SYSTEM STATUS, 3-3
STEP (CYCLE), 8-7
T
TEACH LOCK, 3-8
TEACH MODE, 2-3
TEACHING POSITIONS AS PROGRAM STEPS, 8-3
TIMER, 14-9
TOOL CENTER POINT DEFINITION, 20-1
TOP MENU KEY, 3-5, 3-6
TRAVERSE RUN TIME (TRT), 11-5

Index
U
USER FRAMES, 18-1
USER FRAMES, CREATING, 18-2
USER FRAMES, ACCESSING, 18-3
V
VARIABLES WITH “IF” CONSTRUCT, 16-1
VARIABLES, 15-1
W
WAIT, 17-5
X
XYZ COORD- WORLD, CYLINDRICAL, TOOL, OR USER, 4-2
XRC START-UP, 1-1
XRC SHUTDOWN, 1-2

XRC Basic

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XRC Robot Controller

XRC Basic Programming

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WHO SHOULD USE THIS MANUAL

HOW TO USE THIS MANUAL

XRC Basic Prograamming Manual Table of Contents-1 © MOTOMAN

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XRC Basic Prograamming Manual Table of Contents-10 © MOTOMAN

1.0 XRC START-UP AND SHUTDOWN

1.1 POWERING UP THE XRC

Main Power Switch

Figure 1-1 Main Power Switch or Circuit Breaker (ON)

If a failure occurs, an error message is displayed on the LCD screen of the

XRC Basic Programming Manual Page 1-1 © MOTOMAN

1.2 TURNING OFF POWER TO THE XRC

Main Power Switch

Playback Panel EMERGENCY

Figure 1-2 Main Power Switch (OFF)

XRC Basic Programming Manual Page 1-2 © MOTOMAN

2.0 PLAYBACK PANEL

Figure 2-1 Playback Panel

2.1 PANEL OPERATION BUTTONS

XRC Basic Programming Manual Page 2-1 © MOTOMAN

2.1.4 Servo On Ready

In PLAY mode, fully depressing the SERVO ON READY button initiates a

2.2 PANEL MODE BUTTONS

2.2.1 Play Mode

XRC Basic Programming Manual Page 2-2 © MOTOMAN

2.2.2 Teach Mode

2.2.3 Remote Mode

2.3 ALARM/ERROR INDICATOR LIGHT

If an error or alarm occurs, the ALARM/ERROR indicator light illuminates and

2.4 EDIT LOCK KEY SWITCH

XRC Basic Programming Manual Page 2-3 © MOTOMAN

XRC Basic Programming Manual Page 2-4 © MOTOMAN

3.0 PROGRAMMING PENDANT

Figure 3-1 Programming Pendant

3.1 DISPLAY SCREEN

XRC Basic Programming Manual Page 3-1 © MOTOMAN

3.1.1 Display Areas

The screen is divided into four areas, as shown in Figure 3-2.

GENERAL DISPLAY AREA

HUMAN INTERFACE AREA

Figure 3-2 Display Areas

Figure 3-3 Screen Title

XRC Basic Programming Manual Page 3-2 © MOTOMAN

3.1.2 General Purpose Display Area

3.1.3 Menu Area

3.1.4 Status Display Area

Joint, World, Cylindrical, Tool, or User Frame

Manual Speed Setting

Inching, Low, Medium, or High

Step, 1-Cycle, or A Auto

E-Stop, Stop, Running/Start, Hold, or Alarm

The symbol for additional pages when applicable.

XRC Basic Programming Manual Page 3-3 © MOTOMAN

3.1.5 Human Interface Area