Floppy Disk Emulator For Windows User's Manual: ERC, MRC, and XRC Controller

ERC, MRC, and XRC Controller
Floppy Disk Emulator

for Windows
User's Manual
Part Number 141457-1
Revised 6/9/99
July 31, 1998

MOTOMAN
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-HOUR SERVICE HOTLINE: (937) 847-3200
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.
1998 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications
without notice. YASNAC and MOTOMAN are registered trademarks of YASKAWA Electric
Manufacturing.
TABLE OF CONTENTS
Section
Page
LIST OF FIGURES.......................................................................................................................................................iv
LIST OF TABLES.........................................................................................................................................................iv
1
INTRODUCTION
1.1
General Description....................................................................................................................1-1
1.2
How to Use this Manual...........................................................................................................1-1
1.3
Equipment and Supplies Required.....................................................................................1-2
1.4
Floppy Disk or CD Precautions............................................................................................1-2
1.5
Write-Protect Window..............................................................................................................1-2
SAFETY
2.1
Introduction....................................................................................................................................2-1
2.2
Standard Conventions...............................................................................................................2-2
2.3
General Safeguarding Tips.....................................................................................................2-3
2.4
Mechanical Safety Devices.....................................................................................................2-3
2.5
Installation Safety........................................................................................................................2-4
2.6
Programming Safety .................................................................................................................2-4
2.7
Operation Safety ..........................................................................................................................2-5
2.8
Maintenance Safety....................................................................................................................2-6
INSTALLING THE PROGRAM

3.1
Communication Cable...............................................................................................................3-1
3.2
Installation and Startup............................................................................................................3-2
OPERATING FDE WITH AN ERC CONTROLLER

4.1
Memory Display Limitations .................................................................................................4-1
4.2
Formatting Disks .........................................................................................................................4-1
4.3
Jobs....................................................................................................................................................4-1
4.3.1 Saving All Jobs.............................................................................................................4-2
4.3.2 Saving Selected Jobs................................................................................................4-2
4.3.3 Loading Jobs.................................................................................................................4-3
4.4
Conditional Program Data ......................................................................................................4-3

4.4.1 Saving Conditional Program Data......................................................................4-4
4.4.2 Loading Conditional Program Data ...................................................................4-4
4.5
All Users Programs...................................................................................................................4-5
4.6
Parameters .....................................................................................................................................4-5
4.6.1 Saving Parameters .....................................................................................................4-5
4.6.2 Loading Parameters...................................................................................................4-5
MOTOMAN
FDE for Windows Users Manual
Section
4.7
Page
I/O System Data...........................................................................................................................4-6
4.7.1 Saving I/O System Data...........................................................................................4-6
4.7.2 Loading I/O System Data ........................................................................................4-7
4.8
All Data in CMOS.........................................................................................................................4-7

4.8.1 Saving All Data in CMOS.........................................................................................4-7
4.8.2 Loading All Data in CMOS ......................................................................................4-8
4.9
Other FDE Features.....................................................................................................................4-8

4.9.1 Verifying Jobs...............................................................................................................4-8
4.9.2 Deleting Files .................................................................................................................4-9
OPERATING FDE WITH AN MRC CONTROLLER

5.1
5.2
5.3
Setting the Communications.................................................................................................5-1
5.4
Jobs....................................................................................................................................................5-2
5.4.1 Saving All Jobs.............................................................................................................5-3
5.4.3 Loading Jobs.................................................................................................................5-4
5.5
Conditional Files/Universal Data..........................................................................................5-4

5.5.1 Saving Conditional Files/Universal Data..........................................................5-5
5.5.2 Loading Conditional Files/Universal Data.......................................................5-5
5.6
Batch Standard User Memory..............................................................................................5-6

5.6.1 Saving Batch Standard User Memory..............................................................5-6
5.6.2 Loading Batch Standard User Memory ...........................................................5-7
5.7
Parameters .....................................................................................................................................5-7
5.8
C. I/O Program/I/O Name........................................................................................................5-9

5.8.1 Saving C. I/O Program/I/O Name........................................................................5-9
5.8.2 Loading C. I/O Program/I/O Name...................................................................5-10
5.9
Customer Data............................................................................................................................5-11
5.9.1 Saving Customer Data............................................................................................5-11
5.9.2 Loading Customer Data.........................................................................................5-12
5.10 Batch Standard CMOS............................................................................................................5-13

5.10.1 Saving Batch Standard CMOS............................................................................5-13
5.10.2 Loading Batch Standard CMOS.........................................................................5-13
5.11 All CMOS Area ............................................................................................................................5-14
5.11.1 Saving All CMOS Area ............................................................................................5-14
5.11.2 Loading All CMOS Area..........................................................................................5-15
ii
MOTOMAN
Section
Page
5.12 Other FDE Features...................................................................................................................5-16

5.12.1 Verifying Jobs.............................................................................................................5-16
5.12.2 Deleting Files...............................................................................................................5-16
6
OPERATING FDE WITH AN XRC CONTROLLER

6.1
6.2
6.3
Setting the Communications.................................................................................................6-1
6.4
Jobs....................................................................................................................................................6-2
6.4.1 Saving All Jobs.............................................................................................................6-3
6.4.3 Loading Jobs.................................................................................................................6-4
6.5
Condition Files/General Data.................................................................................................6-4

6.5.1 Saving Condition Files/General Data.................................................................6-5
6.5.2 Loading Condition Files/General Data ..............................................................6-5
6.6
Batch User Memory...................................................................................................................6-6

6.6.1 Saving Batch User Memory...................................................................................6-6
6.6.2 Loading Batch User Memory ................................................................................6-7
6.7
Parameters .....................................................................................................................................6-7
6.8
C. I/O Program/I/O Name........................................................................................................6-9

6.8.1 Saving C. I/O Program/I/O Name........................................................................6-9
6.8.2 Loading C. I/O Program/I/O Name...................................................................6-10
6.9
System Data.................................................................................................................................6-11
6.9.1 Saving System Data.................................................................................................6-11
6.9.2 Loading System Data..............................................................................................6-12
6.10 Batch CMOS.................................................................................................................................6-13

6.10.1 Saving Batch CMOS.................................................................................................6-13
6.10.2 Loading Batch CMOS..............................................................................................6-13
6.11 Other FDE Features...................................................................................................................6-14
6.11.1 Verifying Jobs.............................................................................................................6-14
6.11.2 Deleting Files ...............................................................................................................6-15
7
TROUBLESHOOTING
INDEX
MOTOMAN
iii
LIST OF FIGURES
Figure
Page
Figure 3-1
RS-232C Serial Cable Connections Between the Controller and PC..............3-1
Figure 3-2
The FDE for Windows Icon..................................................................................................3-3
Figure 3-3
The FDE for Windows Screen ............................................................................................3-3
Figure 3-4
The FDE Configuration Screen...........................................................................................3-4
LIST OF TABLES
Table
Page
Table 7-1
Troubleshooting (for ERC Controllers) .........................................................................7-1
Table 7-2
Troubleshooting (for MRC Controllers)........................................................................7-2
Table 7-3
Troubleshooting (for XRC Controllers).........................................................................7-3
iv
MOTOMAN
SECTION 1
INTRODUCTION
The Floppy Disk Emulator (FDE) for Windows software package allows robot
programs to be uploaded, downloaded, and deleted from an IBM-compatible
computer via RS232 serial communications. The software package is compatible
with the ERC, MRC, and XRC controllers.
1.1
General Description
FDE for Windows, Version 2.xx software package (P/N 141460-1) includes the
following items:
1.2
CD Browser (141720-1)
25-pin to 25-pin cable (P/N 132389-1)
25-pin to 9-pin adapter (P/N 132520-1)
25-pin to 9-pin adapter (P/N 142960-1)
Hardware key (P/N 141722-1)
FDE for Windows, Version 2 Users Manual (P/N 141457-1)
How to Use this Manual

This manual contains instructions to use the FDE for Windows, Version 2.xx with
an ERC, MRC, or XRC controller. Section 3 contains the installation and startup
instructions for all three controllers. If you have an ERC controller, please see
Section 4 for operating instructions. If you have an MRC controller, please see
Section 5 for operating instructions. If you have an XRC controller, please see
Section 6 for operating instructions. Section 7 contains troubleshooting
information for all three controllers.
Please be sure to read the remainder of Section 1 and Section 2, SAFETY, before
continuing.
MOTOMAN
1-1
INTRODUCTION
1.3
Equipment and Supplies Required

PC or compatible computer with:
1.4
Windows 95, 98, or NT, Service Pack 3 or later
EGA or VGA video adapter
At least one serial communications port, (COM1 through COM4 are

supported)
512k free conventional memory
500k hard disk space available
Floppy Disk or CD Precautions

As with any magnetic recording media, floppy disks are subject to damage and
the data on them may be erased if the disk is exposed to magnetic fields and other
unusual conditions.
DO NOT:
1.5
Expose disks to magnetic fields caused by permanent magnets, electrical

currents, motors, transformers, and welding arcs;
Expose CDs or disks to high or low temperatures, moisture, static electric

charges, dirt or dust, or X-rays;
Open the metal shutter or touch the disk inside the shutter;
Apply pressure to the disk enclosure or force disk into a floppy disk drive.
Write-Protect Window
Each floppy disk has a write-protect window. This is the small opening on the
lower left portion of the floppy disk. With the window closed, it is possible to
write to the disk. With the window open, the disk drive will not overwrite the
existing files. For most operations, ensure that the window is closed and locked.
1-2
MOTOMAN
SECTION 2
SAFETY
2.1
Introduction
It is the purchaser's responsibility to ensure that all local, county,
state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: 313/994-6088
FAX: 313/994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not
been trained!
We recommend that all personnel who intend to operate, program, repair, or use
the robot system be trained in an approved Motoman training course and become
familiar with the proper operation of the system.
This safety section addresses the following:
MOTOMAN
Standard Conventions (Section 2.2)
General Safeguarding Tips (Section 2.3)
Mechanical Safety Devices (Section 2.4)
Installation Safety (Section 2.5)
Programming Safety (Section 2.6)
Operation Safety (Section 2.7)
Maintenance Safety (Section 2.8)
2-1
SAFETY
2.2
Standard Conventions
This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
DANGER
WARNING
CAUTION
NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE:
Information appearing in a NOTE caption provides additional information which is helpful in

understanding the item being explained.
2-2
MOTOMAN
SAFETY
2.3
General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
2.4
Improper operation can result in personal injury and/or damage to the

equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
Do not enter the robot cell while it is in automatic operation. Programmers

must have the teach pendant when they enter the robot cell.
Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs
and Outputs).
The robot must be placed in Emergency Stop (E-STOP) mode whenever it is

not in use.
In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use

lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment
will be operated safely should be reviewed by the user. The user must be aware
of the various national codes, ANSI/RIA R15.06 safety standards, and other local
codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety measures are available:
Safety fences and barriers
Light curtains
Door interlocks
Safety mats
Floor markings
Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.
MOTOMAN
2-3
SAFETY
2.5
Installation Safety
Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace, existing
federal, local, and state laws and regulations. Additional safety measures for
personnel and equipment may be required depending on system installation,
operation, and/or location. Installation tips are as follows:
2.6
Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
Identify the work envelope of each robot with floor markings, signs,
and barriers.
Position all controllers outside the robot work envelope.
Whenever possible, install safety fences to protect against unauthorized

entry into the work envelope.
Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.
Programming Safety
equipment must understand potential dangers of operation. Programming tips are
as follows:
Any modifications to PART 1 of the MRC controller PLC can cause severe
personal injury or death, as well as damage to the robot! Do not make any
modifications to PART 1. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
Some operations require standard passwords and some require special

passwords. Special passwords are for Motoman use only. Y O U R
WARRANTY WILL BE VOID if you use these special passwords.
Back up all programs and jobs onto a floppy disk whenever program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are done and
before any changes are made to options, accessories, or equipment.
The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
2-4
MOTOMAN
SAFETY
2.7

equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
Inspect the robot and work envelope to be sure no potentially hazardous

conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
Be sure that all safeguards are in place.
Check the E-STOP button on the teach pendant for proper operation before
programming.
Carry the teach pendant with you when you enter the workcell.
Be sure that only the person holding the teach pendant enters the workcell.
Test any new or modified program at low speed for at least one full cycle.
Operation Safety
equipment must understand potential dangers of operation. Operation tips are
as follows:
MOTOMAN
Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.
Inspect the robot and work envelope to ensure no potentially hazardous

conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
Ensure that all safeguards are in place.


must have the teach pendant when they enter the cell.

not in use.
This equipment has multiple sources of electrical supply. Electrical

interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage
the robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
2-5
SAFETY
2.8
Maintenance Safety
equipment must understand potential dangers of operation. Maintenance tips are
as follows:
Do not perform any maintenance procedures before reading and

understanding the proper procedures in the appropriate manual.
Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.

Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.

must have the teach pendant when they enter the cell.

not in use.
Be sure all safeguards are in place.
Use proper replacement parts.
This equipment has multiple sources of electrical supply. Electrical

interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage
the robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs
and Outputs).
2-6
MOTOMAN
SECTION 3

This section contains instructions for installation, startup, and operation of the
FDE for Windows Package (P/N 132825-1 or 132825-2) with on an ERC, MRC,
or XRC controller.
3.1
Communication Cable
The communication cable (P/N 132389-1) is a 25-pin to 25-pin cable. The pinouts for the 25-pin to 25-pin cable are shown in Figure 3-1. To connect the
computer to the robot controller, proceed as follows:
1. Connect the 25-pin male end of the serial communication cable (P/N
132389-1) to the 9-pin serial port at the bottom of the teach pendant. Use the
9-pin adapter (P/N 142960-1) provided.
2. Connect the other end of the cable to the serial port on the computer. Use
the 9-pin adapter (P/N 132520-1).
3. Attach the hardware key to the parallel port LPT1 on the computer.
CONTROLLER
PIN 1
CONTROLLER CABLE TO PC
PC
SHIELD (connect at controller end only)
PIN 2
PIN 2
PIN 3
PIN 3
PIN 4
PIN 4
PIN 5
PIN 5
PIN 7
PIN 7
PIN 6
PIN 6
PIN 8
PIN 8
PIN 20
PIN 20
Figure 3-1 RS-232C Serial Cable Connections Between the Controller and PC
MOTOMAN
3-1
3.2
Installation and Startup
NOTE:
This manual assumes that you are familiar with basic Windows terms and operations. If this is
not the case, please consult your Microsoft Windows 95 documentation.
To install FDE, proceed as follows:
1. Insert the CD-ROM Browser disc into your CD-ROM drive.
2. The setup program should execute automatically.
NOTE:
Setup will execute automatically when the CD is inserted into your CD-ROM drive unless
autoexecute has been disabled on your computer. If the setup program does not autoexecute,
you can select demo32.exe from the CD-ROM Open Properties dialog. Demoshield Player
will appear and prompt you for a .dbd file. Double-click *.dbd to begin the install process.
3. An introduction screen will appear. Click Next to continue the installation.
4. Three option buttons are displayed:
Install Motoman Software
Exit
Learn about Motoman Software
Click Install Motoman Software.

5. A Motoman Software License Agreement page will appear. Click Yes to
agree to the terms outlined in the scrolling window.
6. A software selection screen will appear. Click the desired software button to
install the software you purchased.
NOTE:
You can install any of the software titles on the CD-ROM, but you must install a hardware
security key for each package you purchased. If the hardware key is not installed, you will not
be able to run the software you purchased.
7. After you make your software bundle selection, a package selection screen
will appear. Click the desired package button to install the software package
you purchased.
8. The CD-ROM Browser will display a list of software titles included in the
purchased bundle.
9. Click the displayed buttons to begin installation of the software.
10. Installers for each of the selected packages will guide you through the
installation process.
NOTE:
FDE for Windows will not function until you have installed the hardware key (see 1.6.2). All the
software titles within the same package use the same hardware key.
To start FDE for Windows, proceed as follows:
1. Select the Motoman Group from the Windows Program Manager.
2. Double click on the FDE for Windows icon, as shown in Figure 3-2.
3-2
MOTOMAN
Figure 3-2 The FDE for Windows Icon

This will start the FDE for Windows program and open the FDE for Windows
screen, as shown in Figure 3-3.
Figure 3-3 The FDE for Windows Screen

14. Open the Configuration menu and select the Settings option. You can do
this with the mouse or by pressing Ctrl + S.
This opens the FDE Configuration screen, as shown in Figure 3-4. To configure
the program for your application, proceed as follows:
15. Set the serial port used by FDE for Windows (Com 1 thru Com 4 are
supported). Choose the port that connects to the cable.
16. Set the baud rate, the data bits, the parity, and the stop bits for
communication between the computer and the robot controller. The defaults
are 4800, 8, Even, and 1.
17. Select the "Open Comm on Startup" box if you want the FDE for Windows
program to launch automatically on startup of the program. An X will
appear if you click on the box to indicate that this option is selected.
MOTOMAN
3-3
18. Select "Run Minimized on Startup" if you want to display the small "FDE
for Windows" icon on the main Windows File Manager screen when the
FDE for Windows program is running. An X will appear if you click on the
box to indicate that this option is selected.
19. The target directory specifies the path where the robot data will be stored
and retrieved. To select the target directory, click the "Dir" box and doubleclick on the desired directory. The drive can be any valid hard or floppy
drive. The path can be any existing valid directory path. The installation
program will set this line based upon the values specified for the disk drive
and path during the install process. Refer to step 6 above.
Figure 3-4 The FDE Configuration Screen

20. Select "Overwrite Existing Saved Files" if you want to allow existing files in
the computer to be overwritten by the robot controller without displaying an
error message. An X will appear if you click on the box to indicate that this
option is selected. When the overwrite option is not selected the user will
get an error message when a job transferred from the robot controller has the
same name as a job existing in the computer.
21. Click on the "OK" box if you want to accept the configuration choices you
have made. The FDE for Windows screen will appear. Or, click on the
"Cancel" box to exit the FDE Configuration screen without saving any
changes. If you click on the "Default" box, all the configuration settings
will change to the default installation settings.
22. In the FDE for Windows screen, select "Open" to open the com port and
enable the transfer of files.
At this point, data transfer can begin.
If you have an ERC controller, refer to Section 4 for transfer procedures.
If you have an MRC controller, refer to Section 5 for transfer procedures.
If you have an XRC controller, refer to Section 6 for transfer procedures.
3-4
MOTOMAN
SECTION 4

This section contains instructions for the operation of the FDE for Windows (P/N
141460-1) with an ERC controller.
Refer to the following sections for data transfer procedure:
Jobs (Section 4.3)
Conditional Program Data (Section 4.4)
All User's Programs (Section 4.5)
Parameters (Section 4.6)
I/O System Data (Section 4.7)
All Data in CMOS (Section 4.8)
Others (Section 4.9)
All data transfers must be initiated from the robot controller. All program
functions are carried out on the control panel of the robot controller. The file
transfer status can be viewed from the computer. When information transfer is
finished, press Ctrl + X (or double click the system control box in the upper left
corner of the screen) to exit the program.
4.1
Memory Display Limitations

More than 120 files can be saved by the ERC into a single subdirectory, but the
ERC will only be able to recognize and load the first 120 files within a directory
on the personal computer (PC). If you have more than 120 files, separate subdirectories must be created with no more than 120 files in each subdirectory.
4.2
Formatting Disks
The FORMAT function on the ERC controller will not work with the FDE for
Windows program. This is to protect the hard drive from being formatted by
accident and because of the various PC floppy diskette format configurations. All
diskettes must be formatted from the PC using DOS or Windows.
4.3
Jobs
Jobs should be saved to the PC on a regular basis. A twice-monthly backup
system is recommended. This will ensure that a recent copy is on hand if a job on
the ERC has been deleted, corrupted, or inadvertently changed.
It is possible to save all jobs on the ERC to disk (see Section 4.3.1), save selected
jobs on the ERC to disk (see Section 4.3.2), or load jobs from disk to the ERC
(see Section 4.3.3).
MOTOMAN
4-1
4.3.1
Saving All Jobs

To save all jobs from the ERC to disk, proceed as follows:
NOTE:
If the disk has insufficient space available or is write protected, an error will be displayed on
the ERC screen.
1. Press OP1.
2. Press FLOPPY.
3. Press SAVE. A directory of files will appear on the screen.
4. Press ALL JOB.
5. Press EXECUTE.
6. Press BATCH.
7. Press EXECUTE.
The selected information will now be transferred to the PC in the drive and
directory path specified in the target directory in the FDE Configuration screen.
4.3.2
Saving Selected Jobs

To save selected jobs from the ERC to disk, proceed as follows:
NOTE:
The ERC will not overwrite a file that already exists on the disk unless you have
OVERWRITE selected in the FDE Configuration screen. Attempting to save a job that is
already on disk will generate an error message.
If the disk has insufficient space available or is write protected, an error will be displayed
on the ERC screen.
1. Press OP1.
2. Press FLOPPY.
3. Press SAVE. A directory of files will appear on the screen.
4. Press SELECT JOB.
5. Move the cursor to the file to be saved.
6. Press SELECT. An asterisk (*) will appear next to the file selected.
NOTE:
If a mistake was made in tagging a job that is not to be transferred, move the cursor to the job
and press SELECT. This will untag the job.
7. Repeat Steps 5 and 6 as necessary.
8. Press EXIT.
9. Press EXECUTE.
directory path specified in the FDE Configuration screen.
4-2
MOTOMAN
4.3.3
Loading Jobs
To load jobs from the PC to the ERC, proceed as follows:
DANGER!
Do not load data, parameters, or concurrent I/O files from one robot
to another without checking operation in Teach or Slow mode.
Concurrent I/O and parameter changes can change the way a robot
operates. Unexpected operation can cause serious injury or death.
NOTE:
If a job on the ERC has the same name as a job to be copied from the PC, the job on the
ERC must be renamed or deleted before the job can be copied from the PC to the ERC.
Due to memory display limitations on the ERC, a maximum limit of 120 files will be
accessible by the ERC (see Section 4.1).
1. Press OP1.
2. Press FLOPPY.
3. Press LOAD. A directory of files will appear on the screen.
5. Move the cursor to the file to be loaded.
NOTE:
and press SELECT. This will untag the job.
8. Press EXIT.
9. Press EXECUTE. The selected information will now be transferred to
the ERC.
4.4
Conditional Program Data

Conditional program data files should be saved periodically and whenever a
change has been made. Conditional program data files include weave conditions,
welder settings, user coordinate frames, tool frames, and other necessary files.
It is possible to either save conditional program data from the ERC to disk
(see Section 4.4.1) or load conditional program data from disk to the ERC
MOTOMAN
4-3
4.4.1
Saving Conditional Program Data

To save conditional program data from the ERC to disk, proceed as follows:
NOTE:
already on disk will generate an error.
on the ERC screen.
1. Press OP1.
2. Press FLOPPY.
3. Move the cursor to CONDITIONAL PROGRAM DATA.
4. Press SAVE.
5. Move the cursor to file to be saved.
6. Press EXECUTE.
4.4.2
Loading Conditional Program Data

To load conditional program data files from the PC to the ERC, proceed as
follows:
DANGER!
CAUTION!
The FDE for Windows will overwrite the existing ERC file when
loading conditional data files.
NOTE:
Due to memory display limitations on the ERC, a maximum limit of 120 files will be accessible
by the ERC (see Section 4.1).
1. Press OP1.
2. Press FLOPPY.
3. Move the cursor to CONDITIONAL PROGRAM DATA.
4. Press LOAD.
5. Move the cursor to the file to be loaded to the ERC.
the ERC.
4-4
MOTOMAN
4.5
All Users Programs

All user's programs saves all user programs and files as a single hexadecimal
batch file. Saving this file is not necessary if all jobs and conditional data files are
saved on a regular basis.
4.6
Parameters
Parameters should be saved to a master disk on a regular basis or whenever they
have been changed. The parameters include the soft limits, cubes, speeds, etc. It
is possible to either save parameters from the ERC to disk (see Section 4.6.1) or
load parameters from disk to the ERC (see Section 4.6.2).
4.6.1
Saving Parameters
To save parameters from the ERC to disk, proceed as follows:
NOTE:
on the ERC screen.
1. Press OP1.
2. Press FLOPPY.
3. Move the cursor to PARAMETER.
4. Press SAVE.
5. Move the cursor to type of parameter to be saved.
6. Press EXECUTE.
4.6.2
Loading Parameters
To load parameters from the PC to the ERC, proceed as follows:
DANGER!
CAUTION!
NOTE:
1. Press OP2.
MOTOMAN
4-5
DANGER!
2. Enter 00000000 (eight zeros) or your code.
NOTE:
The default code for this operation is "00000000" (eight zeros), but if the default has been
changed, only the user code will work.
3. Press FLOPPY.
4. Move the cursor to PARAMETERS.
5. Press LOAD.
6. Move the cursor to type of parameter to be loaded into memory.
the ERC.
4.7
I/O System Data

I/O system data includes the concurrent I/O of the system, the signal names, the
absolute data of the encoders, and other very important files. This data should
be saved on a master disk on a regular basis or whenever it has been changed
(after recalibrating encoders, for example).
It is possible to either save I/O system data from the ERC to disk (see Section
4.7.1) or load I/O system data from disk to the ERC (see Section 4.7.2).
4.7.1
Saving I/O System Data

To save I/O system data from the ERC to disk, proceed as follows:
NOTE:
on the ERC screen.
1. Press OP1.
2. Press FLOPPY.
3. Move the cursor to I/O System Data.
4. Press SAVE.
5. Move the cursor to file to be saved to disk.
6. Press EXECUTE.
4-6
MOTOMAN
4.7.2
Loading I/O System Data

To load I/O system data from the PC to the ERC, proceed as follows:
DANGER!
CAUTION!
NOTE:
1. Press OP2.
NOTE:
3.
4.
5.
6.
7.
4.8
Press FLOPPY.
Move the cursor to I/O SYSTEM DATA.
Press LOAD.
Move the cursor to file to be loaded into ERC.
Press EXECUTE. The selected information will now be transferred to
the ERC.
All Data in CMOS

All data in CMOS is a large hexadecimal file that includes all the data in the
system. It is normally only saved on a master disk when extensive changes have
been made to the system. It is used as an emergency backup for major system
failures.
It is possible to either save all data in CMOS from the ERC to disk (see Section
4.8.1) or load all data in CMOS from disk to the ERC (see Section 4.8.2).
4.8.1
Saving All Data in CMOS

To save all data in CMOS from the ERC to disk, proceed as follows:
NOTE:
on the ERC screen.
1. Press OP1.
MOTOMAN
4-7
2. Press FLOPPY.
3. Move the cursor to ALL DATA IN CMOS.
4. Press SAVE.
5. Press EXECUTE.
4.8.2
Loading All Data in CMOS

To load all data in CMOS from the PC to the ERC, proceed as follows:
DANGER!
CAUTION!
NOTE:
1. Press OP1.
2. Press FLOPPY.
3. Move the cursor to ALL DATA IN CMOS.
4. Press LOAD.
the ERC.
4.9
Other FDE Features

Other FDE features include verifying jobs (see Section 4.9.1) or deleting files (see
Section 4.9.2).
4.9.1
Verifying Jobs
The VERIFY key allows the operator to ensure that what was saved to disk is the
same as what is in the ERC. This is a way of determining if the latest revision of
a program has been saved. Because it is slow, this function is not normally used.
The quickest way to determine if a job has been changed since last being saved to
disk is to check the job list. The SAVED column will only be indicated if the
program has not been changed since being saved to disk. To verify PC and ERC
data, proceed as follows:
1. Press OP1.
2. Press FLOPPY.
4-8
MOTOMAN
3. Press VERIFY. A directory of files will appear on the screen.

5. Move the cursor to the file to be verified.
8. Press EXIT.
9. Press EXECUTE. The selected information will now be verified.
NOTE:
4.9.2
If any differences occur during the verification process, an error will be displayed on the
ERC screen.
Deleting Files
The Delete function will delete files from the disk, not the ERC memory. You
may wish to use DOS or Windows rather than the Delete function to delete files
from the PC. To delete data on the PC, proceed as follows:
CAUTION!
Deleting a file is permanent and the file cannot be recovered if
accidentally erased.
NOTE:
If your jobs are on a floppy disk, make sure the floppy disk is not write protected.
1. Press OP1.
2. Press FLOPPY.
3. Press DELETE.
A directory of files will appear on the screen.
5. Move the cursor to the file to be deleted.
6. Press SELECT.
An asterisk (*) will appear next to the file selected.
8. Press EXIT.
9. Press EXECUTE.
The selected files will now be deleted from the PC.
MOTOMAN
4-9
NOTES
4-10
MOTOMAN
SECTION 5

This section contains instructions for the operation of FDE for Windows Package
(P/N 141460-1) with an MRC controller. Refer to the following sections for data
transfer procedures:
Jobs (Section 5.4)

Conditional Files / Universal Data (Section 5.5)
Batch Standard User Memory (Section 5.6)
C. I/O Program /I/O Name (Section 5.8)
Customer Data (Section 5.9)

Batch Standard CMOS (Section 5.10)
All CMOS Area (Section 5.11)
transfer status can be viewed from the personal computer (PC). When
information transfer is finished, close the communication port and select "Exit"
from the configuration menu (or press Ctrl + X).
5.1

More than 230 files can be saved by the MRC into a single subdirectory, but the
MRC will only be able to recognize and load the first 230 files within a directory
on the PC. If you have more than 230 files, separate subdirectories must be
created with no more than 230 files in each subdirectory.
5.2
Formatting Disks
The FORMAT function on the MRC controller will not work with the FDE for
5.3
Setting the Communications

To set the MRC controller communications port settings (the FC1 settings),
proceed as follows:
1. Press Customer.
2. Press More.
3. Press Org.
4. Press 00000000 (eight zeros) or your code.
MOTOMAN
5-1
NOTE:
The default code for this operation is "00000000" (eight zeros), but if the default was changed,
only the user code will work.
5. Press PRMTR.
6. Press More.
7. Press RS.
8. Change the communications to match the configuration set in the FDE for
Windows package as follows:
For the connector on the control panel (DB25), set RS-0000 to 3 (the default
is 3).
For the connector on the internal I/O rack (DB9), set RS-0001 to 3 (the
default is 0).
Data bits: RS-0050 = 7 : 7 bits
8 : 8 bits (default)
5.4
Stop bits: RS-0051 = 0 : 1 bits (default)

1 : 1.5 bits
2 : 2 bits
Parity: RS-0052 = 0 : none
1 : odd
2 : even (default)
Baud rate: RS-0053 = 1 : 150
2 : 300
3 : 600
4 : 1200
5 : 2400
6 : 4800 (default)
7 : 9600
8 : 19200 (may result in communication errors)
Jobs
the MRC has been deleted, corrupted, or inadvertently changed.
It is possible to save all jobs on the MRC to disk (see Section 5.4.1), save selected
jobs on the MRC to disk (see Section 5.4.2), or load jobs from disk to the MRC
5-2
MOTOMAN
5.4.1
Saving All Jobs

To save all jobs from the MRC to disk, proceed as follows:
NOTE:
the MRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to JOB.
5. Press SAVE.
6. Press BATCH.
7. Press EXECUTE.
5.4.2

To save selected jobs from the MRC to disk, proceed as follows:
NOTE:
The MRC will not overwrite a file that already exists on the disk unless you have
on the MRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
5 . Press SAVE.
6. Move the cursor to the job to be saved.
7. Press EACH.
NOTE:
and press EACH. This will untag the job.
8. Repeat Steps 6 and 7 until all files to be saved are tagged.
9. Press EXECUTE.
MOTOMAN
5-3
5.4.3
Loading Jobs
To load jobs from the PC to the MRC, proceed as follows:
DANGER!
NOTE:
If a job on the MRC has the same name as a job to be copied from the PC, the job on the
MRC must be renamed or deleted before the job can be copied from the PC to the MRC.
Due to memory display limitations on the MRC, a maximum limit of 230 files will be
accessible by the MRC (see Section 5.1).
1. Press FUNC.
2. Press FDD.
3. Press FC1.
5. Press LOAD.
The screen will show all the jobs on the disk.
6. If all the jobs on disk are to be loaded, press BATCH. If only a few jobs are
to be loaded, move the cursor to the job and press EACH until all jobs to be
loaded are tagged.
NOTE:
the MRC.
5.5
Conditional Files/Universal Data

Conditional files and universal data should be saved periodically and whenever a
change has been made. Conditional files and universal data include weave
conditions, welder settings, user coordinate frames, tool frames, and other
necessary files.
It is possible to either save conditional files and universal data from the MRC to
disk (see Section 5.5.1) or load conditional files and universal data from disk to
the MRC (see Section 5.5.2).
5-4
MOTOMAN
5.5.1
Saving Conditional Files/Universal Data

To save conditional files and universal data from the MRC to disk, proceed as
follows:
NOTE:
on the MRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to COND FILE.
5. Press SAVE.
loaded are tagged.
NOTE:
7. Press EXECUTE.
5.5.2
Loading Conditional Files/Universal Data

To load conditional files and universal data from the PC to the MRC, proceed as
follows:
DANGER!
CAUTION!
The FDE for Windows will overwrite the existing MRC file when
NOTE:
If a job on the MRC has the same name as a job to be copied from the PC, the job on the
MRC must be renamed or deleted before the job can be copied from the PC to the MRC.
Due to memory display limitations on the MRC, a maximum limit of 230 files will be
accessible by the MRC (see Section 5.1).
1. Press FUNC.
MOTOMAN
5-5
DANGER!
2. Press FDD.
3. Press FC1.
4. Move the cursor to COND FILE.
5. Press LOAD.
loaded are tagged.
NOTE:
7. Press EXECUTE.
The selected information will now be transferred to the MRC.
5.6
Batch Standard User Memory

This option saves batch standard user memory as a single hexadecimal batch file.
Batch standard user memory includes user programs and files. Saving this file is
not necessary if all jobs and conditional files and universal data are saved on a
regular basis.
It is possible to either save batch standard user memory from the MRC to disk
(see Section 5.6.1) or load batch standard user memory from disk to the MRC (see
Section 5.6.2).
5.6.1
Saving Batch Standard User Memory

To save batch standard user memory from the MRC to disk, proceed as follows:
NOTE:
on the MRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to BATCH STD USER MEM.
5. Press SAVE.
5-6
MOTOMAN
6. Press EXECUTE.
5.6.2
Loading Batch Standard User Memory

To load batch standard user memory from the PC to the MRC, proceed as
follows:
DANGER!
CAUTION!
The FDE for Windows will overwrite the existing MRC file when loading
conditional data files.
NOTE:
Due to memory display limitations on the MRC, a maximum limit of 230 files will be accessible
by the MRC (see Section 5.1).
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to BATCH STD USER MEM.
5. Press LOAD.
the MRC.
5.7
Parameters
have been changed. The parameters include the soft limits, cubes, speeds, etc.
It is possible to either save parameters from the MRC to disk (see Section 5.7.1)
or load parameters from disk to the MRC (see Section 5.7.2).
5.7.1
Saving Parameters
To save parameters from the MRC to disk, proceed as follows:
NOTE:
on the MRC screen.
1. Press FUNC.
MOTOMAN
5-7
2. Press FDD.
3. Press FC1.
4. Move the cursor to PARAMETER.
5. Press SAVE.
loaded are tagged.
NOTE:
7. Press EXECUTE.
5.7.2
Loading Parameters
To load parameters from the PC to the MRC, proceed as follows:
DANGER!
CAUTION!
NOTE:
1. Press CUSTOMER.
2. Press MORE.
3. Press ORG.
NOTE:
5. Press ENTER.
6. Press MORE.
7. Press FDD.
8. Press FC1.
9. Move the cursor to PARAMETERS.
10. Press LOAD.
5-8
MOTOMAN
loaded are tagged.
NOTE:
the MRC.
5.8
C. I/O Program/I/O Name

This option includes the concurrent I/O program of the system, the signal names,
the absolute data of the encoders, and other very important files. The option for
concurrent I/O program data in the MRC display is abbreviated "C. I/O
Program/I/O Name." This data should be saved on a master disk on a regular
basis or whenever it has been changed (after recalibrating encoders, for example).
It is possible to either save concurrent I/O program data from the MRC to disk
(see Section 5.8.1) or load concurrent I/O program data from disk to the MRC
5.8.1
Saving C. I/O Program/I/O Name

To save concurrent I/O program data from the MRC to disk, proceed as follows:
NOTE:
on the MRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to C. I/O PROGRAMS.
5. Press SAVE.
loaded are tagged.
NOTE:
7. Press EXECUTE.
MOTOMAN
5-9
5.8.2
Loading C. I/O Program/I/O Name

To load concurrent I/O program data from the PC to the MRC, proceed as
follows:
DANGER!
CAUTION!
NOTE:
1. Press CUSTOMER.
2. Press MORE.
3. Press ORG.
NOTE:
5. Press ENTER.
6. Press MORE.
7. Press FDD.
8. Press FC1.
9. Move the cursor to DATA TYPE.
10. Press LOAD.
loaded are tagged.
NOTE:
the MRC.
5-10
MOTOMAN
5.9
Customer Data
Customer data includes absolute data, specified point, alarm histories, and other
very important files. Customer data should be saved on a master disk and
whenever it has been changed (after encoder calibration, for example).
It is possible to either save customer data from the MRC to disk (see Section
5.9.1) or load customer data from disk to the MRC (see Section 5.9.2).
5.9.1
Saving Customer Data

To save customer data from the MRC to disk, proceed as follows:
NOTE:
on the MRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to CUST DATA.
5. Press SAVE.
loaded are tagged.
NOTE:
7. Press EXECUTE.
MOTOMAN
5-11
5.9.2
Loading Customer Data

To load customer data from the PC to the MRC, proceed as follows:
DANGER!
CAUTION!
NOTE:
1. Press CUSTOMER.
2. Press MORE.
3. Press ORG.
NOTE:
5. Press ENTER.
6. Press MORE.
7. Press FDD.
8. Press FC1.
9. Move the cursor to CUST DATA.
10. Press LOAD.
loaded are tagged.
NOTE:
12. Press EXECUTE.
The selected information will now be transferred to the MRC.
5-12
MOTOMAN
5.10
Batch Standard CMOS

Batch standard CMOS is a large hexadecimal file that includes all the batch data
in the system. It is normally only saved on a master disk when extensive changes
have been made to the system. It is used as an emergency backup for major
system failures.
It is possible to either save batch standard CMOS from the MRC to disk
(see Section 5.10.1) or load batch standard CMOS from disk to the MRC
5.10.1
Saving Batch Standard CMOS

To save batch standard CMOS from the XRC to disk, proceed as follows:
NOTE:
on the XRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to BATCH STD CMOS.
5. Press SAVE.
6. Press EXECUTE.
5.10.2
Loading Batch Standard CMOS

To load batch standard CMOS from the PC to the MRC, proceed as follows:
DANGER!
CAUTION!
The FDE for Windows will overwrite the existing XRC file when
NOTE:
1. Press CUSTOMER.
MOTOMAN
5-13
2. Press MOVE.
3. Press ORG.
4. Enter 00000000 (8 zeros) or your code.
NOTE:
The default code for this operation is "00000000" (eight z eros), but if the default has been
5. Press ENTER.
6. Press MORE.
7. Press FDD.
8. Press FC1.
9. Move the cursor to BATCH STD CMOS.
10. Press LOAD.
the MRC.
5.11
All CMOS Area

All CMOS area is a large hexadecimal file that includes all the data (including the
batch data) in the system. It is normally only saved on a master disk when
extensive changes have been made to the system. It is used as an emergency
backup for major system failures.
It is possible to either save all CMOS area from the MRC to disk (see Section
5.11.1) or load all CMOS area from disk to the MRC (see Section 5.11.2).
5.11.1
Saving All CMOS Area

To save all CMOS area from the MRC to disk, proceed as follows:
NOTE:
The XRC will not overwrite a file that already exists on the disk unless you have
on the MRC screen.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to ALL CMOS AREA.
5. Press SAVE.
6. Press EXECUTE.
5-14
MOTOMAN
5.11.2
Loading All CMOS Area

To load all CMOS area from the PC to the MRC, proceed as follows:
DANGER!
CAUTION!
NOTE:
1. Press CUSTOMER.
2. Press MOVE.
3. Press ORG.
4. Enter 00000000 (8 zeros) or your code.
NOTE:
5. Press ENTER.
6. Press MORE.
7. Press FDD.
8. Press FC1.
9. Move the cursor to ALL CMOS AREA.
10. Press LOAD.
the MRC.
MOTOMAN
5-15
5.12
Other FDE Features

Other FDE features include verifying jobs (see Section 5.12.1) or deleting files
5.12.1
Verifying Jobs
same as what is in the MRC. This is a way of determining if the latest revision of
program has not been changed since being saved to disk. To verify PC and MRC
1. Press FUNC.
2. Press FDD.
3. Press FC1.
4. Move the cursor to type of data to be verified.
5. Press VERIFY. The screen will show all the jobs on the disk.
loaded are tagged.
NOTE:
7. Press EXECUTE. The selected information will now be verified.
NOTE:
5.12.2
MRC screen.
Deleting Files
CAUTION!
The Delete function will delete files from the disk, not the MRC
memory. You may wish to use DOS or Windows rather than the
Delete function to delete files from the PC.
To delete data on the PC, proceed as follows:
NOTE:
If your jobs are on a floppy disk, make sure the floppy disk is not write protected. Refer to
Section 1.5.
1. Press FUNC.
2. Press FDD.
3. Press FC1.
5-16
MOTOMAN
4. Move the cursor to type of data to be deleted.

5. Press DELETE. The screen will show all the files of the specified data type
on the disk.
6. If all the jobs on disk are to be deleted, press BATCH. If only a few jobs are
to be deleted, move the cursor to the job and press EACH until all jobs to be
deleted are tagged.
NOTE:
7. Press EXECUTE. The selected files will now be deleted from the PC.
MOTOMAN
5-17
NOTES
5-18
MOTOMAN
SECTION 6

This section contains instructions for the operation of FDE for Windows (P/N
141460-1) with an XRC controller. Refer to the following sections for data
transfer procedures:
Jobs (Section 6.4)

Condition Files / General Data (Section 6.5)
Batch User Memory (Section 6.6)
C. I/O Program / I/O Name (Section 6.8)
System Data (Section 6.9)

Batch CMOS (Section 6.10)
transfer status can be viewed from the personal computer (PC). When
information transfer is finished, close the communication port and select "Exit"
from the configuration menu (or press Ctrl + X).
6.1

More than 230 files can be saved by the XRC into a single subdirectory, but the
XRC will only be able to recognize and load the first 230 files within a directory
on the PC. If you have more than 230 files, separate subdirectories must be
created with no more than 230 files in each subdirectory.
6.2
Formatting Disks
The FORMAT function on the XRC controller will not work with the FDE for
6.3
Setting the Communications

To set the XRC Controller communications port settings (the FC1 settings),
proceed as follows:
1. Press the AREA key.
2. Cursor to SECURITY.
3. Cursor to MANAGEMENT MODE. Press SELECT.
4. Enter 99999999 (eight nines) or your code.
MOTOMAN
6-1
NOTE:
The default code for this operation is "99999999" (eight nines), but if the default was changed,
5. Cursor to PRMTR. Press Select.
6. Cursor to RS. Press Select.
7. Change the communications to match the configuration set in the FDE for
Windows package as follows:
For the connector on the control panel (DB25), set RS-0000 to 2 (the default
is 3).
For the connector on the internal I/O rack (DB9), set RS-0001 to 0 (the
default is 0).
Data bits: RS-0050 = 7 : 7 bits
8 : 8 bits (default)
Stop bits: RS-0051 = 0 : 1 bits (default)
1 : 1.5 bits
2 : 2 bits
Parity: RS-0052 = 0 : none
1 : odd
2 : even (default)
Baud rate: RS-0053 = 1 : 150
2 : 300
3 : 600
4 : 1200
5 : 2400
6 : 4800 (default)
7 : 9600
8 : 19200 (may result in communication errors)
6.4
Jobs
the XRC has been deleted, corrupted, or inadvertently changed.
It is possible to save all jobs on the XRC to disk (see Section 6.4.1), save selected
jobs on the XRC to disk (see Section 6.4.2), or load jobs from disk to the XRC
6-2
MOTOMAN
6.4.1
Saving All Jobs

To save all jobs from the MRC to disk, first open the jobs directory in the FDE
program on the PC. To save all jobs, proceed as follows:
NOTE:
the MRC screen.
1. Cursor to FD/PC. Press Select.
2. Cursor to SAVE. Press Select.
3. Cursor to JOB. Press Select twice..
4. Press the AREA key to go to the menu area of the display. Cursor to edit,
make sure Select All is highlighted in the dropdown menu, and press Select.
An asterisk will appear next to all the jobs.
5. Press ENTER.
6. At the SAVE prompt, cursor to YES and press Select.
6.4.2

To save selected jobs from the XRC to disk, first open the jobs directory in the
FDE program on the PC. To save selected jobs, proceed as follows:
NOTE:
on the XRC screen.
3. Cursor to JOB. Press Select twice.
4. Cursor to the job and press Select. And asterisk will appear next to the
selected job. Repeat this step until all desired jobs are selected.
NOTE:
If you make a mistake and tag a job that is not to be transferred, move the cursor to the job and
press Select. This will untag the job.
5. Press ENTER.
MOTOMAN
6-3
6.4.3
Loading Jobs
To load jobs from the PC to the XRC, proceed as follows:
DANGER!
NOTE:
If a job on the XRC has the same name as a job to be copied from the PC, the job on the
XRC must be renamed or deleted before the job can be copied from the PC to the XRC.
Due to memory display limitations on the XRC, a maximum limit of 230 files will be
accessible by the XRC (see Section 5.1).
2. Cursor to LOAD. Press Select.
4. Cursor to the job to be transferred and press Select. And asterisk will appear
next to the selected job. Repeat this step until all desired jobs are selected.
NOTE:
If you make a mistake and tag a job that is not to be transferred, move the cursor to the job and
press Select. This will untag the job.
5. Press ENTER.
6. At the LOAD prompt, cursor to YES and press Select.
6.5
Condition Files/General Data

Condition files and general data should be saved periodically and whenever a
change has been made. Condition files and general data include weave
conditions, welder settings, user coordinate frames, tool frames, and other
necessary files.
It is possible to either save condition files and general data from the XRC to disk
(see Section 6.5.1) or load condition files and general data from disk to the XRC
6-4
MOTOMAN
6.5.1
Saving Condition Files/General Data

To save condition files and general data from the XRC to disk, proceed as
follows:
NOTE:
on the XRC screen.
3. Cursor to FILE/GENERAL DATA. Press Select twice.
4. Cursor to the files to be transferred and press Select. An asterisk will appear
next to the selected file. Repeat this step until all desired files are selected.
NOTE:
If you make a mistake and tag a file that is not to be transferred, move the cursor to the file and
press Select. This will untag the file.
5. Press ENTER.
6.5.2
Loading Condition Files/General Data

To load condition files and general data from the PC to the XRC, proceed as
follows:
DANGER!
CAUTION!
loading condition data files.
NOTE:
If a file on the XRC has the same name as a file to be copied from the PC, the file on the
XRC must be renamed or deleted before the file can be copied from the PC to the XRC.
Due to memory display limitations on the XRC, a maximum limit of 230 files will be
accessible by the XRC (see Section 6.1).
MOTOMAN
6-5
3. Cursor to FILE/GENERAL DATA. Press Select twice.

4. Cursor to the file to be transferred and press Select. An asterisk will appear
next to the selected file. Repeat this step until all desired files are selected.
NOTE:
If you make a mistake and tag a file that is not to be transferred, move the cursor to the file and
press Select. This will untag the file.
5. Press ENTER.
The selected information will now be transferred to the XRC.
6.6
Batch User Memory

This option saves batch user memory as a single hexadecimal batch file. Batch
user memory includes user programs and files. Saving this file is not necessary if
all jobs and conditional files and general data are saved on a regular basis.
It is possible to either save batch user memory from the XRC to disk (see Section
6.6.1) or load batch user memory from disk to the XRC (see Section 6.6.2).
6.6.1
Saving Batch User Memory

To save batch user memory from the XRC to disk, proceed as follows:
NOTE:
on the XRC screen.
3. Cursor to BATCH USER MEMORY.
4. Press SELECT.
6-6
MOTOMAN
6.6.2
Loading Batch User Memory

To load batch user memory from the PC to the XRC, proceed as follows:
DANGER!
CAUTION!
The FDE for Windows will overwrite the existing XRC file when loading
conditional data files.
NOTE:
Due to memory display limitations on the XRC, a maximum limit of 230 files will be accessible
by the XRC (see Section 6.1).
3. Cursor to BATCH USER MEMORY.
4. Press SELECT.
6.7
Parameters
have been changed. The parameters include the soft limits, cubes, speeds, etc.
It is possible to either save parameters from the XRC to disk (see Section 6.7.1) or
load parameters from disk to the XRC (see Section 6.7.2).
6.7.1
Saving Parameters
To save parameters from the XRC to disk, proceed as follows:
NOTE:
OVERWRITE selected in the FDE Configuration screen. Attempting to save a file that is
on the XRC screen.
3. Cursor to PARAMETER. Press Select twice.
An asterisk will appear next to all the parameters. Or if you only want to
save specific parameters, cursor to that parameter and press Select.
MOTOMAN
6-7
NOTE:
If you make a mistake and tag a parameter that is not to be transferred, move the cursor to the
parameter and press Select. This will untag it.
5. Press ENTER.
6.7.2
Loading Parameters
To load parameters from the PC to the XRC, proceed as follows:
DANGER!
CAUTION!
NOTE:
NOTE:
7. Cursor to PARAMETER. Press Select twice.
save specific parameters, cursor to that parameter and press Select.
NOTE:
If you make a mistake and tag a parameter that is not to be transferred, move the cursor to the
parameter and press Select. This will untag it.
9. Press Select.
6-8
MOTOMAN
6.8
C. I/O Program/I/O Name

This option includes the concurrent I/O program of the system, the signal names,
the absolute data of the encoders, and other very important files. The option for
concurrent I/O program data in the XRC display is abbreviated "C. I/O
Program/I/O Name." This data should be saved on a master disk on a regular
basis or whenever it has been changed (after recalibrating encoders, for example).
It is possible to either save concurrent I/O program data from the XRC to disk
(see Section 6.8.1) or load concurrent I/O program data from disk to the XRC (see
Section 6.8.2).
6.8.1
Saving C. I/O Program/I/O Name

To save concurrent I/O program data from the XRC to disk, proceed as follows:
NOTE:
OVERWRITE selected in the FDE Configuration screen. Attempting to save program data
that is already on disk will generate an error.
on the XRC screen.
3. Cursor to C.I/O PROGRAM. Press Select twice.
4. A menu appears. Cursor to C.I/O PROGRAM or I/O NAME DATA. Press
Select.
An asterisk will appear next to all the data files. Or if you only want to save
specific files, cursor to that file and press Select.
NOTE:
If you make a mistake and tag program data that is not to be transferred, move the cursor to the
file and press Select. This will untag it.
6. Press ENTER.
MOTOMAN
6-9
6.8.2
Loading C. I/O Program/I/O Name

To load concurrent I/O program data from the PC to the XRC, proceed as follows:
DANGER!
CAUTION!
NOTE:
NOTE:
7. Cursor to C.I/O PROGRAM. Press Select twice.
8. A menu appears. Cursor to C.I/O PROGRAM or I/O NAME DATA. Press
Select.
An asterisk will appear next to all the data files. Or if you only want to load
specific files, cursor to that file and press Select.
NOTE:
If you make a mistake and tag program data that is not to be transferred, move the cursor to the
data and press Select. This will untag it.
10. Press ENTER.
6-10
MOTOMAN
6.9
System Data
System data includes absolute data, specified point, alarm histories, and other
very important files. System data should be saved on a master disk and whenever
it has been changed (after encoder calibration, for example).
It is possible to either save customer data from the XRC to disk (see Section
6.9.1) or load customer data from disk to the XRC (see Section 6.9.2).
6.9.1
Saving System Data

To save system data from the XRC to disk, proceed as follows:
NOTE:
on the XRC screen.
3. Cursor to SYSTEM DATA. Press Select twice.
An asterisk will appear next to all the data files. Or if you only want to save
specific data, cursor to it and press Select.
NOTE:
If you make a mistake and tag system data that is not to be transferred, move the cursor to the
5. Press ENTER.
MOTOMAN
6-11
6.9.2
Loading System Data

To load system data from the PC to the XRC, proceed as follows:
DANGER!
CAUTION!
NOTE:
NOTE:
7. Cursor to SYSTEM DATA. Press Select twice.
save specific data, cursor to it and press Select.
NOTE:
If you make a mistake and tag system data that is not to be transferred, move the cursor to the
9. Press ENTER.
6-12
MOTOMAN
6.10
Batch CMOS
Batch CMOS is a large hexadecimal file that includes all the batch data in the
system. It is normally only saved on a master disk when extensive changes have
been made to the system. It is used as an emergency backup for major system
failures.
It is possible to either save batch CMOS from the XRC to disk (see Section
6.10.1) or load batch CMOS from disk to the XRC (see Section 6.10.2).
6.10.1
Saving Batch CMOS

To save batch CMOS from the XRC to disk, proceed as follows:
NOTE:
on the XRC screen.
3. Cursor to BATCH CMOS. Press Select twice.
4. Press SELECT.
6.10.2
Loading Batch CMOS

To load batch CMOS from the PC to the XRC, proceed as follows:
DANGER!
CAUTION!
NOTE:
MOTOMAN
6-13
NOTE:
7. Cursor to BATCH CMOS. Press Select twice.
8. Press Select.
6.11
Other FDE Features

Other FDE features include verifying jobs (see Section 6.12.1) or deleting files
6.11.1
Verifying Jobs
same as what is in the XRC. This is a way of determining if the latest revision of
program has not been changed since being saved to disk. To verify PC and XRC
2. Cursor to VERIFY. Press Select.
An asterisk will appear next to all the jobs.
5. Press ENTER.
NOTE:
XRC screen.
6-14
MOTOMAN
6.11.2
Deleting Files
CAUTION!
The Delete function will delete files from the disk, not the XRC
memory. You may wish to use DOS or Windows rather than the
Delete function to delete files from the PC.
To delete data on the PC, proceed as follows:
NOTE:
If your jobs are on a floppy disk, make sure the floppy disk is not write protected. Refer to
Section 1.5.
2. Cursor to DELETE. Press Select.
4. Cursor to the job you want to delete and press Select. An asterisk will
appear next to the selected file. Repeat this step until all desired jobs are
selected. An asterisk will appear next to all the jobs.
5. Press ENTER.
6. At the DELETE prompt, cursor to YES and press Select.
MOTOMAN
6-15
NOTES
6-16
MOTOMAN
SECTION 7
TROUBLESHOOTING
If FDE for Windows is not installed or configured correctly, the controller will
display an error or alarm on the screen. Some of the errors, causes, and corrective
actions are displayed below.
See the appropriate Programming Manual for additional error codes.
Table 7-1 Troubleshooting (for ERC Controllers)

Alarm No.
Cause
Remedy
You cannot overwrite an
existing file. To load a
file from floppy disk into
the robot controller, the
duplicate file in the robot
controller must be erased.
Plug in the cable between
the robot controller and
the PC.
Check and correct the
communication
parameters.
Insert a floppy disk or
remove the floppy disk
from the drive and
reinsert.
Ensure that the Write
Protect window (the small
square slide located on the
lower left side of the disk)
is closed and locked.
Erase the file on the
floppy disk.
2030
Duplicate job
name.
The job already exists in

the robot controller and
you are trying to overwrite
the file from FDE for
Windows.
4010
Connect cable
of floppy disk
drive.
4020
Insert floppy
disk.
Cable is loose or not

connected to the robot
controller.
The communication
parameter (baud rate) has
been changed.
There is no floppy disk in
the floppy disk drive.
4030
The floppy disk

is protected
from WRITE
operation.
The floppy disk Write

Protect window is open.
4050
The file already

exists on the
floppy disk.
Transmission
error with
floppy disk
drive.
The file is already on the

floppy disk.
4096
4097
4110
MOTOMAN
Message
Syntax error.
The serial cable connection

is bad.
The cable came loose
during transmission of
files.
Wrong communication
settings.
The file has been corrupted
by using the incorrect
symbol for editing the
command. For example,
misspelling AWELD as
WWELD.
7-1
Ensure that the RS-232C

serial cable is secured at
both ends.
Ensure that the communication settings are correct.
See Section 3.2.
Edit the file and correct
the error. If the error
cannot be found, delete
the file and start over.
TROUBLESHOOTING
Table 7-1 Troubleshooting (for ERC Controllers) - continued

Alarm No.
4170
4250
Message
Format error.
Cause
Remedy
The file format has been

changed.
Check the file structure on

an IBM-compatible
computer. Correct error if
noted. Do not attempt to
load the file into the robot
controller until the error is
corrected.
If it cannot be corrected,
erase the file and start
over.
The file is not
You are trying to load a file If the file needs to be
allowed to load. such as a parameter data
loaded, it is necessary to
file from the OP1 FLOPPY use the OP2 function
menu.
menu.
Problems
The ERC controller TAPE Ensure that the cable ends
recording to the OUT switch is not set
are attached correctly to
floppy disk
correctly.
the controller and the PC.
drive.
The cable is plugged in
Ensure that all parameters
incorrectly.
are set correctly on the
floppy disk recorder.
Table 7-2 Troubleshooting (for MRC Controllers)

Error No.
Message
3010
Floppy disk
drive cable not
connected.
3020
Floppy disk not

inserted into
floppy disk
drive.
Floppy disk
protection is
ON.
3030
3040
3050
3060
3070
File not saved

on floppy disk.
File saved on
floppy disk.
Out of memory
on floppy disk.
Number of files
on floppy disk
is full.
Cause
Remedy
Cable connection error on

floppy disk drive or power
not supplied (no response
from floppy disk drive).
Connect cable.
Ensure FDE for Windows
is running and com port is
open.
from the drive and
reinsert.
The floppy disk is set to
Ensure that the write
write prohibit.
protect window (the small
The file is not saved on the Save the file on the floppy
floppy disk.
disk.
floppy disk.
floppy disk.
No space in storage area in Insert a new floppy disk
floppy disk.
into the floppy disk drive.
Too many files in the
Copy files to a different
directory.
directory or select a
different directory.
7-2
MOTOMAN
TROUBLESHOOTING
Table 7-2 Troubleshooting (for MRC Controllers) - continued

Error No.
3080
3090
Message
I/O error on
floppy disk.
Transmission
error with
floppy disk
drive.
Cause
Remedy
Excess allowance number of

retransmissions.
Framing error.
Overrun error.
Parity error.
Try a new disk.

Check the
communications
parameters on the
controller and the
computer. If the error
continues, select a lower
baud rate.
Table 7-3 Troubleshooting (for XRC Controllers)

Error No.
Floppy disk
drive cable not
connected.
3020
Floppy disk not

inserted into
floppy disk
drive.
Floppy disk
protection is
ON.
3030
3040
3050
3060
3070
3080
3090
MOTOMAN
Message
3010
File not saved

on floppy disk.
File saved on
floppy disk.
Out of memory
on floppy disk.
Number of files
on floppy disk
is full.
I/O error on
floppy disk.
Transmission
error with
floppy disk
drive.
Cause
Remedy
Cable connection error on

floppy disk drive or power
not supplied (no response
from floppy disk drive).
Connect cable.
Ensure FDE for Windows
is running and com port is
open.
from the drive and
reinsert.
The floppy disk is set to
Ensure that the write
write prohibit.
protect window (the small
The file is not saved on the Save the file on the floppy
floppy disk.
disk.
floppy disk.
floppy disk.
No space in storage area in Insert a new floppy disk
floppy disk.
into the floppy disk drive.
Too many files in the
Copy files to a different
directory.
directory or select a
different directory.
Excess allowance number Try a new disk.
of retransmissions.
Framing error.
Check the
Overrun error.
communications
Parity error.
parameters on the
controller and the
computer. If the error
continues, select a lower
baud rate.
7-3
TROUBLESHOOTING
NOTES
7-4
MOTOMAN
INDEX
A
All
CMOS Area, 5-14
Data in CMOS, 4-7
Users Programs, 4-5
B
Batch CMOS, 6-13
Standard CMOS, 5-13
Standard User Memory, 5-6
User Memory, 6-6
C
C. I/O Program/I/O Name, 5-9
Communication Cable, 3-1
Condition Files/General Data, 6-4
Conditional Files/Universal Data, 5-4
Conditional Program Data, 4-3
Customer Data, 5-11
D
Deleting Files, 4-9, 5-16, 6-15
List of Figures, iv
List of Tables, iv
Loading All CMOS Area, 5-15
All Data in CMOS, 4-8
Batch CMOS, 6-13
Batch Standard CMOS, 5-13
Batch Standard User Memory, 5-7
Batch User Memory, 6-7
Condition Files/General Data, 6-5
Customer Data, 5-12
I/O System Data, 4-7
Jobs, 4-3, 5-4, 6-4
Parameters, 4-5, 5-8, 6-8
System Data, 6-12
Equipment and Supplies Required, 1-2
Maintenance Safety, 2-6

Mechanical Safety Devices, 2-3
Memory Display Limitations, 4-1, 5-1, 6-1
Floppy Disk or CD Precautions, 1-2

Formatting Disks, 4-1, 5-1, 6-1
Operation Safety, 2-5

Other FDE Features, 4-8, 5-16, 6-14
General Description, 1-1

Safeguarding Tips, 2-3

Programming Safety, 2-4
How to Use this Manual, 1-1
Saving All CMOS Area, 5-14

All Data in CMOS, 4-7
All Jobs, 4-2, 5-3, 6-3
Batch CMOS, 6-13
Batch Standard CMOS, 5-13
Batch Standard User Memory, 5-6
Batch User Memory, 6-6
I
Installation and Startup, 3-2
Installation Safety, 2-4
Introduction, 2-1
J
Jobs, 4-1, 5-2, 6-2
MOTOMAN
INDEX
S - continued
Saving Condition Files/General Data, 6-5
Customer Data, 5-11
Selected Jobs, 4-2, 5-3, 6-3
System Data, 6-11
Setting the Communications, 5-1, 6-1
Standard Conventions, 2-2
System Data, 6-11
V
Verifying Jobs, 4-8, 5-16, 6-14
W
Write-Protect Window, 1-2
MOTOMAN

Floppy Disk Emulator For Windows User's Manual: ERC, MRC, and XRC Controller

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Floppy Disk Emulator For Windows User's Manual: ERC, MRC, and XRC Controller

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ERC, MRC, and XRC Controller

Floppy Disk Emulator

July 31, 1998

How to Use this Manual...........................................................................................................1-1

Equipment and Supplies Required.....................................................................................1-2

Floppy Disk or CD Precautions............................................................................................1-2

General Safeguarding Tips.....................................................................................................2-3

Mechanical Safety Devices.....................................................................................................2-3

Programming Safety .................................................................................................................2-4

Operation Safety ..........................................................................................................................2-5

INSTALLING THE PROGRAM

Installation and Startup............................................................................................................3-2

OPERATING FDE WITH AN ERC CONTROLLER

Memory Display Limitations .................................................................................................4-1

Formatting Disks .........................................................................................................................4-1

Conditional Program Data ......................................................................................................4-3

All Users Programs...................................................................................................................4-5

FDE for Windows Users Manual

All Data in CMOS.........................................................................................................................4-7

Other FDE Features.....................................................................................................................4-8

OPERATING FDE WITH AN MRC CONTROLLER

Memory Display Limitations .................................................................................................5-1

Formatting Disks .........................................................................................................................5-1

Setting the Communications.................................................................................................5-1

Conditional Files/Universal Data..........................................................................................5-4

Batch Standard User Memory..............................................................................................5-6

C. I/O Program/I/O Name........................................................................................................5-9

5.10 Batch Standard CMOS............................................................................................................5-13

5.12 Other FDE Features...................................................................................................................5-16

OPERATING FDE WITH AN XRC CONTROLLER

Memory Display Limitations .................................................................................................6-1

Formatting Disks .........................................................................................................................6-1

Setting the Communications.................................................................................................6-1

Condition Files/General Data.................................................................................................6-4

Batch User Memory...................................................................................................................6-6

C. I/O Program/I/O Name........................................................................................................6-9

6.10 Batch CMOS.................................................................................................................................6-13

FDE for Windows Users Manual

RS-232C Serial Cable Connections Between the Controller and PC..............3-1

The FDE for Windows Icon..................................................................................................3-3

The FDE for Windows Screen ............................................................................................3-3

The FDE Configuration Screen...........................................................................................3-4

Troubleshooting (for ERC Controllers) .........................................................................7-1

Troubleshooting (for MRC Controllers)........................................................................7-2

Troubleshooting (for XRC Controllers).........................................................................7-3

FDE for Windows Users Manual

25-pin to 25-pin cable (P/N 132389-1)

25-pin to 9-pin adapter (P/N 132520-1)

25-pin to 9-pin adapter (P/N 142960-1)

Hardware key (P/N 141722-1)

FDE for Windows, Version 2 Users Manual (P/N 141457-1)

How to Use this Manual

FDE for Windows Users Manual

Equipment and Supplies Required

Windows 95, 98, or NT, Service Pack 3 or later

EGA or VGA video adapter

At least one serial communications port, (COM1 through COM4 are