Motoman Technical Education Center Specialized/On-Site Training Topics

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XRC Training Topics Page 1 of 5

XRC Description and Operations

XRC System Components
Powering Up the XRC
Turning Off Power to the XRC
Playback Panel
E-Stop
Operating Controls
Programming Pendant
Screen Display
Function Keys and Soft Keys
Servo On Light
Enable/Disable
E-Stop
Teach Lock
Editing Keys
EIA232D (RS232C) Port
Coordinates/Axes
Joint Coordinates SLURBT
World/Cylindrical Coordinate Frame
Tool Coordinate Frame
User Coordinate Frame
Alarms and Errors
Error Messages
Minor Alarms
Major Alarms
User Alarms
Displaying Major/Minor Alarms
Specified Point (Second Home)
Alarm 4107 Recovery
Checking Specified Point
Creating a Job
Naming a Job Numerically
Naming a Job Alphanumerically
Selecting a Job
Registration of Master Job
Calling the Master Job to the Screen
Path Creation
Joint Motion Type
Linear Motion Type
Play Speed Selection
Teaching Positions as Program Steps
Overlapping First and Last Steps
Path Confirmation

Playing a Job
Circular and Spline Motion Types
Editing the Job List
Copy Job
Rename Job
Delete Job
Detail Job List
Capacity
INSERT, MODIFY, DELETE steps
Change Motion Types
Position Level Specification
Adding Position Levels
Cut, Copy, Paste, & Reverse Paste
General Line Edit and DETAIL EDIT
Speed Correction/Adjustment
Play SPD Edit - General/Detail Edit
Change Speed - Relative/Absolute
Speed Override Utility
Traverse Run Time (TRT)
Set Up Special Run
Low Speed Start
Speed Limit
Dry-Run Speed
Check-Run
Machine Lock
Control Instructions
Linking Jobs with CALL and RET (Return)
Direct Open Key
JUMP
LABEL
Commenting
TIMER
PAUSE
Displaying and Editing Arithmetic Variables
INC
DEC
SET
CLEAR
Conditional IF Statement
Programming within New Line Instruction
Adding to An Existing Line Instruction
Input/Output Instructions
Digital Output instructions

Digital Input Instructions

Analog Output Instruction
Monitoring Input/Output Status
Creating User Frames
Accessing User Frames
Edit Protection
Edit Lock Key switch
Software Edit Protection for Jobs
Step Only Changing - Permit/Prohibit
Tool Center Point Definition
Manual Modify TCP Data
Automatic Calibration for X, Y, & Z Tool Data
Introduction to XRC Welding
Equipment Definition and Location in Cell
Interconnections
Sample Part Welding
Welding Parts with Preset Conditions
Troubleshooting Weld Defects
Changing Weld Parameters During Welding
Variables in a Weld System
Amp/Volt Relationship, Affect on Arc
Wire Size and Type
Gas Mix and Flow Rate
Electrical Stick-Out (ESO)
Welding Alarms and Errors
Lack of Arc
Wire Stick
Welding Instructions
Standard Weld File Construction
Enhanced Weld File Construction
Using Call Jobs for Starting and Ending Welds
Using In-Line or One-Line ARCON and ARCOF
Using Arc Start Files (ASF) and Arc End Files (AEF)
Troubleshooting and correcting defects
Basic Explanation of Weave Files
Weaving with Single, Smooth pattern of specified
Introduction
Safety Video and Safety Discussion
Course Objectives Overview
Advanced Use of CONTROL Instructions
Binary Values for Byte/Groups/Half Groups
CALL or JUMP to B-VAR or UNIV-IG
Review of IF Criteria.

Motoman Technical Education Center Specialized/On-Site Training Topics

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XRC Training Topics Page 2 of 5

Security System
Security Modes
Edit Review
The Set-Up Icon
Teaching Conditions
Set Word
User ID
Reserve Job Name
Key Allocation
Date/Time
Set Speed
Operate Cond
The Parameter Icon
SC Parameters
AP Parameters
RS Parameters
Soft Limits
Axis Limits
Cube Soft Limits
Robot Origin
Home Position
Operation Origin
Interference Zones
Defining Cubes by CENTER POSITION
Defining Cubes by MIN-MAX
Modifying Cubes
Display of SP OUT Diagnostics for Cubes
WAIT SOUT = ON for In Cube1
Axis Interference
C. I/O User Messages & Alarms
Registering User Messages
Registering User Alarms
Default Speeds
NWAIT tag and CWAIT control instruction
UNTIL tag
Variable Types and Addresses
Local/Global
Scalar/Array Address
Arithmetic, Position, & System Type
Setting Position Variable Data Type
Cartesian Coordinate Frames
Registering/Editing Position Variables
Motion Steps Using Position Variables

Incremental Moves [IMOV]

Arithmetic Functions
System Variables Function
Position Variable Functions
Calculating Functions
Value Setting Functions
Counting Functions
Trigonometric Functions
Boolean Logic Functions
Shift Function
Temporary Shift Instructions (SFTON/SFTOF)
MSHIFT
Parallel & Mirror Shift
Dynamic Editing (PAM)
Relative Job
Creating a User Frame TEACH COORD
3-D Shift Using Relative Job Conversion
Position Modification for Tool (PMT)
Saving New TCP Data
Shifting points
Multiple Tool Path Function (TCPON/TCPOF)
Interrupt Job Function
Setting Table Priority Levels
Programming EI/DI
Search Function
Independent Control/Concurrent Jobs
Robot/Concurrent Job Types
Programming PSTART/PWAIT
Coordinated Motion
Internal Shock Sensor
Shock Sensor Levels/Operation
Job Instructions for Shock Sensor
Additional Options
Endless Rotation
Independent T-Axis
External Reference Point
Form-Cut
Introduction
Explain Course Objectives
Review Course Outline
Introduction to XRC Welding
Equipment Definition and Location In Cell
Interconnections

Welding Power Source

Wire Feeder
Gas
Interface
Troubleshooting Weld Defects
Variables In A Weld System
AmpVolt Relationship, Effect on Arc
Wire Size and Type
Gas Mix and Flow Rate
Electrical Stick-Out (ESO)
Welding Alarms and Errors
Lack of Arc
Wire Stick
Changing Weld Parameters During Welding
Changing Voltage
Changing Current
Welding Instructions
Standard Weld File Construction Review
Enhanced Weld File Construction Review
Using Call Jobs for Starting and Ending Welds
Job Construction
Using In-Line or One-Line Arc Start and Arc End
Explanation of Available Instructions
Editing
Welder Condition Files Set-Up
Choosing a File for Use
Naming a File
Data Collection by Welding Samples
Data Registration
Saving and Selecting a File for Use
Arc Adjust Compensation
Polarity Selection
% -vs- Actual Voltage Settings
Software Weaving
Standard Base Weave
Reference Points; Registration and Accessing
Editing reference points
Weave pattern types; L, triangle, and simple
Editing weld paths containing weave instructions
Welding & Weaving Using Circular and Spline
Circular Interpolated Welding Paths
Curve Fit (Spline) Interpolated Paths
Maintaining Proper Torch Angles

Motoman Technical Education Center Specialized/On-Site Training Topics

Company
Contact
Phone

Please complete this form by indicating desired

training topics and then fax to the Motoman Training
Coordinator at (937) 847-6277. Please complete the
contact info on the left on each sheet you fax.

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XRC Training Topics Page 3 of 5

User Frames
Creating User Frames
Accessing User Frames
SECURITY MODE Features
Changing the Registered User ID Number
Setting Time/Date
Accessing/Checking System Information
Registering Variable & VO Names
Creating User Messages with Concurrent I/O
Creating User Alarms with Concurrent I/O
Customizing 8 Preset Speed Choices
Temporary Release of Soft Limits
Defining and Modifying Soft Limits
Releasing Mechanical Interference Limits
Home Position Calibration
Changing Absolute (ABSO) Data
Subset, Standard, or Expanded
Learning Function Parameter ON/OFF
Use of Tags for Learning
Programming using enable SPD tag
Programming using Position LVL tag
XRC User Word List
Programming job names into list
Using Reserve Job names
Search Options
Searching for a Line, Step, or instruction
Searching for a Label ,or Tag
Default Speeds
Using CONST
Using VAR
Programming NWAIT, CWAIT, & UNTIL
Explanation of IMOV
Programming Using IMOV
Explanation of PSHIFT
Shifting a Job Using PSHIFT
System Variables
Programming using $PX
Programming using GETS
Advanced Arithmetic Functions
Using CNVRT
Using GETE & SETE
Floppy Disk back-up
FC2

FDE
Overview of ComArc III
ComArc Seam Tracking
Basic Explanation of Functions
System Overview
Hardware and Software
Necessary Boards and Software
Concurrent I/O Ladder Modifications
ComArc Box (if required)
Front Panel
Connections
Definition of Terms
PC1 and PC2
Measurement Modes
Upper Current
Offset
Passover
Dead-Zones
Measurement Set-up
Measurement Modes Overview
Enabling Measurement Modes
Location of ComArc Instructions
Device Screen
COMARCON
COMARCOF
Additional Instructions
Location of Various ComArc Screens
Rapid Input (RIN) Screen
ComArc Files
Correction Quantity Files
Measurement Screens
Current
Programming a ComArc Welding Path
Procedural Overview
Basic Instructions
Seam Finding (Touch Sensing)
Reference Points Required
Necessary Instructions
SEARCH
IMOV
GETE and SETE
Additional Instructions
Programming the Touch1 Job

Troubleshooting Seam Tracking

Troubleshooting Touch Sensing
Advanced Touch Sensing
Explanation of Touch2 Job
Explanation of Touch3 Job
Programming Custom Touch Jobs
Lap Touch
Multiple Touch
Electrical Electronic Components
Electrical Safety Procedures
XRC Internal Component Layout
CPU Rack (Major Unit)
Electrostatic Discharge Safety
Circuit Card Removal and Handling
Electrical Power Flow
Power Flow Overview
Block Level Diagram
Signal Flow
Signal Flow Overview
Block Level Diagram
Elementary Wiring Diagrams
Layout/Coordinate System
Trace Circuit Card Signal/Power Flow
Power Supply Module
Control Processor Module
Servo Control Module
Servo ON
Block Level Diagram
Servo ON Sequence
Servo Pack and Converter
Description of Components
Setting Information
Basic Troubleshooting
Alarm Message List
Elementary Diagrams
Electrical Power
Input/Output (I/0) Components
I/O Motherboard
Configuration and Components
I/O Circuit Cards
XTU01 Board
XIO01 I/O Board
XIO02 I/O Board

Motoman Technical Education Center Specialized/On-Site Training Topics

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XRC Training Topics Page 4 of 5

Input/Output Addressing
Input Addresses as 2000 Series
Output Addresses as 3000 Series
Dedicated Inputs/Outputs
External E-Stop Input
Servo ON Input
External Hold Input
Remote Mode Select Input
Servo ON Output
Shock Sensor Input
External Controller Power Control
Jumper Location
Power Control Switch Wiring
Encoders
Position Feedback Using Encoders
Absolute Encoders
Incremental Encoders
Robot Calibration
Manipulator Information
Robot/Controller Connection Drawings
Maintenance/Inspection Procedures
Recommended Spare Parts List
Illustrated Parts Breakdown
Saving Controller Information
General Purpose
Arc Welding
Spot Welding
Material Handling
Accessing the Ladder Program
Input/Output devices
Inform Language Instructions
DOUT
PULSE
WAIT
DIN
Ladder Hardware Components
XCP01
XIU01
XIO01
XIO02
MARIO / MIF05
Logical Addressing (Operands)
Universal Inputs #0XXX; Outputs #1XXX

External Inputs #2XXX; Outputs #3XXX

Specified Inputs #4XXX; Outputs #5XXX
Auxiliary Relays #7XXX
Control Status/Pseudo Inputs #80XX
Data Link Inputs #8200
Network Inputs #9XXX
M-registers (Timers/Counters)
System Information
Robot and System Version Display
Displaying Names and Monitoring I/O
Registering Names for Universal I/O
Simple I/O Monitor Screen
C. I/O Software Components
Ladder Configuration
Program I/O scan time
Software Construction
Mapping of I/O for General Purpose
Mapping of I/O for Arc Welding
Mapping of I/O for Spot Welding
Mapping of I/O for Material Handling
Editing the User Ladder
Edit/Compiling the I/O User Ladder
Examples of Ladder Diagram
Ladder Programming Instructions
Ladder Symbols
Ladder Programming Instructions
GSTR; GOUT
STR; STR-NOT
OUT
AND; AND-NOT
OR; OR-NOT
AND-STR; OR-STR
TMR; CNT
Ladder use for Cubic Interference Zones
Teaching Cubes 1-8
MIN/MAX Method
CUBE LENGTH Method
NUM KEY Method
Modifying Cubes
Using the WAIT for Cube SOUT#81-88.
Ladder User Messages/Alarms
Registering C. I/O User Messages
Registering C. I/O User Alarms

Program Message/ Alarm Display Ladders

I/O Control Parameters
Parity of General I/O Groups
Data of General I/O Groups
Alarm Code Specific Output Data
16 Bit Instructions
Arithmetic Flags
Data Conversion: BCD, BIN
Math Instructions: MOV, ADD,SUB, MUL, DIV, MOD
Boolean: WAND, WOR, WXOR, WNOT
Bit Moves: SHL, SHR, ROL, ROR,
Introduction to ArcWorld 6000 Series
Overview of Course Objectives
Robot Safety
Introduction to Arc World 6200 System
System Components and Location
XRC100 Dual Robot Controller
MRM2 Series Positioner
Welding Equipment
Safety Interlocks
System Variations
Component Interconnections
Jogging the Group Axes
Selection of Group to jog
Jogging robots
Jogging Station
Development of Jobs
Robot Jobs
Station Jobs
Robot and Station Jobs
Concurrent Job
Concurrent Jobs
Robot Jobs
Use of Special Instructions
PSTART
PWAIT
Testing the Jobs
FWD/BWD
Test Start
Multi Job/ Single Job
Modification of Points
Independent Control
Special Key Assignments

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XRC Training Topics Page 5 of 5

Travel Speed Control

Coordinated Control
Travel Speed Control
Special Key Assignments
Using Synchronous/Single Operation
Synchronizing through TSYNC
Travel Speed Control
Special Key Assignments
Using TSYNC Instruction
Job Duplication
Mirror Shift
Parallel Shift
Twin Coordinated
SYNC tag
Job Modification
6200 I/O assignments
User I/O Assignments
Servo Drive
Cycle Start/Station Ready
Auto/Manual Selector Switch
At SideA
At SideB
Dedicated I/O Assignments
Emergency Stops/Overtravel
Master Job Start
Manual Sweep/Rotate Operations
Sweeping the Positioner to SideA
Sweeping the Positioner to SideB
Rotating the Headstock
Welding Screens
Arc Start files
Arc End Files
Cube Defn and Assignment
Defining Cubes (Cubic)
Cube Assignments (Parameters)
Viewing Specified Outputs
Operating Procedures
Startup, Loading, E-Stop Recovery
Shock Sensor Recovery
Standard Fault Recovery Procedures

Fax
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Date

Please complete this form by indicating desired

training topics and then fax to the Motoman Training
Coordinator at (937) 847-6277. Please complete the
contact info on the left on each sheet you fax.