Running a Program in Test Mode

Set the three-mode switch to T1

Turn the controller mode switch to T1, the low-speed test mode. In T1 the tool center point and flange speeds are limited to 250 mm/sec or slower even at 100% override, so a taught 2000 mm/sec move runs no faster than 250 mm/sec. In T1 a program can be executed only from the teach pendant.

Caution: If you want to work with the safety fence open, the switch must be in T1 or T2 before you start operating, and the robot runs only while the teach pendant is enabled and the deadman switch is gripped.

Enable the teach pendant and confirm operation-enable conditions

Turn the teach pendant enable switch on and grip the deadman switch. Before a program with motion instructions can start, the ENBL peripheral input must be on and no alarm can be present. Disabling the pendant or releasing the deadman while in T1 puts the robot in an alarm condition so it cannot run.

Caution: Do not hold the deadman while turning the mode switch, since a system error can result. Release the deadman, switch modes, then grip it again.

Open the TEST CYCLE screen

Press MENU and select TEST CYCLE. The screen shows Group Motion, Digital/Analog I/O, Step statement type, and Step path node for the selected group. Press F2 GROUP to change the group number on a multi-group system.

Choose the step statement type

Step statement type sets where single-step execution pauses. STATEMENT pauses at each line, MOTION pauses at every motion instruction, and ROUTINE behaves like STATEMENT but does not pause inside a CALLed program. Pick STATEMENT for the closest line-by-line inspection of a new program.

Start with the robot locked to check logic and I/O first

The typical test procedure begins with machine lock on. On the TEST CYCLE screen set Group Motion to DISABLE, which locks the robot so it ignores all motion instructions while still running logic. This lets you confirm instructions, registers, and signal flow before any axis moves.

Caution: Even with the robot locked, servo power is treated as on and the robot still cannot move while the emergency stop is pressed. Do not treat a locked robot as a substitute for keeping clear.

Decide whether peripheral I/O is live or simulated

Digital/Analog I/O set to ENABLE lets the robot exchange real signals with peripherals. Set to DISABLE, all I/O carries the simulated (S) flag, outputs to devices do not change, and inputs are held by the controller. Use DISABLE to dry-run logic without driving external equipment, then set ENABLE to hand control back to the peripheral.

Select the program and position the cursor

Press SELECT to open the program list, highlight the program to test, and press ENTER to open the edit screen. Move the cursor to the program start line so execution begins where you intend.

Lower the feed rate override

Press the override key to step the feed rate override down through the sequence VFINE, FINE, 1%, 5%, 50%, 100%. An inexperienced operator should use a low override, and the value should match the cell condition and motion type. A low override reduces speed further even inside the T1 250 mm/sec cap.

Enter single-step mode

Press the STEP key to select single-step mode. The STEP LED lights when step mode is active and is off during continuous operation. Confirm the LED before you start so you know each start advances only one line.

Step forward through the program

Press and hold SHIFT, then press and release FWD to execute one line, then the program halts. After a motion instruction the cursor stays on the executed line, and after a logic instruction the cursor moves to the next line. Repeat SHIFT and FWD to advance line by line, keeping SHIFT held until each line completes.

Caution: Execution causes robot motion that can produce unpredictable results. If you must stop before the line finishes, release SHIFT or the deadman, or press HOLD or the emergency stop button.

Use backward execution to re-check a move

Press and hold SHIFT, then press and release BWD to run in reverse. Only motion instructions execute in reverse; skip, time-before, time-after, and similar optional move instructions are ignored, and incremental (INC) moves cannot run. The cursor moves to the previous line after each backward step.

Caution: Backward execution cannot pass certain lines, including PAUSE, ABORT, END, JMP, UALM, and RUN. Insert a PAUSE where you want to block backward stepping.

Unlock the robot and step again with motion

Once logic and I/O look correct, set Group Motion back to ENABLE on the TEST CYCLE screen and repeat forward step execution. Now watch the actual robot motion, path, and timing at each line from a safe position outside the reach envelope.

Run a continuous test at low speed

Press STEP so the STEP LED goes off, confirming continuous mode, and move the cursor to the start line. Press and hold SHIFT, then FWD to run from the current line to the program end. Backward execution is disabled during a continuous test, and releasing SHIFT halts the run.

Caution: Keep SHIFT held until the cycle completes. The program runs to the end, is forcibly terminated, and the cursor returns to the first line.

Watch execution on the monitor screen

During a run the pendant shows a monitor screen whose cursor follows the executing line, and you cannot edit there. Press F2 LOOK to browse other lines while the program keeps running, then F2 MONITOR to return to the executing line. The status line shows the mode, RUNNING or ABORTED state, and override, for example T1 RUNNING JOINT 30%.

Make a final full-speed check only if your procedure allows T2

T1 cannot verify true tool path or cycle time because speed is capped. T2 removes the program speed limit so you can confirm path and timing at production speed, though jogging in T2 is still capped at 250 mm/sec. When you switch to T2 the default override is limited so speeds stay at or below 250 mm/sec until you raise it deliberately.

Caution: T2 is a final check for qualified personnel only. Raise the override in steps and keep the deadman gripped, since releasing or hard-pressing it re-limits the speed on CE or NRTL specification controllers.

What can go wrong: robot will not move and shows an alarm

In T1 or T2 the robot runs only when the pendant is enabled and the deadman is gripped. Turning the enable switch off or releasing the deadman stops the robot and raises an error. Set the enable switch on, grip the deadman, then press RESET to clear the error before continuing.

Caution: Correct the cause of any stop before restarting. Never bypass, jumper, or defeat the deadman, enable switch, or a safety-critical stop to keep a test running.

What can go wrong: speed feels capped even at 100% override

This is expected in T1, where the tool center point and flange are held to 250 mm/sec regardless of taught speed. A warning about the T1 speed limit can appear when the operation speed is being limited. To verify real cycle time you must move to a sanctioned T2 check rather than force higher speed in T1.

What can go wrong: outputs never reach the peripheral

If Digital/Analog I/O is set to DISABLE on the TEST CYCLE screen, all signals carry the simulated flag and outputs to devices do not change. The simulated flag cannot be released until you set the item back to ENABLE. Re-enable I/O when you are ready for the robot to actually drive external equipment.

Document sign-off before releasing to AUTO

Record that the program passed step and continuous verification at reduced speed, and any T2 check, before switching the mode to AUTO for production. In AUTO the robot can run from external devices at maximum speed and jogging is disabled, so the safety fence must be closed. Confirm the fence and clearances one last time.