DX Operators Book (04!12!10)

DX100 Robot Controller
Operators
Training Manual
Revised 04/12/10
NOT FOR RESALE
2009 by MOTOMAN
All Rights Reserved
First Edition September 23, 2009
MOTOMAN, Inc.
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-HOUR HOTLINE: (937) 847-3200
www.motoman.com
PREFACE
PURPOSE OF THIS MANUAL
MOTOMAN Technical Education Center training manuals are not intended for use
as stand alone training tools. This manual is to be used in conjunction with
the DX100 Operators course.
WHO SHOULD USE THIS MANUAL

This manual is only issued to attendees of the DX100 Operators course. Do
not use this manual as a reference tool unless you have attended this course
and have received certification from the instructor through the MOTOMAN
Technical Education Center.
HOW TO USE THIS MANUAL

This training manual has been written according to the daily structure of the
DX100 Operators course. It is designed to assist students in understanding the
basic operations and functions for the DX100 controller and a corresponding
MOTOMAN robot. Use this manual as a step-by-step guide through the course.
DISCLAIMER
Information in this manual is based on the assumption that the DX100
controller is in the EDITING Security Level and is using the STANDARD
Language. Be aware that the keystrokes described in this manual may vary
based on other settings, software versions, and options.
The information contained within this document is the proprietary property

of Motoman, Inc., and may not be copied, reproduced or transmitted to other
parties without the expressed written authorization of Motoman, Inc.
Because we are constantly improving our products, we reserve the right to

change specifications without notice. YASNAC and MOTOMAN are registered
trademarks of YASKAWA Electric Manufacturing.
NOTE: This manual is not for resale and will not be sold separately.
All training manuals developed by MOTOMAN Technical Education
Center are copyrighted. Do not copy any portion of these manuals.
CONTENTS
1.0 DX100 STARTUP & SHUTDOWN................................................ 1-1
1.1 DX100 Controller Hardware.......................................................... 1-1
1.1.1 Main Circuit Breaker Power Switch.................................................. 1-1
1.2 Powering Up The DX100 Controller............................................... 1-2
1.3 Turning Off Power To The DX100 Controller.................................. 1-3
2.0 DX100 PENDANT......................................................................... 2-1

2.1 Mode Selection Switch ................................................................. 2-3
2.1.1 Teach Mode .................................................................................... 2-3
2.1.2 Play Mode . ..................................................................................... 2-3
2.1.3 Remote [Play] Mode ....................................................................... 2-3
2.2 Operation Buttons.......................................................................... 2-3
2.2.1 Emergency Stop (E-STOP) Button; Status Icon........................... 2-3

2.2.2 Start Button .................................................................................... 2-4
2.2.3 Hold Button ..................................................................................... 2-4
2.2.4 Servo On/Ready Button................................................................... 2-4
2.3 Servo Enable Switch..................................................................... 2-5
2.4 Area Key........................................................................................ 2-5
2.5 Cursor Key..................................................................................... 2-5
2.6 Select Key...................................................................................... 2-6
2.7 Cancel........................................................................................... 2-6
2.8 Assist Key...................................................................................... 2-6
2.9 Number Keypad............................................................................. 2-6
2.10 Shift Keys....................................................................................... 2-7
2.11 Interlock Key.................................................................................. 2-7
2.12 Main Menu Key.............................................................................. 2-8
3.0 DX100 PENDANT SCREEN......................................................... 3-1

3.1 Main Menu Area............................................................................ 3-1
3.2 General-Purpose Display Area...................................................... 3-2
3.3 Menu Area..................................................................................... 3-3
3.4 Human Interface Display Area....................................................... 3-4
DX Operators Training Manual i MOTOMAN

3.4.1 Edit Buffer Line................................................................................ 3-4
3.4.2 Message Line.................................................................................. 3-4
3.5 Status Display................................................................................ 3-5
3.6 Main Menu Selections................................................................... 3-6
3.6.1 Job................................................................................................... 3-7
3.6.2 Arc Welding, General, Handling, Spot Welding, Laser, Paint, etc.... 3-7
3.6.3 Variable............................................................................................ 3-7
3.6.4 In/Out............................................................................................... 3-7
3.6.5 Robot............................................................................................... 3-7
3.6.6 System Info...................................................................................... 3-7
3.6.7 EX. MEMORY.................................................................................. 3-7
3.6.8 SETUP............................................................................................. 3-7
3.6.9 DISPLAY SETUP............................................................................. 3-7
4.0 CONTROL GROUP & JOG COORD ........................................... 4-1

4.1 Control Groups.............................................................................. 4-1
4.1.1 ROBOT Key .................................................................................... 4-1
4.1.2 EX. AXIS Key .................................................................................. 4-1
4.2 Coordinates................................................................................... 4-2
4.2.1 Joint Coordinates . .......................................................................... 4-2
4.2.2 Tool Selection for Jog Operation in XYZ type Coordinates.............. 4-3
4.2.3 Rectangular or Cylindrical, Tool, and User ..................................... 4-4
4.2.4 Tool Coordinates . ........................................................................... 4-6
4.2.5 User Frames ................................................................................... 4-7
4.3 Manual Speed Icons & Keys.......................................................... 4-7
4.3.1 MANUAL SPEED............................................................................. 4-7
4.3.2 HIGH SPD Key ............................................................................... 4-8
4.4 Current Position............................................................................. 4-8
4.5 Command Position........................................................................ 4-9
5.0 ALARMS & ERRORS................................................................... 5-1

5.1 Error Message............................................................................... 5-1
5.2 Minor Alarms................................................................................. 5-1
5.3 SECOND HOME (Specified Point)................................................ 5-2
5.4 Internal Shock Sensor / Collision Detection.................................. 5-4
5.5 Overrun & Shock Sensor Action.................................................... 5-6
5.6 Major Alarm................................................................................... 5-7
5.7 Multiple Alarms.............................................................................. 5-7
DX Operators Training Manual ii MOTOMAN

5.8 Displaying Alarm History............................................................... 5-8
5.9 Alarm Display................................................................................ 5-9
6.0 SELECTING A JOB...................................................................... 6-1

6.1 Selecting A Job.............................................................................. 6-1
6.2 Displaying the Active Job............................................................... 6-1
6.3 Master Job Call.............................................................................. 6-2
7.0 ROBOT & TOOL PATH.................................................................. 7-1

7.1 Motion Types.................................................................................. 7-1
7.2 Robot/TCP Speeds........................................................................ 7-2
7.3 Command Position........................................................................ 7-2
7.4 Moving to a Command Position..................................................... 7-2
7.5 Job Path Confirmation................................................................... 7-3
7.5.1 Method 1: Confirmation by FWD and BACK Keys.......................... 7-3
7.5.2 Method 2: Confirmation with INTERLOCK + TEST START............ 7-4
7.6 Job Cycle Selection....................................................................... 7-5
7.7 Playing A Job................................................................................. 7-6
8.0 MODIFY COMMAND POSITION.................................................. 8-1

8.1 Editing Mode Security Level.......................................................... 8-1
8.2 EDIT LOCK:ON/OFF Job Protection............................................. 8-1
8.3 STEP ONLY CHANGING for EDIT LOCK Jobs............................. 8-2
8.4 Modify Command Position............................................................. 8-3
9.0 NON-MOTION INSTRUCTIONS................................................... 9-1

9.1 CALL and RET.............................................................................. 9-1
9.1.1 Direct Open...................................................................................... 9-2
9.1.2 Use of the RET Instruction.............................................................. 9-2
9.2 JUMP*LABEL and *LABEL............................................................ 9-3
9.2.1 JUMP to Skip/Omit Lines................................................................. 9-3
9.2.2 JUMP to Create a Repeat Loop....................................................... 9-4
9.2.3 Use of the *LABEL Instruction......................................................... 9-4
9.3 JUMP JOB..................................................................................... 9-4
9.4 TIMER........................................................................................... 9-4
9.5 PAUSE........................................................................................... 9-5
DX Operators Training Manual iii MOTOMAN

9.6 IF Conditional Tag....................................................................... 9-5
9.7 Monitoring Variables...................................................................... 9-6
9.7.1 Display Variable Files....................................................................... 9-6
9.7.2 Instructions with Variables............................................................... 9-6
9.8 Monitoring Universal Inputs & Outputs.......................................... 9-7
9.8.1 Monitoring Universal Inputs............................................................. 9-7
9.8.2 Monitoring Universal Outputs.......................................................... 9-8
9.9 Binary Status and I/O Groups....................................................... 9-9
9.10 DOUT (Digital Output)................................................................. 9-10
9.11 WAIT............................................................................................ 9-10
9.12 Sequence Wait Message............................................................. 9-10
A.0 DX100 PASSWORD FEATURE ................................................ A-1

A.1 Password Protection Option..........................................................A-1
DX Operators Training Manual iv MOTOMAN

DX100 Startup & shutdown
1.0 DX100 STARTUP & SHUTDOWN

The controller cabinet has limited controls and programming features. The Main
Power Switch and connections for cables are on the controller.
DX100
TYPE ERDR-
POWER SUPPLY
3PHASE AC200V 50/60Hz PEAK kVA
AC220V 60Hz AVERAGE kVA
INTERRUPT CURRENT kA
SERIAL No.
DATE
MADE IN JAPAN NJ2960-1
ON
O
F
F
WARNING
High Voltage
Do not open the door
with power ON.
THE MANIPULATOR AND CONTROLLER

SHOULD HAVE SAME ORDER NUMBER.
ORDER NO.
NJ1530
CHECK ALL THE DOOR LOCKS

PROPERLY.
NJ3005-1
PROGRAMMING PENDANT
X81
Figure 1-1 DX100 Robot/System Controller
1.1 DX100 Controller Hardware

1.1.1 Main Circuit Breaker Power Switch
The Main Circuit Breaker Power Switch provides power to the controller. This is
usually fed from a bus or a source breaker.
ON
O
F
F
Figure 1-2 Main Circuit Breaker
DX Basic Programming Training Manual Page 1-1 MOTOMAN

DX100 Startup & Shutdown
1.2 Powering Up The DX100 Controller

The DX100 controller door should be fully closed and latched before turning the
Main Power Switch (or the supply breaker) to the power ON position.
The controller boots the software and initializes the DX100 diagnostic function.
NOTE: A robot cell in which the DX100 interfaces with other equipment may be left
powered ON at all times at the main circuit breaker so that power may be
applied/removed via another device.
During the diagnostics, a Start-up screen and other boot-up screens will be displayed
until the controller is ready for operation.
Figure 1-3 DX100 Controller Start-up Screen
If a failure of any of the diagnostic tests occurs, an alarm screen is displayed.

With no failures, an Initial Window display follows a Windows screen.
Figure 1-4 Initial Pendant Window
NOTE: If the LOG-ON software option is installed, the operator may be prompted to
Log-on with User ID Name and Password Number.

DX100 Startup & shutdown
1.3 Turning Off Power To The DX100 Controller

Before turning off the DX100 controller power, all servo motors should be shutdown
via any E-Stop if the system will be left in the PLAY mode, or place the system in
TEACH mode before shutdown.
Figure 1-5 E-STOP Servo Motors before Shutdown
NOTE: The servo power should not be left ON when the system is not Operating.
Press an E-Stop or switch to TEACH mode. (All preventive maintenance
grease procedures are based on accumulated Servo Power Hours.)
After servo motors are shutdown, turning the Main Circuit Breaker OFF removes all
external power to the DX100 controller.
ON
O
F
F
Figure 1-6 Main Power Switch (OFF)

DX100 Startup & Shutdown
NOTES

DX100 Pendant
2.0 DX100 PENDANT

The pendant is a single-point control device for all robot system operations and
programming with the DX100 Controller.
Start button Hold button
Emergency
Mode switch START HOLD stop button
REMOTE TEACH
PLAY
Menu area JOB EDIT DISPLAY UTILITY
JOB CONTENT
TEST01 S:0000
CONTROL GROUP:R1 TOOL:
0000 NOP
General-purpose
0001 SET B000 1
0002 SET B001 0 Slot for
Compact Flash
0003 MOVJ VJ=80.00
display area 0004 MOVJ VJ=80.00

0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
MOVJ VJ=0.78
Main Menu Short Cut Turn on servo power Page key
LAYOUT TOOL SEL GO BACK

DIRECT
Cursor key COORD OPEN

Multi PAGE AREA
ENTRY
SERVO
SELECT
Select key
MAIN SIMPLE ON CANCEL
MENU MENU READY ASSIST
X- X+
SERVO ON
X- X+
S- S+ R- R+
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST Manual speed keys
Z- Z+ MANUAL SPEED
Z- Z+
U- U+ T- T+
SLOW
E- E+ 8- 8+
Axis keys
INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START
Enable switch ROBOT INFORM

LIST
4 5 6 BACK FWD
EX.AXIS
WELD 1 2 3 DELETE INSERT
ON/OFF
MOTION 0 . -
AUX
Enter key
MODIFY ENTER
TYPE
Motion Numeric keys / Function keys

Type key
Figure 2-1 DX100 Pendant
DX Operators Training Manual Page 2-1 MOTOMAN

DX100 Pendant
The overall control of the system is provided on the pendant, including an E-STOP,
a keyed selector switch for TEACH, PLAY, & REMOTE [PLAY] Mode selection, a
SERVO ON/READY button, as well as HOLD and START control buttons.
Also included on the pendant is a CompactFlash memory slot and USB connector.
START HOLD
REMOTE TEACH
PLAY
JOB EDIT DISPLAY UTILITY
JOB CONTENT
TEST01 S:0000
CONTROL GROUP:R1 TOOL:
0000 NOP
0001 SET B000 1
0002 SET B001 0
Insertion slot for

0003 MOVJ VJ=80.00
0004 MOVJ VJ=80.00
0005 DOUT OT#(10) ON
0006 TIMER T=3.00
0007 MOVJ VJ=80.00
0008 MOVJ VJ=100.00
the Compact Flash
0009 MOVJ VJ=100.00
0010 MOVJ VJ=100.00
0011 MOVJ VJ=100.00
MOVJ VJ=0.78 Insertion direction
Main Menu Short Cut Turn on servo power
top surface
LAYOUT TOOL SEL GO BACK
DIRECT
COORD OPEN
Multi PAGE AREA
ENTRY
SERVO
SELECT
MAIN SIMPLE ON CANCEL
MENU MENU READY ASSIST
X-
S-
X+
S+
SERVO ON
X-
R-
X+
R+
Notch Click
HIGH
SPEED
Y- Y+ Y- Y+
L- L+ B- B+
FAST
Z- Z+ MANUAL SPEED
Z- Z+
U- U+ T- T+
SLOW
E- E+ 8- 8+
INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START
ROBOT INFORM 4 5 6 BACK FWD

LIST
EX.AXIS
ON/OFF
MOTION 0 . -
AUX MODIFY ENTER
TYPE
USB Connector
Insertion position
Top surface
USB memory stick
Figure 2-2 Pendant CF and USB Connections

DX100 Pendant
2.1 Mode Selection Switch REMOTE

PLAY
TEACH
Three mode selections determine control of the robot system. These are Teach, Play,
and Remote [Play].
2.1.1 Teach Mode; Status Icon T
In TEACH mode, the user has control for jogging the robot(s) and External Axis
motors. Programming, editing, customizing, and other menu choices become
available based on the level of Security.
2.1.2 Play Mode; Status Icon P
In PLAY mode, the START button becomes functional and the DX100 has control of
job execution. Special playback UTILITY menu choices become available.
NOTE: Changing modes from PLAY to TEACH during playback will cause the
program to cease execution. !Stopped by switching mode
To resume, select PLAY, SERVO ON, and START.
2.1.3 Remote [Play] Mode; Status Icon P
The REMOTE mode allows control from an optional external device such as a remote
operator station, programmable logic controller or a host computer.
2.2 Operation Buttons
2.2.1 Emergency Stop (E-STOP) Button; Status Icon

Pressing the Emergency Stop (E-STOP) removes servo motor power and causes the
brakes to be applied.
Robot stops by P.P. emergency stop is displayed, and the SERVO ON indicator
light turns off. This takes priority over any informational prompt messages.
Fully twist the E-STOP knob clockwise until it unlatches to reset it.
When all E-Stops are released, the Status Line displays the stop icon.

DX100 Pendant
2.2.2 Start Button; Status icon

In Play mode, with servo power ON, pressing the START button will begin execution
of a job from the line the cursor is on in the JOB CONTENT.
The START button remains lit the entire time the controller is running the program.
Also, the START buttons indicator light will be ON whenever the TEACH mode
INTERLOCK+TEST START method of operation is performed.
2.2.3 Hold Button; Status icon
Pressing the HOLD button stops execution of a job in the PLAY mode; the START
light turns off. The HOLD button light does not latch ON while the system is in this
pendant HOLD. Servo power remains ON, and the brakes are not applied.
To resume execution of the program, press the START button.
If the system was put into hold remotely [External Hold] from an Operators Station
button, etc., the message line will display External holding .
It must be released before restart is possible.
A HOLD (or E-stop) activated by Shock Sensor setting must also be released/RESET
before resuming.
SERVO
ON
2.2.4 Servo On/Ready READY Button
In PLAY mode, pressing the SERVO ON/READY button initiates a sequence that
sends power to the servo motors and releases all brakes. The SERVO ON light will
indicate the status. Playback of any job (with or without motion steps) is not possible
unless servo power is applied.
In TEACH mode, pressing the SERVO ON/READY button will only cause the
indicator SERVO ON to blink that it is ready for the servos to be engaged.
Servo power can be applied by activating the Servo Enable Switch located on the
back left side of the pendant.
NOTE: All Alarms, Errors, and E-STOPs must be cleared prior to pressing the
SERVO ON/READY button in either PLAY mode or TEACH mode.

DX100 Pendant
2.3 Servo Enable Switch

The Servo Enable Switch provides user control of servo power in TEACH mode.
Servo power is required for jogging with the Axis Keys, stepping through a job with
FWD/BACK, or continuous operation with INTERLOCK+TEST START. Also servo
power must be engaged before pressing ENTER for INSERT, MODIFY or DELETE
with regard to motion step programming only.
In order to turn on servo power in Teach mode, perform the following:
1. Release all E-Stops.
2. Press the SERVO ON/READY button. The SERVO ON lamp will blink
signifying ready status.
3. Hold the SERVO ENABLE switch in its middle ON position.
NOTE: Fully released or fully compressed causes the servo motors to turn OFF and
all brakes to be applied.
Figure 2-3 Servo Enable Switch
2.4 Area Key AREA
The AREA key can be used in place of touching the screen to access the following
areas for editing and selection purposes: Main Menu, Menu Area, General Display
Area, the Inform List menu if active, as well as the Human Interface Area when the
edit buffer line is active. The background surrounding the active area is blue.
NOTE: The Status Display line is not an accessible area.
2.5 Cursor Key

The CURSOR key moves the active cursor up/down or right/left to highlight a desired
item on any screen. When the cursor is on an item that has a black background with
yellow characters, such as the job list names, the highlighted selection cannot be
accessed by touching the screen; the SELECT key must be used.
Holding Up or Down will activate rapid scroll to top/bottom of a job or list.
Use SHIFT + Up/Down for previous/next section of screen view within a job content
or list.

DX100 Pendant
SELECT
2.6 Select Key
The SELECT key is used to choose the item currently highlighted by the cursor.
INTERLOCK + SELECT is used to force Universal Outputs ON/OFF.
2.7 Cancel CANCEL
The CANCEL key is located next to the SELECT key. If an undesired selection or
entry has been made, press CANCEL.
Also, the CANCEL key is used to clear all ERROR Messages.
2.8 Assist Key ASSIST
The ASSIST key provides the UNDO/REDO feature enabled in the EDIT menu.
Also, the ASSIST key can be used in conjunction with the SHIFT key and the
INTERLOCK key to view a list of uses for either of these two keys
2.9 Number Keypad

Although the Programming Pendant number keypad is used primarily for entering
numeric values, these keys are also labeled with device operating instructions specific
to the application for which the controller has been initialized.
7 8 9 7 8 9 7 8 9
f 5 f 6 SYNCRO
SINGLE ARCON FEED
4 5 6 4 5 6 4 5 6
f 3 f 4
SMOV ARCOFF RETRACT
1 2 3 1 2 3 1 2 3
TOOL ON f 1 f 2
TOOL ON JOB TIMER GAS CUR/VOL
0MANUAL . - 0 . - 0 . -
TOOL OF TOOL1 TOOL2
OPEN TOOL OF JOB REFP ON/OFF ON/OFF REFP CUR/VOL
Figure 2-4 General, Handling, and Arc Welding Keypad

DX100 Pendant
2.10 Shift Keys SHIFT
There are two SHIFT keys on either side of the pendant keypad. These are used in
conjunction with another key; particularly those having a silver-blue bar across the
top labeled with the alternate function.
Press + SHIFT to view displays/functions associated with the SHIFT key.

ASSIST
Figure 2-5 Shift Help Screen
2.11 Interlock Key INTER

LOCK
The INTERLOCK key is used in conjunction with keys labeled in blue and outlined
in bright orange.
INTER
Press + LOCK
to view displays/functions for the INTERLOCK key.
ASSIST
Figure 2-6 Interlock Help Screen

DX100 Pendant
2.12 Main Menu Key MAIN

MENU
The MAIN MENU key is used to display the top level menu choices on the left side
of the pendant screen. Pressing the MAIN MENU key toggles the display on and off.
MAIN
MENU
+ UP/DOWN CURSOR increases/decreases brightness.

DX100 Pendant Screen
3.0 DX100 PENDANT SCREEN

The initial DX100 pendant screen has five display areas. Four of these areas can be
made active either by touch or by the use of the Area key. Once active, (indicated
by blue background) the cursor can be moved to elements of the area either by touch
or by the cursor key. With the cursor on the element, the SELECT key can open the
element for change. The Status Area is for display only and cannot be an active area.
Menu area Status display area
Main menu area

General-purpose display area
Human interface
display area
Figure 3-1 Screen Areas
3.1 Main Menu Area

The Main Menu area contains the top level selections of display categories.
Availability of some Main Menu icons is dependant on the Security level.
Figure 3-2 Main Menu Area
The Main Menu icons may be concealed or re-displayed by toggling MAIN MENU
key, or by touching the screens Main Menu softkey.

Selecting an icon causes a Sub Menu to be displayed as a drop-down menu.

The Sub Menu selection is displayed in the General-Purpose display area.
Figure 3-3 Sub Menu Screen
NOTE: The extent of some Sub Menu choices differs based on Security Level.
3.2 General-Purpose Display Area

The General-Purpose area is where the content of the currently selected Main/Sub
Menu choice is displayed. Every screen shows a title-bar description.
Figure 3-4 Job List
To access a desired item from the General Display area, if a list of choices is shown,
use the Cursor key, then press the SELECT key.
To EDIT an item in the General Display area, cursor to highlight the element and
press SELECT.

For programming within a JOB CONTENT, the MOTION TYPE key or the
INFORM LIST key is used.
Figure 3-5 Job Content
NOTE: The figure above has the Main Menu concealed, thereby displaying the
General Display Area of the active JOB CONTENT across the entire screen.
3.3 Menu Area

The Menu Area at the top of the screen is a permanent display that changes according
to the active General Display on the screen.
The items and drop-down choices are accessible by touch or by using the AREA,
CURSOR, and SELECT keys.
Figure 3-6 Default Menu Area
The figure above is the default Menu Area for all cases of Main/Sub Menu selections
in the General Display Area except for jobs.
When a JOB CONTENT is displayed, the Menu Area has the selections as shown in
the figure below.
Figure 3-7 Job Content Menu Area

3.4 Human Interface Display Area

3.4.1 Edit Buffer Line
The Edit Buffer Line (white background) appears when a job content is displayed in
EDITING MODE or MANAGEMENT MODE. It is used for temporary
display and editing of the selected instruction prior to insertion into the job.
Figure 3-8 Edit Buffer Line [white background]
3.4.2 Message Line

Prompts for operating or editing are displayed on the Message Line with the
information icon; such as Turn on servo power .
An ERROR message, takes precedence over all other messages and must be
cleared by pressing the CANCEL key.
Multiple messages are indicated with the 2-page icon. Selecting the message area
and using the up/down cursor sequences the messages.
5/9
Cannot load macro job at current security mode
HELP
Cannot insert/modify/delete for group axis detachment
CLOSE
Cannot insert/modify/delete for axis detachment
Figure 3-9 Message Line with 2-page Icon
Any E-Stop Cautions, Robot is stopped by ... emergency stop takes priority
over information and question type messages. If a message is too long
to display on a single line, the screen automatically scrolls to the left, repeatedly
displaying the entire message.
NOTE: The message Encoder battery weak. will appear on the Message Line of the
Pendant display when the robot battery needs to be replaced. The message
Memory battery weak will appear on the Message Line of the Pendant
display when the DX100 controller battery needs to be replaced.
CAUTION! Do not turn off the DX100 controller until the appropriate battery has
been replaced!

3.5 Status Display

The Status Display shows the current controller condition and pendant settings.
The cursor cannot access this display; changes are made via the appropriate keys.
WARNING! The status line should always be referenced before operating the
system in TEACH. Always set (A) Control Group, (B) Coordinate System,
and (C) Manual Speed before jogging any component!
A. Group operation axis K. Saving Data

B. Operation coordinate system J. Weak battery
C. Manual speed I. Multi Mode
H. Page
G. Mode
F. State under execution
E. Operation cycle
D. Security mode
A. Control Group B. Coordinate Systems C. Manual Speed
: Joint Coordinates : Inching

to : Robot Axes
: Cartesian Coordinates
: Low Speed
to : Base Axes
: Cylindrical Coordinates
: Medium Speed
to : Station Axes : Tool Coordinates
: High Speed
: User Coordinates
D. Security Mode E. Operation Cycle F. State Under Execution
: Operation Mode : Step : Stop Status
: Hold Status
: Edit Mode : Cycle

: Emergency Stop Status
: Alarm Status
: Management Mode : Continuous
: Operating Status
G. Mode H. Page I. Multi-Window J. Weak Battery K. Busy!
: Teach mode
T
P : Play mode
Figure 3-10 Status Display Icons

NOTE: Do not interrupt the pendant when busy with the hour-glass status. Also, all
Errors and Alarms must be cleared before operation/programming is possible.

3.6 Main Menu Selections

The number of available icons in the MAIN MENU depends on the current Security
Level. With the MAIN MENU open, SECURITY settings are available under the
SYSTEM INFO selection.
The levels of SECURITY are as follows:
OPERATION MODE (no password ID number required)
EDITING MODE (4 to 8-digit ID number = 00000000 default)
MANAGEMENT MODE (4 to 8-digit ID number)
NOTE: The EDITING MODE security level is required in this training manual for
performing Modify Command Position in Section 8.0.
The Touch Screen MAIN MENU selections are as follows:

JOB
ARC WELDING or GENERAL or HANDLING or SPOT WELDING
VARIABLE
IN/OUT (Additional items in mode)
ROBOT (Additional items in mode)

SYSTEM INFO
EX. MEMORY (SAVE all levels; LOAD restrictions except in )
SETUP (Not Available in ; additional items in mode)

DISPLAY SETUP
NOTE: The MAIN MENU icons and the choices available will vary depending on the
SECURITY level, as well as Application.

3.6.1 Job
The JOB menu accesses selections for the active JOB, the MASTER JOB, the
SELECT JOB list, CYCLE Selection, as well as JOB CAPACITY.
In TEACH mode, the CREATE NEW JOB selection becomes available only when in
EDITING MODE or MANAGEMENT MODE.
3.6.2 Arc Welding, General, Handling, Spot Welding, Laser, Paint, etc.
The second Main Menu selection is labeled with the application for which the DX100
has been initialized. This menu provides access to application specific information.
3.6.3 Variable
The VARIABLE menu accesses the four kinds of Arithmetic variable files used for
number storage, the Position variable file(s) used for Robot (Station/Base) position
and shift data storage, and the String variable file for text storage.
3.6.4 In/Out
The IN/OUT menu offers access to the simple and detail monitor screens for viewing
I/O status and forcing Universal Outputs ON/OFF.
3.6.5 Robot
The ROBOT menu allows the display of the robots status including CURRENT
POSITION and SECOND HOME POS. Also, the function for setting TOOL data and
USER COORDINATE data is accessed through this menu.
3.6.6 System Info
The SYSTEM INFO menu provides SECURITY selection, VERSION information on
hardware and software, an ALARM HISTORY, and MONITORING TIME for power
on, servo on, job play, robot travel time, and device/tool operating time.
3.6.7 EX. MEMORY
The EX. MEMORY menu provides selections for functions using the external
memory device medium.
3.6.8 SETUP
The SETUP menu, available in at least Editing Mode, allows the user to customize
TEACHING CONDITION settings and other features involving the pendant
operation and editing shortcuts.
3.6.9 DISPLAY SETUP
The DISPLAY SETUP menu allows the user to customize the font size and icon size.
The Initialize layout will set the systems font back to the factory default. Also, seven
different Window Pattern selections for split screen viewing are available.

In the Main Menu area under the DISPLAY SETUP icon, the four options given
are as follows: CHANGE FONT, CHANGE BUTTON, WINDOW PATTERN, and
INITIALIZE LAYOUT.
The CHANGE FONT selection allows the user to customize the font style and size
within the General Purpose Display area. There are four different font sizes available,
from very large to very small.
Figure 3-11 Default Font Size Setting & Large Font Size
The CHANGE BUTTON selection allows the user to customize the font style and
size of the buttons within three areas: the Main Menu area, the Menu area, and
the Inform List area. This figure shows all three areas with the font enlarged and
boldfaced.
Figure 3-12 Pendant Buttons Displayed In Large Format
The INITIALIZE LAYOUT selection converts all font changes back to the initial
default status. This selection changes the screen layout back to standard (default) size.
CAUTION! Do not interrupt the pendant with other keystrokes until the hour-glass
symbol 6 disappears.

Multi-Window Function
The multi-window function divides the general-purpose display area from just 1
to 2, 3, or 4 windows to be shown simultaneously.
There are seven dividing patterns to be optionally chosen as desired.
Figure 3-13 Access to the Seven Different Window Patterns

The title of the active window is displayed in deep blue and the non-active are light
blue. The active window is the subject of key operation. Also, the menu area or the
operational buttons under the general-purpose displaying area are displayed for the
operation of only the active window.
LAYOUT
To toggle between Single/Multi Window, press SHIFT + keys.

Multi
Pressing just the [MULT] key while in Single-Window allows the previously set
Multi-Windows to appear individually as full screen in the order they were setup
(1g2g3g4g1).
NOTE: The content view of a window in multi-window mode may be different from the
same window when it is in single-window mode because of its limited size.
The content becomes normal when displayed in the single-window mode.
Edit buffer in JOB CONTENT displayed only when window is active.
No auxiliary window appears.

NOTES

Control Group & Jogging Coordinate
4.0 CONTROL GROUP & JOGGING COORDINATE

Before jogging any component of the system, set or verify the active Control Group
and a desired jogging coordinate with appropriate manual speed.
4.1 Control Groups

The DX100 system can be configured with multiple robots, station axes, and base
axes; therefore, for jog operations, the appropriate group of axes to be controlled
must be selected by the operator. The active selection is displayed in the status line.
ROBOT
4.1.1 ROBOT Key
The ROBOT selection is active by default at power ON. Pressing the ROBOT key
chooses the desired robot, R1 to R8. The jogging Axis keys on the Pendant are
labeled for both single motor/link operation of the robot with (+/-) [SLURBT], and
also for manipulating a robots tool control point, TCP, in (+/-) X, Y, Z and rotating
the tools posture with the (+/-) Rx, Ry, & Rz keys. Robots with more than 6 axes use
the E and 8 keys also.
EX.AXIS
4.1.2 EX. AXIS Key
Pressing the EX. AXIS key configures the axis keys to move the servo motors for
STATION axes S1 to S24 or BASE track axes B1 to B8. Typically, the setup uses the
first pair of keys, [-X/S] & [+X/S], for the first Station S1 axis or Base B1 track, the
second pair for S2 or B2, third for S3 or B3, etc.
NOTE: Pressing SHIFT+ ROBOT or SHIFT+ EX. AXIS is required when the desired
control group for jogging is not identified in the selected job.
Robot
Station
Base
Figure 4-1 Robot, Base, and Station Axes

4.2 Coordinates
The active Coordinate system, identified in the status line, determines how each of the
eight sets of multifunctional axis keys with + and - will operate. Four of the five
types are actively available on the COORD key. (Either RECT or CYL is SETUP on
the TEACHING CONDITION list.) The X, Y, Z, Rx, Ry, & Rz labels are active for
all jogging Coordinates except when set for Joint [SLURBT].
: Joint Coordinates [SLURBT]
: Robot Frame Rectangular Coordinates [RECT]
: Cylindrical Coordinates [CYL]
: Tool Frame Coordinates [Tool No.00-63]

TOOL SEL
63
COORD : User Frame Coordinates [UF#1-63]
U
Figure 4-2 Pendant COORD Key & Status Display Icons
4.2.1 Joint Coordinates
6-Axis Robot [SLURBT]

When in Joint coordinates, the letters S, L, U, R, B, T on the six pair of axis keys are
applicable, allowing the operator to move each motor/link in a positive or negative
direction. JOINT is the default coordinate system upon power up.
U-axis
Z+
U+
R-axis
X+
R+ B-axis
Y+
B+
T-axis
Z- Z+
U- X- T+
L-axis R- Y-
B-
Y-
L- Z-
T-
Y+
L+
S-axis
X- X+
S-
S+
Figure 4-3 Axis Keys and JOINT (S,L,U,R,B,T) Operation

NOTE: When two or more axis keys are pressed simultaneously, the robot will
perform a compound movement, but if two opposites are pressed at the same
time, such as [X-/S-] and [X+/S+], then neither operates.

7-Axis Robot [SLURBT & E]

When in Joint coordinates, the additional 7th Axis, E-Axis, can be jogged by pressing
the E- E+ keys.
U-axis Z+
U+
R-axis
X+
R+ B-axis
Y+
B+
T-axis
Z+
X- T+
Z- R-
U- Y-
B-
X- X+ X- X+ E-axis E- Z-
S- S+ R- R+ E+
T-
Y- Y+ Y- Y+ L-axis Y-
L- L+ B- B+ L-
Y+
Z- Z+ Z- Z+
L+
U- U+ T- T+ X-
S-axis S-
X+
S+
E- E+ 8- 8+
Figure 4-4 Axis Keys and JOINT (S,L,U,R,B,T, & E) Operation
4.2.2 Tool Selection for Jog Operation in XYZ type Coordinates

The robots currently selected TOOL No. is referred to as its Tool_Control_Point
[TCP]. The TCP is not only for recording or modifying points in a job, but also for
jogging in Rectangular or Cylindrical , Tool and User .
To set the active Tool No. 00-63, perform the following steps:
TOOL SEL
1. Choose any COORD except User Coordinates with the COORD COORD
key.
TOOL SEL
SHIFT COORD
2. Hold key, then press TOOL SELECT . Cursor to highlight the
desired Tool number. Repeat SHIFT + COORD/TOOL SELECT to close the list.
Figure 4-5 Tool Select List

4.2.3 Rectangular or Cylindrical , Tool and User

In all of the XYZ type coordinate systems, the axis keys labeled X, Y, Z control the
robots active Tool No.00-63 referred to as the Tool Control Point (TCP). The keys
labeled Rx, Ry, Rz change the tools posture or orientation while maintaining its
current position point.
RECT controls the active TCP in a straight line vector using

ROBOT FRAME(RF) with the XYZ axis keys operating as a
Right-Hand Rule front/back, left/right, up/down.
CYL controls the active TCP with Cylindrical/Radial jogging
when using the XY axis keys; the Z keys operates the same as
with RECT coordinate; up/down in the ROBOT FRAME(RF).
TOOL controls the active TCP (Tool No. 00-63) based on current
TOOL FRAME (TF). It is not a stationary coordinate system; the
XYZ origin floats with tools movement. The [Z+]/[Z-] setup for
operation is typically the direction of approach/departure, but is
application related.
USER moves TCP based on current selected USER FRAME

(UF#01-63) where the origin/plane in space are user defined.
Operation of the X, Y, and Z-axis keys with moves the active TCP as illustrated
in the figure below.
Y-axis Z-axis
X- X+ Z+
S- S+ U+
Y+
L+
Z-axis
X-axis Z-
U-
Y-axis Y-
L-
X-axis
X- X+ Moves parallel to X-axis.

S- S+
Y- Y+ Moves parallel to Y-axis.

L- L+
Z- Z+ Moves parallel to Z-axis.

U- U+
Figure 4-6 Operation of X, Y, & Z Axis Keys in RECT Coordinate.

When using Rectangular , Cylindrical , Tool or any User

Coordinates, pressing a rotate-about Rx, Ry, Rz axis key will change the tools
angle of orientation, but maintain the TCPs present position.
After jogging to an intended program position with X, Y, and Z keys, use the Rx, Ry,
and Rz keys to adjust the TCP to the desired posture before entering the motion step
into the job.
Wrist Axes Wrist axes move with the TCP
X- X+ fixed. These movements differ
R- R+ depending on cartesian,
cylindrical, tool and user
coordinates.
Y- Y+
B- B+
Z- Z+
T- T+
E -a x is * A va ila ble only for the ma nipula tor

E- E+ with seven axes
The posture of arm changes while
the position and posture of the tool
remain fixed. (The Re degree
changes.)
Figure 4-7 Rx, Ry, & Rz Axis Keys to Change Tools Angle of Orientation
The Cylindrical coordinates are, set as CYL, takes the place of access to RECT.
Operation of the X, Y, and Z-axis keys with moves the active TCP as illustrated
in the figure below.
Moves TCP in Radius Path of Cylinder
Y-
L-
Y-
L-
Y+
L+
S- S+
X- X+ Y+
L+
Y+, Radial Axis
Moves TCP in Circumference Path of Cylinder

Y+, Radial Axis
Z-axis
Z+
U+
Moves TCP parallel to Robot Frame Z-axis
Z-
U-
Figure 4-8 Operation of X, Y, & Z Keys in CYL Coordinates

To set either the RECT or CYL coordinate system, perform the

following keystrokes in TEACH mode EDITING Security level:
1. Verify the Main Menu is open.
2. Choose SETUP by touch or use the Cursor & SELECT keys.
3. Choose TEACHING COND by touch or use the Cursor & SELECT keys.
4. Cursor to highlight the RECT/CYL indicator box.
5. Press the SELECT key to toggle to CYL or RECT.
To close, choose another icon selection from the MAIN MENU.
Figure 4-9 Teach Condition RECTANGULAR or CYLINDRICAL Selection
4.2.4 Tool Coordinates

The TOOL coordinate system allows the jogging of the robots TCP based on the current
Tool No. Selection. The Cartesian X, Y, Z directions in Tool Frame [TF] are oriented to the
active TCP, and move with the tool.
Z-
U-
Z+
U+
X+
S+
X-
S-
Figure 4-10 Tool Coordinate XYZ Directional Jogging
The origin of the TF is always at the TCP. Therefore, the CURRENT POSITION can
never be expressed in the Tool Frame data type.

4.2.5 User Frames

A User Frame Coordinate is based on a user-defined origin for an XYZ frame aligned
parallel with a fixtures plane of work. Up to 63 User Frames can be defined. Selection is
by COORD key to choose User Coordinate, then SHIFT+COORD to display the list.
Z-axis
+

Y-axis

+ X-axis
+
User coordinates Fixture
Z-axis
Y-axis Fixture Fixture
X-axis
User coordinates
Figure 4-11 Example User Frame Coordinates
4.3 Manual Speed Icons & Keys

The Manual Speed determines the velocity at which the Axis keys or the FWD &
BACK keys will move the ROBOT or EX. AXIS.
4.3.1 MANUAL SPEED
The four speed settings, INCHING, LOW, MEDIUM, and HIGH, are selected by
using the MANUAL SPEED keys FAST and SLOW. The status line symbol indicates
the currently active speed setting.
: High Speed
FAST : Medium Speed

MANUAL SPEED
: Low Speed
SLOW
: Inching
Figure 4-12 Manual Speed Icons and Keys
When INCHING has been selected, each press of +/- S,L,U,R,B,T will move the
Robot/Station/Base motor one pulse count in JOINT coordinate system.
In all other coordinate systems the default setting for INCHING will move the
Robots TCP in the +/- X,Y,Z direction or rotate the tools posture with the +/- Rx, Ry,
Rz keys by an amount specified in the controller parameters.
NOTE: The Pendant defaults to LOW manual speed upon power-up.

HIGH
4.3.2 HIGH SPD Key SPEED
While using only a single axis key or only the FWD key, pressing and holding the
HIGH SPD key will momentarily override the L, M, or H manual speed setting with a
preset faster speed. Releasing the key defaults back to the selected manual speed.
NOTE: The HIGH SPD key will not override Inching manual speed, and it is not
functional with the BACK key.
4.4 Current Position

The CURRENT POSITION can be displayed in several formats. The robot position
in PULSE format is the default display in [SLURBT] for a 6-axis robot.
All External Axis data is expressed in PULSE for each motor.
Any robots active TCP location can be displayed in BASE [BF], ROBOT [RF], or
USER for UF#( ) as XYZ data type in millimeters from the origin and the Rx, Ry,
Rz in degrees of rotation.
To display the CURRENT POSITION, perform the following keystrokes:

1. Choose ROBOT from the Main Menu.
2. Choose CURRENT POSITION
3. Press SELECT and cursor to PULSE, BASE, ROBOT, or USER and
press SELECT again.
4. If USER is selected, then enter the frame number on the data line
(>User_coord_no.= ) and press ENTER.
Figure 4-13 Current Position

4.5 Command Position

When the jobs CONTROL GROUP is programmed to MOV_ to a point location,
this is termed a COMMAND POSITION. All COMMAND POSITION data in a
STANDARD JOB TYPE setup is expressed in PULSE for each External Axis motor,
and for each Robot link/motor.
To display the COMMAND POSITION for a step in a JOB CONTENT,

1. Put the cursor on the desired step and press the DIRECT OPEN key as shown
below:
DIRECT
OPEN
Figure 4-14 Direct Open Key/Command Position Screen
The left column displays the Robot COMMAND POSITION [CMD] for that step and
the right column displays the CURRENT POSITION [CURR] of the Robot.
2. Press the Direct Open key again to close the display.

NOTES

Alarms & Errors
5.0 ALARMS & ERRORS

ERROR messages appear in the Message Line at the bottom of the pendant screen.
All ALARM information appears in the General Display Area, and the icon indicating
alarm status appears on the status line. No further operation or editing is possible
until all ERROR/ALARM situations are cleared.
5.1 Error Message

An ERROR message occurs when a keystroke mistake has been made. An example
of a keystroke error is when pressing the START button while not being in PLAY
mode. This would cause the following ERROR message:
Figure 5-1 Example Error Message
CANCEL
The ERROR message is cleared by pressing the key.
5.2 Minor Alarms

Minor Alarms usually indicate a jogging problem or programming mistake that
requests the controller to perform tasks it is not capable of performing. The four-digit
alarm code and description appear in the General Display area. Minor Alarm codes
begin with 4xxx through 8xxx and also 9xxx for Application/User type.
Job execution is stopped, but Servo Power remains ON. Minor Alarms are cleared
by touching the RESET softkey on the pendant screen. The cause of any minor alarm
should be fixed immediately to avoid reoccurrence.
Figure 5-2 Minor Alarm Example

NOTE: An additional procedure, Check Position, is required after a RESET for
ALARM 4107: ABSO DATA OUT OF RANGE.

Alarms & Errors
5.3 SECOND HOME (Specified Point)

If the controller determines there is a significant difference in encoder data (pulse)
between power off and power on, it will generate the minor alarm ALARM:4107
OUT OF RANGE (ABSO DATA).
Figure 5-3 Out of Range Absolute Data
After touching the alarm RESET, attempting to turn the servo power ON will prompt
with the message Check Position.
Checking position involves forwarding the robot to SECOND HOME, ensuring the
robot is at the proper position, and performing a DATA CONFIRM POSITION.
Attempting to play a job without confirming the position check will result in the
ERROR message shown below.
Figure 5-4 Position Not Checked
CAUTION! An error in the pulse generator (PG) system can cause an alarm. If PG
failure is suspected, then do not FWD until checking each suspected
axis separately by jogging + and - in JOINT coordinates to confirm valid
operation.
Alarms brought about by a crash may have caused damage to the

drive(s). Verify smooth drive operation prior to continuing.

Alarms & Errors
To Check Position at SECOND HOME (Specified Point), perform the

following steps:
1. Touch RESET to clear the alarm screen.

2. In TEACH mode, press the SERVO ON/READY button.
3. From MAIN MENU, choose ROBOT, then choose SECOND HOME POS.
This displays a data screen with columns as shown in the figure.
Figure 5-5 Second Home Position Display (Specified Point)
CAUTION! The operation below may cause a crash when the FWD key is pressed if
there are obstacles between the robots current position and the Second
Home position. Jog the robot, as necessary, to avoid any obstacles.
NOTE: The default SECOND HOME (Specified Point) location for the robot is where
the alignment arrows and keyways for each axis are aligned and the Pulse
data for each axis is displayed as all zeros.
4. Turn Servos ON with the ENABLE switch. The Message Line should indicate
Check Position. (If ALARM:4511 DROP VALUE appears, simply touch
RESET and continue.)
5. Ensure a clear path, select an appropriate Manual Speed, then press and hold
the FWD key to move the robot to the Second Home position. The data display
changes to all zeros in the DIFFERENCE column.
6. Visually verify that the robot is at the Second Home position.
NOTE: If the robot does NOT appear to be at the proper location, maintenance on the
robot may be required.
7. Choose DATA from the Menu Area.
8. Choose CONFIRM POSITION by touch or press SELECT. The message line
will display Home position checked.

Alarms & Errors
5.4 Internal Shock Sensor / Collision Detection

The DX100 controlled robot has an internal shock sensor system of Collision
Detection that can protect both the tool and the robot arm during an impact by
monitoring the torque of the servomotors. If the torque exceeds a specified value, the
Alarm:4315 COLLISION DETECT will be generated. This is often caused by the
tool or robot arm coming in contact with a part of fixture, also known as a crash.
The Alarm screen will show highlighted axes for which collision was detected.
Figure 5-6 ALARM 4315: COLLISION DETECT

This Internal Shock Sensor function is based on the DETECTION LEVEL setting in
the Shock Sensor Condition File that is currently being used.
The procedure of setting the detection INVALID may be required to be able to
move away from the site of collision as follows:
1. With the controller in TEACH, from MAIN MENU, choose ROBOT.
2. Choose SHOCK SENS LEVEL.
3. Press PAGE in the General Display Area, enter 9 and press ENTER.
(The COND. NO.:9 file is for TEACH only).
Figure 5-7 Shock Sensor Display

Alarms & Errors
4. Cursor to VALID and press SELECT, changing the function to INVALID.
Figure 5-8 Shock Sensor - Invalid
CAUTION! Servo power can now be applied as the controller overlooks the motor
torque values. The Internal Shock Sensor is temporarily disabled while
set to INVALID.
5. Choose the desired COORD and jog the robot in LOW manual speed until clear
of all interfering objects.
6. Restore the VALID setting by selecting on INVALID.
Shock Sensor Detection may be set in both PLAY and TEACH. Setting any one of
the 9 Condition Files to INVALID will make all of the files INVALID.
The default COND NO.:8 (STANDARD) for PLAY may not be appropriate for all
jobs or sections in a job.
The SHKSET SSL#( ) instruction under OTHER on the Inform List allows use of
Files 1-7, which may be setup with different Detection Level settings.
The SHKRST instruction will reactivate the PLAY default COND NO.:8
(STANDARD).
NOTE: The Detection Level setting can only be changed in Management Mode
DETECT LEVEL range is 1- 500.

Alarms & Errors
5.5 Overrun & Shock Sensor Action

The OVERRUN switch is located on the robots S-axis. Jogging the robot past this
switch could cause damage to the internal harnesses. Opening this switch causes
ALARM: 4100 OVERRUN IN ROBOT AXIS.
In some robot installations, there is a device called a shock sensor mounted

between the robot flange and the tool. This device helps protect the robot/tool from
damage in the event of a crash. Crashing the tool causes loss of signal from this
device to the DX100 controller. The ALARM: 4110 SHOCK SENSOR ACTION
will be displayed on the teach pendant screen.
NOTE: The SHOCK SENSOR STOP COMMAND default setting is E-STOP.
In Editing or Management Security Level, this can be set to HOLD.
To perform Overrun or Shock Sensor recovery, perform the following:

1. From MAIN MENU, choose ROBOT, or use cursor keys and SELECT key.
2. Choose OVERRUN&S-SENSOR.
Shown below are examples of the OVERRUN&S-SENSOR screens.
Figure 5-9 Overrun and Shock Sensor
NOTE: This selection is only available in the Editing and Management modes.
3. Choose RELEASE. This temporarily deactivates the trigger for the sensor.
4. Choose RESET. This clears the ALARM condition and Status Display icon.
Servo Power may now be turned on in the TEACH mode only. The robot may be
jogged in any coordinate system .
NOTE: The RELEASE is only in effect when this screen is displayed. If the screen is
changed to any other prior to the Shock Sensor being reset, the controller will
return to an Alarm condition and E-Stop the robot.

Alarms & Errors
5.6 Major Alarm

A Major Alarm may occur because of equipment failure or what the controller
considers a potential failure during operation. Any hardware failures will require
repair or replacement of the affected components. The four-digit alarm code
1xxx, 2xxx, or 3xxx. and its text description appear in the General Display area.
Servo power turns OFF. A Major Alarm can only be cleared by cycling the DX100
controller power OFF/ON.
NOTE: An Off-line Alarm occurs during initial diagnostics upon detection of a failure
that requires a maintenance procedure. These four-digit alarm codes that
begin with a 0xxx cannot be cleared by simply cycling the DX100 controller
power.
Figure 5-10 Major Alarm Example
5.7 Multiple Alarms

It is also possible for several alarms to appear simultaneously as shown in the figure
below. Multiple alarms are displayed in order of occurrence. If any of the multiple
alarms are Major Alarms, the controller must be powered down to resolve these
Major Alarms.
Figure 5-11 Multiple Alarm Screen Example

Alarms & Errors
5.8 Displaying Alarm History

The Pendant keeps a log of the last 100 alarms of each type: Major Alarms,
Minor Alarms, User Alarms (System), User Alarms (User), and Off-Line Alarms.
It also displays the login name of the user logged-on when the alarm occurred if
individualized security levels are used.
To display the history of ALARMS, perform the following keystrokes:
1. From MAIN MENU, choose SYSTEM INFO.
2. Choose ALARM HISTORY.
3. Use PAGE key for next Alarm type; SHIFT + PAGE for previous page.
4. Move the cursor to choose a specific alarm. Details for this alarm will appear at
the bottom of the screen display.
NOTE: Errors are not registered in the pendants ALARM HISTORY display.
Figure 5-12 Alarm History

Alarms & Errors
5.9 Alarm Display

It is possible for a current Alarm not to be displayed on the screen if the display has
been changed before RESET has been selected for a Minor Alarm. The controller is
still locked from the alarm occurrence with the indicator icon on the status line.
An attempt to restore Servo Power ON may re-display the minor alarm, or it may also
be accessed in the menu as described below.
To re-display the Minor Alarm for access to RESET, perform the following:
1. From MAIN MENU, touch SYSTEM INFO, or cursor and press SELECT.
2. Touch ALARM, or use cursor keys and SELECT key.
Figure 5-13 Alarm Display

Alarms & Errors
NOTES

Selecting a Job
6.0 SELECTING A JOB

6.1 Selecting A Job
All job names appear on the JOB LIST from the SELECT JOB menu. Any job can be
selected while in TEACH mode. In PLAY mode, any job can be selected if a job is
not currently running.
NOTE: Another job cannot be selected during program execution in Play mode.
To bring an existing job to the screen in Teach or Play mode, if a job is not
currently running, use the following keystrokes:
1. From MAIN MENU, choose JOB.
2. Choose SELECT JOB to access the JOB LIST.
3. Cursor to the name of the desired job and press SELECT.
Figure 6-1 Job List
6.2 Displaying the Active Job

When the screen display has been changed to something other than the active job,
there is only one way to get this active JOB CONTENT back on the screen.
NOTE: Only the Active Job can be accessed during program execution in Play mode.
(Start Lamp ON and Status icon displayed for Running.)
To return to the active JOB CONTENT, perform the following:

1. From MAIN MENU, choose the JOB icon.
2. Choose JOB. The currently active job will appear on the screen.

Selecting a Job
Figure 6-2 Active Job Selection
6.3 Master Job Call

Only one job name can be registered as the Master Job in a standard configuration.
Access this job with Call Master Job selection from the JOB menu. Do not change
the Master Job registration without permission from supervisory personnel.
To call the Master Job to the screen in Teach or Play mode from the Main Menu,
perform the following:
1. From MAIN MENU, choose JOB.
2. Choose MASTER JOB and press SELECT.
3. With the cursor on CALL MASTER JOB, press SELECT.
NOTE: The Master Job cannot be called when the START light is on during program
execution in PLAY mode.
NOTE: When in a Job Content, the JOB selection in the MENU Area also has
choices for Creating Jobs, Selecting Jobs, Calling the Master Job, etc.
Figure 6-3 Call Master Job from Menu Area

Robot/TCP Path
7.0 ROBOT & TOOL PATH

Robot/Tool path is not based on the jogging coordinate system when the controller is
playing a job. The path is based on job instructions. There are 4 different types of
motion instructions that command Robot/ Tool Control Point to a destination.
7.1 Motion Types

The four standard motion type instructions are as follows:
MOVJ Joint motion controls only the robot by running each
motor, SLURBT, to the Command Position of the step.
The path of the TCP is not controlled.
MOVL Linear motion moves the active TCP in a straight line as
it moves the robot to the Command Position of the step.
MOVC Circular motion moves the TCP in a circular arc requiring
at least three MOVC steps, or four to complete full circle.
MOVS Spline motion moves the TCP in a parabolic path through
at least three MOVS steps, or follows a free curve
through a string of multiple MOVS steps.
The figure below illustrates a sample JOB CONTENT that includes MOVJ for
approach/departure points and a MOVL as the linear application move.
The first/last positions (L:0001 & L:0006) are at the same start/end location.
LINE INSTRUCTION
0000 NOP
0001 MOVJ VJ=0.78
0002 MOVJ VJ=100.00
0003 MOVJ VJ=25.00
0004 MOVL V=276
0005 MOVJ VJ=50.00
0006 MOVJ VJ=100.00
0007 END
Figure 7-1 Job Path with Linear Motion Step

Robot/TCP Path
7.2 Robot/TCP Speeds

The motion instruction may express velocity with one of three speed tags in order to
tell the controller how fast to move the robot or active TCP.
The MOVJ VJ=Joint_speed tag for velocity of the joints is expressed as a percent.
The MOVL, MOVC, and MOVS may have either a V=Control_point_speed for
velocity of the TCP or a VR=Angle_speed for velocity of rotation of the TCP.
7.3 Command Position

The position where the controller moves the robot is called the Command Position
because the controller is commanding the robot to move to a point. Figure 7-1
shows a cursor resting on 0001. This number is called the Line Number. Every
instruction has a Line Number. However, if enable for display, the Step number is
only assigned to MOV_ instrucitons.
Address Side Instruction Side
Line number
Step number
Figure 7-2 Address Line/Step Numbers

When the cursor is resting on a motion instruction, the instruction may be blinking
when servos are on. The controller is comparing the Command Position to the robots
current position. If the robot is not at the Command Position, the cursor blinks.
When the robot is at the Command Position, the cursor is not blinking.
7.4 Moving to a Command Position

With the cursor on a MOV_ instruction, the robot can be forwarded at the Manual
Speed to the Command Position by pressing and holding the FWD key If the robot
will collide with an obstruction, use the jogging keys with the appropriate Coordinate
System to move around the obstacle, then continue using the FWD key.
CAUTION! The robot will Forward (FWD) directly to the cursored Command
Position with the motion type (MOV_) of the cursored step. Care should
be taken to place the cursor on the correct line. Always ensure a clear
path when moving the robot.

Robot/TCP Path
7.5 Job Path Confirmation

Prior to running a program in PLAY mode with full playback speed, the TEACH
mode provides two methods to check positions and path interpolation.
The first method, using the FWD and BACK keys allows step-by-step execution.
The second method, INTERLOCK + TEST START, uses continuous operation.
FWD BACK
7.5.1 Method 1: Confirmation by and Keys
Robot motion will be executed only while the FWD key (or BACK key) is pressed;
releasing the key will stop robot motion. [Manual Speed selection L, M, or H]
FAST
MANUAL SPEED
SLOW
Backward & Forward

INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

LIST
EX.AXIS
ON/OFF
MOTION 0 . -
AUX MODIFY ENTER
TYPE
Figure 7-3 Position and Path Confirmation
To perform Position/Path confirmation with FWD key, perform the following:

1. Cursor to the first step in the job and verify that there is a clear path to this
command position from where the robot is currently positioned.
2. Choose manual speed setting: : Low Speed : Medium Speed : High Speed
3. With Servos enabled, press and hold the FWD key. The robot will move to the
step and cease motion; the cursor will no longer be flashing.
4. Release, then press and hold the FWD key again to advance the cursor and move
the robot through each successive step.
NOTE: Regarding non-motion, either cursor past instructions that do not need to
be executed, or use INTERLOCK+FWD keys with servos on to execute any
desired/necessary non-motion instructions.
CAUTION! Do not use the cursor key to move the cursor to next/previous step
when performing path confirmation with FWD/BACK; otherwise each
step will be treated as an isolated Motion Type.

Robot/TCP Path
INTER TEST
7.5.2 Method 2: Confirmation with LOCK + START
This method allows the robot to act as if it were in the playback mode, but with speed
limitation. Also, DEVICE instructions such as ARCON, GUNON, or LASERON are
prohibited. (HAND ON/OFF is not restricted.)
The cycle selection is active during the TEST START program execution, therefore
the single CYCLE setting is recommended.
Motion steps recorded with speed tags greater than the limit, 25% of
maximum, will be executed as follows:
MOVJ VJ=25.00
MOVL or MOVC or MOVS V=375.0 mm/sec (2250 cm/min, 886 in/min)
MOVL or MOVC VR=90.0 deg/sec.
Interlock + Test Start
INTER 7 8 9 TEST
SHIFT
SHIFT
LOCK START

LIST
EX.AXIS
ON/OFF
MOTION 0 . -
AUX MODIFY ENTER
TYPE
Figure 7-4 Interlock and Test Start Keys
To use the Interlock + Test Start method, perform the following procedure:
1. Touch EDIT, then TOP LINE to move the cursor to L: 0000 NOP.
2. Enable the Servos.
3. While pressing the INTERLOCK key, press and hold the TEST START key.
(The INTERLOCK key may be released once the robot is in motion.)
The START button on the pendant will light and the robot will move continuously
through all steps of the programmed path.
Release the TEST START key or Servo Enable switch to interrupt/stop the program
execution.
NOTE: Some systems allow INTERLOCK to be held while TEST START is released.

Robot/TCP Path
7.6 Job Cycle Selection

The three cycle selections are STEP, CYCLE, and AUTO. The current selection, as
indicated on the pendant Status Display Line, effects not only PLAY mode, but also
TEACH using INTERLOCK + TEST START.
NOTE: Cycle selection is accessible from both TEACH or PLAY mode.
STEP
The controller will execute only the one line on which the cursor is
located in the selected job each time the START button is pressed.
Tool Device instructions are not executed.
CYCLE
The controller will execute the selected job one time from the cursor
location to the END statement of that job when START button is pressed.
AUTO
The controller will execute the selected job repetitively beginning from
the cursor location when the START button is pressed.
NOTE: The cycle setting may be changed at any time during PLAY mode. To stop at
the END instruction of a job running in AUTO, change to the CYCLE setting.
To select the desired cycle, perform the following keystrokes:

1. From MAIN MENU choose JOB.
2. Choose CYCLE from the sub menu.
Figure 7-5 Cycle Selection
3. With the cursor on WORK SELECT, press SELECT.

4. Cursor to the desired Cycle, and press SELECT.

Robot/TCP Path
7.7 Playing A Job

Job Selection can be performed in Play Mode only if a job is not currently running.
Cycle selection, however, can be changed at any time regardless of mode or status.
To play a job, perform the following steps:
1. Select a job and verify where the cursor will begin execution of the job NOP.
2. Switch from TEACH to PLAY with the Mode Selector Switch.
3. Press the SERVO ON/READY button.
4. Choose AUTO, CYCLE, or STEP cycle selections. Verify desired icon in the
Status Display.
5. Press the START button to initiate job execution.
NOTE: If a job is running in AUTO cycle, select CYCLE setting in order to stop
execution at the END instruction of the job.

Modify Command Position
8.0 MODIFY COMMAND POSITION

To Modify the Command Positions in a job, the Pendant must be in at least Editing
Mode Security Level. Also, if the JOB HEADER has Edit-Lock:ON, then the
Teaching Condition for STEP ONLY CHANGING must be set to PERMIT.
8.1 Editing Mode Security Level

The DX100 Controller must in at least EDITING MODE to modify positions in a job.
The key icon in the Status Area indicates the current security level.
The Operation and Editing icons are as follows:
OPERATION MODE (no password ID number required)
EDITING MODE (4 to 8-digit ID number = 00000000 default)

Figure 8-1 Security Level Icons for Operation & Editing
NOTE: No password is necessary to change to a lower level of security.
To change the Security level setting to EDITING, complete the following steps:
1. From MAIN MENU, choose SYSTEM INFO.
2. Choose SECURITY.
3. With the cursor on the current MODE; press SELECT. Cursor to EDITING, and
press SELECT.
4. Enter the password (default=00000000) using the number keypad; press ENTER.
8.2 EDIT LOCK:ON/OFF Job Protection

The software job protection feature, EDIT LOCK: ON/OFF, is set within each
individual JOB HEADER in Management Mode only.
Figure 8-2 Job Header Display
DX Operstors Training Manual Page 8-1 MOTOMAN

To display a JOB HEADER, from the desired JOB CONTENT, complete the
following keystrokes:
1. In TEACH mode from JOB CONTENT, choose DISPLAY in the Menu Area.
2. Choose JOB HEADER.
If the JOB HEADER displays Edit Lock:OFF, then it can be fully edited in the
Editing Security level.
If it is set for Edit Lock:ON, then only the servo COMMAND POSITIONS can
be modified in Editing Mode provided the Teaching Condition for STEP ONLY
CHANGING is set for PERMIT.
NOTE: To return to the Job Content, touch DISPLAY in the Menu Area, and choose
JOB CONTENT.
8.3 STEP ONLY CHANGING for EDIT LOCK Jobs

The Teaching Condition STEP ONLY CHANGING: PERMIT allows the editor to
MODIFY only existing servo COMMAND POSITION steps in Edit Protected jobs.
Setting this condition to PROHIBIT fully protects the locked job.
Figure 8-3 Teaching Condition List
To set STEP ONLY CHANGING to allow MODIFY for Command Positions,

complete the following keystrokes in at least EDITING Security level:
1. In TEACH mode from MAIN MENU, choose SETUP.
2. Choose TEACHING CONDITION.
3. Cursor to the item line for STEP ONLY CHANGING.
4. Press SELECT to toggle between PERMIT or PROHIBIT.
NOTE: The setting will remain until changed by the editor. The PROHIBIT setting
provides full edit protection for all EDIT LOCK:ON jobs, the PERMIT setting
allows position modifications for servo captured COMMAND POSITIONS only.

8.4 Modify Command Position

The cursor must be on the Address side of the Job Content to use the MODIFY key.
The key is next to the ENTER key, and has an L.E.D. to indicate its active status.
Address Side Instruction Side
TEST
SHIFT
START
BWD FWD
DELETE INSERT
Line number ENTER

MODIFY
Step number
Figure 8-4 Address Side of Job Content and MODIFY/ENTER Keys
NOTE: The Address Side may include each Step number next to the Line number
address by activating the ENABLE STEP NO under the DISPLAY menu.
Using the MODIFY key ON, with servos enabled, allows only the COMMAND
POSITION for a motion step address to be recaptured with the ENTER Key
(The Instruction Side information does not change.)
To MODIFY the Command Position of a motion step, perform the following:
1. In TEACH mode, select the JOB CONTENT to be edited, and cursor to the
Address Side of the line/step be modified.
2. Ensure a clear path; Forward to the original Command Position (until cursor
stops blinking). This helps to confirm the correct address and also the need for it
to be modified.
TEST
3. If multiple
START tools are in use, choose the appropriate Tool No. 00-63 using
SHIFT
SHIFT+COORD for opening/closing the list.

BWD FWD
TEST
4. Jog the Robot/TCP to START
the new desired position.
SHIFT
(The cursor
DELETE
will
INSERT
now be blinking.)
BWD FWD
MODIFY ENTER
5. Press ; confirm that theINSERT
DELETE
LED on the key is ON.
MODIFY ENTER
6. With servos enabled, press . (The cursor will stop blinking.)
NOTE: The Pendant beeps when the cursor stops blinking as confirmation that the
position data was accepted for that motion step address.
CAUTION! Before running the job in PLAY mode, always confirm the edited path
by first using FWD/BACK with desired Manual Speed, and secondly by
using INTERLOCK+TEST START.
DX Operstors Training Manual Page 8-3 MOTOMAN

NOTES

Non-motion Instructions
9.0 NON-MOTION INSTRUCTIONS

The Control instructions, such as CALL/RET, JUMP/LABEL PAUSE and TIMER,
are used to control sequencing within a job or multiple jobs. The Digital Output
instruction, DOUT, is used to operate a Universal Output. The WAIT instruction is
used to ensure proper I/O status exists before allowing the program to continue.
9.1 CALL and RET

The CALL instruction allows one job to open another as a subroutine. The job doing
the calling is referred to as the parent job. The job being called is referred to as a
child job in which an optional return RET instruction or the END completes that
child job. The controller will resume execution of the parent job with the next line of
instruction beneath the corresponding CALL instruction.
Figure 9-1 Linking Jobs Using CALL

NOTE: The FWD/BACK keys do not execute non-motion instructions. The CALL
can be executed while in TEACH by using INTERLOCK + FWD to execute
one line, or by using INTERLOCK + TEST START for continuous operation.
Also, the Direct Open key can access the child Job Content.
CAUTION! If the called job is also a motion job, care should be taken when
modifying points to ensure a clear path to and from each child job.

9.1.1 Direct Open

Pressing the DIRECT OPEN key on while the cursor is highlighting the Address or
the Instruction line of a first level CALL JOB:(child name) will open its Job Content.
Figure 9-2 Displaying a child Job Using Direct Open

Pressing DIRECT OPEN again to turn the key off will close the child job display
and return to the parent Job Content. Nested child jobs of 2nd-12th level cannot be
direct opened unless within the Job Content of its immediate parent.
NOTE: While in the DIRECT OPEN Job Content, the child job can be edited. Also,
the FWD/BACK and INTERLOCK+TEST START functions can be operated.
9.1.2 Use of the RET Instruction

The optional return RET instruction is used to have the controller terminate or close
the child job prior to the child jobs END.
In the following parent/child job sample, if the conditional is true, the child job will
terminate when Line L:0003 is executed and then resume execution of the parent job
at Line L:0004. If the conditional is false, the child job will continue execution to its
END, and then return to the parent to resume.
PARENT CHILD
J:ABC J:123
0000 NOP 0000 NOP
0001 MOVJ VJ=50.00 0001 MOVL V=276
0002 MOVJ VJ=6.25 0002 MOVL V=276
0003 CALL JOB:123 0003 RET IF IN#(1)=ON
0004 MOVJ VJ=25.00 0004 MOVL V=276
0005 MOVJ VJ=100.00 0005 MOVL V=276
0006 END 0006 END
Figure 9-3 RET Instruction in Called Child Job

9.2 JUMP*LABEL and *LABEL

The JUMP *LABEL instruction works only with the *LABEL instruction.
Together they instruct the controller to go from the line of the JUMP*LABEL to the
matching *LABEL within the same job and resume execution on the next line.
The JUMP*LABEL can be used in combination with *LABEL to omit a portion of

lines in the job or to create a repeat loop.
NOTE: The label automatically includes the asterisk (). The programmer can
redefine the default characters, LABEL, with 1 to 8 characters using any
combination of upper or lowercase letters, numbers, and symbols.
9.2.1 JUMP to Skip/Omit Lines

To skip a section of lines, the JUMP*LABEL must precede its matching *LABEL.
In the following job sample, the controller will jump over lines L:0006, L:0007, and
L:0008, and search for the matching label on L:0009, then resume execution with the
instruction on L:0010 (only if the conditional is true); otherwise, the controller will
execute all lines in between.
0000 NOP
0001 MOVJ VJ=0.78
0002 MOVJ VJ=100.00
0003 MOVJ VJ=25.00 PL=0
0004 MOVL V=675
0005 JUMP *LABEL1 IF IN#(4) = ON
0006 MOVL V=675
0007 MOVL V=675
0008 MOVL V=675
0009 *LABEL1
0010 MOVL V=675
0011 MOVJ VJ=25.00
0012 MOVJ VJ=100.00
0013 END
Figure 9-4 Jump to Omit Lines
CAUTION! Ensure a clear path from the last step preceding the JUMP *LABEL to
the next step after the corresponding *LABEL.

9.2.2 JUMP to Create a Repeat Loop

To create a repeat loop, the *LABEL must precede the JUMP*LABEL instruction.
In the following job sample, the controller will initially ignore the *LABEL on
L:0005 until it reaches the corresponding JUMP *LABEL instruction on L:0011.
The job execution will then repeatedly loop back to perform Lines L:0006 through
L:0010 if the conditional is true upon each execution of L:0011.
If the condition upon execution of L:0011 is not true, the controller will continue with
the next line after the JUMP, in this case L:0012.
0000 NOP
0001 MOVJ VJ=0.78
0002 SET B001 3
0003 MOVJ VJ=100.00
0004 MOVJ VJ=25.00
0005 *LABEL
0006 MOVC V=725
0007 MOVC V=725
0008 MOVC V=725
0009 MOVC V=725
0010 DEC B001
0011 JUMP *LABEL IF B001 > 0
0012 MOVJ VJ=25.00
0013 MOVJ VJ=100.00
0014 END
Figure 9-5 Jump to Repeat Lines
9.2.3 Use of the *LABEL Instruction

A matching *LABEL instruction must be defined in a program when a paired
JUMP *LABEL instruction is used in reference to it. The Label characters must be
exactly the same as the Label name specified in the corresponding JUMP *LABEL.
9.3 JUMP JOB

The JUMP JOB:(name) instruction is used to abort the currently active job and begin
execution of an entirely different job. The controller will not return to the original job
after jumping to another job unless nested in other called jobs.
9.4 TIMER
The TIMER instruction causes a delay in execution of the job until the designated
time expires. The cursor remains on this instruction line while the controller executes
the TIMER. The TIMER instruction is used when the robot needs to remain at a
certain position for some length of time, such as establishing an arc, gripping, nozzle
cleaning, etc.
The TIMERs range is 0.01 to 655.35 seconds.

9.5 PAUSE
The Pause instruction is used whenever a programmed hold is required to suspend
execution of the job. The start lamp turns OFF, and the robot maintains its position.
The message line displays
To resume, press the START button.
9.6 IF Conditional Tag

The IF condition tag is a CONTROL construct to execute the instruction only if a
single condition has been met. It can be added to the Edit Buffer Line for a new
instruction from the address side, or it may be added to an existing line from the
instruction side.
The IF can only be used on the CONTROL instructions as listed below:

JUMP
CALL
RET
PAUSE
The conditional options available for use with the IF tag are as follows:
IN# - check status of an Input (ON or OFF)
IG# - check status of Input group (= or <>; 0 to 255)
Var - compare variable value (=, <>, >, >=, <, or <=)
The job below shows use for IF conditional tag with various CONTROL instructions.
0000 NOP
0001 CALL JOB:START
0002 CALL JOB:A IF IN#(1) = ON
0003 CALL JOB:B IF IN#(2) = ON
0004 JUMP*LABEL1 IF IG#(1) = 0
0005 SET B004 2
0006 *LABEL2
0007 MOVL V=558
0008 MOVL V=558
0009 MOVL V=558
0010 DEC B004
0011 JUMP *LABEL2 IF B004 > 0
0012 MOVL V=558
0013 *LABEL1
0014 MOVJ VJ=25.00
0015 MOVJ VJ=100.00
0016 PAUSE IF IN#(7) = OFF
0017 END
Figure 9-6 Job Sample with IF Conditional Tags

9.7 Monitoring Variables

Whenever any data is not expressed as a CONSTANT value, an appropriate type of
VARIABLE address is used to store and reference for current content data that may
vary during job execution.
The DX100 controller has the following types of Variable files:

ARITHMETIC [Byte, Integer, Double Precision, and Real]
POSITION [Robot, Station, Base]
STRING [ASCII Characters]
Global Variable files are available to all jobs so that any information stored from one
job may be used by another.
9.7.1 Display Variable Files
To display a variable file and view the content value in any variable address,
(regardless of TEACH or PLAY mode), perform the following steps:
1. From MAIN MENU, choose VARIABLE.
2. Choose the variable type.
3. Cursor to locate the appropriate variable address.
or
With the cursor on any variable address, press SELECT, enter
the desired address number from the keypad, and press ENTER.
9.7.2 Instructions with Variables

Example Job instructions that are programmed with B, I, D, and R type Variables are
the ARITH menu choices such as INC for counting up by one, or DEC for counting
down by one.
Instructions that use the Position type Variables involve motion with any MOV_;
incremental/relative motion with IMOV; or shift instructions with SFTON/SFTOF.
The String type variables can be used with the Comment/MSG instruction.
Examples:
0021 MOVL P005 V=2500
0022 SFTON P107 UF#(3)
0023 MOVJ VJ=50.00
0024 MOVL V=375 PL=0
0025 MOVJ VJ=75.00
0026 SFTOF
0027 MOVJ VJ=100.00
0028 INC D007
0029 END

9.8 Monitoring Universal Inputs & Outputs

It is possible to monitor the status and/or determine the name description of all
Universal Inputs and Universal Outputs whether in TEACH mode or PLAY mode.
NOTE: The I/O Monitor screens for Universal Inputs/Outputs offer two different
displays. The DETAIL display shows a single group with name and status.
The SIMPLE display shows multiple groups with only the Byte/Bit indicators.
9.8.1 Monitoring Universal Inputs
To access the Universal Input display screen, use the following keystrokes:
1. From MAIN MENU, choose IN/OUT.
2. Choose UNIVERSAL INPUT.
3. To change the display, choose DISPLAY in the Menu Area.
4. Choose DETAIL or SIMPLE.
Figure 9-7 Universal Input Detail and Simple Displays
To search for a specific Input number from the DETAIL display screen:
1. In the DETAIL display, put the cursor on any IN# ( ) and press SELECT.
2. Enter the desired Input number and press ENTER.
NOTE: There are 256 Universal Input Groups available on the DX100 controller.
Individually they are numbered IN#(1) through IN#(2048).

9.8.2 Monitoring Universal Outputs
To monitor Universal Outputs, use the following keystrokes:

1. From MAIN MENU, choose IN/OUT.
2. Choose UNIVERSAL OUTPUT.
3. To change the display, choose DISPLAY in the Menu Area.
4. Choose DETAIL or SIMPLE.
To search for a specific Output number from the DETAIL Display screen:
Place the cursor on any OT#( ), press SELECT, enter the desired number and
press ENTER.
or
Choose EDIT in the Menu Area, choose SEARCH SIGNAL NO. Enter the
Output number and press ENTER.
The DETAIL Output screen allows Universal Outputs to be forced ON/OFF.
Figure 9-8 Universal Output Detail Display
To force an Output ON/OFF, perform the following in TEACH mode:

1. Cursor to the status symbol [] for the Output to be changed.
2. Hold the INTERLOCK key and press SELECT to toggle the Output status
between [] ON and [] OFF.
NOTE: There are 256 Universal Output Groups available on the DX100 controller.
Individually they are numbered OT#(1) through OT#(2048).

9.9 Binary Status and I/O Groups

The two states of a Digital I/O signal are either [] ON =1 or [] OFF =0.
The 8-bits of an I/O group are looked at as a full byte with a Binary value.
This can be converted to a Decimal value.
The status of the entire Sample group in the table below is 128+16=144.
Table 9-1 8-Bit Place Values in Binary
IN#/OT# (8) (7) (6) (5) (4) (3) (2) (1)
Binary place value 27 26 25 24 23 22 21 20
Decimal value 128 64 32 16 8 4 2 1
Sample ON/OFF 1 0 0 1 0 0 0 0 =144
The binary status for each group is displayed as a decimal equivalent shown as
__:DEC at the top of the groups page.
Figure 9-9 Universal Input and Output Displays
In the figure above, the first Universal Input Group, IG#001 has a status of 107:DEC
(1 + 2 + 8 + 32 + 64).
The first Universal Output Group, OG#001 has a status of 205:DEC

(1 + 4 + 8 + 64 + 128).

9.10 DOUT (Digital Output)

The DOUT instruction operates Universal Output(s).
The following is an example of the DOUT instruction used with a single

Universal Output (OT#):
0003 DOUT OT#(3) ON
0004 MOVL V=2000
0005 MOVL V=2000
0006 DOUT OT#(3) OFF
Figure 9-10 Example DOUT Instruction
NOTE: By default, once an Output has been turned ON, it will remain ON until it is
turned OFF by a job instruction or manually turned OFF.
9.11 WAIT
The WAIT instruction is used when a robot program is dependent on a signal from
a limit switch, proximity sensor, PLC, or other source. A timer may also be used
with the WAIT instruction. When a timer is used the robot will wait for either the I/O
status to be true or for the timer to expire; whichever comes first.
NOTE: If the I/O status is already true when the controller gets to the WAIT
instruction in the job, then there will be no waiting.
The following are WAIT instructions with/without a timer tag:

WAIT IN#(3)=ON [waits indefinitely for Input 3 to be ON]
WAIT IN#(5)=OFF T=3.25 [waits either for Input 5 to be OFF or for
3.25 sec., then continues to next line]
Figure 9-11 Job Examples Using the Wait Instruction
9.12 Sequence Wait Message

A Cubic Interference Zone or an Axis Interference Zone is an area that the
programmer has defined for monitoring the location of the active TCP. The controller
recognizes when the TCP is inside the cube, and its Specific Output turns ON.
Many systems have a cube defined as a safe robot location where the controller can
start running the Master Job or perhaps flip or rotate a positioner safely. Otherwise,
crash conditions could occur if the controller started running the job when the TCP is
not in the desired zone.

Through internal instructions setup, if the robot is not in this safe cube zone when
the START button is pressed, the controller will not run the job. Additionally, the
message line may display the reason for the controller not starting the job, or the
cursored instruction in the job will indicate the reason.
When multiple robots are in use, one robot will go into Program sequence wait
until the other robots TCP is out of the monitored interference zone.
CAUTION! The robot suspended by Program sequence wait will begin moving
immediately after the other robots TCP is out of the Interference Zone
that is prohibiting entrance.

NOTES

Appendix A: DX100 Password Feature
A.0 DX100 PASSWORD FEATURE

A.1 Password Protection Option
The DX100 Password option is capable of storing 100 case-sensitive user names
and passwords with individualized security levels. Using password protection allows
only one user at a time to be Logged-On to the controller.
A timeout value can also be entered to automatically Log-Off the user into Operation
Mode if a key is not pressed within a defined amount of time.
To Log-On, perform the following keystrokes:

1. Choose SYSTEM INFO and LOGON.
2. With the cursor on USER NAME press SELECT.
3. Enter the Users defined name.
NOTE: User Names are case sensitive.

4. Cursor to PASSWORD, press SELECT.
5. Using the number keypad, enter the users PASSWORD, press ENTER.
The user is now logged ON.
Figure A-1 The Log-in Screen for Entering User Name and Password
To Log-Off, perform the following keystrokes:

1. Choose SYSTEM INFO and LOGOFF.
2. Verify the USER NAME, then choose EXECUTE.
DX Operators Training Manual A-1 MOTOMAN

Appendix-A :DX100 Password Feature
NOTES
DX Operators Training Manual A-2 MOTOMAN

INDEX
A
ACTIVE JOB SELECTION 6-1
ACTIVE TOOL NO. SELECTION 2-7, 4-3, 8-3
ALARM DISPLAY 5-9
ALARM HISTORY 5-8
ALARMS AND ERRORS 5-1
AREA KEY 2-5
ARITH VARIABLES AND INSTRUCTIONS 9-8
ASSIST KEY 2-6
B
BACKWARD KEY 7-3
BINARY STATUS I/O GROUPS 9-9
BUTTON SIZE SETTING 3-7
BYTE VARIABLE FILE 9-8
C
CALL AND RET 9-1
CALLING MASTER JOB 6-2
CANCEL KEY 2-6
CHANGE MOTION TYPE 11-7
CHANGE SPEED 12-3
CHARACTER SCREEN 3-10
CHECK-RUN A-2
CIRCULAR MOTION TYPE (MOVC) 7-1
COLLISION DETECT ALARM 4315 5-4
COMMAND POSITION 4-9, 7-2, 8-1, 8-3
COMPACT FLASH CONNECTION 2-2
CONTROL GROUPS AND COORDINATES 4-1
CONTROL INSTRUCTIONS 9-1
COORD KEY 4-2, 4-3
COORDINATES 4-2
CURRENT POSITION 4-8
CURSOR KEY 2-5
CYCLE SELECTION 7-5
CYLINDRICAL RECTANGULAR COORD SELECTION 4-6
D
DEC (DECREMENT) 9-8
DIRECT OPEN KEY 4-9, 9-2
DISPLAY SETUP 3-7
DISPLAYING A CHILD JOB USING DIRECT OPEN 9-2
DISPLAYING VARIABLE FILE/ADDRESS 9-8
DISPLAYING CURRENT POSITION 4-8
DISPLAYING THE ACTIVE JOB 6-1
DOUT (DIGITAL OUTPUT) 9-10
DX100 CONTROLLER HARDWARE 1-1
DX100 CONTROLLER START-UP/SHUTDOWN 1-1, 1-2
DX100 PASSWORD FEATURE A-1
DX100 PENDANT SCREEN 3-1
DX100 PENDANT 2-1
DX Operators Training Manual Index 1 MOTOMAN

E
EDIT BUFFER LINE 3-4
EDIT LOCK:ON/OFF 8-1
EMERGENCY STOP (E-STOP) BUTTON ON PENDANT 2-3
ENTER KEY 8-3
ERROR MESSAGE 5-1, 5-4
EXTERNAL AXIS KEY 4-1
EXTERNAL MEMORY COMPACTFLASH/USB 2-2
F
FONT SIZE SETTING 3-8
FORWARD KEY 7-3
G
GENERAL, HANDLING, AND ARC WELDING KEYPAD 2-6
GENERAL-PURPOSE DISPLAY AREA 3-2
H
HIGH SPEED KEY 4-8
HOLD BUTTON 2-4
HUMAN INTERFACE DISPLAY AREA 3-4
I
I/O INSTRUCTIONS 9-10
IF CONDITION 9-5
INC (INCREMENT) 9-8
INPUT AND OUTPUT DISPLAYS 9-9
INTERLOCK AND TEST START KEYS 7-4
INTERLOCK KEY 2-7
INTERNAL SHOCK SENSOR / COLLISION DETECTION 5-4
J
JOB CONTENT 7-1, 7-2, 8-3
JOB HEADER EDIT PROTECTION 8-1
JOB LIST 6-1
JOB PROTECTION 8-1, 8-2
JOINT COORDINATES 4-2
JOINT MOTION TYPE (MOVJ) 7-1
JUMP *LABEL AND *LABEL 9-3
JUMP TO A JOB 9-4
L
LINEAR MOTION TYPE (MOVL) 7-1
LOG-IN SCREEN FOR ENTERING USER NAME AND PASSWORD A-1
M
MAIN CIRCUIT BREAKER 1-1
MAIN MENU AREA 3-1
MAIN MENU KEY 2-8
MAIN MENU SELECTIONS 3-6
MAIN POWER SWITCH (OFF) 1-3
MAJOR ALARMS 5-7
MANUAL SPEED ICONS AND KEYS 4-7

MASTER JOB CALL 6-2
MENU AREA 3-3
MESSAGE LINE 1-2, 2-3, 2-4, 3-4, 9-5, 9-11
MESSAGE LINE WITH 2-PAGE ICON 3-4
MINOR ALARMS 5-1
MODE SELECTION SWITCH 2-3
MODIFY KEY 8-3
MODIFYING A COMMAND POSITION 8-1, 8-3
MONITORING INPUTS AND OUTPUTS 9-9
MOTION TYPES 7-1
MULTIPLE ALARMS 5-7
N
NUMBER KEYPAD 2-6
O
OPERATION BUTTONS 2-3
OUT OF RANGE ABSOLUTE DATA 5-2
OVERRUN AND SHOCK SENSOR 5-6
P
PASSWORD PROTECTION DX100 LOGON OPTION A-1
PATH CONFIRMATION METHODS 7-3, 7-4
PAUSE 9-5
PLAY MODE 2-3
PLAYING A JOB 7-6
POSITION NOT CHECKED 5-2
POWERING UP THE DX100 CONTROLLER 1-2
R
RECTANGULAR OR CYLINDRICAL SELECTION 4-6
REMOTE [PLAY] MODE 2-3
RET 9-1, 9-2
ROBOT FRAME 4-4
ROBOT KEY 4-1
ROBOT, BASE, AND STATION AXES 4-1
RX, RY, & RZ AXIS KEYS TO CHANGE TOOLS ANGLE OF ORIENTATION 4-5
S
SCREEN AREAS 3-1
SECOND HOME POSITION 5-2
SELECT KEY 2-6
SELECTING A JOB 6-1
SERVO ON/READY & ENABLE SWITCH 2-4, 2-5
SETUP 3-7
SHIFT KEYS 2-8
SHOCK SENSOR 5-6
SIDES OF THE JOB CONTENT SCREEN 7-1, 8-1
SPLINE MOTION TYPE (MOVS) 7-1
START BUTTON 2-4
STATUS DISPLAY 3-5
STEP ONLY CHANGING FOR EDIT LOCKED JOBS 8-2
SUB MENU SCREEN 3-2
SYSTEM INFO 3-7

T
TEACH MODE 2-3
TEACHING CONDITION LIST 4-6, 8-2
TIMER 9-4
TOOL COORD 4-6
TOOL SELECTION 4-3
TURNING OFF POWER TO THE DX100 CONTROLLER 1-3
U
UNIVERSAL INPUT AND OUTPUT DISPLAYS 9-9
USB CONNECTION 2-2
USER COORD 4-7
V
VARIABLES 9-6
VELOCITY DATA 7-2
W
WAIT 9-10
WINDOW PATTERNS 3-9

DX Operators Book (04!12!10)

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DX100 Robot Controller

WHO SHOULD USE THIS MANUAL

HOW TO USE THIS MANUAL

The information contained within this document is the proprietary property

Because we are constantly improving our products, we reserve the right to

2.0 DX100 PENDANT......................................................................... 2-1

2.2.1 Emergency Stop (E-STOP) Button; Status Icon........................... 2-3

3.0 DX100 PENDANT SCREEN......................................................... 3-1

DX Operators Training Manual i MOTOMAN

4.0 CONTROL GROUP & JOG COORD ........................................... 4-1

5.0 ALARMS & ERRORS................................................................... 5-1

DX Operators Training Manual ii MOTOMAN

6.0 SELECTING A JOB...................................................................... 6-1

7.0 ROBOT & TOOL PATH.................................................................. 7-1

8.0 MODIFY COMMAND POSITION.................................................. 8-1

9.0 NON-MOTION INSTRUCTIONS................................................... 9-1

DX Operators Training Manual iii MOTOMAN

A.0 DX100 PASSWORD FEATURE ................................................ A-1

DX Operators Training Manual iv MOTOMAN

1.0 DX100 STARTUP & SHUTDOWN

MADE IN JAPAN NJ2960-1

THE MANIPULATOR AND CONTROLLER

CHECK ALL THE DOOR LOCKS

Figure 1-1 DX100 Robot/System Controller

1.1 DX100 Controller Hardware

Figure 1-2 Main Circuit Breaker

DX Basic Programming Training Manual Page 1-1 MOTOMAN

1.2 Powering Up The DX100 Controller

Figure 1-3 DX100 Controller Start-up Screen

If a failure of any of the diagnostic tests occurs, an alarm screen is displayed.

Figure 1-4 Initial Pendant Window

DX Basic Programming Training Manual Page 1-2 MOTOMAN

1.3 Turning Off Power To The DX100 Controller

Figure 1-5 E-STOP Servo Motors before Shutdown

Figure 1-6 Main Power Switch (OFF)

DX Basic Programming Training Manual Page 1-3 MOTOMAN

DX Basic Programming Training Manual Page 1-4 MOTOMAN

2.0 DX100 PENDANT

Start button Hold button

Menu area JOB EDIT DISPLAY UTILITY

display area 0004 MOVJ VJ=80.00

Main Menu Short Cut Turn on servo power Page key

LAYOUT TOOL SEL GO BACK

Cursor key COORD OPEN

Enable switch ROBOT INFORM

Motion Numeric keys / Function keys

Figure 2-1 DX100 Pendant

DX Operators Training Manual Page 2-1 MOTOMAN

JOB EDIT DISPLAY UTILITY

Insertion slot for

ROBOT INFORM 4 5 6 BACK FWD

USB memory stick

Figure 2-2 Pendant CF and USB Connections

DX Operators Training Manual Page 2-2 MOTOMAN

2.1 Mode Selection Switch REMOTE

2.1.2 Play Mode; Status Icon P

To resume, select PLAY, SERVO ON, and START.

2.1.3 Remote [Play] Mode; Status Icon P

2.2 Operation Buttons

2.2.1 Emergency Stop (E-STOP) Button; Status Icon

DX Operators Training Manual Page 2-3 MOTOMAN

2.2.2 Start Button; Status icon

2.2.3 Hold Button; Status icon