Skip to content

Motoman / Yaskawa Robot — Moving Out of Limits Using the Pendant

DANGER — AUTHORISED USE ONLY BOLT X COBRA

Authorised / trained personnel only

This procedure involves operating a robot arm under direct pendant control outside of Flair's software limits. It must only be performed by operators who have been trained on the specific robot and pendant, or under direct guidance from MRMC Support. Do not attempt this procedure without that training. Verify against current MRMC documentation before use.

Summary

When a Motoman/Yaskawa robot (Bolt X or Cobra) goes outside its software limits, Flair will not engage or move the robot. The recovery method is to use the robot's Teach Pendant to manually jog the arm back inside the limits, then return the controller to Remote mode so Flair can re-engage.

The procedure covers pendant Teach mode, Servo On Ready, the deadman switch, Robot Coordinates jogging, FAST speed selection, axes SLURBT / 1–6, and returning to Remote mode. For Bolt X, use Ex. Axis for the track rather than Robot.

When This Applies

  • Bolt X or Cobra goes out of software limits and Flair will not engage.
  • The Yaskawa YRC1000 or DX200 controller shows a limit fault.
  • The robot cannot be moved via Flair and needs to be jogged back to a safe position with the pendant.

This is not for general zeroing or re-zeroing after power loss — see Bolt X Re-Zero After Power Loss for that procedure.

Procedure (From Community Field Guide — Simon, 2023-02-02)

Step 1 — Switch the Pendant to Teach Mode

On the YRC1000/DX200 controller:

  1. Turn the mode key on the pendant or controller to Teach mode.
  2. The pendant will activate and show the Teach mode screen.

Step 2 — Enable Servo On Ready

  1. Hold the deadman switch on the back of the pendant at the mid-position (half-press). The deadman must be held continuously during jogging — releasing it fully will cut servo power.
  2. Press Servo On (or the equivalent enable button on your pendant model). The servos should power on and the robot is now ready to jog.

Step 3 — Select Robot Coordinates

In the pendant motion mode display, select Robot Coordinates (also referred to as "Robotic Coordinates" or XYZ frame). This jogs the arm in Cartesian space, which is generally easier for recovery moves.

Alternatively, use Joint Coordinates (axes SLURBT) to move individual joints:

Axis label Joint
S Swing (base rotation)
L Lower arm / shoulder
U Upper arm / elbow
R Wrist rotation
B Wrist bend
T Tool rotation

For Bolt X with a track axis: the track is Ex. Axis (External Axis), not Robot. Select the External Axis group when jogging the track.

Step 4 — Set Speed to FAST

Select FAST speed on the pendant. This ensures responsive movement while jogging back to the in-limits position. Adjust speed as needed — do not use maximum speed for recovery moves near mechanical limits.

Step 5 — Jog the Robot Back Into Limits

Use the jog keys on the pendant to move the robot axis (or the track via Ex. Axis) back inside the software limits. Move slowly and carefully — watch the position readout on the pendant.

Step 6 — Return to Remote Mode

  1. Once the robot is inside limits, release the deadman switch.
  2. Turn the mode key back to Remote (or Play) mode.
  3. Return the pendant to its holder.
  4. Flair should now be able to engage and communicate with the robot normally.

Notes

  • Cobra robots use the same Yaskawa pendant procedure. Axis labels (SLURBT) apply.
  • After returning to Remote, check Flair for any residual limit or zero faults and clear them before running a move.
  • If the robot repeatedly goes out of limits during operation, investigate the source — it may be a software axis limit set too tight, an incorrect zero, or a move that exceeds the robot's working envelope.

"MoveMotoman procedure — Teach mode, Servo On, deadman, Robot Coordinates, FAST, axes SLURBT/1-6, then back to Remote. For Bolt X use Ex. Axis for the track, not Robot." — Simon (field guide, 2023-02-02)

Official Documentation

Flair Classic Manual — Ch.14A High Speed Robots / EtherCAT — p.235

Flair 7 Manual — Ch.11 High Speed Robots / EtherCAT — p.195