COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

Kawasak
C CONTROLLER ARC WELDING
OPERATIONS AND PROGRAMMING
MPOCARCW20E

Kawasak
Kawasaki Robotics (USA), Inc.
 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted
without the express written permission of Kawasaki Robotics (USA), Inc. The contents
of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical,
electrical, photocopy, facsimile, or electronic data media, without the express written per-
mission of Kawasaki Robotics (USA), Inc.

All Rights Reserved.

Copyright © 2000, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393

The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.

This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.

KAWASAKI ROBOTICS (USA), INC. TRAINING

Training courses covering operation, programming, electrical maintenance, and me-

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

For additional information contact:

Kawasaki Robotics (USA), Inc.

Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
 C CONTROLER
Kawasak

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ARC WELDING OPERATIONS AND PROGRAMMING MANUAL

REVISION HISTORY

Revision Release
Description of Change Initials
Number Date

-0 5/23/00 Initial release, based on rev. 0 of print copy CB

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INTRODUCTION

I.0 INTRODUCTION ................................................................................................. I-2

I.1 Mechanical Unit................................................................................................... I-2
I.1.1 Mechanical Unit Design Specifications ............................................................... I-3
I.2 Robot Controller .................................................................................................. I-4
I.2.1 Robot Controller Design Specifications ............................................................... I-4

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I.0 INTRODUCTION

The C Controller Arc Welding Operations and Programming Manual is designed to

assist the user whose primary responsibility is to program and operate the Kawasaki arc
welding robot on a daily basis. This manual provides specific information on safety,
basic operation, programming path and auxiliary data, setting the Auxiliary Data
screens, and error information.

I.1 MECHANICAL UNIT

The Kawasaki FS-series AC servo driven industrial robot is an articulated coordinate-

type robot designed for many applications in the industrial environment. The robot, with
its AC servo closed-loop drive system, is built with high rigidity. This design allows it to
perform tasks that require high accuracy, speed, and wrist load capacities, while achiev-
ing significant energy reduction through the use of high efficiency brushless AC servo
motors.

The mechanical unit has six standard axes and may be configured for up-to twelve axes.

The major axes are:

• JT1 (R-axis) rotary; rotation of the base

• JT2 (O-axis) out and in; rotation of the lower arm
• JT3 (D-axes) down and up; rotation of the upper arm

The minor axes are:

• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

• JT5 (B-axis) bend; provides pitch/yaw wrist motion
• JT6 (T-axis) twist; provides rotation of the tool only

The Kawasaki robot system supports Cartesian coordinate motion which includes:

• Base (World) coordinates

• Tool coordinates

These coordinate systems are used manually when operating the robot in the teach
mode. The coordinate systems are used by program instructions for shifting programs
(positional data), defining tool center points, and recording positional data. The left-
hand-rule applies to Kawasaki robot systems to determine the orientation of the base
and tool coordinate systems.

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I.1.1 MECHANICAL UNIT DESIGN SPECIFICATIONS

Table I-1 Robot Specifications

ROBOT MODEL FS06E FS06L FS06N FS20N

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)*
JT1 200°/sec 200°/sec 240°/sec 160°/sec
JT2 140°/sec 140°/sec 200°/sec 140°/sec
JT3 200°/sec 200°/sec 250°/sec 160°/sec
Maximum JT4 360°/sec 430°/sec 430°/sec 330°/sec
Velocity JT5 360°/sec 430°/sec 430°/sec 330°/sec
JT6 600°/sec 600°/sec 720°/sec 500°/sec
1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1200 mm/sec
JT7
(47.24) (47.24) (47.24) (47.24)
Maximum Linear 9,200 mm/sec 8,250 mm/sec 8,000 mm/sec 8,500 mm/sec
Tool Tip Speed (362.2) (324.8) (314.9) (334.6)
JT1 ±160° ±160° ±160° ±160°
JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105°
JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225°
Work
JT4 ±270° ±270° ±270° ±270°
Envelope
(Stroke) JT5 ±145° ±145° ±145° ±145°
JT6 ±360° ±360° ±360° ±360°
Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths
Max. Payload
6 (13) 6 (13) 6 (13) 20 (44)
(lbs.)
39.3 N m
JT4 12 N m (8.8) 12 N m (8.8) 12 N m (8.8)
(28.9)
Wrist Rated
JT5 39.3 N m
Torque 12 N m (8.8) 12 N m (8.8) 12 N m (8.8)
(28.9)
(ft. lbs.)
JT6 19.6 N m
6 N m (4.4) 6 N m (4.4) 6 N m (4.4)
(14.4)
JT4 0.24 kg m s2 0.24 kg m s2 0.24 kg m s2 0.88 kg m s2
(1.72 ) (1.72 ) (1.72 ) (6.37)
Wrist Rated
JT5 0.24 kg m s2 0.24 kg m s2 0.24 kg m s2 0.88 kg m s2
Moment of
(1.72) (1.72) (1.72) (6.37)
Inertia
0.07 kg m s2 0.07 kg m s2 0.07 kg m s2 0.25 kg m s2
JT6
(0.51) (0.51) (0.51) (1.81 )
Repeatability (in.) ±0.1 (0.004) ±0.1 (0.004) ±0.05 (0.002) ±0.1 (0.004)
JT1 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 2.1 kw (2.82)
JT2 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 2.1 kw (2.52)
JT3 475 w (0.64) 475 w (0.64) 475 w (0.64) 1.0 kw (1.34)
Drive
JT4 100 w (0.13) 100 w (0.13) 100 w (0.13) 200 w (0.27)
Source (hp)
JT5 100 w (0.13) 100 w (0.13) 100 w (0.13) 200 w (0.27)
JT6 100 w (0.13) 100 w (0.13) 100 w (0.13) 200 w (0.27)
JT7 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)
Weight 6
125 kg (276) 115 kg (254) 110 kg (243) 210 kg (463)
(lbs.) Axes

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INTRODUCTION

I.2 ROBOT CONTROLLER

The Kawasaki C controller consists of printed circuit boards, multi function panel or
teach pendant, optional interface panel, and servo amplifiers. The controller is available
in three versions; standard, North American, and European. Table I-2 lists the various
robot models (FS00x) and codes for the controller type (Cxx).

Table I-2 Robot Controller Versions

C Controller
Type and Code
Robot Standard North Amer. European
Model Specification Specification Specification
FS06E C11, C50 C30 C40
FS06L C11, C50 C30 C40
FS06N C11, C50 C30 C40
FS20N C11, C50 C30 C40

I.2.1 ROBOT CONTROLLER DESIGN SPECIFICATIONS

Cotrol System: 32 bit RISC main CPU

32 bit RISC CPU for multi function panel unit
32 bit RISC servo CPU controller (one per 3 axes)
Software controlled AC servo drive system using PWM
(pulse width modulation) circuitry

Number of Axes: 6 standard; 7 through 12 optional

Motion Control: Teach mode - Joint

Base
Tool

Repeat mode - Joint move

Linear move
Circular move
FLIN move (optional)
Cooperative motion (optional)

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Memory: CMOS RAM

Memory Capacity: Standard - 1024 KB (approx. 9,000 steps)

Optional - 4096 KB (approx. 36,000 steps)

Accuracy: Four levels for block step programs

(adjustable between 0.1 mm - 5,000 mm)

Speed: 10 levels for block step programs

(adjustable between 0% - 100%)

Data Editing: Step insertion and deletion

Rewriting of auxiliary and positional data.

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

Time delays
Coordinate modification
Process control programs (three)
Peripheral equipment control
Interrupt signal control
Error interrupt control
Input of real, string, and interger variables
Local variables
Subroutine calls with arguments (maximum stack=20)
Program weld conditions, direct and indirect
Servo shutdown timer
Auto start function

I/O Signals: 1GW I/O board 32 inputs/32 outputs (128 maximum

including dedicated signals)

1FS RI/O board (option)

Robot I/O 256 I/O (including dedicated signals)
Robot internal 256
A-B PLC 64 I/O
Non-retentive 128 I/O
Retentive 16 I/O
Timers 16 I/O
Counters 16 I/O
Message display 64 I/O
Slogic status 16 I/O

Control Net (option)

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Dedicated Signals: Outputs - Motor power ON

Error occurrence
Automatic
CYCLE_START
Teach mode
HOME1
HOME2
Power ON
RGSO
Ext. program select (RPS) enabled
Positioner ON signal
Positioner SPEED signal
WCR
WELD_ON/OFF
ROBOT_HOLD

Dedicated Signals: Inputs - Ext. motor power ON

Ext. error reset
Ext. cycle start
Ext. program reset
Ext. program select start (JUMP)
JUMP_ON
JUMP_OFF
JUMP_ST
Ext. program select (RPS)
RPS_ON
RPS_ST
Number of RPS code signals
First signal number of RPS code
Program reset
Ext. hold (EXT_IT)
Ext. slow repeat mode
Ext. weld signal
Wire retract signal
Positioner OFF signal
EXT_HOLD_RESET

Message Displays: Error code messages, self-diagnosis, error logging,

operation logging

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Special Features: Program check mode

Adjustable restriction of JT1, JT2, JT3
Terminal box on robot arm (optional)
Robot application interface panel (optional)
Power lockout
Ethernet (option)

Multi Function Panel: Enabling device (deadman safety switches)

(option) 8 inch color LCD
Touch panel
Teach-lock function
Emergency stop switch
Pen for touch panel
PC card insertion section

Teach Pendant: Enabling device (deadman safety switches)

(option) Teach-lock function
Emergency stop switch
Membrane switch keypad
Alphanumeric LCD

Supplemental
Data Storage: PC SRAM memory card, 2 or 4 MB, PCMCIA 2.1 slot
Floppy disk drive (option)
Personal computer (option)

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Power Requirements: Standard Spec.: 3-phase 200/220 VAC

North Am Spec.: 3-phase 400/440/460/480/515/575 VAC

European Spec.: 3-phase 380/400/415/440/460/480 VAC

Tolerance: +/- 10%

Frequency: 50/60 Hz

Rated Load: 10.5 kVA

Ground: less than 100 ohm ground line separated

from welder power ground

Dimensions: Standard Spec.: W x D x H, 460.8mm x 430mm x 1240mm

(inches: 18.1 x 16.9 x 48.8)

North Am. Spec.: WxDxH, 550mm x 500mm x 1150mm

(inches: 21.7 x 19.7 x 45.3)

European Spec.: WxDxH, 550mm x 500mm x 1150mm

(inches: 21.7 x 19.7 x 45.3)

Weight: Standard Spec.: approx. 80 kg (176 lbs)

North Am. Spec.: 250 kg (550 lbs)

European Spec.: 250 kg (550 lbs)

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OVERVIEW

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

1.1 Major Features of the Robot System.................................................................. 1-2
1.2 Major Components Of The Robot System ......................................................... 1-3
1.3 User Interface Devices ....................................................................................... 1-5
1.3.1 Multi Function Panel............................................................................................ 1-6
1.3.2 SRAM PC Card.................................................................................................... 1-6
1.3.3 Small Teach Pendant.......................................................................................... 1-7
1.3.4 Controller Switch Panel ...................................................................................... 1-8
1.3.5 Personal Computer ............................................................................................ 1-9
1.3.6 Optional Interface Panel ..................................................................................... 1-9
1.3.7 Software Interface Panel .................................................................................. 1-10
1.3.8 Floppy Disk Drive Unit ...................................................................................... 1-11
1.4 Robot Controller Main Circuitry Overview ........................................................ 1-12
1.5 C Series Controller Digital Servo Control Overview ......................................... 1-15
1.6 Mechanical Unit Overview ................................................................................ 1-17

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OVERVIEW

1.0 OVERVIEW

1.1 MAJOR FEATURES OF THE ROBOT SYSTEM

The Kawasaki F-series robot system consists of a mechanical unit, controller, controller
software, and supporting peripheral equipment. The following major features are sup-
ported by C-series controllers:

• Joint coordinate movement

• Linear movement in Base and Tool coordinate systems

• Circular movement

• Fixed linear interpolation (FLIN) movement (optional)

• Cooperative motion with external axes (optional)

• Block step programming

• AS Language programming

• User friendly menu system for programming and system configuration

• Multi-tasking with the capability to run three Process Control programs

• Error message display, self diagnosis

• Error and operation logging

• Digital and analog input/output interface

• PC Programming

• Remote I/O with Slogic programming or ControlNet, Ethernet compatible (option)

• Bilingual menus

• Program editing, storage, and monitoring via personal computer

• Software controlled AC servo drive system and excellent mechanical unit design
provide accurate, repeatable, high speed program playback .

• High mechanical unit efficiency and smooth arm movement are assured through the
use of close tolerance bearings, gears, and speed reducers.

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The robot system, with proper tooling and interface, is capable of performing many tasks
in the industrial environment including gas metal arc welding, gas tungsten arc welding,
and plasma cutting.

1.2 MAJOR COMPONENTS OF THE ROBOT SYSTEM

The two major components of the robot system are the controller and mechanical unit.
The C-series controllers are illustrated in figures 1-1 through 1-3. The F-series me-
chanical units are illustrated in figure 1-4.

Figure 1-1 Standard C Controller

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OVERVIEW

ON OFF

TEACH LOCK

EMERGENCY STOP

ERROR MOTOR POWER

ERROR RESET CYCLE START

TEACH REPEAT HOLD RUN

HOST

MFP
AC115V 1A

Figure 1-2 European C Controller

ON OFF

TEACH LOCK

EMERGENCY STOP

ERROR MOTOR POWER

ERROR RESET CYCLE START

TEACH REPEAT HOLD RUN

HOST

MFP
AC115V 1A

Figure 1-3 North American C Controller

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OVERVIEW

Figure 1-4 F-Series Mechanical Units

1.3 USER INTERFACE DEVICES

The user interface devices include the following:

• Multi function panel (option)

• PC card (option)

• Small teach pendant (option)

• Controller switch panel

• Personal computer (PC) using KCMON or KCWIN monitor software (option)

• Optional interface panel

• Optional software programmed interface panel with multi function panel

• USER 2000 software for interfacing with the Servo Robot vision system (option)

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1.3.1 MULTI FUNCTION PANEL

The multi function panel, shown in figure 1-5, is equipped with a back lit 8 inch color
graphics LCD (liquid crystal display) touch panel, PC card slot, teach lock switch, en-
abling device (deadman switches), and emergency stop switch.

All of the robot functions are accessible through the multi function panel including sys-
tem configuration, teaching, and program editing. In addition, an SRAM (static random
access memory) PC card inserted into the multi function panel can be used for program
and system configuration upload/download or system software download.

ON OFF

TEACH LOCK

Figure 1-5 Multi Function Panel

1.3.2 SRAM PC CARD

The SRAM PC card is used to upload/download programs and system configuration

data, and install new AS software, multi function panel, and servo system software. PC
cards are available in 1 MB, 2 MB and 4 MB capacities. The PC card utilizes batteries to
maintain its memory and is not considered a permanent backup media for data. For a
permanent data backup, download the contents of the PC card onto the floppy disk or
hard disk of a PC.

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1.3.3 SMALL TEACH PENDANT

The small teach pendant, shown in figure 1-6, provides basic teaching and manual
operation capabilities for the robot. Program editing and system configuration are not
accessible through the small teach pendant.

Kawasak

ARM
WRIST
3Z 2Y
1 1
X X
3Z 2Y

TRG TRG
W A
TRG TRG
J W A
REC B
T JOG

CL3 CL4
RST S CHK
CL1 CL2

Figure 1-6 Small Teach Pendant

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1.3.4 CONTROLLER SWITCH PANEL

The controller switch panel, shown in figures 1-7 and 1-8, is composed of switches used
to apply motor power, cycle start programs, hold or stop programs, select operation
modes, and reset errors. An hour meter that indicates controller power on time, a con-
trol power lamp, and error lamp are also included. On the North American and Euro-
pean controllers, the hour meter indicates servo motor power on time. The North Ameri-
can and European switch panels are configured differently than the standard panel. The
same switches are included but the hour meter and control power lamp are placed to
the left of the controller door.

CONTROL ERROR ERROR RESET HOLD RUN TEACH REPEAT CYCLE START MOTOR POWER EMERGENCY STOP
POWER
HOUR METER

Figure 1-7 North American/European Switch Panel

EMERGENCY STOP

ERROR MOTOR POWER

ERROR RESET CYCLE START

TEACH REPEAT HOLD RUN

HOST

MFP
AC115V 3A

Figure 1-8 Standard Controller Switch Panel

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1.3.5 PERSONAL COMPUTER

A PC (personal computer) can be linked to the C controller for program uploading/

downloading, program editing, and system monitoring. The PC requires the Kawasaki
KCMON or KCWIN interface software to communicate with the robot controller.

1.3.6 OPTIONAL INTERFACE PANEL

The optional interface panel is designed to interface with peripheral equipment that is
connected to the robot. The interface panel is located on the robot controller door and is
available in many configurations including custom designs to suit specific applications.
Figure 1-9 illustrates an interface panel typically used for arc welding applications.

AUTO MAINT. RUN MANUAL EXTERNAL

INTLK POS. HOLD WELD / PURGE
HOLD RESET HOLD ON

B G
SS1 PB2 PL1
KS2

NO
WELD WELD

ROBOT
BYPASS
AUTO LINE
INTLK BYPASS SS2

KS3

TEACH
EMERGENCY STOP
OFF ON

KS1 PB1

Figure 1-9 Optional Interface Panel

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1.3.7 SOFTWARE INTERFACE PANEL

The optional software interface panels are programmed and displayed with the multi
function panel. The software interface panels are designed to interface the robot with
peripheral equipment used in the automated process. The interface panel must be
programmed by the user and can support the creation of lamps, switches, and digital
displays. Figure 1-10 shows the software interface panel configured for an arc welding
operation.

IN T E R FA C E PA N E L (1/2)
A U TO M A N U O FF LIN E
O FF WORK PROGRAM
Torch Maint. KIND No.
HOME
Clean Pos. 0 02 2 0 02 2

MODE MODE
M ANUAL O FF
A U TO O FF -L IN E 0 22 0 22
A U TO

00 00

0 0

Figure 1-10 Software Interface Panel

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1.3.8 FLOPPY DISK DRIVE UNIT

The optional floppy disk drive unit (figure 1-11) is a portable disk drive used to upload
and download programs to the C controller. The floppy disk drive unit is connected to
the host communication port and the AC outlet on the front of the controller door. For
more information about program upload and download procedures using the floppy disk
drive, refer to unit 11 of this manual.

Figure 1-11 Floppy Disk Drive Unit

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OVERVIEW

1.4 ROBOT CONTROLLER MAIN CIRCUITRY OVERVIEW

The Kawasaki C controller circuit board block diagram shown in figure 1-12 illustrates
the major printed circuit boards inside of the controller.

The 1GA board is the main central processing unit (CPU) board in the C controller and
is equipped with a 32 bit reduced instruction set computer (RISC) running at 32 MHz.
AS Language, program, and servo software data is stored in FLASH memory. User
programs and system configuration data reside in battery backed static random access
memory (SRAM). The standard SRAM (1 MB) can be expanded to 4 MB. A super
capacitor on the 1GA board provides approximately 30 minutes of memory backup
when the board is removed from the card rack. When the board is reinstalled the super
capacitor is recharged by the 3.6 volt lithium batteries located on the motherboard
(1HZ). The 1GA board processes the data needed for the execution of the AS Lan-
guage software, operation planning, servo position loop operations, coordinate conver-
sions, path planning, and detection of abnormal +/- 12 VDC and +5 VDC levels. The
1GA board communicates with the servo board (1GB), power circuit control board
(1HP), I/O boards (1GW, 1FS), optional boards for vision, or analog input (IP), multi
function panel, small teach pendant, and external equipment such as a personal com-
puter.

The 1GB board is the servo CPU. The standard 1GB board is equipped with two RISCs
that control six axes. The optional 1GB board is equipped with a third RISC to control a
seventh robot axis and allow a conveyor input for line tracking. The 1GB board receives
path data from the 1GA board, encoder data from the robot axes and conveyor, and
current data from the current detect modules, to generate the pulse width modulation
(PWM) signals that are sent to the intelligent power modules (IPM) located on the power
block. The IPMs, in turn, allow current to flow through the three phase servo motor
windings and produce motor rotation. A 1GM board is attached to the 1GB board to
provide an interface for the current sensors. In addition, the 1GB board also controls
servo motor brake functions, overtravel limit switch signal processing, and servo system
error processing.

The 1GC or 1GD board is the servo system power block. The 1GC board is used for
robots with payload capacities of 30 kg or more and the 1GD board is used for robots
with payload capacities lower than 30 kg. The power block is comprised of two sections:
the power unit and the amplifier. The power unit section rectifies and filters three phase
AC power for use by the servo motors, monitors DC voltage levels, controls regenerative
voltage levels, and reports voltage level and regenerative resistor circuit errors. The
amplifier section receives PWM signals from the 1GB board. The PWM signals are
used by the IPMs to control current flow through the servo motor windings. Current
detect modules are used to send current level data back to the 1GB board to indicate
robot load. The amplifier section also incorporates various protective functions that are
monitored by the 1GB board.

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The 1HP board controls the power up sequence of the controller and serial communica-
tion for the multi function panel/small teach pendant and 1GA/1GB board. In addition,
the 1HP board powers down the controller if an abnormality of the +/-12 VDC, +5 VDC,
or 24 VDC levels exists.

The 1GW board is a parallel I/O board providing 32 input channels and 32 output chan-
nels including dedicated signals. An optional 1GW board is available that provides two
channels of analog output in addition to the 32 parallel input/output channels. Up to four
1GW boards can be installed in the C controller for a total of 128 inputs and outputs and
two channels of analog output.

The 1FS board (optional) is available in two versions: R/IO and RS485 communication
or ControlNet communication. The board is equipped with a 32 bit RISC processor
running at 20 MHz and 2 MB or 4 MB of FLASH memory for software/Slogic program
storage. The RI/O version 1FS board can be configured as a remote rack of a PLC and
provides serial PLC and weld timer communication.

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OVERVIEW

MULTI FUNCTION PANEL 1GA

1FT RISC
COLOR LCD MEMORY
TOUCH PANEL MULTI FUNCTION PANEL I/F
PC CARD READER PATH PLANNING
COORDINATE CONVERSION
VOLTAGE MONITORING
CONTROL PANEL
SWITCHES & LAMPS
AVR
+5 VDC

1HZ (VME BUS) +12 VDC

-12 VDC
+24 VDC

1HP 1GW 1FS (OPTION) OPTION PCBs

POWER CONTROL I/O RELAYS REMOTE I/O VISION
VOLTAGE MON. ANALOG OUTPUT CONTROL NET ARC I/F
SERIAL COMM.

1GB
A B C
JOINTS 1, 2, 3 JOINTS 4, 5, 6 JOINT 7, CONVEYOR
RISC RISC RISC
ENCODER I/F ENCODER I/F ENCODER I/F

BRAKE CONTROL SEQUENCE

1GM

PWM CURRENT BRAKE

FEEDBACK
ENCODER
FEEDBACK
1GC (Large Type)
or
1GD (Small Type)
IPM SERVO MOTOR

CURRENT DETECT MODULES

1FG
200 VAC POWER UNIT
BATTERY BACKUP
+12VDC to +5VDC
H20/M21
ENCODER

Figure 1-12 Circuit Board Block Diagram

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OVERVIEW

1.5 C SERIES CONTROLLER DIGITAL SERVO CONTROL OVERVIEW

This section provides general information on the operation of the digital servo drive
system and circuitry. Figure 1-13 provides a block diagram of the servo amplifier. For
additional information on this subject, reference Kawasaki’s C Series Controller Electri-
cal Maintenance Manual.

There are four major components in the C controller servo drive system:

• Power block assembly

• 1GB board and servo software

• AC servo motor assembly

• Hybrid encoder assembly

The 1GB board receives path data from the 1GA board, encoder data from the robot
axes, external axes and load data from the current detect modules. The servo software
uses these signals to calculate and produce an all digital command signal. The com-
mand signal is combined with a triangular wave reference signal to determine the sam-
pling rate of the command signal and to generate the PWM (pulse width modulation)
signals that are sent to the IPMs (intelligent power modules) located on the power block.

A PWM signal is a pulsed signal with a width or duration that is changed proportionally
to motor demands. For example, when the motor starts from a stopped condition, the
width of the PWM signals are very wide in order to overcome inertia, in comparison to
the PWM signals required to sustain motor velocity.

The power block is comprised of two sections: the power unit and the amplifier. The
power unit receives 210 VAC/60 Hz input power from the main transformer assembly.
This voltage is filtered and rectified to provide 300 VDC to the IPMs. The amplifier
section receives the PWM signals from the 1GB board. The PWM signals are used by
the IPMs to control current flow through the servo motor windings. The IPMs are ar-
ranged in pairs, with each pair connected to a specific motor winding. When the IPMs
are gated by the PWM signals, current flows through the U, V, and W phases of the AC
servo motor causing motor rotation.

Current detect modules located on the power block provide feedback to indicate the
current levels of the U and V phases. Signals from the modules are sent to the 1GB
board where they are used to calculate the W phase current, determine torque require-
ments, and detect overcurrent errors and current limiter conditions that could damage
the servo motor and power block.

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OVERVIEW

The hybrid (both magnetic and optical data) encoder assembly is mounted to the end of
the servo motor and coupled to the servo motor shaft. Its function is to sense the servo
motor shaft position, direction of rotation, and velocity. This data is sent to the 1GB
board for phase calculation and processing by the software position and velocity loop
amplifiers.

W
SERVO MOTOR

ENCODER
H20/M21
U

V
CD

CD

IGBT
IGBT

Control

Control
Wø
IC

IC
IGBT

IGBT
IPM

HIC
Control

Control
Vø

+15 VDC
IC

IC
IGBT

IGBT

REGENERATION
SIGNAL
Control

Control
Uø
IC

IC

MONITORING
N

VOLTAGE
P

MODULE
DIODE
R

T
AC 200V

PWM

ENCODER SIGNAL
CURRENT FEEDBACK
+12 VDC

IPM ERR
ERROR SIGNAL

BOARD
1GB
TO

Figure 1-13 Servo Amplifier Block Diagram

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OVERVIEW

1.6 MECHANICAL UNIT OVERVIEW

The mechanical unit consists of the arms, linkages, and drive components necessary to
provide smooth, accurate, and repeatable movement for consistent teaching and pro-
gram playback. The typical mechanical unit provides six axes of motion and is available
in a variety of configurations that are suited for numerous applications under a variety of
conditions. Table 1-1 lists the basic drive components of the robot axes.

Table 1-1 Drive Mechanisms

Robot Drive Mechanisms

FS06 (All) and FS20 (All)
JT1 Cycloidal Reduction Unit
JT2 Cycloidal Reduction Unit
JT3 Cycloidal Reduction Unit
JT4 Harmonic Drive
JT5 Harmonic Drive
JT6 Harmonic Drive

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SAFETY

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

2.1 Introduction ........................................................................................................ 2-2
2.2 Safety Conventions and Symbology .................................................................. 2-3
2.2.1 Warning/Caution Symbols .................................................................................. 2-3
2.3 Safety Categories ............................................................................................... 2-4
2.3.1 Personal Safety .................................................................................................. 2-4
2.3.2 Safety During Operation ..................................................................................... 2-6
2.3.3 Safety During Programming ............................................................................... 2-7
2.3.4 Safety During Inspection and Maintenance ....................................................... 2-8
2.4 Welding Safety ................................................................................................... 2-9
2.5 Safety Features ................................................................................................ 2-10
2.6 Work Envelope Drawings ................................................................................. 2-11

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SAFETY

2.0 SAFETY

2.1 INTRODUCTION

Safety is an important consideration in the use of automated and robotic equipment in

the industrial environment. All operators, maintenance personnel, and programmers
must be aware of all automated equipment, peripheral and robotic equipment that occu-
pies the work cell, and their associated operational and maintenance procedures. For
this reason it is recommended that all personnel who operate, maintain, and program
Kawasaki robots, attend a Kawasaki approved training course that would be pertinent to
each employee’s specific job responsibilities.

The following safety sections in this text are designed to support and augment existing
safety guidelines that may be in use in your plant, and/or are provided by municipal,
state, or federal governments, but are NOT designed to supplant or supersede any
existing rules, regulations, or guidelines that may be in use. Because safety is the
primary responsibility of the user, owner, and/or employer, Kawasaki recommends that
specific safety guidelines and recommendations be adopted from groups or individuals
that are professionals in safety design and implementation.

Two recommended sources for national and federal safety laws and regulations include:

1. OCCUPATIONAL SAFETY AND HEALTH STANDARDS, available from the Depart

ment of Labor, Washington, D.C.

2. AMERICAN NATIONAL STANDARD FOR INDUSTRIAL ROBOTS AND ROBOT

SYSTEMS-SAFETY REQUIREMENTS (ANSI/RIA R15.06-1992), available from the
American National Standards Institute, Inc. 1430 Broadway, New York, New York
10018

All safety related issues and descriptions, either presented in written or oral form from
any representative of Kawasaki Robotics (USA), Inc., are intended to provide general
safety precautions and procedures and, therefore, are not intended to provide all safety
measures necessary for the protection of all personnel in the work environment.

Kawasaki robots are considered safe for use in industrial environments when all safety
guidelines are adhered to. Adherence to the safety guidelines for safe robot operation
and the protection of personnel and equipment is the responsibility of the end user.

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SAFETY

2.2 SAFETY CONVENTIONS AND SYMBOLOGY

2.2.1 WARNING/CAUTION SYMBOLS

The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines, as set forth in the text, are designed to provide
pertinent information for the protection of personnel:

! WARNING
This warning symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
serious injury or death to personnel.

The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines as set forth, are designed to provide pertinent
information for the protection of robotic related equipment:

! CAUTION
This caution symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
damage to robotic or peripheral equipment.

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SAFETY

2.3 SAFETY CATEGORIES

Personnel safety can be described in one of four categories:

• Personal safety

• Safety during operation

• Safety during programming

• Safety during inspection and maintenance

A description of each follows in this section.

2.3.1 PERSONAL SAFETY

Safety procedures must be an integral part of operational procedures for the operator,
programmer, and maintenance person. These procedures must be followed explicitly
and on a regular basis. If consistent safety procedures are followed on a daily basis,
they should become a regular part of everyday operational procedures which are de-
signed to protect the user. Some guidelines are presented in brief in the following sec-
tion:

• Before operating or maintaining the robot or robot controller, be sure you fully un-
derstand and comprehend all maintenance, operating, and programming proce-
dures, and ensure that all safety related precautions are taken and complied with
before these procedures are attempted.

• Avoid wearing loose clothing, scarves, wrist watches, rings, and jewelry when work-
ing on the controller and robot. It is also recommended that if ties must be worn in
your shop environment that they be the clip-on variety rather than tied ties.

• Always wear safety glasses or goggles and approved safety shoes for your shop
conditions. Follow all applicable OSHA, NIOSHA, MHSA, local, state, federal, and
plant safety specifications and procedures.

• Know the entire work cell or area that the robot occupies.

• Be aware of the entire work envelope of the robot and any peripheral devices.

• Locate all emergency stop buttons or switches.

• Avoid trap points in which personnel could become trapped between a moving
device and any stationary devices.

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SAFETY

• Personnel should never enter the work envelope during automatic operations.

• Ensure that all personnel are clear of the work envelope before initiating any motion
commands for the robot.

• Before initiating any motion commands, KNOW beforehand how the robot will per-
form when that command is given.

• Be sure that the entire work area is free of any debris, tools, fixturing, lubricants,
and cleaning equipment before operation of the robot is attempted.

• If any personnel observe unsafe working conditions, report them immediately to the
supervisor or plant safety coordinator.

• All personnel should identify by name and function all switches, indicators, and
control signals that could initiate robot motion.

• Never defeat, render useless, jumper out, or bypass any safety related device,
whether mechanical or electrical in design.

• All safety devices approved for use in your plant must be properly installed and
maintained to ensure personnel safety.

• NEVER attempt to stop or brake the robot during operation with your body or per-
son.

• Utilize E-stops to stop robot motion in emergency situations only.

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SAFETY

2.3.2 SAFETY DURING OPERATION

• During operation of the robot, identify the maximum reach of the robot in all direc-
tions, which is referred to as the work envelope.

• Always keep your work area clean and free of any debris which includes, but is not
limited to, oil, water, tool, fixturing, electronic test equipment, etc.

• During operations that involve teaching, the only person allowed in the work enve-
lope is the teacher, or the person operating the teach interface. The teach interface
has provisions to protect the operator. These safety provisions include an E-stop,
trigger switch, and enabling device (deadman) switch.

• Never block the operator’s path of retreat.

• During the teach operation of the robot always have a path of retreat planned.

• AVOID pinch points.

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SAFETY

2.3.3 SAFETY DURING PROGRAMMING

• During operation of the robot, be sure you are able to identify the maximum reach of
the robot in all directions, which is referred to as the work envelope.

• During teach operations the only person allowed in the work envelope is the
teacher, or the person operating the teach interface. The teach interface has provi-
sions to protect the operator including E-stop, trigger switch, and enabling device
(deadman) switch.

• AVOID pinch points.

• During point-to-point playback operations, be aware that the robot is only cognizant
of its present location and the next point it is requested to move to. It will execute
this move with total disregard to what may lie in its path when the move is executed.

• Playback accuracy and speed can affect the geometry of the path coordinates.
Therefore, when changing accuracy or speed, always test run the program at a slow
speed or point-to-point mode before attempting the continuous path operation in the
repeat mode.

• ALWAYS test run a new path program at a reduced speed or in point-to-point mode
prior to attempting a high-speed playback operation in the repeat mode.

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SAFETY

2.3.4 SAFETY DURING INSPECTION AND MAINTENANCE

Before entering the work envelope to perform either inspection or maintenance proce-
dures, turn off three-phase power on the disconnect and tag and lockout the disconnect
switch.

! WARNING
The input side (top) of the controller disconnect may still
be live when the controller disconnect is turned OFF. If
work is to be performed at the controller disconnect
switch, turn OFF the three-phase power at the source,
and tag and lockout the source disconnect.

• When removing an axis motor, be aware that the axis will fall if left unsupported.
The brake assembly is in the servo drive motor, therefore, the axis of the robot will
be unsupported if removed.

• When using the axis brake release switches in the controller, be aware that the axis
may fall if left unsupported.

• Before working on pneumatic, high pressure water or gas supplies, turn off supply
pressure and purge all lines to remove any residual pressure.

• Assign only qualified personnel to perform all maintenance procedures.

• Consult all available documentation before attempting any repair or service proce-
dures.

• Use only replacement parts approved by Kawasaki Robotics (USA), Inc.

• Before attempting to adjust or repair a device in the robot controller that may have
yellow interlock control circuit wires attached, locate the source of the power and
remove it by disconnecting the appropriate disconnect at its source.

• During inspection and maintenance procedures, if your installation is equipped with

safety fences and safety plugs, remove and hold the safety plug while performing
these operations. In addition, the safety procedures outlined above should be
adhered to.

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SAFETY

2.4 WELDING SAFETY

• Adequate eye protection should be worn during any welding procedure. A Lens
Selector Chart is available in American National Standards Institute’s current publi-
cation #Z49.1. Selection of the proper lens shade number is determined by the type
of welding process being used (e.g., MIG WELDING) and the maximum ampere
setting you are welding with.

• All welding should take place inside areas protected by approved welding curtains.
Refer to current ANSI publication #Z49.1, Section 4.1.3.

• Adequate ventilation is necessary to keep the atmosphere around the operator

clean. Refer to current ANSI publication #Z49.1, Section 5.

• Protect all welding cables and hoses from damage and do not touch any
uninsulated electrodes or connections. Refer to current ANSI publication #Z49.1,
Section 11.

• Handle gas cylinders with care. Use protective cylinder caps whenever cylinders
are being moved or stored. Secure cylinders to a permanent fixture.

• Before connecting a regulator to a cylinder, open the valve slightly for a few seconds
with the opening pointed away from personnel and then close. This should clear out
any dirt or dust that may have accumulated in the cylinder valve. If you see any oil
or other foreign material still present inside the valve opening, do not connect the
regulator and use. Mark and send this tank back to the vender.

• Before opening a cylinder valve, ensure the adjusting screw on the regulator
(gauge) has been backed out. Next, stand so that the regulator is positioned be-
tween you and the cylinder valve. Open the valve slowly. Refer to current ANSI
publication #Z49.1, Section 10.

• Be sure to set the WELD ON/OFF key to OFF before using CHECK MODE, unless
welding is desired.

• Base material will be very hot after welding, do not touch with bare hands.

• Cover all exposed skin when welding. The ultraviolet radiation (UVA and UVB)
causes severe skin burns. The amount of UV radiation increases as the welding
current increases. Refer to the current ANSI publication #Z49.1, Section 11.

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SAFETY

2.5 SAFETY FEATURES

To safeguard the user, the Kawasaki robot system is equipped with many safety fea-
tures. Some of these safety items include:

• All E-stops are hard-wired.

• The teach pendant, multi function panel, and optional interface panel are all
equipped with red mushroom-type E-stop push buttons.

• Robot velocities are constantly monitored by software. Should an over-velocity

condition be detected, the robot will fault in a velocity error condition.

• Teach velocities and check mode velocities are limited to a maximum of 250 mm/
sec (9.84 in/sec).

• The JT1 (R-axis) is equipped with overtravel limit switches (F-series mechanical
units).

• All robot axes have software limits.

• All robot axes are monitored by the robot controller for velocity and deviation errors.

• All robot axes are equipped with 24 VDC electromechanical brakes. Should the
robot lose line power, the robot arm will not drop because the brakes are engaged
when power is off at the robot controller.

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SAFETY
2.6 WORK ENVELOPE DRAWINGS
Figure 2-1 FS06L Work Envelope
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SAFETY
Figure 2-2 FS06N Work Envelope
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SAFETY
Figure 2-3 FS20N Work Envelope
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C SERIES CONTROLLER

3.0 C SERIES CONTROLLER ................................................................................... 3-2

3.1 C Series Controllers ............................................................................................. 3-2
3.2 Control Panel Switches ......................................................................................... 3-5

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C SERIES CONTROLLER

3.0 C SERIES CONTROLLER

This unit provides information about the switches and keys located on the main body of
the controller.

3.1 C SERIES CONTROLLERS

The C-series controller is available in three versions; standard, North American, and
European. The controllers are shown in figures 3-1, 3-2, and 3-3 respectively.

Multi Function
Panel (option)

(4) (7)

(3) (8)

(9)
(1)
(6)
(2) (5)

Teach Pendant or
Multi Function Panel Circuit Breaker
Connector
Power Cable
Opening
Frame for RS-232C
Castor Assistant Connector

Figure 3-1 Standard C Controller

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C SERIES CONTROLLER

Multi Function Panel

Operation Panel
9
Disconnect Switch 3
8
4
7
5

6
I/F Switch Panel RS-232C Connector
AC Outlet

Multi Function Panel

1 Connector (X1)
2

Door Lock

Figure 3-2 North American C Controller

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C SERIES CONTROLLER

Figure 3-3 European C Controller

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C SERIES CONTROLLER

3.2 CONTROL PANEL SWITCHES

The control panel switches are located on the controller door and provide control for
basic robot operations. The function of these components is described in table 3-1.

Table 3-1 Control Panel Switches

No. Switch Function

CONTROL POWER
The white CONTROL POWER lamp indicates that the
1
controller power supply is turned ON.

2 The HOUR METER indicates the total servo motor

power ON time.

ERROR The red ERROR lamp indicates that an error has oc-
3 curred.

ERROR RESET
The yellow ERROR RESET button resets the system
4 and the error lamp is turned off. This switch will not clear
the error if the error is continuous.

HOLD RUN The RUN position allows program execution and robot
5 motion; the HOLD position places the robot into a tempo-
rary stop condition.

TEACH REPEAT

6 The TEACH REPEAT switch selects the teach or

repeat mode of operation.

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C SERIES CONTROLLER

Table 3-1 Control Panel Switches (Continued)

No. Switch Function

CYCLE START
The green CYCLE START switch initiates execution of the
7 selected program. The lamp remains ON during program
execution.
MOTOR POWER
The orange MOTOR POWER switch turns servo motor power ON.
8
The lamp remains ON while motor power is ON.

EMERGENCY STOP The red EMERGENCY STOP switch turns the servo motor
power OFF, the brakes are applied, and the robot stops. The
9
motor power lamp and cycle start lamp are turned OFF.

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POWER ON/OFF PROCEDURES

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

4.1 Controller Power On/Off Procedures .................................................................. 4-2
4.1.1 Controller Power On Procedures ....................................................................... 4-2
4.1.2 Controller Power Off Procedures ....................................................................... 4-2
4.2 Servo Motor Power-On Procedures ................................................................... 4-7
4.2.1 Servo Motor Power-On in the Repeat Mode ...................................................... 4-7
4.2.2 Servo Motor Power-On in the Teach Mode......................................................... 4-7
4.3 Methods for Stopping the Robot ........................................................................ 4-8
4.3.1 Emergency Stop Switch ..................................................................................... 4-8
4.3.2 Hold/Run Switch................................................................................................. 4-8
4.3.3 Teach/Repeat Switch ......................................................................................... 4-8

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POWER ON/OFF PROCEDURES

4.0 POWER ON/OFF PROCEDURES

This unit provides the power ON/OFF procedures for the robot controller and servo
motors. Refer to figures 4-1 through 4-7 during these procedures.

4.1 CONTROLLER POWER ON/OFF PROCEDURES

4.1.1 CONTROLLER POWER ON PROCEDURES

1. Ensure that all personal are clear of the work cell, and that all safety devices are in
place and operational.

2. Turn the HOLD/RUN switch to the HOLD position.

3. Place the controller main disconnect switch in the ON position. The CONTROL
POWER indicator lamp illuminates.

4.1.2 CONTROLLER POWER OFF PROCEDURES

1. Turn the HOLD/RUN switch to the HOLD position; if in motion the robot decelerates
to a stop, and the MOTOR POWER lamp turns off.

2. Press the EMERGENCY STOP switch and the CYCLE START lamp turns off.

3. Place the controller main disconnect switch in the OFF position.

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POWER ON/OFF PROCEDURES

Disconnect
Switch

Figure 4-1 Standard C Controller

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POWER ON/OFF PROCEDURES

Figure 4-2 North American C Controller

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POWER ON/OFF PROCEDURES

Figure 4-3 European C Controller

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POWER ON/OFF PROCEDURES

EMERGENCY STOP

ERROR MOTOR POWER

ERROR RESET CYCLE START

TEACH REPEAT HOLD RUN

Figure 4-4 North American and European C Controller Switch Panel

CONTROL ERROR ERROR RESET HOLD RUN TEACH REPEAT CYCLE START MOTOR POWER EMERGENCY STOP
POWER
HOUR METER

Figure 4-5 Standard C Controller Switch Panel

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POWER ON/OFF PROCEDURES

4.2 SERVO MOTOR POWER-ON PROCEDURES

4.2.1 SERVO MOTOR POWER-ON IN THE REPEAT MODE

1. Place the TEACH LOCK switch on the multi function panel in the OFF position.

2. Place the TEACH/REPEAT switch in the REPEAT position.

3. Press the MOTOR POWER push button. The MOTOR POWER lamp illuminates.

4. Place the HOLD/RUN switch in the RUN position.

5. The robot is ready to execute a program.

4.2.2 SERVO MOTOR POWER-ON IN THE TEACH MODE

1. Place the TEACH/REPEAT switch in the TEACH position.

2. Place the TEACH LOCK switch on the multifunction panel in the ON position.

3. Set the HOLD/RUN switch to RUN.

4. At the BLOCK TEACHING screen, press and hold one of the enabling devices
(deadman switches) and press the MOTOR POWER push button. The MOTOR
POWER lamp illuminates.

Emergency Stop
Switch Teach Lock

ON OFF

TEACH LOCK

Enabling Device
(Deadman Switches)

Figure 4-6 Multi Function Panel

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POWER ON/OFF PROCEDURES

4.3 METHODS FOR STOPPING THE ROBOT

One of three methods can be used to stop robot motion. Each of these methods is
described in the following sections.

4.3.1 EMERGENCY STOP SWITCH

When the EMERGENCY STOP switch is pressed, motor power is turned off and the
brakes are applied, stopping the robot immediately. This places abnormally high loads
upon the robot and is recommended for emergency situations only. To stop the robot
during non-emergency situations refer to section 4.3.2, HOLD/RUN SWITCH.

4.3.2 HOLD/RUN SWITCH

When the HOLD/RUN switch is turned to the HOLD position the robot decelerates
smoothly to a stop and the brakes are applied. This places the robot into a temporary
stop condition. The motor power lamp turns OFF and the CYCLE START lamp remains
ON. When the HOLD/RUN switch is again turned to the RUN position the robot contin-
ues the motion it was executing prior to HOLD. To create a permanent stop condition,
press the EMERGENCY STOP switch or turn the TEACH/REPEAT switch to the TEACH
position (the CYCLE START and MOTOR POWER indicator lamps turn off in either
case).

4.3.3 TEACH/REPEAT SWITCH

When the TEACH/REPEAT switch is turned to the TEACH position motor power is
turned off and the brakes are applied stopping the robot immediately. This places ab-
normally high loads upon the robot and is recommended for emergency situations only.
To stop the robot during non-emergency situations refer to section 4.3.2, HOLD/RUN
SWITCH.

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5.0 MULTI FUNCTION PANEL ............................................................................ 5-2

5.1 Multi Function Panel Description .................................................................... 5-2
5.2 General Multi Function Panel Keys ................................................................. 5-4
5.2.1 Program and Step Selection Keys .................................................................. 5-4
[Link] Program Selection .......................................................................................... 5-5
[Link] Cursor Movement Keys ................................................................................... 5-7
[Link] Step Selection ................................................................................................ 5-7
5.3 Screen Selection Menu Keys .......................................................................... 5-9
5.3.1 Teaching Menu Key ...................................................................................... 5-10
[Link] Block Teaching Key ....................................................................................... 5-11
[Link] Program Edit Key .......................................................................................... 5-12
[Link] AS Teaching Key ........................................................................................... 5-13
[Link] AS Location Key ........................................................................................... 5-14
[Link] Check Mode Key ........................................................................................... 5-15
5.4 Status Menu Key........................................................................................... 5-16
5.4.1 Status Key .................................................................................................... 5-17
5.4.2 Program List Key .......................................................................................... 5-18
5.4.3 Monitor Key ................................................................................................... 5-19
5.4.4 Current Position Key ..................................................................................... 5-20
5.4.5 Arc Status Key .............................................................................................. 5-21
5.5 Menu Key ...................................................................................................... 5-22
5.5.1 Function Key ................................................................................................. 5-23
[Link] Figure Input and Cursor Selection ................................................................ 5-24
5.5.2 Keyboard....................................................................................................... 5-25
[Link] Character Input ............................................................................................. 5-27
5.6 Robot Manual Operation Keys ...................................................................... 5-28

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5.0 MULTI FUNCTION PANEL

5.1 MULTI FUNCTION PANEL DESCRIPTION

The multi function panel, shown in figure 5-1, is equipped with an eight inch color LCD
(liquid crystal display) touch panel, a pen to operate the touch panel keys, a PC card
slot, and various switches. The function of these components is described in table 5-1.

If the multi function panel display is not touched for a period of ten minutes, the display
automatically darkens for the screen saver mode. Touching any area of the display
screen, when it is in this mode, reactivates the colored display.

1. 2.

3. 3.

4.

6.

5.
7.

Figure 5-1 Multi Function Panel

NOTE
If the LCD display screen of the multi function panel is
exposed to high levels of static electricity, the display
may go blank for a short period. The display will show
the opening screen when the static electricity has dissi-
pated. This condition will not cause an error message.

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Table 5-1 Multi Function Panel

No. Switch Function

The red EMERGENCY STOP switch turns the servo motor

power OFF, the brakes are applied, and the robot stops.
1.
The motor power lamp and cycle start lamp are turned
OFF at this time.
Teach lock ON - cycle start (program execution) is
disabled; teaching, jogging, and check mode operations
can be performed.
2.
Teach lock OFF - cycle start is enabled; teaching, jogging,
and check mode operations cannot be performed.
One
One ooff the
two two
triggenabling
er (dead(deadman)
man) switchdevices
es must must
be prbe
essed
Enabling
3. Trigger switch pressed
to enable motor power in the teach mode and checkand
to activate motor power in the teach mode
device
check
mode. mode.

Provides touch keys for teaching, editing, check mode

Liquid crystal operations, and configuring and monitoring the robot
4.
display system. Also provides display areas for system status,
error messages, program data, system data, etc.

Opening to insert a PC card for backing-up or restoring

5. PC card slot
data in the controller memory.

Contrast
6. Adjusts the brightness of the LCD backlight.
adjustment

7. Touch panel pen Pen used for operation of the keys on the touch screen.

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5.2 GENERAL MULTI FUNCTION PANEL KEYS

There are several keys which appear in the variety of screens on the multi function
panel. General descriptions of these keys are provided in the following sections.

PROGRAM STEP PC
pg1 1

5.2.1 PROGRAM AND STEP SELECTION KEYS

The keys shown above are displayed in the upper left portion of the LCD. They are used
to select robot programs, process control (PC) programs, program steps, and to display
the selected program name and step number. The function of these keys is described in
table 5-2.

Table 5-2 Function of Program and Step Selection Keys

Key Function

PROGRAM The PROGRAM key displays the currently selected program. When this
pg1 key is pressed the program select screen appears, and another program
can be selected.

STEP
The STEP key displays the currently selected program step. When this
key is pressed the step selection screen appears, and another program
1
step can be selected.

PC
The PC key displays the currently selected process control (PC)
program.

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[Link] PROGRAM SELECTION

The PROGRAM key is used to select programs for playback and editing, delete pro-
grams, create names for new programs (teach mode only), and display the selected
program name. To select a program, press the PROGRAM key. Use the arrow keys to
scroll through the list highlighting the desired program and press RETURN. Figure 5-2
illustrates the use of the PROGRAM key for program selection.

PROGRAM

8 9
PROGRAM SELECT

pg?? 6 7
pg10 pg1
work1 pg2
test pg8
4 5 DELETE EXIT

2 3 BS

PROGRAM
LIST
CHARACTER
0 1
RETURN

RETURN

Figure 5-2 Program Selection Methods

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To delete a program, select the program with the cursor keys then press the DELETE
key. When asked for confirmation to delete, press ENTER to continue or EXIT to abort
the process. The example in figure 5-3 shows program pg10 being deleted.

DELETE

pg??
pg1 pg10
pg2 pg8
test work1

OK to delete the program? (ENTER/EXIT)

pg10

ENTER

pg??
pg1 pg2
pg8 test
work1

pg

Figure 5-3 Program Delete Function

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[Link] CURSOR MOVEMENT KEYS

The cursor movement keys are used to select items or data entry fields. Figure 5-4
illustrates the use of the cursor keys for program selection.

PROGRAM SELECT PROGRAM SELECT

ð ð
Pg?? Pg??
pg10 pg1 pg10 pg1
work1 pg2 work1 pg2
work2 work3 work2 work3

ñ
ò

ò ñ
PROGRAM SELECT PROGRAM SELECT
Pg?? Pg??
pg10
work1
pg1
pg2
ð ð pg10
work1
pg1
pg2
work2 work3 work2 work3

Figure 5-4 Cursor Movement Keys

[Link] STEP SELECTION

The STEP key is used to select steps for program playback and editing. Four methods
of step selection are available using the FIRST STEP, BACKWARD, FORWARD, and
STEP SELECT keys. The FIRST STEP key always selects step one of the program.
Pressing the S key changes the FIRST STEP key to LAST STEP. The LAST STEP key
selects the last step of the program. The BACKWARD and FORWARD keys decrement
and increment the steps respectively. The STEP SELECT key allows a specific step to
be selected. In repeat mode, when a step number greater than the total number of
steps in the program is entered, the last step is selected. In teach mode (provided the
teach lock is ON) one step beyond the last is selected. Press the EXIT key to return to
the previous mode. Figure 5-5 illustrates the use of the STEP SELECT key.

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Figure 5-5 Step Selection

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5.3 SCREEN SELECTION MENU KEYS

TEACHING STATUS NEXT MENU

The keys shown above are located at the top center portion of the LCD and are used to
select teaching methods, robot status screens, and auxiliary menus. Each key, when
selected, displays a pull-down menu of more screen selections (Figure 5-6).

TEACHING STATUS MENU

BLOCK STATUS
TEACHING
STATUS

PROGRAM PROGRAM
EDIT LIST

AS
TEACHING
MONITOR

AS CURRENT
LOCATION POSITION

CHECK ARC
MODE STATUS

Figure 5-6 Pull-Down Menus

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5.3.1 TEACHING MENU KEY

TEACHING
ð
TEACHING

BLOCK
TEACHING

PROGRAM
EDIT

AS
TEACHING

AS
LOCATION

CHECK
MODE

Figure 5-7 Teaching Keys

Pressing the TEACHING key reveals a drop down menu with five screen select buttons.
The five buttons are BLOCK TEACHING, PROGRAM EDIT, AS TEACHING, AS LOCA-
TION, and CHECK MODE. The STATUS and FUNCTION menus can be accessed
from any TEACHING screen .

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[Link] BLOCK TEACHING KEY

Status Area

TEACHING
PROGRAM STEP PC 1
BLOCK
_ +
TEACHING
pg1 1
TEACHING STATUS NEXT MENU

M-OFF 2
System Messages HOLD _
PROGRAM TEACH +
EDIT
Title Area TEACHING(BLOCK TEACHING) WELD OFF

INTERP AC SPEED ACCU INCHING 3

AS RETRACT _ +
TEACHING JOINT 9 4 [Link]

4
AS
Auxiliary Data Area AC WS WC WE AS _ +
LOCATION
INCHING

TEACH WELD ETC. OX TEACH [Link]

5
CHECK RECORD _ +
MODE
DATA SIGNAL WX NEW OFF

6
AUX COORDINATE _
CHECK CHECK S JOINT +
BACKWARD FORWARD ONCE SET&DISP

Figure 5-8 Block Teaching Screen

Pressing the BLOCK TEACHING key from the TEACHING pull-down menu displays
various input keys and information windows as shown in figure 5-8. The various areas
of the display are described below.

• System message area - this area is reserved for robot system errors or operational
errors.

• Title area - this area displays the title of the selected screen or menu item, for ex-
ample, STATUS, TEACHING (BLOCK TEACHING), ARC STATUS, etc.

• Auxiliary data area - this area displays the auxiliary data that is used for block step
programming.

• Status area - this area displays current conditions of the robot system as shown in
figure 5-8. Motor power ON/OFF (M-ON/M-OFF), hold/run conditions, repeat/teach
modes, slow repeat, wait conditions, and weld ON/OFF conditions are displayed.

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[Link] PROGRAM EDIT KEY

PROGRAM STEP PC

pg1 1
TEACHING TEACHING STATUS MENU
M-OFF
BLOCK HOLD
TEACHING TEACH
PROGRAM EDIT(TEACH DATA)

PROGRAM INTERP AC SPEED ACCU INCHING

EDIT RETRACT DELETE CANCEL
JOINT 9 4

AS AC WS WC WE AS
TEACHING CUT PASTE

AS TEACH WELD ETC OX LOCATION MODE

LOCATION DATA SIGNAL DATA COPY IN S E R T /
O V E R W R IT E

CHECK AUX PARTS

MODE SET&DISP S
ONLY
ENTER

Figure 5-9 Program Edit Screen

Pressing the PROGRAM EDIT key from the TEACHING pull-down menu displays the
program edit screen. This screen provides simple editing of a program without jogging
the robot (Figure 5-9). Steps can be copied and pasted in different areas of the pro-
gram. Input and output data can also be programmed from this screen. A detailed
explanation of program editing is presented in unit 7.

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[Link] AS TEACHING KEY

PROGRAM STEP PC
pgsrt01 1
TEACHING TEACHING STATUS MENU
M-OFF
BLOCK HOLD
TEACHING TEACH
AS INSTRUCTION TEACHING WELD OFF

AC JOINT SPEED 7 ACCU 4 TIMER 0 OX=WX= #[-77.993, -2.3447, -100.132,

PROGRAM CHARACTER
EDIT

AS
TEACHING - PROGRAM
INPUT

AS
LOCATION 5 6 7 8 9 , . TEACH
OVERWRITE

CHECK
MODE 0 1 2 3 4 SPACE SHIFT RECORD

Figure 5-10 AS Teaching Screen

Pressing the AS TEACHING key from the TEACHING pull-down menu displays the AS
Teaching screen. Each step of a program can be edited in the AS Language (Figure 5-
10). Steps can be inserted, edited or deleted. The variables, instructions and com-
ments can be programmed beforehand as an AS language character string. For addi-
tional information see Aux. function 133 in unit 11.

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[Link] AS LOCATION KEY

PROGRAM STEP PC

Pg1 1
TEACHING TEACHING STATUS MENU

BLOCK
TEACHING

AS INSTRUCTION POSITION TEACHING (TEACH DATA)

PROGRAM AC JOINT SPEED 7 ACCU 4 TIMER 0 OX=WX= #[-77.998.5,
EDIT
CUR. POS. : JT1 -78.138
JT2 5.366 [Link]
JT3 -58.108
JT4 5.132
AS JT5 -113.300
TEACHING JT6 -38.066

INCHING

AS
LOCATION TEACH WELD ETC. TEACH
INTERP RECORD
JMOVE DATA SIGNAL OVERWRITE

CHECK
MODE VAR. NAME COORDINATE
CHECK CHECK
S JOINT
BACKWARD ONCE INPUT
FORWARD

Figure 5-11 AS Location Screen

The AS LOCATION screen is set up to perform program editing and teaching functions
while viewing numeric positional data for each robot joint (Figure 5-11). Signal data can
also be programmed from this screen.

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[Link] CHECK MODE KEY

PROGRAM STEP PC SPEED 50% ‘99-04-14

12:40

Pg1 1 REPT. CONT.

STEP CONT.
RPS OFF
TEACHING TEACHING STATUS MENU

BLOCK
TEACHING

CHECK MODE
PROGRAM
EDIT
INSTRUCTION INTERP. AC SPEED ACCU. TIMER [Link]. AS COND.
1 AC JOINT 9 4 0
2 AC JOINT 9 4 0
3 AC JOINT 9 4 0
AS 4 AC LINEAR 5 1 0
TEACHING
5 AC LINEAR 5 1 0

AS
LOCATION

CHECK Page Down Page Up

NEXT DISP CHECK
MODE CHECK
ONCE SPEED
BACKWARD FORWARD

Figure 5-12 Check Mode screen

CHECK
CHECK CHECK
BACKWARD FORWARD ONCE

The keys shown above are used to check a newly taught or edited program prior to
playback in the repeat mode. The CHECK FORWARD key is pressed to execute the
next step in the program. The CHECK BACKWARD key is pressed to execute the
previous step in the program. The CHECK ONCE key toggles from CHECK ONCE to
CHECK CONT each time the key is pressed. A detailed explanation of program check-
ing is presented in unit 7 of this manual.

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5.4 STATUS MENU KEY

STATUS STATUS

STATUS

PROGRAM
LIST

MONITOR

CURRENT
POSITION

ARC
STATUS

Figure 5-13 Status Keys

Pressing the STATUS key reveals a pull-down menu with the following screen selection
keys; STATUS, PROGRAM LIST, MONITOR, CURRENT POSITION, and ARC STATUS.

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5.4.1 STATUS KEY

PROGRAM STEP PC SPEED 10% ‘97-03-18

pg5 5 REPT. CONTINUE

17:30
RPS ON
3
STEP CONTINUE DRYRUN OFF
STATUS TEACHING STATUS NEXT MENU

STATUS

STATUS
ERROR RUN REPEAT CYCLE MOTOR E-STOP NORMAL RELEASE
PROGRAM
START POWER EXT. HOLD
LIST 4

MONITOR
REPEAT REPEAT SLOGIC WELD RECORD
1 50% CONDITION STOP ON / OFF ACCEPT 5
CURRENT
POSITION
4 ACJOINT SPEED9 ACCU1 TIMER0
5 ACLINEAR SPEED8 ACCU3 TIMER1
2 7 ACJOINT SPEED9 ACCU1 TIMER0

ARC
STATUS JT1 JT2 JT3 JT5 JT6
JT4
0.000 0.000 0.000 0.000 0.000
X Y Z
0.000
O A T 6
0.000 60.000 1754.000 90.000 55.000 -90.000

Figure 5-14 Status Screen

Pressing the STATUS key from the STATUS pull-down menu displays the STATUS
screen, (Figure 5-14). System information displayed includes: current program, step/
repeat conditions, time, date, switch STATUS, and robot position. The following is a
description of the STATUS screen.

1. REPEAT CONDITION keys - display the current repeat speed and provides a key to
make changes to the speed. A key is provided to view and control the execution of
the SLOGIC program (option). The WELD ON/OFF key allows the user to activate
or deactivate the dedicated output signal for arc ON and OFF.

2. Program display area - displays a portion of the program list with the current step
highlighted.

3. REPEAT CONDITION STATUS area - displays current repeat speed as a percent-

age and in bar graph format. Displays repeat settings, time and date, RPS and
DRY RUN (option) conditions.

4. Switch status area - displays the current switch positions.

5. Displays the setting (record accept) of AUX 71.

6. Displays the current position of the robot arm and the location of TCP.

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5.4.2 PROGRAM LIST KEY

STATUS

STATUS INSTRUCTION INTERP. AC SPEED ACCU. TIMER W. COND. AS COND.

1 AC JOINT 9 4 0
2 AC JOINT 9 4 0
3 WS JOINT 0 0
PROGRAM 4 WC LINEAR 2
LIST 5 WE LINEAR 2
6 AC LINEAR 7 3 0
7 AC JOINT 9 4 0
8 AC JOINT 9 4 0
9 AC JOINT 9 4 0
MONITOR
10 AC JOINT 9 1 0

CURRENT
POSITION NEXT PG

ARC
STATUS

Figure 5-15 Program List Screen

Pressing the PROGRAM LIST key from the STATUS pull-down menu displays the
screen shown in figure 5-15. The current step is highlighted. Three screens are avail-
able in PROGRAM LIST. Press the NEXT PG key to view the second screen. Press the
NEXT PG key again to see the third screen. After pressing the NEXT PG key the PRE
PG key appears. Use these two keys to move from one screen to the other. Each
screen displays ten steps of the program. The Page Down or Page Up keys are used to
scroll through the program.

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5.4.3 MONITOR KEY

STATUS

STATUS

1 WX1 9 WX9 17 WX17 25 WX25

2 WX2 10 WX10 18 WX18 26 WX26
PROGRAM Dedicated signals and
LIST 3 WX3 11 WX11 19 WX19 27 WX27 signals that are assigned
4 WX4 12 WX12 20 WX20 28 ROBOT_HOLD through auxiliary functions
5 WX5 13 WX13 21 WX21 29 WX29 will have names
MONITOR 6 WX6 14 WX14 22 WX22 30 WX30
7 WX7 15 WX15 23 WX23 31 WX31
Signals that are on are
indicated by highlighting
8 WX8 16 WX16 24 WX24 32 Wx32
CURRENT
POSITION

OUTPUT INTERNAL IN/OUT

NEXT PG
SIGNAL
ARC
STATUS

Figure 5-16 Monitor Screen

Pressing the MONITOR key from the STATUS pull-down menu, shown in figure 5-16,
displays the input, output or internal signals on/off status. Press the INPUT, OUTPUT, or
INTERNAL keys at the bottom of the screen to select the type of signal to monitor.
Press the NEXT PG and [Link] keys to view the next or previous page of signals.
Signals that are in an ON state are displayed in reverse video. Press the GRAPH key to
view the selected signals states on a time based graph. For more information refer to
unit 8 Program Execution.

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5.4.4 CURRENT POSITION KEY

STATUS
CURRENT POSITION
STATUS
JOINT

PROGRAM
LIST JT1 JT2 JT3 JT4 JT5 JT6
-26.248 -5.513 -37.812 71.102 -75.092 11.449

MONITOR
XYZ

CURRENT X Y Z O A T
POSITION
532.690 656.487 1022.774-154.463 113.890 46.616

ARC
STATUS

Figure 5-17 Current Position Screen

Pressing the CURRENT POSITION key from the STATUS pull-down menu, displays the
current position of the robot in terms of joint angles and Cartesian coordinates. Joint
angles represent the degrees of rotation for each joint from the zeroed position. Carte-
sian coordinates represent the location and orientation of the tool center point relative to
the origin of the base coordinate system.

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5.4.5 ARC STATUS KEY

STATUS

STATUS

PROGRAM INSTRUCTION: AC
LIST
INTERPOLATION: JOINT

MONITOR
[INPUT SIGNAL]
CURRENT DETECT WIRE TOUCH WIRE STUCK TORCH INTERFER

CURRENT POLE STUCK

POSITION
[OUTPUT SIGNAL]
[Link] .: 0.00 [V] [Link]. : 0.00 [V]

ARC ARC ON WIRE INCHING WIRE RETRACT

STATUS GAS ON TOUCH SENSOR ON WELD ON / WELD OFF

Figure 5-18 Arc Status Screen

Pressing the ARC STATUS key from the STATUS pull-down menu, displays the ARC
STATUS screen. In this screen, the current step type and motion is displayed. Dedi-
cated signals used for arc welding are shown as input and output names. When a signal
name is highlighted, that signal is on. During a welding step, the commanded analog
voltage outputs for arc current and arc voltage are displayed.

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5.5 MENU KEY

MENU MENU

STATUS

Figure 5-19 Menu Keys

Pressing the MENU key reveals a pull-down menu with four screen selection keys;
STATUS, FUNCTION, I/F (interface), and KEYBOARD.

This STATUS key is the same as the STATUS key described in section 5.4.1. The
FUNCTION key is described in section 5.5.1, the I/F key in section 11.17, and the key-
board in section 5.5.2.

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5.5.1 FUNCTION KEY

PROGRAM STEP PC SPEED 10% ‘97-03-18

17:30
TEACH

MENU TEACHING FUNCTION MENU

8 9
STATUS AUX
2 LOCATION & SPEED DISPLAY
3 DATA TRANSFER
5 KILL PROGRAM
6 7
6 MIRROR CONVERSION
9 DATA CONVERSION
10 MEMORY ->PC CARD (SAVE)
4 5 _ EXIT
11 PC CARD->MEMORY (LOAD)
12 FILE DIRECTORY (FDIRECTORY)
14 PC CARD AUX. FUNCTION
28 ARC WELD CONDITION
2 3 BS
FUNCTION NUMBER:
F1 F2 F3 F4

NEXT PG 0 1 CLEAR
RETURN

Figure 5-20 Function Screen

Pressing the FUNCTION key displays the auxiliary functions screen (Figure 5-20).
Auxiliary functions are used to set system data and perform operations which do not
involve programming. For more detail, reference unit 9, Auxiliary Functions.

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BASIC MULTI FUNCTION PANEL OPERATIONS

[Link] FIGURE INPUT AND CURSOR SELECTION

Various screens allow selections to be made by figure input or cursor key. Program
selection, editing, and the AUX menu allow selections to be made either way. Figure 5-
21 illustrates AUX menu selection using both methods.

Figure 5-21 Figure Input or Cursor Key Selection

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5.5.2 KEYBOARD

Pressing the KEYBOARD key displays the keyboard screen shown in figure 5-22. The
keyboard is used to enter alphanumeric characters and AS Language commands into
the robot system. The function of the keys is explained in table 5-3.

! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0

Q W E R T Y U I O P

[
] “EXIT”
A S D F G H J K L EXIT Key

: “ ~ =
Z X C V B N M ; ‘ _ + BS “BS”
Key

CTRL+N ® < > ?

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

“Shift” “Next PG” “CTRL+N “Space”

Key Key CTRL+L” Key
Key

Figure 5-22 Keyboard

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Table 5-3 Function of Keyboard Keys

Switch Function

BS The BS (back space) key is used to delete characters one at a time.

EXIT The EXIT key is used to exit back to the status screen from the
keyboard screen.

Enter
The ENTER key is used to enter AS Language commands for
execution.

The SHIFT key selects the upper character of dual character keys
Shift i.e., pressing the 1 key after the shift key inputs the (!) character.
The shifted keys are displayed yellow.

CTRL+N The CTL+L/CTL+N key brings up the last 10 lines that were entered.
CTRL+L If you press the SHIFT key, CTL+L changes to CTL+N. The CTL+N
key takes you to the next line in the program.

SPACE Key The SPACE key inputs a blank space into a character string.

The CURSOR key is used to cursor left (normal) and right (shifted)
in a step of a program for editing. To use the cursor key, enter "o"
(for overwrite) in the AS Language editor mode.

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[Link] CHARACTER INPUT

Screens that contain the CHARACTER key allow character input through the keyboard.
Screens that use AS language commands or the CHARACTER key, utilize the keyboard.
Use the touch panel pen at the bottom of the multi function panel to type characters
from the keyboard. Press the BS (back space) key to delete characters that have been
typed. After the information is typed press the ENTER key. Press the EXIT key to exit
the character input mode. Figure 5-23 illustrates the use of the keyboard.

CHARACTER

ò
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0

Q W E R T Y U I O P

[
A S D F G H J K L ] EXIT

: “ ~ =
Z X C V B N M ; ‘ _ + BS

CTRL+N ® < > ?

® , . / _
Shift Next PG CTRL+L Space Enter

ò
... ...
A Z 1 0

Enter

Figure 5-23 Character Input

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BASIC MULTI FUNCTION PANEL OPERATIONS

5.6 ROBOT MANUAL OPERATION KEYS

The keys shown below are used to jog the robot in the teach mode. The function of
each key is described in table 5-4.

1
_ +

2
_ +

3
_ +
[Link]

4
_ +
INCHING

[Link]
5
_ +
OFF

6
COORDINATE _ +
JOINT

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Table 5-4 Function of Robot Jogging Keys

Key Function

The [Link] key selects and displays the speeds for jogging
and check mode operation. This key toggles between three available
speeds. Selected speed is indicated by the number of highlighted
vertical LEDs, i.e., one LED = speed 1, two LEDs = speed 2, three
[Link]
LEDs = speed 3. The red LED in the upper left corner lights up any
time the key is pressed to indicate this is the active mode. When the
key is not active, the LED is blue.
The INCHING key selects and displays the distance for inching
speed. This key toggles between three available distances.
Selected distance is indicated by the number of highlighted vertical
LEDs, i.e., one LED = distance 1, two LEDs = distance 2, three
INCHING
LEDs = distance 3. The red LED in the upper left corner lights up
any time the key is pressed to indicate this is the active mode.
When the key is not active, the LED is blue.
The [Link]/ROBOT key is used to select additional axes in the
robot system for jogging. The appearance of this key varies
depending on system configuration. If the robot system is configured
[Link]
OFF
or ROBOT for 7-axes the key toggles between [Link] OFF and [Link]
1
ON. If the robot system is configured for two arm control the key
toggles between ROBOT1, ROBOT2, and COOPERATION. This key
does not appear on a 6-axes robot system multi function panel.

The COORDINATE key selects and displays the coordinate system

COORDINATE
JOINT that is used for jogging the robot. This key toggles between JOINT,
BASE, and TOOL coordinate systems.

1 The AXIS keys select robot axes or directions of movement. The

_ + labeling of each key varies depending upon the coordinate system
selected for jogging. If joint coordinates are selected, the keys are
6
labeled 1~6. If base coordinates are selected, the keys are labeled
_ + X, Y, Z, RX, RY, RZ. If tool coordinates are selected, the keys are
labeled x, y, z, rx, ry, and rz.

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JOGGING OPERATION
JOGGING OPERATION

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

6.1 Keys Used for Jogging Operation ................................................................... 6-2
6.2 Jogging Operation Procedures ....................................................................... 6-3
6.3 Optional Axes Operation ................................................................................. 6-5
6.4 Coordinate Systems ....................................................................................... 6-6
6.4.1 Joint Coordinates ............................................................................................ 6-6
6.4.2 Base Coordinates ........................................................................................... 6-8
[Link] Align Operation ............................................................................................... 6-9
6.4.3 Tool Coordinates ........................................................................................... 6-11
6.4.4 Linear Movement Errors ............................................................................... 6-13

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JOGGING OPERATION

6.0 JOGGING OPERATION

This unit provides information for manual robot operation or jogging. Information pro-
vided includes the keys required for manual robot operation, movement modes, and an
explanation of the coordinate systems.

6.1 KEYS USED FOR JOGGING OPERATION

The multi function panel keys used for jogging the robot are shown in figure 6-1.

TRIGGER Switch TRIGGER Switch

ON OFF

TEACH LOCK

TEACH ING

3
M AN . S P E ED

4
IN C H IN G

EX [Link] IS 5
OFF

C OORD INATE
6
JOIN T

AXIS Keys

COORDINATE Key

[Link]/ROBOT Key

INCHING Key

MAN. SPEED Key

TEACHING Key

Figure 6-1 Jogging Operation Keys

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JOGGING OPERATION

The keys used for jogging the robot include the following:

• TEACHING key for teach mode selection

• Axis keys for joint or linear movement

• COORDINATE key for coordinate system selection

• [Link] key for speed selection

• INCHING key for distance selection

• [Link] or ROBOT key for optional axes selection

• Trigger switches to enable motor power in the teach mode.

6.2 JOGGING OPERATION PROCEDURES

MOTOR POWER TEACH REPEAT HOLD RUN ON OFF

TEACH LOCK

1. Ensure that all personal are clear of the work cell, and that all safety devices are in
place and operational.

2. Ensure the HOLD/RUN switch is in the HOLD position.

3. Place the controller main disconnect switch in the ON position. The CONTROL
POWER indicator lamp illuminates.

4. Turn the TEACH/REPEAT switch to the TEACH position.

5. Turn the HOLD/RUN switch to the RUN position.

6. Turn the TEACH LOCK to the ON position.

7. Press the TEACHING key.

8. From the TEACHING pull-down menu, select BLOCK TEACHING.

9. Press one of the deadman switches then press the MOTOR POWER key or the
button on the control panel. The MOTOR POWER lamp illuminates.

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10. Select a coordinate system by pressing the COORDINATE key. This key toggles
between the JOINT, BASE, and TOOL coordinate systems and changes the defini-
tion of the axis keys as shown in figure 6-2.

COORDINATE COORDINATE COORDINATE

JOINT BASE TOOL

1 X x
_ + _ + _ +

2 Y y
_ + _ + _ +

3 Z z
_ + _ + _ +

4 RX rx
_ + _ + _ +

5 RY ry
_ + _ + _ +

6 RZ rz
_ + _ + _ +

Figure 6-2 Axis Key Definitions

Slow Fast
[Link]

INCHING

Figure 6-3 Speed and Inching Selection

11. Press the [Link] or INCHING key to select continuous or incremental robot
motion. Each key toggles between three selections. The selected speed or inching
increment is shown by the number of LEDs that are lit (see figure 6-3). When
[Link] is selected, the robot moves continuously while an axis key is
pressed. When INCHING is selected, the robot moves only the selected distance
each time an axis key is pressed.

12. Press one or more of the axis keys to select the joint or direction for robot motion.

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6.3 OPTIONAL AXES OPERATION

[Link] ROBOT
OFF 1

Robot systems that utilize traversing tables, head and tail stock, or a second manipula-
tor, will have an [Link] or ROBOT key on the multi function panel. The [Link]/
ROBOT key is used to select the additional axes for manual operation. The appearance
of this key varies depending upon system configuration. If the robot system is config-
ured for additional axes (traversing tables, etc.) the key will toggle between [Link]
OFF and [Link] ON. If the robot system is configured for two arm control the key
toggles between ROBOT1, ROBOT2, and COOPERATION. The appearance of the axis
keys changes when the [Link] key is pressed as shown in figure 6-4. Only the
installed axes appear as axis keys. These keys do not appear on a 6-axes robot system
multi function panel.

[Link]
ON

7
_ +

Figure 6-4 External Axis Keys

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6.4 COORDINATE SYSTEMS

The robot uses three coordinate systems for program playback and teaching/editing
operations. The coordinate systems - joint, base, and tool, provide the means for linear
and non-linear motion control and program location modification.

6.4.1 JOINT COORDINATES

The joint coordinate system, allows the robot axes to be driven without regard to torch
orientation and other coordinate systems.

COORDINATE
JOINT

In the teach mode, when the COORDINATE JOINT button is selected, the robot axes
are jogged individually to set arm position or orientation. Figures 6-5 and 6-6 illustrate
the robot joint coordinate mode and the positive and negative directions of movement.

JT4
JT5
JT3

JT6

JT2

Figure 6-5 Robot Joint Coordinate Mode

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1 4
_ + _ +

2 5
_ + _ +

3 6
_ + _ +

Figure 6-6 Robot Joint Movement

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JOGGING OPERATION

6.4.2 BASE COORDINATES

COORDINATE
BASE

The base coordinate mode allows jogging the tool center point (TCP) in a straight line,
at a constant velocity, while maintaining tool orientation. The base coordinate system
origin is initially located in the robot base with an orientation defined by the left hand
rule. The origin and the orientation of the base coordinate system are modified using
AUX 47 or the BASE command. In the teach mode, the TCP is driven in X, Y, or Z
directions or rotated about the X, Y, and Z axes using the RX, RY, and RZ keys (see
figure 6-7).

_
Z
_

+
+

Figure 6-7 Base Coordinate System Mode

An easy way to determine the orientation and direction of the base coordinate system is
illustrated by the “left hand rule”, shown in figure 6-8. When using the left hand rule,
orient your left hand so that your arm represents the cables entering the base of the
robot. From this orientation the middle finger, held 90 degrees from the direction your

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arm points is the positive X direction. The extended index finger points in the positive Y
direction and the extended thumb points in the positive Z direction.

+Z

-Z

-Y +Y

-X

+X

Figure 6-8 Left Hand Rule

[Link] ALIGN OPERATION

COORDINATE WELD ETC.

SIGNAL ALIGN
BASE

The align function is used prior to teaching weld paths that are parallel to the base
coordinate system. Use this function to rotate the torch parallel with the base X, Y, or Z
axis or to a 45 degree angle from the axis. This function reduces the time required for
setting the correct torch angle.

Select the base coordinates for jogging, then press the WELD ETC. SIGNAL key to
display the ALIGN key. Press and hold one of the trigger switches (deadman switch)
and turn motor power on. Press the ALIGN key to rotate the torch parallel with the
closest base coordinate axis. Press the S key, then the ALIGN key to rotate the torch 45
degrees from the base axis.

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JOGGING OPERATION

X RX
_ + _ +

Y RY
_ + _ +

Z RZ
_ + _ +

Figure 6-9 Base Coordinate System Movement

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JOGGING OPERATION

6.4.3 TOOL COORDINATES

COORDINATE
TOOL

The tool coordinate mode is another means for jogging the tool center point (TCP) in a
straight line, at a constant velocity, while maintaining torch orientation. The tool coordi-
nate system origin is the TCP, and is initially located and oriented at the center of the
tool mounting flange as shown in figure 6-10. When torch dimensions are entered into
the robot system, using AUX 48 or the TOOL command, the tool coordinate system
origin and orientation change accordingly. The orientation of the tool coordinate system
is typically set so that its positive Z axis points in the direction of wire feed through the
contact tip. During jogging operation the tool coordinate system maintains this orienta-
tion, but changes the directionality of the coordinate axes when changes are made to
the robot position (see figure 6-10). In addition to moving in the tool coordinate X, Y, or
Z directions, the TCP can also be rotated about the torch’s X, Y, and Z axes using the rx,
ry, and rz keys (see figure 6-11).

Figure 6-10 Tool Coordinate System

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JOGGING OPERATION

x rx
_ + _ +

y ry
_ + _ +

z rz
_ + _ +

Figure 6-11 Tool Coordinate System Movement

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6.4.4 LINEAR MOVEMENT ERRORS

When moving the robot in either base coordinate or tool coordinate mode, certain arm
or wrist positions do not allow linear movement (see figure 6-12). For example, when
JT2 and JT3 align to a straight position, insufficient reach or velocity errors can occur.
Another condition known as singularity occurs when JT5 moves to a 0° (straight) posi-
tion during linear movement. If any of these conditions occur during linear movement,
the robot shuts down displaying an error related to arm configuration or speed. To avoid
this condition, reteach the affected locations with a different arm configuration or change
motion to joint interpolation.

Figure 6-12 Linear Movement Errors

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RECORDING AND EDITING PROGRAMS

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

7.1 Preparation for Teaching ................................................................................. 7-2
7.1.1 Weld Etc. Signal Key ....................................................................................... 7-2
7.2 Program Names .............................................................................................. 7-3
7.3 Creating a Program ........................................................................................ 7-5
7.3.1 Recording Program Steps .............................................................................. 7-5
[Link] Record Key ..................................................................................................... 7-6
[Link] Teach New Key ............................................................................................... 7-6
7.4 Non-Welding Programming Keys .................................................................... 7-8
7.4.1 Interp Key ....................................................................................................... 7-8
7.4.2 Air Cut Speed Key .......................................................................................... 7-8
7.4.3 Air Cut Key ...................................................................................................... 7-9
7.4.4 Accuracy Key .................................................................................................. 7-9
7.4.5 Timer Key ........................................................................................................ 7-9
7.4.6 Jump/End Key ............................................................................................... 7-10
7.4.7 Inching Retract Keys ..................................................................................... 7-10
7.4.8 Teach Data Key ............................................................................................. 7-11
7.4.9 OX (Output External) and WX (Wait External) Selection Keys ..................... 7-11
7.5 Weld Programming Keys .............................................................................. 7-12
7.5.1 Weld Start Key .............................................................................................. 7-12
7.5.2 Weld Continue Key ....................................................................................... 7-13
7.5.3 Weld End Key ............................................................................................... 7-13
7.5.4 Arc Spot Key ................................................................................................. 7-14
7.5.5 Weld or Arc Spot Condition and Aux Set & Display Keys ............................. 7-14
[Link] Setting Weld Conditions Direct Method ........................................................ 7-15
[Link] Setting Weld Conditions Indirect Method ...................................................... 7-17
[Link] Setting Weld Conditions Auto Set Method .................................................... 7-18
7.6 Checking Program Operation ....................................................................... 7-20
7.7 Editing Program Information ......................................................................... 7-21
7.7.1 Overwriting Steps ......................................................................................... 7-21
7.7.2 Deletion of Steps .......................................................................................... 7-22
7.7.3 Insertion of Steps.......................................................................................... 7-22
7.7.4 Position Rewrite ............................................................................................ 7-23
7.7.6 Real Time Weld Condition Modification ........................................................ 7-24
7.7.5 Auxiliary Rewrite ........................................................................................... 7-24
7.7.7 How to Cut and Paste Steps within a Program ............................................. 7-26
7.7.8 How to Copy and Paste Steps within a Program .......................................... 7-28
7.7.9 How to Copy and Paste Steps to Another Program ...................................... 7-30
7.7.10 How to Delete Steps within a Program ......................................................... 7-32
7.7.11 Deleting Programs ........................................................................................ 7-34
7.8 Program Confirmation ................................................................................... 7-35

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RECORDING AND EDITING PROGRAMS

7.0 RECORDING AND EDITING PROGRAMS

This unit covers the teaching and recording of program locations and auxiliary program
information. Program verification with the check step procedure and program editing are
also covered in this unit.

7.1 PREPARATION FOR TEACHING

Prior to teaching a program path, it is important to prepare a program plan and verify all
data in related auxiliary menus. A good program plan serves as a guide for ensuring
that all required points are taught and the correct auxiliary data is used for those points.
Verifying auxiliary data will ensure that the program will have the correct accuracy,
speed, timer, and weld settings.

7.1.1 WELD ETC. SIGNAL KEY

WELD ETC.
SIGNAL

The WELD ETC. SIGNAL key provides access to non-programming screens which allow
the user to manually operate the functions listed below. The functions listed below are
used primarily to verify system operation is correct prior to teaching a new program.

• WIRE INCHING
• WIRE RETRACT
• SHIELD GAS ON
• WELD ON/OFF
• ALIGN
• REAL TIME COND. MOD

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RECORDING AND EDITING PROGRAMS

7.2 PROGRAM NAMES

PROGRAM

The selection of a new program name is at the discretion of the programmer. Program
names should be consistent with company practices and the names of other programs
in system memory. The multi function panel must be in the teaching display to create a
new program. See unit five of this reference manual for display screen locations.

To name a new program, press the PROGRAM key to display the PROGRAM SELECT
screen shown in figure 7-1.

8 9
PROGRAM SELECT

pg?? 6 7
Pg10 pg1
Work1 pg2
Stanton pg8
Test 4 5 DELETE EXIT

2 3 BS

PROGRAM
LIST
PREV
PG
NEXT
PG
CHARACTER
0 1
RETURN

Figure 7-1 Program Select Screen

From the PROGRAM SELECT screen the user has two options for naming programs. If
the program is to have a numeric name, up to thirteen digits can be entered after the
highlighted pg?? in this screen, however, only the first eight characters are displayed in
the directory on the PROGRAM SELECT screen. Numeric program names must be
preceded by the pg prefix or any other alphabetic character.

After the desired number for the program name has been typed, press the RETURN key
to record the name of the new program. The new program is now on the stack at step
one. If the new program is to have an alpha or alphanumeric name without the pg
prefix, press the CHARACTER key to display the screen shown in figure 7-2.

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pg

! “ # $ % & ‘ ( ) =
BS
1 2 3 4 5 6 7 8 9 0 -
~ NEXT MENU
Q W E R T Y U I O P @
CTL+L
A S D F G H J K L ; :
< > ? |
Z X C V B N M , . /
*
{ } SHIFT
[ ] ^ -
ENTER

Figure 7-2 Character Set

To remove the default prefix characters pg, press the BS (back space) key twice. Pro-
grams named without the pg prefix, must begin with an alpha character. If the default pg
prefix is maintained, the characters can be an alphanumeric mix. Spaces cannot be
used in program names and the only special characters allowed in program names are
the dot (.) and underscore (_) characters. Program names cannot exceed fifteen char-
acters including the pg prefix, however, only eight characters are shown as part of the
display to identify the selected program.

After the desired characters for the program name are typed, press the ENTER key to
both record the new program name and return to the program select screen. The new
program name is displayed at the bottom of the PROGRAM SELECT screen. Press the
RETURN key to place the progam on the stack at step one.

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RECORDING AND EDITING PROGRAMS

7.3 CREATING A PROGRAM

The recording of program steps includes two elements. The positional element is the
location in the work space the robot moves to each time a particular step is executed. In
addition to the positional information recorded in each step, auxiliary information is also
recorded. The auxiliary information includes the step type and motion interpolation to
the taught location, the speed of travel to the location, output signals generated in the
step, input signals to wait for at the location, and weld conditions for welding steps.
When new positions are recorded the auxiliary data from the previous step is carried
forward to the next unrecorded step; if this auxiliary data is to be different for the new
step it must be changed before the RECORD key is pressed.

7.3.1 RECORDING PROGRAM STEPS

Using the jogging methods covered in unit 6 of this manual, position the torch at the
desired location to be recorded. The method used to jog the robot into position for the
recording of a point is not part of the program, the auxiliary interpolation data controls
the playback path. When the RECORD key is pressed, the location and auxiliary data
are entered into memory. The step display of the teaching screen is incremented by
one, and the comment area of the screen displays the message “step # recorded”. The
key to the right of the RECORD key displays “TEACH NEW” which identifies the current
step number displayed as not yet being recorded. The robot is jogged to the next loca-
tion and the process repeated.

Figure 7-3 shows the TEACHING screen with and without motor power applied and the
keys used to record program steps. After the last step of the program has been re-
corded, it is not necessary to identify the end of the program. The controller recognizes
the last taught step as the end of the program and automatically places an .END state-
ment following the last step.

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RECORDING AND EDITING PROGRAMS

[Link] RECORD KEY

RECORD

The RECORD key is used to record program data. When this key is pressed, new
program data is recorded or existing steps are modified. The step number shown at the
top of the screen advances by one to the next recorded or unrecorded step. If the next
step has not been recorded, the TEACH NEW key appears to the right of the RECORD
key, otherwise, the OVERWRITE key appears.

[Link] TEACH NEW KEY

TEACH
NEW

The TEACH NEW key appears when the displayed step has not been recorded. When
modifying an existing program, the OVERWRITE key is displayed and toggles between ,
DELETE, INSERT, [Link] (position rewrite), and [Link] (auxiliary rewrite)
modes.

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Status Area

PROGRAM STEP PC
pg1 1
TEACHING STATUS NEXT MENU
M-OFF
System Messages HOLD
TEACH
Title Area TEACHING(BLOCK TEACHING) WELD OFF

INTERP AC SPEED ACCU INCHING

RETRACT
JOINT 9 4 [Link]

Auxiliary Data Area AC WS WC WE AS

INCHING

TEACH WELD ETC. OX TEACH [Link]

RECORD
DATA SIGNAL WX NEW OFF

AUX COORDINATE
CHECK CHECK S JOINT
BACKWARD FORWARD ONCE SET&DISP

MOTOR POWER OFF

MOTOR POWER ON

Figure 7-3 Teaching Screen

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7.4 NON-WELDING PROGRAMMING KEYS

The programming keys of the multi function panel allow the user to record positional and
auxiliary information. These keys are used to specify the type of motion used in a step
of the program and control the interfacing with periphrial equipment.

7.4.1 INTERP KEY

INTERP
JOINT

The INTERP key (interpolation) sets the path taken by the robot to reach a taught posi-
tion. The interpolation is selected by pressing and releasing the INTERP key until the
desired type is displayed on the key.

In JOINT interpolation, each joint moves independently. The TCP (tool center point)
moves with no regard to orientation. In LINEAR interpolation, the joints move in a coor-
dinated motion to make the path of the TCP linear. CIR 1 and CIR 2 interpolated mo-
tions cause the torch to follow a circular path maintaining orientation based on three
points along an arc, and are valid for welding steps only.

Motion to air cut point, weld start, or arc spot: JOINT ⇒ LINEAR⇒

Motion to weld continue point: LINEAR ⇒ CIR 1⇒ CIR 2⇒

Motion to weld end point: LINEAR ⇒ CIR 2⇒

7.4.2 AIR CUT SPEED KEY

AC SPEED
9

Selects the speed (0-9) of the step as a percentage of maximum possible machine
speed. Maximum possible machine speed unit is degrees/second. This applies only to
joint moves. Linear and circular moves are slower than joint moves and speed units are
mm/second. The air cut speed is selected by pressing and releasing the AC SPEED
key until the desired speed is displayed on the key. Ten settings are available (set in
auxiliary function 54).

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7.4.3 AIR CUT KEY

The AC key is used to specify a non-welding motion step in the program. Pressing the
AC key displays the screen shown below. Access to the screen for progamming timers
and the JUMP/END function is gained by pressing the arrow key.

TEACHING(BLOCK TEACHING)
INTERP AC SPEED ACCU INCHING
RETRACT
JOINT 9 4

AC WS WC WE AS

7.4.4 ACCURACY KEY

ACCU
1

Selects the accuracy range (1-4) that the robot must achieve before transition to the
next position. Four settings are available (set in auxiliary function 53) by toggling the
key.

ACCU 1⇒ ACCU 2⇒ ACCU 3⇒ ACCU 4⇒ ACCU 1

7.4.5 TIMER KEY

Selects a wait timer (1-9) that starts timing when the robot reaches the accuracy range
of the taught position. 0 is used for no timer selected and additional settings are avail-
able (set in auxiliary function 58) by toggling the key.

TIMER 0 => TIMER 1 => TIMER 2 =>………. TIMER 9 => TIMER 0

Press the arrow key shown below to return to the air cut screen.

TEACHING(BLOCK TEACHING)
TIMER
J/E
0

AC WS WC WE AS

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7.4.6 JUMP/END KEY

When JUMP is selected the program leaves the current program and executes another
program until an END statement is encountered in that second program. Jump/End
returns to blank after RECORD is pressed. The Jump/End program command must be
used in conjunction with dedicated signals set in auxiliary function 111.

BLANKÞJUMPÞENDÞ

Press the arrow key shown below to return to the air cut screen.

TEACHING(BLOCK TEACHING)
TIMER
J/E
0

AC WS WC WE AS

7.4.7 INCHING RETRACT KEYS

WIRE WIRE
INCHING RETRACT

The WIRE INCHING and WIRE RETRACT keys allow the user to extend (Wire Inching)
or retract (Wire Retract) the filler wire at the specified feed speed setting. The keys are
functional only when the welding power supply is ON.

Wire inching and retracting speed is set in auxiliary function 31.

7-10 February 15, 2000

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7.4.8 TEACH DATA KEY

TEACH
DATA

The TEACH DATA key is functional when in the progam edit location data, weld etc.
signal, or OX/WX screens, it allows the user to switch from these screens back to the
program edit, or teaching screen.

7.4.9 OX (OUTPUT EXTERNAL) AND WX (WAIT EXTERNAL) SELECTION KEYS

OX
WX

The OX/WX key toggles between the output signal and input signal selection keys. The
OX keys select output signals required during program execution of the step. The WX
keys select input signals required prior to execution of the step. These keys toggle on
and off. The down arrow key is used to display the next group of signals. OX signals
remain on in the steps where they are programmed. WX signals in a particular step
cause the robot to wait until they are on or overridden. A key that is dark blue indicates
the signal is dedicated for a specific purpose, and cannot be selected for program use.
The number of available outputs is dependent upon total system I/O.

OX1 OX2 OX3 OX4 WX1 WX2 WX3 WX4

ON OFF OFF OFF ON OFF OFF OFF

OX5 OX6 OX7 OX8 WX5 WX6 WX7 WX8

OFF OFF OFF OFF OFF OFF OFF OFF

OX OX
WX WX

February 15, 2000 7-11

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7.5 WELD PROGRAMMING KEYS

These keys enter auxiliary information for arc welding. The controller uses the auxiliary
welding information to start and stop the welding process and send the appropriate
command signals to the welding power suppy. Numeric values recorded in welding
steps must specifically apply to the items being welded (e.g., alloys, joint type, weldment
positioning, dimensions, etc.).

Each of the weld programming keys is color coded. Pressing any of these keys displays
the related auxiliary keys above, which match the color of that programming key.

NOTE
During program creation, auxiliary information recorded
as part of a step is carried forward to the following unre-
corded step. Verify auxiliary information is correct prior
to recording new program steps.

7.5.1 WELD START KEY

The weld start (WS) key is used to specify the beginning of a welding step. Joint or
linear interpolation is used to move the robot to the weld start location. Welding condi-
tions are not recorded in the weld start step. At this step (when the robot reaches the
recorded location), the robot controller sends a dedicated signal for arc on to the weld
controller.

When the WS key is pressed, the related keys are displayed above, which match the
color of the WS key.

TEACHING(BLOCK TEACHING)
INTERP AC SPEED TIMER
JOINT 9 0

AC WS WC WE AS

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7.5.2 WELD CONTINUE KEY

The weld continue (WC) key is used to specify a point along a welding path. A recorded
weld continue step includes weld conditions as auxiliary information. Repeatedly press-
ing the WELD COND key (shown below) allows the user to scroll through the data table
of preset welding conditions.

When the WC key is pressed, the related keys are displayed above, which match the
color of the WC key.

TEACHING(BLOCK TEACHING)
INTERP
LINEAR 0

AC WS WC WE AS

7.5.3 WELD END KEY

The weld end (WE) key is used to specify the end of a welding path. A recorded weld
end step includes weld conditions as auxiliary information. Repeatedly pressing the
WELD COND key (shown below) allows the user to scroll through the data table of
preset welding conditions.

When the WE key is pressed, the related keys are displayed above, which match the
color of the WE key.

TEACHING(BLOCK TEACHING)
INTERP
LINEAR 0

AC WS WC WE AS

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7.5.4 ARC SPOT KEY

The arc spot (AS) key is used to record a point in the program which installs a tack weld.
A step recorded as an arc spot has weld conditions included as auxiliary information.
Repeatedly pressing the AS COND key (shown below) allows the user to scroll through
the data table of preset welding conditions. Joint or linear interpolation is used to move
the torch to the arc spot location.

When the AS key is pressed, the related keys are displayed above, which match the
color of the AS key.

TEACHING(BLOCK TEACHING)
INTERP AC SPEED ACCU AS COND TIMER
JOINT 9 4 0 0

AC WS WC WE AS

7.5.5 WELD OR ARC SPOT CONDITION AND AUX SET & DISPLAY KEYS

AUX AS COND AUX

WELD COND
DIRECT + SET&DISP or 0
+ SET&DISP

Pressing the WELD COND or AS COND key with the AUX SET&DISPLAY key displays
the associated auxiliary screen of welding conditions.

Auxiliary information set in the weld condition screen includes: travel speed, voltage,
current, weave amplitude, weave frequency, pattern No. (option), polarity ratio (option),
and crater conditions. Auxiliary information set in the arc spot conditions screen include:
crater time, voltage, and current.

Weld condition parameters are entered with the direct, indirect or the auto set (data
base) method. The direct method is convenient for making changes to welding steps
which have been recorded using the indirect or auto set methods. Steps recorded with
the direct method can be modified using auxiliary functions 150 or 151. Weld condition
parameters entered with the indirect or auto set are saved in memory and do not require
parameters to be entered each time they are selected. Auxiliary functions 150 and 151
are used to modify multiple steps recorded with the indirect method.

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[Link] SETTING WELD CONDITIONS DIRECT METHOD

From the TEACHING screen (Figure 7-4), press the WELD COND key while pressing
the AUX SET&DISP key to display the AUX 28 ARC WELD CONDITION screen (Figure
7-5). Using the numeric keys, enter the value 100 (default value for Direct method) at
the WELD CONDITION NUMBER line. Press the RETURN key to display the AUX. 28
ARC WELD CONDITION screen (Figure 7-6). Crater parameters are displayed in this
screen for weld end steps only.

`
PROGRAM STEP PC 1
_ +
pg1 1
TEACHING STATUS NEXT MENU

M-OFF 2
HOLD _
TEACH +
WELD OFF
TEACHING(BLOCK TEACHING)
INTERP ACCU INCHING 3
WELD COND
DIRECT RETRACT _ +
JOINT 4 [Link]

4
AC WS WC WE AS _ +
INCHING

TEACH WELD ETC. OX TEACH [Link]

5
RECORD _ +
DATA SIGNAL WX NEW OFF

6
AUX COORDINATE _
CHECK CHECK S JOINT +
BACKWARD FORWARD ONCE SET&DISP

Figure 7-4 Weld Condition Select Direct

8 9
AUX 28 ARC WELD CONDITION
28 ARC WELD CONDITION
WELD CONDITION NUMBER 100 6 7

4 5 _ EXIT

2 3 BS

F1 F2 F3 F4

PRE DATA
0 1 CLEAR
RETURN

Figure 7-5 Weld Condition Select Direct

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8 9
AUX 28 ARC WELD CONDITION
WELD CONDITION DIRECT
WELD SPEED 0 cm/min 6 7
CURRENT 0.0 A
VOLTAGE 0.0 V
WEAVING AMPLITUDE 0.0 mm
FREQUENCY 0.0 Hz
4 5 _ EXIT
PATTERN 0
POLE RATIO 0
CRATER TIME 0.0 s
CURRENT 0A
VOLTAGE 0.0 V 2 3 BS

F1 F2 F3 F4

AUTO SET PRE PG NEXT PG

0 1 CLEAR
RETURN

Figure 7-6 Parameter Setting Direct

1. Position the cursor with the up or down arrow key to select a weld parameter.

2. Enter a value for the parameter with the numeric keys. Pressing the CLEAR key
enters a zero value for the selected parameter.

3. When all values have been entered, press the RETURN key. The message “Nor-
mally completed” is displayed in the message area.

4. Press the EXIT key twice to return to the TEACHING screen. The weld condition
data is ready to record as auxilary data for the current step in the TEACHING
screen.

Press the AUTO SET key to display the weld type menu. For information on AUTO SET
see section [Link]. Press the F2, NEXT PG or F3, PRE PG key to change from direct
method to a weld condition number.

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[Link] SETTING WELD CONDITIONS INDIRECT METHOD

From the TEACHING screen (Figure 7-7), press the WELD COND key while pressing
the AUX SET&DISP key to display the AUX 28 ARC WELD CONDITION screen (Figure
7-8). Using the numeric keys, enter the desired weld condition number (0-99) at the
WELD CONDITION NUMBER line. Press the RETURN key to display the AUX. 28 ARC
WELD CONDITION screen (Figure 7-9). Crater parameters are displayed in this screen
for weld end steps only.

PROGRAM STEP PC 1
_ +
pg1 1
TEACHING STATUS NEXT MENU

M-OFF 2
HOLD _
TEACH +
WELD OFF
TEACHING(BLOCK TEACHING)
INTERP ACCU INCHING 3
WELD COND
RETRACT _ +
JOINT 0 4 [Link]

4
AC WS WC WE AS _ +
INCHING

TEACH WELD ETC. OX TEACH [Link]

5
RECORD _ +
DATA SIGNAL WX NEW OFF

6
AUX COORDINATE _
CHECK CHECK S JOINT +
BACKWARD FORWARD ONCE SET&DISP

Figure 7-7 Weld Condition Select Indirect

8 9
AUX 28 ARC WELD CONDITION
28 ARC WELD CONDITION
WELD CONDITION NUMBER 100 6 7

4 5 _ EXIT

2 3 BS

F1 F2 F3 F4

PRE DATA
0 1 CLEAR
RETURN

Figure 7-8 Weld Condition Select Indirect

February 15, 2000 7-17

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1. Position the cursor with the up or down arrow key to select a weld parameter.

2. Enter a value for the parameter with the numeric keys. Pressing the CLEAR key
enters a zero value for the selected parameter.

3. When all values have been entered, press the RETURN key. The message “Nor-
mally completed” is displayed in the message area.

4. Press the EXIT key twice to return to the TEACHING screen. The weld condition
data is ready to record as auxilary data for the current step in the TEACHING
screen.

Press the AUTO SET key to display the weld type menu. For information on AUTO SET
see section [Link]. Press the F2, NEXT PG or F3, PRE PG key to change the weld
condition number.

8 9
AUX 28 ARC WELD CONDITION
WELD CONDITION 0
WELD SPEED 0 cm/min 6 7
CURRENT 0.0 A
VOLTAGE 0.0 V
WEAVING AMPLITUDE 0.0 mm
FREQUENCY 0.0 Hz
4 5 _ EXIT

CRATER TIME 0.0 s

CURRENT 0A
VOLTAGE 0.0 V 2 3 BS

F1 F2 F3 F4

AUTO SET NEXT PG

0 1 CLEAR
RETURN

Figure 7-9 Parameter Setting Indirect

[Link] SETTING WELD CONDITIONS AUTO SET METHOD

From the TEACHING screen (Figure 7-7), press the WELD COND key while pressing
the AUX SET&DISP key to display the AUX 28 ARC WELD CONDITION screen shown
in figure 7-8. Using the numeric keys, enter the desired weld condition number (0-99) or
(100) for Direct at the WELD CONDITION NUMBER line. Press the RETURN key to
display the AUX. 28 ARC WELD CONDITION screen (Figure 7-9). Press the F1 AUTO
SET key to display two sets of numbered buttons shown in figure 7-10. The arrow key to
the right of each set of buttons allows acess to additional buttons (7-12).

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The upper set of buttons (1-12) are used to select a specific weld type, i.e., No.1 button
can represent a lap joint, No. 2 button can represent a fillet joint, etc.

The lower set of buttons (1-12) are used to select a weld condition that represents the
specific weld type selected using the upper set of buttons. There are 12 different weld
conditions available for each of the 12 (upper) weld type buttons.

The following procedure is used to select weld parameters.

1. Press a weld type button number (upper set) to select the desired weld type.

2. Press a weld condition button number (lower set) to select the desired welding
conditions, for the weld type chosen.

3. Press the RETURN key. The message “Normally completed” is displayed in the
system message area.

4. Press the EXIT key twice to return to the TEACHING screen. The weld condition
data is ready to be recorded as auxiliary data for the current step in the TEACHING
screen.

The data base weld conditions are global and changing them effects all programs using
weld data base information.

No. 1 No. 2 No. 3

AUX 28 ARC WELD CONDITION
WELD COND. 1
WELD SPEED 0 cm/min
No. 4 No. 5 No. 6
CURRENT 0A
VOLTAGE 0V
WEAVING AMPLITUDE 0.0 mm
FREQUENCY 0.0 Hz
No. 1 No. 2 No. 3

No. 4 No. 5 No. 6

F1 F2 F3 F4
EXIT
RETURN

Figure 7-10 Weld Condition Select Auto Set

The arc weld data base used in AUTO SET is available for selecting welding parameters
based on standard weld types. Registering or changing weld parameters for this data
base is performed using AUX 30 ARC WELD DATA BASE. For information on this
procedure see section 9.11.

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7.6 CHECKING PROGRAM OPERATION

CHECK CHECK
CONT CHECK CHECK
ONCE FORWARD BACKWARD

After the program has been completed and the controller is still in the teach mode, the
program check feature is used to confirm program playback. The CHECK key switches
between CHECK CONT and CHECK ONCE each time it is pressed. With motor power
ON, press and hold the CHECK FORWARD key. The robot moves to the location re-
corded in the displayed step and stops. When CHECK FORWARD is released and
pressed again, the robot moves to the next step location in the program.

When CHECK CONT is displayed, and MOTOR POWER is ON, pressing and holding
the CHECK FORWARD key causes the robot to move through the program at the se-
lected check speed.

The program stops at the last step of the program and the STEP SELECT key is used to
select the first step of the program if the process is to be repeated.

When CHECK CONT or CHECK ONCE is displayed, with motor power on, press and
hold the CHECK BACKWARD key. The robot moves through the program backwards to
the previous step. The CHECK BACKWARD key must be released then pressed again
to move to the previous step.

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7.7 EDITING PROGRAM INFORMATION

Once a program has been written there are a number of ways that it can be modified:
steps can be added or deleted, locations changed, and auxiliary data modified. Pro-
gram editing is done in the teach mode. From the teaching screen, when a taught step
is shown, the key to the right of the RECORD key displays TEACH OVERWRITE. When
TEACH OVERWRITE is selected, a row of selectable editing keys on the bottom of the
display become available to the operator: OVERWRITE, DELETE, INSERT,
[Link], [Link].

7.7.1 OVERWRITING STEPS

TEACH
OVERWRITE

When the TEACH OVERWRITE key is displayed, pressing the RECORD key overwrites
the displayed step with the current position and auxiliary information. The previous
location and auxiliary information are replaced by the new information. The message
display area of the multi function panel shows a message that the step is recorded and
the step number is incremented to the next step.

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7.7.2 DELETION OF STEPS

TEACH
DELETE

To delete steps within a program, use the step select process (reference unit 5, Basic
Multi Function Panel Operations, for a description of the step select process) to select
the step for deletetion. If a number of steps are to be deleted, start with the highest
number first, this eliminates the need to recalculate the new numbering sequence.
When the step for deletetion is selected and TEACH DELETE is displayed, pressing the
RECORD key deletes the step. Figure 7-11 shows the renumbering process that takes
place when steps are deleted.

STEP 1 STEP 1

STEP 2 STEP 2

STEP 3 DELETED STEP STEP 3

STEP 4 STEP 4

STEP 5 STEP 5

STEP 6

Figure 7-11 Deleting Program Steps

7.7.3 INSERTION OF STEPS

TEACH
INSERT

The TEACH INSERT key allows the user to program new steps into a program. New
steps are inserted into current positions and existing steps are incremented forward by
one in the program. Figure 7-12 shows the renumbering that takes place. To insert a
new step with TEACH INSERT, select the step where the new step is to be located.

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Jog the robot to the new position and set all auxiliary data. Press RECORD and this
becomes the selected step with all following steps incremented forward by one and
renumbered automatically. The multi function panel remains in the TEACH INSERT
mode, ready to accept additional steps for insertion.

BEFORE STEP INSERTION AFTER STEP INSERTED

STEP 1 STEP 1

STEP 2 STEP 2
NEW STEP NEW STEP
INSERTED STEP 3 STEP 3
HERE
STEP 4 STEP 4

STEP 5 STEP 5

STEP 6

Figure 7-12 Inserting Program Steps

7.7.4 POSITION REWRITE

TEACH
[Link]

To change the location of a taught position, the position rewrite process can be used.
Jog the robot to the desired position, ensure the multi function panel is displaying the
TEACH POS. REWRT key and the correct step number for the new position. Press the
RECORD key to enter the new position maintaining the original auxiliary information.
The multi function panel displays a message that the step is recorded and increments to
the next step.

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7.7.5 AUXILIARY REWRITE

TEACH
[Link]

To change the auxiliary information for a program step, the auxiliary rewrite process is
used. Ensure the multi function panel is displaying the TEACH AUX. REWRT key and
the correct step number for the new auxiliary data. Change the auxiliary data for the
step. Press the RECORD key to enter the new auxiliary data maintaining the original
position information. The multi function panel displays a message that the step is re-
corded and increments to the next step number remaining in the aux. rewrite mode.

7.7.6 REAL TIME WELD CONDITION MODIFICATION

WELD ETC.
SIGNAL

The Real Time Condition Modification function is used primarily to create the lineariza-
tion table (auxiliary function 31, screen 1) which matches the controller’s command
voltage outputs to the welding power supply’s actual outputs. When executing a welding
path in repeat or teach mode with ARC ON, the travel speed, current and voltage are all
adjustable. If the arc signal is off, only the travel speed is adjustable. None of the pa-
rameters are adjustable when the arc signal is off in teach mode.

Press the WELD ETC. SIGNAL key to display the REAL TIME COND MOD key shown in
figure 7-13. Change the display by pressing the REAL TIME COND MOD key to display
the screen shown in figure 7-14. Select the weld parameter to modify by pressing the
appropriate parameter key, SPEED, CURRENT, or VOLTAGE. The up and down arrows
are used to increase or decrease the selected parameter value respectively.

Speed adjustments are 1 cm/min for each time the arrow key is pressed to a maximum
of 999 cm/min. Current adjustments are 1 A for each time the arrow key is pressed to a
maximum of 999 A. Voltage adjustments are 0.1 V for each time the arrow key is
pressed to a maximum of 99.9 V.

Press the COND. SET key during the weld to record the current weld parameters. Weld-
ing steps recorded with the indirect method are overwritten and become direct. Press
the PRE DATA key to return the original weld parameters.

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PROGRAM STEP PC 1
_ +
Pg05 6
TEACHING STATUS NEXT MENU

M-OFF 2
HOLD _
TEACH +
WELD OFF
TEACHING(WELD ETC.)
WIRE WIRE SHIELD 3
INCHING RETRACT GAS
WELD ALIGN _ +
ON/OFF
ON [Link]

REAL
4
TIME _ +
COND. MOD INCHING

TEACH WELD ETC. OX 5

RECORD
TEACH _ +
DATA SIGNAL WX NEW

6
CHECK CHECK
AUX
S COORDINATE
JOINT
_ +
BACKWARD
SET&DISP
FORWARD

Figure 7-13 Real Time Weld Condition Modify Key Display

PROGRAM STEP PC 1
_ +
Pg01 5
TEACHING STATUS NEXT MENU

M-OFF 2
HOLD _
TEACH +
WELD OFF
TEACHING (WELD ETC.)
SPEED CURRENT
3
VOLTAGE _
100cm/min 230A 25.0V
EXIT +
[Link]

COND.
4
PRE DATA _ +
SET
INCHING

TEACH WELD ETC. OX 5

RECORD
TEACH _ +
DATA SIGNAL WX OVERWRITE

6
CHECK CHECK
AUX
S COORDINATE
JOINT
_ +
BACKWARD
SET&DISP
FORWARD

Figure 7-14 Real Time Weld Condition Modify Screen

February 15, 2000 7-25

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7.7.7 HOW TO CUT AND PASTE STEPS WITHIN A PROGRAM

NOTE

This procedure may also be used to copy and paste

individual program steps by omitting steps 12-13 below.

PROGRAM STEP PC

pg1 1
TEACHING MENU

M-OFF
FIRST STEP
STEP EXIT HOLD
SELECT
BACKWARD FOREWARD TEACH

PROGRAM EDIT(TEACH DATA)

INTERP AC SPEED ACCU INCHING

RETRACT DELETE CANCEL
JOINT 9 4

AC WS WC WE AS CUT PASTE

TEACH WELD ETC OX LOCATION MODE

DATA SIGNAL DATA COPY IN S E R T /
O V E R W R IT E

AUX PARTS
SET&DISP S
ONLY
ENTER

Figure 7-15 Step Editing

1. Set the TEACH LOCK switch to ON.

2. Set the TEACH/REPEAT switch to TEACH.

3. Select AUX 96 to enable the PROGRAM EDIT function.

4. Press the EXIT key twice.

5. Press the TEACHING key.

6. Press the PROGRAM EDIT key from the drop down TEACHING menu.

7. Press the PROGRAM key, and select the program to edit.

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RECORDING AND EDITING PROGRAMS

8. Press the STEP key.

9. Press the BACKWARD or FORWARD key to scroll to the first step to cut.

10. Press the CUT key.

11. Press the STEP key (the auxiliary data keys change from yellow to magenta).

12. Press the FORWARD key to scroll to the last step to cut (10 steps maximum;
the auxiliary data keys change from magenta to yellow).

13. Press the STEP key (the auxiliary data keys change from yellow to magenta).

14. Press the EXIT key.

15. Press the RETURN key (the auxiliary data keys change from magenta to yellow).

16. Press the STEP key (the auxiliary data keys change from yellow to magenta).

17. Press the BACKWARD or FORWARD key to select the insertion point.

18. Press the EXIT key.

19. (Optional) Press the INSERT/OVERWRITE key to select the type of insertion.

20. Press the PASTE key (the auxiliary data keys change from yellow to magenta).

21. Press the RETURN key (the auxiliary data keys change from magenta to yellow;
the copied steps are inserted before the program step selected in step 19 above).

22. (Optional) Repeat steps 8-21 above to cut and paste up to 10 more program
steps.

23. Exit the PROGRAM EDIT function.

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RECORDING AND EDITING PROGRAMS

7.7.8 HOW TO COPY AND PASTE STEPS WITHIN A PROGRAM

NOTE

This procedure may also be used to copy and paste

individual program steps by omitting steps 12-13 below.

PROGRAM STEP PC

pg1 1
TEACHING MENU

M-OFF
FIRST STEP
EXIT HOLD
STEP SELECT
BACKWARD FOREWARD TEACH

PROGRAM EDIT(TEACH DATA)

INTERP AC SPEED ACCU INCHING

RETRACT DELETE CANCEL
JOINT 9 4

AC WS WC WE AS CUT PASTE

TEACH WELD ETC OX LOCATION MODE

DATA SIGNAL DATA COPY IN S E R T /
O V E R W R IT E

AUX PARTS
SET&DISP S
ONLY
ENTER

Figure 7-16 Step Editing

1. Set the TEACH LOCK switch to ON.

2. Set the TEACH/REPEAT switch to TEACH.

3. Select AUX 96 to enable the PROGRAM EDIT function.

4. Press the EXIT key twice.

5. Press the TEACHING key.

6. Press the PROGRAM EDIT key from the drop down TEACHING menu.

7. Press the PROGRAM key, and select the program to edit.

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RECORDING AND EDITING PROGRAMS

8. Press the STEP key.

9. Press the BACKWARD or FORWARD key to scroll to the first step to cut.

10. Press the COPY key.

11. Press the STEP key (the auxiliary data keys change from yellow to magenta).

12. Press the FORWARD key to scroll to the last step to copy (10 steps maximum;
the auxiliary data keys change from magenta to yellow).

13. Press the STEP key (the auxiliary data keys change from yellow to magenta).

14. Press the EXIT key.

15. Press the RETURN key (the auxiliary data keys change from magenta to yellow).

16. Press the STEP key (the auxiliary data keys change from yellow to magenta).

17. Press the BACKWARD or FORWARD key to select the insertion point.

18. Press the EXIT key.

19. (Optional) Press the INSERT/OVERWRITE key to select the type of insertion.

20. Press the PASTE key (the auxiliary data keys change from yellow to magenta).

21. Press the RETURN key (the auxiliary data keys change from magenta to yellow;
the copied steps are inserted before the program step selected in step 19 above).

22. (Optional) Repeat steps 8-21 above to copy and paste up to 10 more program
steps.

23. Exit the PROGRAM EDIT function.

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RECORDING AND EDITING PROGRAMS

7.7.9 HOW TO COPY AND PASTE STEPS TO ANOTHER PROGRAM

NOTE

This procedure may also be used to copy and paste

individual program steps by omitting steps 12-13 below.

PROGRAM STEP PC

pg1 1
TEACHING MENU

M-OFF
FIRST STEP
EXIT HOLD
STEP SELECT
BACKWARD FOREWARD TEACH

PROGRAM EDIT(TEACH DATA)

INTERP AC SPEED ACCU INCHING

RETRACT DELETE CANCEL
JOINT 9 4

AC WS WC WE AS CUT PASTE

TEACH WELD ETC OX LOCATION MODE

DATA SIGNAL DATA COPY IN S E R T /
O V E R W R IT E

AUX PARTS
SET&DISP S
ONLY
ENTER

Figure 7-17 Step Editing

1. Set the TEACH LOCK switch to ON.

2. Set the TEACH/REPEAT switch to TEACH.

3. Select AUX 96 to enable the PROGRAM EDIT function.

4. Press the EXIT key twice.

5. Press the TEACHING key.

6. Press the PROGRAM EDIT key from the drop down TEACHING menu.

7. Press the PROGRAM key, and select the program to copy lines from.

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RECORDING AND EDITING PROGRAMS

8. Press the STEP key.

9. Press the BACKWARD or FORWARD key to scroll to the first step to cut.

10. Press the COPY key.

11. Press the STEP key (the auxiliary data keys change from yellow to magenta).

12. Press the FORWARD key to scroll to the last step to copy (10 steps maximum;
the auxiliary data keys change from magenta to yellow).

13. Press the STEP key (the auxiliary data keys change from yellow to magenta).

14. Press the EXIT key.

15. Press the RETURN key (the auxiliary data keys change from magenta to yellow).

16. Press the PROGRAM key, and select the destination program.

17. Press the STEP key.

18. Press the BACKWARD or FORWARD key to select the insertion point.

19. Press the EXIT key.

20. (Optional) Press the INSERT/OVERWRITE key to select the type of insertion.

21. Press the PASTE key (the auxiliary data keys change from yellow to magenta).

22. Press the RETURN key (the auxiliary data keys change from magenta to yellow;
the copied steps are inserted before the program step selected in step 18 above).

23. (Optional) Repeat steps 7-22 above to copy and paste up to 10 more program
steps.

24. Exit the PROGRAM EDIT function.

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RECORDING AND EDITING PROGRAMS

7.7.10 HOW TO DELETE STEPS WITHIN A PROGRAM

NOTE

This procedure may also be used to copy and paste

individual program steps by omitting steps 12-13 below.

PROGRAM STEP PC

pg1 1
TEACHING MENU

M-OFF
FIRST STEP
EXIT HOLD
STEP SELECT
BACKWARD FOREWARD TEACH

PROGRAM EDIT(TEACH DATA)

INTERP AC SPEED ACCU INCHING

RETRACT DELETE CANCEL
JOINT 9 4

AC WS WC WE AS CUT PASTE

TEACH WELD ETC OX LOCATION MODE

DATA SIGNAL DATA COPY IN S E R T /
O V E R W R IT E

AUX PARTS
SET&DISP S
ONLY
ENTER

Figure 7-18 Step Editing

1. Set the TEACH LOCK switch to ON.

2. Set the TEACH/REPEAT switch to TEACH.

3. Select AUX 96 to enable the PROGRAM EDIT function.

4. Press the EXIT key twice.

5. Press the TEACHING key.

6. Press the PROGRAM EDIT key from the drop down TEACHING menu.

7. Press the PROGRAM key, and select the program to edit.

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RECORDING AND EDITING PROGRAMS

8. Press the STEP key

9. Press the BACKWARD or FORWARD key to scroll to the first step to cut.

10. Press the DELETE key.

11. Press the STEP key (the auxiliary data keys change from yellow to magenta).

12. Press the FORWARD key to scroll to the last step to delete (10 steps maximum;
the auxiliary data keys change from magenta to yellow).

13. Press the STEP key (the auxiliary data keys change from yellow to magenta).

14. Press the EXIT key.

15. Press the RETURN key (the auxiliary data keys change from magenta to yellow).

16. (Optional) Repeat steps 8-15 above to delete up to 10 more program steps.

17. Exit the PROGRAM EDIT function.

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RECORDING AND EDITING PROGRAMS

7.7.11 DELETING PROGRAMS

To delete a program, select the program with the cursor keys then press the DELETE
key. When asked for confirmation to delete, press ENTER to continue or EXIT to abort
the process. The example in figure 7-19 shows program pg10 being deleted.

DELETE

pg??
pg1 pg10
pg2 pg8
test work1

OK to delete the program? (ENTER/EXIT)

pg10

ENTER

pg??
pg1 pg2
pg8 test
work1

pg

Figure 7-19 Program Delete Function

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7.8 PROGRAM CONFIRMATION

REPEAT ST EP STEP
CONT O NCE FORWARD

STATUS

Operation of new programs can be confirmed in the REPEAT mode by selecting the
STEP ONCE key (this key toggles between STEP CONT and STEP ONCE) and press-
ing the STEP FORWARD key to execute one step of the program at a time. In this
mode, the program executes program steps at their repeat condition speed. It is recom-
mended that the speed be reduced the first time the “step through” process is executed.

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PROGRAM EXECUTION

8.0 PROGRAM EXECUTION .................................................................................. 8-2

8.1 Program Selection .............................................................................................. 8-3
8.2 Repeat Condition ............................................................................................... 8-4
8.2.1 Repeat Condition Display ................................................................................... 8-4
8.2.2 Repeat Speed .................................................................................................... 8-5
8.2.3 Repeat Cont/Once ............................................................................................. 8-5
8.2.4 Step Cont/Once ................................................................................................. 8-5
8.2.5 RPS Off/On ........................................................................................................ 8-6
8.2.6 Dry Run Off/On (Option) .................................................................................... 8-6
8.3 Running a Program ............................................................................................ 8-6
8.4 Monitoring the Program ...................................................................................... 8-7
8.4.1 Program List Screens ......................................................................................... 8-8
8.4.2 Monitor Screens ............................................................................................... 8-10
8.4.3 Arc Status Screen ............................................................................................ 8-12
8.4.4 Current Position Screen ................................................................................... 8-13
8.5 Stopping a Running Program ........................................................................... 8-14
8.6 Slow Repeat Mode ........................................................................................... 8-14
8.7 Wait Override ................................................................................................... 8-15

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PROGRAM EXECUTION

8.0 PROGRAM EXECUTION

This unit provides information on how to select, execute, monitor, and stop programs.
Setting repeat conditions, slow repeat and overriding wait signals are also covered.

! WARNING
Before beginning the process of program execution, en-
sure that all personnel are outside the safety fencing
system and clear of robot operations. Ensure that the
robot work space is properly configured to execute the
program selected.

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PROGRAM EXECUTION

8.1 PROGRAM SELECTION

PROGRAM

pg1

To select a program, ensure control power is ON, the HOLD RUN switch is in the HOLD
position, and the controller is in the repeat mode of operation, reference unit 4, Power
On/Off Procedures.

Pressing the PROGRAM key at the upper left portion of the multi function panel screen
brings up a display similar to figure 8-1. The program select screen displays the names
of all programs in controller memory. The cursor keys are used to highlight the desired
program and the return key is pressed to select the program. The selected program
name is shown on the program key (pg1 in the example above), confirming that it was
properly selected.

PROGRAM SELECT
pg??
pg10 pg1
work1 pg2
test pg8

PROGRAM
CHARACTER
LIST

Figure 8-1 Program Select

NOTE

Many operators utilize a “mainline” program to select all

robot control programs. Mainline programs are routinely
named pg00. If your robot is integrated into a system
that is designed to operate with a mainline program, it is
important that the mainline program is selected to start
production. If an individual program is selected and
runs independent of the mainline program, the required
operations of the mainline program are not processed.

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PROGRAM EXECUTION

8.2 REPEAT CONDITION

REPEAT
CONDITION

The repeat conditions are accessed from the multi function panel status screen, press-
ing the REPEAT CONDITION key displays three additional repeat condition keys (RE-
PEAT CONT/ONCE, STEP CONT/ONCE, RPS ON/OFF). The repeat condition keys
and display are shown in figure 8-2. The REPEAT (speed), REPEAT CONT/ONCE and
STEP CONT/ONCE keys are available to the operator during program execution.

SPEED 10% ‘9 7-03 -1 8

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

REPEAT STEP RPS DRYRUN

CONT CONT OFF OFF

Figure 8-2 Repeat Condition Keys and Display

8.2.1 REPEAT CONDITION DISPLAY

The repeat condition display is shown in figure 8-3. This display is in the upper right
portion of the multi function panel screen and shows the status of the repeat condition
items. The repeat speed is shown as a percentage and on a horizontal bar graph.

SPEED 10% ‘97-0 3-18

17:30
REPT. CONT RPS ON
STEPCONT DRYRUN OFF

Figure 8-3 Repeat Conditions Display

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PROGRAM EXECUTION

8.2.2 REPEAT SPEED

REPEAT
10% 10% 10%

Pressing the REPEAT (speed) key displays the 10% up and 10% down keys. The play-
back speed of the program is adjusted in 10 percent increments by pressing these
additional arrow keys. When the speed is changed, the new speed is displayed on the
REPEAT (speed) key and the REPEAT CONDITION display.

8.2.3 REPEAT CONT/ONCE

REPEAT REPEAT
CONT ONCE

Pressing the REPEAT CONT key toggles the key to REPEAT ONCE. Selecting the
CONT option allows the program to run continuously. Selecting ONCE causes the
program to execute one time.

8.2.4 STEP CONT/ONCE

STEP
FORWARD

STEP STEP
CONT ONCE

Pressing the STEP CONT key toggles the key to STEP ONCE. Selecting the CONT
option allows the program to run continuously from one step to the next. Selecting
ONCE causes the program to execute one step only. When ONCE is selected for this
key an additional STEP FORWARD key is displayed directly above it. Pressing the
STEP FORWARD key allows the user to execute the program one step at a time.

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PROGRAM EXECUTION

8.2.5 RPS OFF/ON

RPS
OFF

The RPS (random program selection) key is used to identify programs that are selected
from a remote source. Pressing the RPS key changes the display from OFF to ON. If
the RPS key is displaying ON, an input signal to the controller selects the program to
run. If the RPS key is displaying OFF, programs are selected by the user as described
in section 8.1 of this unit.

8.2.6 DRY RUN OFF/ON (OPTION)

DRYRUN
OFF

The DRY RUN key allows the user to execute programs without executing robot motion.
Signals are output and program logic is executed but there is no movement of the robot
when dry run is ON. When dry run is OFF programs will run with full robot motion.

8.3 RUNNING A PROGRAM

! WARNING
It is important to realize that when CYCLE START is
pressed, the robot begins the program from where it is
and moves to the next taught position. The robot makes
this move with total disregard for anything that may be
in its path.

When a program is selected and the repeat conditions set, program execution can
begin. Turn the RUN/HOLD switch to HOLD, then press MOTOR POWER and CYCLE
START. Turn the RUN/HOLD switch to RUN to begin execution. This avoids an unex-
pected external cycle start.

Pressing the CYCLE START button starts the program at the step displayed on the multi
function panel. If the program is to be started from a step other than the current step,
the step select function is used to place the program at the desired step.

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PROGRAM EXECUTION

8.4 MONITORING THE PROGRAM

The status screens display updated information about the condition of the robot when a
program is running. Information about the speed, location, signal status, and program
progress are all displayed. Figure 8-4 shows the initial status screen and the informa-
tion it provides for program monitoring. The numbered areas in figure 8-4 are described
below:
PROGRAM STEP PC SPEED 10% ‘97-03-18

REPT. CONTINUE
17:30
RPS ON
3
STEP CONTINUE DRYRUN OFF
TEACHING STATUS NEXT MENU

STATUS
ERROR RUN REPEAT CYCLE MOTOR E-STOP NORMAL RELEASE
START POWER EXT. HOLD
4

REPEAT REPEAT SLOGIC WELD RECORD

1 50% CONDITION STOP ON / OFF ACCEPT 5
4 ACJOINT SPEED9 ACCU1 TIMER0
5 ACLINEAR SPEED8 ACCU3 TIMER1
2 7 ACJOINT SPEED9 ACCU1 TIMER0

JT1 JT2 JT3 JT4 JT5 JT6

0.000 0.000 0.000 0.000 0.000
X Y Z
0.000
O A T 6
0.000 60.000 1754.000 90.000 55.000 -90.000

Figure 8-4 Current Conditions

1. REPEAT CONDITION keys - display the current repeat speed and include a key for
changing the speed. A key is provided to view and control the execution of the
SLOGIC program if the controller is equiped with the optional 1FS board. The
WELD ON/OFF key allows the user to activate or deactivate the dedicated output
signal for arc on and off.

2. Program display area - displays a portion of the program list with the current step
highlighted.

3. REPEAT CONDITION STATUS area - displays current repeat speed as a percent-

age and in bar graph format. Displays repeat settings, time and date, RPS and
DRY RUN conditions.

4. Switch status area - displays the current switch positions.

5. Displays the current setting (RECORD ACCEPT) of AUX 71.

6. Displays the current position of the robot arm.

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PROGRAM EXECUTION

8.4.1 PROGRAM LIST SCREENS

PROGRAM
LIST
STATUS

Pressing the PROGRAM LIST key from the STATUS pull-down menu displays the
screen shown in figure 8-5a or b. The current step is highlighted. Three screens are
available in PROGRAM LIST. Press the NEXT PG key to view the second screen.
Press the NEXT PG key again to see the third screen. After pressing the NEXT PG key
the PRE PG key appears. Use these two keys to move from one sceen to the other.
Each screen displays ten steps of the program. The Page Down or Page Up keys are
used to scroll through the program.

The first screen displays general step information and weld condition numbers pro-
grammed with the indirect method. The second screen (Figure 8-6a and 8-6b) displays
weld conditions programmed using the direct (manual) method. The third screen (Figure
8-7) displays OX and WX signal numbers programmed in each step.

INSTRUCTION INTERP. AC SPEED ACCU. TIMER W. COND. AS COND.

1 AC JOINT 9 4 0
2 AC JOINT 9 4 0
3 WS JOINT 0 0
4 WC LINEAR 2
5 WE LINEAR 2
6 AC LINEAR 7 3 0
7 AC JOINT 9 4 0
8 AC JOINT 9 4 0
9 AC JOINT 9 4 0
10 AC JOINT 9 1 0

NEXT PG

Figure 8-5a Program List Screen (1/3) Indirect

INSTRUCTION INTERP. AC SPEED ACCU. TIMER [Link]. AS COND.

1 AC JOINT 9 4 0
2 WS JOINT 9 0
3 WC LINEAR DIRECT
4 WE LINEAR DIRECT
5 AC LINEAR 9 4 0
6 AS JOINT 9 1 0 DIRECT

NEXT PG

Figure 8-5b Program List Screen (1/3) Direct

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PROGRAM EXECUTION

1
2
3
4
5
6
7
8
9
10

PRE PG NEXT PG

Figure 8-6a Program List Screen (2/3) Indirect

1
2
3 WELD COND. SP=80 A=290 V=32.0 PO=1 WV=1.5 f=2.1 PN=1
4 WELD COND. SP=30 A=300 V=28.0 PO=1 WV=0.0 f=0.0 Ct=0.5 CA=220 CV=19.0
5
6 AS COND. Ct=1.0 CA=170 CV=22.5

PRE PG NEXT PG

Figure 8-6b Program List Screen (2/3) Direct

OX WX
1 [ ] [ ]
2 [ ] [ ]
3 [ ] [ ]
4 [ ] [ ]
5 [ ] [ ]
6 [ ] [ ]
7 [ ] [ ]
8 [ ] [ ]
9 [ ] [ ]
10 [ ] [ ]

PRE PG

Figure 8-7 Program List Screen (3/3)

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PROGRAM EXECUTION

8.4.2 MONITOR SCREENS

MONITOR

STATUS

Pressing the MONITOR key from the STATUS pull-down menu reveals the MONITOR
screens shown in the following figures. Specific signal types are viewed by selecting the
signal type from the keys at the bottom of the display. The IN/OUT key displays both,
inputs and outputs. Each signal type has a graphing feature which displays a real-time
display of signal status in gaphical form. Activate the graphing feature (option) by press-
ing the GRAPH key.

1 OX1 9 OX9 17 OX17 25 OX25

2 OX2 10 OX10 18 OX18 26 OX26
Dedicated signals and
3 OX3 11 OX11 19 OX19 27 OX27
signals that are assigned
4 OX4 12 OX12 20 OX20 28 ROBOT_HOLD through auxiliary functions
5 OX5 13 OX13 21 OX21 29 OX29 will have names
6 OX6 14 OX14 22 OX22 30 OX30
7 OX7 15 OX15 23 OX23 31 OX31 Signals that are on are
indicated by highlighting
8 OX8 16 OX16 24 OX24 32 OX32

INPUT INTERNAL IN/OUT

NEXT PG
SIGNAL

OX 1
OX 2
OX 3
OX 4
OX 5
OX 6
OX 7
OX 8
OX 9
OX 10
OX 11
OX 12
OX 13
OX 14
OX 15
OX 16

NEXT SIG. GRAPH GRAPH

STOP EXIT

Figure 8-8 Output Signal Screens

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1 WX1 9 WX9 17 WX17 25 WX25

2 WX 10 WX10 18 WX18 26 WX26
Dedicated signals and
3 WX3 11 WX11 19 WX19 27 WX27 signals that are assigned
4 WX4 12 WX12 20 WX20 28 ROBOT_HOLD through auxiliary functions
5 WX5 13 WX13 21 WX21 29 WX29 will have names
6 WX6 14 WX14 22 WX22 30 WX30
7 WX7 15 WX15 23 WX23 31 WX31
Signals that are on are
indicated by highlighting
8 WX8 16 WX16 24 WX24 32 Wx32

OUTPUT INTERNAL IN/OUT

NEXT PG
SIGNAL

WX 1
WX 2
WX 3
WX 4
WX 5
WX 6
WX 7
WX 8
WX 9
WX 10
WX 11
WX 12
WX 13
WX 14
WX 15
WX 16

NEXT SIG. GRAPH GRAPH

STOP EXIT

Figure 8-9 Input Signal Screens

INPUT OUTPUT

1 WX1 9 WX9 1 OX1 9 OX9

2 WX2 10 WX10 2 OX2 10 OX10
3 WX3 11 WX11 3 OX3 11 OX11
4 WX4 12 WX12 4 OX4 12 OX12
5 WX5 13 WX13 5 OX5 13 OX13
6 WX6 14 WX14 6 OX6 14 OX14
7 WX7 15 WX15 7 OX7 15 OX15
8 WX8 16 WX16 8 OX8 16 OX16

INPUT OUTPUT INTERNAL NEXT PG

Figure 8-10 IN/OUT Signal Screen

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PROGRAM EXECUTION

1 INT1 9 INT9 17 INT17 25 INT25

2 INT2 10 INT10 18 INT18 26 INT26
3 INT3 11 INT11 19 INT19 27 INT27
4 INT4 12 INT12 20 INT20 28 INT28
5 INT5 13 INT13 21 INT21 29 INT29
6 INT6 14 INT14 22 INT22 30 INT30
7 INT7 15 INT15 23 INT23 31 INT31
8 INT8 16 INT16 24 INT24 32 INT32

INPUT OUTPUT IN/OUT

NEXT PG
SIGNAL

Figure 8-11 Internal Signal Screen

8.4.3 ARC STATUS SCREEN

STATUS

Press the STATUS key to display the pull-down menu and select ARC STATUS. Figure
8-12 illustrates the ARC STATUS screen. In this screen, the current step type and
motion is displayed. Dedicated signals used for arc welding are shown as input and
output names. When a signal name is highlighted, that signal is on. During a welding
step, the commanded analog voltage outputs for arc current and arc voltage are dis-
played.

INSTRUCTION: AC
INTERPOLATION: JOINT

[INPUT SIGNAL]
CURRENT DETECT WIRE TOUCH WIRE STUCK TORCH INTERFER
POLE STUCK
[OUTPUT SIGNAL]
[Link] .: 0.00 [V] [Link]. : 0.00 [V]
ARC ON WIRE INCHING WIRE RETRACT
GAS ON TOUCH SENSOR ON WELD ON / WELD OFF

Figure 8-12 Arc Status Screen

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PROGRAM EXECUTION

8.4.4 CURRENT POSITION SCREEN

STATUS

Press the STATUS key to display to the pull-down menu and select CURRENT POSI-
TION. Figure 8-13 illustates the CURRENT POSITION screen. In the CURRENT POSI-
TION screen, data is continuously updated as the robot moves. The joint angle position
of each joint is represented in degrees from a zero reference point. The XYZ section of
the screen shows the coordinate location of the tool center point in millimeters from the
origin of the base coordinate system. The orientation angle of the torch is represented
by OAT and is expressed in degrees.

CURRENT POSITION

JOINT

JT1 JT2 JT3 JT4 JT5 JT6

-26.248 -5.513 -37.812 71.102 -75.092 11.449

XYZ

X Y Z O A T
532.690 656.487 1022.774-154.463 113.890 46.616

Figure 8-13 Current Position

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PROGRAM EXECUTION

8.5 STOPPING A RUNNING PROGRAM

HOLD RUN EMERGENCY STOP MOTOR POWER CYCLE START

The EMERGENCY STOP button (located on the multi function panel and controller
cabinet) should be pressed anytime an operator needs to stop robot motion immediately.
However, it is recommended that the emergency stop button not be used as a routine
method of stopping robot motion. When the emergency stop button is pressed, power to
the motors is immediately turned off and the brakes applied. Normal deceleration of the
robot does not occur in an emergency stop, the mechanical unit may be subjected to
severe dynamic shock loads.

If the running program needs to be stopped and motor power turned off, the following
procedure is used:

1. Switch the HOLD RUN switch to the HOLD position, deceleration of robot motion
begins when the switch is turned to HOLD, the robot comes to a complete stop after
deceleration. The CYCLE START lamp remains ON.

2. Pressing the EMERGENCY STOP button turns OFF the CYCLE START lamp,
removes motor power, and applies the mechanical brakes.

3. Control power can be turned OFF.

To restart a program from the point it was stopped, move the HOLD RUN switch from
the HOLD to the RUN position while the CYCLE START lamp is ON. This resumes
program execution from the point it was stopped.

8.6 SLOW REPEAT MODE

The slow repeat mode speed is set between 1 and 25 percent in auxiliary function 55,
reference unit 9, section 9.23. A dedicated input signal is assigned to the slow repeat
function, reference unit 9, section 9.23. When the slow repeat signal is ON, the program
executes at the slow repeat speed. When the slow repeat signal is OFF, the program
executes at the speeds set in the program and the repeat speed set in the repeat condi-
tions. When the state of the slow repeat signal changes, the program momentarily stops
before it resumes at the new speed.

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PROGRAM EXECUTION

8.7 WAIT OVERRIDE

M-ON
RUN WAIT
WAITING SCREEN

The wait override procedure is a method of bypassing an expected input signal when a
program is running and a WX (input) signal is not received.

When a wait condition occurs with any teaching or status screen displayed, the status
display changes to “WAIT SCREEN”. The user can access the wait override screen
(see figure 8-14) by pressing the WAIT SCREEN key. From this screen the user can
press the individual WX signal number(s) to select the signal(s) to override, or select
ALL to override all WX signals that are not received.

The WAIT SCREEN key changes to “RETURN TO LAST” key when the wait override
screen is displayed. Pressing the RETURN TO LAST key returns to the screen dis-
played before the wait override screen was accessed.
RETURN
TO LAST

WX WX WX WX
1 2 3 4 ALL

CONDITION WAIT
OVERRIDE

5 LINEAR SPEED8 ACCU3 TIMER1 TOOL1 WORK0 CLAMP1

Figure 8-14 Wait Override Screen

SPEED 50% 99-07-12

19:43
WAITING
MENU

Figure 8-15 Repeat Condition Wait Display

When a wait condition occurs with a function or interface panel screen displayed, the
repeat condition area indicates a wait condition (see figure 8-15). The user can access
the wait override screen by exiting the function or interface panel screen and pressing
the WAIT SCREEN key.

When a wait condition occurs with the keyboard screen displayed, a wait condition is not
indicated. The user can access the wait override screen by exiting the keyboard screen
and pressing the WAIT SCREEN key.

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AUXILIARY FUNCTIONS
AUXILIARY FUNCTIONS

9.0 AUXILIARY FUNCTIONS ............................................................................. 9-4

9.1 Auxiliary Function List ................................................................................... 9-5
9.2 Location & Speed Display, AUX 2 ............................................................... 9-10
9.2.1 Auxiliary Function 2, First Menu Display Selection ..................................... 9-12
9.2.2 Auxiliary Function 2, Second Menu Display Selection ................................ 9-14
9.3 Data Transfer, AUX 3 ................................................................................... 9-17
9.4 Kill Program, AUX 5 .................................................................................... 9-18
9.5 Memory ® PC Card (Save), AUX 10 ........................................................... 9-19
9.6 PC Card ® Memory (Load), AUX 11 ........................................................... 9-21
9.7 File Directory, AUX 12 ................................................................................. 9-22
9.8 PC Card Aux. Function, AUX 14 ................................................................. 9-22
9.9 Arc Welding Condition, AUX 28................................................................... 9-23
9.10 Arc Spot Welding Condition, AUX 29 .......................................................... 9-25
9.11 Arc Weld Data Base, AUX 30 ...................................................................... 9-27
9.12 Arc Weld Auxiliary Data, AUX 31 ................................................................ 9-29
9.12.1 Weld Auxiliary Data, AUX 31, 1, Linearization ............................................ 9-30
9.12.2 Weld Auxiliary Data, AUX 31, 2, Offset/Gain .............................................. 9-32
9.12.3 Weld Auxiliary Data, AUX 31, 3, Weld Start Sequence ............................... 9-33
[Link] Threshold for Scratch/Stopping Start .......................................................... 9-33
[Link] Scratch Start ............................................................................................... 9-34
[Link] Stopping Start ............................................................................................. 9-36
[Link] Weld Start Retry.......................................................................................... 9-36
[Link] Turn Back Speed ......................................................................................... 9-36
[Link] Overlap Distance in Restart ........................................................................ 9-36
9.12.4 Weld Auxiliary Data, AUX 31, 4, Software Slow Down ................................ 9-38
9.12.5 Weld Auxiliary Data, AUX 31, 5, Wire Stuck Cancel Sequence .................. 9-38
[Link] Number of Detecting Times......................................................................... 9-39
[Link] Detecting Wire Stuck ................................................................................... 9-39
[Link] Welding Time .............................................................................................. 9-39
9.12.6 Arc Weld Auxiliary Data, AUX 31, 6, Arc Spot Sequence ........................... 9-39
[Link] Retry ........................................................................................................... 9-39
[Link] After Arc Spot .............................................................................................. 9-40
9.12.7 Weld Auxiliary Data, AUX 31, 7, Preflow/Afterflow ...................................... 9-40
9.12.8 Weld Auxiliary Data, AUX 31, 8, Wire Inching/Retract ................................ 9-41
9.12.9 Weld Auxiliary Data, AUX 31, 9, Weld ON/OFF in Check ........................... 9-41
9.13 Zeroing, AUX 41 .......................................................................................... 9-42
9.14 Pos. Error Range at E-Stop, AUX 42 ........................................................... 9-43
9.15 Encoder Error Range, AUX 43 .................................................................... 9-44
9.16 Zeroing Data Set/Display, AUX 44 .............................................................. 9-45
9.17 Robot Mounting Posture ............................................................................. 9-45
9.18 Base Coordinate, AUX 47 ........................................................................... 9-47
9.19 Arc Weld Torch Dimensions, AUX 50 .......................................................... 9-48
9.20 Software Limit, AUX 51 ............................................................................... 9-49
9.21 Accuracy, AUX 53 ....................................................................................... 9-50

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9.22 Speed, AUX 54........................................................................................... 9-51

9.23 Slow Repeat Mode, AUX 55 ....................................................................... 9-52
9.24 Check Speed, AUX 56 ............................................................................... 9-52
9.25 Teach Speed, AUX 57 ................................................................................ 9-53
9.26 Timer, AUX 58 ............................................................................................ 9-54
9.27 Memory Available, AUX 70 ......................................................................... 9-54
9.28 Record Data (PRG CHG) Inhibit, AUX 71 .................................................. 9-55
9.29 System Switch, AUX 75 ............................................................................. 9-56
9.29.1 Optional System Switches ......................................................................... 9-57
9.29.2 ARC Switch ................................................................................................ 9-57
9.29.3 [Link] Switch ................................................................................ 9-57
9.29.4 CP (Continuous Path) Switch ..................................................................... 9-58
9.29.5 [Link] Switch ................................................................................. 9-58
9.29.6 [Link] Switch ................................................................................... 9-59
9.29.7 [Link] Switch ....................................................................... 9-59
9.29.8 REP_ONCE (Repeat Once) Switch ........................................................... 9-60
9.29.9 RPS (Remote Program Selection) Switch .................................................. 9-60
9.29.10 STP_ONCE (Step Once) Switch ................................................................ 9-60
9.29.11 [Link] TIMER Switch ...................................................................... 9-60
9.29.12 MESSAGES Switch ................................................................................... 9-60
9.29.13 SCREEN Switch ......................................................................................... 9-60
9.29.14 [Link] Switches ......................................................................... 9-60
9.29.15 [Link] Switch ............................................................................... 9-61
9.29.16 DISPIO_01 Switch ..................................................................................... 9-61
9.29.17 [Link] ............................................................................................... 9-61
9.29.18 [Link] ............................................................................................... 9-61
9.30 Home Position, AUX 76 .............................................................................. 9-62
9.31 Clear Check Sum Error, AUX 78 ................................................................ 9-63
9.32 Change Program Name, AUX 88 ............................................................... 9-63
9.33 Software Version Display, AUX 90 .............................................................. 9-65
9.34 Environment Data, AUX 91 ........................................................................ 9-66
9.35 Environment Data2, AUX 95 ...................................................................... 9-67
9.36 Environment Data of Panel, AUX 96 .......................................................... 9-67
9.37 Check Spec. (Check Specification), AUX 99 .............................................. 9-68
9.38 System Init. (System Initialization), AUX 100 ............................................. 9-69
9.39 Battery Error Check, AUX 101 .................................................................... 9-70
9.40 Touch Panel Short Circuit Check, AUX 103 .............................................. 9-70
9.41 Time, AUX 110 ........................................................................................... 9-71
9.42 Dedicated Input Signal, AUX 111 ............................................................... 9-71
9.43 Dedicated Output Signal, AUX 112 ............................................................ 9-72
9.44 Dedicated Signal Display, AUX 113 ........................................................... 9-75
9.45 Error Logging, AUX 120 ............................................................................. 9-76
9.46 Operation Logging, AUX 122 ..................................................................... 9-77
9.47 Encoder Rot. Counter Reset, AUX 140 ..................................................... 9-78

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9.48 Arc Weld Condition Modify, AUX 150 ................................................................ 9-79

9.49 Arc Spot Weld Condition Modify, AUX 151 ........................................................ 9-80

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AUXILIARY FUNCTIONS

9.0 AUXILIARY FUNCTIONS

MENU

The auxiliary functions are accessed with the multi function panel and provide the user
the ability to view and change numerous settings that affect robot operation. The first of
seven auxiliary function screens are accessed by pressing the MENU key on the multi
function panel. Figure 9-1 shows the first auxiliary screen, additional screens are ac-
cessed by pressing the F3 key.

PROGRAM STEP PC SPEED 10% ‘97-03-18

17:30
TEACH

TEACHING FUNCTION MENU

8 9
AUX
2 LOCATION & SPEED DISPLAY
3 DATA TRANSFER
5 KILL PROGRAM
6 7
6 MIRROR CONVERSION
9 DATA CONVERSION
10 MEMORY ->PC CARD (SAVE)
4 5 _ EXIT
11 PC CARD->MEMORY (LOAD)
12 FILE DIRECTORY (FDIRECTORY)
14 PC CARD AUX. FUNCTION
28 ARC WELD CONDITION
2 3 BS
FUNCTION NUMBER:
F1 F2 F3 F4

NEXT PG 0 1 CLEAR
RETURN

Figure 9-1 Auxiliary Function Screen

NOTE

Some auxiliary functions are optional and must be pur-

chased separately. The optional auxiliary functions are
covered in unit 11 of this manual. The optional auxiliary
functions are listed in section 9.1 of this unit for refer-
ence purposes.

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AUXILIARY FUNCTIONS

9.1 AUXILIARY FUNCTION LIST

The auxiliary function numbers, the function names and a brief description of each are
identified below in the Auxiliary Function List. A detailed explanation of each function
and its use follows the auxiliary function list.

Auxiliary Function List

No Function Name Function Description

2 LOCATION & SPEED Displays present position information.

DISPLAY

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

another.

5 KILL PROGRAM Removes the selected program from the stack,

does not delete program.

6 MIRROR CONVERSION Converts programmed locations into locations

(option) with mirror symmetry with the Y and Z planes of
the base coordinate system.

9 DATA CONVERSION Provides the ability for off-line data to be con-

(option) verted into data for use in an on-line machine.

10 MEMORY PC CARD Saves data from the system memory to a

SRAM PC card.

11 PC CARD MEMORY Loads file information from a SRAM PC card to

system memory.

12 FILE DIRECTORY Displays a list of files currently on the PC card.

14 PC CARD AUX. FUNCTION Used to format SRAM PC cards and delete files
stored on SRAM PC cards.

20 MEMORY->FDD (FD_SAVE) Provides method of saving data to floppy disk.

(option)

21 MEMORY->FDD (FD_LOAD) Provides method to load data from floppy disk.

(option)

28 ARC WELD CONDITION Used to view or set welding parameters in weld

continue and weld end steps.

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Auxiliary Function List (continued)

No Function Name Function Description

29 ARC SPOT WELD Used to view or set welding parameters in arc

CONDITIONS spot steps.

30 ARC WELD DATA BASE Used to view or set welding parameters for
predefined weld types in the data base.

31 ARC WELD AUX DATA Used to access auxiliary weld data menu.

40 AUTO TOOL SET Used to automatically dimension tools.

(option)

41 ZEROING Used to set zeroing data for encoders with a

location reference to ensure proper motion of
the robot.

42 POSITION ERROR RANGE Sets a deviation range for error message dis-
play AT EMERGENCY STOP after E-stop has
been used.

43 ENCODER ERROR RANGE Sets a deviation range for error message dis-
play when the controller power is applied.

44 ZEROING DATA SET DISPLAY Allows the user to set zeroing data from the
numeric keypad.

45 FIXED TOOL DIMENSIONS Used to set tool center point coordinates (op-
tion) relative to a fixed point.

46 INSTALLATION POSTURE Sets mounting configuration for robot installa-

tion.

47 BASE COORDINATES Allows the user to set the base coordinate

system at a position other than zero.

49 WORK DIMENSIONS Sets a reference frame for the robot other than
(option) the base coordinate system.

50 ARC WELD TORCH Used to register torch dimensions manually.

DIMENSIONS

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Auxiliary Function List (continued)

No Function Name Function Description

51 SOFTWARE LIMIT Sets the upper and lower ranges for robot
motion.

53 ACCURACY Used to set the distances of the four accuracies

used in block step programming.

54 SPEED Sets the ten speeds used in block step pro-

gramming.

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

down the program execution speed.

56 CHECK SPEED Sets the robot speeds used when performing

the check step function.

57 TEACH SPEED Used to set the three teach speeds and the
three inching distances.

58 TIMER Sets the timer values for the nine timers avail-
able for use in block step programming.

70 MEMORY AVAILABLE Displays the system memory status.

71 RECORD DATA (PRG CHG) Prevents the recording of data if set to inhibit.
/INHIBIT Prevents changing program data if set to in-
hibit.

75 SYSTEM SWITCH Used to set various system software switches.

76 HOME POSITION Used to set and view robot home positions.

77 WORK SPACE OUTPUT The top and the bottom position of the work
(option) space are set from this function.

78 CLEAR CHECK SUM ERROR Provides a method to clear check sum errors.

80 XYZ SHIFT Used to shift programmed locations in the base

(option) coordinate system.

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AUXILIARY FUNCTIONS

Auxiliary Function List (continued)

No. Function Name Function Description

81 JOINT SHIFT (option) Used to change the joint values for selected
programmed points.

82 TOOL SHIFT (option) Used to shift programmed locations in the tool

coordinate system.

83 WORK SHIFT (option) Used to shift programmed locations in a work

coordinate system.

88 CHANGE PROGRAM NAME Used to change the name of an existing pro-

gram.

90 SOFTWARE VERSION Displays the version numbers of the installed

DISPLAY system software.

91 ENVIRONMENT DATA Sets a timer to turn off servo motors and iden-
tify installed equipment.

95 ENVIRONMENT DATA2 Used to identify installed hardware.

96 ENVIRONMENT DATA OF Used to activate user interfaces.

PANEL

99 CHECK SPECIFICATION Enables or disables a number of program in-

structions.

100 SYSTEM INITIALIZATION Program information is deleted and system is

reset to default settings.

101 BATTERY ERROR CHECK Enables or disables RAM low battery error
checking at power up.

103 TOUCH PANEL SHORT Information about this item was not available
CIRCUIT CHECK at the time of publication.

110 TIME Sets date and time for the controller processor.

111 DEDICATED INPUT SIGNAL Used to set dedicated input signals.

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AUXILIARY FUNCTIONS

Auxiliary Function List (continued)

No. Function Name Function Description

112 DEDICATED OUTPUT Used to set dedicated output signals.

SIGNAL

113 DEDICATED SIGNAL Displays dedicated input and output signals.

DISPLAY

117 OX SPECIFICATION Sets output signal characteristics.

(option)

120 ERROR LOGGING Displays a history of error messages.

122 OPERATION LOGGING Displays the history of operation activity.

130 PC PROGRAM RUN/STOP Provides control of process control programs.

131 INTERFACE PANEL Used to configure the software interface panel.

(option)

133 AS INSTRUCTION Allows user to assign program instructions to

DEFINITION (option) keys for repeated use during AS programming.

140 ENCODER ROTATION Used to reset the encoder values as part of the
COUNTER RESET zeroing process.

150 ARC WELD CONDITION Used to change weld conditions in multiple

MODIFY welding steps of a program.

151 ARC SPOT WELD CONDITION Used to change weld conditions in multiple
MODIFY welding steps of a program.

180 RI/O MONITOR Provides access to remote I/O functions.

(option)
181 RI/O PLC (NAC) SETTING Used to view PLC Node Adapter Chip settings.
(option)

183 RI/O SLOGIC CONTROL Used to control Slogic program functions.

(option)

184 RI/O SLOGIC FORCED Used to force RI/O outputs.

OUTPUT (option)

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AUXILIARY FUNCTIONS

Auxiliary Function List (continued)

No. Function Name Function Description

197 PASSWORD SET Provides means to password protect auxiliary functions.

198 AUXILIARY FUNCTION Used to set password level for auxiliary func-
SELECT tions.

9.2 LOCATION & SPEED DISPLAY, AUX 2

The LOCATION & SPEED DISPLAY provides a method to view positional information
regarding the movement and location of the robot in the work envelope. The LOCATION
& SPEED DISPLAY function provides six different methods to view positional informa-
tion. When the location and speed display is selected, function keys F1 to F6 are used
to select the type of positional information to be displayed. Figure 9-2 shows the initial
joint angle display when auxiliary function F2 is selected.

AUX 2 LOCATION&SPEED DISPLAY JOINT ANGLE

JOINT
JT1 JT2 JT3 JT4 JT5 JT6
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000

F1 F2 F3 F4 F5 F6

JOINT JOINT JOINT MENU EXIT

XYZOAT ENCODER
ANGLE COMMAND OFFSET SELECT

Figure 9-2 Location and Speed Display

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The information displayed in the LOCATION & SPEED DISPLAY screens is continuously
being updated and scrolls from the bottom of the screen. When the ENTER key is
pressed the screen will stop scrolling. When the ENTER key is pressed again the
screen will resume scrolling. Pressing the EXIT key will change the display from the
LOCATION & SPEED DISPLAY back to the AUX function screen. Table 9-1 provides
information about the six different screens that are accessed from the location and
speed display.

Table 9-1 Location and Speed Display F Keys

Function Key Description Unit

F1 JOINT ANGLE The present angle of each joint. Degrees
The TCP position in the base coordinate
F2 XY ZOAT Millimeters/Degrees
system (XY Z), and angle (OAT).
F3 JOINT COMMAND The present commanded position for each joint. Degrees
The deviation between the commanded position
F4 JOINT OFFSET Degrees
and the actual position.
J5 ENCODER The encoder count for each joint. Bits
J6 JOINT SPEED The speed of each joint in degrees per second. Degrees/Second

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AUXILIARY FUNCTIONS

9.2.1 AUXILIARY FUNCTION 2, FIRST MENU DISPLAY SELECTION

The F keys displayed in the auxiliary function 2 screen provide access to specific types
of location information. The F6 (MENU SELECT) key provides access to additional keys
and displays. Figure 9-3 shows the display for joint speeds when the F6 key is pressed.
Table 9-2 describes the function of the F key displayed after pressing the F6 key the first
time. Figures 9-4 through 9-6 show the screen displays associated with each F key.

AUX 2 LOCATION&SPEED DISPLAY JOINT ANGLE

Joint speed
JT1 JT2 JT3 JT4 JT5 JT6
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000

F1 F2 F3 F4 F5 F6

XYZOAT XYZOAT MENU EXIT

JOINT MOTOR CUR.
[Link] COMMAND SELECT

Figure 9-3 First Menu Select Screen

Table 9-2 First Menu Select F Keys

Function Key Description Unit

F1 JOINT (speed) Displays the speed of each joint. Degrees/Second

F2 XYZOAT Displays the TCP position in the base coordinate (XYZ) (OAT)
[Link] system and position of external axes. Millimeters Degrees

F3

(XYZ) (OAT)
F4 XYZOAT Command Displays commanded XYZOAT.
Millimeters Degrees

F5 MOTOR CURRENT Displays motor currents for all servos. Amps (A)

F6 MENU SELECT Displays next group of function keys.

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The screen shown in figure 9-4 is displayed by pressing the F1 key while viewing any
other display from the first menu.

AUX 2 LOCATION&SPEED DISPLAY JOINT SPEED

Joint speed
JT1 JT2 JT3 JT4 JT5 JT6
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000

F1 F2 F3 F4 F5 F6

XYZOAT XYZOAT MENU EXIT

JOINT MOTOR CUR.
[Link] COMMAND SELECT

Figure 9-4 Joint Speed Display

Press the F2 key to display the current tool center point location in base coordinates and
the position of external axes. Press the F4 key to display the commanded TCP location.
Transformation values are the distances from the base coordinates’ origin in the X, Y,
and Z planes. The O, A, and T represent the orientation of the torch relative to the base
coordinates (Figure 9-5).

AUX 2 LOCATION&SPEED DISPLAY XYZOAT INCLUDE EXTERNAL AXIS

Transformation value
X [mm] Y [mm] Z [mm] O [deg] A [deg] T [deg]
228.732 1240.957 58.265 88.455 130.084 134.294

F1 F2 F3 F4 F5 F6

XYZOAT XYZOAT MENU EXIT

JOINT MOTOR CUR.
[Link] COMMAND SELECT

Figure 9-5 TCP Location

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Press the F5 key to display the servo motor currents shown in figure 9-6.

AUX 2 LOCATION&SPEED DISPLAY MOTOR CURRENT

Motor current (A)

JT1 JT2 JT3 JT4 JT5 JT6
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000

F1 F2 F3 F4 F5 F6

XYZOAT XYZOAT MENU EXIT

JOINT MOTOR CUR.
[Link] COMMAND SELECT

Figure 9-6 Motor Current Display

9.2.2 AUXILIARY FUNCTION 2, SECOND MENU DISPLAY SELECTION

Press the F6 (MENU SELECT) key to display the second group of F keys. The display
shown in figure 9-7, Servo Motor Speed, is the first screen in the second menu. This
display is viewable any time the second group of F keys are displayed. Table 9-3 on the
next page describes the function of the second menu F keys.

AUX 2 LOCATION&SPEED DISPLAY MOTOR SPEED

Motor speed (rpm)

JT1 JT2 JT3 JT4 JT5 JT6

-1 -1 -1 0 0 0
-1 -1 -1 0 0 0
-1 -1 -1 0 0 0
-1 -1 -1 0 0 0
-1 -1 -1 0 0 0
-1 -1 -1 0 0 0

F1 F2 F3 F4 F5 F6

MOTOR CUR. ENCODER MENU EXIT

MOTOR SPD.
COMMAND ORG. DATA SELECT

Figure 9-7 Servo Motor Display

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AUXILIARY FUNCTIONS

Table 9-3 Second Menu Select F Keys

Function Key Description Unit

Revolutions per Minute

F1 MOTOR SPEED Displays each servo motor's speed.
(rpm)

F2

F3

Displays current for each servo

F4 MOTOR CURRENT COMMAND AMPS (A)
motor.
Displays encoder values for each
F5 ENCODER ORIGINAL DATA Bits (hex notation)
joint.

F6 MENU SELECT Displays next function key.

Press the F4 key to display the servo motor current command display shown in figure 9-
8. This display can be used to isolate servo current and joint errors.

AUX 2 LOCATION&SPEED DISPLAY MOTOR CURRENT

Motor current (A)

JT1 JT2 JT3 JT4 JT5 JT6
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000

F1 F2 F3 F4 F5 F6

XYZOAT XYZOAT MENU EXIT

JOINT MOTOR CUR.
[Link] COMMAND SELECT

Figure 9-8 Motor Current Command Display

February 15, 2000 9-15

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AUXILIARY FUNCTIONS

Press the F5 key to display the servo encoder data shown in figure 9-9. Data presented
on the encoder screen is in hexadecimal notation to reduce the number of digits in the
display.

AUX 2 LOCATION&SPEED DISPLAY ENCODER ORIGINAL DATA

Joint encoder value

JT1 JT2 JT3 JT4 JT5 JT6

1fdc9940 1bff0e34 1ffu083 1felbe89 701f 326f6

F1 F2 F3 F4 F5 F6

MOTOR SPD.
MOTOR CUR. ENCODER MENU EXIT
COMMAND [Link]. SELECT

Figure 9-9 Encoder Data

Press the MENU SELECT key a third time to display the TCP SPEED screen, shown in
figure 9-10. This display presents the tool center point speed in mm/sec. The display
shows columns for joints 1 through 6, however, data for speed is displayed in the joint 1
column only.

AUX 2 LOCATION&SPEED DISPLAY TCP SPEED

Tcp. Speed (mm/s)

JT1 JT2 JT3 JT4 JT5 JT6
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000
0.000 0.000 0.000 0.000 0.000 0.000

F1 F2 F3 F4 F5 F6

TCP MENU EXIT

SELECT

Figure 9-10 TCP Speed Display

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AUXILIARY FUNCTIONS

9.3 DATA TRANSFER, AUX 3

The DATA TRANSFER function allows the user to transfer program information from one
program to a different program or to a different location within the same program. Figure
9-11 shows the DATA TRANSFER screen.

AUX 3 DATA TRANSFER

SOURCE PROGRAM Pgsrt1

SOURCE STEP 5

NUMBER OF STEPS 21

DESTINATION PROGRAM Pgsrt2

DESTINATION STEP 4

(0: Append at the last step)

F1 F2 F3 F4

PROGRAM
INPUT

Figure 9-11 Data Transfer

Use of the DATA TRANSFER function is outlined in the following steps. Use the cursor
keys to select a field within the display to enter values:

1. Press the F1 PROGRAM INPUT key to select a source program for information to
be transferred from. A screen showing a list of available programs in system
memory is displayed. Use the cursor keys to select the program containing the
information to be transferred and press the ENTER key.

2. Use the numeric key pad to enter the first step to be transferred.

3. Use the numeric key pad to enter the number of steps to be transferred, including
the first step.

4. Press the F1 PROGRAM INPUT key to select the program for the selected steps to
be transferred to. The list of available programs in the system memory is displayed.
Use the cursor keys to select the program for the data to be transferred to and press
the ENTER key.

5. Use the numeric key pad to enter the first step of the destination program for the
transferred data to be inserted. If 0 is entered the data is inserted following the last
step of the destination program. If data is inserted into a program the existing steps
are renumbered.

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AUXILIARY FUNCTIONS

9.4 KILL PROGRAM, AUX 5

The KILL PROGRAM function is used to remove the current program from active status.
The KILL PROGRAM function does not delete the program from system memory. Fig-
ure 9-12 shows the KILL PROGRAM screen.

AUX 5 KILL PROGRAM

Are you sure?

F1 F2 F3 F4

YES

Figure 9-12 Kill Program

Press the F1 key to respond yes to the prompt, confirming the program is to be removed
from the stack. If the KILL PROGRAM selection is made in error, pressing the F2 key
returns the display to the AUX function screen. An executing program cannot be re-
moved from the stack.

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AUXILIARY FUNCTIONS

9.5 MEMORY → PC CARD (SAVE), AUX 10

This function is used to save information in the controller’s memory onto a PC card. The
PC card must be inserted into the slot on the back side of the multi function panel.
Figure 9-13 shows the screen displayed when the save function is selected.

AUX 10 MEMORY -> PC CARD (SAVE)

1 ALL DATA
2 PROGRAM
3 AUXILIARY DATA
4 ALL DATA (selected program only)
10 ROBOT DATA
11 ERROR LOGGING
12 ARC WELDING DATA

FUNCTION NUMBER:

F1 F2 F3 F4

Figure 9-13 Memory → PC Card (Save)

The MEMORY PC CARD (SAVE) screen has seven selections available for storing
different types of information. Data is saved on the PC card in numbered files. The
numeric keypad or cursor key are used to select the desired option and then the enter
key is pressed. The user must enter a file number and press the enter key. The options
for saving information on PC cards are displayed in table 9-4.

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AUXILIARY FUNCTIONS

Table 9-4 Memory to PC Save

Option Extension Description

Includes all robot system, auxiliary, program, variable, and

1 ALL DATA .AS
program data.

Saves program data only. System data and variables are

2 PROGRAM .PG not saved. If the saved program calls other programs
(subroutines), the called program will also be saved.

Includes auxiliary information such as accuracy, timer, and

3 AUXILIARY DATA .AU
teach speed settings, HOME positions, etc.

Saves all information for up to five selected programs. This

ALL DATA
option saves variables, system data and auxiliary
4 (SELECTED .AS
information. If subroutines are called they will not be saved
PROGRAM ONLY)
unless they are identified individually.

Includes robot type, number of axes, and specific software

10 ROBOT DATA .RB
settings.

Saves the information from the error log, up to the last

11 ERROR LOGGING .EL
1,000 entries, including the date and time of the entry.

ARC WELDING
12 .AW Saves weld database information.
DATA

When data is stored onto a PC card a file number must be specified. The display
prompts the user to enter a number for file identification. A file extension is added to the
file name based on the file type selected for saving. If a file is identified with the same
file number as an existing file, a backup file is automatically created. The original file is
given an extension ending with a “b” for backup. Only one backup file is created, if
additional files of the same name are saved the backup file is overwritten.

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AUXILIARY FUNCTIONS

9.6 PC CARD → MEMORY (LOAD), AUX 11

This function is used to load information into the controller’s memory from a PC card.
The PC card must be inserted into the drive slot on the back side of the multi function
panel. Figure 9-14 shows the screen displayed when the load function is selected.

AUX 11 PC CARD→MEMORY (LOAD)

1. ALL DATA
2. SELECTED DATA

FUNCTION NUMBER:

F1 F2 F3 F4

Figure 9-14 PC Card → Memory (Load)

The numeric keypad or cursor keys are used to select the option number for the type of
information to be loaded from the PC card into controller memory. Select option one
and the display prompts the user with weather or not to include the robot data. Robot
data is information pertaining to a specific robot. After the response to loading robot
data is entered, the remainder of the data contained in the selected file is loaded. Se-
lect option two and the user is prompted with whether or not a specific category of
information should be loaded.

When a program being loaded from the PC card has the same program name as a
program in controller memory, the program in controller memory is overwritten.

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AUXILIARY FUNCTIONS

9.7 FILE DIRECTORY, AUX 12

This function allows the user to view the file names of all files contained on the PC card.
The file extensions identify the file type, see table 9-4 on page 9-19 for a description of
file extensions. Figure 9-15 shows an example of the FILE DIRECTORY screen.

AUX 12 FILE DIRECTORY (FDIRECTORY)

FILE01 AS 37872 99-03-30 15:17

FILE001 PG 2871 99-03-31 08:53
FILE002 AU 7605 99-03-31 08:53
FILE003 RB 9153 99-03-31 08:54
FILE004 EL 6401 99-03-31 08:54
FILE005 AW 14306 99-03-31 08:55

F1 F2 F3 F4

Figure 9-15 File Directory

9.8 PC CARD AUX. FUNCTION, AUX 14

This function allows the user to format a PC card or delete files from a PC card. When a
PC card is formatted, any information on the PC card is deleted. When the PC card
formatting option is selected, the display prompts the user to confirm the action. Select-
ing the file delete option displays a prompt for the user to select files for deletion from a
list of files contained on the PC card. Once a file has been deleted there is no way to
recover it. Figure 9-16 shows the PC CARD AUX. FUNCTION.

AUX 14 PC CARD AUX. FUNCTION

1. PC CARD FORMATTING (FORMAT)

2. FILE DELETE (DELETE)

FUNCTION NUMBER:

F1 F2 F3 F4

Figure 9-16 PC Card Aux. Function

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.9 ARC WELDING CONDITION, AUX 28

Auxiliary function 28 sets welding parameters used in weld continue and weld end steps
of block step programs. 100 sets of welding conditions are available for the user to
program. The weld condition numbers range from 0 to 99 and are selected by toggling
the NEXT PG and PRE PG keys at the bottom of the screen.

8 9
AUX 28 ARC WELD CONDITION
28 ARC WELD CONDITION
WELD CONDITION NUMBER 100 6 7

4 5 _ EXIT

2 3 BS

F1 F2 F3 F4

PRE DATA
0 1 CLEAR
RETURN

Figure 9-17 Arc Weld Conditions (0-99)

Figure 9-17 shows the first weld condition screen when auxiliary function 28 is selected.
Using the numeric keys, select a number (0-99) to be displayed in the WELD CONDI-
TION NUMBER field. Press the RETURN key to display the screen shown in figure 9-
18.

Use the F2 and F3 keys at the bottom of the screen (Figure 9-18) to change or select
additional weld condition numbers (0-99) for parameter registration. The F1 (AUTO
SET) key displays weld types registered in the AUX 30 WELD DATA BASE. The user
may select predefined weld types (and any of the 12 corresponding weld condition
numbers) from this data base. The values selected are not programmable with AUX 28.

The following procedure is used to register weld parameters for the 100 different weld
conditions.

1. Use the original weld condition selected or use the F2 and F3 keys to select a
different weld condition number.

February 15, 2000 9-23

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AUXILIARY FUNCTIONS

2. Use the cursor keys to highlight each parameter and enter a value with the numeric
keys. Table 9-5 lists the ranges for parameter values.

3. When all values are entered, press the RETURN key to register the parameters.

8 9
AUX 28 ARC WELD CONDITION
WELD CONDITION 0
WELD SPEED 0 cm/min 6 7
CURRENT 0.0 A
VOLTAGE 0.0 V
WEAVING AMPLITUDE 0.0 mm
FREQUENCY 0.0 Hz
4 5 _ EXIT

CRATER TIME 0.0 s

CURRENT 0A
VOLTAGE 0.0 V 2 3 BS

F1 F2 F3 F4

AUTO SET NEXT PG

0 1 CLEAR
RETURN

Figure 9-18 Arc Weld Conditions

Table 9-5 Welding Parameter Ranges

Range of
Set Item Unit
Setting
SPEED 0 - 999 cm/min
WELD
CURRENT 0 - 999 A
CONDITION
VOLTAGE 0.0 - 99.9 V
AMPLITUDE 0.0 - 40.0 mm
WEAVING FREQUENCY 0.0 - 4.0 Hz
CONDITION
PATTERN
0 -10 ---
(option)
TIME 0.0 - 9.9 sec
CRATER
CURRENT 0 - 999 A
CONDITION
VOLTAGE 0.0 - 99.9 V
POLARITY RATIO (option) 0 -15 ---

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9.10 ARC SPOT WELDING CONDITION, AUX 29

Auxiliary function 29 sets welding parameters used in arc spot weld steps of block step
programs. 100 sets of welding conditions are available for the user to program. The arc
spot weld condition numbers range from 0 to 99 and are selected by toggling the NEXT
PG and PRE PG keys at the bottom of the screen.

8 9
AUX 29 ARC SPOT WELD CONDITION
AS CONDITION NUMBER 0
6 7

4 5 _ EXIT

2 3 BS

F1 F2 F3 F4

PRE DATA
0 1 CLEAR
RETURN

Figure 9-19 Arc Spot Conditions (0-99)

Figure 9-19 shows the first arc spot weld condition screen when auxiliary function 29 is
selected. Using the numeric keys, select a number (0-99) to be displayed in the AS
CONDITION NUMBER field. Press the RETURN key to display the screen shown in
figure 9-20.

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8 9
AUX 29 ARC SPOT WELD CONDITION
AS CONDITION NUMBER 0
6 7

4 5 _ EXIT

ARC SPOT TIME 0.0 s

CURRENT 0A
VOLTAGE 0.0 V 2 3 BS

F1 F2 F3 F4

PRE DATA PRE PG NEXT PG

0 1 CLEAR
RETURN

Figure 9-20 Arc Spot Conditions

Use the F2 and F3 keys at the bottom of the screen (Figure 9-20) to change or select
additional arc spot (AS) condition numbers (0-99) for parameter registration. The follow-
ing procedure is used to register weld parameters for the 100 different AS weld condi-
tions.

1. Use the original AS condition number selected or use the F2 and F3 keys to select
a different number.

2. Use cursor keys to highlight a parameter and enter a value with the numeric keys.

3. When all values are entered, press the RETURN key to register the parameters.

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9.11 ARC WELD DATA BASE, AUX 30

The arc weld data base is created for those users who select welding parameters based
on standard weld types. Variations of common weld types are programmed in this data
base for easy selection by the operator. Figure 9-21 (AUX 30) displays two sets of
numbered buttons (upper and lower) on the right side of the screen. The arrow key to
the right of each set of buttons allows access to additional buttons (7-12).

The upper set of buttons (1-12) are used to select a user definable weld type, i.e., No.1
button can represent a lap joint, No. 2 button can represent a fillet joint, etc.

The lower set of buttons (1-12) are used to select a weld condition that represents the
weld type number selected using the upper set of buttons. 12 different weld conditions
are available for each of the 12 (upper) weld type buttons. The values shown in figure 9-
21 are data base default values and may differ from values the operator typically uses.

Registering values for the weld data base is performed using auxiliary function 30.
Select AUX 30 (Figure 9-21) from the auxiliary function menu.

Normally completed
No. 1 No. 2 No. 3
AUX 30 ARC WELD DATA BASE
WELD SPEED 11 cm/min
CURRENT 11 A
No. 4 No. 5 No. 6
VOLTAGE 1.1 V
WEAVING AMPLITUDE 1.1 mm
FREQUENCY 1.1 Hz

CRATER TIME 1.1 s No. 1 No. 2 No. 3

CURRENT 11 A
VOLTAGE 1.1 V

No. 4 No. 5 No. 6

F1 F2 F3 F4
EXIT

Figure 9-21 Arc Weld Data Base

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AUXILIARY FUNCTIONS

The following procedure is used to register weld parameters (lower set of buttons) for
the 12 different weld type numbers (upper set of buttons).

1. Select the weld type by pressing the appropriate numbered weld type button (upper
set). The down arrow key to the right of the upper set of buttons allows access to
buttons 7-12.

2. Select the corresponding weld condition number (lower set) by pressing the appro-
priate numbered button. The down arrow key to the right of the lower set of buttons
allows access to buttons 7-12.

3. Press the MODIFY key to display the numeric and cursor keys.

4. Use cursor keys to highlight a parameter and enter a value with the numeric keys.

5. When all values are entered, press the RETURN key to register the parameters.
The message “Normally completed” is displayed in the message area.

6. Press the EXIT key to return to the previous screen.

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9.12 ARC WELD AUXILIARY DATA, AUX 31

The arc weld auxiliary data set is used to define system configurations. The system is
configured to meet application requirements. Figure 9-22 displays the AUX 31 menu.

AUX 31 ARC WELD AUX DATA AUX 31 ARC WELD AUX DATA

1 LINEARIZATION 11 SPECIAL PATTERN WEAVING

2 OFFSET/GAIN F3
3 WELD START SEQUENCE
4 SOFTWARE SLOW DOWN ï NEXT PG ï
5 WIRE STUCK CANCEL SEQUENCE
6 ARC SPOT SEQUENCE
7 PREFLOW/AFTERFLOW
8 WIRE INCHNG/RETRACT F2

ï ï
9 WELD ON/OFF IN CHECK
10 TOUCH SENSING PRE PG
FUNCTION NUMBER:
F1 F2 F3 F4 F1 F2 F3 F4

NEXT PG PRE PG

Figure 9-22 Auxiliary Weld Data Menu

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AUXILIARY FUNCTIONS

9.12.1 WELD AUXILIARY DATA, AUX 31, 1, LINEARIZATION

In the AUX 31 function screen, item 1 LINEARIZATION, is a table containing values

used to match the robot controller’s output signals for welding to the welding power
supply’s output. The robot controller outputs two analog signals (command signals) to
specify welding voltage and welding current. Welding power supplies use these com-
mand signals to apply voltage and current to the welding wire. Since welding power
supplies vary in design, the linearization table is assembled to provide constant, predict-
able weld characteristics. The linearization table allows the programmer to specify
welding voltages and currents in welding programs which are correct for the application.
The controller converts the programmed welding parameters into analog voltage outputs
between zero and fifteen volts DC.

Arc welding robots shipped with welding power supplies require no adjustment of the
linearization table. Creation of the linearization table is required when robots are
shipped without welding power supplies or when a power supply is changed. To create
the linearization table, select AUX 31 from the auxiliary function menu. Figure 9-24
shows the screens used to create the table. Separate screens are used for voltage, and
current values. Welding power supplies, which have limits on input signal voltage, re-
quire the use of the third screen in which the robot output voltages are limited to the
value entered in the MAX. OUTPUT VOLTAGE screen. The maximum settable voltage is
15 V.

Creation of the linearization table requires the user to program a welding path on a test
plate that maintains a specific wire extension (stickout). Travel speed should be similar
to the speed used for the application. Figure 9-23 is an example of the test plate. The
length of the weld should be long enough to establish a stable arc and the weld beads
should not overlap.

Figure 9-23 Linearization Test Plate

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AUX 31 ARC WELD AUX DATA

1 LINEARIZATION
1 CURRENT
2 VOLTAGE
3 MAX. OUTPUT VOLTAGE

FUNCTION NUMBER:

F1 F2 F3 F4

1 2 3
RETURN RETURN RETURN

1 CURRENT 2 VOLTAGE 3 MAX. OUTPUT VOLTAGE

1 64 A 147 mV 1 3.2 V 1328 mV MAX. OUTPUT VOLTAGE`15.0 V

2 96 A 735 mV 2 6.4 V 2656 mV
3 128 A 1500 mV 3 9.6 V 3983 mV
4 160 A 2450 mV 4 12.8 V 5311 mV
5 192 A 3530 mV 5 16.0 V 6639 mV
6 224 A 4740 mV 6 19.2 V 7967 mV
7 256 A 5980 mV 7 22.4 V 9395 mV
9 288 A 6830 mV 8 25.6 V 10622 mV

F1 F2 F3 F4 F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG PRE DATA NEXT PG PRE DATA

Figure 9-24 Auxiliary Weld Data Screens

Initial current and voltage values are entered in the beginning of the process. Begin with
the CURRENT screen. Starting at line 1 in the table, set the current to 50 A and its
command voltage to 0.5 V (500 mV). The range for command voltage is 0.0 mV to
15,000 mV. For the following item numbers in the table, increase the currents 25 A for
each increase in command voltage of 250 mV. Press the F3, NEXT PG key to enter
values in the remaining eight lines.

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AUXILIARY FUNCTIONS

Exit the CURRENT screen and select the VOLTAGE screen. Starting at line 1 in the
table, set the voltage to 3 V and its command voltage to 1.3 V (1,300 mV). The range for
command voltage is 0.0 mV to 15,000 mV. For the following item numbers in the table,
increase the voltages 3 V for each increase in command voltage of 1,300 mV. Press the
F3, NEXT PG key to enter values in the remaining eight lines.

When both the current and voltage tables have been completed, create and execute a
weld program that welds from a starting point to an ending point similar to the example
shown in figure 9-23. Repeat conditions should be set to once. Observe the amperage
and voltage meters on the welding power supply during the weld. Modify the pro-
grammed welding current as many times as required to match the value entered in the
linearization table. Select the ARC STATUS screen to view the commanded output
voltages used for completing the weld.

Return to the AUX 31 menu and select the CURRENT screen. Enter the commanded
voltage value noted from the ARC STATUS screen which produced the matching cur-
rents at the line number for each current. This process is repeated for the VOLTAGE
table screen also.

The linearization table is complete when program welding currents and voltages match
actual values indicated on the welding power supply.

9.12.2 WELD AUXILIARY DATA, AUX 31, 2, OFFSET/GAIN

The OFFSET/GAIN function allows the user to adjust the commanded analog output
voltages from the robot controller without changing the linearization table. The offset is
a constant value (mV) which is added to the commanded voltage value. The gain is a
multiplier (0.001) of the added offset and linearized values whose product is added to
the original linearization table value. The resulting analog output voltage is increased or
decreased. Offset values range from -9,999 to 9999 mV and gain values range from 0.0
to 9.999.

AUX 31 ARC WELD AUX DATA

2 OFFSET/GAIN

CURRENT OFFSET 0 mV
CURRENT GAIN 1.000

VOLTAGE OFFSET 0 mV
VOLTAGE GAIN 1.000

F1 F2 F3 F4

PRE DATA

Figure 9-25 Offset Gain Screen

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AUXILIARY FUNCTIONS

9.12.3 WELD AUXILIARY DATA, AUX 31, 3, WELD START SEQUENCE

Robot motion at a weld start point is improved by setting values in the start sequence to
compensate for metal imperfections. Two types of weld start sequences, scratch start
and stopping start are set by the weld start sequence function. Figure 9-26 shows the
two screens used to setup the weld start sequence.

AUX 31 ARC WELD AUX DATA AUX 31 ARC WELD AUX DATA

3 WELD START SEQUENCE 3 WELD START SEQUENCE

F3
THRESHOLD FOR SCRATCH/STOPPING START WELD START RETRY
100 mm ï NEXT PG ï NUMBER OF TIMES 0
SCRATCH START RETRACT TIME 0.7 s
KEEP WELDING DISTANCE 20 mm RETRACT SPEED 14 %
TURN BACK DISTANCE 20 mm TURN BACK SPEED 99 cm/min
STOPPING START F2 OVERLAP DISTANCE IN RESTART -1 mm
STOPPING TIME 2.0 s
ï PRE PG ï

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG PRE DATA PRE PG

Figure 9-26 Weld Start Sequence

[Link] THRESHOLD FOR SCRATCH/STOPPING START

Sets a distance limit (area 1, Figure 9-27) for the processor, which determines whether
a scratch start or stopping start method is used. If the threshold value setting (Figure 9-
26) is less than the distance between the weld start point and the next weld continue or
weld end point, the scratch method is used. If the threshold value setting (Figure 9-26)
is greater than the distance between the weld start point and the next weld continue or
weld end point, the stopping start method is used. The setable range for threshold
distance is 0.0 to 999.0 mm.

February 15, 2000 9-33

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

[Link] SCRATCH START

• KEEP WELDING DISTANCE

Sets a limiting distance (area 1, Figure 9-28) which allows robot motion to continue
beyond the taught weld start point with no arc established. When reaching the
specified distance, without arc initiation, the robot moves the torch back to the weld
start point and retries the arc start. If the arc is initiated in this area, the welding will
start at the point of initiation and continue welding towards the next weld continue or
weld end point.

• TURN BACK DISTANCE

Sets a limiting distance (area 2, Figure 9-29) which allows robot motion to continue
beyond the KEEP WELDING DISTANCE limit (area 1, Figure 9-28). If the arc is
initiated within this distance limit (area 2), welding then begins at the point of initia-
tion and the robot moves back to the weld start position before proceeding to the
next weld continue or weld end point. If the arc is not initiated, an arc failure error is
displayed and execution stops.

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

Figure 9-27 Scratch Start

Figure 9-28 Keep Welding Distance

Figure 9-29 Turn Back Distance

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

[Link] STOPPING START

• STOPPING TIME

Sets a time value (0.0 to 9.9) seconds which causes robot motion to stop at the
weld start point until the arc is established. When the arc is established within the
specified amount of time, motion to the next weld continue or weld end point begins.
If the arc is not established within the specified time, an arc failure error is displayed
and program execution stops.

[Link] WELD START RETRY

• NUMBER OF TIMES

Sets a number (0-9) for how many times the arc start sequence is performed
before generating an arc failure error.

• RETRACT TIME

Sets a weld wire retract time value (0.0 to 9.9) seconds for retracting the wire
before the retry.

• RETRACT SPEED

Sets wire retract speed at (0 to 999) percent before the retry.

[Link] TURN BACK SPEED

Sets the robot motion speed in (1 to 999) cm/min for moving the torch back to the weld
start point for an arc start retry.

[Link] OVERLAP DISTANCE IN RESTART

When an arc failure or a robot hold occurs between a weld start point and weld con-
tinue/end point, the robot enters the retry mode. The overlap function causes the torch
to move to the location of the arc failure and fill the crater. The distance value in (-1 to
99) millimeters is the distance the torch is moved back in the weld bead to start the
crater filling. Shown in figure 9-28, the overlap weld distance demonstrates where the
torch moves to fill the crater

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

Figure 9-30 Overlap Distance

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.12.4 WELD AUXILIARY DATA, AUX 31, 4, SOFTWARE SLOW DOWN

This function is used to improve the establishment of an arc when the base metal sur-
face is resistant to current flow. The parameters set with this function can be different
from the weld parameters set in the weld conditions for the step. The parameters speci-
fied in this function are valid for arc establishment only. Figure 9-31 displays the SOFT
WARE SLOW DOWN screen. Select 1: EFFECT to activate this function.

AUX 31 ARC WELD AUX DATA

4 SOFTWARE SLOW DOWN

SOFTWARE SLOW DOWN 0

(0:INEFFECT 1: EFFECT)
WELD CURRENT 0A
VOLTAGE 0.0 V
WEAVING AMPLITUDE 0.0 mm
FREQUENCY 0.0 Hz

F1 F2 F3 F4

PRE DATA

Figure 9-31 Software Slow Down

9.12.5 WELD AUXILIARY DATA, AUX 31, 5, WIRE STUCK CANCEL SEQUENCE

This function provides a means to separate a stuck welding wire from the puddle. The
crater conditions set in the weld end step are generated again to melt the wire and not
overfill the crater. Figure 9-32 displays the wire stuck cancel sequence screen.

AUX 31 ARC WELD AUX DATA

5 WIRE STUCK CANCEL SEQUENCE

NUMBER OF DETECTING TIMES 3

DETECTING WIRE STUCK
WAITING TIME 0.2 s
TIME 0.2 s
WELDING TIME 0.5 s

F1 F2 F3 F4

PRE DATA

Figure 9-32 Wire Stuck Cancel

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

[Link] NUMBER OF DETECTING TIMES

Sets the number of times (0-9) the arc on signal is output following the arc off.

[Link] DETECTING WIRE STUCK

• WAITING TIME

Sets a waiting time in seconds (0.0-9.9) that monitors for a wire stuck signal after
the arc turns off.

• TIME

Sets the amount of time to scan for wire stuck signal. If the wire stuck signal is
received in this time frame, the processor assumes the wire is stuck.

[Link] WELDING TIME

Sets the amount of time, in seconds (0.0-9), to turn the arc signal on.

9.12.6 ARC WELD AUXILIARY DATA, AUX 31, 6, ARC SPOT SEQUENCE

This function is used to specify a spot weld retry sequence when no current detect
signal is received. Figure 9-33 displays the ARC SPOT SEQUENCE screen.

AUX 31 ARC WELD AUX DATA

6 ARC SPOT SEQUENCE

RETRY
NUMBER OF TIMES 2
WIRE RETRACT TIME 0.7 s
WIRE RETRACT SPEED 14 %

AFTER ARC SPOT

WIRE RETRACT TIME 0.0 s
WIRE RETRACT SPEED 0 %

F1 F2 F3 F4

PRE DATA

Figure 9-33 Arc Spot Sequence

[Link] RETRY

• NUMBER OF TIMES

Sets the number (0-9) of retry sequences.

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AUXILIARY FUNCTIONS

• WIRE RETRACT TIME

Sets the length of time in seconds (0.0-9) for retracting the wire before retrying the
arc spot.

• WIRE RETRACT SPEED

Sets the wire retracting speed as a percentage (0-100) of wire feed speed, before
retrying the arc spot.

[Link] AFTER ARC SPOT

• WIRE RETRACT TIME

Sets the length of time in seconds (0.0-9) for retracting the wire after the arc spot
ends.

• WIRE RETRACT SPEED

Sets the wire retracting speed as a percentage (0-100) of wire feed speed after the
arc spot ends.

9.12.7 WELD AUXILIARY DATA, AUX 31, 7, PREFLOW/AFTERFLOW

This function is used to set timing, in seconds (0-9.9), for turning the shielding gas on
prior to and following the arc ON output signal. The preflow time specifies how many
seconds prior to arc ON that the shielding gas begins flowing. Afterflow specifies how
many seconds the gas continues flowing after the arc is OFF.

AUX 31 ARC WELD AUX DATA

7 PREFLOW / AFTERFLOW

PREFLOW TIME 0.0 s

AFTERFLOW TIME 0.0 s

F1 F2 F3 F4

PRE DATA

Figure 9-34 Shield Gas Preflow and Afterflow Times

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.12.8 WELD AUXILIARY DATA, AUX 31, 8, WIRE INCHING/RETRACT

This function is used to advance or retract the welding wire during an air cut motion.
The speed for inching, or retracting, is set as a percentage (0-100) of the maximum wire
feed speed. Steps of the program which use this function inch, or retract, the wire for
0.5 seconds. The speed setting is the only control of how much wire is inched or re-
tracted.

AUX 31 ARC WELD AUX DATA

8 WIRE INCHING / RETRACT

WIRE INCHING SPEED 4 %

WIRE RETRACT SPEED 4 %

F1 F2 F3 F4

PRE DATA

Figure 9-35 Wire Inching

9.12.9 WELD AUXILIARY DATA, AUX 31, 9, WELD ON/OFF IN CHECK

This function selects whether the arc ON signal is output when checking a program.
Use the cursor to highlight the desired condition and press the enter key.

AUX 31 ARC WELD AUX DATA

9 WELD ON / OFF IN CHECK

WELDING IN CHECK ON / OFF

F1 F2 F3 F4

PRE DATA

Figure 9-36 Weld in Check Mode

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.13 ZEROING, AUX 41

Auxiliary function 41, ZEROING, is used to set the value of the encoder count to a zero
degree reference position. From this screen, the user can select a single joint to be
zeroed or select all joints to be zeroed. The zeroing data, set with function 41, is en-
tered in conjunction with data recorded in auxiliary function 140. Figure 9-37 shows the
display screen when function 41 is selected.

! CAUTION
Users must be cognizant of the effect changes made in
this function will have on the position of programmed lo-
cations. Changing this data without following the com-
plete zeroing process may move programmed locations
to positions that will cause damage to the robot, fix-
tures, or work.

AUX 41 ZEROING
SETTING CURRENT
JT1 268422562 268422562
JT2 268437254 268437254
JT3 268421269 268421269
JT4 268433264 268433264
JT5 268427274 268427274
JT6 268428465 268428465

JOINT NO. = 0
(0 = all joint)
SET DEGREE = 0 deg

F1 F2 F3 F4

PRE DATA

Figure 9-37 Zeroing

The process for simple zeroing follows:

1. Jog all axes to be zeroed to the zeroing scribe marks.

2. Select auxiliary function 140, encoder count reset, and enter the joint number to be
zeroed. If all joints are to be zeroed, “0” is entered for the joint number.

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

3. Set the zero position value from the auxiliary function 41, ZEROING screen, by
entering the joint number to be zeroed. If all joints are to be zeroed, “0” is entered
for the joint number.

4. Confirm the new zero position by operating the robot in the check mode on a previ-
ously taught program to verify the playback accuracy of locations.

For further information about the zeroing process, reference C Controller Electrical
Maintenance Manual, unit 8, Zeroing.

9.14 POS. ERROR RANGE AT E-STOP, AUX 42

The POS. ERROR RANGE AT E-STOP function is used to set a comparison range for
checking the robot’s commanded position, when an emergency stop was applied, with
the position when motor power is reapplied. If the difference, between the robot’s posi-
tion when motor power is reapplied and when the emergency stop was pressed, is
greater than the set value, a position offset error is displayed. The position offset error
generated by this function cannot be reset and motor power cannot be applied. The
error range must be reset to a value that will not cause an error. The purpose of this
function is to prevent interference with fixtures, jigs, or work pieces when the robot is
restarted after an emergency stop condition.

The acceptable range of data for the position error range at emergency stop is from 0.1
degree to 10.0 degrees for axes one to six and from 0.1 mm to 100 mm for a seventh
axis. If 0 is entered the error check is not performed. The default setting for this function
is 0. The POS. ERROR RANGE AT E-STOP function screen is shown in figure 9-38.

AUX 42 POS. ERROR RANGE AT E-STOP

JT1 0.0deg
JT2 0.0deg
JT3 0.0deg
JT4 0.0deg
JT5 0.0deg
JT6 0.0deg

RANGE : Rotation 0.0deg - 10.0deg

Linear 0.0mm - 100.0mm

0.0 : error check not executed

F1 F2 F3 F4

PRE DATA

Figure 9-38 Position Error Range at E-Stop

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.15 ENCODER ERROR RANGE, AUX 43

This function sets the range of encoder deviation that is allowed before an error is dis-
played upon applying power to the controller. The encoder value when control power is
turned off is compared to the encoder value when control power is turned on. If the
difference is larger than the range set, a JT encoder abnormality error is displayed. The
range of acceptable data for this function is from 0.1 degree to 10.0 degrees for axes
one to six and from 0.1mm to 100mm for a seventh axis. The default setting for the
ENCODER ERROR RANGE function is 2.0 degrees. Operators should be aware that if
this range is set too low, error messages may be displayed when the system is perform-
ing within design performance specifications.

The display screen to set the values for the ENCODER ERROR RANGE function is
shown in figure 9-39. The F1, PRE. DATA, key is used to restore the settings if the enter
key has not been pressed.

AUX 43 ENCODER ERROR RANGE

JT1 2.0deg
JT2 2.0deg
JT3 2.0deg
JT4 2.0deg
JT5 2.0deg
JT6 2.0deg

RANGE :Rotation 0.1deg -10.0deg

Linear 0.1mm - 100.0mm

F1 F2 F3 F4

PRE DATA

Figure 9-39 Encoder Error Range

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.16 ZEROING DATA SET/DISPLAY, AUX 44

The ZEROING DATA SET/DISPLAY function allows the user to set encoder counts and
encoder offsets. Figure 9-40 shows the ZEROING DATA SET/DISPLAY. The first
screen shows the current encoder reading and setting. Setting allows the user to
specify a desired encoder count. The second screen shows the offset of the encoders.

AUX 44 ZEROING DATA SET / DISPLAY AUX 44 ZEROING DATA SET / DISPLAY

SETTING CURRENT OFFSET

JT1 268427264 267427264 JT1 65251

JT2 268427264 267427264 JT2 57343
JT3 268427264 267427264 JT3 0
JT4 268427264 267427264 JT4 65242
JT5 268427264 267427264 JT5 65534
JT6 268427264 267427264 JT6 65532

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG PRE DATA PRE PG

Figure 9-40 Zeroing Data Set/Display

9.17 ROBOT MOUNTING POSTURE

F-series robots can be installed in four positions, shown in figure 9-42. Auxiliary function
46 allows the user to enter system data which specifies the orientation of the base
coordinate system. Refer to figure 9-40 when setting system data with AUX 46 (Figure
9-41).

AUX 46 INSTALLATION POSTURE

INSTALLATION POSTURE 0

(0:FLOOR 1:CEILING 2:WALL 3:WALL2)

F1 F2 F3 F4

Figure 9-41 Robot Installation Posture

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

WALL WALL2

Figure 9-42 Mounting Posture

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.18 BASE COORDINATE, AUX 47

This function allows the user to redefine the base reference frame by effectively shifting
the base transformation values XYZ and OAT. When the machine is initialized, the
transformation values of the base coordinate system are set to a null or zero position. A
null base has the transformation values 0,0,0,0,0,0. The BASE COORDINATE function
can be used to change the base reference location.

Programmers must be aware of the impact shifting the base coordinate origin has on
program playback. Shifting the base coordinate origin results in the equivalent shift
occurring for all transformation locations stored in controller memory. However, loca-
tions recorded as precision points are played back based on the joint angles of the
robot’s six axes and will not be affected by a base coordinate shift. The acceptable
range for the base coordinate shift function is from -9,999.9 mm to 1,000 mm in the XYZ
directions and from -180° to 180° for OAT angles. The BASE COORDINATE function
screen is shown in figure 9-43.

AUX 47 BASE COORDINATE

BASE COORDINATE SHIFT VALUE

X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg

F1 Rotation
RANG: F20.0deg - F3
10.0deg F4
Traverse 0.0mm - 100.0mm
PRE DATA

Figure 9-43 Base Coordinate

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.19 ARC WELD TORCH DIMENSIONS, AUX 50

This function allows the user to register the torch dimensions which defines the tool
center point. Figure 9-44 displays the torch dimensions screen. Three values must be
entered to define the tool center point. Refer to figure 9-44 when entering values for
length, angle, and wire extension (stickout).

AUX 50 ARC WELDING TORCH DIMENSION

LENGTH 404 mm
ANGLE 55 deg
WIRE EXTENSION 15 mm

F1 F2 F3 F4

LENGTH item A dimension range: 0-999 mm

ANGLE item B dimension range: 0-180 degrees
WIRE EXTENSION item C dimension range: 0-999 mm

Figure 9-44 Torch Dimensions

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.20 SOFTWARE LIMIT, AUX 51

This function allows the user to set the upper and lower limits of robot travel, expressed
in degrees of axes rotation. The robot does not move to locations that are outside of
these limits. When jogging the robot, an audio beep is transmitted to identify the ap-
proach of a software limit. The frequency of the audio beep increases as the manipula-
tor gets closer to the limit. When the limit is reached the robot stops moving in that
direction and the audio transmitted is constant, no error message is generated. The
robot is jogged away from software limits by simply changing its direction. If the robot is
moved using the brake release, to a location beyond the software limits or the software
limits have changed, you can jog back into the software limits envelope.

The SOFTWARE LIMIT display is shown in figure 9-45. The allowable maximum and
minimum settings are displayed along with the current settings. Use the cursor keys and
numeric keypad to change the settings. If data is entered that is beyond the allowable
settings, the display does not accept the change and identifies that data as out of range.
The first screen displayed shows the upper limits, the lower limits are displayed by
pressing the F3 key. The user must be aware that the minus sign for the lower limit
settings is not assumed and must be included when data for the lower limits is set.

AUX 51 SOFTWARE LIMIT AUX 51 SOFTWARE LIMIT

UPPER LOWER
SET ABLE UPPER SETTING SET ABLE LOWER SETTING

JT1 160.000 deg 160.000 deg JT1 -160.000 deg -160.000 deg
JT2 140.000 deg 140.000 deg F3 JT2 -105.000 deg -105.000 deg
JT3 120.000 deg 120.000 deg JT3 -155.000 deg -155.000 deg
JT4 270.000 deg 270.000 deg ï NEXT PG ï JT4 -270.000 deg -270.000 deg
JT5 145.000 deg 145.000 deg JT5 -145.000 deg -145.000 deg
JT6 360.000 deg 360.000 deg JT6 -360.000 deg -360.000 deg

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG PRE DATA PREV PG

Figure 9-45 Software Limit

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.21 ACCURACY, AUX 53

When function 53, ACCURACY, is selected from the auxiliary function menu, the screen
shown in figure 9-46 appears. From this screen, the user can set the four accuracies
that are used in block step programming. The acceptable accuracy range is from
0.1 mm to 5,000 mm. When the robot is in the repeat mode of operation, the playback
accuracy is affected by a number of things, including: the distance between the taught
points, the setting of the CP switch, and if the step contains timers or other wait condi-
tions.

AUX 53 ACCURACY

ACCURACY1 1.0 mm
ACCURACY2 10.0 mm
ACCURACY3 50.0 mm
ACCURACY4 100.0 mm

F1 F2 F3 F4

PRE DATA

Figure 9-46 Accuracy

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.22 SPEED, AUX 54

When function 54, SPEED, is selected from the auxiliary function menu, the screen
shown in figure 9-47 appears. From this screen, the user can set the ten speeds that
are used in block step programming. The acceptable speed range is from 0.1 to 100%.
For joint interpolated moves, the playback speed percentage is determined by the speed
of the fastest joint. For linear and circular interpolated moves, the playback speed
percentage is determined by the maximum linear interpolation speed. When the robot is
in the repeat mode of operation, the playback speed is a function of both the step speed
and the repeat condition speed.

AUX 54 SPEED

SPEED 0 10.0%
SPEED 1 20.0%
SPEED 2 30.0%
SPEED 3 40.0%
SPEED 4 50.0%
SPEED 5 60.0%
SPEED 6 70.0%
SPEED 7 80.0%
SPEED 8 90.0%
SPEED 9 100.0%

F1 F2 F3 F4

[Link]

Figure 9-47 Speed

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.23 SLOW REPEAT MODE, AUX 55

When function 55, SLOW REPEAT MODE, is selected from the auxiliary function menu,
the screen shown in figure 9-48 is displayed. This function allows the user to set the
slow repeat mode speed of the robot from 1 to 25% of maximum speed. A dedicated
input signal must be assigned for the slow repeat mode function. When this signal is
ON, the SLOW REPEAT MODE of operation is activated.

Figure 9-48 Slow Repeat Mode

9.24 CHECK SPEED, AUX 56

The check speed function sets the three speeds available for single step program play-
back using the check forward and check backward keys in teach mode. The check
speed corresponds to the , , , indicators, representing speeds one, two, and
three and is set in millimeters per second. The default settings are shown in figure 9-49.

AUX 56 CHECK SPEED

SPEED1 10.0 mm/s

SPEED2 80.0 mm/s
SPEED3 250.0 mm/s

F1 F2 F3 F4

PRE DATA

Figure 9-49 Check Speed

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.25 TEACH SPEED, AUX 57

When function 57, TEACH SPEED, is selected from the auxiliary function menu, the
display changes to the screen shown in figure 9-50. From this screen, the three jogging
speeds and inching distances are set. The teach speed set from this function corre-
sponds to the speed selected on the mulit function panel displayed by , , or ,
representing speeds one, two, and three. The teach speed function can be set up to a
maximum of 250.0 mm/sec. The maximum allowable teach speed is defined by ANSI/
RIA standards. The inching distances set from this function correspond to the inching
selection on the multi function panel, displayed by , , or representing distances
one, two, and three. The maximum setable inching distance is 1.000 mm.

AUX 57 TEACH SPEED

[Link] INCHING

SPEED1 10.0 mm/s 0.001 mm

SPEED2 80.0 mm/s 0.500 mm
SPEED3 250.0 mm/s 1.000 mm

F1 F2 F3 F4

PRE DATA

Figure 9-50 Teach Speed

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AUXILIARY FUNCTIONS

9.26 TIMER, AUX 58

The TIMER function allows the user to set nine timers for use in block step programs.
The timers can range from 0.1 second to 99.9 seconds. Figure 9-51 shows the TIMER
function screen.

AUX 58 TIMER

TIMER.1 0.1s
TIMER.2 0.2s
TIMER.3 0.3s
TIMER.4 0.4s
TIMER.5 0.5s
TIMER.6 0.6s
TIMER.7 0.7s
TIMER.8 0.8s
TIMER.9 0.9s

F1 F2 F3 F4

[Link]

Figure 9-51 Timer Settings

9.27 MEMORY AVAILABLE, AUX 70

This function is used to display the amount of memory available for programming. The
available memory is displayed in both bytes and percentage of usable memory. Figure
9-52 shows the MEMORY AVAILABLE display.

AUX 70 MEMORY AVAILABLE

All Memory Size 940824 Bytes

Available Memory Size 935972 Bytes (99%)

F1 F2 F3 F4 F5 F6
EXIT

Figure 9-52 Memory Available

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.28 RECORD DATA (PRG CHG) INHIBIT, AUX 71

The RECORD DATA (PRG CHG) INHIBIT function allows the user to prevent the record-
ing of blockstep information by selecting INHIBIT for record. AS Language programs
cannot be edited if the RECORD DATA (PRG CHG) INHIBIT is set to INHIBIT. When
set to INHIBIT, attempts to change data causes an error and a message is displayed.
The error message instructs the programmer to set the respective switch to the AC-
CEPT status. The RECORD DATA (PRG CHG) INHIBIT display screen is shown in
figure 9-53.

AUX 71 RECORD DATA(PRG CHG) INHIBIT

RECORD ACCEPT / INHIBIT

PRG CHANGE ACCEPT / INHIBIT

F1 F2 F3 F4

PRE DATA

Figure 9-53 Record Data Inhibit

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.29 SYSTEM SWITCH, AUX 75

The SYSTEM SWITCH function allows the user to turn software switches on and off to
alter various functions of the system. It is important to realize that any changes made to
the status of these switches are global and affect all programs in system memory. When
function 75 is selected from the aux function menu, the screens shown in figure 9-54 are
displayed individually. The F3 key is used to display the remaining switches and the F2
key is used to return to the previous screen.

AUX 75 SYSTEM SWITCH AUX 75 SYSTEM SWITCH

ARC OFF WVDIR OFF

RTPM OFF [Link] OFF
RTCMDI OFF CP ON
RTCONT OFF [Link] OFF
RTLOG OFF [Link] ON
AVC OFF [Link] OFF
SSENSING OFF QTOOL OFF
AVCBASE OFF REP_ONCE OFF

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG ON/OFF PRE DATA PREV PG ON/OFF

AUX 75 SYSTEM SWITCH AUX 75 SYSTEM SWITCH

RPS OFF [Link] OFF

STP_ONCE OFF DISPIO_O1 OFF
[Link] OFF [Link] OFF
MESSAGES ON WS_COMPOFF OFF
SCREEN ON [Link] OFF
[Link] OFF [Link] OFF
[Link] OFF
[Link] OFF

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG ON/OFF PRE DATA PREV PG ON/OFF

Figure 9-54 System Switches

To change the setting of any system switch, use the cursor keys to select the switch title
then press the F4 key. Verify the switch status and press the return key to register the
new setting.

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AUXILIARY FUNCTIONS

9.29.1 OPTIONAL SYSTEM SWITCHES

The following is a list of optional system switches, refer to unit 11 for further details.

• RTPM

• RTCMDI

• RTCONT

• RTLOG

• AVC

• SSENSING

• AVCBASE

• WVDIR

9.29.2 ARC SWITCH

The ARC switch is used to activate the dedicated output signal to the welding power
supply. This switch must be ON to energize the weld wire in a welding step. If the
switch is OFF during a welding step, the weld is not executed.

9.29.3 [Link] SWITCH

The function of the [Link] switch involves the use of the AS Language com-
mands EXECUTE, DO, STEP, MSTEP and CONTINUE. When the [Link]
switch is ON, these commands are available when the HOLD/RUN switch is in the
HOLD position. The controller will accept these commands with the RUN/HOLD switch
in the HOLD position, but robot motion is not initiated until the switch is manually placed
in the RUN position.

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AUXILIARY FUNCTIONS

9.29.4 CP (CONTINUOUS PATH) SWITCH

The CP switch is used to activate the continuous path function during program execu-
tion. When this switch is ON and the accuracy ranges are large, the robot makes
smooth transitions from point-to-point, as indicated in figure 9-55 When the switch is
OFF, the robot decelerates and stops at each recorded point regardless of the accuracy
set for those points.

Robot path with CP ON

Robot path with CP OFF
TAUGHT POSITION

ACCURACY RANGE

Figure 9-55 CP Switch

9.29.5 [Link] SWITCH

The [Link] switch is used in conjunction with an external input signal used to
stop the motion of the robot. With the switch ON, when the input signal is received the
robot stops and the CYCLE START light turns off. When the program is started again, it
starts at the beginning. If the program was called from another program, the program
restarts at the beginning of the main program. With the switch OFF, when the input
signal is received the robot stops and the CYCLE START light remains ON. The robot is
in a hold condition and when the program is restarted it continues at the point in the
cycle where it stopped. The default setting for the [Link] switch is off.

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AUXILIARY FUNCTIONS

9.29.6 [Link] SWITCH

The [Link] switch affects the timing of output signal generation in block step
programs. When the switch is ON, an output programmed for a given point is turned on
as soon as the robot begins motion to that point. With the [Link] switch OFF, an
output programmed for a given point is not turned on until the robot reaches the accu-
racy range of the point. Figure 9-56 shows the different effects the [Link] switch
has on signal timing.

With the OX preout switch

off, output 2 turns on here
2
With the OX preout switch
on, output 2 turns on here
Program step containing
2 output (OX) signal 2

Robot path

Accuracy range

Figure 9-56 [Link] Switch

9.29.7 [Link] SWITCH

The [Link] switch is used in conjunction with AS Language instructions

and has the same affect on signal timing that the [Link] switch has with
blockstep instructions.

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AUXILIARY FUNCTIONS

9.29.8 REP_ONCE (REPEAT ONCE) SWITCH

When the REP_ONCE switch is ON, programs will run one time. With the switch OFF
the program will run continuously.

9.29.9 RPS (REMOTE PROGRAM SELECTION) SWITCH

This switch enables the processor to scan for a binary input from peripheral devices and
select a program to execute. The AS Language instructions: EXTCALL, JUMP, and
END combined with the input signal and RPS function determine which program is
selected to run.

9.29.10 STP_ONCE (STEP ONCE) SWITCH

When the STP_ONCE switch is ON, the repeat condition function of progressing
through a program one step at a time becomes active. The step forward key is used to
progress through a program. When the switch is OFF, the program runs continuously.

9.29.11 [Link] TIMER SWITCH

When the [Link] TIMER switch is in the ON condition, timers do not begin their
timing at a specified step until all wait conditions are satisfied. With the switch in the
OFF position, timers begin timing when the robot reaches coincidence of the taught
point.

9.29.12 MESSAGES SWITCH

The MESSAGES switch permits PRINT or TYPE information in an AS Language pro-

gram to be displayed on the multi function panel. If the messages switch is OFF this
information is not displayed.

9.29.13 SCREEN SWITCH

This switch enables or disables the scrolling of the screen when the amount of informa-
tion being sent by the processor is larger than the screen can display.

9.29.14 [Link] SWITCHES

The [Link], [Link], AND [Link] switches automati-

cally start the associated PC program when control power is applied.

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9.29.15 [Link] SWITCH

When specified errors occur, a PC program is started if the [Link] switch is in

the ON position.

9.29.16 DISPIO_01 SWITCH

This switch allows the user to select the type of display that is available to view the
status of inputs and outputs. If the switch is ON, 1s and 0s are displayed to identify the
signal state of individual signals. A signal that is on is represented by a 1, while 0 is
used to represent a signal that is off. If the switch is OFF, Xs and Os are used to repre-
sent the signal states. A signal that is ON is represented by an O, while X is used to
represent a signal that is OFF. The X and O display also identifies if a signal number
has a dedicated function. Dedicated signals are represented by uppercase Xs and Os.

9.29.17 [Link]

When the hold/run switch is placed in the hold position, the multi-function panel displays
the actual/current step motion.

9.29.18 [Link]

This function enables a watchdog timer between the controller’s 1GA board CPU and
the CPU of a Sharp sequencer board.

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AUXILIARY FUNCTIONS

9.30 HOME POSITION, AUX 76

The HOME POSITION function allows the user to set two home positions for the robot.
These home positions can be set to any location within the work envelope. Home posi-
tions have two unique characteristics. A dedicated output signal can be assigned to
each home position. Whenever the robot is in that position the signal is generated.
Home positions are also recognized as AS Language commands. The only code
needed to send the robot to a home position is the instruction “HOME or HOME2”.
When this instruction is encountered, the robot performs a joint move to the home
position.

Figure 9-57 shows the screen to set HOME POSITION 1. The user can choose to enter
the desired home position expressed in joint angles or the current position of the robot.
To enter a HOME position other than the current position, use the cursor keys to high-
light KEY-IN and move to the desired joint number. Enter the desired number of de-
grees for each joint and press ENTER when completed. The range for the home posi-
tion is also set from this screen. When the robot reaches a point within the specified
range, the output signal is generated. It is recommended that the range for the home
position be set between 5 mm and 10 mm. This ensures the home position output is
generated with the robot in a safe position.

AUX 76 HOME POSITION

HOME POSITION 1

SET [Link]./KEY-IN
JT1 0.000deg
JT2 0.000deg
JT3 0.000deg
JT4 0.000deg
JT5 0.000deg
JT6 0.000deg

RANGE 10.0mm

F1 F2 F3 F4

[Link] NEXT PG

Figure 9-57 Home Position

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AUXILIARY FUNCTIONS

9.31 CLEAR CHECK SUM ERROR, AUX 78

The CLEAR CHECK SUM ERROR function allows the user to clear error 1019, abnor-
mal check sum. An abnormal check sum error is generated when the processor calcu-
lates a difference between data when the controller is powered up compared to an
expected value. When this error occurs the programmer selects AUX 78, the first (left)
screen shown in figure 9-58 is displayed, and change the setting to “EFFECT”. When
control power is cycled, the error may be cleared and the setting returned to “EFFECT”.
If the clear check sum error does not clear with the cycling of control power, the second
screen (right) shown in figure 9-58 is displayed, identifying additional troubleshooting
paths.

AUX 78 CLEAR CHECK SUM ERROR AUX 78 CLEAR CHECK SUM ERROR

CLEAR CHECK SUM ERROR EFFECT/INEFFECT Cannot clear sum check error.
Confirm the following function.

ZZERO
DEFSIG
:
:

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA

Figure 9-58 Clear Check Sum Error

9.32 CHANGE PROGRAM NAME, AUX 88

Aux 88, CHANGE PROGRAM NAME, allows the user to change the names of existing
programs. To change the name of a program, select Aux 88 from the function screen.
The CHANGE PROGRAM NAME screen appears as shown in figure 9-59. Perform the
following steps to change the name of the program.

1. Position cursor in the “Old program name” field using cursor keys. Press F1 PRO-
GRAM INPUT and the PROGRAM SELECT screen appears.

2. Scroll to the program name to be changed.

3. Press RETURN. The CHANGE PROGRAM NAME screen reappears with the name
of the selected program in the “Old program name” field.

4. Position cursor in the “New program name” field using cursor keys.

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5. Press F1 PROGRAM INPUT, the PROGRAM SELECT screen re-appears with “pg”
at the bottom of the window.

6. Press the CHARACTER key and enter the new program name.

7. Press RETURN, the PROGRAM SELECT screen appears with the new name in the
bottom of the window.

8. Press RETURN. The CHANGE PROGRAM NAME screen re-appears with both the
old and the new name.

9. Press RETURN again and the prompt “Are you sure?” appears.

10. Press the YES key.

Figure 9-59 Change Program Name

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AUXILIARY FUNCTIONS

9.33 SOFTWARE VERSION DISPLAY, AUX 90

This function allows the user to view the version of software that is operating in the
controller and multi function panel. The screen that is displayed when function 90 is
selected is shown in figure 9-60.

AUX 90 SOFTWARE VERSION DISPLAY

AS
Robot name : FA006L-A001
Software version : version 08000I0E .... 99/02/04 21:04
Servo : AIAOU-FA006L-02 (F502); 1999.02.03 FA006L-A001
Seq. board : version NAC042 ... 98/12/07 15:53
Number of signals : output = 128 input = 128 internal = 256
Clamp number : 2

TP
Software version : version T800IOE ...99/02/03 19:21

F1 F2 F3 F4 F5 F6

RETURN

Figure 9-60 Software Version Display

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AUXILIARY FUNCTIONS

9.34 ENVIRONMENT DATA, AUX 91

The ENVIRONMENT DATA function is used to set an AUTO SERVO OFF TIMER and
identify if the controller is operating with a teach pendant, or multi function panel, in-
stalled.

The AUTO SERVO OFF TIMER sets a time period that motor power remains ON if no
movement of the robot has occurred, e.g., WX or wait condition. The AUTO SERVO
OFF TIMER function is designed to save energy by allowing the brakes to maintain
robot position as opposed to using electrical power and servo motors. When the robot
has not moved and the auto servo timer has reached its set value, the brakes are ap-
plied and power is removed from the servo motors. The motor power light remains ON
and the robot begins motion under the same conditions it would have if the auto servo
timer had not removed power from the motors.

The ENVIRONMENT DATA function also allows the user to identify weather or not a
teach pendant is installed. The deadman buttons and the emergency stop button are
hard-wired and a jumper (or a different user interface) must be installed if the teach
pendant is removed.

Figure 9-61 shows the screen that is displayed when AUX 91 is selected.

AUX 91 ENVIRONMENT DATA

AUTO SERVO OFF TIMER 0 sec

(0: Not servo off)
TEACH PENDANT CONN./DISCONN.

F1 F2 F3 F4

[Link]

Figure 9-61 Environment Data

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9.35 ENVIRONMENT DATA2, AUX 95

The ENVIRONMENT DATA2 function allows the user to identify if a multi function panel
or terminal is installed. The deadman buttons and the emergency stop buttons of the
multi function panel are hard-wired and a jumper (or a different user interface) must be
installed if the multi function panel is removed. Figure 9-62 shows the ENVIRONMENT
DATA2 screen.
AUX 95 ENVIRONMENT DATA2

PANEL CONN./DISCONN.
TERMINAL CONN./DISCONN.

F1 F2 F3 F4

[Link]

Figure 9-62 Environment Data 2

9.36 ENVIRONMENT DATA OF PANEL, AUX 96

The AS INSTRUCTION. [Link], KEYBOARD, PROGRAM EDIT, and AS

INSTRUCTION TEACHING menu items from this function affect the menus available in
the teaching screens of the multi function panel. When ON is selected for these items,
they are available when the teaching key is pressed. When OFF is selected, pressing
the teaching key wil not display the associated functions and screens. Figure 9-63
shows the ENVIRONMENT DATA OF PANEL screen.

AUX 96 ENVIRONMENT DATA OF PANEL

AS INSTRUCTION [Link] ON/OFF

KEYBOARD ON/OFF
PROGRAM EDIT ON/OFF
AS INSTRUCTION TEACHING ON/OFF

CHECK MODE ON/OFF

2 PUSH RECORD MODE ON/OFF
BLOCK TEACHING ON/OFF
PROGRAM COMMENT ON/OFF

F1 F2 F3 F4

PRE DATA

Figure 9-63 Environment Data of Panel

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9.37 CHECK SPEC. (CHECK SPECIFICATION), AUX 99

The CHECK SPEC. function is used to select whether certain AS Language instructions
are performed when programs are run in the check step mode. The following com-
mands can be set as EFFECT (on) or INEFFECT (off) during the check step process:
CALL, TIMER, JUMP/END, OX, WX. If INEFFECT is selected for any of these com-
mands, when a program is executed using the check mode process, the command is
not processed as a program instruction and is bypassed.

When the check step process is conducted in reverse order, only the OX instructions are
dependent on the settings of auxiliary function 99. The AS Language instructions CALL,
TIMER, JUMP/END, and WX are not processed when reverse order check stepping.
Figure 9-64 shows the auxiliary function 99, CHECK SPEC. screen.

AUX 99 CHECK SPEC.

CALL EFFECT/INEFFECT
TIMER EFFECT/INEFFECT
JUMP/END EFFECT/INEFFECT
OX EFFECT/INEFFECT
WX EFFECT/INEFFECT

STEP CONTINUOUS EFFECT/INEFFECT

VELOCITY PRIORITY EFFECT/INEFFECT
VELOCITY PRIORITY2 EFFECT/INEFFECT

F1 F2 F3 F4

PRE DATA

Figure 9-64 Check Spec. Screen

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! CAUTION
Initializing the system erases all program and variable
data. If a PC is connected to the controller and the ini-
tialization function is selected, care must be taken not to
initialize the hard drive of the PC.

9.38 SYSTEM INIT. (SYSTEM INITIALIZATION), AUX 100

The SYSTEM INIT. function is used to clear everything from system memory. When the
system is initialized, all programs and variables are deleted and system settings are set
to default. The only information not affected by the initialization process is the error and
operations logs. Figure 9-65 shows the screen that appears when function 100, SYS-
TEM INIT. is selected. ENTER is selected to activate initialization of the system from
this screen. If the system is not to be initialized, EXIT is selected returning the screen to
the first auxiliary function screen.

AUX 100 SYSTEM INIT.

**************
* WARNING *
**************

If this function is performed, all

data in memory will be deleted.
And all system switches will be
reset to default setttings.

OK to initialize? (ENTER/EXIT)

F1 F2 F3 F4

Figure 9-65 System Initialization

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9.39 BATTERY ERROR CHECK, AUX 101

If EFFECT is selected from this function, when control power is applied, the batteries
that maintain RAM memory are checked for low voltage. If a low voltage is detected, an
error message is displayed. If INEFFECT is selected from this function, the batteries
are not checked when control power is applied. Figure 9-66 shows the screen for the
battery error check.

AUX 101 BATTERY ERROR CHECK

BATTERY ERROR CHECK EFFECT/INEFFECT

F1 F2 F3 F4

PRE DATA

Figure 9-66 Battery Error Check

9.40 TOUCH PANEL SHORT CIRCUIT CHECK, AUX 103

The touch panel short circuit check function enables (EFFECT), or disables
(INEFFECT), the touch screen short circuit test at power up. When enabled, the control-
ler tests the multi function panel’s touch screen when control power is turned on. Should
a short be detected, an error is displayed on the screen.

AUX 103 TOUCH PANEL SHORT CIRCUIT CHECK

TOUCH PANEL SHORT CIRCUIT EFFECT/INEFFECT

F1 F2 F3 F4

PRE DATA

Figure 9-67 Touch Panel Short

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9.41 TIME, AUX 110

The TIME function is used to set the current year, month, day, and time. The controller
automatically displays the day of the week based on date information. The cursor keys
are used to select the data field to be modified. Error and operations logs are date and
time stamped using the information from this function. Figure 9-68 shows the TIME
function screen.

AUX 110 TIME

DATE : 97-5-20 (TUE)

TIME : [Link]

F1 F2 F3 F4

Figure 9-68 Time

9.42 DEDICATED INPUT SIGNAL, AUX 111

The DEDICATED INPUT SIGNAL function allows the user to identify signal numbers
that are assigned specific functions and cannot be used for other purposes. Figure 9-69
shows the screens that are used to set dedicated input signals. Five pages of signals
are contained within AUX 111, use the NEXT PG and PRE PG keys to select the de-
sired page for signal dedication.

AUX 111 DEDICATED INPUT SIGNAL AUX 111 DEDICATED INPUT SIGNAL

EXT. MOTOR_ON SET/RESET EXT. Prog. Select (JUMP) SET/RESET

SIGNAL/NUMBER: 1032 JUMP_ON 0
EXT. ERROR RESET SET/RESET JUMP_OFF 0
SIGNAL/NUMBER: 0 JUMP_ST 0
EXT. CYCLE START SET/RESET EXT. Prog. Select (RPS) SET/RESET
SIGNAL/NUMBER: 1030 RPS_ON 0
EXT. PROGRAM RESET SET/RESET RPS_ST 0
SIGNAL/NUMBER: 0 Number of RPS code signals 0
First signal No. of RPS code 0
Code (0: Binary 1: BCD) 0

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG PRE DATA PRE PG NEXT PG

Figure 9-69 Dedicated Input Signal

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AUX 111 DEDICATED INPUT SIGNALS AUX 111 DEDICATED INPUT SIGNALS AUX 111 DEDICATED INPUT SIGNALS

EXT_IT SET/RESET Positioner off signal SET/RESET ARC SIGNAL (INPUT) SET/RESET
SIGNAL NUMBER: 0 SIGNAL NUMBER: 0 POLE STUCK 2002
EXT. SLOW REPEAT MODE SET/RESET EXT_HOLD_RESET SET/RESET TORCH INTERFERE 1029
SIGNAL NUMBER: 0 SIGNAL NUMBER: 0 WIRE STICK SIGNAL 2003
Wire inching signal SET/RESET I/F PANEL PAGE1 SELECT SET/RESET WIRE TOUCH 2004
SIGNAL NUMBER: 0 SIGNAL NUMBER: 0 WCR 1010
External weld signal SET/RESET I/F PANEL PAGE2 SELECT SET/RESET
SIGNAL NUMBER: SIGNAL NUMBER: 0
Wire retract signal SET/RESET
SIGNAL NUMBER: 0

F1 F2 F3 F4 F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA PRE PG NEXT PG PRE DATA PRE PG NEXT PG PRE DATA PRE PG

Figure 9-69 Dedicated Input Signal (continued)

Use the up or down cursor key to select the desired signal. Use the right or left cursor
key highlight SET or RESET. Press the RETURN key to register the setting. When
setting a dedicated signal, the numeric keys are used to select the desired signal num-
ber.

9.43 DEDICATED OUTPUT SIGNAL, AUX 112

The DEDICATED OUTPUT SIGNAL function allows the user to identify signal numbers
that are assigned specific functions and cannot be used for other purposes. Ten pages
are included in AUX 112 for signal dedication. Figure 9-70 shows the screens used to
set dedicated output signals.

AUX 112 DEDICATED OUTPUT SIGNAL AUX 112 DEDICATED OUTPUT SIGNAL

MOTOR_ON SET/RESET Step continuous SET/RESET

SIGNAL NUMBER: 32 TEACH LOCK OFF. SET/RESET
ERROR SET/RESET CYCLE START ON. SET/RESET
SIGNAL NUMBER: 31 RGSO ON. SET/RESET
AUTOMATIC SET/RESET Dryrun mode off. SET/RESET
SIGNAL NUMBER: 30 CYCLE START SET/RESET
Run in panel switch SET/RESET SIGNAL NUMBER: 0
EXT_IT not set to hold SET/RESET TEACH MODE SET/RESET
Repeat in panel switch SET/RESET SIGNAL NUMBER: 31
Repeat continuous SET/RESET

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA NEXT PG PRE DATA PRE PG NEXT PG

Figure 9-70 Dedicated Output Signal

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AUX 112 DEDICATED OUTPUT SIGNAL

HOME1 SET/RESET Positioner on signal SET/RESET

SIGNAL NUMBER: 0 SIGNAL NUMBER: 0
HOME2 SET/RESET Positioner speed signal SET/RESET
SIGNAL NUMBER: 0 No. of sig.: 0
POWER_ON SET/RESET SIGNAL NUMBER: 0
SIGNAL NUMBER: 0 ERROR #1 SET/RESET
RGSO SET/RESET SIGNAL NUMBER: 0
SIGNAL NUMBER: 0 Error code start n 0
Ext. Prog select (RPS) enabled SET/RESET Error code end number: 0
SIGNAL NUMBER: 0

F1 F2 F3 F4

PRE DATA PRE PG NEXT PG

AUX 112 DEDICATED OUTPUT SIGNALS AUX 112 DEDICATED OUTPUT SIGNALS

ERROR #2 SET/RESET ERROR #4 SET/RESET

SIGNAL NUMBER: 0 SIGNAL NUMBER: 0
Error code start number: 0 Error code start number: 0
Error code end number: 0 Error code end number: 0
ERROR #3 SET/RESET ERROR #5 SET/RESET
SIGNAL NUMBER: 0 SIGNAL NUMBER: 0
Error code start number: 0 Error code start number: 0
Error code end number: 0 Error code end number: 0

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA PRE PG NEXT PG PRE DATA PRE PG NEXT PG

AUX 112 DEDICATED OUTPUT SIGNALS AUX 112 DEDICATED OUTPUT SIGNALS

ERROR #6 SET/RESET ERROR #8 SET/RESET

SIGNAL NUMBER: 0 SIGNAL NUMBER: 0
Error code start number: 0 Error code start number: 0
Error code end number: 0 Error code end number: 0
ERROR #7 SET/RESET WCR SET/RESET
SIGNAL NUMBER: 0 SIGNAL NUMBER: 0
Error code start number: 0 WELD_ON/OFF SET/RESET
Error code end number: 0 SIGNAL NUMBER: 25
ROBOT_HOLD SET/RESET
SIGNAL NUMBER: 28

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA PRE PG NEXT PG PRE DATA PRE PG NEXT PG

Figure 9-70 Dedicated Output Signal (Continued)

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AUX 112 DEDICATED OUTPUT SIGNALS AUX 112 DEDICATED OUTPUT SIGNALS

ARC SIGNAL (OUTPUT) SET/RESET ARC CURRENT (OUTPUT) SET/RESET

TOUCH SENSING 10 NUM. OF SIG. 0
STICK DETECT 98 NUM. OF START SIG. 0
FEEDER ON 99 Code (0:Binary 1:BCD) 0
GAS ON 22 ARC VOLTAGE OUTPUT SET/RESET
WIRE INCHING 24 NUM. OF SIG. 0
WIRE RETRACT 23 NUM. OF START SIG. 0
ARC ON 21 Code (0:Binary 1:BCD) 0

F1 F2 F3 F4 F1 F2 F3 F4

PRE DATA PRE PG NEXT PG PRE DATA PRE PG

Figure 9-70 Dedicated Output Signal (Continued)

Use the up or down cursor key to select the desired signal. Use the right or left cursor
key to highlight SET or RESET. Press the RETURN key to register the setting. When
setting a dedicated signal, the numeric keys are used to select the desired signal num-
ber.

9-74 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.44 DEDICATED SIGNAL DISPLAY, AUX 113

The DEDICATED SIGNAL DISPLAY, function 113, is a screen displaying the settings of
both dedicated input and output signals. This function is used to review the status of the
dedicated signals and cannot be used to set or release dedicated signals. Figure 9-71
shows the screens that are displayed when function 113 is selected.

Dedicated signals are set

EXT. MOTOR ON = 1060
EXT. CYCLE START = 1003
ARC SIGNAL (INPUT)
POLE STUCK = 2002
TORCH INTERFERE = 1029
WIRE STICK SIGNAL = 2003
WIRE TOUCH = 2004
WCR = 1010
MOTOR ON = 32
ERROR = 28

F1 F2 F3 F4 F5 F6

NEXT PG
EXIT
ð

F3
ð

NEXT PG
ð

F2

PRE PG
ð

AUX 113 DEDICATED SIGNALS DISPLAY

CYCLE START = 27
HOME1 = 30
WELD_ON/OFF = 25
ARC SIGNAL (OUTPUT)
TOUCH SENSING = 10
STICK DETECT = 98
FEEDER ON = 99
GAS ON = 22
WIRE INCHING = 24
WIRE RETRACT = 23
ARC ON = 21

F1 F2 F3 F4 F5 F6

PREV PG
EXIT

Figure 9-71 Dedicated Signal Display

February 15, 2000 9-75

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.45 ERROR LOGGING, AUX 120

The ERROR LOGGING function allows the user to view the history of errors that have
occurred on the controller. Up to 1,000 errors are stored by the controller. The errors
are listed in chronological order with the most recent entry first. The date, time, error
number, and a description of the error are listed. Error messages cannot be deleted or
edited and remain in memory even after controller initialization. Figure 9-72 shows an
example of the error logging function screen. Pressing the F3 key moves the display to
the next group of errors in the log.

AUX 120 ERROR LOGGING

1 [97/02/25 [Link] (-50) Warning! Cannot move along straight line in this configuration.]
2 [97/02/25 [Link] (-600) Motor power OFF.]
3 [97/02/25 [Link] (-842) Nonexistent subroutine.]
4 [97/02/25 [Link] (-303) Robot is moving now.]
5 [97/02/25 [Link] (-600) Motor power OFF.]
6 [97/02/25 [Link] (-1504) Position envelope error jt x]
7 [97/02/25 [Link] (-600) Motor power OFF.]
8 [97/02/25 [Link] (-842) Nonexistent subroutine.]
9 [97/02/25 [Link] (-303) Robot is moving now.]
10[97/02/25 [Link] (-1504) Position envelope error jtx]
11[97/02/25 [Link] (-1504) Position envelope error jtx]

F1 F2 F3 F4 F5 F6

NEXT PG
EXIT

Figure 9-72 Error Logging

9-76 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.46 OPERATION LOGGING, AUX 122

The OPERATION LOGGING function allows the user to view a history of the operations
that have occurred on the controller. Up to 100 previously performed operations are
recorded by the controller. The operations are listed in chronological order with the most
recent operation first. The operation logging function also displays the user interface the
operation was performed on, date, time, and a description of the operation performed.
Operation log entries cannot be deleted or edited and remain in memory even after
controller initialization. Figure 9-73 shows an example of the operations logging function
screen. Pressing the F3 key moves the display to the next group of operations in the
log.

AUX 122 OPERATION LOGGING

1-(TP), [97/02/25 [Link] WHERE 1:6 3,1]
2-(TP), [97/02/25 [Link] SAVE FILE3]
3-(TP), [97/02/25 [Link] list/r]
4-(TP), [97/02/25 [Link] dir]
5-(TP), [97/02/25 [Link] list/r]
6-(TP), [97/02/25 [Link] dir]
7-(TP), [97/02/25 [Link] list/r]
8-(TP), [97/02/25 [Link] edit]
9-(TP), [97/02/25 [Link] WHERE]
10-(TP), [97/02/25 [Link] SAVE FILE2]
11-(TP), [97/02/25 [Link] SAVE FILE1]

F1 F2 F3 F4 F5 F6

NEXT PG
EXIT

Figure 9-73 Operations Logging

February 15, 2000 9-77

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.47 ENCODER ROT. COUNTER RESET, AUX 140

The ENCODER ROT. (rotation) COUNTER RESET function is used in conjunction with
auxiliary function 41, ZEROING and auxiliary function 44, ZEROING DATA SET DIS-
PLAY, as part of the zeroing process. When maintenance has been performed that
moves the robot from the position that the encoders identify as zero, or a servo motor
has been changed, zeroing is required.

CAUTION
Users must be cognizant of the effect changes made in
this function will have on the position of programmed
locations. Changing this data without following the com-
plete zeroing process may move programmed locations
to positions that will cause damage to the robot, fixtures
or work.

Auxiliary function 140 provides the user with the option of selecting a single joint or all
joints to the reset encoder rotation count. If a single joint is selected, a set degree angle
for that axis may also be entered. When the data for this function has been entered, the
encoder rotation count(s) are stored on the 1GA board to provide accurate robot motion.
Figure 9-74 shows the ENCODER ROT. COUNTER RESET screen.

AUX 140 ENCODER ROT. COUNTER RESET

SETTING CURRENT

JT1 268427264 268427264

JT2 268427264 268427264
JT3 268427264 268427264
JT4 268427264 268427264
JT5 268427264 268427264
JT6 268427264 268427264

JOINT number = 0
(0 = reset all joint)
SET DEGREE = 0deg, mm
F1 F2 F3 F4

PRE DATA

Figure 9-74 Encoder Rot. Counter Reset

9-78 February 15, 2000

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.48 ARC WELD CONDITION MODIFY, AUX 150

Auxiliary function 150 ARC WELD CONDITION MODIFY is used to change welding
parameters recorded in weld continue and weld end steps. This function makes it pos-
sible to change multiple welding steps without editing individual steps.

Select AUX 150 to display the screen shown in figure 9-75. Press the F1 key to display
the program select screen and select the program for modification. Use the cursor key
to enter the START STEP field and enter the first welding step number to be modified.
Use the cursor key to enter the END STEP field and enter the last welding step number
to be modified. When both fields have the correct numbers entered, press the RETURN
key.

AUX 150 ARC WELD CONDITION MOD.

PROGRAM NAME

START STEP
0
END STEP (0: start step only)
0

F1 F2 F3 F4

PROGRAM
INPUT

Figure 9-75 Weld Condition Modify

The screen shown in figure 9-76 is displayed and the first welding step’s weld conditions
are shown for modification.

AUX 150 ARC WELD CONDITION MOD.

PROGRAM NAME pg55 1 20 START STEP to END STEP

WELD SPEED 120 cm/min

CURRENT 230 A
VOLTAGE 26.0 V
WELDING AMPLITUDE 0.0 mm
FREQUENCY 0.0 Hz
PATTERN 0
POLE RATIO 0
CRATER TIME 0.5 s
CURRENT 140 A
VOLTAGE 21.0 V
F1 F2 F3 F4

AUTO SET No change

Figure 9-76 Setting New Weld Parameters Screen

February 15, 2000 9-79

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

AUXILIARY FUNCTIONS

9.49 ARC SPOT WELD CONDITION MODIFY, AUX 151

Auxiliary function 151 ARC SPOTWELD CONDITION MODIFY is used to change weld-
ing parameters recorded in arc spotweld steps. This function makes it possible to
change multiple welding steps without editing individual steps.

Select AUX 151 to display the screen shown in figure 9-77. Press the F1 key to display
the program select screen and select the program for modification. Use the cursor key
to enter the START STEP field and enter the first welding step number to be modified.
Use the cursor key to enter the END STEP field and enter the last welding step number
to be modified. When both fields have the correct numbers entered, press the RETURN
key.

AUX 151 ARC SPOT WELD CONDITION MOD.

PROGRAM NAME

START STEP
0
END STEP (0: start step only)
0

F1 F2 F3 F4

PROGRAM
INPUT

Figure 9-77 Arc Spot Condition Modify

The screen shown in figure 9-78 is displayed and the first arc spot step’s weld conditions
are shown for modification.

AUX 151 ARC SPOT WELD CONDITION MOD.

PROGRAM NAME pg55 1 20 START STEP to END STEP

POLE RATIO 0
ARC SPOT TIME 0.5 s
CURRENT 140 A
VOLTAGE 21.0 V
F1 F2 F3 F4

No change

Figure 9-78 Setting New Spot Weld Parameters Screen

9-80 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

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

10.1 Error Recovery .................................................................................................. 10-2
10.2 Error Codes ....................................................................................................... 10-5
10.3 Troubleshooting Flowcharts ............................................................................ 10-75

February 15, 2000 10-1

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

10.0 ERROR CODES/TROUBLESHOOTING

This unit provides error recovery flowcharts, error code information, and error code
troubleshooting flow charts. In addition, typical causes and remedies for the errors are
also provided.

10.1 ERROR RECOVERY

Figure 10-1 shows troubleshooting processes that may be helpful if the controller be-
comes unresponsive to commands or an error code has been encountered that cannot
be cleared. Troubleshooting should begin with confirmation of basic integrity of the
system: ensure that the power supply is on and meeting supply requirements, all cables
are correctly attached, all peripheral equipment is wired correctly, software is properly
configured, etc.

10-2 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

Locate error in the error code

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

Source of error unknown

Error cleared and robot Run program

Press the yellow
runs normally and continue
reset button on the
controller panel to monitor

Error will not clear or

machine is in a “locked” mode

Have any changes been

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

Error or “locked” Run program

Cycle the
condition cleared and continue
controller power
off and on to monitor

Error still present

With control Error or “locked” Run program

power on, press the condition cleared and continue
red reset button on the
to monitor
1GA board

Continued on next page

Figure 10-1 Troubleshooting Process

February 15, 2000 10-3

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

Continued from previous pg

Create Error or “locked” Reset Run program

backup information condition cleared system settings not and continue
files and initialize the set to defaults after to monitor
system initialization

Error still present

Remove the
1GA board from the
rack and allow RAM
memory to deplete

Reinstall Error clears and robot

1GA board, Run program
runs normally
initialize the and continue
system, zero to monitor

Begin electrical
troubleshooting and repair if
qualified, call service
technician for further
assistance

Figure 10-2 Troubleshooting Process (cont’d)

10-4 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

10.2 ERROR CODES

This unit provides information about the error codes that are displayed on the multi
function panel or other user interfaces that provide display screen information. The error
codes are listed in numerical order by code number with the message that is displayed
with the associated code. An expanded explanation of the message is provided along
with possible methods to clear or prevent the specific error. Troubleshooting information
is preceded by a Þ symbol.

_____________________________________________________________________

ERROR CODE -50 Warning! Cannot move along straight line in this configura-
tion.

Joint speed may exceed maximum, joints 4 and 6 aligned.

⇒Change angle of joint 5, slow the speed, change to joint mode.

_____________________________________________________________________

ERROR CODE -57 Set low speed because of exceeding joint max. speed in
check.

When joint speed is checked with commanded speed, the difference exceeds accept-
able range.

⇒Slow the speed.

_____________________________________________________________________

ERROR CODE -100 Matrix Calculation Error.

The vector element of the matrix cannot be operated because of 0.

⇒ Change and recalculate value.

_____________________________________________________________________

ERROR CODE -101 Turn off motor power.

Motor power cannot turn on according to command and instruction.

⇒ Turn motor power OFF and execute command and instruction.

_____________________________________________________________________

February 15, 2000 10-5

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -102 Application is changed. Turn OFF & ON the control power.

The robot configuration was changed from spot welding/material handling to a paint/
sealant application using AUX function 907.

⇒Turn controller power OFF then ON.

_____________________________________________________________________

ERROR CODE -200 Cannot execute a program because motor power is OFF.

Program will not start because motor power is not on.

⇒Turn motor power ON.

_____________________________________________________________________

ERROR CODE -201 Cannot execute a program in TEACH mode.

Programs cannot run when in the teach mode of operation.

⇒Ensure that the controller is in the REPEAT mode of operation.

_____________________________________________________________________

ERROR CODE -202 Cannot execute a program because teach lock is ON.

Programs cannot be run with the teach lock in the ON position.

⇒Turn the TEACH LOCK switch to OFF and execute the program again in repeat mode.

_____________________________________________________________________

ERROR CODE -207 Turn to HOLD at HOLD/RUN sw.

Occurs when an attempt to perform DO, STEP, MSTEP, CONTINUE, or EXECUTE

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

⇒Turn the RUN/HOLD switch to HOLD position.

_____________________________________________________________________

10-6 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -208 Teach pendant is not connected.

Hardwired switches for teach pendant and multi function panel must be jumpered and
equipment configuration identified in environmental data functions.

⇒Install teach pendant or configure system accordingly.

_____________________________________________________________________

ERROR CODE -211 Cannot edit a program because the TEACH LOCK switch
is ON.

Programs cannot be edited if the TEACH LOCK switch is ON.

⇒Turn TEACH LOCK switch OFF.

_____________________________________________________________________

ERROR CODE -300 Program is already running.

Occurs when an attempt is made to edit or execute a program that is currently running.

⇒Stop the program prior to editing or checking.

_____________________________________________________________________

ERROR CODE -302 Can’t continue. Use EXEC.

The CONTINUE command is not permitted because of program selection status.

⇒Use the EXECUTE command to start program.

_____________________________________________________________________

ERROR CODE -303 Robot is moving now.

Displayed if any of the following commands are entered while a program is running:
EXECUTE, CONTINUE, TOOL, BASE, DO. SYSINIT or CYCLE START.

⇒Stop the program or confirm the operation to be performed.

_____________________________________________________________________

February 15, 2000 10-7

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -304 Cannot execute because in error now. Reset error.

Occurs when attempt is made to start robot motion if an error has not been cleared.

⇒Clear any errors and re-enter the command.

_____________________________________________________________________

ERROR CODE -306 Cannot execute with DO command.

Displayed when the DO command is entered with an instruction that is not of acceptable
format.

⇒Execute the instruction from within a program or use acceptable instruction format for
DO command.
_____________________________________________________________________

ERROR CODE -308 PC program is running.

Occurs when a PC program is running and instructions are entered that are not allowed.

⇒Stop the PC program and enter the command.

_____________________________________________________________________

ERROR CODE -314 Cannot execute because the program is already used.

Occurs when a program being edited is selected to run by a CALL, ON, ONI or PC
program instruction.

⇒Stop editing the program or stop the program that is calling the program being edited.
_____________________________________________________________________

ERROR CODE -316 Waiting weld completion.

Displayed when a command to change the step is entered while a welding sequence is
in progress.

⇒Wait until after the weld sequence is completed or force a weld complete condition.
_____________________________________________________________________

10-8 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -317 Position offset error at last E-stop JTxx.

The error message is generated when an E-stop is applied and the position of the robot
is not within a range of the commanded position. The error deviation range is specified
in auxiliary function 42.

⇒Before the error is reset, operators must be aware of the robot’s position within the
work envelope.
_____________________________________________________________________

ERROR CODE -318 Waiting retract or extend pos. input signal.

One of the following operations were attempted when the robot was processing a spot
weld sequence (waiting for the Retract/Extend signal after the weld complete signal had
been received).
1. Cycle start (including EXECUTE, CONTINUE command).
2. Program selection or step change.
3. Record.

⇒Input the Retract/Extend detection signal to the robot or press the WX key and wait
override key on the multi function panel.
_____________________________________________________________________

ERROR CODE -319 Spot sequence is running.

Step change, program change, or program execution were attempted while the spot
weld sequence was executing (after Retract/Extend input signal and weld complete
signal have been received). For example, the robot is executing move delay time after
weld complete.

⇒Perform step change, program registration or program execution after the spot weld-
ing sequence.
_____________________________________________________________________

ERROR CODE -320 Cannot operate because teach pendant in operation.

You cannot perform functions on the personal computer while the multi function panel is
in use.

⇒ Perform functions on the PC after the multi function panel has completed operation.
_____________________________________________________________________

February 15, 2000 10-9

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -324 Cannot execute with MC instruction.

MC instruction could not be carried out.

⇒ Use instruction which can be executed by MC instruction.

_____________________________________________________________________

ERROR CODE -325 Cannot execute the instruction in robot program.

Command and instruction cannot be used or executed.

⇒ Rewrite the command or instruction.

_____________________________________________________________________

ERROR CODE -326 Cannot delete because used by another command.

Cannot COPY, DELETE or XFER command because current step is being executed.

⇒ Perform DELETE commands after execution ends.

_____________________________________________________________________

ERROR CODE -327 Used in programs.

The variable used with the program was deleted.

⇒ Confirm the deleted variable.

_____________________________________________________________________

ERROR CODE -328 Used in editor.

When the program was used in the editor, the program was deleted.
_____________________________________________________________________

ERROR CODE -329 KILL or PCKILL to delete program.

Occurs when an attempt to delete a program is made and that program is still on the
stack (selected).

⇒Select another program or KILL/PC KILL the program, then delete.

_____________________________________________________________________

10-10 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -350 Illegal input data.

Input data from AS Language monitor command is improper for the instruction.

⇒Enter data that is within acceptable range.

_____________________________________________________________________

ERROR CODE -351 Too many arguments.

Input data from AS Language editor commands exceeds the number of user specified
items allowed by the format.

⇒Verify input data and format of command.

_____________________________________________________________________

ERROR CODE -353 Input data is too big.

Data entered for the POINT or HERE commands exceeds the allowable range.

⇒Enter data that is within acceptable range.

_____________________________________________________________________

ERROR CODE -360 Illegal WHERE parameter.

Occurs if data entered with the WHERE command is not an integer between 1 and 6.

⇒Ensure that data is within acceptable range.

_____________________________________________________________________

ERROR CODE -361 Illegal PC number.

Unused
_____________________________________________________________________

ERROR CODE -365 Illegal Robot number.

Unused
_____________________________________________________________________

February 15, 2000 10-11

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -367 Illegal priority.

Priority level designation is wrong.

⇒ Input a correct priority level.

_____________________________________________________________________

ERROR CODE -368 Invalid coordinate value.

Upper limit value is less than value of lower limit.

⇒ Input the correct upper limit coordinates.

_____________________________________________________________________

ERROR CODE -400 Syntax error.

Occurs when an AS Language command is entered that does not follow the correct
format or contains typing or spelling errors.

⇒Correct format or spelling of command/instruction.

_____________________________________________________________________

ERROR CODE -401 Invalid statement.

Occurs when an AS Language command is entered that has typing errors, incorrect
spelling or is in the wrong format.

⇒Correct the input data spelling or format.

_____________________________________________________________________

ERROR CODE -402 Ambiguous statement.

Displayed when an abbreviation is entered incorrectly or has missing letters.

⇒Enter the correct abbreviation or entire command.

_____________________________________________________________________

ERROR CODE -403 Cannot use this command or instruction here.

Displayed because a program or monitor command was entered that could not be
executed while a program is running.

⇒Stop program execution or wait for completion.

_____________________________________________________________________

10-12 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -404 Cannot execute with DO command.

A program instruction that is not acceptable to use with the DO command was entered.

⇒Place the desired instruction within a program or choose an acceptable instruction for
use with a DO command at the monitor prompt.
_____________________________________________________________________

ERROR CODE -405 Statement cannot be executed.

Occurs when the AS Language instruction entered was not acceptable for the mode of
operation. For example: a monitor command was entered in the editor mode.

⇒Use instructions and commands that are compatible with the input mode.
_____________________________________________________________________

ERROR CODE -406 Not a program instruction.

An instruction was entered into a program that is not a valid program instruction, i.e., a
monitor command, editor command, etc.

⇒Refer to the AS Language Manual for proper use of AS Language commands.

_____________________________________________________________________

ERROR CODE -407 Too many arguments

Input data from AS Language editor commands exceeds the number of user specified
items allowed by the format.

⇒ Verify input data and format of command.

_____________________________________________________________________

ERROR CODE -408 Missing argument.

Displayed when a DO command is not followed by an acceptable program instruction.

⇒Correct the input and re-enter.

_____________________________________________________________________

February 15, 2000 10-13

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -410 Illegal expression.

A real number expression must be present for processing DECOMPOSE command(s).

Also displayed when incorrect numerical information is entered with arguments.

⇒Ensure correct format and numerical expressions are entered.

_____________________________________________________________________

ERROR CODE -411 Illegal function.

Occurs when functions are used to assign values to variables but the data is incompat-
ible. For example: assigning XYZ coordinate data to precision points.

⇒Ensure function is compatible with variables.

_____________________________________________________________________

ERROR CODE -412 Illegal argument of function.

Occurs when function and argument are not in correct format.

⇒Use correct format for functions and arguments.

_____________________________________________________________________

ERROR CODE -413 Invalid variable (or program) name.

Displayed when illegal variable or program name is entered from the editor or monitor
modes. For example: JM ##a (to many precision symbols) or CALL #a (not an accept-
able program name).

⇒Define program names and variables correctly.

_____________________________________________________________________

ERROR CODE -414 Illegal variable type.

Displayed when illegal variable is entered from editor or monitor modes.

For example: b = #a + b (combining location and real variables using an arithmetic
operator).

⇒Use compatible variable type for commands or instructions.

_____________________________________________________________________

10-14 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -415 Illegal array index.

Displayed when an attempt is made to use a variable that has previously been defined
as an array. May also occur if the order of an array is reversed when editing or entering
monitor commands.

⇒Enter the correct array variable information.

_____________________________________________________________________
ERROR CODE -416 Missing parenthesis.

Occurs when parentheses are not entered as a pair, containing both a left and right
parenthesis.

⇒Enter parentheses in left and right pairs.

_____________________________________________________________________

ERROR CODE -417 Expected to be a binary operator.

A non-binary operator has been entered where a command expected a binary operator.

⇒Input a binary operator.

_____________________________________________________________________

ERROR CODE -419 Illegal qualifier.

Displayed when monitor commands are followed by unexpected qualifiers. For example:
LIST W (expected characters would include P, L, and R for program, location, and real
variables; “W” causes error).

⇒Use only acceptable qualifiers.

_____________________________________________________________________

ERROR CODE -420 Invalid label.

Occurs in the editor mode when a GOTO instruction is combined with a reserved char-
acter. For example: GOTO #a (“#” is a reserved character).

⇒Do not use reserved characters in label identification.

_____________________________________________________________________

February 15, 2000 10-15

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -421 Invalid name.

Displayed when an unidentified program, file, variable, etc., is used in a command.

⇒Use only names that have been defined.

_____________________________________________________________________

ERROR CODE -422 Missing expected character.

Occurs when commands or instructions are entered with an incorrect format. For ex-
ample: TOOL a=b (TOOL a would be correct, “=b” causes error).

⇒Use correct format for commands and instructions.

_____________________________________________________________________

ERROR CODE -423 Illegal switch name.

Displayed when a system switch is incorrectly identified. For example: SWITCH light
(there is no system switch named “light”).

⇒Use only available switch names.

_____________________________________________________________________

ERROR CODE -424 Ambiguous switch name.

Displayed when a switch name has been entered that is not available for the software
version that is operating in the controller.

⇒Use only system switches that are compatible with the software version that is operat-
ing.
_____________________________________________________________________

ERROR CODE -425 Illegal format qualifier.

Occurs when the TYPE or PRINT command is not used with an acceptable format
portion of the instruction.

⇒Use only specified format instructions with TYPE and PRINT commands.
_____________________________________________________________________

10-16 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -426 Duplicate statement label.

A specific program label name can only be used once per program. Error is displayed if
the same label name is entered a second time in the same program.

⇒Use label names only once per program.

_____________________________________________________________________

ERROR CODE -430 Cannot define as array.

A non-array variable with the same name as the array variable that was attempted to be
created, already exists.

⇒Use a different name for the new variable. Refer to the AS Language Manual for
proper use of AS Language commands.
_____________________________________________________________________

ERROR CODE -431 Dimension exceeds 3.

Attempted to create an array variable with more than 3 dimensions.

⇒Refer to the AS Language Manual for proper use of AS Language commands.

_____________________________________________________________________

ERROR CODE -432 Different dimensional array exist.

An array variable with same name but a different number of dimensions already exists.

⇒Change the name of the new variable or provide the same number of dimensions as
the existing variable. Refer to the AS Language Manual for proper use of AS Language
commands.
_____________________________________________________________________

ERROR CODE -433 Array variable exist.

Attempted to create a non-array variable with the same name as an existing array vari-
able.

⇒Confirm array variable exists. Select new name for non-array variable or select array
variable.
_____________________________________________________________________

February 15, 2000 10-17

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -434 Non array variable exist.

Attempted to create an array variable with the same name as an existing non-array
variable.

⇒Confirm non-array variable exists. Select new name for array variable or select non-
array variable.
_____________________________________________________________________

ERROR CODE -435 Array variable expected.

A non-array variable exists with the same name as the array variable that was specified
for the decompose instruction.

⇒Select a new name for the array variable that was specified for the decompose in-
struction.
_____________________________________________________________________

ERROR CODE -440 Local variable expected.

A subroutine call to a program with a local variable found a program with the same
name but without a local variable.

⇒Refer to the AS Language Manual for proper use of AS Language commands.

_____________________________________________________________________

ERROR CODE -441 Unexpected suffix.

No data was provided in the brackets of an array variable.

⇒Refer to the AS Language Manual for proper use of AS Language commands.

_____________________________________________________________________

ERROR CODE -442 Mismatch of arguments at subroutine call.

The order of the local variable in the called program and the order of the local variable in
the actual program are different.

⇒ Check the order of the local variable in the actual program and modify the subroutine
call accordingly. Refer to the AS Language Manual for proper use of AS Language
commands.
_____________________________________________________________________

10-18 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -443 Mismatch of argument type at subroutine call.

The type of argument, i.e. location variable, real variable, is different than the argument
in the origin program.

⇒Correct the type of the argument in the called program or origin program.
_____________________________________________________________________

ERROR CODE -450 Control structure error.

Displayed when an illegal program control flow structure is evaluated.

⇒Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE -451 Step:xxx Wrong END statement.

Occurs when an illegal END statement is entered during editing.

⇒Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE -452 Step:xxx Extra END statement.

Occurs when an extra END statement is present and there is no corresponding struc-
ture.

⇒Use correct syntax and components in control flow structures, check structure of END
statements.
_____________________________________________________________________
ERROR CODE -453 Step:xxx Cannot terminate DO with END.

This error is displayed when the control flow structure DO….UNTIL is entered with an
END statement .

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

February 15, 2000 10-19

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -454 Step:xxx No VALUE statement after CASE.

Occurs when the control flow structure CASE OF….END is entered without a value to
evaluate.

⇒Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE -455 Step:xxx Preceding IF missing.

Displayed when control flow structure does not contain the correct structure for
IF…THEN… ELSE…END commands.

⇒Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE -456 Step:xxx Preceding CASE missing.

Displayed when control flow structure does not contain the correct structure for
CASE…of… VALUE…ANY…END commands.

⇒Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE -457 Step:xxx Preceding DO missing.

Displayed when control flow structure does not contain the correct structure for
DO…UNTIL.

⇒Use correct syntax and components in control flow structures.

_____________________________________________________________________
ERROR CODE -458 Step:xxx Can’t find END of xxx.

Occurs when control flow structure that requires an END statement does not contain the
necessary END.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

10-20 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -459 Step:xxx Too many control structures.

Occurs when 11 layers of control flow structure are exceeded.

⇒Limit control flow structure to 11 layers.

_____________________________________________________________________

ERROR CODE -460 Variable (or program) already exists.

Displayed when a variable is entered that is already part of the system memory. For
example: a location named “weld1” is entered when a program named “weld1” is already
in the memory.

⇒Do not use variable names for more than one item.
_____________________________________________________________________

ERROR CODE -461 Variable of different type already exists.

Displayed when a variable is entered that is already part of the system memory. For
example: a location named “weld1” is entered when a program named “weld1” is already
in the memory.

⇒Do not use variable names for more than one item.
_____________________________________________________________________

ERROR CODE -464 Internal buffer over.

Attempted to solve a complex mathematical equation in a program.

⇒ Rewrite to reduce the complexity of the operations required to solve the equation.
_____________________________________________________________________

ERROR CODE -465 Undefined Variable (or program).

Attempt call a subroutine or process a variable that does not exist.

⇒Verify the variable or program exists.

_____________________________________________________________________

February 15, 2000 10-21

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -466 Illegal clock value.

Time or date was entered in the wrong format.

⇒Re-enter the values correctly; time - military, date - yy/mm/dd.

_____________________________________________________________________

ERROR CODE -470 Expect “=”

The argument is missing the necessary “=”.

⇒Check the argument and correct it.

_____________________________________________________________________

ERROR CODE -471 Expect “)”

The argument is missing the necessary “)”.

⇒Check the argument and correct it.

_____________________________________________________________________

ERROR CODE -472 Expect “]”

The argument is missing the necessary “]”.

⇒Check the argument and correct it.

_____________________________________________________________________

ERROR CODE -473 “Expect “TO”

The argument is missing the necessary “TO”.

⇒Check the argument and correct it.

_____________________________________________________________________

ERROR CODE -474 “Expect “BY”

The argument is missing the necessary “BY”.

⇒Check the argument and correct it.

_____________________________________________________________________

10-22 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -475 Expect “:”

The argument is missing the necessary “:”.

⇒Check the argument and correct it.

_____________________________________________________________________

ERROR CODE -476 “Expect ”ON/OFF”

An instruction other than ON/OFF was used with a SYSTEM SWITCH.

⇒Check the ON/OFF status SYSTEM SWITCH and input it correctly.

_____________________________________________________________________
ERROR CODE -490 Program name not specified.

Displayed when no program is on the stack and the EDIT command is entered without
specifying a program name.

⇒Identify the name of the program to be edited.

_____________________________________________________________________

ERROR CODE -494 Program is interlocked by another procedure.

Attempt to edit a running program was made.

⇒Stop program execution before editing the program.

_____________________________________________________________________

ERROR CODE -499 Invalid statement.

Occurs when the program is executed and instructions are encountered that cannot be
processed as AS Language commands.

⇒Use correct syntax and components for AS Language commands.

_____________________________________________________________________

ERROR CODE -507 Communication error.

When a vision system is incorporated and the transmission of data is interrupted (trans-
mission line problem or stoppage of the program) this error will be displayed.
_____________________________________________________________________

February 15, 2000 10-23

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -514 Device is not ready.

Unused
_____________________________________________________________________

ERROR CODE -523 Illegal file name.

Unused
_____________________________________________________________________

ERROR CODE -543 Data read error.

Unused
_____________________________________________________________________

ERROR CODE -544 Floppy disk data transfer error.

Specific information on this error code was not available at the time of publication.
_____________________________________________________________________

ERROR CODE -545 Record inhibited. Set “”record accept”” and operate again.

Displayed when an attempt was made to enter data, but the RECORD INHIBIT system
switch was set to inhibit.

⇒Change the setting of the RECORD INHIBIT system switch.

_____________________________________________________________________

ERROR CODE -551 Cannot open the file.

Unused
_____________________________________________________________________

ERROR CODE -580 Retry error.

Occurs when there is a problem with the communication link between the controller and
a host communication PC.

⇒Check the integrity of the controller and host PC link.

_____________________________________________________________________

10-24 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -581 Stop of process.

(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________

ERROR CODE -583 Receive not data after receive request.

(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________

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

(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________

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

(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________

ERROR CODE -586 Time out.

(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________

ERROR CODE -591 Illegal device number.

Two types of selections are possible for the serial port. This error occurs when port
numbers other than the sensor port are specified.

(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________

February 15, 2000 10-25

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -596 Cannot attach terminal.

The prompt instruction was executed by two or more programs at the same time.

⇒Do not execute the prompt instruction from two or more programs at the same time.
_____________________________________________________________________

ERROR CODE -597 Cannot attach communication port

The RECEIVE instruction and the SEND instruction were executed by two or more
programs at the same time.

⇒Do not execute these instructions from two or more programs at the same time.
_____________________________________________________________________

ERROR CODE -598 Cannot execute on this terminal.

Attempt was made to execute a command that cannot be used at that terminal. Some
commands can only be used at the multi function panel and some only at the PC.

⇒Use the above command from the proper terminal.

_____________________________________________________________________

ERROR CODE -599 Waiting input data for PROMPT. Connect input device.

The input device specified by the prompt command, i.e., PC or MFP, was not connected.

⇒Verify that the specified device is connected.

_____________________________________________________________________

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

stop is encountered.

⇒Reset emergency stop button and reapply motor power.

_____________________________________________________________________

ERROR CODE -610 Weld completion time over.

Occurs when a weld complete signal is not received in a specified time period.

⇒Override the wait condition, ensure that weld complete signal specifications are cor-
rectly identified, check the operation of the weld gun or controller.
_____________________________________________________________________

10-26 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -611 Illegal extend (retract) output signal.

Occurs when the output signals for the extend and retract operation of a spot welding
application are not properly set.

⇒Check the setting in auxiliary function 114.

_____________________________________________________________________

ERROR CODE -612 Weld fault input.

Displayed when the controller receives a weld fault signal.

⇒Check operation of welding equipment, ensure signal numbers are correctly set.
_____________________________________________________________________

ERROR CODE -613 Retract pos. monitor error.

Occurs when the input signal for the retract operation of a spot welding application is not
received.

⇒Check the operation of welding equipment, check the signal number setting in auxil-
iary function 114-10.
_____________________________________________________________________

ERROR CODE -614 Extend pos. monitor error.

Occurs when the input signal for the extend operation of a spot welding application is
not received.

⇒Check the operation of welding equipment, check the signal number setting in auxil-
iary function 114-10.

_____________________________________________________________________

ERROR CODE -615 Weld completion signal is already inputted.

Displayed when the weld complete signal has been received before the weld initiate
output has not been issued.

⇒Check operation of welding equipment, check the signal number setting in auxiliary
function 114-11.
_____________________________________________________________________

February 15, 2000 10-27

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -616 Gun retract position mismatch.

In the check mode, retractable gun output signals are monitored and compared to open/
close data for a specific step. If the data does not compare, an error is displayed.

⇒Check settings in clamp conditions, check operation of gun with clamp key.
_____________________________________________________________________

ERROR CODE -653 Illegal DOUBLE OX output.

Mutually exclusive dichotomy OX. For example, when OX1 and OX2 are set in a mutu-
ally exclusive dichotomy, the dichotomy is inhibited. Both are being turned ON (OX+1,2)
or OFF (OX=-1,2).

⇒Modify using the teaching screen.

_____________________________________________________________________

ERROR CODE -654 Cannot use DOUBLE OX.

Mutually exclusive dichotomy OX. The signal set in mutually exclusive dichotomy OX
was operated with BITS, PULSE, and DLYSIG, etc. (inhibit).

⇒Modify using the teaching screen.

_____________________________________________________________________

ERROR CODE -662 Start point position error for circle.

The robot was stopped after it began executing a circular motion and moved 4 mm or
more away from its calculated path (jogging or brake slippage, etc.). Attempting to
continue execution of the path from this position will result in this error.

⇒ Move the robot closer to the calculated path or restart the program a step prior to the
circular path.
_____________________________________________________________________

ERROR CODE -671 Cannot execute in check back mode.

The program reached an instruction which cannot be executed in check back mode.

⇒Execute after selecting a step that can be checked backward. If possible, check
forward.
_____________________________________________________________________

10-28 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -672 Cannot execute in ONE program.

The instructions specified in the ONE program area not valid for this type of program.

⇒Refer to the AS Language manual for proper use of the AS Language commands.
_____________________________________________________________________

ERROR CODE -673 Angle between JT2 and JT3 is out of range at start loca-
tion.

Movement from the current position to the start location position would cause JT2 and
JT3 to move beyond their limits.

⇒Modify the position of the start location of the program.

_____________________________________________________________________

ERROR CODE -674 Angle between JT2 and JT3 is out of range at end loca-
tion.

Movement from the current position to the end location position would cause JT2 and
JT3 to move beyond their limits.

⇒Modify the position of the end location of the program.

_____________________________________________________________________

ERROR CODE -675 Terminal is not connected.

A PRINT, TYPE, or PROMPT command is specified for display on a PC that is not

connected.

⇒Verify the PC connections or modify the commands for display on the MFP.
_____________________________________________________________________

ERROR CODE -676 Cannot input /output to multi function panel.

A PRINT, TYPE, or PROMPT command is specified for display on the MFP, although no
MFP connection is present.

⇒Verify the MFP connections or modify the commands for display on the PC.
_____________________________________________________________________

February 15, 2000 10-29

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -700 No free memory.

No free memory is available to teach or edit programs.

⇒Delete unused programs and variables, or, expand system memory to maintain the
required capacity.
_____________________________________________________________________

ERROR CODE -800 Program does not exist.

No program is on the stack at the time of cycle start or execution command (without a
program being specified).

⇒Identify program to be executed.

_____________________________________________________________________

ERROR CODE -801 No program step. The step specified for execution does
not exist.

⇒Select valid step numbers for execution.

_____________________________________________________________________

ERROR CODE -802 Nonexistent label.

Occurs when executing the GOTO command and the destination label is not defined.

⇒Ensure valid labels are used within the program.

_____________________________________________________________________

ERROR CODE -803 Undefined variable. Variable data for a specific argument
in a command is not defined.

⇒Ensure variables are properly defined.

_____________________________________________________________________

ERROR CODE -804 Undefined location data.

The location variable for the BASE, TOOL or POINT command is not specified. Also, a
named position in a program is not defined in system memory.

⇒Define all locations identified in programs.

_____________________________________________________________________

10-30 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -805 Undefined string variable. String variables that are evalu-
ated by ASC and LEN functions are not defined.

⇒Define the string variables to be evaluated or correct the name of the string variable
used for evaluation.
_____________________________________________________________________

ERROR CODE -807 Undefined program or label.

The program name or label associated with an ON or ONI command does not exist.

⇒Define the program or label used with the ON or ONI command.

_____________________________________________________________________

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

⇒Enter data that is within acceptable range.

_____________________________________________________________________

ERROR CODE -809 Undefined array suffix.

Attempt to process an array variable with undefined suffixes, i.e., attempting to process
A=B[C,D,E], but C, D, E have no values.

⇒Rewrite the program to define the array suffix before attempting to process the array.
_____________________________________________________________________

ERROR CODE -810 Divided by zero.

Occurs when the system encounters a mathematical evaluation that involves division by
“0”. Typically associated with the FRAME function and circular interpolation.

⇒Check data source for calculations.

_____________________________________________________________________

ERROR CODE -812 Character string is too long.

Character strings associated with arithmetic or comparative operators or the LEN func-
tion are too long.

⇒Correct the program.

_____________________________________________________________________

February 15, 2000 10-31

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -813 Illegal exponential operation.

Numeric values that have exponents must be positive in value.

⇒Correct equations in program.

_____________________________________________________________________

ERROR CODE -814 Expression too complicated.

A numeric calculation too complex to be evaluated was encountered.

⇒Simplify mathematical equations.

_____________________________________________________________________

ERROR CODE -815 No expressions to evaluate.

The type of data in an argument is incompatible with the operation being performed.

⇒Correct the program to evaluate compatible expressions.

_____________________________________________________________________

ERROR CODE -816 Unexpected error while evaluating expression.

Occurs when the system is evaluating the argument in an expression and the data of
the argument is found to be incompatible or missing.

⇒Correct the program so that data is compatible with arguments and expressions.
_____________________________________________________________________

ERROR CODE -817 SQRT parameter is negative.

In the argument of a SQRT function, a negative number was entered for evaluation.

⇒Do not enter negative numbers for evaluation by the SQRT function.
_____________________________________________________________________

ERROR CODE -820 Illegal array index.

Occurs when the array subscript number exceeds the acceptable range from 0 to 9999.

⇒Ensure the range of array subscripts is acceptable.

_____________________________________________________________________

10-32 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -821 Illegal argument value.

Displayed when the parameter specified for an command or instruction is illegal. For
example: TOOL 2112 (after the TOOL command a defined transformation location or null
is expected, 2112 causes error).

⇒Use correct argument values.

_____________________________________________________________________

ERROR CODE -822 Illegal joint number.

The joint numbered entered does not exist or is in the wrong format.

⇒Retype the command using the correct format.

_____________________________________________________________________

ERROR CODE -823 Illegal signal number.

This is displayed when the SIG or BITS command is used and the specified signal
number is beyond the range permitted by the system configuration.

⇒Use acceptable signal numbers for system configuration.

_____________________________________________________________________

ERROR CODE -824 Illegal timer number.

Displayed when a timer was specified that was not within the acceptable range of be-
tween 1 and 10.

⇒Specify timers in the range between 1 and 10.

_____________________________________________________________________

ERROR CODE -825 Illegal signal number.

When the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT commands are used with a
signal number that exceeds the range permitted by system configuration, this error is
displayed.

⇒Check signal number specified in instruction and ensure it is within system configura-
tion.
_____________________________________________________________________

February 15, 2000 10-33

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -826 Illegal clamp number.

Displayed when the clamp number entered exceeds the maximum permitted by system
configuration.

⇒Use only clamp numbers that are supported by system configuration.

_____________________________________________________________________

ERROR CODE -827 Illegal time value.

Displayed when a negative number is entered as part of a DELAY or TIMER command.

⇒Correct the time setting to a positive number.

_____________________________________________________________________

ERROR CODE -828 No value set.

Occurs when an instruction like the BITS command is evaluated and there is no corre-
sponding value set.

⇒Correct program code to evaluate existing values.

_____________________________________________________________________

ERROR CODE -829 Illegal signal number.

This error is displayed when the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT com-
mands are used with a signal number that exceeds the range permitted by system
configuration.

⇒Check signal number specified in the instruction and ensure it is within system con-
figuration.
_____________________________________________________________________

ERROR CODE -832 Illegal time input data.

Occurs when erroneous data has been entered in the setting of the TIME and DATE
function. For example: a date of Feb. 30.

⇒Input time and date information correctly, mm/dd/yy.

_____________________________________________________________________

10-34 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -834 Program name already exists.

When using the RENAME command a new program name must be specified. If an
existing name is used to rename a program this error will be displayed.

⇒Specify unused program names when renaming programs.

_____________________________________________________________________

ERROR CODE -835 Can’t KILL because the program is running.

Displayed when an attempt was made to KILL a program that was in the process of
executing.

⇒Stop program execution with HOLD or ABORT commands before program is removed
from the stack with a KILL command.
_____________________________________________________________________

ERROR CODE -837 Cannot use dedicated signal.

Occurs when a previously dedicated signal was used as a general purpose signal.

⇒Use signals that have not been dedicated for general functions.
_____________________________________________________________________

ERROR CODE -838 Not RPS mode.

Occurs when the required input signals are not dedicated at the time an attempt to run
an externally selected program is made.

⇒If RPS is to be used the necessary signals must be dedicated.

_____________________________________________________________________

ERROR CODE -839 Cannot use negative number. Displayed when a negative
number has been used in conjunction with the PULSE or
ACCURACY commands.

⇒Use only positive numbers in the acceptable range for the PULSE and ACCURACY
commands.
_____________________________________________________________________

February 15, 2000 10-35

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -840 Too many subroutines.

Occurs when more than 20 subroutines are nested with EXTCALL or CALL instructions.

⇒Do not exceed 20 nested subroutines.

_____________________________________________________________________

ERROR CODE -842 Nonexistent subroutine. Displayed when the program

identified by a CALL, ON, or ONI does not exist.

⇒Select only existing programs to be run as subroutines.

_____________________________________________________________________
ERROR CODE -846 No program exist.

Pertinent program does not exist in DIRECTORY and LIST commands.

⇒Correct program or make program.

_____________________________________________________________________

ERROR CODE -850 Out of absolute lower limit.

Displayed when an attempt has been made to set the software lower limits of robot
travel to a value that is too low.

⇒Set lower software travel limits to an acceptable range.

_____________________________________________________________________

ERROR CODE -851 Out of absolute upper limit.

Displayed when an attempt has been made to set the software upper limits of robot
travel to a value that is too high.

⇒Set upper software travel limits to an acceptable range.

_____________________________________________________________________

ERROR CODE -852 Out of user lower limit.

Displayed when an attempt has been made to set the software lower limits of robot
travel to a value that is too low.

⇒Set lower software travel limits to an acceptable range.

_____________________________________________________________________

10-36 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -853 Out of user upper limit.

Displayed when an attempt has been made to set the software upper limits of robot
travel to a value that is too high.

⇒ Set upper software travel limits to an acceptable range.

_____________________________________________________________________

ERROR CODE -855 Motion start location of jt-x is out of range.

Prior to beginning a program or motion to a step, the software has calculated the loca-
tion to be outside of the allowable upper or lower software limits.

⇒Correct location to within working envelope or expand software limits to accept loca-
tion.
_____________________________________________________________________

ERROR CODE -856 Motion and location of jt-x is out of range.

While executing a motion to a step, the software has calculated the location destination
of the specific joint number to be outside of the allowable upper or lower software limits.

⇒Correct location to within working envelope or expand software limits to accept loca-
tion.
_____________________________________________________________________

ERROR CODE -857 Destination is out of range.

While executing a motion to a step, the software has calculated the location destination
of all joints to be outside of the allowable upper or lower software limits.

⇒Correct location to within working envelope or expand software limits to accept loca-
tion.
_____________________________________________________________________

ERROR CODE -858 Illegal configuration for linear motion.

System software has determined that the start and end points of a linear move will
cause the robot to exceed the acceptable motion parameters.

⇒Change motion interpolation to a joint move; move location to avoid configuration.

_____________________________________________________________________

February 15, 2000 10-37

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -871 Illegal joint number.

Occurs when the DRIVE command is used and specifies a joint number that is not part
of the robot configuration.

⇒Confirm robot configuration before using the DRIVE command.

_____________________________________________________________________

ERROR CODE -872 Cannot execute motion instruction in PC program.

A PC program cannot contain instructions that initiate robot motion. If a motion instruc-
tion is encountered in a PC program this error will be displayed.

⇒Correct the PC program by removing motion instructions.

_____________________________________________________________________

ERROR CODE -873 Illegal auxiliary data number.

The value selected for auxiliary data (speed, timer, tool etc.) exceeds allowable range.

⇒Correct the value of auxiliary data.

_____________________________________________________________________

ERROR CODE -874 No circular location.

Program circular motion instructions must have C1 moves followed by either a C1 or C2

move.

⇒Correct program instructions.

_____________________________________________________________________

ERROR CODE -875 No C1MOVE(CIR1) ins.

Program circular motion instructions must have C2 moves preceded by a C1 move.

⇒Correct program instructions.

_____________________________________________________________________

10-38 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -876 Cannot create circle.

Circular interpolation moves cannot be processed because the points identified are too
narrow or are on a straight path.

⇒Correct program instructions.

_____________________________________________________________________

ERROR CODE -877 Cannot execute, because of sealing type.

Occurs when a command for a sealing application is evaluated by a controller that is not
configured for sealing applications.

⇒Correct program instructions to match software configuration.

_____________________________________________________________________

ERROR CODE -879 Cannot execute, because of not sealing type.

Occurs when a GUNON, GUNOFF, GUNONTIME or GUNOFFTIME command for a

sealing application is evaluated by a controller that is not configured for sealing applica-
tions.

⇒Correct program instructions to match software configuration.

_____________________________________________________________________

ERROR CODE -896 Option is not set up, can’t execute.

⇒Contact customer service for option specifications after confirming the purchase
specification.
_____________________________________________________________________

ERROR CODE -900 Arc failure.

The signal (current detection: WCR) that indicates the robot is executing the weld did not
return from the welder for 1 sec. or more after welding started.

⇒Check for insulating debris that prevents welding.

⇒Confirm that adequate supply of wire is available.
⇒Confirm that wire is not stuck to the welding tip.
_____________________________________________________________________

February 15, 2000 10-39

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -901 Wire stuck.

The wire is stuck to the base metal at the weld end.

⇒Cut the wire.

⇒Change weld conditions if problem occurs frequently.
_____________________________________________________________________

ERROR CODE -902 Electric pole stuck.

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

10-40 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

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

⇒Contact KRI Customer Service.

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

ERROR CODE -919 No RS485 Special Communication board.

⇒Contact KRI Customer Service.

_____________________________________________________________________

ERROR CODE -920 Illegal welding condition number.

⇒Contact KRI Customer Service.

_____________________________________________________________________

ERROR CODE -921 Weld data not set up.

⇒Contact KRI Customer Service.

_____________________________________________________________________
ERROR CODE -922 Weld data out of range.

⇒Contact KRI Customer Service.

_____________________________________________________________________

February 15, 2000 10-41

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -934 No weld data base.

⇒Contact KRI Customer Service.

_____________________________________________________________________
ERROR CODE -935 Cannot change condition.

⇒Contact KRI Customer Service.

_____________________________________________________________________

ERROR CODE -951 No RTPM board. (RTPM)

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

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

⇒Contact KRI Customer Service.

_____________________________________________________________________

ERROR CODE -963 Out of RTPM tracking capacity. (RTPM)

⇒Contact KRI Customer Service.

_____________________________________________________________________

ERROR CODE -964 RTPM current deviation error. (RTPM)

⇒Contact KRI Customer Service.

_____________________________________________________________________

10-42 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -999 No welding interface board.

The welding interface board was not detected at control power on.

⇒Turn control power off and confirm that the weld interface board is mounted.
⇒Confirm that the weld interface board is not loose. Insert the board firmly.
_____________________________________________________________________

ERROR CODE -1003 Data base error.

The program storage area of the system memory has been damaged and is not linking
data correctly.

⇒Turn on the 1GA board switch SW2-8 to initialize the memory, do not use AUX100 or
SYSINIT command. Reload the teach data.
⇒Check that system is properly isolated from electrical noise.
⇒Check the memory backup battery. Replace if necessary.
⇒Replace the 1GA board if the error re-occurs.
_____________________________________________________________________

ERROR CODE -1012 Command position of jt-x has suddenly changed.

In the repeat mode, the commanded position of the joint identified has exceeded 1.3
times the maximum arm speed. In the check mode, the commanded position of the joint
identified has exceeded 200 mm/sec.

⇒Check for singularity condition during robot motion and reteach to correct.
⇒Check for loose or defective servo system harnesses and circuit boards.
_____________________________________________________________________

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

The commanded position for the joint identified has exceeded the software limits. Con-
dition is monitored in both the check and repeat modes.

⇒Correct taught positions to avoid the software limits.

⇒Adjust the software limits to provide the necessary work envelope.
_____________________________________________________________________

February 15, 2000 10-43

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1017 Angle between JT2 and JT3 is out of range.

The commanded position for JT2 and JT3 cannot be reached due to the nature of the
mechanical links that exist between these points for the U-series, EH, and ES robots.
This error does not apply to JS-series robots. The main cause of this error is that the
taught positions, including positions through which the robot moves, are bad.

⇒Change the taught positions.

_____________________________________________________________________

ERROR CODE -1019 Check sum error of system data.

The check sum of the system data of the AS software was changed when the system
information such as model number, number of axis, and option setting, was downloaded.
When the error occurs in situations other than downloading, the error is caused by
defective memory back-up, defective 1GA board, or memory error from noise.

⇒Use Aux 78 CLEAR CHECK SUM ERROR or CHSUM command to reset the data.
When the error cannot be reset using the check sum commands, the command with the
abnormality is shown. Rewrite the command and use CHSUM or Aux 78 to clear the
error.
⇒Check the memory backup battery. Replace if necessary.
⇒Replace the 1GA board if the error re-occurs.
_____________________________________________________________________

ERROR CODE -1022 RAM battery low voltage <board name>.

When control power is applied or motor power is turned on, a voltage check is per-
formed on the batteries that maintain SRAM memory when power is off. This message
is displayed when a voltage of 2.5 VDC or less is detected (normal is 3.6 VDC).

⇒Back up system and program data, check and replace batteries as required.
⇒Check batteries for defective connections. Repair the defective connection.
⇒Defective battery voltage monitoring circuit. Replace the circuit board.
_____________________________________________________________________

10-44 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1025 AS Flash memory sum check error.

A check sum error of AS system data in flash memory on 1GA board occurred when the
power was turned on. The check sum data is created when the FCHK command is
executed and is recorded in flash memory during download. Main causes of the error
are:
1. When the AS system was downloaded, the FCHK command was not executed.
2. The addressing of the FCHK command was wrong.
3. The flash memory and 1GA board are defective.
4. The system data in the flash memory is damaged.

⇒Confirm the content of the command as_load.cmd file in the IC card if error occurs
immediately after downloading the AS system. Download system again. If error contin-
ues after download, exchange the 1GA board.
_____________________________________________________________________

ERROR CODE -1026 Servo Flash memory sum check error.

A check sum error of the servo system in flash memory on 1GA board occurred when
the power was turned on. The check sum data is created when the FCHK command is
executed and is recorded in flash memory during download. Main causes of the error
are:
1. When the servo system was downloaded, the FCHK command was not executed.
2. The addressing of the FCHK command was wrong.
3. The flash memory and 1GA board are defective.
4. The system data in flash memory is damaged.

⇒If the error occurs immediately after download, confirm the content of as_load.cmd in
the PC card and download again. If the error persists, change the 1GA board.
_____________________________________________________________________

ERROR CODE -1051 Cannot execute in this robot arm.

Unused
_____________________________________________________________________

February 15, 2000 10-45

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1100 CPU Error (Code = ****).

The 1GA board CPU has stopped (detected with the AS software). This error is caused
by defective AS or servo software, defective hardware, or noise related malfunction.

⇒Confirm which board the error occurred on by referring to the message that appears
on the PC. This error does not appear on the multi function panel or the small teach
pendant.
I/O BUS ERROR: error in the address of the 1FR or 1GW board.
PSB BUS ERROR: error with the 1FP or 1HP power sequence board.
VME BUS ERROR: error in the address of the boards that use the VME bus.
⇒If the initialization prompt appears, answer “no”, then reload software. If the error
returns, initialize the system and reload software. If the multi function panel or PC are
not functional, system initialization cannot be performed.
⇒If this error occurs during certain specific operations it may indicate a defect in the AS
system.
⇒Replace the 1GA board if the error cannot be reproduced or cleared.
_____________________________________________________________________

ERROR CODE -1101 Main CPU BUS error.

On the 1GA board, a bus error (in the VME bus line, data processing was not able to be
done normally) has occurred (detected with the AS software). This error is caused by
defective AS or servo software, defective 1GA board, or noise related malfunction.

⇒Confirm which board the error occurred on by referring to the message that appears
on the PC. This error does not appear on the multi function panel or the small teach
pendant.
I/O BUS ERROR: error in the address of the 1FR or 1GW board.
PSB BUS ERROR: error with the 1FP or 1HP power sequence board.
VME BUS ERROR: error in the address of the boards that use the VME bus.
⇒If the initialization prompt appears, answer “no”, then reload software. If the error
returns, initialize the system and reload software. If the multi function panel or PC are
not functional, system initialization cannot be performed.
⇒If this error occurs during certain specific operations it may indicate a defect in the AS
system.
⇒Replace the 1GA board if the error cannot be reproduced or cleared.
_____________________________________________________________________

10-46 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1102 VME BUS error.

This error occurs when the CPU does not receive a response from one of the I/O bus
devices within a specific time. This error is caused by defective AS or servo software,
defective 1GA board, or noise related malfunction.

⇒Confirm which board the error occurred on by referring to the message that appears
on the PC. This error does not appear on the multi function panel or the small teach
pendant.
I/O BUS ERROR: error in the address of the 1FR or 1GW board.
PSB BUS ERROR: error with the 1FP or 1HP power sequence board.
VME BUS ERROR: error in the address of the boards that use the VME bus.
⇒If the initialization prompt appears, answer “no”, then reload software. If the error
returns, initialize the system and reload software. If the multi function panel or PC are
not functional, system initialization cannot be performed.
⇒If this error occurs during certain specific operations it may indicate a defect in the AS
system.
⇒Replace the 1GA board if the error cannot be reproduced or cleared.
_____________________________________________________________________

ERROR CODE -1200 Encoder board is not installed.

Unused
_____________________________________________________________________

ERROR CODE -1201 Power sequence board is not installed.

The first address of the No.1 power sequence board (1FP/1HP board) cannot be read
when control power is turned ON. Main causes for this error include:
1. The power sequence board (1FP/1HP board) is not installed in the correct card slot.
2. Mistake in the address of the power sequence board.
3. Defect in the power sequence board.

⇒Make sure the 1FP/1HP board is addressed as power sequence board No. 1 and is
installed in the 1FP/1HP card rack slot. Check and replace the board if necessary.
_____________________________________________________________________

February 15, 2000 10-47

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1202 No2 power sequence board is not installed.

The first address of the No.2 power sequence board (1FP/1HP board) cannot be read
when the control power is turned ON. Main causes for this error include:
1. The power sequence board (1FP/1HP board) is not installed in the correct card slot.
2. Mistake in the address of the power sequence board.
3. Defect in the power sequence board.

⇒Make sure the 1FP/1HP board is addressed as power sequence board No. 2 and is
installed in the 1FP/1HP card rack slot. Check and replace the board if necessary.
_____________________________________________________________________

ERROR CODE -1203 No x-M I/O board is not installed.

Cannot read the first addresses of I/O boards (1GW board, etc.) based on the number
of signals that have been set with DO (output point), or DI (input point) of the
ZSIGSPEC command, when the control power supply is turned on. This error is not
used when a 1FS board is installed. Main causes include:
1. Incorrect value set with the ZSIGSPEC command.
2. Error in board address of I/O board (1GW board, etc.).
3. Defect of I/O board (1GW board, etc.).

⇒Set the correct number of signals with the ZSIGSPEC command. I/O cards are typi-
cally mounted in the card rack from right to left in ascending order. But, because of
VME buss communication, this is not critical. The robot can run without I/O boards.
However, the number of maximum signals in the software which can be set with the
ZIGSPEC command is DO, DI=256, INT=512, but DO and DI are restricted by hardware
and other options.
⇒Set board address switches correctly.
⇒Replace the 1GW board.
_____________________________________________________________________

10-48 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1204 Option SIO port is not installed.

The 1GA board sets more than seven axes at control power ON, but the IC (SIO) for
serial communications for command line 3 and 4CH communication with the servo
board is not installed. This error typically does not occur because SIO is installed on
standard 1GA boards but may not be on the prototype boards. Main causes of this error
include more than seven axes set with a prototype board with SIO not mounted or a
defect in the 1GA board.

⇒Replace the 1GA board.

_____________________________________________________________________

ERROR CODE -1205 Power sequence board any error.

An error signal, not classified through the error summary, is generated by the 1FP/1HP
board and not recognized by the AS software. Main causes include:
1. The error detection function of the power sequence board does not correspond to
the error processing function of the AS software.
2. Defect in the power sequence board.
3. Defect in the AS software.

⇒Replace the power sequence board.

⇒Install a higher version of the AS software.
_____________________________________________________________________

ERROR CODE -1206 Built-in sequence board is not installed.

Installation of the built-in sequencer board is checked when the control power supply is
turned ON. This error occurs when the built-in sequencer board is not installed.

⇒Install the built -in sequencer board.

_____________________________________________________________________

February 15, 2000 10-49

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1247 Axis setting data incorrect.

The command channel line for the external axis was incorrectly set using AUX 901,
External Axis Set.

⇒Input the correct value.

_____________________________________________________________________

ERROR CODE -1248 Number of Axis Changed! SYSINI

The number of axis assigned to the robot has changed.

⇒Change the number of axes and initialize the system.

_____________________________________________________________________

ERROR CODE -1249 Servo parameter Changed! Control power turn OFF & ON.

Servo parameters in system data changed during LOAD.

⇒Turn control power supply OFF and ON.

_____________________________________________________________________

10-50 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1250 Servo board (X) Initialize error.

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

A 0 7

7: Servo program download error

6: Servo parameter download error
4: Trap error (Servo software initialization error)

CPU channel of servo board

Main causes include:

1. Defect in the servo board (one axis amplifier).
2. Defect of the harness between power sequence board and servo board.
3. Error in mother board jumper setting.
4. The servo software is not in the flash memory on the 1GA board.
5. Malfunction caused by noise, etc.
6. Servo software and AS software versions incompatible.
7. Versions of ROM in servo software and servo board not compatible.

⇒Replace the 1GA, servo board, and each harness.

⇒Confirm the servo software and the servo board monitor ROM version and install the
corresponding servo software again. Confirmation of the version can be confirmed by
AUX 90, Software Version Display, or ID command.
_____________________________________________________________________

February 15, 2000 10-51

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1251 Servo board (X) communication error.

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

Relay to Power Sequence

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

1. Defect in the 1GA board.

2. Defect in the servo board.
3. Defect in each communication harness.
4. Encoder defect if JT3 (A) or JT4 (B) are displayed.
4. Noise malfunction.

⇒Replace the 1GA, servo board, and each harness.

_____________________________________________________________________

10-52 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1252(A), -1253(B), -1254(C), -1255(D)

Servo board (x) hardware error code = xxxx.

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

Relay to Power Sequence

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

Main causes of this problem include the following abnormalities:

1. Defect in the servo software.
2. Noise malfunction.
3. Defect in the harness between servo board and power sequence board.
4. Defect of the servo board.
5. Versions of servo and AS software incompatible.
6. Malfunction in the servo or AS software.

⇒Install upgraded versions of servo and AS software.

⇒Replace the 1GA board, the servo board, and each harness.
⇒When this error occurs, contact KRI to report the details.
_____________________________________________________________________

February 15, 2000 10-53

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1256(A), -1257(B), -1258(C), -1259(D)

Servo board (x) software error code = xxxx.

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

Relay to Power Sequence

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

Main causes of this problem include the following abnormalities:

1. Defect in the servo software.
2. Noise malfunction.
3. Defect in the harness between servo board and power sequence board.
4. Defect of the servo board.
5. Versions of servo and AS software incompatible.
6. Malfunction in the servo or AS software.

⇒Install upgraded versions of servo and AS software.

⇒Replace the 1GA board, the servo board, and each harness.
⇒When this error occurs, contact KRI to report the details.
_____________________________________________________________________
ERROR CODE -1260 Option changed! SYSINI

Unused
_____________________________________________________________________

10-54 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1261 Servo board (x) parameter setting error.

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

Relay to Power Sequence

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

Main causes of this error include:

1. Defect in the 1GA board.
2. Defect in the servo board.
3. Defect of each communication harness.
4. Versions of servo and AS software incompatible.
5. Malfunction by noise.

⇒Replace the 1GA board, the servo board and each harness.
⇒Install upgraded versions of AS and servo software.
⇒If error cannot be reset, reset data with AUX 976.
⇒If error cannot be reset, cycle control power.
_____________________________________________________________________

February 15, 2000 10-55

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1300 Servo CPU-(x) watch dog error.

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

Relay to Power Sequence

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

⇒Replace the servo board.

_____________________________________________________________________

ERROR CODE -1306 Servo board command error

Servo software has returned the error code to the AS software. Main causes include:
1. Malfunction in the servo or AS software.
2. Noise malfunction.
3. Defect in the harness between servo board and power sequence board.
4. Defect of the servo board or the 1GA board.
5. Versions of servo and AS software incompatible.

⇒Install upgraded versions of servo and AS software.

⇒Replace the 1GA board, the servo board, and each harness.
_____________________________________________________________________

10-56 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1308 Motor power off.

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

⇒Replace the power sequence board.

⇒Replace the relay board.
⇒Replace the magnetic contactor.
_____________________________________________________________________

ERROR CODE -1333 Monitor ID of servo board mismatch!

The monitor ROM software version of each unit on the 1GB board is different, caused by
a defect of the 1GB board.

⇒Replace the 1GB board.

_____________________________________________________________________

ERROR CODE -1334 Servo control line error.

Brake open command is not returned within 2 seconds when the servo control on
(SVCN) signal is sent from the AS software to the servo board (1GB) through the EPLD
register of the power sequence board (1FP/1HP). This abnormality is caused by a
defective power sequence board, servo board, or harness between the two boards.

⇒Exchange the power sequence board and the servo board, etc.
_____________________________________________________________________

ERROR CODE -1336 Safety gate circuit open.

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

⇒Reinsert the safety plug.

⇒Repair open circuit.
⇒Replace the power sequence board (1FP/1HP).
_____________________________________________________________________

February 15, 2000 10-57

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1337 Two MC lines are not consistent.

A problem has been detected with the MC lines controlling the K1/K2 contactors, due to
an open safety circuit, loose connectors or defects of the 1HP, 1HY, or 1HZ boards.

⇒Check the safety circuit.

⇒Check connections to the 1HP, 1HY, and 1HZ boards.
⇒Replace the 1HP, 1HY, or 1HZ boards as necessary.
_____________________________________________________________________

ERROR CODE -1338 K1 and/or K2 works wrong.

Feedback from the auxiliary contacts of the K1/K2 contactors was not received within a
fixed time, when the contactor was energized. Main causes are safety circuit failures,
K1/K2 auxiliary contact fault (welded, etc.), loose connectors or defects of the 1HP, 1HY,
or 1HZ boards

⇒Check the safety circuit.

⇒Check connections to the 1HP, 1HY, and 1HZ boards.
⇒Replace the 1HP, 1HY, or 1HZ boards as necessary.
_____________________________________________________________________

ERROR CODE -1401 Amp over current jt x-M.

The feedback current from a current sensor in the power block exceeded 144% of the
maximum instantaneous motor current rating. This error can be caused by the following
abnormalities:
1. Short in the U, V, W from the power block to motor and ground wire.
2. Defect in the motor.
3. Defect in the power block.
4. Defect in the servo board (1GB board, etc.)

⇒Check the connection for the U, V, W and ground line to the power block. Replace the
separation harness if necessary.
⇒Replace the motor or servo unit.
_____________________________________________________________________

10-58 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1407 AMP power unit error.

General servo system error. This error indicates that a servo system error has occurred.
Main causes include a defect in the connection of the harness between the power
sequence board and the servo board.

⇒Check the servo error codes that follow this error for additional information. Check the
harness connections between the 1HP board and 1GB board. Replace the 1HP board.
_____________________________________________________________________

ERROR CODE -1413 Regenerative resistor overheat or disconnect.

Unused
_____________________________________________________________________

ERROR CODE -1420 Current detector type (x) mismatch!

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

Relay to Power Sequence

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

Main causes include:

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

⇒Install the 1GB board equipped with 1GM board.

⇒Load the robot system data when this error occurs immediately after initializing.
⇒Re-initialize and reload the robot/system data if this error occurred immediately after
loading the data.
_____________________________________________________________________

February 15, 2000 10-59

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1500 Motor overload jt-x.

The current feedback from the power block exceeded maximum continuous ratings
longer than the time allowed. Main causes include:
Mechanical -
1. The robot arm has contacted an external item hindering movement.
2. The harness is caught in the robot arm.
3. The decelerator, the gear, or the bearing are damaged.
4. Gear decelerator backlash is too narrow.
5. Payload weight exceeds robot specifications for capacity.
6. Robot motion pattern exceeds ratings of the motor.
7. Motor brake is not released.
Electrical-
1. Motor power line U, V, and W phase are disconnected.
2. The brake line is disconnected or brake drive circuit is damaged.
3. The power block is damaged.
4. Defect in the servo board.
5. Malfunction of the motor.

⇒Check the decelerator, etc. for mechanical failure. Replace as necessary.

⇒Re-teaching robot motion is necessary.
⇒Check the harness and servo unit for electrical malfunctions and replace if necessary.
_____________________________________________________________________

10-60 February 15, 2000

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1501 Overheat or motor harness is disconnected (x)

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

Relay to Power Sequence

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

Main causes include:

1. Disconnected thermal line.
2. Defective connection in the separation harness.
3. Defect in the servo board.
4. When the thermal is built-in:
The robot rated weight capacity is exceeded.
The ambient temperature exceeds limits for use.
Constant execution of abrupt high speed direction changes.
Defect robot cooling fan or cooling air purge system.
Servo system holding the robot arm in high load position for extended periods.
Defect in the thermal switch.

⇒When the thermal switch opens, error cannot be reset until cooling is complete.
⇒Confirm continuity of thermal line.
⇒Replace the harness or servo board as necessary.
⇒Use the auto servo off function, AUX 91, to prevent the servo system holding a high
load arm position for extended periods.
_____________________________________________________________________

February 15, 2000 10-61

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1503 Speed error jt-x.

Joint speed calculated with encoder value exceeded a regulated value. In the Repeat
mode: the rated joint speed * 1.2. In the Teach/Check modes: 250mm/sec. * 1.5, at the
equivalent radius position for a rotating joint or actual command value speed for a linear
joint. This error is caused by the following abnormalities:
1. Disconnected motor power line U, V, and W phase, and defective power block.
2. Wiring error in motor power line and encoder line.
3. Disconnected encoder single line, short circuit and defective main body of encoder.
4. Robot dependent upon singularity motion.
5. Defect in the servo board and power block.
6. Moment of inertia exceeded the motor torque.

⇒Check for disconnection, short circuit, and proper wiring. Replace the harness and
encoder if necessary.
⇒Replace the servo unit.
⇒Rewrite program teach data such as speed and position in the case of singularity
motion.
_____________________________________________________________________

10-62 February 15, 2000

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1504 Position envelope error jt-x.

The difference between the current value from the encoder and the command value in
the AS software exceeded a regulated value which varies by robot model. Main causes
include singularity motion or the following abnormalities:
Mechanical -
1. The robot arm has contacted an external item hindering movement.
2. The harness is caught in the robot arm.
3. The decelerator, the gear, or the bearing are damaged.
4. Gear decelerator backlash is too narrow.
5. Payload weight exceeds robot specifications for capacity.
6. Robot motion pattern exceeds ratings of the motor.
7. Motor brake is not released.
Electrical-
1. Motor power line U, V, and W phase are disconnected.
2. The brake line is disconnected or brake drive circuit is damaged.
3. The power block is damaged.
4. Defect in the servo board.
5. Malfunction of the motor.

⇒Check the decelerator, etc. for mechanical failure. Replace as necessary.

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

ERROR CODE -1505 Velocity envelope error jt-x

The robot’s current velocity is unable to keep up with the velocity command signal.

⇒Refer to Error Code -1504: Position envelope error jt-x

_____________________________________________________________________

ERROR CODE -1506 Commanded speed error jt-x.

Unused.
_____________________________________________________________________

ERROR CODE -1507 Commanded acceleration error jt-x.

Unused.
_____________________________________________________________________

February 15, 2000 10-63

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1510 Encoder harness broken jt-x.

The encoder signal is lost.

⇒Machine signal or separate signal harness

⇒+12 VDC or +5 VDC at the 1FG board
⇒1GB or 1FG board
_____________________________________________________________________

ERROR CODE -1511 Encoder battery voltage low [Servo (A)].

Voltage of the encoder back up battery on the 1FG board decreased to 3.2 volts, or the
encoder battery alarm signal (BAL_AL) was disconnected. This error is only detected at
control power on or motor power on. This is caused by the following:
1. Discharged batteries.
2. Defective encoder battery board (1FG board).
3. Defective encoder.
4. Short in the harness from the encoder battery backup board to the encoder.
5. Battery discharge.
6. Defective servo board (1GB board).

This error is reported by servo board unit A.

⇒Exchange the battery. There is a possibility that internal encoder data may be lost.
Check the robot zeroing.
⇒Check each harness for short circuit.
⇒Replace the encoder, the servo board, or the encoder battery backup board, if neces-
sary.
_____________________________________________________________________

ERROR CODE -1513 Encoder rotation data abnormal jt-x.

Occurs when there is a difference between the rotation data in the serial encoder data
and the calculated rotation data by incremental technique.

⇒Check connections at encoder, 1FG board, and separation harness.

⇒Check for noise and shield integrity.
⇒Check connections, jumpers, and switches on 1GB board.
⇒Check for continuity in the machine harness and separation harness.
⇒Replace 1FG board.
⇒Replace the 1GB board.
⇒Replace the encoder.
_____________________________________________________________________

10-64 February 15, 2000

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1516 Encoder data abnormal jt-x.

When control power is switched ON, the current encoder value is compared to the
stored encoder value when the power was turned OFF. If the difference is more than the
value set by AUX 43, Encoder Error Range, or the ENCCHK_DATA command, this error
occurs. Normal occurrence is due to the following:
1. Back up battery failure due to disconnection or discharged battery.
2. Control power was turned off during robot motion by an abnormal power supply,
etc., causing the robot to stop in a position other than the last position memorized
by the AS software.
3. Motor replacement/encoder replacement.
4. Robot arm or motor operated by force when control power was off.
5. Robot was initialized.

⇒ Data may have been lost due to backup battery. See error -1511. Exchange the
battery. There is a possibility that internal encoder data may be lost. Check the robot
zeroing.
⇒Check each harness for short circuit.
⇒Replace the encoder, the servo board or the encoder battery backup board if neces-
sary.
_____________________________________________________________________

ERROR CODE -1517 Cannot read initial data encoder jt-x.

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

⇒Check for disconnection or short circuit for encoder signal line.

⇒Replace the encoder.
⇒Replace the servo board (1GB board).
_____________________________________________________________________

ERROR CODE -1518 Miscount of encoder data jt-x.

Not used
_____________________________________________________________________

February 15, 2000 10-65

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1521 Mismatch ABS and INC encoder of jt-x.

Occurs when there is a large difference between the value in the serial encoder data
and the data calculated by incremental technique.

⇒Replace encoder, replace 1GB board.

⇒Check connections at encoder, 1FG board, and separation harness.
⇒Check connections, jumpers, and switches on 1GB board.
⇒Check for continuity in the machine harness and separation harness.
⇒Replace 1FG board.
_____________________________________________________________________

ERROR CODE -1524 Encoder line error of jt-x

Not used
_____________________________________________________________________

ERROR CODE -1550 Encoder initialize error jt-x.

The encoder is not able to fix the absolute position at control power on. The scanning of
absolute data is begun immediately after a shift from the state of non-operation or back-
up operation to normal encoder operation. BUSY=1 is output until the absolute position
has been determined.

⇒In the case of a conveyor encoder, ensure power-up speed is below 300 RPM.
⇒Check connections at encoder, 1FG board, jumpers, and switches on 1GB board.
⇒Replace encoder, replace 1GB board, replace 1FG board.
⇒Check for continuity in the machine harness and separation harness.
_____________________________________________________________________

ERROR CODE -1553 Encoder response error jt-x.

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

⇒Check connections at encoder, 1FG board, and separation harness.

⇒Check connections, jumpers, and switches on 1GB board.
⇒Replace encoder, replace 1GB board.
⇒Check for continuity in the machine harness and separation harness.
⇒Replace 1FG board.
⇒Check for noise malfunction and shield integrity.
_____________________________________________________________________

10-66 February 15, 2000

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1554 Encoder communication error jt-x.

Occurs when the encoder serial data is not correctly transmitted according to communi-
cation protocol.

⇒Check connections at encoder, 1FG board, and separation harness.

⇒Check connections, jumpers, and switches on 1GB board.
⇒Replace encoder, replace 1GB board.
⇒Check for continuity in the machine harness and separation harness.
⇒Replace 1FG board.
_____________________________________________________________________

ERROR CODE -1555 Encoder data conversion error jt-x.

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

⇒Replace encoder, replace 1GB board.

⇒Check connections at encoder, 1FG board, and separation harness.
⇒Check connections, jumpers and switches on 1GB board.
⇒Check for continuity in the machine harness and separation harness.
⇒Replace 1FG board.
_____________________________________________________________________

ERROR CODE -1556 Encoder ABS-track error jt-x.

The absolute data and the incremental data in the encoder are different. ABSALM=1 is
output from the encoder when this error occurs.

⇒Defective encoder
⇒Defective 1GB or 1FG boards
⇒Open or short-circuited encoder harness
_____________________________________________________________________

ERROR CODE -1557 Encoder INC-pulse error jt-x.

Occurs when the encoder A and B incremental pulses are abnormal. The encoder
INALM bit sent with the serial data=1.

⇒Replace encoder, replace 1GB board.

⇒Check connections at encoder, 1FG board, and separation harness.
⇒Check connections, jumpers, and switches on 1GB board.
⇒Check for continuity in the machine harness and separation harness.
⇒Replace 1FG board.
_____________________________________________________________________

February 15, 2000 10-67

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1558 Encoder MR-sensor error jt-x.

The state of the MR sensor in the encoder does not match with JT ENCODER in one
rotation.

⇒Replace the encoder harness.

_____________________________________________________________________

ERROR CODE -1559 Power module error jt-x.

An error signal from the IPM module in the power block was detected. This error may be
caused by:
1. Defect in the power block.
2. Defect in the servo board.
3. Short-circuit of the motor power line U, V, and W phase.
4. Defective cooling fan in the servo unit.
5. Defect in the harness between the servo board and the power blocks.

⇒Replace the servo unit.

⇒Check for short circuit in the motor harness and replace if necessary.
_____________________________________________________________________

ERROR CODE -1561 Current sensor disconnect [Servo (x)].

The current sensor cable between the servo board and the power blocks is not con-
nected. The x indicates the servo board unit reporting the error. Check the following
harnesses as indicated below.

Unit A - 1GB-CN9 ⇔ power block CN1, CN2 CN3,

Unit B - 1GB-CN10 ⇔ power block CN4, CN5, CN6
Unit C - 1GB-CN11 ⇔ power block CN7
This error may be caused by a defect in the 1GB board.

⇒Check connection and continuity in the current sensor cable between the 1GB board
and the power block.
⇒Replace the 1GB board if necessary.
_____________________________________________________________________

10-68 February 15, 2000

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1563 Servo unit 12V DC error [Servo (A)].

The +/-12V supply to the 1GB board is below specified limits of +10.75V and -10.4V.
This error may be caused by a defect in the harness between the 1GB board, the
mother board and the AVR, or a defect in the 1GB board. This error is reported by servo
board unit A.

⇒Check the voltage and replace the 1GB board and the AVR as necessary.
_____________________________________________________________________

ERROR CODE -1567 Regenerative resistor error [Servo (A)].

Current was sent to regenerative resistors for six or more consecutive seconds. Main
causes include:
1. Abrupt direction changes at high speed.
2. Burned out resistors or defective power block.
3. Defect in the servo board (1GB board).
4. Defective connection or harness between the servo board and the power block
(1GB-CN13 ⇔ power block CN9).
5. Defect in the optional second regenerative resistance unit (when used).

This error is reported by servo board unit A.

⇒Avoid abrupt high speed direction changes. Change accuracy, speed, add points.
⇒Install optional second regenerative resistance unit.
_____________________________________________________________________

ERROR CODE -1568 Servo unit P-N low voltage [Servo (A)].

The voltage between P-N supplied to the power block is 60VDC or less at servo on.
Main causes include:
1. Defect of MS (K3).
2. Defect in the relay board (1FY/1HY board).
3. Defect in the power sequence board (1FP/1HP board).
4. Defect in the power unit.
5. Defect in the servo board.
6. Defect in the motor power circuit (diode bridge, K3, etc).
7. Defect in the harness between the operation unit and the servo units or the connec-
tions.

⇒Check the motor power circuit and the equipment, replace as necessary.
⇒Check the power sequence board, the relay board ,and the servo unit, and replace as
necessary.
_____________________________________________________________________

February 15, 2000 10-69

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1569 Servo unit P-N- high voltage [Servo (A)].

The voltage between P-N supplied to the power block exceeded 410VDC. This error is
caused by:
1. Defect in regenerative resistance control circuit, failed scorch of regenerative resis-
tance, defect in the voltage monitoring circuit, or defect in the power block.
2. Defect of servo board (1GB board)
3. Defect in the regenerative resistance unit.
4. Defect in the servo board (1GB board).
5. High inertia loads due to tool weight or program data.

This error is reported by servo board unit A.

⇒Replace the servo unit and the regenerative unit.

⇒Add the second regenerative resistor unit.
_____________________________________________________________________

ERROR CODE -1570 Regenerative resistor over-heat [Servo (A)].

The thermal for the power block regenerative resistor unit or thermal for the optional
regenerative resistor unit reached 130° C (266°F), or the heat sink thermal reached
90°C (194°F). This error is reported by servo board unit A.

⇒Defective cooling fans

⇒High inertia loads
⇒High ambient controller temperature
⇒Defective power block
⇒Defective regenerating resistor unit
⇒Defective 1GB board
⇒Defect in the following harnesses: 1GB-CN13 ⇔ power block CN9,
1GC-CN21 ⇔ optional regenerative resistor unit.
_____________________________________________________________________

10-70 February 15, 2000

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1600 Uncoincidence error jt-x.

During the execution of a program, all joints must reach total coincidence within a given
accuracy and time (approx. 5 seconds) This error occurs if the difference between the
designated value and current value exceeds the established accuracy. Typical causes
are listed below.

Mechanical:
• Damaged bearings.
• Insufficient gear backlash.
• Motor brake not released.
• Arm movement restricted by harnesses or peripheral devices.

Electrical:
• Defective servo board (1GB board).
• Defective power block.
• Disconnected motor power or brake lines.
• Defective encoder or encoder harness.

Program data:
• Wrist positions at the beginning and end of a path that utilize the same XYZ coordi-
nate.

⇒Repair mechanical or electrical failures.

⇒Check interference from external devices.
⇒Modify taught wrist positions as required.
_____________________________________________________________________

ERROR CODE -1601 Limit switch of joint-x is ON.

This error occurs when the software can specify the axis that has caused the over travel
condition. If the joint number cannot be specified, ERROR CODE 1602 Limit switch is
broken, is displayed. Main causes include:
1. Software limits are set incorrectly.
2. Axis was moved using the manual brake release and the limit switch was turned ON.
3. The limit switch was turned ON by overshoot from inertia.

⇒Check and exchange the harness and the limit switch.

⇒Set the software limits to an appropriate value.
⇒Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒Replace the power sequence board if necessary.
_____________________________________________________________________

February 15, 2000 10-71

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1602 Limit switch signal line is broken.

This error occurs when the software cannot specify the axis that has caused the over
travel condition. If the joint number can be identified, the “ERROR CODE 1601 Limit
switch of jt-x is ON.”

⇒Set the software limits to an appropriate value.

⇒Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒Check harness and limit switch and replace as necessary.
⇒Check the power sequence board and replace if necessary.
_____________________________________________________________________

ERROR CODE -1610 Torch is interfered.

The limit switch for torch interference detection has been tripped.

⇒Move the robot away from the interference to close the limit switch. Inspect the torch
for damage.
⇒Determine the cause of the interference before continuing operation.
_____________________________________________________________________

ERROR CODE -1735 GROUP is not primed.

The GROUP instruction is not programmed before a motion instruction, with external
axis system.

⇒This error occurs if the program is interrupted after a GROUP instruction and before
the motion commands pertaining to the GROUP instruction are complete. When restart-
ing the program prime the program before the GROUP instruction
⇒In check mode, if the GROUP instruction is used, start checking before the GROUP
instruction.
_____________________________________________________________________

10-72 February 15, 2000

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ERROR CODES/TROUBLESHOOTING

ERROR CODE -1800 AC primary power off.

This error occurs when there is an instantaneous decrease in the primary power to the
AVR for control power supply (AC130-145V or less for 20-30 msec from 0 phase). The
main causes for this error are:
1. NFB for the control power supply was turned OFF.
2. AC200/220V supplied to AVR for the control power supply caused the instantaneous
decrease.
3. Defective AVR for control power supply.
4. Defective NFB for control power supply or NFB tripped.
5. Defect in the primary power supply.
6. Defective power sequence board.
7. Defect in the relay board.

⇒It is normal for this error to occur when NFB for control power supply is turned OFF.
⇒Check power supply circuit in AVR for the control power supply and NFB.
⇒Confirm that primary power is supplied according to specifications.
_____________________________________________________________________
ERROR CODE -1801 24VDC power source is low.

24VDC to the power sequence board has dropped below 21.6V. Main causes include
the following abnormalities:
1. Defect in the AVR for control power supply.
2. Defect in the power sequence board.
3. Defect in the relay board.
4. Short circuit in the motor power on circuitry, the EMERGENCY STOP switch and axis
restriction limit switch circuits.
5. Short in machine valve and sensor circuits.

⇒Check the power supply, machine valve, and the sensor circuits for short circuits.
⇒Check the AVR, the power sequence board, and the relay board and replace as
necessary.
_____________________________________________________________________

ERROR CODE -1802 Primary power source is high.

Voltage level of the AVR for the control power supply was too high (AC2667-277V or
more for 1-2 sec.). The main causes of this error include a defect in the AVR, the power
sequence board, the relay board or the power supply circuit.

⇒Verify that the power supply to the controller are within ratings.
⇒Check power supply circuit to the AVR.
⇒Confirm that the supply power is within specifications.
_____________________________________________________________________

February 15, 2000 10-73

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ARC WELDING OPERATIONS AND PROGRAMMING

ERROR CODES/TROUBLESHOOTING

ERROR CODE -1803 Primary power source is low.

Voltage level of the AVR for the control power supply was too low (AC150-158V or less
for 1-2 sec.). The main causes of this error include an instantaneous drop in the power
supply; a defect in the AVR or NFB, the power sequence board, the relay board or the
power supply circuit.

⇒Verify that the power supply to the controller is within ratings.

⇒Check the AVR and NFB.
⇒Confirm that the supply power is within specifications.
_____________________________________________________________________
ERROR CODE -1804 5 VDC or ± 12 VDC is abnormal.

5 VDC or +/-12 VDC supplied to the 1GA board is out of specifications.

+5 VDC: less than +4.85 VDC - more than +5.45 VDC
+12 VDC: +10.75 VDC or less
-12 VDC: -10.4 VDC or more
Main causes include:
• Defective DC power supply.
• Defective 1GA board.
• Power supply contacts in the mother board are bad.
• Defective MFP, small teach pendant, or harness.
• Defective servo board or power block.
• Defective 1FG board.
• Short in the harness between the servo unit and the 1FG board.
• Short in the optional circuit boards, i.e., vision, etc.
• Insufficient DC power supply capacity to support optional boards.

⇒Replace the AVR and each board for the control power supply.
⇒Check for short circuits in the MFP, the operation panel, and separation harness and
replace as necessary.
_____________________________________________________________________

ERROR CODE -1805 Memory is locked because of AC_FAIL.

The memory was accessed during the controller shut down due to a power supply
abnormality (ACFAIL).

⇒Cycle the controller power OFF and ON.

_____________________________________________________________________

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ERROR CODES/TROUBLESHOOTING

10.3 TROUBLESHOOTING FLOWCHARTS

The following flowcharts are arranged in the numerical order of the error code. Refer
also to the corresponding error code information in section 10.2 during troubleshooting
procedures.

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ERROR CODES/TROUBLESHOOTING

Error 1513

Does this
error occur just Follow
Yes troubleshooting
after resetting error
1553, 1554, or flowchart for each
1555? error

No

Replace encoder

Yes

Does No
problem still END
exist?

Yes

Replace 1GB board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Figure 10-3 Error 1513 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 10-4 Error 1513 Flowchart (2)

February 15, 2000 10-77

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ERROR CODES/TROUBLESHOOTING

Error 1521

Does this
error occur just Follow
Yes troubleshooting
after resetting error
1553, 1554, or flowchart for each
1555? error

No

No
Replace encoder END

Yes

Does
problem still
exist?

Yes

Replace 1GB board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Figure 10-5 Error 1521 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 10-6 Error 1521 Flowchart (2)

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ERROR CODES/TROUBLESHOOTING

Error 1550

Does the
Reduce conveyor
encoder revolve over
Yes encoder revolution
300 RPM?
speed under 300
(Case of conveyor
RPM at power-up
encoder)

No END
Check connections at the
encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Figure 10-7 Error 1550 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Replace 1GB board

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Service call

Figure 10-8 Error 1550 Flowchart (2)

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ERROR CODES/TROUBLESHOOTING

Error 1553

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Check connections at the Yes Does the error

encoder connector reoccur?

No
Check connections on the
1FG board
END

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Figure 10-9 Error 1553 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Replace 1GB board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 10-10 Error 1553 Flowchart (2)

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ERROR CODES/TROUBLESHOOTING

Error 1554

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Check connections at the Yes Does the error

encoder connector reoccur?

No
Check connections on the
1FG board
END

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Figure 10-11 Error 1554 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Replace 1GB board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 10-12 Error 1554 Flowchart (2)

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ERROR CODES/TROUBLESHOOTING

Error 1555

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Replace encoder Yes Does the error

reoccur?
Yes
No
Does No
problem still END
exist?

Yes

Replace 1GB board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Figure 10-13 Error 1555 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 10-14 Error 1555 Flowchart (2)

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ERROR CODES/TROUBLESHOOTING

Error 1556

Replace encoder

Does No
problem still END
exist?

Yes

Replace 1GB board

Does
No
problem still END
exist?

Yes
Check connections at the
encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Does
No
problem still END
exist?

Yes

Figure 10-15 Error 1556 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 10-16 Error 1556 Flowchart (2)

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ERROR CODES/TROUBLESHOOTING

Error 1557

Replace encoder

Does No
problem still END
exist?

Yes

Replace 1GB board

Does
No
problem still END
exist?

Yes
Check connections at the
encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GB board

Does
No
problem still END
exist?

Yes

Figure 10-17 Error 1557 Flowchart (1)

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ERROR CODES/TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

Figure 10-18 Error 1557 Flowchart (2)

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OPTIONAL FUNCTIONS

11.0 OPTIONAL FUNCTIONS ........................................................................... 11-3

11.1 Mirror Conversion, AUX 6 ........................................................................... 11-3
11.2 Data Conversion, AUX 9 ............................................................................ 11-5
11.3 Floppy Disc Drive (FD_SAVE), AUX 20...................................................... 11-6
11.4 Floppy Disc Drive (FD_LOAD), AUX 21 ..................................................... 11-7
11.5 File Directory (FD_FDIR), AUX 22 ............................................................. 11-8
11.6 FDD Aux Function, Aux 23 ......................................................................... 11-8
11.7 Auto Tool Set, AUX 40 ................................................................................ 11-9
11.7.1 Setting Tool Coordinates .......................................................................... 11-12
11.8 Fixed Tool Dimensions, AUX 45 ............................................................... 11-13
11.9 Work Dimensions, AUX 49 ....................................................................... 11-15
11.10 Work Space Output, AUX 77 .................................................................... 11-16
11.11 XYZ Shift, AUX 80 .................................................................................... 11-17
11.12 Joint Shift, AUX 81 ................................................................................... 11-18
11.13 Tool Shift, AUX 82 .................................................................................... 11-19
11.14 Work Shift, AUX 83 .................................................................................. 11-20
11.15 OX Specification, AUX 117....................................................................... 11-21
11.16 PC Program Run/Stop, AUX 130 ............................................................. 11-23
11.17 Interface Panel, AUX 131 ......................................................................... 11-25
11.17.1 Push Button Switch Setting ...................................................................... 11-26
11.17.2 Push Button with Lamp ............................................................................ 11-27
11.17.3 Two Notch Selector Switch ....................................................................... 11-27
11.17.4 Three Notch Selector Switch .................................................................... 11-28
11.17.5 Pilot Lamp ................................................................................................ 11-28
11.17.6 Digital Switch ............................................................................................ 11-29
11.17.7 Digital Display........................................................................................... 11-30
11.17.8 Text Window ............................................................................................. 11-30
11.17.9 Software Dedicated Signal ....................................................................... 11-31
11.17.10 I/F Panel Programmed by PC................................................................... 11-32
11.18 AS Instruction Definition, AUX 133........................................................... 11-33
11.19 Online Edit, AUX 135 ............................................................................... 11-34
11.20 SLOGIC .................................................................................................... 11-40
11.21 Remote I/O and Slogic Specifications ...................................................... 11-43
11.22 RI/O Monitor, AUX 180 ............................................................................. 11-45
11.23 RI/O PLC (NAC) Setting, AUX 181........................................................... 11-49
11.24 RI/O Slogic Control, AUX 183 .................................................................. 11-50
11.25 RI/O Slogic Forced Output, AUX 184 ...................................................... 11-51
11.26 Password Set, AUX 197 ........................................................................... 11-51
11.27 Auxiliary Function Select, AUX 198 .......................................................... 11-52
11.28 Direct Speed ............................................................................................ 11-53
11.29 Touch Sensing Function ........................................................................... 11-54
11.30 Wire Check Function ................................................................................ 11-54
11.31 Work Detect Function .............................................................................. 11-58
11.32 Work Modification Function ...................................................................... 11-61

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OPTIONAL FUNCTIONS

11.32.1 Search Patterns ........................................................................................ 11-61

11.32.2 Teaching the Work Modification ................................................................ 11-62
11.33 Search Pattern Combinations ................................................................... 11-66
11.33.1 Teaching Pattern Combinations ................................................................ 11-67

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OPTIONAL FUNCTIONS

11.0 OPTIONAL FUNCTIONS

This unit covers information pertaining to the optional functions of the C controller.
Options include data conversion, remote input and output through serial communication,
touch sensing, seam tracking, special weave patterns, and additional auxiliary functions.

11.1 MIRROR CONVERSION, AUX 6

F1
PROGRAM
INPUT

This function allows the user to perform mirror imaging of taught location points. This
function mirrors data taught in the X-axis of the base coordinate system about the YZ
plane. Figure 11-1 shows an application of the mirror conversion function. Another
application for the MIRROR CONVERSION function is for two robots directly opposite
each other on a line and performing the same motion. In this case, one program is
recorded, transferred, mirrored, and used as a basis for the robot program on the oppo-
site side of the line.

Figure 11-1 Mirror Conversion

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OPTIONAL FUNCTIONS

The screen to perform the MIRROR CONVERSION function is shown in figure 11-2.

AUX 6 MIRROR CONVERSION

PROGRAM NAME

START STEP 0

END STEP(O:START STEP ONLY) 0

F1 F2 F3 F4
PROGRAM
INPUT

Figure 11-2 Mirror Conversion Screen

Enter the program name that contains the points that are to be mirrored by pressing the
F1 PROGRAM INPUT key. The screen that is displayed next is the PROGRAM SE-
LECT screen. Select the program name that contains the locations to be mirrored. The
START STEP is the first step to be mirrored in the program. If a 0 is entered for the
START STEP information, the first step to be mirrored will be step 1. The END STEP is
the last step to be mirrored in the program. If a 0 is entered for the END STEP informa-
tion, the START STEP will be the only step mirrored.

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OPTIONAL FUNCTIONS

11.2 DATA CONVERSION, AUX 9

The DATA CONVERSION function allows the user to utilize off-line programming pro-
cesses to load program data to a production machine. One advantage of this process is
that a robot that is in a production operation does not need to be taken off-line for the
teaching of new programs. Programmers can work off-line with computer simulation
models to develop and test various program scenarios while keeping on-line machines
in production. The screen for the DATA CONVERSION function is shown in figure 11-3.

AUX 9 DATA CONVERSION

1 START TRANSFORMING
2 REGISTER TOOL DIMENSIONS
3 MEASURE A TOOL AUTOMATICALLY
4 GRAVITY COMPENSATION

FUNCTION NUMBER:

F1 F2 F3 F4

Figure 11-3 Data Conversion

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OPTIONAL FUNCTIONS

11.3 FLOPPY DISK DRIVE (FD_SAVE), AUX 20

The FLOPPY DISK DRIVE (FD_SAVE) function allows the user to save program data
from RAM to an optional floppy disk drive unit. There are six options available which
are:

Option 1: ALL DATA-includes robot data, system data, auxiliary data, program data,
and variable data.
Option 2: PROGRAM-contains the contents of a selected program.
Option 3: AUX DATA-includes data settings from the Data Set menus.
Option 4: ALL DATA (SELECTED PROGRAM ONLY)-includes robot data, system
data, auxiliary data, selected program data, and variable data associated
with selected programs.
Option 10: ROBOT DATA-includes the robot type, number of axes, robot specific soft
ware settings.
Option 11: ERROR LOGGING-includes error data present in the error log.

AUX 20 MEMORY ->FDD (FD_SAVE)

1 ALL DATA
2 PROGRAM
3 AUX DATA
4 ALL DATA (SELECTED PROGRAM ONLY)
10 ROBOT DATA
11 ERROR LOGGING

F1 F2 F3 F4

Figure 11-4 AUX 20, FDD (FD_SAVE)

To access this function press the MENU key on the top tool bar, then press the FUNC-
TION key of the drop down menu. Use the arrow keys to navigate through the AUX.
functions until AUX 20 is reached and highlighted, or type in the AUX function number
desired, then press the ENTER key. The illustration for AUX 20 is shown in figure 11-4.

Options 2 and 4, in AUX 20, have “next page” displays which allow the user to save
specific programs by navigating through and utilizing specific display functions. Figure
11-5 shows a typical “next page” display.

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OPTIONAL FUNCTIONS

AUX 20 MEMORY ->FDD (FD_SAVE) AUX 20 MEMORY ->FDD (FD_SAVE)

2 PROGRAM 2 PROGRAM
F3
ï
NEXT PG SELECTED PROGRAM 1:
2:
3:
4:
5:

F2
FILE 0 ï ï
[Link]
F1 F2 F3 F4 F1 F2 F3 F4

Figure 11-5 AUX 20, Typical “Next Page” Display

11.4 FLOPPY DISK DRIVE (FD_LOAD), AUX 21

Loading of data is accomplished through AUX 21: (FD_LOAD). The data that is cur-
rently on the disk will be transferred to the controller’s RAM memory. There are two
options available which are:

Option 1: ALL DATA

Option 2: SELECTED DATA

These options are shown in figure 11-6.

AUX 21 FDD ->MEMORY (FD_LOAD)

1 ALL DATA
2 SELECTED DATA

F1 F2 F3 F4

Figure 11-6 AUX 21, FDD (FD_LOAD)

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OPTIONAL FUNCTIONS

11.5 FILE DIRECTORY (FD_FDIR), AUX 22

This function displays all files currently in the Floppy Disk Drive directory.

11.6 FDD AUX FUNCTION, AUX 23

The FDD AUX FUNCTION allows four auxiliary functions to be used. The options are:

Option 1: FDD FORMATTING (FD_FORMAT)-allows the user to format the floppy

disk drive to either 1.44 MB or 1.25 MB.
Option 2: FILE DELETE (FD_FDEL)-allows the user to delete files from the direc-
tory.
Option 3: FILE RENAME (FD_RENAME)-allows the user to rename files.
Option 4: FDD CONFIG.-allows user to configure the optional floppy disk drive unit
connection and disconnection.

Figure 11-7 shows the AUX 23 options.

AUX 23 FDD [Link]

1 FDD FORMATTING (FD_FORMAT)

2 FILE DELETE (FD_FDEL)
3 FILE RENAME (FD_RENAME)
4 FDD CONFIG.

F1 F2 F3 F4

Figure 11-7 AUX 23, FDD AUX Function

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OPTIONAL FUNCTIONS

11.7 AUTO TOOL SET, AUX 40

The auto tool set function allows the user to define the tool center point for the welding
torch automatically. When the auto tool set function is selected, the display shown in
figure 11-8 appears. The user must select a tool number using the numeric keypad, or
create a name for the tool using the character set. Press the F1 key to access the
character set. After the tool number or name has been selected, use the cursor key to
highlight the type field and enter the number 1 with the numeric keypad. Entering the
number 1 in the type field allows the user to define the X, Y, Z coordinates and O, A, T
angles. If the number 1 is not entered, only the X, Y, Z coordinates of the tool center
point are defined. Press the RETURN key to display the screen shown in figure 11-9.

PROGR AM S TE P PC S P E E D 1 0% '9 7 -0 3-1 8

1 7 :30
TEAC H
TE A C H IN G FU N C T IO N N E X T M E N U

8 9
AUX 40 AUTO TOOL SET

(1) REGISTER TOOL NAME 6 7

TOOL NAME (*) 1
TYPE 0
(0:XYZ, 1:XYZOAT)
4 5 - E X IT
(*) The case of “1”-”9” is set for
AUX TOOL 1-9, the other is
set for SYSTEM TOOL.
2 3 . BS

F1 F2 F3 F4
[Link] 0 1 CLEAR
INPUT RETURN

Figure 11-8 Auto Tool Set

PROGRAM STEP PC 1
_ +
TEACHING STATUS MENU
M-OFF 2
HOLD _
EXIT TEACH +
WELD OFF
AUX 40 AUTO TOOL SET
(2) RECORD BASE POINTS 1 3
?1 :POINT A1 _ +
?2 :POINT A2 [Link]
?3 :POINT A3
?4 :POINT A4 4
?5 :POINT B _ +
?6 :POINT C INCHING

Select point with cursor, 5

[Link]
and then RECORD. RECORD _ +
Record all points, and then ENTER. OFF

F1 F2 F3 F4 6
COORDINATE
JOINT
_ +
PRE PG
RETURN

Figure 11-9 Tool Positioning Screen

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OPTIONAL FUNCTIONS

Points A1 through A4 are individual tool positions that must be recorded when defining
the tool center point. While in the tool positioning screen shown in figure 11-9, highlight
and record each of the positions A1 through A4 with the torch positioned as shown in
figure 11-10. Press the RECORD key for each point.

The tool center point (weld wire end) must be touching the fixed pointer at each position.
The Z-axis of the tool should be 90 degrees from the Z-axis of the fixed pointer for
positions A1, A3, and A4. For position A2, the Z-axis of the tool should be parallel to the
Z-axis of the fixed pointer. Refer to figure 11-10 and 11-11.

Tool Z-axis

+X A2
A3

Base +Y-axis -Y
A1 A4

Fixed pointer

Base X-axis

Base Z-axis

Figure 11-10 Tool Orientation, View From Side

NOTE

Tool center point is the end of the welding wire. Proper

stickout must be used at each position and the wire
must not be bent.

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OPTIONAL FUNCTIONS

Base +X-axis

A3

Base +Y-axis -Y side of fixed pointer

A1 A4

-X side of fixed pointer

Figure 11-11 Tool Orientation, View From Top

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OPTIONAL FUNCTIONS

11.7.1 SETTING TOOL COORDINATES

See figure 11-12, Tool XYZ, for points B and C. When all points are recorded, press
ENTER. The user is then prompted to answer YES or NO to set tool dimensions. An-
swer YES to accept the tool coordinates. Press EXIT to return to the original display on
the multi function panel. Use the following procedure to perform this operation.

• Jog the torch to the position recorded as point A2 (Figure 11-10).

• Jog the torch away (100 mm min.) from point A2 in base mode. Select point B and
press REC. This sets the torch Z-axis.
• Jog the torch back to the position recorded as point A2.
• Jog the torch away (100 mm min.) from point A2 in base mode. Select point C and
press REC. This sets the torch Y-axis.

Point B
-Tool Z

Point C
+Tool Y

Base Y axis

Fixed Pointer

Base Z axis

Figure 11-12 Tool XYZ

When all points are recorded, press the ENTER key. The new tool points are recorded
and “normally completed” appears in the message window. Next, press the NEXT PG.
key and then the YES key to complete the recording procedure.

Press the Exit key to access the AUX Function menu and select AUX 50 TORCH DI-
MENSIONS. At this screen press the ENTER key to apply the new tool dimensions (the
new dimensions appear and are entered to apply).

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11.8 FIXED TOOL DIMENSIONS, AUX 45

The FIXED TOOL DIMENSIONS function allows the user to program moves that are
relative to an external fixed point in the work envelope. This type of interpolation is
called fixed linear interpolation (FLIN). In a FLIN move the robot path is calculated to
maintain a set relationship to a fixed point. Applications for FLIN moves include moving
a part around a fixed sealing dispenser or a fixed stud welding gun. Figure 11-13 shows
the auxiliary function screen used to enter the dimensions for a fixed tool to be used
with FLIN moves. Figure 11-14 shows how the path of a windshield being moved by a
robot would be different with linear and FLIN interpolation. The FLIN path enables the
programmer to reduce the number of programmed points needed to maintain a fixed
distance from the sealing dispenser.

FIXED TOOL1

X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg

Figure 11-13 Fixed Tool Dimensions

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FIXED TOOL LOCATION

POINT A POINT B
TAUGHT HERE TAUGHT HERE

SEALANT
DISPENSER

PART BEING CARRIED BY

ROBOT TO RECEIVE SEALANT

LINEAR INTERPOLATED PATH FROM POINT A TO POINT B

FIXED LINEAR INTERPOLATION PATH

FROM POINT A TO POINT B

Figure 11-14 Fixed Tool Dimensions and FLIN

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11.9 WORK DIMENSIONS, AUX 49

The WORK DIMENSIONS function is active in the teach mode and allows the user to
jog the robot relative to an alternative coordinate system. Figure 11-15 shows the dis-
play that is used to set WORK DIMENSIONS 1-9.

AUX 49 WORK DIMENSIONS

WORK 1

X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg

F1 F2 F3 F4
RANG: Rotation 0.0deg - 10.0deg
[Link]
Traverse 0.0mmNEXT PG
- 100.0mm

Figure 11-15 Work Dimensions

The WORK DIMENSIONS are determined using the AS Language FRAME and POINT
commands to define a coordinate system based on the orientation of the work where
points will be taught. Reference the KRI AS Language Manual for information on the
FRAME function and the commands needed to enter WORK DIMENSIONS information.
Figure 11-16 shows how the orientation of the work dimensions is different from the
base coordinate orientation.

X Z
NS
IO
X
S
EN
M
DI
RK
O
W

Z
Y Y
Figure 11-16 Work Dimensions Orientation

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11.10 WORK SPACE OUTPUT, AUX 77

When the TCP is within the space defined by the WORKSPACE OUTPUT function, the
assigned signal is turned on. Figure 11-17 shows the display to set the UPPER and
LOWER X, Y, and Z dimensions. Figure 11-18 shows an example of how the dimen-
sions are determined. Jog the robot to the UPPER and LOWER locations and record
the X, Y, and Z positional information for input into AUX 77. Whenever the TCP is within
the three dimensional space defined by the WORK SPACE OUTPUT function an as-
signed output signal is on.

AUX 77 WORK SPACE OUTPUT

WORK SPACE 1
UPPER X DIRECTION 0mm
Y DIRECTION 0mm
Z DIRECTION 0mm
LOWER X DIRECTION 0mm
Y DIRECTION 0mm
Z DIRECTION 0mm

OUTPUT SIGNAL 16

F1 F2 F3 F4

[Link] NEXT PG

Figure 11-17 Work Space Output

UPPER XYZ
LOCATION Z
X
PUT
DIME CE OUT
NS
NSIO
A
K SP

Y
WOR

LOWER XYZ
LOCATION

Figure 11-18 Work Space Output Dimensions

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11.11 XYZ SHIFT, AUX 80

The XYZ SHIFT function is used in conjunction with block step programs and shifts
programmed locations in the base coordinate system. The display screen used to set
the shift information is shown in figure 11-19.

AUX 80 XYZ SHIFT

PROGRAM NAME
START STEP 0
END STEP (0:START STEP ONLY) 0

X SHIFT VALUE 0.0mm

Y SHIFT VALUE 0.0mm
Z SHIFT VALUE 0.0mm

RANGE IN TEACH +_ 500mm

IN REPEAT +
_ 10mm

F1 F2 F3 F4
PROGRAM
INPUT

Figure 11-19 XYZ Shift

Enter the name of the program that contains the points that are to be shifted by pressing
the F1 PROGRAM INPUT key. The screen that is displayed next is the PROGRAM
SELECT screen; select the program name that contains the locations to be shifted. The
START STEP is the first step to be shifted in the program. If a 0 is entered for the
START STEP information, the first step to be shifted is step 1. The END STEP is the
last step to be shifted in the program. If a 0 is entered for the END STEP information,
only the START STEP is shifted. The distance and direction of shifting in the base
coordinate system is entered in the X,Y,Z section of the screen. The value of the shift in
each coordinate direction is entered in mm. In the TEACH mode of operation the shift
value can be as much as ±500mm, in the REPEAT mode of operation the maximum
shift is ±10mm.

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11.12 JOINT SHIFT, AUX 81

The JOINT SHIFT function is used in conjunction with block step programs and shifts
programmed locations based on joint angle information. The display screen used to set
the information is shown in figure 11-20.

AUX 81 JOINT SHIFT

PROGRAM NAME
START STEP 0
END STEP (0:START STEP ONLY) 0

JOINT SHIFT VALUE RANGE:

JT1 0.0deg IN TEACH
JT2 0.0deg +
_ 10deg
JT3 0.0deg +
_ 500mm
JT4 0.0deg IN REPEAT
JT5 0.0deg +
_ 1deg
JT6 0.0deg +
_ 10mm

F1 F2 F3 F4
PROGRAM
INPUT

Figure 11-20 Joint Shift

Enter the program name that contains the points that are to be shifted by pressing the
F1 PROGRAM INPUT key. The screen that is displayed next is the PROGRAM SE-
LECT screen. Select the program name that contains the locations to be shifted. The
START STEP is the first step to be shifted in the program. The END STEP is the last
step to be shifted in the program. If a 0 is entered for the END STEP information, only
the START STEP is shifted. The angular distance and joint to be shifted is entered in
the JT1 to JT6 sections of the screen. The value of the shift in each joint is entered in
degrees. In the TEACH mode of operation the shift value can be as much as ±10°, in
the REPEAT mode of operation the maximum shift is ±1°.

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11.13 TOOL SHIFT, AUX 82

The TOOL SHIFT function is used in conjunction with block step programs and shifts
programmed locations in the tool coordinate system. The display screen used to set the
tool shift information is shown in figure 11-21.

AUX 82 TOOL SHIFT

PROGRAM NAME
START STEP 0
END STEP (0:START STEP ONLY) 0

X SHIFT VALUE 0.0mm

Y SHIFT VALUE 0.0mm
Z SHIFT VALUE 0.0mm

RANGE: IN TEACH +_ 500mm

IN REPEAT +
_ 10mm

F1 F2 F3 F4
PROGRAM
INPUT

Figure 11-21 Tool Shift

Enter the program name that contains the points that are to be shifted by pressing the
F1 PROGRAM INPUT key. The screen that is displayed next is the PROGRAM SE-
LECT screen. Select the program name that contains the locations to be shifted. The
start step is the first step to be shifted in the program. If a 0 is entered for the start step
information, the first step to be shifted is step 1. The END STEP is the last step to be
shifted in the program. If a 0 is entered for the END STEP information, only the START
STEP is shifted. The distance and direction of shifting in the tool coordinate system is
entered in the X,Y,Z section of the screen. The value of the shift in each tool coordinate
direction is entered in mm. In the TEACH mode of operation the shift value can be as
much as ±500mm, in the REPEAT mode of operation the maximum shift is ±10mm.

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11.14 WORK SHIFT, AUX 83

The WORK SHIFT function is used in conjunction with block step programs and shifts
programmed locations in the coordinate system defined as “work”. The display screen
used to set the information is shown in figure 11-22.

AUX 83 WORK SHIFT

PROGRAM NAME
START STEP 0
END STEP (0:START STEP ONLY) 0

X SHIFT VALUE 0.0mm

Y SHIFT VALUE 0.0mm
Z SHIFT VALUE 0.0mm

RANGE: IN TEACH +_ 500mm

IN REPEAT +
_ 10mm

F1 F2 F3 F4
PROGRAM
INPUT

Figure 11-22 Work Shift

Enter the name of the program that contains the points that are to be shifted by pressing
the F1 PROGRAM INPUT key. The screen that is displayed next is the program select
screen. Select the program name that contains the locations to be shifted. The START
STEP is the first step to be shifted in the program. If a 0 is entered for the start step
information, the first step to be shifted is step 1. The END STEP is the last step to be
shifted in the program. If a 0 is entered for the end step information, only the start step
is shifted.

The distance and direction of shifting in the work coordinate system is entered in the
X,Y,Z section of the screen. The value of the shift in each work coordinate direction is
entered in mm. In the TEACH mode of operation the shift value can be as much as
±500mm, in the REPEAT mode of operation the maximum shift is ±10mm.

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11.15 OX SPECIFICATION, AUX 117

The OX specification function allows the user to set the characteristics of output signals.
Four types of signals can be specified, they include the STEP, KEEP, DOUBLE, and
PULSE types. The settings of the OX PREOUT and [Link] switches affect
signal timing; unit 9 of this manual covers the function of these switches.

• The STEP type signal is the standard type of signal that is output without the op-
tional OX specification function. The STEP type signal is turned on at each step of
the block step program that identifies the signal number. When the robot moves to
a location that does not include the signal number in the auxiliary data, the signal is
turned off. A 0 is entered to specify a STEP type of signal from the OX specification
table.

• The KEEP type of signal remains on until it is turned off at a specific step. The
number 1 is entered to specify a KEEP type of signal in the OX specification table.

• The DOUBLE type of signal turns one signal on and one off, DOUBLE type signals
must be entered in pairs. The number 2 is entered to specify DOUBLE types of
signals in the OX specification table.

• The PULSE type of signal remains on for the specified length of the pulse in sec-
onds. The number 3 is entered to specify a PULSE type of signal in the OX specifi-
cation table, the length of the pulse is also entered in this screen.

Figure 11-23 shows the OX specification screen used to set the signal characteristics
and figure 11-24 is a graph showing the affect of each type of signal on signal timing.

8 9
AUX 117 OX SPECIFICATION SET
OX No. 1 2 3 4 5 6 7 8
TYPE 0 0 0 0 0 0 0 0 6 7
PULSE 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
WIDTH [sec]
OX No. 9 10 11 12 13 14 15 16
TYPE 0 0 0 0 0 0 0 0 4 5 EXIT
PULSE 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
WIDTH [sec]

TYPE(0:STEP, 1:KEEP BS
2:DOUBLE, 3:PULSE
2 3

F1 F2 F3 F4

[Link] NEXT PG 0 1 CLEAR

RETURN

Figure 11-23 OX Specification

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Figure 11-24 Output Timing

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11.16 PC PROGRAM RUN/STOP, AUX 130

AUX 130 enables the user to control the PC program and determine the status of the
program. The process control (PC) program allows the user to coordinate the robot
controller with assembly line or process control. The PC program runs in the back-
ground and monitors I/O, sets internal signals, and performs mathematical computa-
tions. The PC program executes I/O commands, performs logic operations and math-
ematical computations, but cannot execute motion instructions. Refer to Table 11-2 for
PC Program Run/Stop Commands.

A U X 130 P C P R O G R A M R U N /S TO P

1 START (PCEXECUTE)
2 ABORT (PCABORT)
3 STOP (PCEND)
4 CONTINUE (PCONTINUE)
5 KILL (PCKILL)
6 STATUS (PCSTATUS)

FUNCTION NUMBER: •@

F1 F F3 F4

Figure 11-25 PC Program Run/Stop

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Table 11-1 PC Program Run/Stop Commands

AS Language
Item Explanation Command
Executes the designated PC program. The
START number of execution and start steps can also PCEXECUTE
be designated.

ABORT Interrupts currently executing PC program. PCABORT

Stops the execution of the program when the

currently executing PC program, followed by a
STOP PCEND
STOP instruction, has been executed, or when
the final step of a program has been executed.
Re-runs the execution of a PC program which
CONTINUE is interrupted by an execution interrupt PCCONTINUE
(PCABORT)or an execution end (PCEND).

KILL Cancels currently selected PC program. PCKILL

Displays information concerning currently

STATUS PCSTATUS
executing C program status.

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11.17 INTERFACE PANEL, AUX 131

On the C-series controller, the operation (interlock) panel which contains the lamps and
switches to operate the robot, is programed on the multi function panel. AUX function
131 allows the user to program the same switches and lamps for use and display on the
interface panel (I/F). Figure 11-26 shows an example of the interface panel.

AUX 131 allows the user to program specific items to appear in various locations of the
I/F panel. The numbered locations (Figure 11-27) correspond to the locations on the I/F
panel shown in grey numbers (Figure 11-26).

PROGRAM STEP PC SPEED 10% ‘97-03-18

I/F 17:30
pg99 5 REPT. CONTINUE RPS ON
STEP CONTINUE DRYRUN OFF
TEACHING I/F NEXT MENU

INTER FA CE PANEL (1/2)

AUTO MAN U O F F LIN E E N A B LE
OFF AUTO
HOME PALLE T
REMOVE 6 7 8
M ODE M ODE
M AN U AL OF F
9 10 A U TO O F F-LIN E
A U TO
13 14 15 16
17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32

Figure 11-26 Interface Panel

Figure 11-27 AUX 131 Interface Panel

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The characteristics of each interface panel function are set by pressing the PARAM-
ETER SET key. Pressing this key reveals the PARAMETER SET window for each
function.

When programming each of the interface panel functions, specify the following items:
label, color, signal number and operate inhibit. See figure 11-26, Push Button Param-
eters.

Switches and lamps have up to four lines available for labels. Each line may contain up
to 10 characters. To enter text for a line, use the F4 CHARACTER key to access the
keyboard.

Scrolling down to the color specification line, the switch type/number keys change to
various colors for input. When ENTER is pressed, the message NORMALLY COM-
PLETED appears on the screen.

Specify signal numbers according to desired output signals.

Operation of specific items are set to be enabled or disabled using the OPERATE IN-
HIBIT function. Choose YES or NO accordingly.

11.17.1 PUSH BUTTON SWITCH SETTING

Push button switches are set up to activate signals. The switch is labeled with up to four
lines of characters. Specify the desired color for signal status on and off. Assign the
desired output signal to the switch in the SIGNAL NUMBER field. When the push button
is pressed, the specified signal is generated. Figure 11-28 shows an example of a push
button switch.

A U X 13 1 IN TE R FA C E PA NE L
P O S IT IO N 1 P U S H B UT TO N
LA B E L 1
2 HOM E
3
HOME 4
C O L O R (O N ) 2
(O F F) 1
S IG N A L N U M B E R (S W IT C H ) 2001
O P E R AT E IN H IB IT Y E S /N O

F1 F F3 F4
P R EV.D ATA C H A R A C TE R

Figure 11-28 Push Button Parameters

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11.17.2 PUSH BUTTON WITH LAMP

A push button with a lamp is set up similarly to a push button. However, different signals
can be specified for the lamp and the switch. Figure 11-29 shows the parameters for a
pallet remove switch.

A U X 13 1 IN TE R FA C E PA NE L

P O S IT IO N 2 P U S H B UT TO N W ITH LA M P
LA B E L 1
2 PA L LE T
3 REM O VE
PAL L E T 4
R E M O VE COLOR (O N ) 2
(O F F) 1
S IG N A L N U M B E R (S W IT C H ) 2001
(LA M P ) 2002
O P E R AT E IN H IB IT Y E S /N O
F1 F F3 F4
P R EV.D ATA C H A R A C TE R

Figure 11-29 Push Button With Lamp

11.17.3 TWO NOTCH SELECTOR SWITCH

AUX 131 provides set up for a two notch selector switch. Figure 11-30 shows the set up
of an AUTO/MAN switch. Colors can be specified for each position of the switch. Enter
the appropriate signals numbers for each.

A U X 13 1 IN TE R FA C E PA NE L
P O S ITIO N 3 2-N O TC H S EL E C TO R S W IT C H
LA B E L 1 M A N U A U TO
A U TO MANU
2
3
4
MODE C O L O R (LE F T ) (U P ) 6 A U TO M A N U
M AN U A L (R IG H T ) (D O W N ) 2
A U TO
S IG N A L N o. (LE FT ) (U P ) 2001
(R IG H T ) (D O W N ) 2002
D IS P LAY TY P E U P DO W N / R O TA R Y MODE
O P E R AT E IN H IB IT Y E S /N O M AN U A L
A U TO
F1 F F3 F4
P R EV.D ATA C H A R A C TE R

Figure 11-30 Two Notch Selector Switch

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11.17.4 THREE NOTCH SELECTOR SWITCH

Switches with three notches are set similar to two notch switches. Colors and signals
can be set for all three positions. The three notch switch can also be set up to be a
rotary switch or a linear up and down switch.

MODE O F F L IN E
OFF AUTO
OFF
O F F-L IN E
A U TO

MODE
A U X 13 1 IN TE R FA C E PA N E L OFF A U X 13 1 IN TE R FA C E PA N E L
P O S ITIO N 4 3 -N O TC H S E L EC TO R SW ITC H
O F F-L IN EP O S ITIO N 4 3 -N O TC H S E L EC TO R SW ITC H
LA B E L 1 O FF LIN E A U TO
2 O FF A U T O O P E R AT E IN HIB IT Y E S /N O
3 F3
4
C O LO R (LE FT ) (U P ) 6 ð NEXT PG ð
(M ID D LE ) 2
(R IG H T )(D O W N ) 1
S IG N A L N o . (LE F T) (U P ) 2001
(M ID D LE ) 2002
(R IG H T )(D O W N ) 2003
D IS P LAY T Y P E U P D O W N / R O TA R Y F
F1 F F3 F4
ï P R E V.P G ï F1 F F3 F4
P R EV.D ATA N E XT PG C H A R A C TE R P R EV.D ATA P R E V.P G C H A R A C TE R

Figure 11-31 Three Notch Switch

11.17.5 PILOT LAMP

Pilot lamps are set up to display the status of a specific signal (Figure 11-32). The color
specified for ON indicates the activation of the signal specified.

A U X 13 1 IN TE R FA C E PA NE L

P O S IT IO N 5 P ILO T L AM P
LA B E L 1 E N A B LE
2
E N A BL E 3
4
COLOR (O N ) 6
(O F F) 1
S IG N A L N U M B E R (LA M P ) 2001

F1 F F3 F4
P R EV.D ATA C H A R A C TE R

Figure 11-32 Pilot Lamp

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11.17.6 DIGITAL SWITCH

A digital switch can be created to generate output based digital inputs. The outputs are
based on the number displayed on the switch. The programmer dictates the outputs by
setting the number on the switch. The data from the switch is interpreted as either a
binary or decimal input. Table 11-3 shows the parameters to set a digital switch.

Table 11-2 Digital Switch Input

Digital Switch Parameter

Figures Specifies the number of digits displayed
This digital signal indicates which outputs will be on or off. Digital
input data can be directly entered with the numeric keys or the value
Input Data
increased by one each time the switch is pressed, it returns to the
minimum value when the maximum value is exceeded.
Limit Data The range of the input data can be limited (Y ES) or not limited (NO).
Specifies first number of the signal defined for a digital switch
Top Signal No.
(Internal signal number or output signal number).
Number of
Specifies the channel numbers of signals used as a digital switch.
Signals to Use
Outputs correspond to either a binary or decimal number.
Signal Type BCD: Decimal number
BINARY: Binary Number
Upper Limit
Specify the maximum/minimum value which can be set.
Lower Limit

A U X 13 1 IN TE R FA C E PA NE L
P O S IT IO N 7 D E G ITA L S W IT C H
LA B E L 1 WORK
2 K IN D
W ORK F IG U R E S (1∼4) 4
KIND IN P U T D ATA T E N K E YS /P U S H S W ITC H
0 02 2 LIM IT D ATA Y E S /N O
TO P S IG N A L N O . 2008
N U M B E R O F S IG N A LS TO U S E 16
S IG N A L T Y P E B C D /B IN A RY
U P P E R LIM IT 9999
LO W E R LIM IT 0
O P E R AT E IN IH IB IT Y E S /N O

F1 F F3 F4
P R EV.D ATA C H A R A C TE R

Figure 11-33 Digital Switch

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11.17.7 DIGITAL DISPLAY

Set up of a digital display is similar to the digital switch in the previous section.

A U X 13 1 IN TE R FA C E PA NE L
P O S IT IO N 8 D E G ITA L DIS PAY
LA B E L 1 PRO GRA M
2 NUM BE R
F IG U R E S (1∼4) 4
P R O G R AM TO P S IG N A L N O . 2008
No. N U M B E R O F S IG N A LS TO U S E 6
0 02 2 S IG N A L T Y P E B C D /B IN A RY

F1 F F3 F4
P R EV.D ATA C H A R A C TE R

Figure 11-34 Digital Display

11.17.8 TEXT WINDOW

A TEXT WINDOW is used in conjunction with an AS Language command to print a

message in a designated area of the interface panel. Up to four text windows can be
programmed and used.

A U X 13 1 IN TE R FA C E PA NE L

P O S ITIO N 1 T E X T W IN D O W
W in do w N um b er 1
W in do w S ize 4
D e fa ult B ack G ro und C o lo r 6

F1 F F3 F4
P R EV.D ATA

Figure 11-35 Text Window Parameters

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The window number corresponds to one of the four windows specified. Enter a number
from 1-4 in the Window Number field. The window size corresponds to the size of the
area that the message is displayed in. An area up to 4 times the sizes of a standard I/F
display area can be specified. Enter a number 1-4 in the Window Size field according to
the desired size of the window. The default background color identifies the background
color for the area where the message is shown. When this field is selected, a color
palette is displayed to specify the desired color.

The AS Language command that is used to display messages in the TEXT WINDOW is
IFPWPRINT. The format for this command is: IFPWPRINT window number (1 to 4), line
number to display message (1 to 4), number of spaces from the far left of the TEXT
WINDOW the first character is displayed, the background color of the TEXT WINDOW =
“the message”.

11.17.9 SOFTWARE DEDICATED SIGNAL

The interface panel can be automatically displayed by using external input signals.
External input signals are set with the DEFSIG INPUT command or “Auxiliary 111”.

• I/F panel, One page selection.

• I/F panel, Two page selection.

There are two software dedicated signals. The interface panel changes to the pertinent
page when the signal changes from OFF to ON.

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11.17.10 I/F PANEL PROGRAMMED BY PC

The interface panel can also be programed from a personal computer.

Specify switch type and position as follows when the file is loaded or is saved (xxxxxx is
file name).
LOAD [Link] -when the file with data is loaded in memory.
SAVE/if xxxxxx -when saving to disk file.
The following example shows set up of the interface panel using a personal computer.

.INTER_PANEL
1,1, “ “,”HOME”,” “,” “,1,2,1,0
2,2, “MANUAL”,”CLEAN”,” “,” “,2,3,2,2,0
3,3, “AUTOMANU”,” “,” “,” “,3,4,3,4,0,-1
4,4, “ OFFLINE”,”OFF AUTO”,” “,” “,4,5,6,5,6,7,0,0
5,5, “ ENABLE”,” “,” “,” “,5,6,1
7,6, “ AUTO”,” CLEAN”,4,-1,0,8,8,0,999,0,0
8,7, “ PROGRAM”,” No.”,4,8,8,0
11,3,” MODE”,” MANUAL”,” AUTO”,” “,3,4,3,4,-1,-1
12,4,” MODO”,” OFF”,” OFFLINE”,” AUTO”,”4,5,6,5,6,7,-1,0
15,6,” “,” “,3,-1,0,8,8,0,999,0,0
16,7,” “,” “,3,8,8,0
23,6,” “,” “,2,-1,0,8,8,0,999,0,0
24,7,” “,” “,2,8,8,0
31,6,” “,” “,1,-1,0,8,8,0,999,0,0
32,7,” “,” “,1,8,8,0

.END

* Specify the data in the following order from left to right.

The parameter for display position (1-64), type code (0-7), the detailed data (the same
order as setting screen, AUX 131), and the selection item shows that the following is
selected:

0 : The right side.

-1 : The left side.

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OPTIONAL FUNCTIONS

11.18 AS INSTRUCTION DEFINITION, AUX 133

AUX 133 allows the user to assign program instructions to keys for repeated use during
AS programming. You can define up to 32 variables, instructions or commands and
assign them to corresponding buttons (Figure 11-36).

A U X 13 3 A S  IN ST R U C T IO N D E FIN ITION

1 JM O VE 9
2 LMOVE 10
3 # pick 11
4 p la ce 1 2
5 13
6 14
7 15
8 16

F1 F F3 F4
PRE DATA N E XT PG CHARACTER

P R O G R AM S TE P PC S P E E D 1 0% '9 7-0 3-1 8

1 7:3 0
RPS ON
p gsrt0 1 1 R E P T. C O N T
TE A C H IN G S TATU S NEXT M ENU STEP CON T DRYRUN OFF
M -O FF
H O LD
TE A C H
A S IN S T R U C TIO N TE A C H IN G
DEFINED ?JMOVE
INSTRUCTION ? CHARACT ER

BUTTONS

{ J M O VE LM OVE # p ic k p la c e - PROGRAM
IN P U T

5 6 7 8 9 , . TE A C H
NEW

0 1 2 3 4 S PAC E S H IFT RECORD

Figure 11-36 AS Instruction Definition

Instructions 17 through 32 can be accessed by pressing the “NEXT PG” (F3) key. Char-
acter strings can be defined by 8 characters or less. The character string can be de-
fined only when “Record Accept” is set by AUX 71 RECORD “(PRGCHG) INHIBIT.”
Press the F4 CHARACTER key to access the keyboard for definition string input or
editing.

Once the instructions are defined, pressing the corresponding key inserts the instruction
into the AS program as shown in the lower screen of figure 11-36.

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11.19 ONLINE EDIT, AUX 135

Block step programs can be edited by using the multi function panel in the teach and
repeat modes. Online program data includes auxiliary data (SPEED, ACCURACY,
TIMER, TOOL, WORK, J/E, and COMMENT), clamps, guns and OX/WX signals. This
online data can be edited using AUX 135 Online Edit.

AUX 135 ONLINE EDIT

PROGRAM NAME mtu

STEP NUMBER 10
(0 : FIRST STEP)

F1 F2 F3 F4
PROGRAM
INPUT

Figure 11-37 Online Edit

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A U X .13 5 O N LIN E E D IT p g1
1 JOINT 9( 100.0%) 1( 1.0) 0(0.0) 1 0 ;START
2 LINEAR 4( 50.0%) 2( 10.0) 0(0.0) 1 0
3 CIR1 4( 50.0%) 3( 100.0) 0(0.0) 1 0
4 CIR2 4( 50.0%) 3( 100.0) 0(0.0) 1 0
5 FLIN 9( 100.0%) 1( 1.0) 1(0.1) 2 0
6 FCIR1 9( 100.0%) 1( 1.0) 2(0.2) 2 0 JUMP

. -
5 6 7 8 9 (S E T +) (S E T -) BS

0 1 2 3 4 S EX IT
R E TU R N

S S

PRE PG NEXT PG SCREEN SCREEN

A U X .1 35 O N L IN E E D IT pg 1

STEP
5 6 7 8 9 CHARACTER P R E D ATA
S E LE C T

0 1 2 ! 4 S E X IT
RETURN

Figure 11-38 Online Edit Screen, AUX 135

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OPTIONAL FUNCTIONS

With the S key activated, you can scroll to the next and previous pages, CLAMP DATA,
OX/WX, and other function screens. When the appropriate screen is displayed, deacti-
vate the S key and use the arrow keys to move the cursor to the item you want to
change. Use the SET + and SET- keys to change the data.

PRE PG N E XT PG SCREEN SCREEN

The screen will display the PRE PG and NEXT PG buttons for programs that have more
than seven steps. Use PRE PG and NEXT PG to scroll up and down the steps. The
SCREEN buttons take you to the next screen containing data for other functions.

SCREEN SCREEN

Pressing the SCREEN key takes you to the following screens:

The clamp data (gun data) screen allows you to edit clamp signals for each individual
step. Figure 11-39 shows a spot welding/handling application and a painting/sealing
application.

Spot Welding and Handling Application

A U X .13 5 O N LIN E E D IT pg1

C LA M P D ATA
1 1 (O FF, 0 , 0 ,O ) 2 (O FF, 0, 0 ,O ) 3 (O FF, 0 , 0 ,O ) 4 (O FF, 0 , 0 ,O )
2 1 (O N , 0 , 0 ,O ) 2 (O FF, 0, 0 ,O ) 3 (O FF, 0 , 0 ,O ) 4 (O FF, 0 , 0 ,O )
3 1 (O N , 0 , 0 ,O ) 2 (O FF, 0, 0 ,O ) 3 (O FF, 0 , 0 ,O ) 4 (O FF, 0 , 0 ,O )
4 1 (O N , 1 , 1 ,C ) 2 (O FF, 0, 0 ,O ) 3 (O FF, 0 , 0 ,O ) 4 (O FF, 0 , 0 ,O )
5 1 (O FF, 0 , 0 ,O ) 2 (O FF, 0, 0 ,O ) 3 (O FF, 0 , 0 ,O ) 4 (O FF, 0 , 0 ,O )
6 1 (O FF, 0 , 0 ,O ) 2 (O FF, 0, 0 ,O ) 3 (O FF, 0 , 0 ,O ) 4 (O FF, 0 , 0 ,O )
7 1 (O FF, 0 , 0 ,O ) 2 (O FF, 0, 0 ,O ) 3 (O FF, 0 , 0 ,O ) 4 (O FF, 0 , 0 ,O )

Painting and Sealing Application

A U X .13 5 O N LIN E E D IT p g 1

1 1 (O FF , 0 , 0 ,O ) 2 (O FF , 0 , 0 ,O ) 3 (O FF , 0 , 0 ,O ) 4 (O FF , 0 , 0 ,O )
2 1 (O N , 2 00 , 0 ,O ) 2 (O FF , 0 , 0 ,O ) 3 (O FF , 0 , 0 ,O ) 4 (O FF , 0 , 0 ,O )
3 1 (O N ,-2 00 , 0 ,O ) 2 (O FF , 0 , 0 ,O ) 3 (O FF , 0 , 0 ,O ) 4 (O FF , 0 , 0 ,O )
4 1 (O N , 2 00 , 0 ,O ) 2 (O FF , 0 , 0 ,O ) 3 (O FF , 0 , 0 ,O ) 4 (O FF , 0 , 0 ,O )
5 1 (O FF , 0 , 0 ,O ) 2 (O FF , 0 , 0 ,O ) 3 (O FF , 0 , 0 ,O ) 4 (O FF , 0 , 0 ,O )
6 1 (O FF , 0 , 0 ,O ) 2 (O FF , 0 , 0 ,O ) 3 (O FF , 0 , 0 ,O ) 4 (O FF , 0 , 0 ,O )

Figure 11-39 Clamp Data Screens

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OPTIONAL FUNCTIONS

Use SET+ and SET- to program OX and WX signals on or off for various steps.

The OX signals can be edited from the next screen (Figure 11-40). From this screen
each OX signal can be programmed to be on or off at each individual step of the pro-
gram. Scrolling to the next screen reveals OX signals 32 and higher.

A U X .13 5 O N LIN E E D IT pg 1
OX 01 05 10 15 20 25 30 ★:O N
1 ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
2 M★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
3 M M★M M M M M★M M M M M M M M M M M M M M M M M M M M M M M
4 M M M★M M M M M M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M
6 M M M M M★M M M M M M M M M M M M M M M M M M M M M M M M M M
7 M M M M M M★M M M M M M M M M M M M M M M M M M M M M M M M M

ñ ò
SCREEN SCREEN
Use the SCREEN keys
to show more signals.

ñ ò

A U X .13 5 O N LIN E E D IT pg1

O X 35 40 45 50 55 60 ★:O N
1 ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
2 M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
3 M M★M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M
4 M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M★ M M M M M M M M M M M M M M M M M M M M M M M M M M M
6 M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M
7 M M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M

Figure 11-40 OX Edit Screen

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Use the SCREEN keys to scroll to the WX Edit Screen. WX signals can be edited the
same as OX signals shown above. SET+ and SET- are used to change signal status
from on to off. See Figure 11-41.

A U X .13 5 O N LIN E E D IT p g 1
W X 01 05 10 15 20 25 30 ★:O N
1 ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
2 M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
3 M M ★M M M M M ★ M M M M M M M M M M M M M M M M M M M M M M M
4 M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M
6 M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M
7 M M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M

ñ ò
SCREEN SCREEN
Use the SCREEN keys
to show more signals.

ñ ò

A U X .13 5 O N LIN E E D IT pg1

W X 35 40 45 50 55 60 ★:O N
1 ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
2 M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
3 M M★M M M M M★M M M M M M M M M M M M M M M M M M M M M M M
4 M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M M M
5 M M M M★ M M ★ M M M M M M M M M M M M M M M M M M M M M M M M
6 M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M M
7 M M M M M M ★M M M M M M M M M M M M M M M M M M M M M M M M M

Figure 11-41 WX Edit Screen

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The robot location can be edited and configured from the location edit screen. Use the
SCREEN keys to scroll to the screen. This screen allows you to change the numeric
joint angle value for each individual joint at each step (Figure 11-42).

Use the arrow keys to scroll to the joint position you want to change and enter the de-
sired numeric value with the number keys. Joint angle data cannot be changed if the
online edit program is executing.

A U X .13 5 O N LIN E E D IT p g 1
JT 1 JT 2 JT3 JT4 JT5 JT6 JT7
1 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
2 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
3 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
4 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
5 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
6 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
7 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0

ñ ò
SCREEN SCREEN
If more than 7 axis are present,
use the SCREEN keys to view
more axis.
ñ ò

A U X .13 5 O N LIN E E D IT pg1

JT8 JT 9 JT1 0 JT11 JT 1 2
1 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
2 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
3 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
4 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
5 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
6 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0
7 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0 0 .0 0 0

Figure 11-42 Joint Location Edit Screen

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11.20 SLOGIC

Relay circuitry for the robot interface is reduced by replacing it with the Slogic software
function. Slogic is similar to ladder logic, used with programmable logic controllers
(Table 11-3). Making signal assignments using Slogic is much easier than making
changes on hardwired systems. For hardwired systems, changes are made by physi-
cally making connections. Using Slogic, changes are made by simply making changes
to the Slogic program.

Slogic program instructions can be used to specify outputs, timers, and counters.
Slogic program instructions are edited on the 1GA board (main CPU) via the multi
function panel, and then transferred to the 1FS (R I/O) board, which executes the Slogic
program.

The remote input/output (R I/O) function is performed by the optional 1FS board. The
RI/O system provides Allen-Bradley (A-B) programmable logic controller (PLC) serial
communication, weld control serial communication, and Slogic execution.

The R I/O function provides the status of all signals, including A-B PLC and weld control
serial signals. Internal Slogic signals can be displayed via the multi function panel.

The R I/O system performs the following functions:

• A-B PLC serial communication is performed by the A-B node adapter chip (NAC).
Robot controllers are daisy chained through the NAC, enabling communication with
the line PLC system. A maximum of 128 I/O channels are available.

• Weld control serial communication is performed by the 1FS board serial I/O func-
tion, which is capable of controlling a maximum of four weld controllers. A maxi-
mum of 16 I/O channels are available for each weld controller.

• The Slogic function is similar to a PLC instruction which uses Slogic instructions for
outputs, timers, and counters. The Slogic instructions are edited on the robot
controller through the 1GA board (main CPU), and then transferred to the 1FS
board for execution of Slogic programs.

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Table 11-3 Slogic

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The following is an example of the process used to edit the Slogic programs using the
keyboard screen. At the monitor prompt, the following is entered.

$SS “SLOGIC Stop”

$SU “S Upload” - Upload Slogic from the 1FS board to the 1GA board to edit
the program SPG.
$ED SPG Program SPG is opened in the edit mode.

1 SOUT 301 = 101

1?
2 SOUT 302 = 101 and 102
2?
3 SOUT 303 = 101 or 102
3?
4 SOUT 304 = (-101 and -102) or -103
4?
5 SOUT 305 = (101 or 103) and (102 or -104)
5?
6 STIM 2601 = 101, 5.0
6?
7 SOUT 306 = 2601
7?
8 SCNT 2701 = 101, 110, 102, 10
8?
9 SOUT 307 = 2701
9?

10?E Exit
$SD “S Download” - Download the program from the 1GA board to the 1FS board.
Password 4989 (same for all controllers)

$$SR SLOGIC Run

Editing SLOGIC

S STEP# The step number to be edited.

I Insert lines before the current step.
D Delete the program step.
O Places the cursor on the current step for editing (overwrite)(laptop only).
E Exits from the editor to the monitor mode.

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11.21 REMOTE I/O AND SLOGIC SPECIFICATIONS

The following are specifications for remote I/O and Slogic functions:

Control method: Stored program (Slogic)

Program size: Approximately 1,500 steps (max. 72,000 characters)

Note 1: The following example Slogic instruction is con-

sidered two steps: SOUT XXXX=YYYY + 80 comment
characters= 96 total characters

Note 2: The following example Slogic instruction is con-

sidered three steps: SOUT XXXX=YYYY AND ZZZZ +
119 comment characters = 144 total characters

Execution cycle time: 1-300 steps 5ms

301-900 steps 10ms
901-1500 steps 15ms

Number of parallel signals: Standard signals: 32 I/O channels

(one additaional 1GW board)
24 VDC, 100mA

Optional signals: 64 I/O channels

(one additional 1GW board)
96 I/O channels
(two additional 1GW boards)
128 I/O channels
(three additional 1GW boards)

Number of internal signals: Non-retentive relay: 128

Retentive relay: 16
Timer: 16 (range: 0.1 to 999.9 seconds)
Counter: 16 (range: 1 to 9,999 counts)
Message display: 64
Slogic status: 16

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Robot CPU (1GA)

Robot Output 1 ~ 256 OX signals = Robot Output signals 1-64
Robot Input 1001 ~ 1256 WX signals = Robot Input signals 1001-1064
Robot Internal 2001 ~ 2256

1001 ~ 1256 1 ~ 256

PLC Weld
Serial Serial
Input Input
1501 ~ 1564 1601 ~ 1632
1FS Board
Allen-Bradley Weld
PLC *SLOGIC Functions Controllers
(Internal Signals) (maximum 8)

501 ~ 564 601 ~ 632

PLC Weld
Serial Serial
Output 1301~1428 301~428 Output

I/O Boards
(1GW, maximum 4,
optional)

*SLOGIC Functions (Internal Signals)

Relays: Non-Retentive 2301 ~ 2428

Relays: Retentive 2501 ~ 2516 An additional magnetic
Relays: Timers 2601 ~ 2616 relay output "SRUN" signal
Relays: Counters 2701 ~ 2716 is available. This signal
SLOGIC Status Signals 2801 ~ 2816 indicates that SLOGIC is
W/C #1 Not Connected 2801 running. It does not have
W/C #2 Communication Error 2802 a signal number.
NAC Communication Error 2803
Battery Error 2804
W/C #2 Not Connected 2805
W/C #2 Communication Error 2806
Spare 2807 ~ 2816
Message Display 2901 ~ 2964

SLOGIC messages must be named $w2901 ~ $w2964.

Refer to AS Language manual for steps to create
string variables (e.g., $w2901 = "message").

Signal for Last Weld Current 2965

Figure 11-43 Robot Signal Numbers

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11.22 RI/O MONITOR, AUX 180

This optional function allows the user to enable various functions regarding the remote
I/O functions (Figure 11-44).

A U X .18 0 R I/O M O N ITO R

1 SIG NAL S TAT US

2 TIM ER AN D C O U N T ER
STATU S
3 SL O G IC M O N ITO R
4 L AST W ELD DATA
5 SL O G IC STAT US

FU N CT IO N N UM BER :
F1 F F3 F4

Figure 11-44 RI/O Monitor

The signal status screens shown in figure 11-45 allows the user to view the status of all
Remote I/O and robot signals. Figure 11-45 shows two of five signal status screens.
Use the NEXT PG buttons to display the remaining screens.

February 15, 2000 11-45

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Figure 11-45 RI/O Signal Status Screens

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The TIMER AND COUNTER STATUS function allows the user to view the timer or
counter values (Figure 11-46). The elapsed time or number of counts is also displayed.
The first screen shows the status of timers and the second screen shows the status of
counters. Navigate between the screens using the PRE PG and NEXT PG buttons.

Figure 11-46 Timer and Counter Status Screens

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The SLOGIC MONITOR screen (Figure 11-47) allows the user to monitor output signals
which are used by the Slogic program. It also displays the status of the signal. When
this function is accessed, key in the desired output signal at the prompt and press the
ENTER key on the multi function panel.

A U X .18 0 R I/O M O N ITO R

3 S LO G IC M O N ITO R

S IG N A L N U M B E R 0

F1 F F3 F4
Select signal number
by pressing the numeric
keys and the press ENTER.
ò
0 9
ENTE R

ò
A U X .18 0 R I/O M ON ITO R 3 S LO G IC M O N ITO R

2 SOUT 3 02 = 2
3 SOUT 3 03 = 3
4 SOUT 1 00 1 = 15 01
5 SOUT 1 00 2 = 15 02
6 SOUT 1 00 3 = 15 04
7 SOUT 1 00 4 = 15 04
8 SOUT 1 00 5 = 15 05
9 SOUT 1 00 6 = 15 06
10 SOUT 1 00 7 = 15 07

F1 F F3 F4 F5 F6

PRE PG N E XT PG E X IT

Figure 11-47 Slogic Monitor Screen

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The SLOGIC STATUS screen allows the user to view the status of the Slogic program
(Figure 11-48). It displays the status of the Slogic program as active (RUN) or inactive
(STOP). It also indicates how many steps are used in the Slogic program, the number
of bytes free in the memory, and the date and time the Slogic program was downloaded.

A U X .18 0 R I/O M O N ITO R

S LO G IC S TAT U S

S L O G IC S TATU S R U N /S TO P

S L O G IC S TE P S 0

S L O G IC M E M O R Y 0 BY TE S FR E E

D O W N L O A D E D D ATA 9 8 -0 4 -0 9 1 6 :50 :3 1

F1 F F3 F4

Figure 11-48 Slogic Status Screen

11.23 RI/O PLC (NAC) SETTING, AUX 181

AUX function 181 allows the user to view information about the PLC Node Adapter Chip
(NAC) settings (Figure 11-49). Changes cannot be made on this screen; it is used only
for displaying the current settings.

A U X .18 1 R I/O P LC (N A C) S E TTIN G

*N A C C O NT R O L

U S ED Y ES /N O
B AU D R ATE (b p s ) 5 7 6 0 0 /11 5 2 0 0/2 3 0 40 0
R A C K A D D R E SS 0
L A ST R A C K Y ES /N O
S TA RT IN G Q U A R TE R 1
R A C K S IZE [1 /4 ]/[1 /2 ]/[3 /4 ]/[FU L L ]
S IG N A L BITS 3 2 /6 4

F1 F F3 F4

Figure 11-49 RI/O PLC(NAC) Setting

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ARC WELDING OPERATIONS AND PROGRAMMING

OPTIONAL FUNCTIONS

11.24 RI/O SLOGIC CONTROL, AUX 183

The RI/O Slogic Control screen allows the user to control the Slogic program or function.
The user can activate (run) or deactivate (stop) the Slogic program by selecting S-
LOGIC RUN or SLOGIC STOP respectively. To edit Slogic program instructions, S-
LOGIC STOP must be selected to deactivate Slogic. Then load the Slogic program into
the user memory area by selecting SLOGIC UPLOAD. Once the program is uploaded,
editing of the Slogic program can be performed using the keyboard function. Slogic
programs can also be started and stopped from the keyboard function. See figure
11-50, Slogic Control.

A U X .18 3 R I/O S LO GIC CO N TR OL

1 S L O G IC RUN (S R U N )
2 S L O G IC STO P (S S TO P )
3 S L O G IC D O W NL O A D (S D O W N LOA D )
4 S L O G IC U P LO A D (S U P LO A D )

F U N CT IO N N U M B E R :
F1 F F3 F4

Figure 11-50 Slogic Control

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ARC WELDING OPERATIONS AND PROGRAMMING

OPTIONAL FUNCTIONS

11.25 RI/O SLOGIC FORCED OUTPUT, AUX 184

Function 184 allows the user to force outputs that are used by the RI/O system. This
function cannot be used when Slogic is in the active (run) state.

A U X.1 8 4 R I/O S L O G IC F O R C E D O U TP U T

S IG N A L N U M B E R 0

F1 F F3 F4

Figure 11-51 Slogic Forced Output

11.26 PASSWORD SET, AUX 197

AUX 197 can be used to set a password level for AUX functions. The password corre-
sponds to the level entered for each auxiliary function in AUX 198. The password level
entered corresponds to which auxiliary functions appear on the function screen. Func-
tions assigned levels 2 and 3 do not appear in the function screen when a password
level 1 is entered.

A U X.1 9 7 PAS S W O R D S E T

P a ssw ord 1

F1 F F3 F4

Figure 11-52 Password Level

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OPTIONAL FUNCTIONS

11.27 AUXILIARY FUNCTION SELECT, AUX 198

Auxiliary functions are set to appear or be hidden from the auxiliary function menu. By
setting password levels for functions, functions only appear in the menu when the pass-
word level is set to the corresponding level or higher. Auxiliary functions assigned levels
2 and 3 do not appear in the menu when the password level is 1.

A U X.1 9 8 AU X IL IA RY FU N C TIO N SE L EC T
1 2 3 4 5 6 7 8
[0 ] [1 ] [1 ] [0 ] [1 ] [0 ] [0 ] [0 ]
9 10 11 12 13 14 15 16
[0 ] [1 ] [1 ] [1 ] [0 ] [1 ] [0 ] [0 ]
17 18 19 20 21 22 23 24
[0 ] [0 ] [0 ] [0 ] [0 ] [0 ] [0 ] [0 ]
25 26 27 28 29 30 31 32
[0 ] [0 ] [0 ] [0 ] [0 ] [0 ] [0 ] [0 ]
33 34 35 36 37 38 39 40
[0 ] [0 ] [1 ] [0 ] [0 ] [0 ] [0 ] [0 ]

F1 F F3 F4
P R E D ATA N E XT P G

Figure 11-53 Auxiliary Function Select

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OPTIONAL FUNCTIONS

11.28 DIRECT SPEED

The optional Direct Speed function allows the user to select the absolute speed for joint
and linear moves in degrees per second, or millimeters per second respectively. The
function is accessible to the user during the teach mode of operation for the current
program. The user must first determine the interpolation for the current step of the
program from the program edit menu. The user must then press the AUX SET & DISP
key and the SPEED key simultaneously. A screen labeled Direct Speed will appear on
the multi function panel as shown in figure 11- 54. The INTERP. and SPEED keys in the
upper left corner of the display are inoperative. The SPEED key displays the numeric
value selected by the user from the numeric keypad on the right side of the display.

8 9
DIRECT SPEED

INTERP. SPEED 6 7

4 5 _ EXIT

2 3 BS

0 1
RETURN

Figure 11-54 Direct Speed Display

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ARC WELDING OPERATIONS AND PROGRAMMING

OPTIONAL FUNCTIONS

11.29 TOUCH SENSING FUNCTION

Robotic arc welding requires consistency in all aspects of the process. The touch sens-
ing function allows the user to correct for inconsistencies in the production environment.
The burn back characteristics of welding wire affect the generation of a stable arc, and
the accuracy of the search patterns used while touch sensing. Parts to be welded need
to be located in fixtures. Accurate base metal positioning is critical when installing a
weld. Touch sensing is used to maintain wire stickout, eliminate the need for special
sensors, and overcome dislocations in the work pieces to be welded.

The touch sense function is classified into three separate functions which may be com-
bined to produce the desired results.

• Wire Check function

• Work Detection function

• Work Modification function

11.30 WIRE CHECK FUNCTION

When performing welding operations in automatic, the amount of weld wire left as
stickout varies from one welded object to another. The wire check function is used to
assure the correct stickout is maintained prior to starting a weld and to detect work
piece position

! WARNING
The wire check function is a touch sensing function
which uses the weld wire as a sensing device. The weld
wire is energized with a standard 15 VDC or an optional
100 VAC charge between it and the work ground. To
avoid electrial shock, do not touch the weld wire or base
metal when using any touch sense function.

The wire check function involves teaching points relative to a fixed reference. The per-
formance of the wire check function causes the weld wire to retract momentarily, then to
advance (inch) until contact with the reference point is made. The parameters used to
retract and advance the wire are set in auxiliary function 31. Refer to figure 11-55 for
setting system values for the wire check function.

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OPTIONAL FUNCTIONS

System settings for the wire check function are entered in the auxiliary function 31 item
10 display. By default, the wire check function retracts and advances the welding wire
for 0.5 second when executed. The only control the operator has over this function is
the speed of wire feed. The wire speed is entered in the RETRACT and INCHING fields
of the screen shown in figure 11-55. These two speeds are entered as a percentage of
maximum wire feed speed.

Press the FUNCTION menu key to display the auxiliary function menu list. Select AUX
31 and press the RETURN key. Select item 10 from the ARC WELD AUX DATA screen
to display the screen shown in figure 11-55. Use the cursor keys to highlight either
speed field and enter values using the numeric keys. Press the F1 (PRE DATA) key to
return the original values. Press the ENTER key to register the desired values.

AUX 31 ARC WELD AUX DATA

10 TOUCH SENSING

TOUCH SENSING
DISTANCE 20 mm
SPEED 15 mm/s

WIRE CHECK
RETRACT SPEED 1%
INCHING SPEED 8%

F1 F2 F3 F4

PRE DATA

Figure 11-55 Wire Check Settings

PROGRAM STEP PC 1
_ +
TEACHING STATUS NEXT MENU
M-OFF 2
HOLD _
TEACH +
WELD OFF
TEACHING(BLOCK TEACHING)
INTERP AC SPEED ACCU
3
TOUCH _ +
JOINT 9 4 SENSING
[Link]

4
AC WS WC WE AS _ +
INCHING

TEACH WELD ETC. OX 5

RECORD
TEACH [Link] _ +
DATA SIGNAL WX NEW OFF

6
CHECK CHECK
AUX
S
COORDINATE
JOINT
_ +
BACKWARD FORWARD
ONCE SET&DISP

Figure 11-56 Teaching Screen

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OPTIONAL FUNCTIONS

The following procedure describes the steps used when teaching the wire check func-
tion. All motion steps must be recorded as an air cut. Figure 11-57 is an example of
torch positioning for recording wire check points.

1. Record an air cut step at position A above the reference surface.

Figure 11-57 Wire Check Points

2. Position the torch at point B above the reference surface equal to the desired stick-
out length.

a. Select the smallest accuracy.

b. Press the TOUCH SENSING key in the teaching screen (Figure 11-56) to display
the touch sense function keys (Figure 11-58).

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OPTIONAL FUNCTIONS

TEACHING(BLOCK TEACHING) TEACHING(BLOCK TEACHING)

INTERP AC SPEED ACCU TOUCH INTERP AC SPEED ACCU TOUCH
JOINT 9 4 SENSING 9 4 SENSING
JOINT

WIRE WIRE WIRE WORK

AC WS WC WE AS INCHING RETRACT CHECK DETECT WORK
SET MODIF.
SET SET SET

Figure 11-58 Touch Sense Function Keys

c. Press the WIRE CHECK SET key (Figure 11-58). The key changes color to
indicate the wire check function is activated for the step.

d. Press the RECORD key after completing a, b, and c of this step. Cancel the wire
check by pressing the TOUCH SENSING key again.

3. Record an air cut step at position C above the reference surface.

Executing the wire check function in repeat mode causes the weld wire to retract for 0.5
second while the torch moves from point A to point B. When the torch reaches point B,
robot motion stops and the weld wire is inched for 5 seconds or until contact with the
reference surface is made. If contact is not made, error -917 occurs (Wire Check
Failed), and the robot stops. When contact is made, wire inching stops, and the torch is
moved to point C.

NOTE

The touch sense function is active in the step continu-

ous repeat mode only.

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OPTIONAL FUNCTIONS

11.31 WORK DETECT FUNCTION

The work detect function is used to verify the existence of a part in its fixture when
visual observation is not practical.

! WARNING
The work detect function is a touch sensing function
which uses the weld wire as a sensing device. The weld
wire is energized with a standard 24 VDC or an optional
450 VAC charge between it and the work ground. To
avoid electrial shock, do not touch the weld wire or base
metal when using any touch sense function.

The following procedure describes the steps to use when teaching the work detect
function and system settings. All motion steps must be recorded as an air cut. Figure
11-59 is an example of torch positioning for recording work detect points.

Touch sensing distance/speed

Teach point
A
Touch sensing speed
Sensing start point
B'

Teach point
B

Sensing end point

B"

Touch sensing distance

Point Point
A C
Point Workpiece
B'
Point
B

Figure 11-59 Work Detect Points

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OPTIONAL FUNCTIONS

System settings for touch sensing are entered in the auxiliary function 31 item 10 dis-
play. Menu item 10 contains the setting fields for the touch sense function (Figure 11-
60). The value entered in the TOUCH SENSING DISTANCE field sets the starting and
ending distance for the search. Position B’ in figure 11-59 identifies where the weld wire
is energized and linear motion to point B is started. Position B” in figure 11-59 identifies
the distance past point B the search ends if the part is not found. The range for distance
is from 0 to 300 mm.

The value entered in the TOUCH SENSING SPEED field sets the travel speed from
position B’ to point B. Travel speed should be set to a value low enough to avoid bend-
ing the weld wire when contact is made. A bent wire affects all touch sense functions.
The range for speed is from 0 to 100 mm/sec.

AUX 31 ARC WELD AUX DATA

10 TOUCH SENSING

TOUCH SENSING
DISTANCE 20 mm
SPEED 15 mm/s

WIRE CHECK
RETRACT SPEED 1%
INCHING SPEED 8%

F1 F2 F3 F4

PRE DATA

Figure 11-60 Touch Sense Settings

1. Record an air cut step at position A (Figure 11-59) away from the work piece sur-
face, this sets the direction for the search, A to B.

2. Position the torch at point B with wire touching the work piece surface. Refer to
figure 11-62 when positioning the torch at the work piece. The arrows show the
torches’ direction of travel.

a. Select the smallest accuracy.

b. Press the TOUCH SENSING key shown in figure 11-56 to display the touch
sense function keys (Figure 11-61).

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OPTIONAL FUNCTIONS

TEACHING(BLOCK TEACHING) TEACHING(BLOCK TEACHING)

INTERP AC SPEED ACCU TOUCH INTERP AC SPEED ACCU TOUCH

JOINT 9 4 SENSING JOINT 9 4 SENSING

WIRE WIRE WIRE WORK

AC WS WC WE AS INCHING RETRACT CHECK DETECT WORK
MODIF.
SET SET SET SET

Figure 11-61 Touch Sense Function Keys

c. Press the WORK DETECT. SET key. The key changes color to indicate the work
detection function is activated for the step.

d. Press the RECORD key after completing a, b, and c of this step. Cancel the
work detect function by pressing the TOUCH SENSING key again.

Teaching point B

Angle 1

wire
extension
(Rough wire) (B)

Angle 2

(B)
wire extension
(Wire extension must be accurate!)

Angle 3 wire
extension
(Wire extension must be accurate)

(B)

Figure 11-62 Touch Angle

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OPTIONAL FUNCTIONS

3. Record an air cut step at position C above the reference surface.

Executing the work detect function in repeat mode causes the torch to move from point
A to point B. When the weld wire touches the work piece, robot motion stops momen-
tarily then moves to point C. If contact is not made, error -910 occurs (Work not de-
tected), and the robot stops.

11.32 WORK MODIFICATION FUNCTION

The work modification function is used to locate a work piece and compare the found
location to its recorded location. The difference, if any, is calculated then applied to all
locations in system memory. When using this function it is important to determine the
direction of work piece shifting. Seven search patterns are available for programming
the work modification function. The pattern selected is determined by the shape of the
work piece and direction of shift. For situations which do not match the predefined
patterns, the user may combine a maximum of three patterns to achieve the desired
results. The selectable patterns are shown in figure 11-63.

Figure 11-63 Search Patterns

11.32.1 SEARCH PATTERNS

Search patterns 1 through 7 are selected to detect dislocations in various planes. The
direction of search and pattern number is planned to accurately determine the disloca-
tion values. The following describes the use of each pattern:

Pattern 1 - used for dislocations in one parallel search direction. This pattern re-
quires one sensing point, searched in the dislocation direction.

Pattern 2 - used for dislocations in two parallel search directions. This pattern re-
quires two sensing points, one in each dislocation direction.

Pattern 3 - used for dislocations in three parallel search directions. This pattern
requires three sensing points, one in each dislocation direction.

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OPTIONAL FUNCTIONS

Pattern 4 - used for dislocations parallel and rotational to the search plane. This
pattern requires three sensing points, one in the parallel dislocation
direction and two for rotation.

Pattern 5 - used for dislocations parallel and rotational to the search plane. This
pattern requires four sensing points, two in the first parallel dislocation
direction and two in the second parallel dislocation direction.

Pattern 6 - used for cylindrical work pieces which are dislocated parallel to the
search plane. This pattern requires three sensing points on the same
search plane.

Pattern 7 - used for dislocations parallel and rotational to the search plane. This
pattern requires three sensing points, one in the parallel dislocation
direction and two for rotation. This is the same pattern as number 4,
however it is used to define a pattern different from number 4 when used
in combination with pattern number 4.

NOTE

Multiple search planes must be within 30 to 150 de-

grees of each other, and sensing points on the same
side of the work piece must be at least 10 mm apart.

11.32.2 TEACHING THE WORK MODIFICATION

The following procedures are used to program the work modification function. Deter-
mine the direction of work piece dislocation. Choose a search pattern that searches in
the required direction(s), and is similar in shape to the work piece. Enter the teach
mode and teach the program steps required prior to the first work modification step.

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OPTIONAL FUNCTIONS

! WARNING
The work modification function is a touch sensing func-
tion which uses the weld wire as a sensing device. The
weld wire is energized with a standard 15 VDC or an op-
tional 100 VAC charge between it and the work ground.
To avoid electrial shock, do not touch the weld wire or
base metal when using any touch sense function.

While viewing the teaching screen, select the TOUCH SENSING key to display the
touch sensing keys (Figure 11-64).

TEACHING(BLOCK TEACHING)
INTERP AC SPEED ACCU TOUCH
JOINT 9 4 SENSING

WIRE WIRE WIRE WORK

WORK
INCHING RETRACT CHECK DETECT
MODIF.
SET SET SET SET

Figure 11-64 Touch Sense Keys

WORK
MODIF.

All steps recorded for the work modification function must be air cut motions. Select the
WORK MODIF. key from the touch sense keys to enter the work modification mode. The
touch sense keys change to work modification keys shown in figure 11-65.

TEACHING(BLOCK TEACHING)

TOUCH
SENSING

WORK PATTERN SET/RESET

MOTHER 1 SET

Figure 11-65 Work Modification Keys

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OPTIONAL FUNCTIONS

! CAUTION
Ensure the work reset is performed prior to all work
modifications. This clears the offsets applied to the
base coordinates from a previous work modification. If
the program is suspended for any reason, i.e., placing
the robot in HOLD, prior to execution of the next search
pattern, the offsets applied from the last search are
used again and may generate an error.

WORK
MOTHER

• Press the WORK MOTHER key from the work modification keys.

SET/RESET
SET

• Toggle the SET/RESET key to display RESET on the key.

• Press the RECORD key to clear any base offsets.

Use figure 11-66 for recording the work modification steps. The example shown in figure
11-66 is for a dislocation in one direction. The position recorded in the step prior to the
sensing step sets the direction of travel for the search. This approach point must be
recorded along the shift plane and be at least 100 mm from the sense point. For other
search patterns, each sense point requires a corresponding approach point at least 100
mm away.

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OPTIONAL FUNCTIONS

ion
cat n
o
slo cti
Di ire
D

2 e
Lin
eld
W

Fixture

Figure 11-66 Single Dislocation

• Position the torch at position 1 and record as an aircut with the work mother reset.

• For position 2, select aircut linear with speed 9 and accuracy 1.

WORK
MODIF.

• Press the WORK MODIF. key.

WORK
MOTHER

• Press the WORK MOTHER key.

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OPTIONAL FUNCTIONS

PATTERN
1

• Select the pattern number by toggling the PATTERN key until the desired pattern
number is displayed on the key.

• Jog the torch to position 2 with the weld wire touching the work piece.

• Press the RECORD key.

• Jog the torch to position 3 and record as an aircut.

The point recorded at position 3 may be used as an approach point for other patterns
provided it is at least 100 mm away from the next sense point.

11.33 SEARCH PATTERN COMBINATIONS

! WARNING
The work modification function is a touch sensing func-
tion which uses the weld wire as a sensing device. The
weld wire is energized with a standard 24 VDC, or an
optional 450 VAC, charge between it and the work
ground. To avoid electrial shock, do not touch the weld
wire or base metal when using any touch sense func-
tion.

Combining search patterns makes it possible to weld work pieces that are commonly
dislocated in planes other than the predefined search patterns. This is accomplished by
making search patterns relative to the base offsets applied by previous search. A maxi-
mum of three patterns may be combined in the work modification process.

The order in which the search patterns are combined follows this order: mother work,
daughter work, baby work. Mother work determines the dislocation value of a work
piece relative to its fixture. Daughter work determines the dislocation value of a work
piece relative to the offsets applied by the mother work, and baby work determines the
dislocation value of a work piece relative to the daughter work offsets.

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ARC WELDING OPERATIONS AND PROGRAMMING

OPTIONAL FUNCTIONS

11.33.1 TEACHING PATTERN COMBINATIONS

! CAUTION
Ensure the work reset is performed prior to all work
modifications. This clears the offsets applied to the
base coordinates from a previous work modification. If
the program is suspended for any reason, i.e., placing
the robot in HOLD prior to execution of the next search
pattern, the offsets applied from the last search are
used again and may generate an error.

The following procedures are used to program the work modification function when
combining multiple patterns. Determine the direction of work piece dislocation(s).
Choose search patterns that search in the required direction(s), and are similar in shape
to the work pieces. Enter the teach mode and teach the program steps required prior to
the first work modification step. All steps recorded for the work modification function
must be air cut motions. Use the example shown in figure 11-67 for the sequence of
recording positions. Select the WORK MODIF. key from the touch sense keys to enter
the work modification mode. The touch sense keys change to work modification keys.

WORK
MOTHER

• Press the WORK MOTHER key from the work modification keys.

SET/RESET
SET

• Toggle the SET/RESET key to display RESET on the key.

• Press the RECORD key to clear any base offsets.

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OPTIONAL FUNCTIONS

The example in figure 11-67 shows dislocation in one direction for work piece A. Select
pattern 1 for the first work modification. Work piece B is cylindrical and may be dislo-
cated in any direction on a single plane. Select pattern 6 for cylindrical objects. The
position recorded in the step prior to the sensing step sets the direction of travel for the
search. This approach point must be recorded along the shift plane and be at least 100
mm from the sense point. For other search patterns, each sense point requires a corre-
sponding approach point at least 100 mm away.

9
ion
cat n 7
o
slo cti
Di ire
D
8
6
4
1
3 B 5

2
Dislocation Weld Line
Direction

Fixture

Figure 11-67 Pattern Combination

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ARC WELDING OPERATIONS AND PROGRAMMING

OPTIONAL FUNCTIONS

! WARNING
The work modification function is a touch sensing func-
tion which uses the weld wire as a sensing device. The
weld wire is energized with a standard 15 VDC or an op-
tional 100 VAC charge between it and the work ground.
To avoid electrial shock, do not touch the weld wire or
base metal when using any touch sense function.

• Jog the torch to position 1 and record as an air cut.

WORK PATTERN
MODIF. 1

• Press the WORK MODIF. key.

• Select the pattern number by toggling the PATTERN key until the desired pattern
number is displayed on the key.

• Ensure the WORK MOTHER key is displayed.

• Jog the torch to position 2 with the weld wire touching the work piece.

• Set interpolation to linear, accuracy to 1, and press the RECORD key.

The point recorded at position 3 may be used as an approach point for the second
pattern provided it is at least 100 mm away from the position 4 sense point.

• Jog the torch to position 3 and record as an air cut.

• Jog the torch to position 4 with the weld wire touching the work piece.

• Set interpolation to linear, and accuracy to 1.

• Press the WORK MODIF. key.

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ARC WELDING OPERATIONS AND PROGRAMMING

OPTIONAL FUNCTIONS

WORK
DAUGHTER

• Toggle the WORK MOTHER key to display the WORK DAUGHTER key.

• Toggle the PATTERN key to display the next search pattern number.

• Press the RECORD key.

The point recorded at position 5 is the approach point for the next sense point in the
pattern and must be at least 100 mm away from the position 6 sense point.

• Jog the torch to position 5 and record as an air cut.

• Jog the torch to position 6 with the weld wire touching the work piece.

• Set interpolation to linear, and accuracy to 1.

• Ensure the WORK DAUGHTER key and correct pattern number is displayed, then
press the RECORD key.

The point recorded at position 7 is the approach point for the next sense point in the
pattern and must be at least 100 mm away from the position 8 sense point.

• Jog the torch to position 7 and record as an air cut.

• Jog the torch to position 8 with the weld wire touching the work piece.

• Set interpolation to linear, and accuracy to 1.

• Ensure the WORK DAUGHTER key and correct pattern number is displayed, then
press the RECORD key.

• Jog the torch to position 9, toggle the SET/RESET key to display RESET and
record as an air cut.

The procedure for teaching a third pattern is the same as teaching two pattern combina-
tions, however, the third pattern (baby work) becomes relative to the daughter work.

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GLOSSARY

GLOSSARY ................................................................................................................ G-2

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GLOSSARY

This glossary contains definitions of terms used by operators, programmers, and main-
tenance personnel who work with Kawasaki robots. The definitions are listed in alpha-
betical order.

A
• ACCELERATE
To speed up a process.

• ACCURACY
A measure of the difference between the commanded robot arm position and the
actual position. Also identifies how well an indicated value conforms to a true value
(i.e., an actual or accepted standard value).

• ACRONYM
A word formed from the initial letters of words in a name or phrase. For example,
ASCII is an acronym for American Standard Code for Information Interchange.

• ADDRESS
A number that identifies a specific location in the computer’s or processor’s memory.
Means of identifying a location or data in a control system.

• ADDRESSING
Computer operations store data in specific memory locations or addresses. The
largest memory location determines the amount of data that can be stored. The
larger the number, the larger the possible program.

• AIR CUT
Moving a weld gun into position but without generating an arc.

• ALGORITHM
A finite set of well-defined rules or procedures for solving a problem step-by-step.

• ALPHANUMERIC
Pertaining to a set of symbols that contain both letters and numbers, either individu-
ally or in combination.

• AMBIENT TEMPERATURE
The temperature of air or liquid that surrounds a device.

• AMPERE (AMP)
A unit of electrical current flow that is equivalent to one (1) coulomb per second.
One (1) volt across one (1) ohm of resistance causes a current flow that is equiva-
lent to one (1) amp.

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GLOSSARY

• ANALOG
A continuously changing electrical voltage signal. In robot systems, the magnitude
or value of the signal represents commanded robot axis motion.

• ANALOG DATA
Information that is represented by a characteristic of the value or magnitude of an
electrical signal, such as the amplitude, phase, or frequency of the voltage, the
amplitude or duration of a pulse, the angular position of a shaft, or the pressure of a
fluid number.

• ANTI-FRICTION BEARING
A rolling element which is used to support a rotating shaft.

• ARC SENSOR
A sensor that detects weld lines utilizing arc characteristics.

• ARGUMENT
A value applied to a procedure; data used by a function or other command. For
instance, in the AS command JMOVE flange, 2. The variable, flange, and the clamp
number 2 are the arguments of the function JMOVE.

• ARRAY
An ordered set of addresses or their values. Elements of an array can be refer-
enced individually or collectively. Array elements all have the same type of data, for
instance, integer or character, and are usually presented in rows and columns.

• ARTICULATED
To join together permanently or semi-permanently by means of a pivot connection
for operating separate segments as a unit.

• ARTICULATED ROBOT
A robot arm which contains at least two consecutive revolute joints, acting around
parallel axes, resembling human arm motion. The work envelope is formed by
partial cylinders or spheres. The two basic types of articulated robots, vertical and
horizontal, are sometimes called anthropomorphic because of the resemblance to
the motions of the human arm.

• ASCII
An acronym for American Standard Code for Information Interchange. This stan-
dard 8-bit code is used by many devices, such as keyboards and printers.

• AS LANGUAGE
Kawasaki robot language used to communicate commands and instructions from a
keyboard to the CPU.

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GLOSSARY

• ASSIGNMENT
An instruction used to express a sequence of operations, or used to assign oper-
ands to specified variables, or symbols, or both.

• ASYNCHRONOUS
A means of data communication where the data is sent a character at a time pre-
ceded by a start bit and followed by a stop bit. No direct timing signal links the
transmitter and receiver.

• AUXILIARY DATA
Information about a point, other than the positional data, such as speed, accuracy,
weld schedule and clamp condition.

• AXIS
A straight line about which sections of the mechanical unit rotate (e.g., joints JT1,
JT2, JT3 etc.).

B
• BACKLASH
The clearance, slack, or play between adjacent gears, or the jar or reaction often
caused by such clearance when the parts are suddenly put in action or are in ir-
regular action.

• BASE COORDINATE
A fixed coordinate system having an origin at the intersection of the X, Y, and Z
axes.

• BAUD RATE
Determines the number of bits per second (bps) or characters transmitted between
devices.

• BCD
An abbreviation for binary coded decimal. The BCD 8-4-2-1 code expresses each
decimal digit by its own 4-bit binary equivalent. The 8-4-2-1 code is identical to
binary through the decimal number 9. Above the decimal number 9 each decimal
digit is represented by its own 4-bit binary equivalent. For example, using the 8-4-2-
1 binary-coded system, the number 10 is interpreted as 0001 0000.

• BINARY CODE
A system in which characters are represented by a group of binary digits, that have
the value of either 0 or 1, true or false, on or off.

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GLOSSARY

• BIT
Acronym for binary digit, having one of two values: 0 or 1.

• BOOT
The method by which computers are brought from a non-operating to an operating
state. During this sequence, the computer memory is usually reset. This is often
performed to restart the computer after a crash, to bring it on-line.

• BUFFER
A temporary memory storage area in a computer or electronic device.

• BUG
A problem in a software or hardware element of a system.

• BUS
The primary communication path in the controller along which internal signals are
sent among processors and memories.

C
• CABLE CARRIER
A device which carries cables and hoses (including power sources) from a station-
ary location to a linear moving device.

• CARTESIAN COORDINATE
A location in space defined by three axes at right angles to each other, commonly
labeled X, Y, Z.

• cc
cubic centimeter

• CELL
A manufacturing unit consisting of two or more work stations or machines, and the
material transport mechanisms and storage buffers that interconnect them.

• CENTER OF GRAVITY
The point at which the entire weight of a body may be considered as concentrated,
so that if supported at this point the body would remain in equilibrium in any posi-
tion.

• CHARACTER
A term that describes all numbers, letters, and other symbols typically found on a
computer keyboard.

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GLOSSARY

• CHECK MODE
A procedure that allows the user to check positional data and auxiliary data while in
the teach mode with the Kawasaki robot . This procedure is in many ways analo-
gous to reverse point and forward point operations in other robot models.

• CHECKSUM
A method by which the contents of data or a transmission are verified to be accu-
rate. This method ‘sums’ all the characters and translates them into a number which
is appended to the data.

• CHEMICAL ANCHOR
A threaded rod installed in a structure (e.g., a concrete floor) and secured by epoxy,
for the purpose of securing hardware.

• CIRCULAR INTERPOLATION
A path taken by the robot that connects at least three points with an arching motion.
The CPU will calculate a path that places the taught points on a section of a circle.

• CLOSED-LOOP SYSTEM
A system in which a command value is output and a feedback value is returned.
The resulting error, the difference between the command and the feedback, is used
to correct the signal. In a robot system, the command signal is output by the con-
troller, causing the robot arm to move, and the feedback signal is produced by the
encoder, which reads the current position of the arm.

• CODE
A set of rules for expressing information in a language that is understood and pro-
cessed by a control system.

Also, a term for instructions in a computer program. Code performs a process, and
data is the information that is processed.

• COMMAND
An analog signal, or group of signals or pulses, which cause a specified function to
be performed. An instruction or request in a computer program that performs a
particular action. Commands that are needed to run the operating system are
called a command language.

• COMMENT
Optional, non-executing remarks added to a program to explain various aspects of
the program.

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GLOSSARY

• COMPILER
A system task that translates a program written in source code, into binary code
that can be understood by the processor.

• COMPOUND TRANSFORMATION
A location in the Cartesian coordinate system that is defined relative to another
Cartesian coordinate location.

• CONTIGUOUS FILE
A file that is stored in continuously adjacent areas of memory, in contrast to a file
which is scattered to make more efficient use of disk space.

• CONTINUOUS PATH CONTROL

A type of robot control in which the robot moves according to a replay of closely
spaced points programmed on a constant time base during teaching.

• CONTROL ERROR CODE

A code which identifies system problems whenever an alarm condition occurs.

• CONTROLLED AXIS
A robot axis that is operated by electrical or hydraulic power.

• CONTROLLER
An electronic device, with processing capabilities and software, which controls the
robot actions and functions.

• CONVEYER TRACKING
Used to make the robot follow a part on a conveyor, without the use of a traverse
axis.

• COORDINATE
A set of numbers that locate a point in space.

• CPU
Abbreviation for central processing unit. A collection of hardware in a computer
which performs all calculations, handles I/O, and executes programmed tasks.

• CRASH
A situation where the computer fails to operate, due to a software or hardware
problem.

• CRT
Abbreviation for cathode ray tube. A CRT is a charge storage tube in which the
information is written by means of the cathode ray beam.

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GLOSSARY

• CURRENT LOOP
A circuit in which a portion of the output is returned to modify the control circuit
output. This circuit may be used as a limiting device, for safety protection.

• CURSOR
A pointer or indicator on a computer screen, that identifies the current position on
the screen.

• CYCLE
A complete path of projectory performed by the robot for a specific application.

• CYCLOIDAL DRIVE
A mechanical gear reduction unit that reduces the speed of the input and increases
the torque capacity. The cycloidal unit consists of an internal arrangement of discs
and pins that are driven by an eccentric drive cam. This type of gear reduction
offers low gear train backlash and the capability to achieve high reduction ratios
from a single contained unit.

D
• DATA
A term given to information, instructions, words or symbols that are usually transmit-
ted, processed, or stored as a group.

• DETENT
A part of a mechanism that locks or unlocks a movement.

• DISCONNECT
A switch that isolates a circuit or one or more pieces of electrical apparatus after the
current has been interrupted by other means.

• DEVIATION ERROR
In all mechanical devices, the actual position of the mechanical unit will lag behind
the electrical command of the controller. An allowable limit is assigned for this
difference. However, if the controller detects a condition where the difference be-
tween this mechanical value and the desired electrical position is larger than the
established value limit, the robot controller will generate a deviation error. This error
is sometimes referred to as a FOLLOWING ERROR in the robot industry.

• DEBUG
The process by which an operator’s program is checked for mistakes and then
corrected.

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GLOSSARY

• DECIMAL NUMBER
Numbers in the base-10 numbering system, which uses the numerals 0 - 9.

• DEDICATED
A term used to describe a system resource, such as an I/O device or terminal,
which is used for only one purpose, or assigned a single function.

• DEDICATED SIGNAL
A term used to describe a signal which is used for only one purpose, or assigned a
single function. Both inputs and outputs can be dedicated.

• DEFAULT
A value or operation that is automatically entered by the system, if the operator
does not specify one. Typically, the default is the standard or expected response.

• DELETE
A command which will eliminate unwanted data.

• DELIMITER
A character which separates a group of items or a character string, from other
groups, or which terminates a task.

• DEVICE
Any peripheral hardware connected to the processor and capable of receiving,
sorting, or transmitting data.

• DIAGNOSTICS
Function performed by the processor to identify and check for error conditions in the
robot arm and peripheral devices.

• DIP SWITCH
DIP is an acronym for dual in-line package. A set of small switches on circuit
boards that can be set for different configurations.

• DIRECTORY
A logical structure that organizes a group of similar files.

• DISK
A high-speed, random-access memory device.

• DISK-BASED SYSTEM
System in which programs and files are stored on the hard disk and are read into
memory when requested by the user.

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GLOSSARY

• DISK PACK
A device which is used to store additional data in a computer system, and is usually
removable.

E
• ECHO
Process in which characters that are typed on a keyboard are also displayed on the
screen or are sent to the printer.

• EDITOR
An aid for entering information into the computer system and modifying existing text.

• EMERGENCY STOP (E-Stop)

An immediate stop of robot motion, selected by the operator with a switch.

• ENCODER
An electromechanical device that is connected to a shaft to produce a series of
pulses that indicate the position of the shaft.

• EPROM
Acronym for erasable programmable read-only memory. The contents of this
memory (computer chip) are retained, even when power to the system is turned off.
Usually stores executive programs and critical system variables.

• ERROR LOG
A report which contains a sequential list of system error messages.

• ERROR MESSAGE
Messages displayed on the plasma screen of the robot controller, when the action
requested by the operator could not be completed. Error messages can occur
when components malfunction or if an incorrect command is typed by the operator.

• EXPRESSION
A combination of real-valued variables and functions, and mathematical and logical
operators. When evaluated, this combination yields a numeric value.

F
• FEEDBACK
The transmission of a signal from a measuring device (e.g., encoder, transducer) to
the device which issued the command signal within a closed-loop system. See
CLOSED-LOOP SYSTEM.

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GLOSSARY

• FIELD SIGNALS
All electrical signals that exit or enter an electrical panel.

• FILE
A set of related records or data elements, which are stored using one name and are
arranged in a structure that can be used by a program.

• FILESPEC
Includes the name, creation date and size of the specified file.

• FIXED DISK
An electromagnetic mass storage device which is not removable. Hard disks have
much higher storage capacity than floppy disks.

• FLOPPY DISK
An electromagnetic mass storage device which can be removed and exchanged.

• FORM FEED
Process which causes a printer to advance the paper to the top of the next page.

• FUNCTION
A formula or routine for evaluating an expression.

G
• GAIN
A proportional increase in power or signal value relative to a control signal. The
ratios of voltage, power, or current as related to a reference or control signal input.

• GLOBAL
Refers to a function or process that affects the entire system or file.

• GRAY CODE
A positional binary number notation in which any two numbers whose difference is
one are represented by expressions that are the same except in one place or col-
umn and differ by only one unit in that place or column.

H
• HALF-DUPLEX COMMUNICATION
Data transmission between two devices, where the signal is sent in only one direc-
tion at a time.

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GLOSSARY

• HANDSHAKING PROTOCOL
Communication rules used for data transmissions between devices. Each device
must recognize the same protocol in order to communicate.

• HANG
A term which refers to the state of a computer system that seems to be inoperative
when processing should be taking place.

• HARDSTOP
A mechanical constraint or limit on motion.

• HARDWARE
Physical equipment and devices such as computer hard disk, cables, printer, etc.

• HAZARDOUS SIDE
The unsafe side of a component or panel, such as the inside of the control panel
when power is applied and functions are being performed.

• HOLD
When an external or an internal input is available for a hold condition, the robot will
stop its motion and servo drive power will be removed from the robot. When an
external hold reset is performed, the servo drive power will be energized.

• HOME POSITION
Refers to the starting or resting position of the robot.

• HYBRID ENCODER
On the Kawasaki robot a hybrid encoder is used to generate positional data, and is
composed of an incremental encoder that generates incremental pulses, and an
absolute encoder that generates gray code binary data.

I
• ID
Abbreviation for Identification.

• INCHING
A value that is used during the jogging process that allows the user to position the
robot in small minute increments.

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GLOSSARY

• INCREMENTAL CODE
A digital closed loop feedback code that provides digital feedback pulses to the
robot controller for the purpose of providing positional information. These incremen-
tal pulses are generated by an encoder through the use of an optical disk with
alternating opaque and transparent bars or lines around the periphery of the disk.
On one side of the disk a light source is mounted, and on the opposite side a
phototransistor When the disk rotates, the phototransistor is alternately forced into
saturation and cutoff, producing the digital signal.

• INPUT
Transmission of an external signal into a control system.

• INTEGRATED CIRCUIT (IC)

A combination of interconnected circuit elements which are within a continuous
substrate.

• INTERACTIVE SYSTEM
System where the user and the operating system communicate directly; the user
through the keyboard, and the operating system via the display screen.

• INTERLOCK
An arrangement whereby the operation of one part or mechanism automatically
brings about or prevents the operation of another.

• INTERPRETER
A program that changes English-like commands into machine language. An inter-
preter translates and executes one command at a time.

• INSTRUCTIONS
Discrete steps in a computer program that are commands or statements that tell a
computer to do something or identify data.

• INTEGER
A whole number, a number without a fractional part such as 7, -318, or 19.

• INTERFACE
The circuitry that fits between a system and a peripheral device to provide compat-
ible coupling between the two pieces of equipment.

• INTERPOLATION
The mathematical process that the CPU utilizes to plot a path for the robot to travel
from one position to another. A mathematical process that evaluates a number of
dependent and independent variables for the purpose of comparison and prediction.

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GLOSSARY

• INTERRUPT
An external signal that halts program execution so that the computer can service
the needs of some peripheral device or subsystem.

• INTRINSIC SAFETY BARRIER (ISB)

An electronic device used in robot controllers to restrict current and voltage to a
safe level.

• INVERTER
A circuit which switches a positive signal to a negative signal, and vice versa.

• I/O
Abbreviation for Input/Output. The interconnections through which the computer
and its peripheral devices communicate.

• IPM
Abbreviation for Intelligent Power Module

J
• JOG
A term used to describe the process in which the user moves the mechanical unit
through interaction with the robot controller and the teach pendant. Sometimes
referred to as slewing.

• JOINT
1. A term used to describe the individual axes of a robot.
2. A term used to describe the jogging process in which the robot is jogged one
axis at a time.

• JOINT MOVE
A mode of operation in which the robot moves from one point to the next with an
arching path. All axes motors (required for the move) begin and end their rotation at
the same time. The tool center point does not follow a linear path to reach the
taught position.

L
• LABEL
An identifier for a program command line. To identify an instruction, memory loca-
tion, or part of a program.

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GLOSSARY

• LAN
An acronym for local area network. A group of computer terminals interconnected
by cables, allowing communication of information via the network.

• LCD
Abbreviation for liquid crystal display. This type of display is made of material
whose reflectance or transmittance of light changes when an electric field is ap-
plied.

• LIMIT SWITCH
An electrical switch positioned to be switched when a motion limit occurs, thereby
deactivating the actuator that caused the motion.

• LINEAR MOVE
An operation where the rate and direction of relative movement of the robot arm are
continuously under computer control.

• LINE PRINTER
A high-speed output device that prints a line at a time.

• LINE TURN-AROUND
Changing the source of transmission in half-duplex communications.

• LOGICAL OPERATION
Any of several operations that manipulate information according to the rules of logic
(e.g., AND, OR, NOT, and exclusive OR).

• LM
Abbreviation for linear motion.

• LOAD
The weight applied to the end of the robot arm.

• LOCKOUT
Serving to prevent operation of a device or part of it.

• LSB
Abbreviation for least significant bit.

M
• MANIPULATOR
Another term for the mechanical portion of the robot system.

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GLOSSARY

• MACHINE LANGUAGE
A low-level computer language, usually written in binary code.

• MASS-STORAGE DEVICE
An input/output device that retains data input to it. Examples include: hard disk
drives, magnetic tapes, floppy diskettes, and disk packs.

• MECHANICAL UNIT
robot (excluding controller)

• MEMORY
An area of the computer which stores data, either permanently or temporarily.
When a program is requested, it is first loaded into memory so it can be accessed
quickly by the processor.

• MHz
Abbreviation for megahertz. One million cycles per second.

• MIRROR IMAGE
A process which converts the positive and negative values of a taught path from a
right-handed robot to a left-handed robot, or vice versa. The actions of the oppos-
ing robots are then coordinated and synchronized.

• mm
Abbreviation for millimeter.

• MNEMONIC
A term used to help the operator remember a large string of words or commands.

• MODEM
A signal conversion device that modulates and demodulates data into an audio
signal for transmission.

• MOMENT OF INERTIA
Used to calculate end of arm tooling and handling weights. The sum of the prod-
ucts formed by multiplying the mass of the load by the square of the distance from
the tool mounting flange.

• MONITOR PROGRAM
An administrative computer program that oversees operation of a system. The AS
monitor accepts user input and initiates the appropriate response, follows instruc-
tions from user programs to direct the robot, and performs the computations neces-
sary to control the robot.

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GLOSSARY

• MSB
Abbreviation for most significant bit.

• MSEC
Abbreviation for millisecond (0.001 seconds).

N
• NOISE
Any unwanted disturbance within a dynamic, mechanical, or electrical system.

• NULLED
An electrical zero state.

O
• OCTAL NUMBER
A numeral in the base-8 numbering system, which uses the numerals 0 - 7.

• OFF LINE
A state in which communications between two devices cannot occur (e.g., between
a printer and a computer, if the printer is off line).

• ON LINE
A state in which communication between two devices can occur.

• OPERATING SYSTEM
A set of system tasks and commands that are entered by the operator and inter-
preted and performed by the system.

• OPEN LOOP
A control which does not use feedback to determine its output.

• OPERATOR
Any mathematical action or function. The arithmetic operators are: add, subtract,
multiply, divide, modulo, and exponentiate. The relational operators are: greater
than, less than, equal to, and their combinations. The logical operators are: AND,
OR, exclusive OR, negate. The binary logical operators are AND, OR, exclusive
OR, ones complement.

• OPTO
An optical isolator or level converter.

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GLOSSARY

• OVERFLOW
When a value or buffer exceeds a predefined limit.

• OVERTRAVEL
An error condition that exists when the robot exceeds its normal software limit
values, and then actuates an overtravel limit switch.

• OVERVELOCITY
When an axis exceeds a preset value for velocity.

• OX (OUTPUT EXTERNAL)
Information transferred from the robot controller through output modules to control
output devices.

P
• PARITY
Method by which errors are detected. In this method the combined binary values of
a byte are flagged as 1 or 0.

• PARSE
To break a command string into individual elements, so it can be interpreted.

• PASSWORD
A code, entered by the user, to permit access to protected information.

• PAYLOAD
The maximum weight that a robot can handle satisfactorily during its normal opera-
tions and extensions.

• PC PROGRAM
PC is an abbreviation for process control. A PC program cannot contain any step
that causes robot motion. PC programs are used to evaluate logic and variables
and execute program CALL and GOTO commands

• PERIPHERAL DEVICE
Hardware equipment which is external to the CPU, but that transmits and/or re-
ceives I/O from the processor. Examples include: printer, CRT screen, or disk.

• PHASE
The angular relationship between current and voltage in alternating current circuits.
In a waveform or period function, the fraction of the period that has elapsed, as
measured from a reference point. Phase angle is determined by multiplying the
phase by 360 degrees.

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GLOSSARY

• PINCH POINT
Any point where it is possible for a part of the body to be injured between the mov-
ing or stationary parts of a robot and the moving or stationary parts of associated
equipment, or between the material and moving parts of the robot or associated
equipment.

• PLA
Abbreviation for programmable logic array. Used in many servo drive circuits.

• PLAYBACK
An operation where a taught path is run for evaluation purposes.

• PLC
Abbreviation for programmable logic controller. Usually referred to as the cell mod-
ule controller.

• POINT-TO-POINT
A robot motion control in which the robot can be programmed by a user to move
from one position to the next. The intermediate paths between these points cannot
be specified.

• POLARITY KEYS
These teach pendant or multi function panel keys allow the user to jog or slew the
robot in the Joint, Base (XYZ), or Tool coordinates system.

• PORT
The connection point of an opening or passage that is usually located outside the
housing of a device.

• POSITIONAL DATA
The location in space of the robot manipulator.

• POUNCE POSITION
A positional location at a point near the workpiece, clear of the transfer mechanism
and part, from which the robot is ready to begin production.

• PRINTED CIRCUIT
An assembly of electronic elements that provide a complete path of electrical cur-
rent through conductive material deposited between terminals on an insulated
surface.

• PRECISION POINT
The play back of robot location based on the angular position of the six axes, joint
angles

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GLOSSARY

• PRINTING
A process in which characters are stamped on a surface, usually paper.

• PROGRAM
A predefined, step-by-step set of instructions that are entered into a computer so a
specific process can be performed repeatedly without reentering all the steps.
Robot paths are stored and run as part of programs.

• PROGRAM EDIT
Modification of an existing program.

• PROCESSOR
Generally, any hardware or software system for carrying out programs and acting on
data.

• PULSE WIDTH MODULATION (PWM)

A modulation process in which the instantaneous sampling of the modulating wave
is caused to modulate the duration of the pulse. This type of modulation is also
referred to as pulse duration modulation (PDM), or pulse length modulation (PLM).

R
• RAM
Acronym for random access memory. An area used by the CPU for processing and
temporarily loading programs so they can be accessed quickly. The contents of
RAM are lost when the computer is powered down, unless battery backup is pro-
vided.

• REAL NUMBER
A number with a fractional part, such as 1.75, -31.89, .5, -4.00, etc.

• REAL-TIME
The actual time during which the computer analyzes and processes data: informa-
tion is usually processed as it is received.

• REAL VARIABLE
AS language term for a variable that has had a real value assigned to it.

• REPEAT MODE
A mode of operation that allows the user to check positional and auxiliary informa-
tion at a selected speed value, in a continuous or a step by step type of movement
of the mechanical unit.

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ARC WELDING OPERATIONS AND PROGRAMMING

GLOSSARY

• REPEATABILITY
The measurement of the closeness of agreement among repeated measurements
of the same variable under the same conditions.

• REWRITE MODE
A mode of operation which allows the user to rewrite positional, or auxiliary data,
and to insert or delete step address locations.

• RISC
Acronym for reduced instruction set computer.

• ROM (read-only memory)

A memory device which is programmed at the factory and whose contents thereaf-
ter cannot be altered.

• RS-232C
An ASCII specification for connections and communication between serial devices.

• RUN
A mode of operation that allows the user to select servo motor power to provide
drive energy to the robot, allowing it to perform such modes of operation as teach,
check, repeat, and rewrite.

S
• SAFETY PLUG
A device used with safety fencing to interlock the opening of the fence with the
removal of power to the robot.

• SCROLL
When more information exists than can be displayed on one screen, the operator
can move up and down through the data to view it. When data is scrolled to the
screen, the information previously viewed moves up off the screen, and new infor-
mation enters the screen from the bottom.

• SENSOR
A device used to detect various conditions: proximity, heat, pressure, etc. An electri-
cal signal from the sensor can be used to communicate information to a robot
program.

• SERIAL
A method of transmitting data by which only one bit is sent or received at any one
point in time.

February 15, 2000 G-21

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ARC WELDING OPERATIONS AND PROGRAMMING

GLOSSARY

• SEQUENTIAL ACCESS
A method used by many computers whereby data is read in the order in which it is
physically stored.

• SINGULARITY POSITION
When the robot is processing a linear or circular move and two or more joints are in
alignment. The CPU can not process the ambiguity of a singularity configuration
and an error is generated.

• SOFTWARE LIMITS
Programmed values that are included in a program at the point before a mechanical
device hits an overtravel limit switch or a hard limit.

• SOFTWARE
A set of written programs and instructions that are executed by a computer system.

• SOURCE CODE
A program that contains the actual software instructions entered by the user, in
contrast to object code which is source code that has been translated into a lan-
guage which can be interpreted by the computer.

• STICKOUT
The length of filler wire extending beyond the face of a contact tip.

• STRING
A series of characters that have been entered in a distinct sequence that can be
interpreted as a valid statement or command.

• STROKE
The movement in either direction of a mechanical part having a reciprocating mo-
tion. The entire distance passed through in such a movement.

• SUBSCRIPT
A set of numbers that identifies an element of an array.

• SUBROUTINE
A set of instructions that is run by another routine.

• SYMBOL
A character or design that has a distinct meaning and/or is associated with some-
thing.

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ARC WELDING OPERATIONS AND PROGRAMMING

GLOSSARY

• SYNTAX
The proper way in which commands and phrases should be typed in order to be
understood by the control system. If the operator incorrectly types a command (i.e.,
misspelled or invalid characters), a syntax error message will be displayed.

• SYSTEM DATA
Data that is specific to a individual robot. Zeroing data, upper and lower software
limits, and software switch settings are all examples of system data.

• SYSTEM SWITCH
Software switches that are set to determine various configurations and characteris-
tics of the robot system performance.

T
• TEACH MODE
A mode selected on the operator panel, during which robot arm axes positions can
be taught by the operator and are recorded by the robot.

• TEACH PENDANT
A hand-held, portable device used by the operator during teach and jogging opera-
tions.

• TOOL COORDINATES
A Cartesian coordinate system in which the origin point is at the face plate of the
robot and the orientation of the tool can be expressed in terms of a 3-dimensional
space representation of X, Y, and Z projections.

• TOOL MODE
A mode of operation in which all motions are calculated to maintain the orientation
of the tool in space.

• TORQUE
Something which produces or tends to produce rotation or torsion and whose effec-
tiveness is measured by the product of the force and the perpendicular distance
from the line of action of the force to the axis of rotation.

• TRANSFORMER
A device to convert the current of a primary circuit into variations of voltage and
current used in secondary circuits.

February 15, 2000 G-23

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ARC WELDING OPERATIONS AND PROGRAMMING

GLOSSARY

• TRANSFORMATION
A mathematical description of a location that defines the position and orientation of
the location without regard for the configuration of the robot when it is at that loca-
tion.

• TRAP POINT
see pinch point

• TTL
Abbreviation for transistor-transistor logic.

• TWO’S COMPLEMENT
A means of representing a negative number as one more than the binary comple-
ment of the absolute value of the number.

• TRIANGULAR WAVEFORM
A waveform that has the shape of a triangle and is used in determining sampling
values for servo drive circuits that utilize pulse width modulation.

U
• UHF
Abbreviation for ultra-high frequency.

V
• VARIABLE
The name of a memory location or stored value. A variable can refer to a scalar or
an array.

• VELOCITY COMMAND
This analog signal is directly proportional to motor speed, and provides the initial
signal that is processed by the servo drive system to drive a servo motor.

• VELOCITY ERROR
When the robot controller detects an axis that has exceeded a preset value for
velocity, the robot controller will E-stop the robot.

• VOLT
A unit of electrical potential difference and electromotive force. One volt is equiva-
lent to the force required to produce one amp of current through one ohm of resis-
tance.

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ARC WELDING OPERATIONS AND PROGRAMMING

GLOSSARY

W
• WORK ENVELOPE
The effective range or reach of a robot’s axes.

• WORLD COORDINATES
A Cartesian coordinate system in which the origin point is near the base of the
robot, and robot movement can be expressed in terms of a 3-dimensional space
representation of X, Y, and Z projections.

• WRITE
In computer systems, a process in which information is output to and stored by a
device or area in memory.

• WS (WELD SCHEDULE)
Data that is stored in the weld controller and provides the specific current, clamp
pressures, etc. for spot welding applications.

• WX (WAIT EXTERNAL)
The wait external signal is one of many inputs that are processed by the robot
controller. When the robot encounters a wait external condition, the robot will cease
motion and the servo power will be removed.

Z
• ZEROING
This procedure provides the robot controller with encoder data that is referenced
from a known mechanical position (zeroing witness marks, in simple zeroing, or
inclinometer values in precision zeroing) and then establishes an encoder value for
this known position. Two methods can be used, simple and precision zeroing.
Some robot manufacturers call this procedure mastering or calibration.

February 15, 2000 G-25

 Kawasak C CONTROLLER

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

INDEX ........................................................................................................................ IN-2

February 15, 2000 IN-1

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

Symbols
1FS (RI/O) Board, 11-40
1FS Board, 1-13, 11-40
1GA Board, 1-12, 11-40
1GB Board, 1-12, 1-15
1GC Board, 1-12
1GD Board, 1-12
1GM Board, 1-12
1GW Board, 1-13
1HP Board, 1-13

A
Absolute Speed, 11-53
AC Key, 7-9
AC SPEED Key, 7-8
Accuracy, I-5, 7-9, 9-50
Accuracy Key, 7-9
Accuracy Range, 9-50
Adjusting Screw, 2-9
[Link] Timer Switch, 9-60
Align Function, 6-9
ALIGN Key, 6-9
Allen-Bradley, 11-40
Alpha Program Name, 7-3
Amplifier, 1-15
ANSI Publication #Z49.1, 2-9
ANSI/RIA, 2-2
ANSI/RIA Standards, 9-53
Approach Point, 11-64
Arc Current, 8-12
Arc Establishment, 9-38
Arc Failure, 9-36
Arc Initiation, 9-34
Arc Signal, 7-24
Arc Spot, 7-14
Arc Spot (AS) Condition Numbers, 9-26
Arc Spot Sequence, 9-39
Arc Spot Weld Condition Modify, 9-80
Arc Spot Welding Conditions, 9-25
Arc Status, 5-21
ARC STATUS Screen, 9-32
Arc Status Screen, 8-12
Arc Switch, 9-57
Arc Voltage, 8-12
Arc Weld Auxiliary Data, 9-29
Arc Weld Condition Modify, 9-79
Arc Weld Data Base, 9-27
Arc Weld Torch Dimensions, 9-48
AS Instruction Definition, 11-33
AS Key, 7-14
AS Location Screen, 5-14
AS TEACHING Key, 5-13

IN-2 February 15, 2000

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

Auto Servo Timer, 9-66

AUTO SET Key, 7-16, 7-18
Auto Tool Set, 11-9
[Link] Switches, 9-60
AUX SET&DISPLAY Key, 7-14
Auxiliary Data, 7-21, 7-23
Auxiliary Data Area, 5-11
Auxiliary Function List, 9-5
Auxiliary Function Select, 11-52
Auxiliary Information for Arc Welding, 7-12
Auxiliary Rewrite, 7-24
AXIS Keys, 6-4

B
Baby Work, 11-66, 11-70
Backup File, 9-20
Base (World) Coordinates, I-2
Base Coordinate Shift, 9-47
Base Coordinate System, 9-45
Base Coordinates, 6-8, 8-13, 9-47
Batteries, 9-70
Battery Error Check, 9-70
Bearings, 1-2
Burn Back, 11-54

C
C controller, I-4
Change Program Name, 9-63
CHECK BACKWARD Key, 5-15, 7-20
CHECK FORWARD Key, 5-15, 7-20
CHECK Key, 7-20
Check Mode Velocities, 2-10
Check Specification, 9-68
Check Speed, 9-52
Check Sum, 9-63
[Link] Switch, 9-57
Checking Program Operation, 7-20
Circuit Boards, 1-12
Clamp Data Screens, 11-36
Clear Check Sum Error, 9-63
CLEAR Key, 7-16
closed-loop, I-2
CMOS RAM, I-5
Command Voltage, 9-32
Commanded Analog Voltage Outputs, 8-12
Computer Simulation Models, 11-5
COND. SET Key, 7-24
Constant Velocity, 6-8, 6-11
Control Panel Switches, 3-5, 3-6
COORDINATE JOINT Button, 6-6
COORDINATE Key, 6-3, 6-4
coordinate systems, I-2

February 15, 2000 IN-3

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

Copy and Paste Steps, 7-28

COPY Key, 7-29, 7-31
CP (Continuous Path) Switch, 9-58
Crater, 9-36
Crater Conditions, 7-14, 9-38
Crater Parameters, 7-15
Creating a Program, 7-5
Current, 7-14, 7-24
Current Adjustments, 7-24
Current Detect Modules, 1-15
Current Detect Signal, 9-39
Current Position Screen, 5-20, 8-13
CURRENT Screen, 9-32
Cursor Movement Keys, 5-7
Cut and Paste Steps, 7-26
CUT Key, 7-27
CYCLE START Button, 8-6
CYCLE START Lamp, 3-6, 8-14
CYCLE START Switch, 3-6
[Link] Switch, 9-58
Cylinder, 2-9
Cylinder Valve, 2-9
Cylindrical Work Pieces, 11-62

D
Data Backup, 1-6
Data Conversion, 11-5
Data Editing, I-5
Data Transfer, 9-17
Daughter Work, 11-66
Dedicated Input Signals, 9-71
Dedicated Output Signals, 9-72
Dedicated Signal Display, 9-75
Dedicated Signals, I-6, 9-75
Delete a Program, 5-6
DELETE Key, 7-33, 7-34
Delete Steps Within a Program, 7-32
Deleting Programs, 7-34
Deletion of Steps, 7-22
Detecting Times, 9-39
Detecting Wire Stuck, 9-39
Digital Command Signal, 1-15
Digital Display, 11-30
Digital Switch, 11-29
Dimensions, I-8
Direct Speed, 11-53
DISPIO_01 Switch, 9-61
Double Typeoutput Signal, 11-21
Dry Run (Option), 8-6
Dynamic Shock Loads, 8-14

IN-4 February 15, 2000

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

E
E-Stops, 2-10
Editing Keys, 7-21
Editing Program Information, 7-21
Electromechanical Brakes, 2-10
Emergency Stop, 9-43
EMERGENCY STOP Button, 8-14
EMERGENCY STOP Switch, 3-6, 4-8
Encoder Abnormality Error, 9-44
Encoder Counts, 9-45
Encoder Deviation, 9-44
Encoder Error Range, 9-44
Encoder Offsets, 9-45
Encoder Rotation Counter Reset, 9-78
END, 9-60
End of the Program., 7-5
Environment Data, 9-66
Environment Data of Panel, 9-67
Environment Data2, 9-67
ERROR CODES/TROUBLESHOOTING, 10-2
Error Lamp, 3-5
Error Logging, 9-76
Error Recovery, 10-2
Errors, 9-61, 9-76
[Link] Switch, 9-61
European C Controller, 3-4
EXTCALL, 9-60
External Axis Keys, 6-5
Eye Protection, 2-9

F
FDD Aux Function, 11-8
FDD CONFIG, 11-8
FDD FORMATTING, 11-8
Figure Input and Cursor Selection, 5-24
FILE DELETE, 11-8
File Directory, 9-22
File Directory (FD_FDIR), 11-8
File Extension, 9-20, 9-22
FILE RENAME, 11-8
File Type, 9-22
Fixed Linear Interpolation (FLIN), 11-13
Fixed Pointer, 11-10
Fixed Reference, 11-54
Fixed Tool Dimensions, 11-13
FLASH Memory, 1-12
Floppy Disk Drive (FD_LOAD), 11-7
Floppy Disk Drive (FD_SAVE), 11-6
Floppy Disk, 1-11
Format, 9-22
FRAME Function, 11-15
Functions, 7-2

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

G
Gas Cylinders, 2-9
Gears, 1-2
General Multi Function Panel Keys, 5-4
Global Changes, 9-56
Graphing Feature (Option), 8-10

H
HOLD/RUN Switch, 4-8, 8-14
HOME, 9-62
Home Position Function, 9-62
Horizontal Bar Graph, 8-4
Hybrid Encoder, 1-15
Hybrid Encoder Assembly, 1-16

I
I/F Panel Programmed by PC, 11-32
I/O, 7-11
I/O (Number of Channels), 11-40
I/O Channels, 11-43
I/O Signals, I-5
IFPWPRINT, 11-31
IN/OUT Key, 8-10
Inching, 11-54
Inching Distance, 9-53
INCHING Key, 6-3, 6-4
Inching Retract Keys, 7-10
Input Channels, 1-13
Insert a New Step, 7-22
Intelligent Power Modules, 1-12
Interface Devices, 1-5
Interface Panel, 11-25
Interface Software, 1-9
Internal Slogic Signals, 11-40
Interp Key, 7-8
Interpolation, 7-8
INTRODUCTION, I-2
IPM, 1-12

J
JA5/JC5/JS5/JW5 Work Envelope, 2-12
Joint Angle, 8-13, 9-10
Joint Coordinate System, 6-6
JOINT Interpolation, 7-8
Joint Location Edit Screen, 11-39
Joint Shift, 11-18
JUMP, 9-60
Jump/End Key, 7-10

IN-6 February 15, 2000

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

K
KCMON, 1-9
KCWIN, 1-9
Keep Type Output Signal, 11-21
Keep Welding Distance, 9-34
Keyboard, 5-25
Keyboard Keys, 5-26
Keys, 3-2
Kill Program, 9-18

L
Ladder Logic, 11-40
Lamps, 11-26
Left Hand Rule, 6-8
LINEAR Interpolation, 7-8
Linear Movement Errors, 6-13
Linearization, 7-24, 9-30
Lithium Batteries, 1-12
Location & Speed Display, 9-10
Lockout, 2-8
Lower Limits, 9-49

M
Main Transformer, 1-15
Mainline Program, 8-3
major axes, I-2
Major Components, 1-3
[Link] Key, 6-3, 6-4
MAX. OUTPUT VOLTAGE Screen, 9-30
Mechanical Unit, I-2, 1-17
Mechanical Unit Design Specifications, I-3
Memory, 1-6, 9-54
Memory - PC Card (Save), 9-19
Memory Available, 9-54
Memory Capacity, I-5
Memory Load, 9-21
Memory Save, 9-19
MENU Key, 5-22, 9-4
Message Switch, 9-60
minor axes, I-2
Mirror Conversion, 11-3
Mirror Imaging, 11-3
MODIFY Key, 9-28
MONITOR Key, 8-10
Monitor Screens, 5-19, 8-10
Monitoring the Program, 8-7
Mother Work, 11-66
Motor Power, 3-6
Multi Function Panel, I-7, 1-6, 5-2, 9-67, 11-40

February 15, 2000 IN-7

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

N
New Program, 7-3
Node Adapter Chip (NAC), 11-40
Non-Welding Programming Keys, 7-8
Null Base, 9-47
Numeric Program Name, 7-3

O
Off Line Programming, 11-5
OFFSET/GAIN Function, 9-32
Online Edit, 11-34
Operation Log, 9-77
Optional Axes Operation, 6-5
Optional Floppy Disc Drive Unit, 11-6
Optional Functions, 11-3
Optional Interface Panel, 1-9
Optional Software Interface Panels, 1-10
Optional System Switches, 9-57
OSHA, 2-2
Output Channels, 1-13
Output Signal, 9-59
Overlap Weld Distance, 9-36
Overriding Wait Signals, 8-2
Overtravel Limit Switches, 2-10
Overwriting Steps, 7-21
OX Edit Screen, 11-37
OX Specification, 11-21
[Link] Switch, 9-59
OX/WX Key, 7-11

P
Parallel I/O, 1-13
Parallel Search Direction, 11-61
Parameter Values, 9-24
Password Level, 11-51
PASTE Key, 7-29, 7-31
Path Coordinates, 2-7
Pattern Combination, 11-68
PATTERN Key, 11-66
Pattern No., 7-14
PC Card, 1-6, 9-19, 9-21
PC Card - Memory (Load), 9-21
PC Card Aux. Function, 9-22
PC Card Formatting, 9-22
PC Key, 5-4
PC Program Run/Stop, 11-23
Personal Computer, 1-9
Personal Safety, 2-4
Phase Calculation, 1-16
Pilot Lamp, 11-28
Pinch Points, 2-6

IN-8 February 15, 2000

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

Playback Accuracy, 9-43, 9-50

Playback Speed, 8-5, 9-51
PLC, 1-13
[Link] Function, 9-61
Polarity Ratio, 7-14
Pos. Error Range at E-Stop, 9-43
Position Rewrite, 7-23
Power Block, 1-12, 1-15
Power Lamp, 1-8
Power On/Off Procedures, 4-2
Power Requirements, I-8
Power Unit, 1-15
Power Up Sequence, 1-13
PRE DATA Key, 7-24
[Link] Switch, 9-59
Preflow/Afterflow, 9-40
Program Confirmation, 7-35
Program Delete Function, 5-6, 7-34
Program Display Area, 8-7
PROGRAM EDIT Function, 7-26, 7-28
PROGRAM EDIT Key, 5-12, 7-30, 7-32
Program Execution, 8-6
PROGRAM Key, 5-4
Program List, 5-18, 8-8
Program List Screens, 8-8
Program Name, 7-3
Program Progress, 8-7
Program Select Screen, 8-3
Program Selection, 8-3
Programmable Logic Controller (PLC), 11-40
Pulse Type Output Signal, 11-21
Pulse Width Modulation, 1-12
Push Button Switch Setting, 11-26
Push Button with Lamp, 11-27
PWM, 1-12
PWM Signal, 1-15

R
REAL TIME COND MOD Key, 7-24
Real Time Weld Condition Modification, 7-24
Record Data (PRG CHG) Inhibit, 9-55
RECORD Key, 7-6
Recording Program Steps, 7-5
Regulator, 2-9
Remote I/O and Slogic Specifications, 11-43
REP_ONCE (Repeat Once) Switch, 9-60
Repeat Condition Display, 8-4
Repeat Condition Keys, 5-17, 8-4
Repeat Condition Speed, 9-51
REPEAT CONT Key, 8-5
Repeat Cont/Once, 8-5
Retract, 11-54

February 15, 2000 IN-9

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

Retracting, 7-10
Retry, 9-39
RI/O Monitor, 11-45
RI/O PLC (NAC) Setting, 11-49
RI/O Signal Status, 11-46
RI/O Slogic Control, 11-50
RI/O Slogic Forced Output, 11-51
RI/O Version, 1-13
RISC, 1-12
RISC CPU, I-4
Robot Controller, I-4
Robot Controller Design Specifications, I-4
Robot Jogging Keys, 5-29
ROBOT Key, 6-3
Robot Manual Operation Keys, 5-28
Robot Motion, 8-14
Robot Mounting Posture, 9-45
ROBOT1, 6-5
ROBOT2, 6-5
RPS Key, 8-6
RPS (Remote Program Selection) Switch, 9-60
Running a Program, 8-6

S
Safety, 2-2
Safety Features, 2-10
Scratch Start, 9-33
Screen Selection Keys, 5-9
Screen Switch, 9-60
Search Pattern, 11-54, 11-61, 11-62
Search Pattern Combinations, 11-66
Search Plane, 11-62
Sense Point, 11-64
Sensing Points, 11-61
Serial Communication, 1-13, 11-40
Servo CPU, 1-12
Servo Drive, 1-15
Servo Motor, 1-15, 1-16
Servo Motor Power On Procedures, 4-7
Servo Software, 1-15
SET+ Key, 11-36
SET- Key, 11-36
Setting Tool Coordinates, 11-12
Setting Weld Conditions Auto Set Method, 7-18
Setting Weld Conditions Direct Method, 7-15
Setting Weld Conditions Indirect Method, 7-17
Shield Gas, 9-40
Signal Dedication, 9-71
Signal States, 9-61
Signal Timing, 9-59
Simple Zeroing, 9-42
Singularity, 6-13

IN-10 February 15, 2000

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

SLOGIC, 11-40, 11-43

Slogic Control, 11-50
Slogic Forced Output, 11-51
Slogic Monitor Screen, 11-48
SLOGIC Number of Internal Signals, 11-43
Slogic Programs, 11-42
Slogic Status Screen, 11-49
Slow Repeat Mode, 8-14, 9-52
Small Teach Pendant, 1-7
Software Dedicated Signal, 11-31
Software Features, I-5
Software Limit, 9-49
Software Slow Down, 9-38
Software Switches, 9-56
Software Version Display, 9-65
Special Features, I-7
Speed, I-5, 7-8, 8-4, 9-51
Speed Adjustments, 7-24
Speed and Inching Selection, 6-4
Speed Range, 9-51
Spot Weld, 9-25
SRAM, 1-6, 1-12
Stable Arc, 11-54
standard axes, I-2
Standard C Controller, 3-2
Status Area, 5-11
STATUS Key, 5-16, 8-12
Status Screens, 8-7
STEP CONT Key, 8-5
Step Cont/Once, 8-5
Step Forward, 9-60
STEP FORWARD Key, 8-5
STEP Key, 5-4
Step Select Function, 8-6
Step Selection, 5-7
Step Speed, 9-51
Step Type Signal, 11-21
Stopping a Running Program, 8-14
Stopping Start, 9-33
Stopping the Robot, 4-8
Stopping Time, 9-36
STP_ONCE (Step Once) Switch, 9-60
Switch Panel, 1-8, 4-6
Switches, 3-2
System Initialization, 9-69
System Message Area, 5-11
System Switch, 9-56

T
Tack Weld, 7-14
TCP, 6-8
TEACH AUX. REWRT Key, 7-24

February 15, 2000 IN-11

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ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

TEACH DATA Key, 7-11

TEACH INSERT Key, 7-22
TEACH NEW, 7-21
TEACH NEW Key, 7-6
TEACH OVERWRITE Key, 7-21
Teach Pendant, I-7, 1-7, 9-66
TEACH POS. REWRT Key, 7-23
Teach Speed, 9-53
Teach Velocities, 2-10
TEACH/REPEAT Switch, 3-5, 4-8
TEACHING Key, 5-10, 6-3
Teaching Screen, 7-7
Teaching Screens, 9-67
Teaching the Work Modification, 11-62
Text Window, 11-30
Three Notch Selector Switch, 11-28
Threshold Value, 9-33
Time Function, 9-71
Timer, 7-9
Timer and Counter Status Screens, 11-47
Timer Function, 9-54
Timer Key, 7-9
Title Area, 5-11
Tool Center Point, 6-8, 9-48
Tool Coordinate Mode, 6-11
Tool Coordinates, 6-11
Tool coordinates, I-2
Tool Dimensions, 6-11
Tool Shift, 11-19
Touch Angle, 11-60
Touch Panel Short Circuit Check, 9-70
Touch Sense Keys, 11-63
Touch Sense Settings, 11-59
Touch Sensing Function, 11-54
Trap Points, 2-4
Travel Speed, 7-14, 7-24
Trigger Switches, 6-3
Troubleshooting Flowcharts, 10-75
Troubleshooting Processes, 10-2
Turn Back Distance, 9-34
Turn Back Speed, 9-36
Two Notch Selector Switch, 11-27

U
Upper Limits, 9-49
UV Radiation, 2-9

V
Ventilation, 2-9
Voltage, 7-14, 7-24
Voltage Adjustments, 7-24
VOLTAGE Screen, 9-32

IN-12 February 15, 2000

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

W
Wait Condition, 8-15
Wait Override Procedure, 8-15
WAIT SCREEN Key, 8-15
Weave Amplitude, 7-14
Weave Frequency, 7-14
Weight, I-8
WELD COND Key, 7-17, 7-18
Weld Condition, 9-23
Weld Condition Data, 7-19
Weld Condition Number, 7-17
Weld Condition Parameters, 7-14
Weld Conditions, 7-5, 8-8
Weld Continue, 7-13
Weld Continue Key, 7-13
Weld Control, 11-40
Weld Data Base, 9-27
Weld End Key, 7-13
WELD ETC. SIGNAL Key, 6-9, 7-2, 7-24
Weld On/Off in Check, 9-41
WELD ON/OFF Key, 2-9, 8-7
Weld Parameters, 7-19, 7-24, 9-23, 9-26, 9-28
Weld Programming Keys, 7-12
Weld Start, 7-12
Weld Start Key, 7-12
Weld Start Retry, 9-36
Weld Start Sequence, 9-33
Weld Type, 7-19, 9-27, 9-28
Weld Type Menu, 7-16
Welding Cables, 2-9
Welding Current, 9-32
Welding Curtains, 2-9
Welding Parameter Ranges, 9-24
Welding Parameters, 9-79
Welding Power Supplies, 9-30
Welding Safety, 2-9
Welding Time, 9-39
Welding Wire, 11-54
Wire Check Function, 11-54
Wire Check Points, 11-56
WIRE CHECK SET Key, 11-57
Wire Extension, 9-48
Wire Feed Speed, 11-55
Wire Inching, 7-10
Wire Inching/Retract, 9-41
Wire Retract Speed, 9-36, 9-40
Wire Retract Time, 9-36, 9-40
Wire Stickout, 9-30, 11-54
Wire Stuck Cancel Sequence, 9-38
Work Cell, 2-4
WORK DAUGHTER Key, 11-70
Work Detect Function, 11-58

February 15, 2000 IN-13

 Kawasak C CONTROLLER

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

ARC WELDING OPERATIONS AND PROGRAMMING

INDEX

Work Detect Points, 11-58

Work Dimensions, 11-15
Work Envelope, 2-4
Work Envelope Drawings, 2-11
Work Modification Function, 11-61
WORK MOTHER Key, 11-64, 11-67
Work Piece, 11-62
Work Shift, 11-20
Work Space Output, 11-16
WX Edit Screen, 11-38

X
X and O Display, 9-61
XYZ Shift, 11-17

Z
Zeroing, 9-6, 9-9, 9-42, 9-43, 9-78, 9-79
Zeroing Data Set/Display, 9-45
Zeroing Scribe Marks, 9-42

IN-14 February 15, 2000