Fanuc RJ-2 to R30iA

Pocket Guide
& Reference

Bruce Johnston
 System
Main Disconnect 9
System Components 10
B Control Cabinet 11
E-Stop 12
Cycle Start 13
Power On (RJ-RJ3iB) 14
Power On (RJ3iC-R30) 15
Key Mode Select Switch 16
User Keys & Indicators 17
SOP Fault Indicator 18
SOP Fault Reset 18
Monochrome Pendant 20
LIVEMAN Switch 21
Colour iPendant 24

2
Operations
Diagnostic/Help Key 25
Display (Screens) Key 26
Operation Keys 28
Robot Motion Keys 30
Coordinate System 32
Jogging Key Groups 33
Joint Jogging 34
Linear Jogging 36
Jog Menu (Tool, Frame) 38
Wrist (Lock) Jogging 40
Program Execution (Hold, Step) 41
Program Execution (Forward) 42
Program Execution (Backward) 43
Editing Keys 44

3
Saving and Backing Up
BMon Menu Caution 46
All Files Backup (File Menu) 48
Backup/restore Menu Caution 50
From & Sram Image Backup 56
False Alarms after Image Restore 58
From & Sram Image Restore (Part 1) 60
Reset SRVO – 38 Pulse Mismatch Alarm 62

4
Service Procedures
Enable Master / Cal Menu Item 64
Reset SRVO – 62 Pulse Coder Alarm 65
Chain Failure Recovery 66
Reset Pulse Not Established 68
Overtravel Release 69
Single Axis Mastering 74
Zero Axis Mastering 78
Preparing to Teach 81
Teaching Local Positions (Px) 82
Teaching Position Registers (PRx) 84
I/O Types 86
Simulating Inputs 88
Simulating Outputs 90
Enabling and Disabling Interconnects 92
Forcing Outputs 94

5
Setup & Selection Procedures
I/ O Details and Setup 96
Coordinate Details and Selection 98

6
Notes:

7
Notes:

8
Warning!
Lethal voltage is present in the controller
WHENEVER IT IS CONNECTED
to a power source.
Be extremely careful to avoid electrical shock.
Turning the disconnect or circuit breaker to the
OFF position removes power from the output side
of the device only. High voltage is always present
at the input side whenever the controller is
connected to a power source.

9
System Components

3
4

2
1

1. Control Cabinet
2. Teach Pendant
3. Robot Manipulator
4. End of Arm Tooling (EOAT)

10
B Cabinet

5
1

3
2
4

1. Standard Operator Interface

2. PSU, CPU and I/O Rack
3. Auxiliary I/O
4. Control Relays
5. Servo Amplifiers

11
Operator Panel E-Stop

E-Stop

The red EMERGENCY STOP button is

located on the front of both teach pendant
styles and the front of the controller cabinet.
It can be pressed to stop the robot
immediately in case of an accident or
failure.

Turn Clockwise to Reset

12
Operator Panel Cycle Start

The CYCLE START input will run the selected

program for one cycle unless the program contains
a loop.
If you select Cycle Start, it implies that you are not
using RSR or PNS, but will use the CYCLE
START input on the Standard Operator Panel
(SOP) to initiate production operation.
You select the program to be run on the teach
pendant SELECT menu.

13
Operator Panel Power On
(RJ - RJ3iB)

Press the ON/OFF button on the operator

panel.

Note: the latest RJ3iC and R30iA Controls

do not have a Power On Switch.

14
RJ3iC and R30iA
Power Cycle Functions are handled through
the Functions Key and are limited to
cycling power to reboot the controller to
commit changes and to access lower level
features such as the Bmon and
Configuration Menus.

1. Press “FCTN”
2. then 0 “Next”
3. then 8 “Cycle Power”

Turning on the robot performs the following

actions:
• Initializes changes to system
variables
• Initializes changes to I/O setup
• Displays the utilities hints screen
(during Cold start only)
• Initializes changes to cell I/O

15
Mode Select Switch

When you change the mode using the MODE

SELECT switch, the robot is paused and a message
indicating which mode is selected is displayed at
the top of the teach pendant screen. This message
will be overwritten by status or error messages
during operation. The mode that is currently
selected is displayed immediately below the first
message, and remains displayed.

Most mode switches do not have a T2 position or

its function is disabled.

16
User Inputs and Indicators

These inputs and corresponding indicators may be

used to trigger programmed operations, including
macros, which can initiate motion by calling
routines with motion instructions.

Generally these inputs and indicators are not used

in cells controlled by supervisory automation.

17
Operator Panel Fault Indicator

Operator Panel Fault Reset

Faults occur because of:

• Hardware problems - a broken cable or
tooling
• Software problems - incorrect program or
data
• External problems - an open safety door or
an overtravel has occurred

18
Depending on the severity of the fault, you must
take certain steps to recover from it.
Some errors require minimal corrective action to
recover from them. Others require more involved
procedures. The first step in the error recovery
process is to determine the kind and severity of the
error. After you determine this information, the
appropriate error recovery procedure can be used.
A complete listing of error codes is provided in the:
FANUC Robotics SYSTEM R-J3iB Controller
Error Code Manual.

Steps
1. Determine the cause of the error.
2. Correct the problem which caused the error.
3. Release the error.
4. Restart the program or robot.
If the basic recovery procedures do not clear the
error, try restarting the controller.

19
Monochrome Teach Pendant

SCREEN: Displays the software menus, all robot

functions can be performed by making selections
from these menus.
ON / OFF SWITCH: Enables and disables
Pendant control of the Robot and Motion in
conjunction with the LIVEMAN switches.
E-STOP: Stops the robot immediately in case of
an accident or failure.

20
Operation Mode Indicators
FAULT: an error condition has occurred.

HOLD: the robot is in a hold condition.

It is not on continuously during a hold
condition.

STEP: the robot is in step mode.

BUSY: the controller is processing information.

RUNNING: a program is being executed.

I/O ENBL: indicates that I/O is enabled.

PROD MODE: the system is in production

mode.

TEST CYCLE: the process is in a dry run

mode.

21
Live Man Switch

LIVEMAN (DEADMAN) Switches are located on

the back of either teach pendant style and are used
as enabling devices. Each LIVEMAN switch is a
three position switch. When the teach pendant is
enabled, this switch allows robot motion only while
the switch is gripped in the middle position.
If the LIVEMAN switch is completely gripped, or
is released, no motion is allowed. Press the
LIVEMAN switch in the middle position to run the
robot.
22
23
Color iPendant

24
This pendant has the same functionality as the
Monochrome unit with the addition of:
• multiple screens displayed simultaneously
• a color graphics interface w popup menus
• an embedded html viewer
• user-customized help and web pages
• customized displays
• internet/intranet access
• integrated Help and Diagnostics

Colour TP Diagnostic/Help Key

Pressing the DIAG/HELP key displays help files

that are available that describe the functions
available for the active window.
Pressing SHIFT and DIAG together display
diagnostic information for the currently active error
or the selected error in the Alarm menu.

25
Colour TP Display Key

26
The DISP key is used to activate the DISPLAY
menu or change the focus.
When you press SHIFT and the DISP key together,
the DISPLAY menu appears.

The DISPLAY menu allows you to change the

number of windows displayed to be Single,
Double, or Triple.

The Status/Single choice displays status in addition

to the single window.

You can also use it to display help or diagnostics,

set up user views and menu favorites, or to display
a menu history.

27
Operation Keys

The F1 through F5 function keys are used to make

choices based on the teach pendant display. Each
function key has a unique label depending on the
menu displayed on the teach pendant screen.

The NEXT page key is used to display the next set

of function keys.

The PREV key restores the most recent state. In

some cases, the screen might not return to the
immediately preceding status.

28
The MENUS key is used to display the screen
menu. All area’s of the Robot and Controller are
accessable through the menu’s.

The FCTN key is used to display the function

menu. A major function is the ABORT ALL
command which stops execution of a running
program.

The SELECT key is used to display the program

selection screen.
The EDIT key is used to display the program edit
screen.
The DATA key is used to display the program data
screen.

29
Motion Keys

The COORD key selects a jog coordinate system.

Each time the COORD key is pressed, it selects the
next jog type in the order: JOINT, JGFRM, World
frame, TOOL, USER.

When this key is pressed while a SHIFT key is

pressed and held down, a jog menu for changing
the referenced coordinate system is displayed. To
close this menu hold SHIFT and press COORD
again

30
The OVERRIDE key adjusts the feedrate override.
Each time the override key is pressed, it selects the
next override in the order: VFINE, FINE, 1%, 2%
3% 4% 5%, 10% 15% 20% and so forth in 5%
increments to 100%. (Set $SHFTOV_ENB to alter
the override settings.)

The SHIFT key is used to jog the robot, teach the

position data, and start a program.
The right and left SHIFT keys have the same
function.

31
Coordinate System
JOINT: indicates that the current jog coordinate
system is JOINT.

XYZ: indicates that the current jog coordinate

system is JOG frame, USER frame, or WORLD.

TOOL: indicates that the

current jog coordinate system is TOOL.

Jogging
The JOG keys are effective only while a SHIFT
key is pressed.
They are used to jog the robot in

• joint mode [(J1) – (J6)]

• linear cartesian mode

XYZ or Tool

• euler reorientation mode

XYZ or Tool

32
Jogging Keys

Linear
XYZ or Tool

Joint J1-J6

ReOrient
XYZ or Tool

33
Joint or Axis Motion

34
To jog an individual axis joint.

1. Select Manual Mode (T1)

2. Turn T.P on
3. Press COORD (cycle to Joint)
4. Hold down SHIFT
5. Press (Jx+) or (Jx-)

Note -the direction of the joint rotation shown is

representative of an R2000i/125L manipulator.

Each individual style of manipulator will contain

cast-in or applied labeling of its own kinematic
organization.

The motion profile of axis jogging is an arc

segment. EOAT will not maintain orientation
while joint jogging

35
Linear Motion

X Y Z (World, Frames, User)

36
To jog in a Linear frame.

1. Select Manual Mode (T1)

2. Turn T.P on
3. Press COORD (cycle to World)
- User, JogFrame or Tool
4. Hold down SHIFT
5. Press Direction i.e. (x+) or (z-)

Note -the direction of motion shown is

representative of an R2000i/125L manipulator
moving in the World frame. Each individual frame
will have its own origin and orientation as
programmed.

37
Jog Menu (Tool, Frame)

The jog menu provides a method to check and

change the following jogging data: the currently
selected frame numbers of each frame (TOOL,
JOG, USER) and/or the
currently selected group number and sub-group
type (ROBOT/EXT)

38
To display the jog menu

1. Press and hold the SHIFT

2. Then press the COORD

Use the up and down arrow keys to move the

cursor to the item you want to change.

To change the number of each frame , press the

appropriate numeric key. The item on which the
cursor is located is changed to the new value.

Valid frame numbers are:

TOOL: 1-10, JOG: 1-5 and USER: 0-9.

Note - To select Tool10, press the "." (period)

key on the teach pendant.

- Tool0 is the default tool and once a

new tool is selected Tool0 will no
longer be selectable

To close the menu repeat 1 & 2 above.

39
Wrist Jogging

You select wrist jog using the FCTN menu. When

you select wrist jog, "W/" appears next to the
coordinate system name displayed on the teach
pendant screen.
The wrist jog function allows you to control how
the robot axes will jog when you are using a
Cartesian coordinate system, such as WORLD,
FRAME or TOOL.

In wrist jog, the wrist axes are fixed and do not

change when jogging in x, y, and z coordinates.
This is helpful when you have to jog in the x, y,
and z directions through a singularity position.
When you jog a wrist axis using wrist jog, the other
wrist axes will remain stationary and the rest of the
robot axes will move to accommodate the
movement of the wrist axes to maintain a fixed
TCP location.

40
Program Execution

The HOLD key causes a program to halt.

The STEP key selects step or continuous test

operation.

41
Forward Program Execution

The FWD + SHIFT key starts a program running

forward in normal operating sequence to the last
statement. In STEP mode it sequences to the next
step.
It will jump out to a called routine and return upon
completion continuing on.

42
Backward Program Execution

The BWD + SHIFT key starts a program running

backward to the first statement.
In STEP mode it sequences to the previous step,
but will not return from a called routine.
When the SHIFT key is released during
regeneration, the program halts operation.

43
Editing Keys

The ARROW keys are used to cursor left or right,

up and down to highlight or select an item on the
screen.

The ITEM key moves the cursor to a line whose

number is specified.

The PREV key restores the most recent state. In

some cases, the screen might not return to the
immediately preceding status.

44
The BACK SPACE key deletes the character or
numeral immediately before the cursor.

The ENTER key is used to process and activate the

current information set.

The function of SELECT and activation by the

ENTER key in numbered menu lists is combined
through the shortcut of choosing a menu item by its
reference number using the numeric keypad.

45
Saving and Backing Up
Warning regarding
Boot Monitor Menu Selections

***BOOT MONITOR for R-J3iB

CONTROLLER***

Base System Version V6.xxxx (FRNA)

Initializing file devices ... done.

1. Configuration Menu
2. All software installation (MC:)
3. INIT start
4. Controller backup/restore
5. Hardware diagnosis
6. Maintenance
7. All software installation (ETHERNET)

Select : _

46
Selecting choice:

3 Init start

will clear the robot saved memory

pools of the running application in
preparation for reloading the robot
application.

Be sure valid backups are available

before executing this option.

47
All Files Backup
It is not necessary to stop program operation in
most cases to backup the controller, however, it is
good practice to do so when the robot interfaces
with other controls, which may be dependant on
uninterrupted signals from the robot.
1. Press MENUS.
2. Press 7, FILE.
Check to see if the device is set to the Memory
Card or USB Stick. If not:
3. Press F5, [UTIL]
4. Press 1, Set Device
5. Press 6, Mem Card (MC:)
Or
Press 8, Mem Card (MC:)
You can now proceed with Step 6

48
6. Press F4 for [BACKUP].
7. Press 7, All of above
(To back up all types of files).

You will see the following message displayed at

the bottom of the screen.

Delete MC: backup all files?

Note: All files on a memory card are deleted

before this type of backup. If the destination
device is networked, files will not be deleted. If a
subdirectory is used only it will be affected. The
file number and total number of files are displayed
during backup.

8. Press F4, Yes (To back up all types of files).

49
Warning regarding
Backup/Restore Menu Selections

***BOOT MONITOR for R-J3iX

CONTROLLER***

**** BACKUP / RESTORE MENU ****

0. Return to Main Menu

1. Emergency Backup
2. Backup Controller as Images
3. Restore Controller Images
4. Bootstrap to Cfg Menu

Select : _

50
Selecting choice:

3 Restore Controller Images

will clear the robot Sram and From

memory in preparation for
reloading the robot image archives.

Be sure valid images are available

before executing this option.

51
All Files Restore
1. If the controller is on, turn it off.
Or Cycle Power as desc. on pg. 13
2. Press and Hold the F1 and F5 keys on the
teach pendant while you
3. Press the ON button on the controller.
Release all of the keys
4. Press 1, for the Configuration Menu then
Press, ENTER
5. Press 3, for Controlled Start
then Press ENTER
6. Press MENU
7. Press 5, File
Check to see if the label of F4 is set to
[RESTOR]

52
 If not:
Press FCTN
Press 2, RESTORE/BACKUP
You can now proceed with Step 8
8. Press F4, [RESTOR]
9. Press 5, All of above.
Restore from Memory card (OVRWRT)?
10. Press F4, YES
You may see the following prompt:

This program is being edited

Before selecting the restore function this file was
open in the editor. You should finish editing and
close the file, or
11. Press F4, SKIP.
See the next pages for other prompts

53
Some prompts you may see, could be:

Could not load file MC:\ABORTIT.TP

Or
Could not load file MC:\CG_ADJST.TP
Or
Could not load file MC:\_________.TP

These files have the write protect attribute currently

set on the system.
Many files with this attribute set are program
prototypes created by Fanuc and do not matter. If
they need to be overwritten this attribute must be
turned off.

54
Note If there are any concerns with the need for
any of these files please consult with the
application programmer.
Otherwise…
12. Press F4, SKIP.
At the end of the restoration you should see a
message like:

Total 14x/15x files restored

When the process is completed

13. Press FCTN.
14. Press 1, START (COLD)

55
FROM and SRAM Image Backup

1. If the controller is on, turn it off.

Or Cycle Power as desc. on pg. 13
2. Press and Hold the F1 and F5 keys on the
teach pendant while you Press the ON button
on the controller.
Release all of the keys
3. Press 4, Controller backup/restore
4. Press 2, Backup controller as Images
then Press, ENTER
5. Press 1, Memory Card (MC:)
then Press, ENTER
Place a memory card enough free space to hold the
full controller image files.

56
For example, a 16MB F-ROM and 2MB S-RAM
configuration will require a card with 18MB of free
space.
6. Press 1, Are you ready?[Y=1]
then Press, ENTER
The files will be written to the memory card.
If the memory card does not have enough free
space for the next image file, you will need to
insert anew memory card.

7. Press ENTER to return>

You will return to the BMON menu
8. Press 1, Configuration Menu
then Press, ENTER
9. Press 2, Cold Start
then Press, ENTER

57
False Alarms after Image Restore
Pulse Mismatch Alarm

SRVO – 038 pulse Mismatch (G:%d A:%d)

This alarm can be ignored if you have just restored

from an image backup file which contains valid
mastering data for all robot axis.

Cause: The pulse count obtained when power is

turned off does not match the pulse count obtained
when power is turned back on. This alarm is
asserted after changing the pulse coder or the back
up battery for pulse coder data, or when loading
back up data into the Main Board. If you see the
“SRVO–222 Lack of Amp (Amp : i)” alarm, refer
to the troubleshooting of SRVO–222.

58
59
FROM and SRAM Image Restore
( Part 1 )
1. If the controller is on, turn it off.
Or Cycle Power as desc. on pg. 13
2. Press and Hold the F1 and F5 keys on the
teach pendant while you Press the ON button
on the controller.
Release all of the keys
3. Press 4, Controller backup/restore
4. Press 3, Restore Controller Images
then Press, ENTER
Place the memory card with the full series of
controller image files into its slot.
5. Press 1, Memory Card (MC:)
then Press, ENTER.

60
Press 1, Are you ready?[Y=1]
then Press, ENTER.
The Robot memory will be erased and the memory
files will be read from the memory card.
6. Press ENTER to return>
You will return to the BMON menu.
7. Press 1, Configuration Menu
then Press, ENTER
8. Press 2, Cold Start
then Press, ENTER
Note: If the robots current serial pulse coder
counts differ from the counts resident in the image
files used to restore the system you may need to
clear pulse count alarms and mastering faults
before resuming operation.

61
Reset Pulse Mismatch Alarm
To reset this alarm
1. From the Teach Pendant, press MENUS
2. Press 0, NEXT
3. Press 6, SYSTEM
4. Press F1, [TYPE]
5. Press 3, MASTER/CAL
If Master/Cal is not listed on the [TYPE]
menu do the following;
a. Press MENUS
b. Press 2, VARIABLE
c. Cursor down to $MASTER_ENB
d. Press 1 and then press, ENTER.
e. Press F1, [TYPE]
f. Press 3, MASTER/CAL
otherwise continue on with step 6.
6. Press F3, [RES-PCA]
7. Press F4, YES

62
8. Press F1, [TYPE]
9. Press 2, VARIABLES
Cursor down to $DMR_GROUP
DMR_GRP_T will be highlighted
10. Press ENTER
11. Press ENTER
12. Press $MASTER_DONE
13. Press F4, TRUE
14. Press F1, [TYPE]
15. Press 3, MASTER/CAL
If Master/Cal is not listed on the [TYPE]
menu repeat steps a – f above;
otherwise continue on with Step 16.

16. Press 6, CALIBRATE

17. Press F4, YES
18. Press F5, DONE
Perform a Cold Start by powering off and
powering on the controller.

63
Enable Master/Cal Menu
To Enable Master/Cal if not on the System Page

1. Press MENUS
2. Press 0, NEXT
3. Press 6, SYSTEM
4. Press F1, [TYPE]
5. Press 2, VARIABLE
6. Cursor down to $MASTER_ENB
7. Press 1
then press, ENTER.
8. Press F1, [TYPE]
MASTER/CAL should now be visible

64
Reset PCA
To Reset a Pulse Coder SRVO-062 Alarm

1. Press MENUS
2. Press 0, NEXT
3. Press 6, SYSTEM
4. Press F1, [TYPE]
5. Press 3, MASTER/CAL
6. Press F3, [RES-PCA]
Reset pulse coder alarm?
7. Press F4, YES
Pulse coder alarm reset!

65
Chain Failure Detection Recovery
A Single Chain Failure Detection fault will be set if
one safety chain is in an Emergency Stop
condition, and the other is not in an Emergency
Stop condition.

When a Single Chain Failure Detection fault

occurs, the system does the following:
1. Shuts off drive power to the servo system and
applies robot brakes
2. Displays an error message indicating that a
single chain failure has occurred.
3. Lights the operator panel FAULT light
4. Lights the teach pendant FAULT LED

Chain Failure Detection Errors Refer to the

FANUC Robotics R-J3iC Controller Maintenance
Manual for more information on chain failure
detection errors, SRVO-230 and 231, SRVO-266
through 275 (external checking -customer), and
SRVO-370 through 385 (internal checking)

66
The system detected either a SRVO-230 Chain 1
(+24V abnormal) or a SRVO-231 Chain 2 (0V
abnormal) error. You cannot reset the chain failure
errors, even after turning the controller OFF and
then ON again.

1. Press MENUS.
2. Press 4, ALARMS.
3. Press F4, RES_CH1.
You will see a screen similar to the following:
SRVO-230 Chain 1(+24V) abnormal
Reset Single Channel Fault [NO]
4. Press F4, YES to reset the fault.
5. Press RESET

Warning If you reset the chain failure fault

without fixing the cause of it, the same alarm will
occur, but the robot can move until the alarm
occurs again. Be sure to fix the cause, before you
continue. Otherwise, you could injure personnel or
damage equipment.

67
Reset Pulse Not Established

To Reset a Pulse Not Established SRVO-075

Alarm
1. Press the RESET
Rotate each axis that lost battery power by at least
one motor revolution in either direction. Failure to
do so will result in the SRVO-075 Pulse Not
Established alarm recurring.

Note For each rotary axis, jog at least twenty

degrees. For each linear axis, jog at least thirty
millimeters.
2. Perform a Single axis mastering procedure
from the MASTER/CAL menu for the affected
axis.

68
Overtravel Release
An overtravel error occurs when one or more of the
robot axes moves beyond the software motion
limits. When this happens one of the overtravel
limit switches is tripped and the
system does the following:

1. Shuts off drive power to the servo system and

applies robot brakes
2. Displays an overtravel alarm error message
3. Lights the operator panel FAULT light
4. Turns on the teach pendant FAULT status
indicator
5. Limits motion for the axes involved in the
overtravel

If you are jogging in JOINT, the axis number

indicating the axis (or axes) in an overtravel will be
displayed in the error log. You can manually
release overtravel on your system from the
MANUAL OT Release screen. The axis that is in
overtravel will display TRUE in either OT_MINUS
or OT_PLUS.
Recovering from an Over-travel Error
69
An axis (or axes) are in over-travel and the over-
travel alarm has occurred. If you are jogging in
JOINT the axis number indicating the axis (or
axes) in an over-travel will be displayed in the error
log.

1. Press MENUS.
2. Select SYSTEM.
3. Press F1, [TYPE].

Select OT Release. The axis that is over-traveled

will display TRUE in either OT_MINUS or
OT_PLUS.

MANUAL OT Release

AXIS OT MINUS OT PLUS

1 FALSE TRUE
2 FALSE FALSE
3 FALSE FALSE
4 FALSE FALSE
5 FALSE FALSE

70
6 FALSE FALSE

71
4. Move the cursor to the OT PLUS or OT
MINUS value of the axis in over-travel
(ie Axis 1 OT Plus = TRUE).

5. Press F2, RELEASE

The value of the over-traveled axis should change

back to FALSE.
If the robot is calibrated, you will see the message
"Can’t Release OT. Press HELP for detail." When
robot is calibrated, over-travel cannot be released.

6. Press SHIFT & RESET to clear the error, and

jog out of the over-travel condition using either
step 7 or step 8.

Note Check CRM68 & CRF7 connection on the

amplifier PCB if the robot is not in an actual over-
travel condition.

72
If the robot is calibrated, perform the following
steps:
Note For the following steps, press and hold down
the SHIFT key until you have completed the
sequence in Step 7.a through Step 7.c.

7. Complete the following sequence

a) Press and Hold SHIFT
Press F2, RESET.
Wait for servo power.

b) Press and Hold the LIVEMAN switch

Turn the teach pendant ON.

c) Jog the over-traveled axis off the over-

travel switch.

When you have finished jogging, you can release

the SHIFT key. If you accidentally release the shift
key during Step 7.a through Step 7.c , you will
have to repeat them.

73
If the robot is not calibrated, perform the following
steps:
Note For the following steps, press and hold down
the SHIFT key until you have completed Step 8.a
through Step 8.d .

8. Complete the following sequence

a) Press and Hold SHIFT
Press F2, RESET.
Wait for servo power.

b) Select the JOINT coordinate system.

c) Press and Hold the LIVEMAN switch

and turn the teach pendant ON

d) Jog the over-traveled axis off the over-

travel switch.

When you have finished jogging, you can release

the SHIFT key. Note If you accidentally release the
shift key during Step 8a through Step 8.d, you will
have to repeat them

74
Single Axis Mastering
You can master a single axis of any robot provided
that there is a reference mark at a known position
on that axis.

When a single axis of a robot is mastered,

mastering data for the other axes remains
unchanged.

Pre-Conditions
You have cleared any servo faults that prevent you
from jogging the robot.
You have jogged each axis that has lost mastering
at least one motor turn.

Steps
Jog the unmastered axis of the robot to the single
axis mastering position. For M-series or S-series
robots only: Using the joint coordinate system, jog
the unmastered axis of the robot to the zero degree
witness mark. If you are single axis mastering the
J2-axis, the J3-axis must be lined up at its zero
degree mark.
1) Press MENUS.
75
2) Select SYSTEM.
3) Press F1, [TYPE].
See Page 66, To Enable Master/Cal. If not visible
4) Select Master/Cal.
5) Press 4 SINGLE AXIS MASTER
6) Move the cursor to SINGLE AXIS MASTER
and press ENTER.

ACTUAL POS (MSTR POS) (SEL) [ST]

J1 15.124 ( 0.000) (0) [2]
J2 3.514 ( 35.000) (0) [2]
J3 -7.164 ( -100.000) (0) [2]
J4 -35.366 ( 0.000) (0) [2]
J5 -1.275 ( -80.000) (0) [0]
J6 4.571 ( 0.000) (0) [2]

Note A "0" in the [ST] or “status” column indicates

that the axis is unmastered.

7) Move the cursor to the (MSTR POS) column

and move it up or down to the unmastered axis.

76
J5 in this example (Any unmastered axis will have
the number 0 in the [ST] column).

8) Enter the position where single axis mastering

is to be performed in the (MSTR POS) column
for the unmastered axis.

For robots where single axis mastering is

performed at the zero degree position,

9) Press the numeric key "0"

Press ENTER.

Here the -80.00 value under MSTR POS would be

reset to 0 since the joint has been moved to is
witness mark.

10) Press and hold the DEADMAN switch

Turn the teach pendant ON.

11) Move the cursor to the SEL “select” column

and move it to the unmastered axis.

12) Press the numeric key "1"

Press ENTER.
77
13) Press F5, EXEC.

Mastering will be performed automatically.

The SEL value will reset to 0 and the ST value will
change to 2 MSTR POS will return to
-80.00 after the robot is powered on again.

ACTUAL POS (MSTR POS) (SEL) [ST]

J5 -1.275 ( 0.000) (0) [2]
14) Press PREV.
15) Press 6 CALIBRATE
Calibrate ? [NO]
16) Press F4, YES.
Robot Calibrated! Cur Jnt Ang(deg):
<15.124> <3.514> <-7.164>
<-35.366> <0.000> <4.571>

Note If you exit the Master/Cal screen by pressing

F5, DONE, the Master/Cal screen will be hidden.
Master/Cal will not be available by pressing 1,
[TYPE].

78
See Page 65, To Enable Master/Cal again.

Zero Degree Mastering

You can zero degree master any robot provided
that there is a reference mark at a known position
on every axis.

When the robot is mastered, mastering data for all

axes changes.

Pre-Conditions
You have cleared any servo faults that prevent you
from jogging the robot.
You have jogged each axis that has lost mastering
at least one motor turn.

Steps
Jog each axis of the robot to the zero degree
mastering position. For M-series or S-series robots
only: Using the joint coordinate system, jog each
axis of the robot to the zero degree witness mark.

79
1) Press MENUS.

2) Select SYSTEM.

3) Press F1, [TYPE].

See Page 66, To Enable Master/Cal. If invisible.

4) Select Master/Cal.

5) Press 2 ZERO POSITION MASTER

Master at zero position ? [NO]

6) Press F4, YES.

Mastering will be performed automatically.

Robot Mastered! Mastering Data:

<0> <11808249> <38767856>
<9873638> <122000309> <2000319>

80
7) Press 6 CALIBRATE

Calibrate ? [NO]

8) Press F4, YES.

Robot Calibrated! Cur Jnt Ang(deg):

<15.124> <3.514> <-7.164>
<-35.366> <0.000> <4.571>

Note If you exit the Master/Cal screen by pressing

F5, DONE, the Master/Cal screen will be hidden.
Master/Cal will not be available by pressing 1,
[TYPE].

See Page 65, To Enable Master/Cal again.

81
Teaching Points:
Positions & Position Registers
You can teach Local TPP positions “P[x?]” or
Global TPP position registers “PR[x?]” from
within any routine that they exist in. Global TPP
position registers “PR[x?]” may also be accessed
from the Data > Position Registers type of variable.

Preparing to Teach
1) Turn the Key selector to T1 (Manual).

2) Turn the Teach Pendant ON.

3) Press Select.

4) Choose the program which needs Touching up.

5) Step through the routine manually in Step

Mode. (see Page 40)

6) Execute the program to the desired touchup

point. (see Page 41)
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Teaching Positions P[x?]
When you have arrived at the programmed position
which needs to be corrected. Check to see that you
have the correct Manual Jogging motion selected.

This is program dependant and may include having

the correct tool, user frame and motion style preset.

For most pick and place applications or dispense

applications a coordinated linear motion which
maintains the tool to frame orientation is the
correct choice. (ie. World)

Manually jog the robot to the new location.

(see Page 32)

Precision can be enhanced to as fine as 0.001mm

by reducing the speed of the robot to fine or vfine
levels

83
Procedure

1. Jog to the new Position

2. Hold down the Shift Key.

3. Press F5 Touchup.

4. Press F5 No to creating a new ID.

Each local position in a routine may be re-used and

altering the ID will affect the programmed motion
therefore avoid creating any new positions unless
advised to do so.

You will see the following confirmation:

Position has been recorded to P[x?].

84
Teaching Position Registers PR[x?]
Procedure

1. Jog to the new Position

2. Hold down the Shift Key.

3. Press F5 Touchup.

Each global position register used in a routine may

be re-used and altering the position will affect the
programmed motion in other routines therefore
avoid any major revisions of these positions unless
advised to do so.

You will see the following confirmation:

Position has been recorded to PR[x?].

85
Alternate Procedure

1. Press Data.

2. Press F1 Type

3. Hold down the Shift Key.

4. Press F2 Move To.

5. Jog to the new Position.

6. Press F3 Record.

Each global position register used in a routine may

be re-used and altering the position will affect the
programmed motion in other routines therefore
avoid any major revisions of these positions unless
advised to do so.

You will see the following confirmation:

Position has been recorded to PR[x?].

86
I/O Types

The I/O menu includes all of the input and output

types available on the robot.

Types such as Profibus, Devicenet and AB remote

I/O may also defined in additional software PAC’s.

The Cell Interface field is meant to be customized

to include the major sets found on the robot.
87
Once an I/O type is selected, you can navigate
between Input and Output types by pressing F3.

You can also navigate between the Configuration

screen and the Monitor screen by pressing F2.

[F1] [F2] [F3] [F4] [F5]

You may choose another I/O type by pressing F1.

88
Simulating an Inputs’ State

Simulation decouples an input variable from the

state of the actual input port so that it can be
manipulated manually.

89
Procedure

1. Select the Input to be altered with the cursor.

2. Cursor left over the Sim field and press F4 to

allow the status to be simulated.
This will disconnect input variables value from
the actual reading and allow you to “force” it.

3. Cursor back to the right and alter the value to

your needs by pressing F4 to turn it on or F5 to
turn it off as necessary.

4. To clear simulated values they can be

individually reconnected to the actual input by
cursoring left again over the Sim field and
pressing F5 to UN-simulate.

5. You may also globally clear ALL simulated

values (input and output) by:
a. Pressing Fctn
b. Then 0 Next
c. Then 6 Unsim All I/O

Note! The simulated values will clear completely.

90
Simulating an Output Variable

Simulation decouples the output port from the state

of the variable so that it can be manipulated
manually and not affect external devices.

91
Procedure

1. Select the Output to be altered with the cursor.

2. Cursor left over the Sim field and press F4 to

allow the status to be simulated. This will
disconnect the output variables value from the
actual output and allow you to “set” the value
without affecting or triggering external devices.

3. Cursor back to the right and alter the value by

pressing F4 to turn it on or F5 to turn it off.

4. To clear simulated values they can individually

be reconnected to the actual output by cursoring
left again over the Sim field and pressing F5 to
un-simulate.

5. You may also globally clear ALL simulated

values (input and output) by:
a. Pressing Fctn
b. Then 0 Next
c. Then 6 Unsim All I/O

Note! The simulated values will clear completely.

92
Enabling or Disabling
an Interconnected Signal

The robot interconnect tables allow signals to pass

directly between robot I/O types without the need
to be referenced or acted upon by programs. These
connections allow a simple PLC like pass thru of
values. i.e. –[DI]--------(RO)-

93
Procedure

1. Select the interconnect type by pressing F3.

Choose the appropriate combination.

2. Cursor to the signal and enable it by pressing

F4 to turn it on or press F5 to disable it as
necessary.

3. To reactivate a specific signal pairing you must

enable it here by pressing F4 again.

Return to the appropriate type selection to continue

and manually affect the signal state.

94
Forcing an Output

95
Procedure

1. Select the Output to be altered with the cursor.

2. Alter the value by pressing F4 to turn it on or

F5 to turn it off.

Note! The forced values will remain in effect until

an executed logical instruction alters it.

They will be cleared, however, if the robot is

powered down and restarted.

96
I / O Details and Setup

The I/O configuration screens are used to setup and

assign all installed input and output modules in the
robot.

Each type of module has a specific range of rack

addresses available to it. Besides type, physical
location in a series can also determine the rack
address value.
97
Module Type Rack Comment

Fanuc I/O Link (Exp. 9030) 1, 2, 3... Phys. Loc.

Profibus Master 66
Profibus Slave 67
Devicenet Master 1 81 Exp. Slot
1
Devicenet Master 2 82 Exp. Slot
2
Devicenet Master 3 83 Exp. Slot
3
Devicenet Master 4 84 Exp. Slot
4
Ethernet I/O 89

98
Coordinate Details and Selection

Cartesian Robotic Motion references the movement

of a defined point (the Tool) in relation to a second
defined point (the World Frame). The location of
the base World frame origin in the robot is fixed,
predefined and directly related to the kinematic
model of the revolute joint geometry. Offsets from
this point (User & Jog Frames) may be created to
align the robots movement with real world objects,

99
Tool Frames:
1. Are created to allow the precise alignment and
positioning of a physical detail on the end of
arm mounting flange.
2. The default tool (Tool=0) acts as the base
reference for all user defined details.
3. Once a user tool is selected in the coordinates
menu the default tool0 is no longer available.
4. To re-establish the default tool the robot must
be either, restarted or a user program resetting
the Utool_num value to 0 must be run.

User Frames:
1. Are created to allow precise motion of the tool
in alignment with a physical object.
2. They may be referenced within a program as
the coordinate system for motion.
3. The default or World frame may be reselected
at any time.

Jog Frames:
1. Are created to allow precise motion of the tool
in alignment with a physical object.
2. They may not be referenced within a program
as the coordinate system for motion.
100
Notes:

101
Notes:

102
Notes:

103
Notes:

104