Software Installation - Fanuc

SYSTEM R-J Software
-Installation-
Manual
To be used ONLY with SYSTEM R-J Software V3 .06P and late r

This publication contains proprietary information of FANUC Robotic s
North America ; Inc . furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotic s
North America, Inc .
FANUC Robotics North America, Inc .
2000 South Adams Roa d
Auburn Hills, Michigan 48326-280 0
' liOTL .1
I
REFERENCE DOCUMEN T
SYSTEM R-J Software 1

Installation Manua l
MARAJINST09206E
To be used ONLY with SYSTEM R-J Software V3 .06P and later
This publication contains proprietary information of FANUC Robotic s
North America, Inc . furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotic s
North America, Inc .
FANUC Robotics North America, Inc .
2000 South Adams Road
Auburn Hills, Michigan 48326-2800
The description and specifications contained in this manual were in effec t

at the time this manual was approved for printing . FANUC Robotics
North America, Inc, hereinafter referred to as FANUC Robotics, reserve s
the right to discontinue models at any time or to change specifications o r
design without notice and without incurring obligations .
FANUC Robotics manuals present descriptions, specifications, drawings ,
schematics, bills of material, parts, connections and/or procedures fo r
installing, disassembling, connecting, operating and programming FANU C
Robotics' products and/or systems . Such systems consist of robots ,
extended axes, robot controllers, application software, the KAREL
programming language, INSIGHT vision equipment, and special tools .
FANUC Robotics recommends that only persons who have been trained i n
one or more approved FANUC Robotics Training Course(s) be permitted
to install, operate, use, perform procedures on, repair, and/or maintai n
FANUC Robotics' products and/or systems and their respectiv e
components . Approved training necessitates that the courses selected b e
relevant to the type of system installed and application performed at th e
customer site .
WARNING
This equipment generates, uses, and can radiate radi o
frequency energy and if not installed and used i n
accordance with the instruction manual, may caus e
interference to radio communications. As temporaril y
permitted by regulation, it has not been tested fo r
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against suc h
interference . Operation of the equipment in a residential
area is likely to cause interference, in which case the user ,
at his own expense, will be required to take whateve r
measure may be required to correct the interference .
FANUC Robotics conducts courses on its systems and products on a

regularly scheduled basis at the company's world headquarters in Auburn
Hills, Michigan. For additional information contac t
FANUC Robotics North America, Inc.
Training and Documentation Department
2000 South Adams Road
Auburn Hills, Michigan 48326-2800
Tel : (810)377-723 4
FAX : (810)377-7367 or (810)377-7362
Copyright 1992, 1993, 1994 by FANUC Robotics North America ,

Inc.
All Rights Reserved
The information illustrated or contained herein is not to be reproduced ,
copied, translated into another language, or transmitted in whole or in par t
in any way without the prior written consent of FANUC Robotics Nort h
America, Inc.
ArcTool, FANUC LASER DRILL, KAREL, INSIGHT ,
INSIGHT II, PaintTool, PAINTWorks, PalletTool ,
SOCKETS, SOFT PARTS and SpotTool, are Registered
Trademarks of FANUC Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names :
ACCUFLOW '
ACUST
.
ARCMate
ARC MateSr
DispenTol
InteliTrak
LaserTool
MotinPars
PAINTWork sI
PALLETMATE
SureWld
TurboMove
FANUC Robotics Hotlin e

For a PRODUCTION robot that is DOW N
call 24 hours a day, 7 days a wee k
810-377-7159
For all other Troubleshooting and Technical Support
contact your local distributor or call the Hotline
Monday - Friday, 8 :00 A.M . - 5:00 P .M . Eastern Time
BEFORE YOU CALL please have your Maintenance and Troubleshootin g

manual, and the following information, ready .
INFORMATION
Customer information
Robot type
(A, L, M, P, or S, & 3-digit number)
Controller style
DETAILS
Include
your company's
name
caller's name
phone number where

caller can be reached ,
including area code an d
extension
On the arm of the robot .
Ask your supervisor.
(RA, RB, RC, RF, RG, RH, RJ)
F Number
Robot serial number
(if no F Number is available)
Controller serial numbe r
(if no F Number is available)
Software edition and
revision numbers
This table is continued
on the next page.
On the identification tag on the robot an d

controller, near the cable connection .
On the identification tag located near th e
cable connection .
On the controller tag located on the doors .
Shown on the CRT or teach pendant statu s
screen during the power-up sequence .
INFORMATION
DETAILS
include
List of error messages
error message number

. message following error message numbe r
any numbers following error messag e
List of diagnostic LEDs
Note the PCB where the LED is located and th e

LED name or designation.
History of problem
Description of events leading up to problem .

List
any application software running on the system
the line number where the program halte d
a description of what is happening on that line
Application software
MARAJINST09205E
Purpose of this Manual
Related Manuals
How to Use this

Manual
Preface
vii
This manual describes FANUC Robotics SYSTEM R-J Softwar e

Installation :
Package contents
Requirements
Procedures
Troubleshooting and error recover y
The entire manual set for this product includes manuals you can use whe n
performing other tasks in the system. You do not need these manuals to
use this manual ; they provide information that you can use in other area s
of the robot, controller, and application system .
Descriptions
Manual
Includes detailed descriptions of the R-J controlle r

hardware features, robot configurations and
specifications, end effector requirements, installatio n
requirements, and application software requirements
and features.
R-J Controller
Connection an d
Maintenanc e
Manual
Contains specific R-J controller electrical maintenanc e

and troubleshooting information and procedures fo r
maintenance operations such as replacing fuses ,
checking wiring, recovering from fault conditions, an d
checking and replacing controller components .
Use this table to locate specific information in the manual .

If you want to
Refer to
Find information about a specific topic
Table of Content s
Determine the installation requirements fo r

your application
Chapter 1, Overview
Set up and check memory requirements
Chapter 2, Setting U p
Controller Memor y
Check and install EPROM chips
Chapter 3, EPRO M
Installatio n
Install core, application, robot library, motion

groups and extended axis software
Chapter 4, Software
Installatio n
Master the robot
Chapter 5, Masterin g
Perform troubleshooting and error recovery
Chapter 6, Troubleshooting
and Error Message s
Use Boot Rom
Appendix A , BootRo m
Operation s
viii
Conventions Used in
this Manual
PREFACE
MARAJINST09205E
This manual includes information essential to the safety of personnel,

equipment, software, and data . This information is indicated by headings
and boxes in the text .
WARNIN G
Information appearing under WARNING concerns the
protection of personnel . It is boxed and in bold type to set
it apart from other text .
CAUTIO N
A
Information appearing under CAUTION concerns the protectio n
of equipment, software, and data . It is boxed to set it apart
from other text .
NOTE Information appearing next to NOTE concerns related information

or useful hints .
Table of Contents
MARAJINST09206E
Preface
Safety
vii
xiii
Chapter 1
OVERVIEW
1-1
1 .1 PACKAGE CONTENTS
1 .1 .1 Software Disks
1 .1 .2 System EPROM Chips
1-2
1-2
1-24
1 .2 INSTALLATION REQUIREMENTS
12 .1 Teach Pendant
1 .2 .2 Disk Drive Unit
1 .2 .3 Controller Hardware Tools
1-2 5
1-25
1-27
1-27
Chapter 2
SETTING UP CONTROLLER MEMORY
2- 1
2 .1 CHECKING SYSTEM MEMORY
2-2
22 INSTALLING CMOS AND FLASH ROM MEMORY

2.3 COPYING CONTROLLER MEMORY
2-3
2-7
Chapter 3
EPROM INSTALLATION
3-1
3 .1 INSTALLING BOOTROM EPROM CHIPS

3 .2 INSTALLING TEACH PENDANT EPROM CHIPS
3-2
3-8
Chapter 4
SOFTWARE INSTALLATION
4-1
Chapter 5
MASTERING
5-1
5 .1 MASTERING TO A FIXTURE (MASTER POSITION MASTER)
5-2
5-4
5 .2 ZERO DEGREE MASTERING

5 .3 SINGLE AXIS MASTERING
5 .4 QUICK MASTERING
5-6
5-8
TABLE OF CONTENTS
MARAJINST09206E
TROUBLESHOOTING AND ERROR MESSAGES
6-1
6 .1 TROUBLESHOOTING USING SYMPTOMS

6 .2 TROUBLESHOOTING USING ERROR MESSAGES
6.3 PERFORMING A RE-INIT START
6-2
6-3
6-7
Chapter 6
Appendix A
BOOTROM OPERATIONS
A.1 STARTUP METHODS
A.1 .1 Hot Start
A.1 .2 Cold Start
A.1 .3 Controlled Start
A.2 BOOTROM UTILITIES
A.3 DIAGNOSTIC UTILITIES (DIAG>)
A.4 EXTENDED BOOT MONITOR UTILITIES (EMON>)
A.5 DEVICE MONITOR UTILITIES (DEV>)
A-1
A-2
A-2
A-3
A-4
A-6
A-8
A-1 0
A-1 1
List of Procedure s
Procedure 2- 1
Procedure 2-2
Procedure 2-3
Procedure 2-4
Procedure 3- 1
Procedure 3-2
Procedure 3-3
Procedure 3-4
Procedure 4- 1
Procedure 4-2
Procedure 4-3
Procedure 4-4
Procedure 4-5
Procedure 4-6
Procedure 4-7
Procedure 4- 8
Procedure 5-1
Procedure 5-2
Procedure 5-3
Procedure 5-4
Procedure 5-5
Procedure 6-1
ProcedureA-1
Procedure A-2
Displaying Memory Status

Installing a CMOS RAM or Flash ROM Module
Copying 3 .5MB (2+1.5) and 4MB (2+2) Controller Memory
Copying 6MB (4+2) Controller Memory
Checking the BootROM Version
Installing New BootROM EPROM Chips
.. . .
Checking Teach Pendant EPROM Versions . . .
.
Installing A New Teach Pendant EPROM Chip
Installing V3 .06P or V3 .06PA Core, Application and Robot Library Software
Installing V3 .06PB Core, Application and Robot Library Software
Installing V3 .06PC and V3.06PD Core, Application and Robot Library Software
Installing R-J Software Options
Installing PaintTool Software Options
Installing R-J Software Updates
Installing Motion Groups
Installing Extended Axes
Mastering to a Fixture
Mastering to Zero Degrees
Mastering a Single Axis
Recording the Quick Master Reference Position
Quick Mastering the Robot
Performing a Re-Init Start (V3 .06PA, V3 .06PB, V3 .06PC)
Performing a Hot Start
Performing a Cold Start
2-2
2-3
2-7
2-1 2
3-2
3-3
3-8
3-9
4-3
4-1 7
4-29
4-39
4-42
4-46
4 49
4-62
5-2
5-4
5-6
5-8
5-1 0
6-7
A-2
A-3
MARAJINST09206E
TABLE OF CONTENTS
Procedure A-3 Performing a Controlled Start

Procedure A-4 Using BootROM Utilities
Procedure A-5 Using DIAG> Utilities
Procedure A-6 Using EMON> Utilities
Procedure A-7 Using DEV> Utilities
xi
A-5
A-7
A-9
A-1 0
A-1 1
List of Figure s
Figure 1-1 . Standard Teach Pendant
Figure 1-2 . Intrinsically Safe Teach Pendant (ISTP)
Figure 1-3 . PS-100 Connected to the Controller
Figure 2-1 . R-J Controller Disconnect Handle and Latch
Figure 2-2 . MAIN CPU Board Location
Figure 2-3 . Removing the MAIN CPU Board
Figure 2-4 . Installing the CMOS RAM or Flash ROM Module
Figure 2-5. Plugging in the Extension Backplane
Figure 2-6 . Plugging in the Extension Backplane
Figure 3-1 . R-J Controller Disconnect Handle and Latch
Figure 3-2. MAIN CPU Board Location
Figure 3-4. Locating the BootROM Chips
Figure 3-5 . Removing the Back Cover of the Teach Pendant
Figure 3-6 . Locating the Teach Pendant EPROM Chip
Figure 3-7 . EPROM Labels
1-25
1-2 6
1-27
2-4
2-4
2-5
2-5
2-8
2-1 2
3-4
3-5
3-6
3-6
3-1 0
3-1 0
3-1 1
List of Table s
Table 1-1 . Software Version Information
Table 2-1 . Memory Status
Table 4-1 . Shot Meter Configuration Items
Table 4-2 . Nordson Configuration Items
Table 4-3 . Schucker Configuration Items
Table 4-4. Jesco Configuration Items
Table 4-5 . Configuration Setup Items
Table 4-6 . Motor Selection Combinations
Table 5-1 . Mastering Methods
Table 6-1 . Troubleshooting Symptoms and Solutions
Table 6-2 . Software Option Messages
Table 6-3 . BootROM Error Messages
Table A-i . Controlled Start Options
Table A-2. BootROM Utilities
Table A-3 . BootROM Diagnostic Utilities
Table A-4. BootROM Extended Monitor Utilities
Table A-5. BootROM Device Monitor Utilities
1-3
2-2
4-9
4-1 1
4-1 2
4-1 3
4-3 7
4-65
5- 1
6-2
6-3
6-4
A-4
A-6
A- 8
A-1 0
A-11
Safety
FANUC Robotics is not and does not represent itself as an expert in safet y
systems, safety equipment, or the specific safety aspects of your compan y
and/or its work force . It is the responsibility of the owner, employer, or
user to take all necessary steps to guarantee the safety of all personnel i n
the workplace .
The appropriate level of safety for your application and installation can
best be determined by safety system professionals . FANUC Robotics
therefore, recommends that each customer consult with such professional s
in order to provide a workplace that allows for the safe application, use ,
and operation of FANUC Robotic systems .
Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot syste m
to recognize and respond to known hazards associated with your roboti c
system and to be aware of the recommended operating procedures for you r
particular application and robot installation .
FANUC Robotics therefore, recommends that all personnel who intend t o
operate, program, repair, or otherwise use the robotics system be trained i n
an approved FANUC Robotics training course and become familiar wit h
the proper operation of the system . Persons responsible for programming
the system including the design, implementation, and debugging of
application programs-must be familiar with the recommende d
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of
safety in the workplace.
xiv
CONSIDERIN G
SAFETY FOR YOU R
ROBOT
INSTALLATION
SAFETY
Safety is essential whenever robots are used . Keep in mind the followin g
factors with regard to safety :
Keeping People and

Equipment Safe
Enhancing Devices
People
External device s
Robot(s)
Tooling
Workpiece
Always give appropriate attention to the work area that surrounds the
robot. The safety of the work area can be enhanced by the installation of
some or all of the following devices :
Setting Up a Safe
Workcell
The safety of people and equipment

Use of safety enhancing device s
Techniques for safe teaching and manual operation of the robot(s )
Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcel l
Proper maintenance of the robot
The safety of people is always of primary importance in an y

situation. However, equipment must be kept safe, too . When
prioritizing how to apply safety to your robotic system, conside r
Using Safety
MARAJINST09205E
Safety fences, barriers, or chains

Light curtains
Interlocks
Pressure mats
Floor markings
Warning light s
Mechanical stop s
EMERGENCY STOP button s
DEADMAN switche s
A safe workcell is essential to protect people and equipment . Observe the

following guidelines to ensure that the workcell is setup safely . Thes e
suggestions are intended to supplement and not replace existing federal,
state, and local laws, regulations, and guidelines that pertain to safety.
Sponsor your personnel for training in approved FANUC Robotic s

training course(s) related to your application . Never permit untrained
personnel to operate the robots .
Install a lockout device that uses an access code to preven t

unauthorized persons from operating the robot .
Use anti-tie-down logic to prevent the operator from bypassing safet y

measures .
Arrange the workcell so the operator faces the workcell and can see
what is going on inside the cell .
MARAJINST09205E
SAFETY
xv
Clearly identify the work envelope of each robot in the system with
floor markings, signs, and special barriers . The work envelope is the
area defined by the maximum motion range of the robot, including any
tooling attached to the wrist flange that extend this range.
Position all controllers outside the robot work envelope .
Never rely on software as the primary safety element .
Mount an adequate number of EMERGENCY STOP buttons o r

switches within easy reach of the operator and at critical points insid e
and around the outside of the workcell .
Install flashing lights and/or audible warning devices that activat e

whenever the robot is operating, that is, whenever power is applied t o
the servo drive system.
Wherever possible, install safety fences to protect against unauthorize d

entry by personnel into the work envelope.
Install special guarding that prevents the operator from reaching int o
restricted areas of the work envelope .
Use interlocks .
Use presence or proximity sensing devices such as light curtains, mats ,

and capacitance and vision systems to enhance safety.
Periodically check the safety joints or safety clutches that can b e

optionally installed between the robot wrist flange and tooling . If the
tooling strikes an object, these devices dislodge, remove power fro m
the system, and help to minimize damage to the tooling and robot .
Make sure all external devices are properly filtered, grounded ,

shielded, and suppressed to prevent hazardous motion due to the
effects of electro- magnetic interference (EMI), radio frequenc y
interference (RFI), and electro-static discharge (ESD) .
Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel coul d
get trapped between a moving robot and other equipment .
Provide enough room inside the workcell to permit personnel to teac h

the robot and perform maintenance safely.
Program the robot to load and unload material safely.
If high voltage electrostatics are present, be sure to provide appropriat e

interlocks, warning, and beacons .
If materials are being applied at dangerously high pressure, provid e

electrical interlocks for lockout of material flow and pressure .
xvi
Staying Safe While

Teaching or Manually
Operating the Robot
SAFETY
MARAJINST09205E
Advise all personnel who must teach the robot or otherwise manually
operate the robot to observe the following rules :
Know whether or not you are using an intrinsically safe teach pendan t
if you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to make
sure that no potentially hazardous conditions exist. The work
envelope is the area defined by the maximum motion range of the
robot. These include tooling attached to the wrist flange that extend s
this range.
The area near the robot must be clean and free of oil, water, or debris .
Immediately report unsafe working conditions to the supervisor or
safety department.
FANUC Robotics recommends that no one enter the work envelope o f

a robot that is on . However, if you must enter the work envelope, b e
sure all safeguards are in place, and check the teach pendant
DEADMAN switch for proper operation. Take the teach pendant with
you, turn it on, and be prepared to release the DEADMAN switch
Only the person with the teach pendant should be in the wor k
envelope .
Know the path that can be used to escape from a moving robot ; make
sure the escape path is never blocked.
Isolate the robot from all remote control signals that can cause motio n
while data is being taught .
Test any program being run for the first time in the following manner:
WARNING
Stay outside the robot work envelope whenever a progra m
is being run . Failure to do so can result in injury.
Using a low motion speed, single step the program for at least one
full cycle .
Using a low motion speed, test run the program continuously for
at least one full cycle.
Using the programmed speed, test run the program continuousl y
for at least one full cycle .
Make sure all personnel are outside the work envelope before running
production.
MARAJINST09205E
Staying Safe During

Production Operation
Staying Safe During

Inspection
SAFETY
xvii
Advise all personnel who operate the robot during production to observe
the following rules :
Know the entire workcell area . The workcell includes the robot and it s
work envelope, plus the area occupied by all external devices an d
other equipment with which the robot interacts .
Understand the complete task the robot is programmed to perfor m

before initiating production operation .
Make sure all personnel are outside the work envelope before
operating the robot .
Never enter or allow others to enter the work envelope during

production operation of the robot.
Know the location and status of all switches, sensors, and control
signals that could cause the robot to move.
Know where the EMERGENCY STOP buttons are located on both th e

robot control and external control devices . Be prepared to press thes e
buttons in an emergency.
Never assume that a program is complete if the robot is not moving .

The robot could be waiting for an input signal that will permit it t o
continue activity.
If the robot is running in a pattern, do not assume it will continue t o

run in the same pattern .
Never try to stop the robot, or break its motion, with your body . The
only way to stop robot motion immediately is to press a n
EMERGENCY STOP button located on the controller panel, teac h
pendant, or emergency stop stations around the workcell.
when inspecting the robot, be sure to
Turn off power at the controller.
Lock out and tag out the power source at the controller according t o
the policies of your plant.
Turn off the compressed air source and relieve the air pressure .
If robot motion is not needed for inspecting the electrical circuits ,

press the EMERGENCY STOP button on the operator panel .
If power is needed to check the robot motion or electrical circuits, b e

prepared to press the EMERGENCY STOP button, in an emergency .
xviii
Staying Safe Durin g

Maintenance
SAFETY
MARAJINST09205E
When performing maintenance on your robot system, observe th e

following rules:
Never enter the work envelope while the robot or a program is i n

operation .
Before entering the work envelope, visually inspect the workcell t o
make sure no potentially hazardous conditions exist .
Consider all or any overlapping work envelopes of adjoining robot s

when standing in a work envelope .
Test the teach pendant for proper operation before entering the wor k
envelope.
If it is necessary for you to enter the robot work envelope while powe r
is turned on, you must be sure that you are in control of the robot . Be
sure to take the teach pendant with you, press the DEADMAN switch ,
and turn the teach pendant on . Be prepared to release the DEADMA N
switch to turn off servo power to the robot immediately .
Whenever possible, perform maintenance with the power turned off .

Before you open the controller front panel or enter the work envelope ,
turn off and lock out the 3-phase power source at the controller.
WARNING
Lethal voltage is present in the controller WHENEVER IT I S
CONNECTED to a power source. Be extremely careful to
avoid electrical shock .
Turning the disconnect or circuit breaker to the OF F

position removes power from the output side of the devic e
only. High voltage is always present at the input sid e
whenever the controller is connected to a power source .
Release or block all stored energy. Before working on the pneumatic

system, shut off the system air supply and purge the air lines .
Isolate the robot from all remote control signals . If maintenance must
be done when the power is on, make sure the person inside the wor k
envelope has sole control of the robot. The teach pendant must b e
held by this person.
Make sure personnel cannot get trapped between the moving robot an d
other equipment . Know the path that can be used to escape from a
moving robot. Make sure the escape route is never blocked.
Use blocks, mechanical stops, and pins to prevent hazardou s

movement by the robot. Make sure that such devices do not create
pinch points that could trap personnel .
MARAJINST09205E
SAFETY
xix
WARNING
Do not try to remove any mechanical component from th e
robot before thoroughly reading and understanding the
procedures in the appropriate manual . Doing so can resul t
in serious personal injury and component destruction .
Be aware that when you remove a servomotor or brake, the associated

axis will fall if it is not supported or resting on a hard stop .
When replacing or installing components, make sure dirt and debris d o

not enter the system.
Use only specified parts for replacement . To avoid fires and damage
to parts in the controller, never use nonspecified fuses .
Before restarting a robot, make sure no one is inside the work

envelope ; be sure that the robot and all external devices are operatin g
normally.
KEEPING MACHIN E
TOOLS AN D
EXTERNAL
DEVICES SAFE
Certain programming and mechanical measures are useful in keeping th e

machine tools and other external devices safe . These measures are
outlined below.
Programming Safety
Precautions
Implement the following programming safety measures to prevent damag e

to machine tools and other external devices.
Mechanical Safety
Precautions
Back-check limit switches in the workcell to make sure they do no t

fail .
Implement "failure routines" in programs that will provide appropriate

robot actions if an external device or another robot in the workcel l
fails.
Use handshaking protocol to synchronize robot and external devic e

operations .
Program the robot to check the condition of all external devices durin g
an operating cycle .
Implement the following mechanical safety measures to prevent damage to

machine tools and other external devices .
Make sure the workcell is clean and free of oil, water, and debris .
Use software limits, limit switches, and mechanical hardstops t o

prevent undesired movement of the robot into the work area o f
machine tools and external devices .
xx
SAFETY
MARAJINST09205 E
KEEPING TH E
ROBOT SAFE
Observe the following operating and programming guidelines to preven t

damage to the robot.
Operating Safety
The following measures are designed to prevent damage to the robo t

during operation .
Precaution s
Use a low override speed to increase your control over the robot whe n
jogging the robot .
Visualize the movement the robot will make before you press the jo g
keys on the teach pendant.
Make sure the work envelope is clean and free of oil, water, or debris .
Use. circuit breakers to guard against electrical overload .
Programming Safety
Precautions
The following safety measures are designed to prevent damage to the robo t
during programming:
Establish interference zones to prevent collisions when two or mor e

robots share a work area .
Make sure that the program ends with the robot near or at the hom e
position .
Be aware of signals or other operations that could trigger operation o f

tooling resulting in personal injury or equipment damage .
In dispensing applications, be aware of all safety guidelines wit h

respect to the dispensing materials .
NOTE Any deviation from the methods and safety practices described i n
this manual must conform to the approved standards of your company . If
you have questions, see your supervisor .
MARAJINST09205E
ADDITIONAL
SAFETY
CONSIDERATION S
FOR PAINT ROBOT
INSTALLATIONS
SAFETY
xxi
Process technicians are sometimes required to enter the paint booth, for
example, during daily or routine calibration or while teaching new paths to
a robot. Maintenance personal also must work inside the paint booth
periodically.
Whenever personnel are working inside the paint booth, ventilatio n
equipment must be used. Instruction on the proper use of ventilating
equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers stil l
exist. Therefore, today's highly automated paint booth requires tha t
process and maintenance personnel have full awareness of the system an d
its capabilities . They must understand the interaction that occurs betwee n
the vehicle moving along the conveyor and the robot(s), hood/deck and
door opening devices, and high-voltage electrostatic tools .
Paint robots are operated in three modes :
Teach or manual mode
Automatic mode, including production and exercise operatio n
Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will
follow a predetermined pattern of movements . In teach mode, the proces s
technician teaches (programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System Controlle r
Center (SCC), Manual Control Panel (MCP), if available, or Manual Pain t
Station (MPS), if available, and can be monitored from outside the pain t
booth. All personnel must remain outside of the booth or in a designate d
safe area within the booth whenever automatic mode is initiated at the
SCC, MCP, or MPS.
In automatic mode, the robots will execute the path movements they were
taught during teach mode, but generally at production speeds .
When process and maintenance personnel run diagnostic routines that
require them to remain in the paint booth, they must stay in a designated
safe area .
SAFETY
Paint System Safety
Features
MARAJINSTO92O5E
Process technicians and maintenance personnel must become totally

familiar with the equipment and its capabilities . To minimize the risk of
injury when working near robots and related equipment, personnel mus t
comply strictly with the procedures in the manuals .
This section provides information about the safety features that ar e
included in the paint system and also explains the way the robot interacts
with other equipment in the system.
The paint system includes the following safety features :
Most paint booths have red warning beacons that illuminate when the
robots are armed and ready to paint. Your booth might have othe r
kinds of indicators. Learn what these are .
Some paint booths have a blue beacon that, when illuminated ,

indicates that the electrostatic devices are enabled . Your booth might
have other kinds of indicators . Learn what these are.
EMERGENCY STOP buttons are located on the Manual Contro l

Panel (MCP), or Manual Paint Station (MPS) panel, if supplied, insid e
the booth, or on the System Controller Center (SCC) outside the
booth . Also, EMERGENCY STOP buttons are located near the
interior corners of each booth, and on the robot controller and teac h
pendant. Become familiar with the locations of all E-STOP buttons .
An intrinsically safe teach pendant is used when teaching in hazardou s

paint atmospheres .
A DEADMAN switch is located on each teach pendant . When thi s

switch is held in, power is applied to the robot servo system . If the
engaged DEADMAN switch is released during robot operation, power
is removed from the servo system, all axis brakes are applied, and the
robot comes to an EMERGENCY STOP. Safety interlocks within the
system might also E-STOP other robots .
WARNIN G
An EMERGENCY STOP will occur if the DEADMAN switc h
is released on a bypassed robot .
Overtravel by robot axes is prevented by software limits . All of the

major and minor axes are governed by software limits . Limit switches
and hardstops also limit travel by the major axes .
MARAJINST09205E
SAFET Y
EMERGENCY STOP limit switches and photoelectric eyes might b e

part of your system . Limit switches, located on the entrance/exit doors
of each booth, will EMERGENCY STOP all equipment in the booth i f
a door is opened while the system is operating in automatic or manua l
mode . For some systems,signals to these switches are bypassed whe n
the switch on the SCC is in teach mode.
When present, photoelectric eyes are sometimes used to monitor
unauthorized intrusion through the entrance/exit silhouette openings.
Staying Safe Whil e

Operating the Paint
Robot
System status is monitored by computer . Severe conditions result i n

automatic system shutdown .
When you work in or near the paint booth, observe the following rules, i n
addition to all rules for safe operation that apply to all robot systems .
WARNIN G
Observe all safety rules and guidelines to avoid injury,
Know the work area of the entire paint station (workcell) .
Know the work envelope of the robot and hood/deck and door opening
devices .
s Be aware of overlapping work envelopes of adjacent robots .
Know where all red, mushroom-shaped EMERGENCY STOP button s

are located.
Know the location and status of all switches, sensors, and/or contro l
signals that might cause the robot, conveyor, and opening devices t o
move .
Make sure that the work area near the robot is clean and free of water ,
oil, and debris . Report unsafe conditions to your supervisor.
Become familiar with the complete task the robot will perform
BEFORE starting automatic mode .
Make sure all personnel are outside the paint booth before turning o n
power to the robot servo system .
Never enter the work envelope or paint booth before turning on powe r
to the robot servo system.
Never enter the work envelope during automatic operation unless a

safe area has been designated.
Never wear watches, rings, neckties, scarves, or loose clothing that

could get caught in moving machinery .
xxiv
Staying Safe Durin g

Maintenance
SAFETY
MARAJINST09205 E
Remove all metallic objects, such as rings, watches, and belts, befor e
entering a booth when the electrostatic devices are enabled .
Stay out of areas where you might get trapped between a movin g
robot, conveyor, or opening device and another object .
Be aware of signals and/or operations that could result in the triggerin g

of guns or bells .
Be aware of all safety precautions when dispensing of paint i s

required.
Follow the procedures described in this manual .
When you perform maintenance on the painter system, observe th e

following rules, and all other maintenance safety rules that apply to all
robot installations . Only qualified, trained service or maintenanc e
personnel should perform repair work on a robot.
Paint robots operate in a potentially explosive environment . Us e

caution when working with electric tools .
When a maintenance technician is repairing or adjusting a robot, th e

work area is under the control of that technician . All personnel not
participating in the maintenance must stay out of the area .
For some maintenance procedures, station a second person at th e

control panel within reach of the EMERGENCY STOP button . This
person must understand the robot and associated potential hazards .
Be sure all covers and inspection plates are in good repair and in place .
Always return the robot to the "home" position before you disarm it.
Never use machine power to aid in removing any component from th e

robot.
During robot operations, be aware of the robot's movements . Exces s

vibration, unusual sounds, and so forth, can alert you to potential
problems .
Whenever possible, turn off the main electrical disconnect before yo u
clean the robot .
MARAJINST09205E
SAFETY
xxv
When using vinyl resin observe the following :

-
Wear eye protection and protective gloves during application and

removal
Adequate ventilation is required . Overexposure could caus e

drowsiness or skin and eye irritation .
If there is contact with the skin, wash with water .
When using paint remover observe the following :

Eye protection, protective rubber gloves, boots, and apron ar e
required during booth cleaning .
-
Adequate ventilation is required . Overexposure could caus e

drowsiness.
If there is contact with the skin or eyes, rinse with water for a t
least 15 minutes.
OVERVIEW
1-1
MARAJINST09206E
This chapter describes the SYSTEM R-J Software Installation Package . It

includes information o n
What you must do to set up and install the components of thi s
package in your syste m
What you have in your SYSTEM R-J Software Installation Packag e
What you need to set up and install the components of this packag e
Installation Tasks
The first time you install the SYSTEM R-J Software Installation Package ,
and whenever you update your controller with components in this package ,
you must do the following :
Make sure you have enough memory in your controller and adjust it i f
you need more . Refer to Chapter 2.
If you are updating your controller, back up all system files . Refer to
the Setup and Operations Manual for more information on backing up
files .
Make sure you have the correct system EPROM chips and install them
if necessary. Refer to Chapter 3.
Install the Core, Core Options, Robot Library, Application/Tool and

Application/Tool Options disks purchased for your system . Refer to
Chapter 4.
Perform the mastering procedures required for your robot . Refer to

Chapter 5 .
NOTE You must satisfy system memory and EPROM requirement s

before you can install the SYSTEM R-J software . If you perform all setup
and installation procedures and still have a problem with the installation ,
refer to Chapter 6 for information to help you solve the problem .
1. OVERVIEW
MARAJINST09206 E
1-2
1 .1
PACKAGE CONTENTS
The SYSTEM R-J controller design features SOCKET software structures ,

allowing application/tool and robot library SOFT PARTS to be added to
meet your specific application requirements .
The R-J software installation package consists o f
Software disk s
Erasable Programmable Read-Only Memory (EPROM) chip s
1 .1 .1
Software Disks
Your R-J software installation package consists of the following kinds of

disks :
Core
Application/Tool
Robot Library
Your package can also contain the following kinds of disks:
Core Option s
Application/Tool Option s
Robot Library Options
Core and Application Updates
A core is the fundamental component of the SYSTEM R-J software . It
provides the robot operating system and SOCKETS for all other layered
software components . Most systems will use the standard core software .
However, other systems could use core software that i s
application-specific . All systems must include core software .
An application/tool is a software component, containing SOFT PARTS ,
which is used in addition to the core software. It provides application
specific functionality. All systems must include application/tool software .
A robot library is a software component, containing SOFT PARTS, whic h
is used with a core and an application/tool. It provides FANUC robo t
model-specific functionality. Most systems will use the standard robo t
library software . However, other systems could use robot library softwar e
that is application-specific . All systems must include a robot library.
An option is a software component that provides specific functionality that
can optionally be used with core, application/tool and robot librar y
software.
An update is a software component that adds specific functionality tha t
must be used with core, application/tool and robot library software .
The kinds of disks listed below are available on 3 -1/2" disks . Table 1-1
lists the following information about each kind of software package yo u
can have :
Contents
CMOS RAM requirements
Flash ROM requirements
BootROM EPROM versio n
Number of 3" disks
1 . OVERVIEW
1-3
MARAJINST09206E
Table 1-1 . Software Version Informatio n
Disk Contents &

Part Number
Product
ArcTool Software
Package
ArcTool Application Software
SBARCTLJ130X3X1
Core Software
Teach Pendant EPRO Mo7rDs01i/o4n

Version :
r
later
Version: 1 .30P
Number of
31/2" Disks
Comment
Required for TAST, AVC, or Touch Sensin g
Includes V3 .06P robot operating syste m

software information .
Includes all currently supported robot models
and supports group motion .
Cannot be installed with AVC option or
Multi-Pass option . ArcTool only.
SFTARTLJ130A3X1
SFTCOREJ306X3XX
Libraries
SFTRBLBJ306X3X2
THRU-ARC Seam Tracking MP/RPM

(option)
SFTTASTJ130X3XX
BootROM EPROM
Version : 1.10P or later
Required:
2MB Flash ROM (min)
2MB CMOS RAM (min)
Memory
AVC with
MP/RPM
Cannot be installed with TAST or Multi-Pas s

option . ArcTool only.
Cannot be installed with TAST or AVC option.

ArcTool only.
Can be used alone or with AVC or TAST .
ArcTool only.
(option)
SFTAVCXJ13OX3XX
Multi- ass Welding

(option)
SFTMULTJ13OX3XX
NOTE : Installation of Touch Sensing

multiple options
(option)
might require
SFTTOSEJ13OX3XX
WS CMOS RAM
Detached Jog
(option )
SFTDEJOJ130X3XX
FANUC Sensor Interface (3D offset)

(option)
PLC I/O (ABRIO/Genius)
(option)
Interface from Application/Tool to an eXterna l

sensor device such as a V 120 visio n
system .
Supports the Allen-Bradley and FANU C
Robotics Genius network I/O interfac e
hardware using the R-H eXtended backplan e
on the R-J controller.
Extended Axis
(option)
Supports independent auxiliary aXes .
Includes all Arc Enable and UOP interfac e

software .
SFTFASEJ306XSXX
SFTPLCIJ306X3X1
SFTEXAXJ306X3XX
Remote Arc Enable / UOP Interface

(update)
SFTUPDTJ306X316
1 . OVERVIEW
MARAJINST09206E
1-4
Table 1-1 . (Cont'd) Software Version Informatio n
Disk Contents &
Part Number
Core Software
Product
DispenseTool
Software Package
Shot
Shot Meter:
SFTCOREJ306A3XX
TLJ120X3
SBDISTLJ120X3X2
Jesco:SBDISTLJ12OX3X3
Schucker:SBDISTLJ120X3X4
Robot Libraries
SFTRBLBJ306ASXX
DispenseTool Software for Nordson

Equipment
SFTDITLJ12OX3X2
Version : 1.20P
Teach Pendant
EPROM
Version : 7D01/04D or
later
Number of
Comment
3-1/2" Disks
Includes all V3 .06PA core softwar e
6
information .
Includes all currently supported robot
1
models.
DispenseTool Application Software for use
1
with Nordson Micro Pro-Flo dispensin g
equipment.
DispenseTool Software for Shot

Meter Equipment
DispenseTool Application Software for use

with Shot Meter dispensing equipment .
DispenseTool Software for Jesco

Equipment
DispenseTool Application Software for us e

with Jesco dispensing equipment.

with Schucker dispensing equipment .
Includes all EOAT software information ,

including the 4-Position Tool ,
Dispense/Material Handling Tool, and th e
Disposable Too l
Robotics Genius network I/O interface
hardware using the R-H extended backplan e
Includes all CRT/KB information .
SFTDITLJ12OX3X3
SFTDITLJ12OX3X 3
BootROM EPROM
Version : 1.10PA or later DispenseTool Software for Schucker
Equipment
Memory Required :
SFTDITLJ120X3X4
2MB FRO M
DispenseTool End-Of-Arm-Tooling
2MB CMOS RAM
(option)
SFTEOATJ120X3Xx
NOTE: Installation of
multiple options
might require
4MB CMOS RAM
(option)
SFTPLCIJ306X3X1
CRT/Keyboard Manager
(option)
SFTCRTKJ306X3XX
KAREL Development Option

Package
(option)
SFTKADPJ306X3XX
KAREL Command Language

(option)
SFTKCLXJ306x3XX
File System/RAM Disk
(option)
SFTFSRDJ306X3XX
Serial Host Communication
Provides serial communication ove r

RS-232-C for file transfer.
Provides data communication over etherne t

for file transfer .
(option)
SFTSEHOJ306X3X1
MOTET Host Communication

(option)
SFTMOHCJ306A3XX
Includes KAREL editor/translator, fil e

system/RAM disk, and CRT/KB manage r
options. 4MB CMOS RAM recommende d
for this optional package.
Includes all KCL commands for progra m
variable manipulation from the CRT/KB . You
must. have a CRT/KB installed to use thi s
option.
Includes all information for file system an d
RAM disk operations.
1 . OVERVIEW
1-5
MARAJINST09206E

SFTEXAXJ306X3XX
Product
DispenseToo l
Software Packag e
Disk Contents &

Part Number
FANUC Sensor Interfac e
(option)
Nordson:SBDISTLJ120X3X1
Number of
Comment
31/2 " Disks
1
Interface from Application/Tool to an external
sensor device such as a V-120 visio n
system.
Shot Meter:
SBDISTLJ120X3X2
Jesco:SBDISTLJ120X3X3
Version : 1 .20P
Teach Pendant
EPRO M
Version : 7D01/04D 0 r
late r
BootROM EPRO M
Version : 1.1PA or late r
Memory Required :
2MB FROM
2MB CMOS RAM
NOTE: Installation of
multiple options
might require
4MB CMOS RAM
Extended Axis (option)

SFTEXAXJ306X3XX
Supports independent extended aXes.
1 . OVERVIEW
MARAJINST09206E
1-6
Product
DispenseTool
Software Package
Shot
Shot Meter:
SBDISTLJ121X3X2
Disk Contents &

Part Number
Core Software
SFTCOREJ306A3XX
Robot Libraries
TLJ12X3
SFTRBLBJ306A3XX
DispenseTool Software for Nordson

Equipment
SFTDITLJ121X311
Version: 1 .21P
Teach Pendant
EPROM
Version: 7D01/04D or
later
DispenseTool Software for Shot

Meter Equipment
Number of
Comment
Disks
6
Includes all V3 .06PA core software
information.
1
Includesall currently supported robot
models.
1
DispenseTool ApplicationSoftware for us e
with Nordson Micro Pro-Flo dispensin g
equipment .
1
with Shot Meter dispensing equipment.
3-1/2"
SFTDITLJ121X32 1
DispenseTool Software for Jesco

Equipment
SFTDITLJ121X331
BootROM EPROM
Version: 1 .10PA or later DispenseTool Software for Schucker
Equipment
SFTDITLJ121X341
Memory Required :
2MB FRO M
DispenseTool End-Of-Arm-Tooling
2MB CMOS RAM
(option)
NOTE: Installation of SFTEOATJ121X3XX
multiple options
might require
4MB CMOS RAM
(option)

with Jesco dispensing equipment .

with Schucker dispensing equipment .
Includes all EOAT software information ,

including the 4-Position Tool,
Dispense/Material Handling Tool, and th e
Disposable Tool.
Includes all CRT/KB information.
SFTPLCIJ306X3X1
(option)
SFTCRTKJ306X3XX

Package
(option)
SFTKADPJ306X3XX
KAREL Command Language

(option)

(option)
SFTKCLXJ306X3XX

options. 4MB CMOS RAM recommended
for this optional package .
Includes all KCL commands for program
variable manipulation from the CRT/KB . Yo u
must have a CRT/KB installed to use thi s
option .
RAM disk operations .
SFTFSRDJ306X3X X

(option)
Provides serial communication ove r

RS-232-C for file transfer.
Provides data communication over etherne t

for file transfer.
SFTSEHOJ306X3X 1
MOTET Host Communication

(option)
SFTMOHCJ306A3XX
1 . OVERVIEW
1-7
MARAJINST09206E
JINST09206E
Table 1-1 . (Cont'd) Software Version Information

Disk Contents &
Part Number
Product
DispenseToo l
Software Packag e
Nordson :SBDISTLJ121X3X1
FANUC Sensor Interfac e

(option)
Number of
31/2" Disks
Comment
Interface from Application/Tool to an externa l

sensor device such as a V-120 visio n
system.
Supports independent eXtended aXes.
SFTFASEJ306X3XX
Shot Meter:
SBDISTLJ121X3X2
Version : 1 .21 P
Teach Pendan t
EPRO M
Version : 7D01/04D
SFTEXAXK306X3XX
or
later
Extended Axis (option)

BootROM EPROM
Version : 1 .10PA or later
Memory Required :
2MB FROM
2MB CMOS RA M
NOTE : installation of
multiple option s
might require
4MB CMOS RAM
1 . OVERVIEW
MARAJINST09206 E
1-8
KAREL Run-Time
Software Package
Disk Contents &

Part Number
KAREL Run-Time Application
Software
SBKARELJ306X3X1
SFTKARTJ306X3X1
Product
Version: 3.06P
Core Software
Number of
Disks
3-1/2 "
SFTCOREJ306X3XX
Teach Pendant EPROM
Robot Libraries
later
SFTRBLBJ306XSX2
BootROM EPROM
RSR/PNS (Remote Program Select)

(option)
Memory Required :
2MB Flash ROM (min)
2MB CMOS RAM (min)
1
1
Commen t
Includes all software to allow you to creat e
teach pendant programs and run them o n
the controller.
Includes all V3 .06P core software
information .
Includes all currently supported robo t
models.
Includes all RSR/PNS software fo r
production operations.
SFTRSRXJ306X3XX
1

Also referred to as KAREL Serial Link (KSL )

option.

(option)
SFTPLCL1306X3X1
S-420 Turbo Move

(option)

Supports : FANUC Robotics S-420F,
S-420A, S-420W, S-420S robot model s
only.

(option)
SFTFSRDJ306XSXX
NOTE: Installation of CRT/Keyboard Manage r

multiple option s
(option)
SFTCRTKJ306X3XX
might require
4MB CMOS RAM
(option)
SFTSEHOJ306X3X1
SFTTUMOJ306X3X1
Extended Axi s
(option)
SFTEXAXJ306X3XX
Supports independent eXtended axes .
1 . OVERVIEW
MARAJINST09206E
1-9

Product
KAREL
Development
Software Package
Disk Contents &

Part Number
Package
Number of
31/2" Disks
1

options . 4MB CMOS RAM recommende d
for this option package .
KAREL Run-Time Application

Software

teach pendant programs and run them o n
the controller.
Core Software

information .

models.

production operations.

option .

(option)

S-420 Turbo Move

(option)
Supports: FANUC Robotics S-420F,

only.
Supports independent extended axes .
SFTKADPJ306XSXX
SBKARELJ306X3X2
Version: 3 .06P
Teach Pendant EPROM
Version:
7D01/04D or
later
SFTKARTJ306X3X1
SFTCOREJ306X3XX
BootROM EPROM
Robot Libraries
Memory Required :
2MB Flash ROM (min )
2MB CMOS RAM (min)

(option)
NOTE : Installation of
multiple options
might require
4MB CMOS RAM
Commen t
SFTRBLBJ306X3X2
SFTRSRXJ306X3XX

(option)
SFTSEHOJ306X3X1
SFTPLIJ306X3X1
SFTTUMOJ306X3X1
Extended Axis
(option)
SFTEXAXJ306X3XX
1 . OVERVIEW
MARAJINST09206E
1-10
Disk Contents &

Number o f
Comment
Part Number
3-1/2" Disks
1 Includes all software to allow you to create
TPP+ (KAREL Run-Time) Application
TPP+ (KAREL
TPP+ programs and run them on th e
Run-Time) Software Software
SFTTPPPJ306B3X1
controller.
Package
SBKARELJ306B3X1
6
Includes all V3.06PB core software
Core Software
information.
Version: 3.06PB
: SFTCOREJ306B3XX
2
Robot Libraries
Teach Pendant EPRO M SFTRBLBJ306B3X4
models.
Version: 7D01/04D or
later
1
(option)
production operations .
BootROM EPRO M
SFTRSRXJ306X3XX
1
Includes all information for file system and
Memory Required :
(option)
RAM disk operations.
SFTFSRDJ306X3XX
2MB CMOS RAM (min)
1
CRT/Keyboard Manage r
NOTE: Installation of (option)
SFTCRTKJ306X3XX
multiple options
might CMO
1
Includes all IntelliTrak software information .
IntelliTrak
4MB CMOSS RAM
(option)
Product
SFTINTRJ306A3XX

(option)

option.
SFTSEHOJ306B3XX
Map Interface
(option)
SFTMAPXJ306B3XX

SFTPLCIJ306X3X1
(option)
S-420 Turbo Move

(option)
Extended Axi s
SFTTUMOJ306X3X1
(option )
SFTEXAXJ306X3XX
Includes the MAP communications protocol

for communications between the R- J
controller and an external device .
S-420FD, S-420A, S-420W, S-420S robo t
models only.
Supports independent extended axes.
1 . OVERVIEW
MARAJINST09206E

Product
KAREL
Developmen t
Packag e
Disk Contents &

Part Number
KAREL Development Optio n
Package
Number of
3i/2" Disks
1

options . 4MB CMOS RAM recommended
for this option package .
Includes all software to allow you to create

TPP+ programs and run them on th e
controller.
Includes all V3.06PB core software
information .
models .
SFTKAPDJ306B3XX
SBKARELJ306B3X2
Version: 3.06P B
Teach Pendant EPROM

later
BootROM EPRO M
Version : 1.10PA or late r
Memory Required:
2MB CMOS RAM (min)
TPP+ (KAREL Run-Time) Application

Software
SFTTPPPJ306B3X1
Core
Software
SFTCOREJ306B3XX
Robot Libraries
SFTRBLBJ306B3X4
RSR/PNS (Remote Program Select )

(option)
SFTRSRXJ306X3XX
NOTE: Installation of IntelliTra

k
multiple option s
(option)
might requir e
SFTINTRJ306A3XX
4MB CMOS RAM
(option)
Comment
Includes all IntelliTrak software information.
Also referred to as KAREL Serial Link (KSL)

option.
SFTSEHOJ306B3XX
Map Interfac e
(option)
Includes the MAP communications protoco l

for communications between the R-J
controller and an external device.
SFTMAPXJ306B3XX

(option)
SFTPLCIJ306X3X1
S-420 Turbo Move

(option)
SFTTUMOJ306X3X1
Extended Axi s
(option)
SFTEXAXJ306X3XX

S-420FD, S-420A, S-420W, S-420S robot
models only.
1 . OVERVIEW
MARAJINST09206 E
1-12
Table 1-1 . (Cont'd) Software Version informatio n

Product
Disk Contents &

Part Number
TPP+ with INSIGHT II

Software Package
TPP+ with INSIGHT II Application

Software
SBKARELJ306B3X3
SFTTPINJ306B3XX
Version: 3.06PB
Core Software
Robot Libraries
SFTRBLBJ306B3X4
later

(option)
Memory Required :
1 .5MB Flash ROM (min)
2MB CMOS RAM (min)
Comment
TPP+ and INSIGHT II programs and ru n
them on the controller.
Includes V3 .06PB core software information .
SFTCOREJ306B3XX
Teach Pendant EPROM
BootROM EPROM
Version : 1 .10P or later
Number of
31h" Disks
2
1

models .
SFTRSRXJ306X3XX

(option)


option.
SFTFSRDJ306X3XX
NOTE : Installation of (option)
multipl e option s
SFTCRTKJ306X3XX
might require
IntelliTrak
4MB CMOS RAM
(option)
SFTINTRJ306A3X X

(option)
SFTSEHOJ306B3X X

Map Interface
(option)
SFTMAPXJ306B3XX

(option)

Supports: FANUC Robotics S-420F,

S-420FD, S-420A, S-420W, S-420S robot
models only.
SFTPLCIJ306X3X1
S-420 Turbo Move

(option)
SFTTUMOJ306X3X1
Extended Axis
(option)
SFTEXAXJ306X3XX
1 . OVERVIEW
1-1 3
MARAJINST09206E

Product
KAREL
Development Option
with INSIGHT II
Software Package
Disk Contents &

Part Number
KAREL Development Option with
INSIGHT II Application Software
Comment
Includes all INSIGHT II software to creat e

and run INSIGHT II programs.
Includes KAREL editor/translator, file

options . 4MB CMOS RAM recommende d
for this option package.
Includes all V3 .06PB core software

information .

models .


option .
SFTTPINJ306B3XX
SBKARELJ306B3X4

Package
Version: 3.06PB
SFTKADPJ306B3XX
Teach Pendant EPROM

Version : 7D01/04D o r
later
Number of
3-1/2" Disks
Core Software
SFTCOREJ306B3XX
Robot Libraries
BootROM EPROM
Version : 1.10PA or later SFTRBLBJ306B3X4
Memory Required:
(option)
SFTRSRXJ306X3XX
2MB CMOS RAM (min)
IntelliTrak
NOTE: Installation of (option)
multiple options
SFTINTRJ306A3XX
might require
4MB CMOS RAM
(option)
SFTSEHOJ306B3XX
Map Interface
(option)

SFTMAPXJ306B3XX

(option)


S-420FD, S-420A, S-420W, S-420S robo t
models only.
Supports independent extended aXes.
SFTPLCIJ306X3X1
S-420 Turbo Move

(option)
SFTTUMOJ306X3X1
Extended Axis
(option)
SFTEXAXJ306X3XX
1 . OVERVIEW
MARAJINST09206E
1-14

Disk Contents &
Part Number
Product
PaintToo l
StandAlone
Software Packag e
SBPAITLJ130X3X1
Version : 1 .30 P
Teach Pendan t
EPRO M
late r
BootROM EPRO M
Memory Required :
2MB FRO M
4MB CMOM RAM
Number of
3%" Disks
Comment
Includes all PaintTool software.
Includes all V3.06PB Core software .

models .
StandAlone PaintTool Setup

SFTSAPTJ130X3XX
Supports StandAlone PaintTool Option .
PaintTool Password Protectio n
Includes all password protection software .
Color Change Software (option)
Includes all color change software to be use d

with color change hardware .
(option)
Includes all CRT/Keyboard manager

information .
Line Tracking (TPP/PaintTool)

(option)
Includes all line and rail tracking software t o

be used with line tracking hardware .
Supports Ethernet communications
PaintTool Application Softwar e

SFTPATLJ130X3X1
Core Software
SFTCOREJ306B3XX
Robot Librarie s
SFTRBLBJ306B3X4
(option)
SFTSAPTJ130X3XX
SFTCOCHJ130X3XX
SFTCRTKJ306X3XX
SFTLNTRJ306B3XX
Motet Host Communications

(option)
SFTMOHCJ306B3XX
1 . OVERVIEW
1-1 5
MARAJINST09206E

Product
PaintToo l
StandAlon e
Software Package
SBPAITLJ130A3X1
Disk Contents &

Part Number
PaintTool Application Software
Number of
Commen t
3-1/2" Disks
3
Includes all PaintTool software .
SFTPATLJ130A3XX

models.

(option)
(option)

Includes all CRT/Keyboard manage r
information .
Core Softwar e
SFTCOREJ306B3XX
Version : 1 .30PA
Teach Pendant
EPROM
late r
BootROM EPROM
Version : 1 .10PA or late r
Memory Required :
2MB FRO M
4MB CMOS RAM
Robot Libraries
SFTRBLBJ306B3X4

SFTSAPTJ130A3XX
SFTPAPRJ130X3XX
SFTCOCHJ130A3XX
SFTCRTKJ306X3XX
Line Tracking (TPP/PaintTool )

(option)

SFTLNTRJ306B3X1
Motet Host Communication s

(option)
SFTMOHCJ306B3XX
1. OVERVIEW
MARAJINST09206 E
1-16
Product
PaintTool
StandAlon e
Software Package
Disk Contents &

Part Number
SFTPATLJ131X3X 1
SBPAITLJ131X3X1
Core Software
Version : 1.31P
Teach Pendant
EPROM
later
BootROM EPROM
Memory Required:
2MB FROM
4MB CMOS RAM
Number o f
Comment
Disks
3
3-1/2 2"
Robot Libraries

models.
PaintTool Password Protection

(option)

with color change hardware.
Includes all CRT/Keyboard manager
information .
SFTCOREJ306B3XX
SFTRBLBJ306B3X4
SFTSAPTJ131X3X X
SFTSAPTJ130X3XX
SFTCOCHJ131X3XX
(option)
SFTCRTKJ306X3XX

(option)

Supports Ethernet communication s
SFTLNTRJ306B3X2
(option)
SFTMOHCJ306B3XX
1. OVERVIE W
1-1 7
MARAJINST09206E

Product
PaintTool Finishing
Software Package
SBPAITLJ130X3X2
Version: 1 .30P
Teach Pendant
EPROM
later
Disk Contents &

Part Number
Number o f
Commen t
31/2" Disks
3
SFTPATLJ130X3X 1
Core Software
Includes all V3 .06PB Core software .
Robot Libraries

models.
Includes all PaintTool setup information.
SFTCOREJ306B3XX
SFTRBLBJ306B3X4
PaintTool Engineering Setup
SFTPTESJ130X3X X
Accuflow Software
BootROM EPROM
(option)
Version : 1 .10PA or later SFTACFLJ130X3X X
Includes all integrated Accuf lolow software t o

be used with Accuflow hardware .
Memory Required :
2MB FROM
4MB CMOS RAM
Color Change Software

(option)
SFTCOCHJ130X3XX

PaintTool Password Protection

(option)
SFTSAPTJ130X3XX
(option)

information.

be used with line tracking hardware.
SFTCRTKJ306X3XX

(option)
SFTLNTRJ306B3XX

(option)
SFTMOHCJ306B3XX
1 . OVERVIEW
MARAJINST09206E
1-18

Product
PaintTool Finishin g
Software Package
Disk Contents &

Part Number
Commen t
Includes all PaintTool software.

models.
Includes all PaintTool setup information.
Accuf lo low Software

BootROM EPROM
(option)
Version : 1 .10PA or later SFTACFLJ130A3XX
Includes all integrated Accuflow software to

Memory Required :
2MB FRO M
4MB CMOS RAM
Includes all color change software to be used


(option)
Includes all password protection software.
(option )

information.

SBPAITLJ130A3X2
Version: 1.30PA
Teach Pendan t
EPROM
later
Number of
3%" Disks
SFTPATLJ130A3XX
Core Software
SFTCOREJ306B3XX
Robot Libraries
SFTRBLBJ306B3X4
PaintTool Engineering Setu p

SFTPTESJ130A3XX

(option)
SFTCOCHJ130A3XX
SFTSAPTJ130X3XX
SFTCRTKJ306X3XX

(option )
SFTLNTRJ306B3X1

(option)
SFTMOHCJ306B3XX
1 . OVERVIE W
1-1 9
MARAJINST09206E

Disk Contents &
Part Number
Product
PaintTool Finishin g
Software Package
SBPAITLJ131X3X2
Version : 1 .31 P
later
Commen t
Includes all V3 .06PB-P Core software.

models .
Includes all PaintTool setup information .
Includes all integrated Accuflow software t o


(option)
SFTCOCHJ131X3XX

with color change hardware . Cannot be
installed with AccuStat or Parallel Purg e
options .

(option)
(option)

information.

Includes AccuStat software . Cannot be use d

with Accuflow, Color Change, or Paralle l
Purge options .
Includes Parallel Purge software . Cannot b e

used with AccuStat or Color Change options .

SFTPATLJ131X3X1
Core Software
SFTCOREJ306B3XX
Robot Libraries
Teach Pendan t
EPRO M
Number of
3W Disks
SFTRBLBJ306B3X4
PaintTool Engineering Setu p

SFTPTESJ131X3XX
Accuflow Software
(option)
r EPROM late ro
BootROM Version: 1.10PA
SFTACFLJ131X3XX
Memory Required :
2MB FROM
4MB CMOS RAM
SFTSAPTJ130X3XX
SFTCRTKJ306X3XX

(option )
SFTLNTRJ306B3X2

(option)
SFTMOHCJ306B3XX
AccuStat
(option)
SFTACSTJ131X3XX
Parallel Purg e
(option )
SFTPAPUJ131X3XX
1 . OVERVIEW
MARAJINST09206E
1 20
Product
PalletTool
Software Package
Disk Contents &

Part Number
PalletTool Application Softwar e
Number o f
Comment
3-1/2" Disks
2
Includes all PalletTool specific information.
SFTPLTLJ120X3X,
SBPALTJL120X3X 1
Version: 1 .20 P
Teach Pendant EPRO M
later
BootROM EPRO M
Core Software
SFTCOREJ306X3XX

information.
Robot Libraries

models.
Includes V1 .20/01 m updated information for

PalletTool
SFTRBLBJ306X3X2
Memory Required :
2MB CMOS RAM (min)
Maintenance Dis k
NOTE: Installation of PalletTool
SFTUPDTJ306X314
s
multiple option
might requir e
4MB CMOS RAM
1 . OVERVIEW
1-2 1
MARAJINST09206E

Product
SpotTool Software
Package
Disk Contents &

Part Number
SpotTool Application Software
Number of
3-1/2" Disks
Comment
Includes all SpotTool information includin g

S-420 TurboMove software (which supports :
FANUC Robotics S-420F, S-420A, S-420W ,
S-420S robot models only .
Includes v3.06P core software information .
SFTSPTLJ210X3X1
SBSPOTLJ210X3X1
Version: 2.10P
Core Software

late r
Robot Libraries
BootROM EPRO M
Version : 1 .10P or later

(option)
Memory Required :
1 .5MB Flash ROM (min)
2MB CMOS RAM (min )
SFTCOREJ306X3XX
SFTRBLBJ306X3X2

models.
option .
SFTSEHOJ306X3X1
PLC O (ABRIO/Genius)
(option)
SFTPLCIJ306X3X1
NOTE : Installation o f
multiple option s
CRT/Keyboard Manager Macro
might require
Suppor t
4MB CMOS RAM
(update)
SFTUPDTJ306X3X4

Includes all update information. This is not
an option .
1 . OVERVIEW
MARAJINST09206 E
1-22

Number of
3-1/2" Disks
Comment

FANUC Robotics S-420F, S-420FD ,
only.

Version : 7D01/06T4 o r
SpotTool Specific Core Software
late r
SpotTool Specific Common
BootROM EPROM
Version : 1 .20P or late r
Includes V3.06PC core software information

specifically for SpotTool .
Includes V3.06PC core software information
Robot Libraries
KSL Interfac e
(option)
Product
Disk Contents &

Part Number
SFTSPTLJ220X3XX
SpotTool Software
Package
SBSPOTLJ220X3X1
Version: 2.20P
SFTCOREJ306C3XS
SFTCOMNJ3O6C3XS
SFTRBLBJ306C3X2
Memory Required:
1 .5MB FFlash
Flash ROM ((min)
2MB CMOS RAM (min )
NOTE : Installation of
multiple options
might require
4MB CMOS RAM
SFTKSLIJ306C3XX

(option)
SFTPLCIJ306C3XX
(option)
SFTCRTKJ306X3XX

models.
option . 2MB FROM required for thi s
option.
information .
1 . OVERVIEW
1-2 3
MARAJINST09206E

Product
SpotTool Software
Packag e
Disk Contents &

Part Number
Number o f
3
SFTSPTLJ220A3XX
SBSPOTLJ220A3X1
Version: 2.20PA
Version : 7D01/06T4 o r
later
BootROM EPROM
Version: 2 .00P or late r
SpotTool Specific Core Software
SFTCOREJ306D3XS
SpotTool Specific Common
SFTCOMNJ306D3XS
Robot Libraries
SFTRBLBJ306D3XX
Flash
y
Required:
hMemor
1 1.5MB
.5MB Flas
Flash ROM (min )
2MB CMOS RAM (min)
KSL Interfac e
(option )
SFTKSLIJ306D3XX
NOTE: Installation of PLC I/O (ABRIO/Genius)

multiple options
(option)
might require
SFTPLCIJ306C3XX
4MB CMOS RAM
(option)
SFTCRTKJ306X3XX
Comment
Disk 2" 3-1/2
FANUC Robotics S-420F, S-420FD ,
S-420A, S-420W, S-420S robot models
only.
Includes V3.06PD core software informatio n
specifically for SpotTool.
Includes V3.06PD core software informatio n
models .
option . 2MB FROM required for this
option.
hardware using the R-H extended backplane
on the R-J controller .
information .
1. OVERVIEW
MARAJINST09206 E
The following system EPROM chips are already installed on your

controller :
Bootstrap ROM (BootROM) EPROM Chip - One EPROM chip
that is installed on the CMOS RAM module on the MAIN CPU board
inside the controller.
Teach Pendant EPROM Chip - One EPROM chip that is installe d
on the teach pendant PCB inside the teach pendant.
You must check the version of EPROM chip in your controller to be sur e
that it is compatible with the version of software you are loading . Refer to
Chapter 3 for information on checking EPROM chips . Refer to Table 1- 1
for information on the correct software version information.
1. OVERVIEW
1-2 5
MARAJINST09206E
1 .2
INSTALLATION
REQUIREMENTS
In order to install a new SYSTEM R-J Application Software Package, yo u

need
1 .2.1
Teach Pendant
The FANUC Robotics teach pendant is an operator interface device that

displays the SYSTEM R-J software . It is connected to the controller via a
cable that plugs into either the MAIN CPU board inside the controller or ,
if it is a disconnectable teach pendant, the standard operator panel .
A teach pendant
A disk drive uni t
Controller hardware tools
The teach pendant is the device you use to load software .

There are two types of teach pendants available :
Standard
Intrinsically Safe (ISTP)
The standard teach pendant provide s

A 16 line x 40 character teach pendant scree n
Eleven status indicators including three indicators dedicated to the

SYSTEM R-J software application .
Teach pendant keys, including keys specific to the SYSTEM R- J

software application.
Figure 1-1 shows the standard teach pendant .

Figure 1-1 . Standard Teach Pendant
1. OVERVIEW
The ISTP, used in most hazardous paint environments, plugs into the
intrinsically safe barrier (ISB) unit within the controller and consists o f
A 16 line x 40 character teach pendant screen
Eleven status indicators displayed on the teach pendant screen.
Teach Pendant keys, including keys specific to the PaintTool softwar e
application.
Figure 1-2 displays the ISTP.
Figure 1-2 . Intrinsically Safe Teach Pendant (ISTP)
1. OVERVIEW
MARAJINST09206E
1-2 7
1 .2.2
Disk Drive Uni t
To perform a software installation, you must have a FANUC Robotic s

PS-100 disk drive unit. The PS-100 connects to the P3 controller port .
The P3 controller port is an RS-232-C interface .
PS-100 Disk Drive
The FANUC Robotics PS-100 disk drive, shown in Figure 1-3, is use d
with 3'/4 inch disks, including 720K double-density disks .
Figure 1-3 . PS-100 Connected to the Controller
1 .2. 3
Controller Hardware
Tools
To perform the EPROM installation, you must have a

Flat-tip screwdriver to open the controller door.
Long cross-tip screwdriver to remove the teach pendant cover.
Dual-inline-pin (DIP) chip removal tool and installation tool to
remove and install EPROM chips .
Anti-static pad with wrist strap to prevent static damage to th e
EPROM chips .
SETTING UP CONTROLLER MEMORY

2-1
MARAJINST09205E
Setting up controller memory involves checking :

Controller memory
Erasable Programmable Read-Only Memory (EPROM) Chip s
Controller Memory
Controller memory consists of both Flash Read Only Memory (Flas h

ROM) and Complementary Metal Oxide Semiconductor Random Acces s
Memory (CMOS RAM). CMOS RAM memory stores some robot syste m
software, some application software, and all user programs . Flash ROM
stores the majority of the robot system software such as core, application ,
and option software .
CMOS RAM is divided into three parts or memory pools . These are
KAREL, TPE, and C-WORK. Flash ROM is divided into two memor y
pools called F-DICT and F-PROG . A teach pendant editor (WE) progra m
uses only the TPE memory pool . A KAREL program uses the KAREL ,
WE, and C-WORK memory pools . An option could use all five memor y
pools .
NOTE If you change the amount of memory in the TPE pool it will affec t
the amount of memory available in the KAREL pool.
CMOS RAM is battery-backed. Flash ROM is not battery-backed but i s
non-volatile. Non-volatile means that all data in Flash ROM, includin g
programs, is saved even after you turn off and turn on the controller .
CMOS RAM is non-volatile only while the batteries are working . If the
batteries are faulty or removed, CMOS RAM is lost.
A CAUTION
Data in CMOS RAM can be lost if the battery is removed o r

loses its charge, or if new core software is loaded on th e
controller . To prevent loss of data back up, or copy, all files fo r
permanent storage .
To set up controller memory you mus t
Install the CMOS and Flash ROM modules on the main CPU boar d
inside the controller.
Check system memory allocatio n
NOTE You can also format a portion of the KAREL memory poo l
(CMOS RAM), as a RAM disk, which can be used as a separate storage
device . Refer to the Setup and Operations Manual for your application fo r
more information.
Refer to Section 2.1 for more information on checking controller memory .
Refer to Section 2.2 for more information on installing CMOS and Flas h
ROM boards.
2. SETTING UP CONTROLLER MEMOR Y

MARAJINST09205 E
2-2
Checking system memory allows you to determine the amount of CMOS, '
and Flash ROM memory available in your system .
2. 1
CHECKING SYSTEM
MEMORY
Table 2--1 lists and describes each memory status item . Use
Procedure 2-1 to check system memory.
Table 2-1 . Memory Statu s
DESCRIPTION
MEMORY STATUS
User
Indicates the amount of memory for user programs: teach pendant programs and KAREL
programs .
Total indicates the original size of the memory area .
Free indicates how much memory is available .
Largest Free indicates the largest contiguous segment of memory .
System
Indicates the amount of memory for system information : F-DICT (dictionary files that
define what is displayed on the screens), F-PROG (application, operating system, an d
option files), and C-WORK (temporary memory used for system operations) .
Total indicates the original size of the memory area.
Free indicates how much memory is available.
Largest Free indicates the largest contiguous segment
Hardware
Indicates the total amount of memory in Flash ROM and CMOS RAM .
Procedure 2-1 Displaying Memory Statu s
Step
Press MENUS .
Select STATUS.
Press F1, [TYPE] .
Select Memory . See the following screen for an example .
2 . SETTING UP CONTROLLER MEMORY

2- 3
MARAJINST09205E
A maximum of four CMOS RAM modules can be used in the R- J

controller. A maximum of two Flash ROM modules can be used in th e
R-J controller. CMOS RAM and Flash ROM are installed on the MAI N
CPU board inside the controller. Use Procedure 2-2 to remove or add a
CMOS RAM or Flash ROM module .
2.2
INSTALLING CMOS
AND FLASH RO M
MEMORY
Procedure 2-2 Installing a CMOS RAM or Flash ROM Module

Condition
The controller is turned off.
WARNIN G
Disconnect electrical power from the controller before yo u
remove or replace components, or you could be injure d
seriously.
A CAUTIO N
Use anti-static devices and observe anti-static safet y

precautions when handling any electronic material, otherwis e
you could damage the equipment .
Step
You are wearing a wrist wrap to prevent static discharge to the CMO S
circuits.
Disconnect electrical power from the controller .

If your controller is equipped with a disconnect handle at the upper
right front corner, pull it to the OFF (down) position .
OR
If your controller is equipped with a circuit breaker handle, turn

the handle to the OFF (open) position.
See Figure 2-1 .
WARNIN G
When the disconnect or circuit breaker handle is OFF ,
power is still present inside the controller . You mus t
unplug the controller from the electrical outlet to remov e
all power from the controller.

MARAJINST09205 E
2-4
2 Open the front door of the controller using a flat-tip screwdriver t o
turn the latch . See Figure 2-1 .
Figure 2-1 . R-J Controller Disconnect Handle and Latc h
POWER DISCONNECT
C-SIZE CONTROLLER
CIRCUIT BREAKE R
B-SIZE CONTROLLER
3
Locate the MAIN CPU board inside the controller . See Figure 2-2 .
Figure 2-2. MAIN CPU Board Locatio n
2 . SETTING UP CONTROLLER MEMOR Y

2-5
MARAJINST09205E
4 Disconnect the cables from the board . See Figure 2-3 .

5
Press and hold both latches of the MAIN CPU board and remove th e
board from the backplane . See Figure 2-3 .
Install the CMOS RAM or Flash ROM modules on the MAIN CPU
board in the appropriate memory slots . See Figure 2-4 .
Figure 2-4. Installing the CMOS RAM or Flash ROM Module

MARAJINST09205 E
7 Insert the MAIN CPU board into the proper slot on the controlle r
backplane.
8
Close the controller door and set the circuit breaker handle or the
power disconnect switch to the ON position.
This completes the installation of the new module .

NOTE CMOS RAM memory will be initialized automatically when th e
software is installed.
2-7
MARAJINST09205E
Instead of reloading an entire controller with software using disks, you ca n

copy controller memory from one controller to another by copying the
CMOS and FLASH ROM memory within the controller . You can copy
the following memory configuration s
3.5MB controller memory : 2MB CMOS and 1 .5MB FROM (2+1 .5)
4MB controller memory : 2MB CMOS and 2MB FROM (2+2 )
6MB controller memory : 4MB CMOS and 2MB FROM (4+2 )
NOTE The source and target MAIN CPU boards must have the same
memory configuration . For example, you can copy a 2MB CMOS and
1 .5MB FROM only to a MAIN CPU board with 2MB CMOS and 1 .5MB
FROM.
2.3
COPYIN G
CONTROLLE R
MEMORY
Use Procedure 2-3 to copy 3 .5MB and 4MB controller memory. Use
Procedure 2-4 to copy 6MB controller memory .
Procedure 2-3 Copying 3.5MB (2+1 .5) and 4MB (2+2) Controller Memory
Condition
You have obtained an R-J portable processor or an R-J controller wit h

an extension backplane (A20B-1004-0510) and two R-H CMO S
memory printed circuit boards (A16B-2200-0760 )
A CAUTIO N
Both R-H CMOS Memory printed circuit boards must b e
installed or the copy will not work.
You are using V 1 .10P-Rev. A BootROM.

The controller is turned off.
The source CPU is plugged into the controller.
Step
Any data that is currently on the target CPU that you want to save ha s
been backed up .
Plug the extension backplane into the R-J card rack . This board plug s
into the side of the R-J backplane on the left side . See Figure 2-5 .
2. SETTING UP CONTROLLER MEMORY

2-8
Figure 2-5. Plugging in the Extension Backplan e
Mount the two R-H CMOS memory cards into the two right slots o f
the extension backplane . The slot names are CM0 and CM1 .
Press and hold the USER PB#1 and USER PB#2 buttons on the
controller (PURGE ENABLE on a P-155 controller) while pressin g
the ON button. The BMON> prompt will be displayed . See the
following screen for an example .
NOTE Slots 0 and 1 on the previous screen indicate that the controlle r
recognizes the R-H CMOS boards. If this information is not displayed ,
the R-H CMOS boards are not installed properly.
4
Press >, NEXT, twice.
Press F4, DEVICE then press ENTER. The DEV> prompt will be
displayed .

2-9
MARAJINST09205E
Press F5, INIT .
7 Press Fl, CM .
8 Press 0, then press ENTER . This will initialize the R-H CMO S
memory in the first slot. The DEV> prompt will be displayed.
9 Press F5, INIT.
10
'w<<_
Press F1, CM.
memory in the second slot. The DEV> prompt will be displayed .
12
Press F2, BACKUP.
13
Press F2, FROM, and then press ENTER . See the following screen
for an example.
14 To cancel the copy, type 0.

To copy the Flash ROM (FROM) contents, type 1 .
The contents of the FROM memory will be copied to CM1 . A
checksum is provided for the FROM and then again as the copy i s
performed . The checksum verifies that FROM is intact Record th e
checksum for later . The checksum performed now should match the
checksum performed when FROM is restored .
When the copy is complete, the DEV> prompt will be displayed .
15
Press F2, BACKUP.
16 Press Fl, CMOS and then press ENTER. See the following screen for
an example .
17
To cancel the copy, type 0 .

To copy the CMOS RAM contents, type 1 .
The contents of CMOS RAM memory will be copied to CM0 . A
checksum is provided for the CMOS RAM and then again as the copy
is performed. This checksum verifies that CMOS RAM is intact .
Record the checksum for later. The checksum performed now should
match the checksum performed when CMOS RAM is restored .
18
Turn off the controller.

MARAJINST09205E
2-10
NOTE The source and target MAIN CPU boards must have the sam e
1 .5MB FROM only to a MAIN CPU board with 2MB CMOS and 1 .5MB
FROM.
19
Insert the target MAIN CPU in the R-J backplane .
20
Press and hold the USER PB #1 and USER PB#2 buttons on the
controller (PURGE ENABLE and ON on a P-155 controller) . The
BMON> prompt will be displayed .
21
Press >, NEXT.
A
CAUTIO N
The next step clears the data currently in CMOS memory .
Cleared data cannot be retrieved . Make sure you have backe d
up any data you want to save to an off-line storage device suc h
as a floppy disk before you perform the next step, otherwise ,
data will be lost .
22
Press Fl, CLEAR.
23
Press Fl, CMOS, then press ENTER .
24
Press >, NEXT.

CAUTION
A
The next step clears the data currently in FROM memory .

data will be lost .
25
Press Fl, CLEAR .
26 Press F2, FROM, then press ENTER .

Press >, NEXT, twice .
28
Press F4, DEVICE, then press ENTER . The DEV> prompt will b e
displayed.
29 Press F3, RESTORE .

30
Press F2, FROM, and then press ENTER . See the following scree n
for an example .

2-1 1
MARAJINST09205E
31 To cancel the restore, type 0.

To restore the Flash ROM (FROM) contents, type 1 .
The contents of CM1 will be copied to FROM . A checksum is
provided for CM1 . This checksum should match the checksum
recorded during BACKUP FROM (Step 14) .
When the restore is finished, the DEV> prompt will be displayed .

32
Verify that this checksum matches the checksum recorded during

BACKUP FROM (Step 14) .
A CAUTIO N
If the checksums do not match, the target memory board coul d

be corrupted. Clear memory and retry the restore . If the
checksums still do not match, try the procedure again with a
different memory board .
33
Press F3, RESTORE .
34
Press F1, CMOS, and then press ENTER . See the following screen
for an example.

To restore the CMOS RAM contents, type 1 .
The contents of CM1 will be copied to CMOS RAM . A checksum i s
provided for the CM0 and for the CMOS RAM. These checksums
should match the checksum recorded during BACKUP CMO S
(Step 17).

36
37 Remove the target MAIN CPU . The target MAIN CPU is now an
exact duplicate of the source MAIN CPU .
38
Insert the target MAIN CPU in its own controller, turn on th e

controller and master the robot.

MARAJINST09205 E
2-12
Procedure 2-4 Copying 6MB (4+2) Controller Memory
Condition
You have obtained an R-J portable processor or an R-J controller wit h

an extension backplane (A20B-1004-0510) and two R-H CMO S
memory printed circuit boards (A16B-2200-0760) .
n You are using V1 .10P-Rev. A BootROM.

n The controller is turned off.
The source CPU is plugged into the controller .
Step
Plug the extension backplane into the R-J card rack . This board plug s
into the side of the R-J backplane on the left side . See Figure 2-6 .
Figure 2-6 . Plugging in the Extension Backplan e
2 Mount the two R-H CMOS memory cards into the two right slots o f
the extension backplane .
2. SETTING UP CONTROLLER MEMOR Y

2-13
MARAJINST09205E
#2 buttons on th e
Press and hold the USER PB#1 and USER PB#2
NOTE Slots 0 and 1 on the previous screen indicate that the controlle r
recognizes the R-H CMOS boards . If this information is not displayed ,
the R-H CMOS boards are not installed properly.
4
,
5 Press F4, DEVICE then press ENTER . The DEV> prompt will be
displayed .
6
Press F5, INIT .
7 Press Fl, CM.

8
Press 0, then press ENTER . This will initialize the R-H CMO S
memory in the first slot. The DEV> prompt will be displayed .
Press F5, INIT.
10
Press Fl, CM .
memory in the second slot . The DEV> prompt will be displayed .
12
Press F2, BACKUP.
13
Press F2, FROM, and then press ENTER .

MARAJINST09205E
2-14
14 To cancel the copy, type 0 .
To copy the Flash ROM (FROM) contents, type I .
The contents of FROM memory will be copied to CM1 . A checksu m

is provided for the CMOS RAM and then again as the copy is
performed. This checksum verifies that FROM is intact. Record the
checksum for later. The checksum performed now should match th e
checksum performed when FROM is restored.
15
16
Insert the target MAIN CPU .
17 Turn on the controller.

18
Press and hold the USER PB#l and USER PB#2 buttons on th e
19
Press >, NEXT
A CAUTIO N
The next step clears the data currently in FROM memory .
data will be lost .
CLEAR
DEV>
20
Press Fl, CLEAR.
21
Press F2, FROM, then press ENTER.
22
23
Press F4, DEVICE, the

displayed.
24
Press F3, RESTORE .
25
Press F2, FROM, and then press ENTER . See the following screen
for an example .
. The DEV> promptnpresENTR will be

2-15
MARAJINST09205E

To restore the Flash ROM (FROM) contents, type 1 .
The contents of CM1 will be copied to FROM . A checksum i s
provided for CM1 . This checksum should match the checksu m
recorded during BACKUP FROM (Step 14) .

27 Verify that this checksum matches the checksum recorded durin g
BACKUP FROM (Step 14) .
A CAUTIO N
If the checksums do not match, the target memory board coul d

be corrupted . Clear memory and retry the restore . If th e
checksums still do not match, try the procedure again with a
different memory board .
28
29
Insert the source MAIN CPU.
30
Turn on the controller.

Press and hold the ER PB#1 and USER PB#2 buttons on th e
32
Perform Steps 4 through 11 to initialize the R-H boards again .
33
Press >, NEXT, twice.
34
Press F4, DEVICE, then press ENTER . The DEV> prompt will be
displayed.
35
Press F2, BACKUP.
36
Press Fl, CMOS and then press ENTER. See the following screen for
an example .
37 To cancel the backup, type 0.

To backup the CMOS RAM contents, type 1 .
The contents of CMOS RAM will be copied to CM0 and CM1 . A
checksum is provided for CMOS RAM . Record the checksum for
later. When the backup is finished, the DEV> prompt will be
displayed .

MARAJINST09205 E
2-1 6
Thin off the controller.
38
NOTE The source and target MAIN CPU boards must have the sam e
2MB FROM only to a MAIN CPU board with 4MB CMOS and 2M B
FROM.
39
Insert the target MAIN CPU in the R-J backplane .
40
Press and hold the USER PB#l and USER PB#2 buttons on th e
the ON button . The BMON> prompt will be displayed. See the
following screen for an example.
41
Press >, NEXT.
A CAUTIO N
The next step clears the data currently in CMOS memory .

data will be lost.
42 Press Fl, CLEAR.

43
Press Fl, CMOS, then press ENTER . The BMON> prompt will be
displayed.
44
45
Press F4, DEVICE, then press ENTER . The DEV> prompt will b e
displayed.
46 Press F3, RESTORE .

47
Press Fl, CMOS, and then press ENTER . See the following screen
for an example .
48 To cancel the restore, type 0 .

To restore the CMOS RAM contents, type 1 .
The contents of CM1 will be copied to CMOS RAM . A checksum i s
provided for the CM() and for the CMOS RAM. These checksums
should match the checksum recorded during BACKUP CMO S
(Step 37) .
49 Turn off the controller.

2-1 7
MARAJINST09205E
50
Remove the target MAIN CPU . The target MAIN CPU is now an
exact duplicate of the source MAIN CPU .
51
Insert the target MAIN CPU in its own controller, turn on th e

controller and master the robot
EPROM INSTALLATION
3-1
The SYSTEM R-J controller uses Erasable Programmable Read-Onl y

Memory (EPROM) chips that contain information specific to a particula r
version of software . They are located on the MAIN CPU board and on th e
teach pendant PCB . Your controller must contain the EPROM chips tha t
are compatible with the version of software you are installing . Refer to
Table 1-1 .
This chapter contains information abou t
Checking and installing BootROM chip located on the MAIN CPU .
Checking and installing the teach pendant EPROM chip located on th e
teach pendant PCB .
3. EPROM INSTALLATION
MARAJINST09205 E
3-2
FANUC Robotics recommends you have the version of BootRO M

EPROM chip that is compatible with the version of R-J software you ar e
using. The BootROM EPROM chip is located on the MAIN CPU boar d
inside the controller .
3.1
INSTALLIN G
BOOTROM EPRO M
CHIPS
Use the procedures in this section when yo u

Check the version of BootROM EPROMs you have .
Install Core and Application software, and BootROMs for th e
first time .
Update Core and Application software and must check the curren t
BootROM version .
Refer to Table 1-1 for specific software version information . Use

Procedure 3-1 to check the BootROM Version you have . Use
Procedure 3-2 to install new BootROM EPROMs .
Procedure 3-1 Checking the BootROM Versio n
Condition
circuits.
WARNING
seriously.
A CAUTIO N

you could damage the equipment .
Step
If the controller is powered up, power it down .
Press and hold the USER PB#1 and USER PB #2 buttons (PURG E
ENABLE and ON if you are using a P-155 controller) on th e
controller operator panel .
3 While still holding these buttons, press the ON button on the

controller operator panel until you see the BMON> prompt on the
CRT/KB or teach pendant screen .
4 Release these buttons. See the following screen for an example .
3 . EPROM INSTALLATION
3-3
MARAJINST09205E
BootRO M
Versio n
Number
Refer to Table 1-1. Compare the BootROM version with the versio n
required for your software.
If the BootROM version is correct for the version of softwar e

you have, DO NOT install new BootROM EPROMs .
If the BootROM version is NOT correct for the version o f

software you have, you must install new BootROMs . Us e
Procedure 3-2 to install a new BootROM EPROM .
Procedure 3-2 Installing New BootROM EPROM Chip s
WARNING
Disconnect electrical power from the controller before you
seriously.
A CAUTIO N
Data in CMOS RAM will be lost if the BootROM chip i s
removed without a battery back-up . To prevent loss of dat a
back up, or copy, all files for permanent storage .
A CAUTION
Use anti-static devices and observe anti-static safety
precautions when handling any electronic material, otherwise
you could damage the equipment.
Condition
circuits.
MARAJINST09205 E
3-4
Step
Disconnect electrical power from the controller .
If your controller is equipped with a disconnect handle at the uppe r

right front corner, pull it to the OFF (down) position.
OR
If your controller is equipped with a circuit breaker handle, tur n
the handle to the OFF (open) position .
WARNING
When the disconnect or circuit breaker handle is OFF ,
power is still present inside the controller . You must
unplug the controller from the electrical outlet to remov e
all power from the controller.
Use a flat-tip screwdriver to turn the latch on the front door of the
controller to the UNLOCKED position. See Figure 3-1 .
Figure 3-1 . R-J Controller Disconnect Handle and Latc h
CIRCUIT BREAKE R
B-SIZE CONTROLLER
POWER DISCONNEC T
C-SIZE CONTROLLER
3. EPROM INSTALLATIO N
3-5
MARAJINST09205E
4 Locate the MAIN CPU Board. See Figure 3-2 .

Figure 3-2 . MAIN CPU Board Locatio n
The MAIN CPU Board is on the backplane of the controller, to the lef t
of the power supply unit, and the vision engine PCBs (if the visio n
option has been installed) .
5
Disconnect the cables from the board. See Figure 3-3 .
Press and hold both latches of the MAIN CPU board and remove th e
board from the backplane . See Figure 3-3 .
MARAJINST09205 E
3-6
7 Find the location of the BootROM chips . See Figure 3-4.

Figure 3-4. Locating the BootROM Chips
NOTE Refer to Table 1-1 to determine the BootROM version that i s

compatible with the version of software you have .
3-7
A CAUTION
The pins on the BootROM EPROM chip are fragile . Whe n
installing an EPROM chip, do not bend any of the pins ,
otherwise, you will not be able to connect the EPROM chip
properly.
8 If you are replacing existing BootROM chips, use a dual-inline-pin

(DIP) chip removal tool to remove each BootROM chip carefully .
9 If you are installing new BootROM chips, use a dual-inline-pi n
(DIP) chip installation tool to install each BootROM chip . Be sure to
orient the notch as shown in Figure 3-4 .
10
Plug in the MAIN CPU Board. Be sure the connector seats properl y
with the backplane connector.
11 Reconnect the cables to the MAIN CPU Board. See Figure 3-4 for a
diagram of where each cable must be connected .
12
Close the controller door and set the circuit breaker handle o r
disconnect handle to ON.
MARAJINST09205 E
3-8
3.2
INSTALLING TEAC H
PENDANT EPRO M
CHIPS
You must have the teach pendant EPROM version that corresponds to th e
version of software you are using . Procedure 3-3 describes how to chec k
the current EPROM version . Procedure 3-4 describes how to install a
new teach pendant EPROM chip .
Use the procedures in this section when you
Check the version of teach pendant EPROMs you have .
Install software for the first time and must install the teach pendant
EPROMs for the first time.
Update software and must check the current version of teach pendan t
EPROMs .
Refer to Table 1-1 for specific software version information. Use
Procedure 3-3 to check the teach pendant EPROM version you have . Use
Procedure 3-4 to install new teach pendant EPROMs .
Procedure 3-3 Checking Teach Pendant EPROM Version s

Step
Hold the teach pendant and look at the screen . The screen shown in
Step 3 is displayed very quickly. Be sure you are looking for thi s
screen otherwise you could miss seeing it .
Press and hold the ON button on the controller.
4 Quickly view the teach pendant display . See the following screen for
an example .
Teac h
Pendant
Versio n
Number
5 If you miss seeing the screen, repeat Steps 1 through 4 .
3. EPROM INSTALLATIO N
3-9
MARAJINST09205E
Refer to Table 1-1 . Compare the EPROM version with required fo r

your software .
If the teach pendant EPROM version is correct for the versio n

of software you have, do not install new teach pendant EPROMs .
If the teach pendant EPROM version is NOT correct for th e

version of software you have, you must install a new teach
pendant EPROMs . Use Procedure 3-4- to install a new teach
pendant EPROM .
Procedure 3-4 Installing A New Teach Pendant EPROM Chi p
WARNIN G

seriously.
A CAUTION

could damage the equipment .
you
Condition
circuits.
Step
Hold the teach pendant so the back of the teach pendant is facing you .
See Figure 3-5 .
Using a cross-tip screwdriver, remove the six screws on the back cove r
of the teach pendant. See Figure 3-6.
A CAUTION
Do not remove or disconnect any cables connected inside th e

teach pendant or damage to equipment could occur .
MARAJINST09205E
3-10
Figure 3-5 . Removing the Back Cover of the Teach Pendan t
4 Find the location of the teach pendant EPROM. See Figure 3-6 .
Figure 3-6. Locating the Teach Pendant EPROM Chi p
NOTE Refer to Table 1-1 to determine the BootROM version that i s

compatible with the version of software you have.
Refer to Figure 3-7 for a description of how the EPROMs are labeled.
3-1 1
MARAJINST09205E
Figure 3-7. EPROM Labels
Product Category
Product Version
Product Revision
Software Serial Number
Blank
Product Name
A CAUTIO N
The pins on the teach pendant EPROM chip are fragile . Whe n
installing an EPROM chip, do not bend any of the pins ,
otherwise, you will not be able to connect the EPROM chip
properly.
5 If you are replacing an existing teach pendant EPROM chip, use a

dual-inline-pin (DIP) chip removal tool to remove the chip carefully.
6 If you are installing a new teach pendant chip, use a dual-inline-pin
(DIP) chip installation tool to install the chip .
7 Replace the teach pendant back cover .
8 Using a cross-tip screwdriver, tighten the six screws on the back cover.
SOFTWARE INSTALLATION
4-1
You install software when you first install a new system or when you ar e
updating an existing system . Installing software involves loading th e
software from floppy disks into controller memory (FROM and CMO S
RAM). You must install :
Core software
Robot libraries
SYSTEM R-J application softwar e
When you have finished installing the core, robot libraries an d

application/tools, you must set up information specific to you r
application.
You can also install :
Software options
Hardware options
Software update s
The SYSTEM R-J software is modular . It is important that each

component of the software is loaded at the appropriate time. The kinds o f
components you will be loading are :
Installation Overview
CORE disks (6 disks)

APPLICATION/TOOL disks (1+ disks )
Robot Library disk (1 disk for V3 .06P and V3 .06PA, 2 disks for
V3.06PB, V3 .06PC and V3 .06PD)
TurboMove Option Disk (1 disk) (optional )
Option disks (1 disk per option)
Update disks (1 disk per update )
The installation procedure begins with the CORE1 disk . During the
CORE1 through CORE6 (CORE4 for SpotTool V3 .06PC and V3 .06PD )
load, you are asked to insert the COMMON! disk once (if you are loadin g
SpotTool V3 .06PC or V3 .06PD), you are asked to insert the TurboMov e
disk once (if you are installing that option with KAREL or SpotTool), an d
you are asked to insert the APPLICATION/TOOL disk three times .
When CORE6 (COMMON1 for SpotTool V3 .06PC or V3 .06PD) is
finished, you will be asked to insert the APPLICATION/TOOL disk again.
Next, you will be asked to insert either one or both LIBRARY disks . At
this point, the robot will begin a controlled start.
During a controlled start, all necessary options can be loaded . When you
have finished loading the options, you will be asked to insert th e
APPLICATION/TOOL disks in order to set up application specific
information .
When all options have been installed, and the application is configured ,
you must cold start the controller.
Refer to Table 1-1 for specific software version information .
4. SOFTWARE INSTALLATIO N
4-2 MARAJINST09206E
A CAUTIO N
pack supplies CMOS RAM memory with powe r

when the controller power is off . Make sure the output voltag e
of the battery pack is at least 2 .5 volts, otherwise th e
information stored in CMOS RAM memory could be lost whe n
controller power is off .
A 3-volt battery
A CAUTIO N
When the software is loaded controller memory and RAM dis k

memory are altered . Software that is currently on the controller
is lost and cannot be recovered .
You should back up all system variables and programs store d
on the controller before you load software . Refer to the Setup
and Operations Manual for your software for more information .
To install ArcTool, DispenseTool, KAREL, PalletTool o r

SpotTool V3.06P, and V3.06PA
Core, application/tools, and robot libraries, use Procedure 4-1 .
Options, use Procedure 4-4 .
Updates, use Procedure 4-6 .
Motion Groups, use Procedure 4-7 .
Extended Axes, use Procedure 4-8 .
To install KAREL, PaintTool, or PalletTool V3 .06PB
Options (except PaintTool), use Procedure 4-4 .
PaintTool Options, use Procedure 4-5 .
To install SpotTooI V3.06PC or V3.06PD
Options, use Procedure 4-4 .
Timetable
The entire installation procedure will take approximately 2 to 3 hours .
4. SOFTWARE INSTALLATION
4-3
MARAJINST09206E
Procedure 4-1
Condition
Installing V3 .06P or V3 .06PA Core, Application and Robo t

Library Softwar e
n
You are loading one of the following applications :

- ArcTool
DispenseTool
- KAREL
- PalletTool
- SpotTool
n The R-J controller is plugged in and is working properly .

n The R-J controller is turned off.
n Enough system memory is available to install all core, application an d
option software . Refer to Table 1-1 for information on the amount o f
memory required for your application software . Refer to Chapter 5
for information on checking the amount of system memory you have .
n The teach pendant ON/OFF switch is OFF and the DEADMAN
switch is released.
n The REMOTE/LOCAL keyswitch on the operator panel is set to
LOCAL .
You have obtained a PS-100 disk drive.
n You have the R-J software core disks and any additional applicatio n
disks that you want to install . (Refer to Table 1-1 for the number of
disks you should have .)
A CAUTIO N
This procedure erases all controller (CMOS RAM) and RA M

disk memory on the R-J controller. Be sure that an y
information you want permanently saved is backed up to a
floppy disk (not RAM disk) . Refer to the Setup and Operation s
Manual, specific to the kind of software you are installing, for
more information .
Step
Connect the PS-100 disk drive cable to the RS-232-C port on the R- J
2 Press the ON button on the controller operator panel .

3
Turn on the disk drive and make sure the light turns on . If not, the
disk drive might be defective . Repair or replace the disk drive and
repeat this step.
4 Press the OFF button on the controller operator panel .
4 . SOFTWARE INSTALLATION
MARAJINST09206E
5 Insert the first disk to be installed into the PS-100 disk drive, normally
labeled CORE1.
6
Installing Software
Automatically
Turn on the controller as follows:
To start the installation procedure automatically ,

a Press and hold the USER PB#l button (PURGE ENABLE
button on a P-155 robot) and the HOLD button while pressin g
the ON button.
b Release all three buttons.
c Type 1 to perform the software auto load . The files will be
loaded from the disk automatically .
d
Go to Step 1 of Installing the CORE Disks .
To start the installation procedure manually while using an y

robot model other than a P-155 ,
a Press and hold USER PB#l and USER PB#2, and press th e
ON button. The BMON> prompt will be displayed .
b
Press >, NEXT.
A CAUTIO N
The next step erases all controller (CMOS RAM) and RAM dis k
memory on the R-J controller. Be sure that any information yo u
want permanently saved is backed up to a floppy disk (no t
RAM disk).
c Press F5, RUN.
d
Type the name of the command file that will begin the loa d
procedure . Typically the name of the file is AUTO .
To display a character from beginning to end one at a

time, press the down arrow key.
To display a character from end to beginning one at a
time, press the up arrow key .
- Press the right arrow key to accept a character.
Press the right arrow and then press backspace to delete a
character.
NOTE When you are finished, press the right arrow key to be sure the
cursor is on the last letter of the command file name. Otherwise the
command file name will not be entered correctly.
e Press ENTER. The files will be loaded from the disk
automatically.
4-5
MARAJINST09206E
Installing the CORE Disks
When the files begin loading, see the following screen for an example .
When the first disk has finished you will see a screen similar to the
following .
2 Install the Core, TurboMove, Application/Tool, and Robot Library

disks as prompted.
ARCTOOL CONFIGURATION If you
are loading ArcTool, when disk CORE2 has finished loading you
will be prompted to select a TPE configuration. See the following screen
for an example.
ArcTool supports two different TPE configurations . The 40010

configuration is the proper choice for systems with 2MB of CMOS RA M
memory. The 1200KB configuration is the proper choice for systems with
4MB of CMOS RAM memory.
4-6
MARAJINST09206E
DISPENSETOOL CONFIGURATION If you are loading DispenseTool, when disk CORE2 has finished loading
you will be prompted to select a TPE configuration . See the following

screen for an example .
DispenseTool supports three different TPE configurations . The 150KB

configuration is the proper choice for most systems with 2MB of CMO S
RAM memory. A 300KB configuration can be selected for a system wit h
2MB of CMOS RAM memory and minimal requirements for softwar e
options. The 1200KB configuration is the proper choice for systems wit h
4MB of CMOS RAM memory.
KAREL CONFIGURATION If you are loading KAREL, when disk CORE2 has finished loading yo u
will be prompted to select a TPE configuration. See the following screen

for an example.
PALLETTOOL CONFIGURATION NOTE If you are loading PalletTool, when disk CORE2 has finishe d
loading, the 130KB TPE configuration will be loaded automatically. G o

to Step 4.
SPOTTOOL CONFIGURATION
NOTE If you are loading SpotTool, when disk CORE2 has finished
loading, the 150KB TPE configuration will be loaded automatically. Go
to Step 4.
3 Make a TPE configuration selection.

For example, in a 2MB CMOS RAM ArcTool system, 400KB i s
recommended.
To select the displayed configuration, press 1 .
If you do not want to select the displayed configuration ,
press 0 .
4 Continue to install the Core, TurboMove, and Application/Tool disks
as prompted.
4-7
MARAJINST09206E
NOTE You will need to insert the Application/Tool disk three time s
during the installation process .
When the Core, and TurboMove, Application/Tool disks are finished ,
you will be prompted to select a robot library . See the following screen for
an example.
Selecting a Robot
Insert the Robot Library disk .
Type the number that corresponds to the type of robot you have an d
press ENTER .
7 The following set of screens require you to specify information

specific to your robot and wrist type . Set each item appropriately.
When you have finished typing all robot information, see the followin g
Loading Servo Parameters
Select 2 to Ioad files from the disk and press ENTER. If you are
loading V3 .06P or V3 .06PA, see the following screen for an example .
NOTE In V3 .06P and V3 .06PA, the load from F-ROM (Flash ROM)
option cannot be used . The non load of servo params is used only in
diagnostic mode.
4-S
MARAJINST09206E
4 . SOFTWARE INSTALLATIO N
4-9
MARAJINST09206E
Loading Motion Parameters
Setting Maximum Robot

Payload
10
Type 2 to load files from the disk, and press ENTER. See the
Type the maximum amount of payload for your robot and pres s
ENTER.
11 Install information specific to your application :

Installing ArcTool
Installing DispenseToo l
Shot Meter Equipment
:.,.
If you are installing ArcTool, the ArcTool setup information will b e

installed automatically. When it is finished, go to Step 12 .
If you are using Shot Meter equipment, see the following screen for
an example .
Select each item and set it as desired . Refer to Table 4-1 .
Table 4-1 . Shot Meter Configuration Items

REM
Equipment Type
default: ULTRA-FLO
Use Atomizing
Air
default: NO
DESCRIPTION
Defines the type of equipment you are using (F4,
[CHOICE], displays alternatives) :
ULTRA-FLO indicates Graco ULTRA-FL O
equipment .
SEALANT EQ indicates Sealant Equipmen t
equipment .
EMC-2K indicates EMC2 equipment .

Defines whether the dispensing system uses atomizing ai r
in dispensing material .
MARAJINST09206 E
4- 10
Table 4-1 . (Cont'd) Shot Meter Configuration Item s
ITEM
Use Volume
Dispensed
default: NO
Use Pressure
default: NO
Use Auto Purg e
default : NO
Use Two Part
Material
default : NO
DESCRIPTIO N
Defines whether the dispensing system monitors materia l
volume after dispensing .
pressure while dispensing .
Defines whether the robot controller performs an automati c
purge after a user-defined idle time .
Defines whether the dispensing system is equipped wit h
two-part material mixing capability.
Press FCTN . See the following screen for an example .
C Insert the Application/Tool dis k

d Select 2, SETUP APPLICATION.
When you are finished, go to Step 12 .
4- 1 1
MARAJINST09206E
Installing DispenseTool
Nordson Equipment
If you are using Nordson Pro-Flo equipment, see the followin g


Table 4-2. Nordson Configuration Items
ITEM
Use Atomizin g
Ai r
default : NO
DESCRIPTION
Defines whether the dispensing system uses atomizing air i n
dispensing material .
Use Pressure
default: NO
Number of
Equipments
default: 1

pressure while dispensing .
Defines the number of dispensing equipments to be
controlled by DispenseTool . Note that multiple dispensin g
equipments must be of the same type .
c Insert the Application/Tool disk.

Select 2, SETUP APPLICATION .
MARAJINST09206 E
4-12
Installing DispenseTool
Schucker Equipment
If you are using Schucker equipment, see the following screen for
an example .
a Select each item and set it as desired. Refer to Table 4-3 .

Table 4-3. Schucker Configuration Items
ITEM
Equipment
Typ e
default : APC2000
Use Atomizin g
Ai r
default : YES
DESCRIPTIO N
Defines the type of equipment you are using (F4 ,
[CHOICE], displays alternatives) :
Schucker 2500
Schucker 2000
Schucker 1000 On-Off gun

Schucker 1000 Servo gu n
Defines whether the dispensing system uses atomizing air
in dispensing material
FUNCTIONS
START (COLD )
SETUP APPLICATION
INSTALL OPTION
INSTALL UPDATE
SAVE
START KC L
PRINT SCREEN
PRINT CONFI G
UNSIM ALL I/ O
Insert the Application/Tool disk.

4-1 3
MARAJINST09206E
Installing DispenseToo l
Jesco Equipment
If you are using Jesco Gear Meter equipment, see the followin g

Table 4-4 . Jesco Configuration Items
ITEM
Number of
Equipments
default : 1
DESCRIPTION
Defines the number of dispensing equipments to b e
controlled by DispenseTool . Note that multiple dispensin g
equipments must be of the same type .
Press FCTN. See the following screen for an example .

d

When you are finished, go to Step 12.
MARAJINST09206E
4-14
Installing KAREL
To install KAREL,
a
" '
. . ..................
...............................
......... ..... . . .
. . . . . . .. . . .
......... ... ... .......
. . . .. .. . . . .
. . . .. . . . . . .
. . .. . . . . . . .
............... ... .... ...........
FUNCTIONS
START (COLD )
SETUP APPLICATIO N
INSTALL OPTIO N
INSTALL UPDAT E
SAVE
START KCL
PRINT SCREE N
PRINT CONFI G
UNSIM ALL I/ O
i
tn
b Insert the Application/Tool disk .

Select 2, SETUP APPLICATION . See the following screen for a n
example .
Each item listed on the screen will be executed automatically . When

the items are finished, press ENTER.
d
Installing PalletTool
AWSETUP Compl
Go to Step 12 .
If you are installing PalletTool, the PalletTool setup information wil l

be installed automatically. When it is finished, go to Step 12 .
4-1 5
MARAJINST09206E
Installing SpotTool
To install SpotTool ,
a Press FCTN . See the following screen for an example .
STATUS Version
<;,
ID
JOINT 10
FUNCTIONS
START (COLD )
SETUP APPLICATIO N
INSTALL OPTIO N
INSTALL UPDAT E
SAV E
START KC L
PRINT SCREE N
PRINT CONFI G
UNSIM ALL I/ O
U n in
96
a .;zed:> >
Select 2, SETUP APPLICATION . See the following screen for

example.
an
d Type the number of spot welding equipment you are using an d

press ENTER . The files will be loaded from the disk and will tak e
approximately 10 minutes to load . Messages will be displayed
during the loading .
Pres ENTER to continue When the load is complete, pres ENTER. Se the fol owin
MARAJINST09206E
4-16
f Type 1 to continue and define this equipment and press ENTER.

See the following screen for an example .
g Select and define each item specific to your installation . Refer to

the SpotTool Setup and Operations Manual for more information.
h When you have configured SpotTool, type 5, EXIT, and pres s
ENTER. The files will be loaded from the disk and will take
approximately two minutes to load . The STATUS Version ID
screen will be displayed.
12 If you want to install options (except PaintTool), refer to

Procedure 4-4 .
If you want to install PaintTool options, refer to Procedure 4-5
If you want to install updates, refer to Procedure 4-6 .
If you do not want to install options or updates,
a Press FCTN.
b
Select 1, START (COLD) .
When the Core, TurboMove, Application Tool, and Robot Librarie s

have been installed and the Controlled Start Initialization is complet e
you can perform the following :
Install Software Options . Refer to Procedure 4-4 .
Install Software Updates . Refer to Procedure 4-6 .
Install Motion Groups . Refer to Procedure 4-7 .
Install Extended Axes . Refer to Procedure 4-8 .
Perform a Cold Start to initialize the robot . Refer to Appendix A.
Perform the Mastering Procedure . Refer to Chapter 5 .
4-17
MARAJINST09206E
Procedure 4-2 Installing V3 .06PB Core, Application and Robot Librar y

Software
Condition
You are loading one of the following applications :
- TPP+ or KAREL
- TPP+ or KAREL with INSIGHT II
- PaintTool
n The R-J controller is plugged in and is working properly .
n The R-J controller is turned off .
option software . Refer to Table 1-1 for information on the amount o f
memory required for your application software . Refer to Chapter 5
n The teach pendant ON/OFF switch is OFF and the DEADMAN switc h
is released.
n The REMOTE/LOCAL keyswitch on the operator panel is set t o
LOCAL .
n
You have obtained a PS-100 disk drive .
n You have the R-J software core disks and any additional applicatio n
disks that you want to install . (Refer to Table 1-1 for the number o f
A CAUTIO N

disk memory on the R-J controller . Be sure that any
Manual, specific to the kind of software you are installing, fo r
more information .
Step
2 Press the ON button on the controller operator panel.

3 Turn on the disk drive and make sure the light turns on. If not, th e
repeat this step.
5 Insert the first disk to be installed into the PS-100 disk drive, normall y
labeled CORE1 .
MARAJINST09206E
4-18
6
Installing Software
Automaticall y
Turn on the controller as follows :

To start the installation procedure automatically ,
a
Press and hold the USER PB#1 button (PURGE ENABLE

the ON button .

c Type 1 to perform the software auto load. The files will be
d Go to Step 1 of Installing the CORE Disks.
Installing Software
Manually
MiN
To start the installation procedure manually while using a

P-155 controller, press and hold the PURGE ENABLE button and
press the ON button .

other robot ,
a
Press and hold USER PB#1 and USER PB#2, and press th e
ON button. The BMON> prompt will be displayed.
Press NEXT, >.
A CAUTION
memory on the R-J controller . Be sure that any information yo u
RAM disk) .
c Press F5, RUN.
d
Type the name of the command file that will begin the load
procedure . Typically the name of the file is AUTO .
To display a character from beginning to end one at a

time, press the down arrow key .
- To display a character from end to beginning one at a
time, press the up arrow key.
- Press the right arrow key to accept a character .
- Press the right arrow and then press backspace to delete a
character.
command file name will not be entered correctly .
-
BMON>RUN AUTOO>v.;
<.<, ....`
{ . '.... <. .,
. ... . . . .
Press ENTER. The files will be loaded from the dis k

automatically.
4-19
MARAJINST09206E
When the first disk has finished you will see a screen similar to th e
following .
Install the Core, TurboMove, Application/Tool, and Robot Librar y

disks as prompted.
you are loading TPP+ or KAREL, you will be prompted to select a

TPE configuration . See the following screen for an example .
TPP+ or KAREL CONFIGURATION If
CONFIGURATION
CONFIGURATION?
0=NO)
(1=
NO)
YES
`
CONFIGURATION ':
:-YES,
CONFIGURATION? ON ( 1=YES,0=NO
A CAUTIO N
Increasing the size of the TPE memory pool will decrease th e

size of the KAREL memory pool . Be sure you know the
memory requirements of your system before you modify thes e
values.
4-20
MARAJINST09206E
TPP+ and KAREL support five different TPE configurations . For 2MB
CMOS RAM KAREL systems using the KAREL Development Package ,
select the 75KB configuration . If your system has 4MB of CMOS RAM ,
select the 300KB configuration . The other three configurations allow yo u
to change the balance of memory in the KAREL and TPE memory pools .
Go to Step 3.
TPP+ or KAREL with INSIGHT II
CONFIGURATION
If you are loading TPP+ or KAREL with INSIGHT II, you will be
prompted to select a TPE configuration . See the following screen for an

example.
A CAUTIO N
Increasing the size of the TPE memory pool will decrease th e

size of the KAREL memory pool . Be sure you know th e
memory requirements of your system before you modify these
values .
TPP+ and KAREL support five different TPE configurations . For 2MB
CMOS RAM KAREL systems using the KAREL Development Package ,
select the 75KB configuration . If your system has 4MB of CMOS RAM ,
select the 300KB configuration. The other three configurations allow you
to change the balance of memory in the KAREL and TPE memory pools .
Go to Step 3.
PAINTTOOL CONFIGURATION
NOTE If you are Ioading PaintTool, when CORE2 has finished loadin g
the 1200KB TPE configuration will be loaded automatically . Go to

Step 4.
3
Make a TPE configuration selection .

For example, in a 4MB CMOS RAM KAREL system, 300KB i s
recommended.
If you do not want to select the displayed configuration ,
press 0.
MARAJINST09206E
TPP+ or KAREL with INSIGHT ll
4-21
If you are loading TPP+ or KAREL with INSIGHT II, see the
NOTE To load INSIGHT II correctly, you must load vision FRO M

software .
To load vision FROM software, type 1.

If you do not want to load vision FROM software, type 0.
4 Continue to install the Core, TurboMove, and Application/Tool disk s

as prompted .
NOTE You will need to insert the Application/Tool disk three times
during the installation process.
A CAUTIO N
If you are loading TPP+ or KAREL with INSIGHT II and yo u
have loaded Core disk 3, Core disk 6, and Library disk 2 yo u
will be prompted to insert Application/Tool disk 1 . THIS
MESSAGE IS INCORRECT . Instead, insert Application/Tool
disk 2 .
When the Core, and TurboMove, Application/Tool1 disks are finished ,

you will be prompted to select a robot library. See the following screen for
an example .
MARAJINST09206E
4-22
Selecting a Robot
Insert the first robot library disk.
Press Fl, [RETRY] . See the following screen for an example .
7 Make a robot selection

If the robot you are using is listed, type the number that correspond s
to the type of robot you have and press ENTER . You will not need to
insert the second robot library disk .
If the robot you are using is not listed, press 0 to display another lis t
of robot selections . See the following screen for an example .
Insert the second robot library disk.
b Press Fl, [RETRY] . See the following screen for an example .
4-23
MARAJINST09206E
Type the number that corresponds to the type of robot you have and .
press ENTER.
NOTE If the robot you want to select is not displayed, press 0 to displa y
the previous page and repeat steps 5 through 8 until you have selected th e
correct robot.
9
The following set of screens require you to specify informatio n

specific to your robot and wrist type . Set each item appropriately.
When you have finished typing all robot information, see the following
screen for an example.
10 Type 1 to load files from the disk and press ENTER . See the
NOTE The non load of servo prams is used only in diagnostic mode .
11
Type 1 to load files from the disk, and press ENTER . See the
4-24

Payload
MARAJINST09206E
12
Type the maximum amount of payload for your robot and pres s
ENTER.

Installing TPP+ or KAREL
To install TPP+ or KAREL,

a Press FCTN. See the following screen for an example .
FUNCTIONS
START (COLD )
SETUP APPLICATION
INSTALL OPTION
INSTALL UPDATE
SAV E
START KC L
PRINT SCREE N
PRINT CONFI G
UNSIM ALL I/ O
b Insert the Application/Tool disk .

c Select 2, SETUP APPLICATION . See the following screen for an
example .
Each item listed on the screen will be executed automatically .

When the items are finished, press ENTER .
d Go to Step 14.
MARAJINST09206E
Installing TPP+ or KAREL
with INSIGHT II
4-25
To install TPP+ or KAREL with INSIGHT II ,

. .ID
STATUS
,
........... Version
....
1
2
3
4
5
6
7
8
9
0
JOINT
FUNCTIONS
START (COLD )
SETUP APPLICATIO N
INSTALL OPTIO N
INSTALL UPDAT E
SAVE
START KCL
PRINT SCREE N
PRINT CONFI G
UNSIM ALL I/ O
10 %
Insert the Application/Tool disk .
c Select 2, SETUP APPLICATION . The INSIGHT II files will b e

loaded automatically.
d Go to Step 14.
4-26
MARAJINST09206E
Installing PaintTool
To install PaintTool,
a Press FCTN . See the following screen for an example .
Insert the Application/Tool1 disk.
If PaintTool was not found on controller memory, the following

screen is displayed.
To load PaintTool, select YES and press ENTER . '
The files will be loaded automatically.

NOTE If an error occurs during the load procedure, press any key t o
display the controlled start menus .
Insert the second and third PaintTool disk as prompted an d
press F2, [RETRY] .
The file names will be displayed on the teach pendant as they ar e
loaded.

PaintTool cannot be reloaded . If you attempt to reload it a screen

similar to the following will be displayed.
MARAJINST09206E
4-27
d After the files from all three PaintTool disks have been loaded, se e
the following screen for an example .
A CAUTIO N
Be sure to run site setup . If site setup is not performed, th e
required system files will not be -loaded and your system will not
run properly.
If you do not want to set up the site now, select NO and press
ENTER.
If you want to set up the site, select YES and press ENTER .
Insert the site specific setup disk and press ENTER .
NOTE This should only be performed now if no PaintTool options are

required . If a PaintTool option is required, refer to Procedure 4-5
Step 10.
- Insert the Setup disk and press ENTER . See the following
4-28
MARAJINST09206E
The I/O setup status will be displayed.
e Load PaintTool options . Go to Step 14 .

14 If you want to install PaintTool options, refer to Procedure 4-5 .
If you want to install options (except PaintTool), refer to
Procedure 4-4 .
If you do not want to install options or updates ,
a
Press FCTN .

have been installed and the Controlled Start Initialization is complete
Install Software Options (except PaintTool) . Refer to Procedure 4-4 .
Install PaintTool Options . Refer to Procedure 4-5 .
Install Motion Groups . Refer to Procedure 4-7 .
Perform a Cold Start to initialize the robot. Refer to Appendix A .
Perform the Mastering Procedure . Refer to Chapter 5 .
4-29
MARAJINST09206E
Procedure 4-3 Installing V3 .06PC and V3.06PD Core, Application and Robo t
Library Software
Condition
You are loading SpotTool
n The R-J controller is plugged in and is working properly.

n The R-J controller is turned off.
option software . Refer to Table 1-1 for information on the amount of
memory required for your application software. Refer to Chapter 5 .
n The teach pendant ON/OFF switch is OFF and the DEADMAN
switch is released.
n The REMOTE/LOCAL keyswitch on the operator panel is set t o
LOCAL .
n You have obtained a PS-100 disk drive .
n You have the R-J software core disks and any additional application
disks that you want to install . (Refer to Table 1-1 for the number o f
A CAUTION

disk memory on the R-J controller. Be sure that any
Manual, specific to the kind of software you are installing, fo r
more information .
Step
Press the ON button on the controller operator panel .
3 Turn on the disk drive and make sure the light turns on. If not, the
repeat this step.
5 Insert the first disk to be installed into the PS-100 disk drive, normally
labeled CORE 1 .
MARAJINST09206E
4-30
6
Installing Software
Automatically
'Rim on the controller as follows :

To start the installation procedure automatically,
a Press and hold the USER PB#l button (PURGE ENABLE
the ON button.
c Type 1 to perform the software auto load . The files will be
d
Go to Step 1 of Installing the CORE Disks .

robot model other than a P-155 ,
a Press and hold USER PB#l and USER PB#2, and press th e
ON button. The BMON> prompt will be displayed.
b Press >, NEXT.
A CAUTION
memory on the R-J controller. Be sure that any information yo u
RAM disk) .
c Press F5, RUN.
d Type the name of the command file that will begin the loa d
procedure . 'Typically the name of the file is AUTO .
- To display a character from beginning to end one at a
time, press the down arrow key.
To display a character from end to beginning one at a
time, press the up arrow key .
Press the right arrow key to accept a character .
character.
cursor is on the last letter of the command file name . Otherwise the
e Press ENTER . The files will be loaded from the dis k
automatically. See the following screen for an example .
4-3 1
MARAJINST09206E
SPOTTOOL CONFIGURATION
You will then be prompted to select a TPE configuration. See the
Make a TPE configuration selection .

If you do not want to select the displayed configuration,
press 0.
MARAJINST09206E
4-32
3 Determine the kind of servo code you want to use :

If you want to use TurboMove servo code, type 1 .
If you do want to use TurboMove servo code, type O . See the
memories
If you want to use Standard Servo Code, type 1 .

If you do not want to use Standard Servo Code, type 0 .
NOTE You must make a servo code selection before you can continu e
loading software.
4 Install the Core, Common1, TurboMove, and Application/Tool disk s
as prompted.
5
Continue to install the Core, Common1, TurboMove, an d

Application/Tool disks as prompted.
NOTE You will need to insert the Application/Tool disk three time s
during the installation process.
When the Core, Common1, and TurboMove, Applicatian/Tool1 disk s
are finished, you will be prompted to select a robot library . See the
4-33
MARAJINST09206E
Selecting a Robot
Insert the first robot library disk.
7 Press Fl, [RETRY] . See the following screen for an example .
Make a robot selection
NOTE Note that the S420 robot model is loaded from the second disk a s
item 16 . The S420 robot was item 2 on previous software versions.
WARNIN G
Do not choose the wrong robot model or the wrong files
will be loaded from the disk .
If the robot you are using is listed, type the number that corresponds
to the type of robot you have and press ENTER. You will not need to
insert the second robot library disk .
s If the robot you are using is not listed, press 0 to display another list
of robot selections. See the following screen for an example .
Insert the second robot library disk .
4-34
MARAJINST09206 E
Press F1, [RETRY] . See the following screen for an example .
Type the number that corresponds to the type of robot you have an d
press ENTER.
NOTE If the robot you want to select is not displayed, press 0 to display
the previous page and repeat steps 5 through 8 until you have selected the
correct robot.
Loading TurboMove
Parameters
10
Type 2 to load files from the disk and press ENTER . See the
NOTE
The non load of TurboMove parameters is used only in diagnosti c
mode.
11 The following set of screens require you to specify informatio n

specific to your robot and wrist type. Set each item appropriately.
4-35
MARAJINST09206E
When you have finished typing all robot information, see the followin g
12 Type 2 to load files from the disk and press ENTER . See the
NOTE The non load of servo params is used only in diagnostic mode .
13
NOTE Make sure that the payload you enter in the next step is accurate .
The payload you enter will affect how the robot moves .
Payload
14 Type the maximum amount of payload for your robot and pres s
ENTER.
MARAJINST09206E
4-36
Installing SPOTTOOL
To install SpotTool ,
STATUS Version ID
1
2
3
4
5
6
7
8
9
0
JOINT 10 %
FUNCTIONS
START (COLD )
SETUP APPLICATION
INSTALL OPTION
INSTALL UPDATE
SAVE
START KCL
PRINT SCREE N
PRINT CONFI G
UNSIM ALL I/ O
b Insert Application/Tool disk #1 .

c Select 2, SETUP APPLICATION. See the following screen for an
example .
d Type the number of spot welding equipment you are using and
press ENTER. The files will be loaded from the disk and will take
approximately 10 minutes to load . Messages will be displaye d
during the loading .
e When the load is complete, press ENTER . See the following
f Type 1 to continue and define this equipment and press ENTER .

4-37
MARAJINST09206E
g Select and define each item specific to your installation. See

Table 4-5.
Table 4-5 . Configuration Setup Items
ITEM
Define Weld Interface
DESCRIPTION
Defines the type of weld interface used : Digital, Serial, or Stud Welder.
If you select a serial weld interface, you will need to define the following:
Gun stroke controlled by weld controller?
Define Spot Weldin g

Equipment
Defines the equipment being used . You must specify the following :
. Gun on a tool changer device? (1=YES, O=NO )
)
Soft touch gun? (1=YES, 00=NO
Does gun have multipressure valving controlled by the robot? (1=YES, 0=NO )
s How many multiple pressures ?

1 = Binary coded (0-15 pressures )
2 = HIGH, LOW
3 = HIGH, MEDIUM, LOW
Extra gun contactors? (1=YES, 0=NO )
Does gun have a backup stroke? (1=YES, 0=NO )
Is this a quick close backup gun? (1=YES, 0=NO )
Detect backup open? (1=YES, 0=NO )
Detect backup closed? (1=YES, O=NO )
Detect gun closed? (1=YES, 0=NO )
Define Weld Controller(s)
Displays the current number of weld controllers and allows you to define the number o f
weld controllers to be used .
If you have a digital or stud weld interface, you will need to define the following:
Major alarm handlin g
1 Active high (high = ALARM, low = OK )
2 Active low (low = ALARM, high = OK)
Minor alarm handlin g

1 Active high (high = ALARM, low = OK )
2 Active low (low = ALARM, high = OK )
If you have a serial interface, you will need to define the following :
Enter a physical port number 5-S (JD12A - JD12D) :
port 5 JD12 A
port 6
JD12 B
port 7 JD12 C
port 8 JD12 D
Using isolation contactors?(1=YES, 0=NO )
Define & Load Standard

Macros
Defines and loads the standard set of SpotTool Macros. Do not perform this option i f
you have backed up your macro programs and your macro setup (SYSMACRO .SV).
This should only be used if you are loading a new controller.
The following selections are available :
1 Continue and load standard macro s
2 Exit and don't load standard macros
MARAJINST09206E
4-38
Table 4-5 . (Cont'd) Configuration Setup Item s

ITEM
Display Configuration
DESCRIPTION
Displays the current configuration after is has been set up . See the following example .
Weld Interface :
Digita l
Number of equipment
1
Number of weld controllers
1
EQ
1
GUN BU QCBU
1.
Y N
MPV
N
STG
N
WC
1
h When you have configured SpotTool, type 6, EXIT, and pres s

ENTER . The STATUS Version ID screen will be displayed .
NOTE If you are not satisfied with the configuration of SpotTool an d
want to do it again, repeat Step 15 .
16 If you want to install options, refer to Procedure 4-4 .

If you do not want to install options or updates ,
a Press FCTN .
b

have been installed and the Controlled Start Initialization is complete
Install Software Options (except PaintTool) . Refer to Procedure 4-4 .
Install Motion Groups. Refer to Procedure 4-7 .
Perform a Cold Start to initialize the robot . Refer to Appendix A .
Perform the Mastering Procedure. Refer to Chapter 5 .
4-39
MARAJINST09206E
Procedure 4-4 Installing R-J Software Option s
CAUTIO N
Do not install the same software option more than once . Doing
so loads the option again which can cause your system t o
operate abnormally.
CAUTION
Be sure to install all option disks before installing any updat e
disks or all files could become corrupted .
Condition
The core, TurboMove (optional), robot libraries, and applicatio n

software are installed . Refer to Procedure 4- 1
You are not loading PaintTool options. If you are loading PaintTool
options, use Procedure 4-5 .
NOTE If you have just completed Procedure 4-1 , press FCTN .

If the FCTN menu is displayed, go to Step 10.
If the FCTN menu is not displayed, continue with Step 1 .
Step
Performing a Controlled Start
; v v : ;< <' >
If the controller is turned on, turn it off.
Press and hold the USER PB#l and USER PB#2 buttons (PURGE
ENABLE if you are using a P-155 controller) on the controlle r
operator panel.
While still holding these buttons, press the ON button on the

teach pendant .
Release these buttons.
At the BMON> prompt press F2 CTRL, and press ENTER.
Now press F5, START, and press ENTER . This performs a controlled
start of the controller.
MARAJINST09206E
7 Type 4, then press ENTER. See the following screen for an example .
NOTE The following screen will be different depending on the softwar e
version you are using .
Insert the option disk in the disk drive .
9 Press FCTN. See the following screen for an example .

.. .. . . . . . . . . .. .. . . . . . . .. . . . . . . . . . . . . . . . . .. . .. . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . .. . . . . . . .. . . . . . . . .. . . . . . . . . . .. . . . . . . .. . . . .
. . .. . . . . .
10 To install a software option, select 3, INSTALL OPTION, and pres s

ENTER. See the following screen for an example .
To continue installing options, press F4, YES .
Ifyou do not want to continue, press F5, NO .
12 When the option has finished loading, remove the option disk fro m
the disk drive.
13
Repeat steps 8 through 12 to install each option you have .
4-4 1
MARAJINST09206E
NOTE If you are installing the PLC 110 option for the Allen-Bradle y
Remote I/O Interface (R-J board in R-J controller), refer to A User's Guide
to the FANUC Robotics Remote I/O Interface for an Allen-Bradley PLC to
complete the software installation.
14 Perform a cold start:

a Press FCTN .
b Select COLD START, and press ENTER .
c When the controller is turned on, you should master and
calibrate the robot. Refer to Chapter 5.
Setting the System Clock
15
Press MENUS .
16
Select SYSTEM .
17 Press F1, [TYPE] .

18 Select Clock . See the following screen for an example .
19 To change the date or time display, press F4, ADJUST and enter th e
new information.
20 When you are finished, press F4, FINISH .
MARAJINST09206E
4-42
Procedure 4-5
Installing PaintTool Software Option s
CAUTIO N
A
Do not install the same software option more than once . Doin g
so loads the option again which can cause your system to
operate abnormally.
A CAUTION
to install all option disks before installing any update
Be sure
or setup disks or all files could become corrupted .
Condition

software are installed . Refer to Procedure 4-1 .
Procedure 4-1 must have been completed .
NOTE If you have just completed Procedure 4-1 ,press FCTN.

If the FCTN menu is displayed, go to Step 10 .
Step
1 if the controller is turned on, turn it off.

2
Press and hold the USER PB#1 and USER PB#2 buttons (PURG E
operator panel .

controller operator panel until you see the BMON> prompt on th e
teach pendant.
MON
INEENSMENNE
Release these buttons .
At the BMON> prompt press F2, CTRL, and press ENTER .
Now press F5, START, and press ENTER . This performs a controlle d
4-43
MARAJINST09206E
7 Type 4, then press ENTER. See the following screen for an example .
Insert the option disk in the disk drive .
MARAJINST09206E
FUNCTIONS
START (COLD )
SETUP APPLICATION
INSTALL OPTIO N
INSTALL UPDAT E
SAVE
START KC L
PRINT SCREE N
PRINT CONFI G
UNSIM ALL I/O
10 To install a software option, select 3, INSTALL OPTION, and press

ENTER. See the following screen for an example .
If an option has already been installed, do not install it again.
Select NO if you do not want to install it again . The controlled start
screen will be displayed.
If an option has not been installed, select YES to install the option.
A CAUTION
Site setup must be performed after the last option has bee n
installed, otherwise you could damage software that ha s
already been installed .
fic setup must be
A CAUTION
Be sure to run site setup . If site setup is not performed, th e

required system files will not be loaded and your system will no t
run properly.
-
If you do not want to set up the option, select NO and pres s

ENTER .
If you want to set up the option, select YES and press ENTER.
Insert the site specific setup disk and press ENTER .
4-45
MARAJINST09206E
When the PaintTool setup is complete, press any key to continue .
,AF
11 When the option has finished loading, remove the option disk fro m
the disk drive .
12 Repeat steps 8 through 11 to install each option you have .
13 Perform a cold start:

a Press FCTN.
calibrate the robot. Refer to Chapter 5 .
14
Press MENUS .
15
Select SYSTEM .
Press Fl, [TYPE] .

17 Select Clock. See the following screen for an example .
16
18 To change the date or time display, press F4, ADJUST and enter the
new information.
19 When you are finished, press F4, FINISH.
NOTE If you are installing the PLC I/O option for the Allen-Bradle y
Remote I/O Interface (R-J board in R-J controller), refer to A User's Guide
to the FANUC Robotics Remote I/O Interface for an Allen-Bradley PLC to
complete the software installation .
MARAJINST09206E
4-46
Procedure 4-6 Installing R-J Software Update s
CAUTIO N
Be sure to install all option disks before installing any updat e
disks or all files could become corrupted .
Condition
Step

software are installed. Refer to Procedure 4-1 .
NOTE If you have just completed Procedure 4-1 , press FCTN .

If the FCTN menu is displayed, go to Step 10 .
1 If the controller is turned on, turn it off.
2
operator panel .
3 While still holding these buttons, press the ON button on th e

teach pendant .
.:,::
v.fy}}}}i}Fr:}vi'i'i'::"I,.'v::'Y. :
XYr+lrr{:Al
.< : :>}:`
'},'':4 R
.=<s>s :
4 Release these buttons .

5 At the BMON> prompt press F2, CTRL and press ENTER .
6
.vv.
Now Press F5, START and press ENTER . This performs a controlle d
r}i:v.}:??ii:
. ..1. .: .:::fi.:n}:?:?-'i
.?i}:-:i}};'}i}r::ì}ji}riini~i}
x
ii i}vi~i'i%%C::..}:.; :ii}}}:.}rn
}'J.ii}:.'i.;4:-0i
:::;:i::?;;:}:{::i::?::ii.: .!:
fin: . .
:'-}iC }i:-
iiY'fL'.};.:.i: :}:in': }i}:}'i')
:Fr.i :f'.}?^.iTry?-.:.4::t
7 Type 4, then press ENTER . See the following screen for an example .
4-47
MARAJINST09206E
8 Insert the update disk in the disk drive .

9
10 To install a software update, select 4, INSTALL UPDATE and pres s

ENTER.
11 To continue installing updates, press F4, YES .
If you do not want to continue, press F5, NO .
12 When the update has finished loading, remove the update disk fro m
the disk drive .
13 Repeat steps 8 through 12 to install each update you have .
14 Perform a cold start :

a Press FCTN.
calibrate the robot. Refer to Chapter 5 .
48 - 4
MARAJINST09206E
15 Press MENUS .
16
Select SYSTEM.
17
Press Fl, [TYPE] .
18
Select Clock . See the following screen for an example .
19 To change the date or time display, press F4, ADJUST and enter the
new information.
20 When you are finished, press F4, FINISH .
4-49
MARAJINST09206E
Procedure 4-7 Installing Motion Group s

Condition
Step
Connect the PS-100 disk drive cable to the RS-232-C port on the R-J
controller operator panel.
Insert the Robot Library disk .
standard operator panel.

teach pendant.
5 Release these buttons.
...:...
m . .nx. .r:.rrn.. . . :.w.v. .n:r. n, r.r. .n .rn. :rn :., n. iJi: :
At the BMON> prompt press F2, CTRL and press ENTER .
7 Now press F5, START and press ENTER . This performs a controlle d
Controlled Start Initializatio n
Type 1 .
Press F4, YES . See the following screen for an example .

?i.Y?C .?
:r~ :4:j:. .vn4:;r

is?:;:iiy:
: Y::
te. . i _}}}}}r:i'>ii:-f::iv: i:'
::i:4::x. ~.v::
nvn4r
::. .N,.::
:iii: . . . :. . :. :. . . :. ::. . :. . . .:
vn:4~~h}:.}:~ir'
:. r::i:i : :}i:Sv~. $:::4i
MARAJINST09206 E
4-50
10
Type 2, and press ENTER.
11 Press F4, YES . See the following screen for an example.

;.'u.{.}:i}} {{{r .
::.v:::::::: ::?{.}..: .-:::: iY:{.Yiir.4;{i
t~il
+?::i"i
}s :i:'
;:::.?
i{?
:E~ i':'i::}iiiY:ii~ii:
?i{Yri}}'.:~v:{v:
U::.{}'4'-}}}i::iiii
:r}ii:1 :?;Y::'::iY.:ii:"ii':i:
Fi-}'}:::i::i
.
:.:: :v:iii
{: r: : : y
::::::r'?ii ii} :Yr:
x:1.?:'ii:..
:.-: is
.[il: :$:'f.::}:ih};?.}:~F
u::.r:?:'Y:4'fr}:O}}:Ln4~nv:.
:vr}}'r'~}'r~:?l
i::- ':'
12 To add motion groups, type 1 .

To delete motion groups, type 2 .
< ci
:WS-... .
13
Press F4, YES . See the following screen for an example .
NOTE At this point you should type the total number of groups to b e
added and not the number of the motion group .
14 Type the total number of motion groups you are adding, and pres s
ENTER . The number of motion groups will be added automatically.
NOTE The number of groups will vary depending on how the hardware is
set up for your system .
: ~:î; .$n'~i
:{`F:-ii' it:ii
:risiiiiiiii :-:ii::,:- ::,::ti i ::i::ji{,:..;?
:1rY}in'
: ::S4i:StC
^: y}h.
i?:::-i
}::1 :::v
.vx~
: 'r':::
s4v..v.{.Fin}i'f:l
. . ii'i.Y
. . . . ..v
. . :vi}?:s i '{+ i:$: :iCi:! :i~::iY:}?Fv-:{'yi.?{i-i::i+i+.v::
.{:~{?p4{:;ii:;i:.
F:::::r
Y :'~:Y:.' vv.. r: i:ti.{:.
::.:. :.v::}}: Y: :v:{{,
r.. ..}'i::'r'4:: Yi:: rr yr::r:rnri}:?v:rv.Y.,.iiiiy}A~
15
Type 3 .
4-5 1
MARAJINST09206E
16 Press F4, YES . See the following screen for an example .

''4EM11181BERNINMEMBEEMEEMENEMBIMMik
17 Press F4, CONT.

NOTE This is the end of the delete motion group procedure .
NOTE The following screen is the first screen in a sequence displaye d

when you are adding a motion group . You will see this sequence o f
screens each time you add a motion group .
Selecting a Robot
18
Type the number that corresponds to the type of robot you are addin g
in the group, and press ENTER .
19
Answer the remaining prompts according to the type of robot you hav e
selected . This information is similar to the information you mus t
specify in Procedure 4-8 .
If you have selected a robot, you will be asked for the following:
Hardware number for starting axi s
Wrist axe s
Standard workcell layout information
MARAJINST09206E
4-52
If you are configuring groups 2 or 3 you must select either a FANUC

Robot C-100, an opener, or a nobot, and you will be asked for th e
following :
Link length information
Motor parameters
Limit parameters
Acceleration parameters
Mastering information
Refer to the FANUC AC Servo Motor Digital Series Descriptions Manua l
for more information . See the following screen for an example .
20
Type 1, and press ENTER . See the following screen for an example .
NOTE Refer to the Motion Group Manual for valid motor size, type, an d
amperage combinations .
21 Select the size of the motor for your nobot . The motor size can b e
found on the motor name plate on your robot . See the following
4-53
MARAJINST09206E
22
Select the motor type for your nobot . Refer to the FANUC AC Servo
Motor Digital Series Descriptions Manual for more information . Se e
23
Select the amplifier current limit for your nobot . Refer to the FANUC
AC Servo Motor Digital Series Descriptions Manual for more
information . See the following screen for an example .
24 Type 2 to load files from a disk, and press ENTER . See the following
MARAJINST09206E
4-54
25
NOTE If the motor combination you specified in the previous steps is no t

supported, the message, "Motor type not found," will be displayed. The
system will ask for the motor information again . Refer to the Motion
Group Manual for valid motor combinations and repeat Steps 21 throug h
25 .
26 If you have a linear axis, type 1 .
If you have a rotary axis, type 2 .
27 Type the gear ratio for the nobot and press ENTER .
The gear ratio for linear axes is the number of millimeters traveled
for one rotation of the motor. For example, if a 50mm pinion on the
motor is directly coupled to the rack, and the radius of the pinion i s
25mm, the gear ratio is 2(pi)(25) = 157 .08.
If the axis has a gear box between the motor and pinion, divide th e
number by the gear ratio. For example, if the motor is connected to a
5:1 gear box and a 50mm pinion, the gear ration is (2)(pi)/5 = 31 .416.
4-55
MARAJINST09206E
The gear ratio for rotary axes is in motor turns per single rotation o f
the rotary axes. The ratio is ng2:ng1, where ng is the number of teet h
on a gear. ng1 is attached to the motor and ng2 is attached to the axis .
For example, if gear 1 has 25 teeth and gear 2 has 50 teeth, the rati o
would be 2 :1 .
NOTE The maximum joint velocity is automatically calculated, based o n

the gear ratio and the maximum RPM of the motor chosen. This value can
be used or it can be lowered .
A CAUTIO N
Do not increase the value of the maximum joint velocity ,

otherwise the maximum motor RPM will be exceeded, possibl y
damaging equipment and causing unexpected results .
28
Type the motor speed. See the following screen for an example.
29
Type the nobot axis motion sign and press ENTER .
MARAJINST09206E
4-56
The direction determines which way the motor turns when the positiv e
jog key is pressed, and should be consistent with axis alignment .
TRUE indicates that the motor will turn counterclockwise whe n
looking at the motor shaft from the front .
NOTE If the rotation is incorrect, you can modify it by performing a
controlled start . Refer to Appendix A and go to Step 15.
30
Type the upper software limit of the nobot and press ENTER .
Set the upper software limit of the axis to a value smaller than the hard
stop.
4-57
31 Type the lower limit of the nobot and press ENTER .
Set the lower software limit of the axis to a value smaller than the har d
stop. This is usually 0 or a negative number.
32
Type the Master Position of the nobot and press ENTER . See the
33
Type the appropriate acceleration constant and press ENTER .

The sum of acc_time_1 and acc_time_2 is the time, in milliseconds, i t
will take for the axis to reach full joint speed . The min_acctime valu e
is used for acceleration/deceleration if the distance between the tw o
points is short enough that the axis cannot reach full speed.
34
Type the appropriate acceleration constant and press ENTER . See the
MARAJINST09206E
4-58
35
Type the appropriate acceleration constant and press ENTER . See the
36
Type the load ratio and press ENTER .
The load ratio adjusts the gain of the axis based on the load inertia and th e
motor inertia. The load ratio is based on the following formula .
Load Ratio =
Load Inertia (kg cm s2)

Motor Inertia (kg cm s2)
A value of 0 continues the program without adjusting the gain .

for more information. See the following screen for an example .
4-59
MARAJINST09206E
A CAUTIO N
Make sure that the brake number is assigned and is connecte d
correctly, otherwise, improper operation will result .
37 Type the brake connection point and press ENTER .

If the nobot axis has brakes, they should be connected in the controller.
Brakes 1 through 3 are reserved for the robot (special connector) ,
brakes 4 through 6 are available for nobot axes . Brakes 4 through 6
are located on the EMG CONT PCB . Each brake requires 0.6A or
0.8A, depending on the specification, and each brake output is fused a t
2.0A.
38
Select whether to enable or disable SERVO OFF press ENTER .

If enabled, SERVO OFF allows the brakes to hold the axis and dro p
servo power after the specified time .
[1
39 Type the servo off time and press ENTER. See the following screen
for an example.
40 When you have finished, see the following screen for an example.
MARAJINST09206E
4-60
41 You can either continue adding axes, or exit .

If you want to add/delete other axes, type 2, Add/delete NOBO T
Axes and repeat Steps 20 through 40.
If you are finished, type 3, Exit . See the following screen for a n
example .
42 Type 7, Exit, and press ENTER. See the following screen for a n
example.
43
Type 4, EXIT, and press ENTER.
44 Press F4, YES . See the following screen for an example . The
following screen will be different depending on the software versio n
you are using.
4-6 1
MARAJINST09206E
45
46
Select START (COLD), and press ENTER.
MARAJINST09206E
4-62
Procedure 4-8 Installing Extended Axe s

Condition
Step
Connect the PS-100 disk drive cable to the RS-232-C port on the R-J
Insert the Extended Axis disk .
Press and hold the USER PB#1 and USER PB #2 buttons (PURG E
ENABLE if you are using a P-155 controller) on the controller
operator panel.

teach pendant.
`,:
`k
~ "}i:~
:Nr' -'<> << ;< .y

rlj ~i ::i?:
:;:i:~ ~r.~i~iii::v'i:~
fi. ::'::::i: ^v-:''':i:':.<:iti:'i'{:$.
Et
Release these buttons .
At the BMON> prompt press F2, CTRL and press ENTER .
7 Now press F2, START and press ENTER . This performs a controlle d
start of the controller. See the following screen for an example .
Type 1 and press ENTER.
Press F4, YES. See the following screen for an example .
4-6 3
MARAJINST09206E
Type 3 and press ENTER .
10
. 11 Press F4, YES . See the following screen for an example .

NOTE The motion group must already be configured in the system .
Refer to Procedure 4-7 .
NOTE For systems using multiple groups, the following screen is
displayed . If you do not have multiple groups, go to Step 13 .

:v4ryr ?:i:::l+i.
'FvF: .i }f :Y :}:
:il sii}:i':'?r'
.:i?i'?`:::xi
':: :}:i.:::.?::1:^:`}.f.+rc:}i~::iY
?:.i}}}}i] `}Yii} ::}}:?:i4:. .:}:.i .:: }?:::.:
:::'iii'.':':eiî'f,.
:~'::i .i`'i"} `:'.':. .}}}}
:v.;, :,}:,::,>:?.:::.: : :.::::::: .. i}:. :rr::i. ~: ? iY;: i
12 Type the group number to be used and press ENTER . The group
number will vary depending on how the hardware is set up for you r
system. See the following screen for an example .
i
~j~j.vJ.'::'
:-is{?i.?ii
i'FF(...}}}:ii
}:':ii }i}if:iii:i}ivY:
}("vF':"r}i::-:}i'J.L .~.:n.}}}r?I.
:ifr :: ~ii,::1:i
.::i:.}:<~~::v':
: :: .
:i?i:$i.`:}.: :+:4;i t%;t;'t?:::if :~-' vi: n~:viv ~ <:}}vY
:f}:i.}>i:::iy .:?:
13 Type the starting number of the extended axis hardware and pres s
ENTER. For example, if you are adding a rail to a six-axis robot, th e
starting number is 7 . The hardware specific information will be adde d
automatically. See the following screen for an example .
NOTE The starting number can vary depending on how the hardware i s
set up for your system.
~:hi: ':>'Yi}}:-:}}}:ri'}:i
in} ~:i {iiii: i:~~::i.:i.'i: : .i?.;.::iii? :: J ::} : :ti :'v.
.i-:.4riA..v::
..::. :u:rvr.:v::
:
}:v:}:-}}:
;r;;;?i:ìi"}
i:CiI
:}:?: v:
:. is}iii
. }rr. . iirn.}:i?-}}}:::iv}
:
'..`/
.-..
-}7::.:a.Rg.:,;i:: : :'.::: ;fi: i:t}~:':.a:rii:! :::;}
::-}::.:::.~.}x..} :;.
:x
.` :
: .- . :{i
:?y}}}:- .}:'r'~ i'iii
. . .: +
: :,:Y ;: ::' C.s..
14 To add or delete an extended axis, type 2.
MARAJINST09206E
15 Type 2, and press ENTER . See the following screen for an example .
16 To add an extended axis, type 1 .

To delete an extended axis, type 2 . See the following screen for an
example of adding an extended axis.
17 Type 1, and press ENTER. See the following screen for an example .
NOTE Extended axes can be added out of order. For example, you can
add extended axis 2 before you add extended axis 1 .
4-65
MARAJINST09206E
18
Select the size of the motor for your extended axis . The motor size
can be found on the motor name plate on your robot . See the
..
.~
:iii ...
!MGM d -- -`--
19 . Select the motor . type for your extende
~64
i$:Zi~Y:.'
.axis . Refer to Table 4-6 .
NOTE All motor combinations might not be supported by the FANU C

Robotics parts department .
Table 4-6 . Motor Selection Combinations
Motor Size
and Type
AC5-0
AC4-0
AC3-0
AC2-0
AC1-0
AC0
AC5
AC10
AC20
AC30
AC30/2000
AC1-0/3000
AC2-0S
AC0S
AC5S
AC6S
AC10S
AC20S
Amperage
2A
4A
4A
12A
12A
40A
40A
40A
80A
80A
100A
32A
AC4-0S 4A
AC3-0S 4A
12A
AC1-0S 12A
40A
40A
40A
40A
80A
Motor Size
and Type
AC30S
Amperage
AC2-0S/30
AC1-0S/3000
AC0S/3000
AC5S/3000
AC10S/3000
AC20S/3000
AC30S/3000
AC4-0F
AC3-0F
AC0F
AC5F
AC10F
AC20F
AC30F
AC5F/3000
AC5F/3000
AC8F/3000
AC30F/2500
AC6L/30
80A
12A
12A
40A
80A
80A
130A
130A
4A
12A
40A
40A
40A
80A
80A
40A
60A
80A
130A
80A
MARAJINST09206 E
20
Select the amplifier current limit for your extended axis . Refer to the
FANUC AC Servo Motor Digital Series Descriptions Manual for more
information. See the following screen for an example.
21 Type 2 to load files from a disk, and press ENTER. See the following
22
4-6 7
23 Select the type of extended axis you are using . For auxiliary linear or
rotary axes, the extended axis is not added into the robot position .
For integrated rail or integrated arm the position on the rail (or arm) i s
added to the robot position . See the following screen for an example i f
integrated rail or integrated arm is selected .
24 Type the direction of the extended axis alignment and press ENTER .
For integrated rail, the rail alignment is usually with respect to the
user frame axes of the robot .
For integrated arm, arm specific information is required . Typically,
the offset length is 0 except for cases where the first axis of the robo t
is replaced by an extension arm . The direction defines about whic h
world axis the arm rotates .
MARAJINST09206E
4-68
25
Type the gear ratio for the extended axis and press ENTER .
The gear ratio for linear axes is in millimeters of travel per revolution o f
motor. The gear ratio for rotary axes is in motor turns per single rotatio n
of the rotary axes . See the following screen for an example .
26
Type the motor speed . See the following screen for an example .
27 Type the extended axis motion sign and press ENTER . The directio n
determines which way the motor turns when the positive jog key i s
pressed, and should be consistent with axis alignment . See the ,
NOTE If the rotation is incorrect, you can modify it by performing a
controlled start. Refer to Appendix A and go to Step 15 .
4-69
NOTE The limits will be displayed in millimeters (mm) if a linear axis i s

used, and in degrees (deg) if a rotational axis is used.
28
Type the upper limit of the extended axis and press ENTER . See the
29
Type the lower limit of the extended axis and press ENTER . See the
MARAJINST09206E
4-70
30
Type the Master Position of the extended axis and press ENTER . Se e
31 Type the appropriate acceleration constant and press ENTER . See the
32
Type the appropriate acceleration constant and press ENTER. See the
4-7 1
MARAJINST09206E
33 Type the appropriate acceleration constant and press ENTER. See the
34
Type the load ratio and press ENTER .
The load ratio is based on the following formula .

Load Ratio =
Load Inertia (kg cm s2)

Motor Inertia (kg cm s 2)

for more information. See the following screen for an example .
35
Type the brake connection point and press ENTER . See the followin g
MARAJINST09206E
4-72
36
Select whether to enable or disable SERVO OFF and press ENTER .

37 Type the servo off time and press ENTER . See the following scree n
for an example .
38 When you have finished, see the following screen for an example .
39
Repeat Steps 15 through 37 for each external axis you are adding .
40 When you have finished type 3, Exit, and press ENTER . See the
4-73
MARAJINST09206E
41 Type 7, Exit, and press ENTER . See the following screen for an
example.
FI
42
Type 4, EXIT, and press ENTER .
43
Press F4, YES . See the following screen for an example . The
following screen will be different depending on the software versio n
you are using .
44

45
:4i'J.ri,::'l..i.,?t'~~i%ii :s:-.ih}.4.::i: isti~:in:ii:-::?:iiJ'y-}>;. .Y:~~ :li.}:i,',.fhvi:
Select START (COLD), and press ENTER.
46 When the controller is turned on, you should master and calibrate
the robot and all new motion groups . Refer to the Robot-Specifi c
Mechanical Unit Service Manual or the Robot-Specific Mechanical
Connection Manual for more information.
MASTERING
5- 1
MARAJINST09205E
When you master a robot you define the physical location of the robot b y
synchronizing the mechanical information with the robot's positional
information . A robot must be mastered to operate properly. Robots
usually have been mastered before they leave FANUC Robotics .
However, it is possible that a robot might lose its mastering data and
require to be remastered .
You can master the robot using several different methods . Refer to
Table 5-1 to select the method that best meets your needs .
Table 5-1 .
Mastering Method s
Mastering Method
Mastering to a fixture
(Master Position
Master)
Mastering to zer o
degrees
Single axis mastering
ii
Recording the quic k

master referenc e
position
Quick mastering
Robot
Models
All
When to Us e
When mastery was lost due t o
mechanical disassembly or repair.
When a quick master reference positio n

was not previously set .
Method of choice for P- and A-serie s
robots . Used for S- and M-series robots
when extreme precision is required.
M-serie s When mastery was lost due t o
mechanical disassembly or repair.
S-series
When a quick master reference positio n
was not previously set.
Method of choice for S- and M-serie s
robots when extreme precision is not
required .
M-series When mastery was lost due to mechanical
S-series disassembly or repair of a single axis (usually
due to motor replacement) .
All
To record mastering data as a reference fo r
future quick mastering .
All
To retrieve mastering data that has been

stored as a quick master reference positio n
when mastery is lost due to an electrical o r
software problem. Do not use if mastery wa s
lost due to mechanical disassembly or repair .
are using a FANUC Robotics A-series or P-series robot you mus t

use a mastering fixture to master your robot. Refer to the Mechanical
Service Manual specific to your robot model for procedures on how to set
up and use a mastering fixture .
If you
._
If you are using a FANUC Robotics M-series or S-series robot you can
either master to a fixture or you can master to zero degrees . Refer to the
Mechanical Service Manual specific to your robot model for mor e
information on mastering using a fixture.
Quick mastering is a convenient way to master an M-series or S-serie s
robot after you have recorded a reference position . You cannot quick
master a robot unless the reference position was taught before masterin g
was lost.
5. MASTERING
MARAJINST09205 E
5-2
A CAUTION
Record the quick master reference position after the robot i s

installed to preserve the factory mastering settings for future
remastering .
5. 1
MASTERING TO A
FIXTURE (MASTER
POSITION MASTER)
When you master to a fixture, you use a mastering fixture to align th e

robot axes and then record the position . You can master any robot to a
fixture. If you have a P-series or A-series robot, you must master it to a
fixture .
Use Procedure 5-1 to master to a fixture.
Procedure 5-1 Mastering to a Fixture

Condition
You have the appropriate mastering fixture for your robot .
Step
Press SYSTEM.
Press Fl, [TYPE] .
3 Select Master/Cal .
If Master/Cal is not listed on the [TYPE] menu, do the following ;
otherwise, continue to Step 4 .
Select VARIABLE from the [TYPE] menu .
Move the cursor to $MASTER_ENB.
c Press the numeric key "1" and then press ENTER on the teac h
pendant .
d
Press Fl, [TYPE] .
Select Master/Cal . See the following screen for an example .
iggggiii.ffitilliEMEiReggligiMMEEiMMOMMEMIli gge
SYSTEM Master/Cal
JOINT 10 %
5 . MASTERING
5-3
4 Refer to the Mechanical Service Manual or Mechanical Connectio n
and Maintenance Manual specific to your robot model for the
procedures on how to set up and use a mastering fixture .
5
Select Master Position Master .
6 Press F4, YES . Mastering will be performed automatically.

7 Continue to Step 8.
8 Select Calibrate.
9 Press F4, YES .
10 Perform a cold start.
a Turn off the robot .
b Press and continue pressing the FAULT RESET button on the
operator panel.
c While still pressing FAULT RESET, press the ON button on th e
operator panel.
5 . MASTERING
MARAJINST09205 E
5-4
When you master to zero degrees, you position all axes at their zero degree
witness marks and record the zero degree position. You can master any
M-series or S-series robot to zero degrees .
5.2
ZERO DEGREE
MASTERING
Use Procedure 5-2 to master to zero degrees.

Procedure 5-2 Mastering to Zero Degree s
Step
Press SYSTEM .
Press F1, [TYPE] .
If Master/Cal is not listed on the [TYPE] menu, do the following ;
a
Select VARIABLE from the [TYPE] menu .
Move the cursor to $MASTER_ENB .
c Press the numeric key "1" and then press ENTER on the teach
pendant.
d
Press Fl, [TYPE].
e Select Master/Cal . See the following screen for an example.

z^:fr ggg:;.'i}::i}S: ;i:}ivr,}:.}y
SYSTEM Master/Cal
JOINT 10 %
4 Align the witness marks on the robot.

5 Select Zero Position Master.
6 Press F4, YES . Mastering will be performed automatically .
7 Select Calibrate .
8
Press F4, YES.
5 . MASTERING
5-5
MARAJINST09205E
Perform a cold start .

a
Turn off the robot .
Press and continue pressing the FAULT RESET button on the

operator panel .
c While still pressing FAULT RESET, press the ON button on the

operator panel .
5 . MASTERING
MARAJINST09205 E
5-6
You can master a single axis of an M-series or S-series robot when mastery
was lost due to mechanical disassembly or repair of a single axis, usuall y
due to motor replacement .
5 .3
SINGLE AXIS
MASTERING
Use Procedure 5-3 to master a single axis .
Procedure 5-3 Mastering a Single Axi s

Step
Clear any servo faults that prevent you from jogging the robot.
Using the JOINT coordinate system, jog the unmastered axis to the
zero degree position.
Press MENUS .
4 Select SYSTEM .
5
Press Fl, [TYPE].
Select Master/Cal .
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 7.
a Select VARIABLE from the [TYPE] menu.

b
Move the cursor to $MASTER_ENB.
pendant .
d Press F1, [TYPE] .

e Select Master/Cal . See the following screen for an example .
5 . MASTERING
5-7
7 Select 4, Single Axis Master. See the following screen for a n
example.
Move the cursor to the MSTR POS column for the unmastered axi s
and press the "0" key .
Continuously press and hold the DEADMAN switch and turn th e

teach pendant ON/OFF switch to ON .
10 Move the cursor to the SEL column for the unmastered axis and pres s
the numeric key "1 . "
11 Press ENTER .
12 Press F5, EXEC . Mastering will be performed automatically .
13
Press PREV.
14 Select Calibrate.
15
Press F4, YES .
16
Perform a cold start.

a Turn off the robot .
b
Press and continue pressing the FAULT RESET button on th e

operator panel .

operator panel .
5 . MASTERING
MARAJINST09205E
5-8
5. 4
QUICK MASTERING
Quick mastering allows you to minimize the time required to remaster th e

robot using a reference position you established when the robot wa s
properly mastered. You cannot quick master the robot unless you hav e
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properl y
mastered . The best time to record the quick master reference position i s
when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can us e
this reference position to master the robot in a minimum amount of time .
If you lose mastery due to mechanical disassembly or repair, you must
master to a fixture or perform zero degree mastering .
You can define a quick master reference position and perform quick
mastering on any robot model .
Use Procedure 5-4 to record the quick master reference position . Use
Procedure 5-5 to quick master the robot .
A CAUTION
Record the quick master reference position after the robot i s

installed to preserve the factory mastering settings for future
remastering .
Procedure 5-4 Recording the Quick Master Reference Positio n

Condition
The robot is properly mastered .
I Align the witness marks on the robot . This is the zero position, whic h
will be the quick master reference position .
If you have a P-series or A-series robot, jog all robot axes to zero
degrees and scribe witness marks on each axis .
2
Press MENUS .
Select SYSTEM.
4 Press Fl, [TYPE] .


b Move the cursor to $MASTER_ENB .
c Press the numeric key "1 " and then press ENTER on the teac h
pendant .
5 . MASTERING
5-9
Press Fl, [TYPE] .

Select Master/Cal . See the following screen for an example .
::x
~:: :::{ij?i}+' ii'.i.
is9ii};?:^:i:::
:iii.;:id1:
,.;: ;i i:ii::'i::ti:
y... .
:::
vr.rr:. ~ nvnvn:ii:::::
} :?:{:jY..i}i:..:::.:::::
::::$.::: :'?: :^};::h:{i:: : :iii:{Jjiii : :~',:y:::~'^.}:ii't{~:. .
Move the cursor to SET QUICK MASTER REF and press ENTER .
7 Press F4, YES .

8
Perform a cold start .

a
Turn off the robot .
Press and continue pressing the FAULT RESET button on th e

operator panel.

operator panel .
5 . MASTERING
MARAJINST09205E
Procedure 5-5
Condition
Quick Mastering the Robot
The robot has lost mastery due to an electrical or software problem .
NOTE If the robot has lost mastery due to mechanical disassembly o r

repair, you cannot perform this procedure . In this case, master to a fixtur e
or master to zero degrees to restore robot mastery .
n
The quick master reference position was recorded before the robot los t
mastery.
1 Jog the robot to the quick master reference position (zero degre e
position) .
2
Press MENUS .
Select SYSTEM .
Press Fl, [TYPE] .
Select Master/Cal.
b
Move the cursor to $MASTER_ENB .
pendant.
d
Press Fl, [TYPE].
e Select Master/Cal . See the following screen for an example .
ii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii
Move the cursor to QUICK MASTER and press ENTER .
Press F4, YES .
Move the cursor to CALIBRATE and press ENTE R
Press F4, YES .
5 . MASTERIN G
5-1 1
MARAJINST09205E
10
Perform a cold start.

a
Turn off the robot
Press and continue pressing the FAULT RESET button on the

operator panel.

operator panel.

TROUBLESHOOTING AND ERRO R
MESSAGES
6-1
MARAJINST09205E
This chapter contains information on how to solve problems that occur

during setup and installation of the R-J Software and EPROM Package .
Troubleshooting information is divided into three sections :
Troubleshooting using symptoms - Use this when you have a

problem with the system but do not see an error message on th e
screen .
Troubleshooting using error messages - Use this when you have a

problem with the system and see an error message on the screen .
Performing a re-init start (for V3 .06PA, V3 .06PB, and V3 .06PC) Use this when a portion of CMOS memory has become fragmented, or
accidentally overwritten.
This troubleshooting information is specific to software installation . Refer

to the Setup and Operations Manual specific for your software for general
system troubleshooting and error message information .
6 . TROUBLESHOOTING AND ERROR MESSAGES

MARAJINST09205E
6-2
6.1
TROUBLESHOOTIN G
USING SYMPTOMS
Symptom
The controller will not turn on .
The controller will turn on but the Boot

Monitor prompt (BMON>) is not
displayed when UPB#1 and UPB#2 ar e
held when the power ON button is
pressed.
The controller will turn on (Boot Monito r
is running) but the R-J software will not
start running.
Refer to Table 6-1 to determine the cause of a problem and to solve it .
Table 6-1 . Troubleshooting Symptoms and Solution s

Possible Cause
Solutio n
The controller disconnect or circuit
Turn on the controller disconnect or
breaker is turned off.
circuit breaker.
The power ON button on the controller Press the power ON button .
has not been pressed .
Internal hardware is not operatin g
Check the Mechanical Unit Connection
and Maintenance Manual for you r
properly.
specific robot model for specific
troubleshooting procedures.
The controller is not receiving the proper Check the Mechanical Unit Connection
power, or the front panel cable is no t
and Maintenance Manual f or your robo t
plugged in.
model for specific troubleshootin g
procedures.
properly.
and Maintenance Manua f or your robot
model for specific troubleshooting
procedures .
The MAIN CPU is not operatin g
properly.
properly, or the BootROM is installe d
upside down .
Replace defective memory boards as

necessary and reload R-J software .
and Maintenance Manual f or your robo t
model for specific troubleshootin g

procedures .
A file will not load and the RETRY
The PS-100 disk drive is not functioning Turn off the power to the disk drive the n
function key is displayed during softwar e properly.
turn the power on again .
installation .
Try using a different or new disk drive .
6. TROUBLESHOOTING AND ERROR MESSAGES

6-3
MARAJINST09205E
6.2
TROUBLESHOOTING
USING ERRO R
MESSAGES
Setup and installation error messages pertain to the robot operating system
(ROS) . The ROM-based portion of the software used during powerup ,
referred to as the Bootstrap ROM or BootROM, directs the controlle r
hardware to load ROS software disk . After the ROS has been loaded, it
directs the remaining software installation .
There are three types of error messages :
Software Option Messages are messages that indicate the success o r
failure of a particular step during installation of a software option .
These messages are from ROS .
General BootROM Messages are numbered messages that indicat e
the success or failure of a particular step during installation .
Boot/Save Messages are status messages that indicate the success or
failure of a step during system startup after installation has bee n
performed . These messages appear alone or can be coupled wit h
general BootROM messages .
Table 6-2 lists the software option messages, their possible cause, and a
typical solution. Table 6-3 lists all the BootROM error messages, their
possible cause, and a typical solution.
Table 6-2.
ROS Error Message

Too many options installed
%s successfully installed
%s already installed
%s incompatible
%s overlayed/reinstalled
Software Option Messages

Solutio n
Possible Cause
The maximum number of softwar e
options/updates is installed . Insufficient
FROM/CMOS/POOL/SYSVAR
resources are available to install this
software option .
Non e
Installation of software option/update

has finished successfully .
Software option was previously installe d
and cannot be overwritten.
Software option/update is incompatibl e
with an already installed softwar e
option/update .
Non e
Do not install software options of th e
same name and version twice .
Install only one of the two mutuall y
exclusive software options .
Software option/update was previously

None
installed and can be overlaye d
(overwritten) as an additional instance of
that software option/update . The
software was successfully overwritten .

MARAJINST09205 E
6-
Table 6-3 .
Error Message
BootROM Error Messages

Possible Cause
Solution
File does not exist
The requested load file does not exis t

on the floppy disk that is currentl y
inserted in the disk drive unit.
Check the command entered from th e

keyboard for a misspelled file name an d
try the command again.
Illegal disk command
An invalid disk command was issued .

This is a software error and should
never occur during normal operation .
End of file
The end of the load file was reache d

while reading from the disk drive unit .
This message should not occur durin g
normal operation, and might indicate a
corrupted or damaged file on the disk
from which loading is occurring .
Check the command entered from th e

keyboard and try the command again . If
the error still occurs, note the file bein g
loaded at the time the error occurred
and the sequence of keyboard-entered
commands that caused the error an d
contact the FANUC Robotics Hotline .
Reset the disk drive unit (or exit and
re-enter the PS-100/PS-200 disk driv e
emulator if using KAREL OLP C
software), and try to load the software
contained on the disk again . If the
problem recurs, note the file bein g
loaded at the time the error occurre d
and the sequence of keyboard-entere d
File already open
A file is already open on the disk drive

unit. This should not occur durin g
normal operation.
Reset the disk drive unit (or exit an d

re-enter the PS-100/PS-200 disk driv e
emulator if using KAREL OLP C
software), and try to load the software
contained on the disk again. If th e
problem recurs, note the file bein g
loaded at the time the error occurre d
and the sequence of keyboard-entere d
Communications error
The disk drive unit has detected a

communications error.
Check all connections and retry th e

operation .
10
Directory read error
There is a problem reading the directory

on the floppy disk that is currentl y
inserted in the disk drive unit . This
indicates a media problem or imprope r
seating of the disk in the disk drive unit .
Reinsert the disk and retry th e

operation . If it fails again, try anothe r
disk.
11
Disk block check error
An error has occurred while reading

from the floppy disk. This is a media o r
disk formatting problem .
Retry the operation or try another disk .
13
Seek error
An error has occurred in the floppy dis k

drive unit. This indicates a medi a
problem or a hardware problem in th e
disk drive unit .
Retry with different disk and/or different

disk drive unit. .
14
Device not ready
16
Volume sequence error
The disk drive unit cannot access th e

disk.
The disk is invalid .
Make sure a disk is inserted in the driv e

unit and the unit is turned on .
Retry using another disk.
20
Invalid file name
The name entered in the "LOAD "

command (ex. "LOA D
BAD#FILENAME") is not a valid nam e
for the MS/DOS file structure .
Make sure you enter the name of the fil e

as an 8-character name, containing th e
letters A-Z, numbers 0-9, and specia l
characters "-" or "_" .
6 . TROUBLESHOOTING AND ERROR MESSAGE S

MARAJINST09205E
6-5
Table 6-3. (Cont'd) BootROM Error Messages

Error Message
Possible Cause
Solution
21
Checksum error reading file
There was an unrecoverabl e

communications problem while readin g
file information from the disk drive unit .
A connection or interface hardware
problem exists.
Check connections and retry .
22
XDA checksum error
An error was detected in the data

Retry using another disk.
received from the floppy disk. This
generally means a problem with the data
on the disk that is currently inserted i n
the disk drive unit exists.
23
Record sync error

received from the floppy disk. This
received from the floppy disk . Retry
generally means a problem with the data using another disk.
on the disk that is currently inserted i n
the disk drive unit exists.
30
Invalid numeric input
Your input is not valid for conversion to a Remove all non-numeric characters
numeric value because of non-numeri c from the string you are entering an d
characters in the string .
repeat the input.
32
Integer value overflow
An integer calculation has produced a

number too large to handle.
33
Board not installed o n

controller
A request was made to load software fo r Check the hardware configuratio n

a processor or other module that is not
before continuing to load software .
installed on the controller.
36
System software not loaded
The starting location is either 0 or F.
Load system software .
40
Invalid device specification
41
Invalid command
The device name that is entered is not

recognizable or is not a valid device .
The command that you just entered i s
not valid .
Check the name and format of you r

previous entry and retry the entry .
Check the command and retry it .
61
Extended monitor not loaded
Load the extended monitor software .
62
Extended monitor versio n

mismatch
The optional extended monitor softwar e

is not loaded .
The extended monitor version is not
compatible with the BootROM version .
63
Requires 2M Byte CMO S

boards
When using backup or restor e

commands, CMOS RAM memory is no t
mounted to the extension backplane
Add two CMOS RAM memory boards t o

the extension backplane .
103
Serial receiver error
During a software load from the disk

drive unit, a fatal error occurred at th e
RS-232-C port .
Check the connections and retry th e

operation .
104
Device request timed out
A software load request was issued but

the disk drive unit did not respond . Thi s
generally indicates that there is an
improper connection between th e
controller and the disk drive unit, or that
the disk drive unit is not powered up.
Check the connection between the dis k

drive and the controller and make sur e
the disk drive is powered up .
110
Flash ROM program verify

error
The last data that was loaded was not

the same as what should have bee n
loaded .
Clear FROM and retry the operation .

The FROM might be defective .
Retry the operation that causes th e

error. If the problem recurs, note th e
sequence of keyboard-entered
Reload the extended monitor softwar e

with the correct version . This might
require you to initialize FROM an d
reload all core and application software .
6 . TROUBLESHOOTING AND ERROR MESSAGES

MARAJINST09205 E
6-6
Table 6-3. (Cont'd) BootROM Error Messages

Error Message
Possible Cause
Solution
111
Flash ROM erase verify error
112
Invalid address for load
113
Invalid CMOS memory

configuration
114
Attempt to reprogram FRO M

memory
During the load to FROM, a memory

location was loaded that already
contained different data .
Clear FROM and retry the operation .
115
Invalid FROM memory

configuration
An improper FROM module was

installed.
Check the hardware configuration an d

try again .
116
Not enough RAM memory
117
RAM data did not compare
When using copy or paste commands ,

4M bytes of CMOS RAM is required.
When using the copy command, th e
data copied from Flash ROM did not
compare .
Make sure 4M bytes of CMOS Ram are

mounted on the MAIN CPU .
CMOS RAM might be bad . Try using
known working CMOS RAM memor y
modules .
118
Invalid BACKUP entry
The backup command requires a

second token and the second token is
not valid .
Re type the command with a valid

second token . For example, DEW
BACKUP CMOS .
119
Invalid RESTORE entry
The restore command requires a

second token and the second token is
not valid.
Re type the command with a valid

second token . For example, DEW
RESTORE FROM .
201
Invalid TEST entry
An invalid TEST command was entered. Reenter the command and try again .
202
Port number out of range
When using the TEST PORT n

command, n was not a valid port
number. The current range of vali d
ports are 2-4.
Reenter the command and try again .
203
Transmit and receive data

does not match
The data received did not match th e

data transmitted.
Check all cable connections and th e

MAIN CPU board to be sure they are
operating properly .
204
SDTR parity error flag set
The data received did not pass th e

parity check .
The data received overran SDTR .
205
SDTR overrun error flag set
206
SDTR framing error flag set
207
DSR not set
208
209
The FROM was not erased during the

Clear FROM and retry the operation.
clear operation .
The FROM might be corrupted .
An invalid memory address was use d
Retry using another disk .
for loading .
An improper number of CMOS RAM
Check the hardware configuration and
modules was inserted in the MAIN CPU . try again .
Or, a corrupted CMOS RAM modul e
was inserted .
The MAIN CPU or SCC PCB might b e

corrupted.
corrupted .
The data received was out of th e

expected range.
The loopback connector is incorrect .

corrupted.
Check the loopback connector and retry
the operation .
Transmit timeout error
The transmit buffer did not empty withi n

the timeout period .
Receive timeout error
The receive buffer did not fill within th e

timeout period .
Check the loopback connector and retr y

the operation .
Check the loopback connector and retr y
the operation .
6 . TROUBLESHOOTING AND ERROR MESSAGE S

6-7
MARAJINST09205E
A re-init start will cause all CMOS resident softparts to be reloaded. Thi s
is useful when some portion of CMOS memory has become fragmented ,
or accidentally overwritten .
6.3
PERFORMING A
RE-INIT START
The file, LOADRAM .CF, located on the CORE1 disk, executes all of the
proper steps needed to perform a re-init start . A re-init start
Clears CMOS memory

Loads the TPE memory pool configuration
INIT starts the controlle r
Use Procedure 6-1 to perform a re-init start .
Procedure 6-1 Performing a Re-Init Start (V3.06PA, V3 .06PB, V3 .06PC)
Condition
Step
A portion of CMOS memory is overwritten or otherwise corrupted.
You have obtained a PS-100 disk drive .
You have the R-J software CORE, COMMON, LIBRARY, OPTION

and UPDATE disks that you want to install . Refer to Table 1-i fo r
the number of disks that you should have .
Press and hold the USER PB#1 and USER PB#2 buttons, and the n
press the ON button. The BMON> prompt will be displayed .
Press >,
NEXT
Press F5, RUN.
5 Type the name of the command file that will begin the re-loa d
procedure. Typically the name of the file is LOADRAM .
To display a character from beginning to end one at a time, press

the down arrow key.
To display a character from end to beginning one at a time, pres s

the up arrow key.
Press the right arrow key to accept a character.

character .

MARAJINST09205 E
Press ENTER. All of the CMOS memory will be cleared before any
files are loaded from disk . See the following screen for an example .
7 You will then be prompted to select a TPE configuration. See the

NOTE For V3.06PA, V3 .06PB, and V3 .06PC applications, selecting a
TPE memory pool configuration is identical to the process performe d
during the original software installation.
NOTE The 75 KB (Test Pars) configuration is only used in diagnosti c

situations, and only when explicitly directed by FANUC Robotics .
8
Finish installing the CORE, COMMON1, and APPLICATION/TOO L

disks as directed. The first disk will be CORE4 .
Re-install all options and updates . Refer to Procedure 4-4 ,

Procedure 4-5 , and Procedure 4-6 .
BOOTROM OPERATION S
A-1
MARAJINST09205E
The BootROM is a device you can use to turn on the robot using differen t
start methods and to use specific system utilities . The BootROM hardware
consists of the BootROM EPROM chip, located on the Main CPU PCB .
This appendix describes how to
Start up the robot and controller using one of the start methods : hot
start, INIT start, cold start, and controlled start.
Access the BootROM prompt, BMON>, and perform operations at th e

prompt .
Access BootROM diagnostic utilities .
Access BootROM extended monitor utilities .
Access BootROM device monitor utilities .
A . BOOTROM OPERATIONS
MARAJINST09205 E
A-2
A1 1
STARTUP METHOD S
BootROM provides the following startup methods :

INIT start
Cold start
Controlled start
In addition, you can turn on power to the robot without using BootROM
using the hot start method . Hot start is active when the system variabl e
$POWERFL is set to TRUE.
INIT start occurs automatically during a software load . Refer to the
appropriate software installation procedure for more information o n
performing an INIT start.
Hot start is the standard method for turning on power to the robot and
A.1 . 1
Hot Start
controller. Hot start is active when the system variable $POWERFL is set
to TRUE. You perform a hot start by making sure no other buttons on th e
operator panel are pressed and then pressing the ON button . The screen
that was displayed before power was turned off is displayed .
The hot start procedure is the same as the procedure for turning on the
robot. Use Procedure A-1 to perform a hot start .
Procedure A-1 Performing a Hot Star t
Condition
All personnel and unnecessary equipment are out of the workcell .
WARNIN G
DO NOT turn on the robot if you discover any problems o r

potential hazards . Report them immediately. Turning on a
robot that does not pass inspection could result in seriou s
injury.
Step
1 Press the ON button on the operator panel.
On the operator panel, the ON button will be illuminated ,

indicating robot power is on .
On the teach pendant screen, you will see the screen displaye d
when the robot was last turned off.
A. BOOTROM OPERATIONS
MARAJINST09205E
A-3
A cold start turns on power to the robot and controller and does the
following :
A.1 .2
Cold Start
Initializes changes to system variable s

Initializes changes to I/O setu p
Displays the UTILITIES Hints scree n
Use Procedure A-2 to perform a cold start .

Procedure A-2 Performing a Cold Star t
Condition
WARNIN G
DO NOT turn on the robot if you discover any problems o r
potential hazards . Report them immediately . Turning on a
injury.
Step
Press and continue pressing the RESET button on the operator panel .
While still pressing RESET, press the ON button on the operato r

panel.
On the operator panel, the ON button will be illuminated,

indicating robot power is on .
On the teach pendant screen, you will see the UTILITY Hints
screen. See the following screen for an example .
MARAJINST09205 E
A- 4
A controlled start turns on power to the robot and controller and allow s
you to do the following :
A.1 .3
Controlled Start
Motion system variable setup

Program initialization
Motion development
'
A CAUTION
The items that appear on the controlled start scree n
control how the robot and controller operate . Do not set
these items unless you are certain of their effect ,
otherwise, you could disrupt the normal operation of th e
robot and controller .
Table A-1 . Controlled Start Option s
DESCRIPTIO N
ITEM
Motion System
Variable Setup
Program Initialization
Motion Development
Initialize System Variable Reruns the robot library setup program for the selecte d
motion group .
Add/Delete Group Allows you to add and delete motion groups .
Extended Axis Setup/Init Allows you to set up and initialize extended axes .
Initialize Motion Softpart Initializes any softparts attached to motion that have not ye t
been initialized .
Display System Setup Status Displays the current robot library and whether it i s
initialized .
Line Tracking Setup/lnit Allows you to initialize the line tracking softpart on system s
that do not have an application installed .
Allows you to set the maximum number of tasks, number of registers, an d
number of position registers in the controller .
Disable Digital Servo Program Start When FALSE, activates the servo system; TRU E
does not activate the servo system .
Start Motion Test Task For FANUC Robotics internal use only.
Enable CMOS Servo Code For FANUC Robotics internal use only .
Use CMOS Servo Code For FANUC Robotics internal use only .
Use Procedure A-3 to perform a controlled start .
MARAJINST09205E
A-5
Procedure A-3 Performing a Controlled Start
Condition
WARNING
DO NOT turn on the robot if you discover any problems or
potential hazards. Report them immediately . Turning on a
injury.
Step
If the controller is powered up, power it down.
On the controller, press and hold the USER PB#1 and USER PB # 2
buttons (PURGE ENABLE if you are using a P-155 controller) on the
controller operator panel.

CRT or teach pendant.
4 Release these buttons .
5
At the BMON> prompt, press F2, CTRL, and press ENTER .
Press F2, START, and press ENTER . This begins the controlled start .
Select the type of setup or initialization you want to perform an d

continue as directed by the prompts on the screen and the informatio n
specific to your installation .
MARAJINST09205E
A-6
A. 2
BOOTROM UTILITIE S
You can perform operations from the BootROM prompt, BMON> .

Table A-2 lists and describes the utilities you can use from the BMON >
prompt.
The DIAG utility gives you access to BootROM diagnostic utilities . Refer
to Section A.3. The EMON utility gives you access to BootROM
extended monitor utilities. Refer to Section A .4.
Use Procedure A-4 to access BootROM and use BootROM utilities .
Table A-2.
BootROM Utilities
UTILITY
DESCRIPTIO N
BUS
Displays the slot number, module type, function level, and module-specific attribut e
information for each printed circuit board connected to the controller backplane .
DIAG
Provides access to the diagnostics utilities . Refer to Section A.3 .
EMON
Provides access to the extended monitor utilities . Refer to Section A.4.
DEVICE
Provides access to the device monitor utilities . Refer to Section A .5 .
TIME
Displays the controller clock time .
COLD
Performs a cold start . Refer to Section A.1 .2 .
CTRL
Performs a controlled start. Refer to Section A .1 .3 .
INIT
Performs an initialized start . An initialized start is only used for a full software load .
Controller memory is altered, and software that is currently on the controller is los t
and cannot be recovered .
START
When the controller is powered up, START begins whatever kind of start (COLD, CTRL, o r
INIT) has been chosen . HOT start cannot be selected .
CLEAR CMOS
Clears CMOS RAM memory. This will destroy the contents of CMOS RAM memory,
including all programs and files.
CLEAR FROM
Clears FROM memory. This will destroy the contents of CMOS RAM memory,
including all programs and files .
CRT
Causes all screen information to be displayed on the CRT/KB .
TP
Causes all screen information to be displayed on the teach pendant screen .
DIR
Displays a listing of the files stored on a floppy disk, if a disk drive is connected to the P3 :
port .
LOAD filename
Loads the specified file into FROM or CMOS RAM . filename is the name of the file to b e
loaded.
RUN filename
Runs the specified command file. filename is the name of the command file to be run .
A-7
MARAJINST09205E
Procedure A-4 Using BootROM Utilities

Condition
Step
The robot power is turned off.

On the operator panel, press and hold USER PB#1 and USER PB# 2
and then press the ON button . For P-155 robots only, press and hol d
PURGE ENABLE and then press the ON button .
The boot monitor prompt, BMON>, is displayed . See the followin g
2 To display more commands, press NEXT, >.
A CAUTION
The INIT utility invalidates the current software in the controller .

Do not use the INIT utility unless you want to fully reload th e
software, otherwise, loss of data occurs.
3 To execute a command, press the appropriate function key and pres s

ENTER .
4 To display a list of menu choices and the proper way to ente r

information, enter a ? (question mark) .,
5 To enter data manually ,
Press the down arrow to display the alphabet from beginning t o
end
s Press the up arrow to display the alphabet from end to beginnin g
s Enter a character by pressing the right arrow
MARAJINST09205 E
A-8
A. 3
DIAGNOSTIC UTILITIES (DIAG>
You can access di agnostic utilities from BootROM . Table A-3 lists and
describes the diagnostic utilities. Use Procedure A-5 to access diagnosti c
utilities .
Table A-3 . BootROM Diagnostic Utilitie s
DESCRIPTION
UTILITY
EXIT
Returns to BMON>.
CLOCK
Allows you to set the controller clock.
DB
Displays the memory,
DW
Displays the memory, by word, after you provide the hexadecimal starting memory loca tion.
MB
Allows you to modify the memory, by byte .
MW
Allows you to modify the memory, by word :
SHOW
Shows the amount of memory installed on the Main CPU PCB .
TEST CMOS
Tests the CMOS RAM memory. This test will destroy the contents of CMOS
TEST MEM
Tests the CMOS RAM memory. This test will destroy the contents of CMOS RA M
memory.
TEST PORT n
Tests the Main CPU
TEST FROM
Reads each Flash-ROM memory byte to insure that the Flash-ROM memory is blank .
Since this test reads only, there is no danger of corrupting memory data .
by byte, after you provide the hexadecimal starting memory location.
RAM
memory.
serial port specified by n .
MARAJINST09205E
A-9
Procedure A-5 Using ":DIAG> Utilities

n
Condition
:1
The BMON> prompt is displayed . Refer to Procedure A-4 .

;
Step
,are
On the teach pendant, press NEXT, >, until F2, DIAG, is displayed .
Press the F2, DIAG.
3 .,d Press ENTER. See the following screen for an example.
4 To display more utilities, press NEXT, >.
A CAUTIO N
The TEST CMOS and TEST MEM tests are destructive to
software loaded into CMOS RAM or controller memory . Do not
use these tests if you want to retain the current software ;
otherwise, loss of data occurs.
5 To execute a utility, press the appropriate function key and press

ENTER.
A. BOOTROM OPERATION S
MARAJINST09205 E
A-10
You can access extended boot monitor utilities from BootROM .

v ble A-4 lists and describes the ex tended boot monitor utilities . Use
Procedure A-6 to access extended b oot monitor utilities .
A. 4
EXTENDEDBOT
MONITOR 'UTILITIE S
(EMON>)
Table A-4. BootROM Extended Monitor Utilitie s
UTILITY DESCRIPTION
VCLEAR FRO M
Clears the FROM on the vision board .
VCLEAR CMO S
Clears the CMOS RAM for vision
VLOAD FILENAME
Leads the
Procedure A-6
Using EMON Utilities

The BMON> prompt is displayed. Refer to Procedure A-4 .
Condition .
Step
vision software .
1 On the teach pendant, Dress NEXT, >, until F3, EMON, is displayed .
2
Press
ss F3, EMON.
Press ENTER. See the following screen for an example .
To display more utilities, press NEXT, > .

~'
C'AUTI 6 , The EMON utilities
current vision software in th e
controller. Do not use these utilities unless you want to reload
the software, otherwise; loss of data occurs .
-the appropriate function key and press
A-1 1
MARAJINST09205E
Table A-4 lists

You can access device monitor
es from Boot ROM
to access
and describes the device monitor for utilities . Use Procedure A-7
.
device monitor utilities monitor utilities.,
,r,~ : >~ c
' "
ru g
A.5
DEVICE MONITO R
UTILITIES (DEV> )
. Device
BootROM
Table,
A-5 Monitor Utilities
UTILITY
otT 9 ; :)
._--
irl
',a'
INIT CMx
x - 0 OR I
RESTORE commands are

Clears the R-H type CMOS-RAM memory, before BACKUP and
tC M .t
= ,c .9: . L .r
COPY
Copies the contents Flash-ROM memory to the upper 2MB Of a 4MB CMOS RA M
memory. Since COPY writes to CMOS' memory the CMOS RAM memory must be recov ered by reloading software to CMOS .
used .
k~
.>,
PASTE
Used in conjunction with COPY Insert a blank FROM board in the Main CPU after COPY
and type the PAS TE command. The contents of the, upper 2MB of CMOS RAM memor y
will be copied to Flash-ROM . The, PASTE command will perform a blank check on th e
Flash-ROM board before try g to write software ., If the module is not blank, you will be
prompted
.
to CLEA RFOM
BACKUP xxx x
xxxx is CMOS or FROM
Copies the contents of CMOS RAM and/or Flash-ROM memory to two R-H style CMO S
RAM memories installed in the R-I-I extension backplane, Since only two 2MB R-H type
CMOS memories can be installed at onetime, 4MB or R-J memory can be backed up .
This can be 4 MB or CMOS memory or 2MB, of Flash-ROM ., A long-word checksu m is dis played to help the operator determine the backup was successful.
RESTORE xxxx
xxxx is CMOS or FROM
Copies the contents of R-H style CMOS RAM memory to R-J CMOS RAM memory and/o r
Flash-ROM memory . To use RESTORE, two R-H CMOS RAM memories must b e
installed the same as with BACKUP . Be aware that RESTORE works even if the data i n
the R-H CMOS RAM is not valid . Make sure that the BACKUP was performed before per forming a RESTORE .
CHKSMF
Calculates and displays the checksum of the Flash-ROM memory.

Procedure A-7:, Using DEV> Utilitie s
Condition
;lye The BMON> prompt is displayed . Refer to Procedure A-4 .
Step 1 On
the teach pendant, press NEXT, >, until F4, DEVICE, is displayed .
2 Press F4, DEVICE
3 Press ENTER. See the following screen for an example .

Wes _ . f f{S .+~ à
4 To display more utilities, press NEXT, > .

5 To execute a utility, press the appropriate function key and pres s
ENTER.

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SYSTEM R-J Software

To be used ONLY with SYSTEM R-J Software V3 .06P and late r

SYSTEM R-J Software 1

The description and specifications contained in this manual were in effec t

FANUC Robotics conducts courses on its systems and products on a

Copyright 1992, 1993, 1994 by FANUC Robotics North America ,

FANUC Robotics Hotlin e

BEFORE YOU CALL please have your Maintenance and Troubleshootin g

phone number where

(RA, RB, RC, RF, RG, RH, RJ)

on the next page.

On the identification tag on the robot an d

List of error messages

error message number

List of diagnostic LEDs

Note the PCB where the LED is located and th e

Description of events leading up to problem .

Purpose of this Manual

How to Use this

This manual describes FANUC Robotics SYSTEM R-J Softwar e

Troubleshooting and error recover y

Includes detailed descriptions of the R-J controlle r

Contains specific R-J controller electrical maintenanc e

Use this table to locate specific information in the manual .

Find information about a specific topic

Determine the installation requirements fo r

Set up and check memory requirements

Check and install EPROM chips

Install core, application, robot library, motion

Master the robot

Perform troubleshooting and error recovery

Use Boot Rom

This manual includes information essential to the safety of personnel,

NOTE Information appearing next to NOTE concerns related information

2 .1 CHECKING SYSTEM MEMORY

22 INSTALLING CMOS AND FLASH ROM MEMORY

3 .1 INSTALLING BOOTROM EPROM CHIPS

5 .1 MASTERING TO A FIXTURE (MASTER POSITION MASTER)

5 .2 ZERO DEGREE MASTERING

TROUBLESHOOTING AND ERROR MESSAGES

6 .1 TROUBLESHOOTING USING SYMPTOMS

Displaying Memory Status

Procedure A-3 Performing a Controlled Start

Keeping People and

The safety of people and equipment

The safety of people is always of primary importance in an y

Safety fences, barriers, or chains

A safe workcell is essential to protect people and equipment . Observe the

Sponsor your personnel for training in approved FANUC Robotic s

Install a lockout device that uses an access code to preven t

Use anti-tie-down logic to prevent the operator from bypassing safet y

Position all controllers outside the robot work envelope .

Never rely on software as the primary safety element .

Mount an adequate number of EMERGENCY STOP buttons o r

Install flashing lights and/or audible warning devices that activat e

Wherever possible, install safety fences to protect against unauthorize d

Use presence or proximity sensing devices such as light curtains, mats ,

Periodically check the safety joints or safety clutches that can b e

Make sure all external devices are properly filtered, grounded ,