ÚßÒËÝ Robotics America Quick Reference Document [Page 1 of 13 ]

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TSL@fanucrobotics.com Aug 26, 2011
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* Note: This document is provided as a courtesy and contains condensed and/or summarized information tailored to assist you with a specific issue. For additional and/or
detailed information, you must refer to the appropriate FANUC Robotics Manual or eDoc which specifically applies to the robotics system(s) at your location.

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B-81455EN/09 MAINTENANCE 5. ADJUSTMENTS

5.3 MASTERING

Mastering is an operation performed to associate the angle of each robot

axis with the pulse count value supplied from the absolute pulse coder
connected to the corresponding axis motor. To be specific, mastering is
an operation for obtaining the pulse count value corresponding to the
zero position.

5.3.1 General
The current position of the robot is determined according to the pulse
count value supplied from the pulse coder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering
in daily operations. However, mastering becomes necessary after:
• Motor replacement.
• Pulse coder replacement.
• Reducer replacement.
• Cable replacement.
• Batteries for pulse count backup in the mechanical unit have gone
dead.

NOTE
Robot data (including mastering data) and pulse
coder data are backed up by their respective backup
batteries. Data will be lost if the batteries go dead.
Replace the batteries in the control and mechanical
units periodically. An alarm will be issued to warn
the user of a low battery voltage.

Mastering method
Table 5.3.1 Types of mastering
Jig position mastering This is performed using a mastering jig before the
machine is shipped from the factory.
Zero-position This is performed with all axes set at the 0-degree
mastering position. A zero-position mark (eye mark) is
(eye mark mastering) attached to each robot axis. This mastering is
performed with all axes aligned to their respective
eye marks.
Quick mastering This is performed at a user-specified position. The
corresponding count value is obtained from the
rotation speed of the pulse coder connected to the
relevant motor and the rotation angle within one
rotation. Simplified mastering uses the fact that the
absolute value of a rotation angle within one rotation
will not be lost.
Single-axis mastering This is performed for one axis at a time. The
mastering position for each axis can be specified by
the user. This is useful in performing mastering on a
specific axis.
Mastering data entry Mastering data is entered directly.

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 5. ADJUSTMENTS MAINTENANCE B-81455EN/09

Once mastering is performed, it is necessary to carry out positioning, or

calibration. Positioning is an operation in which the control unit reads
the current pulse count value to sense the current position of the robot.

NOTE
If mastering is performed incorrectly, the robot may
behave unexpectedly. This is very dangerous. So,
the positioning screen is designed to appear only
when the $MASTER_ENB system variable is 1 or 2.
After performing positioning, press F5 [DONE] on
the positioning screen. The $MASTER_ENB system
variable is reset to 0 automatically, thus hiding the
positioning screen.

5.3.2 Resetting Alarms and Preparing for Mastering

Before performing mastering because a motor is replaced, it is
necessary to release the relevant alarm and display the positioning
menu.

Alarm displayed
“Servo 062 BZAL” or “Servo 075 Pulse mismatch”

Procedure Preparing the Robot for Mastering

Step
1 Display the positioning menu by following steps 1 to 6.
1 Press MENUS.
2 Press NEXT and select [SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variables] from the
$MASTER_ENB=0 is set when you menu.
choose F5[DONE] on the Master/Cal 4 Place the cursor on $MASTER_ENB, then key in “1” and
menu and it hides the Master/Cal press [ENTER].
menu under the System submenus. 5 Press F1 [TYPE], and select [Master/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal]
On R-J Controllers this may labeled RES_SPC.
menu.
If using software prior to R-J v3.6 and RES_SPC 2 To reset the “Servo 062 BZAL” alarm, follow steps 1 to 5.
is not listed above the F3 softkey then do the 1 Press MENUS.
following: 2 Press [ONEXT] and select [6SYSTEM].
3 Press F1 [TYPE], and select [SYSTEM Variables] from the
1) Press MENU, 0[NEXT], System, F1[TYPE] menu.
2) Highlight Variables, Press ENTER 4 Place the cursor on F3 RES_PCA, then press F4 [TRUE].
3) Highlight $MCR, Press ENTER The message “TRUE” appears and disappears immediately.
4) Toggle $SPC_RESET=TRUE 5 Switch the controller power off and on again.
5) Cycle Power 3 To reset the “Servo 075 Pulse mismatch” alarm, follow steps 1 to 3.
1 When the controller power is switched on again, the message
“Servo 075 Pulse mismatch” appears again.
2 Rotate the axis for which the message mentioned above has
appeared through 10 in either direction.
3 Press [FAULT RESET]. The alarm is reset.

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B-81455EN/09 MAINTENANCE 5. ADJUSTMENTS

5.3.4 Zero Position Mastering

Zero-position mastering (eye mark mastering) is performed with all
axes set at the 0-degree position. A zero-position mark (eye mark) is
attached to each robot axis. This mastering is performed with all axes
set at the 0-degree position using their respective eye marks.
Zero-position mastering involves a visual check. It cannot be so
accurate. It should be used only as a quick-fix method.

Procedure Mastering to Zero Position

Step
1 Press MENUS.
2 Select NEXT and press SYSTEM.
3 Press F1, [TYPE].
4 Select Master/Cal.

AUTO
SYSTEM Master/Cal JOINT 1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF
6 CALIBRATE

Press 'ENTER' or number key to select.

[ TYPE ] LOAD RES_PCA DONE

5 Release brake control, and jog the robot into a posture for
mastering.

NOTE
Brake control can be released by setting the system
variables as follows:
$PARAM_GROUP.SV_OFF_ALL: FALSE
$PARAM_GROUP.SV_OFF_ENB[*]: FALSE
(for all axes)
After changing the system variables, switch the
control unit power off and on again.

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5. ADJUSTMENTS MAINTENANCE B-81455EN/09

6 Select Zero Position Master.

AUTO
SYSTEM Master/Cal JOINT 1%
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>

[ TYPE ] LOAD RES_PCA DONE

7 Press F4, YES. Mastering will be performed automatically.

Alternatively, switch the power off and on again. Switching the
power on always causes positioning to be performed.

AUTO

SYSTEM Master/Cal JOINT 1%

TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER

3 QUICK MASTER
4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF

6 CALIBRATE

Robot Calibrated! Cur Jnt Ang(deg):

< 0.0000> < 0.0000> < 0.0000>

< 0.0000> < 0.0000> < 0.0000>

[ TYPE ] LOAD RES_PCA DONE

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B-81455EN/09 MAINTENANCE 5. ADJUSTMENTS

Table 5.3.4 Attitude with position marks aligned

Axis Position
J1-axis 0 deg
J2-axis 0 deg
J3-axis 0 deg
J4-axis 0 deg
J5-axis 0 deg
J6-axis 0 deg

J5-axis

J3-axis
J6-axis
J4-axis

J2-axis

J1-axis

Vernier mark
J1-axis J2-axis J2-axis

J3-axis

Scribing mark

J4-axis J5-axis J6-axis

Fig.5.3.4 (a) Zero degree position arrow mark for each axis (R-2000iA/165F and 125L)

EXAMPLE of ZERO POSITION

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5. ADJUSTMENTS MAINTENANCE B-81455EN/09

5.3.5 Quick Mastering

Quick mastering is performed at a user-specified position. The
corresponding count value is obtained from the rotation speed of the
pulse coder connected to the relevant motor and the rotation angle
within one rotation. Quick mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost.
Quick mastering is factory-performed at the position indicated in Table
5.3.4. Do not change the setting unless there is any problem.
If it is impossible to set the robot at the position mentioned above, it is
necessary to re-set the quick mastering reference position using the
following method. (It would be convenient to set up a marker that can
work in place of the eye mark.)

NOTE
1 Quick mastering can be used, if the pulse count
value is lost, for example, because a low voltage has
been detected on the backup battery for the pulse
counter.
2 Quick mastering cannot be used, after the pulse
coder is replaced or after the mastering data is lost
from the robot control unit.

Procedure Recording the Quick Master Reference Position

Step
1 Select SYSTEM.
2 Select Master/Cal.

3 Release brake control, and jog the robot to the quick mastering
reference position.
4 Move the cursor to SET QUICK MASTER REF and press
ENTER. Press F4, YES.

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B-81455EN/09 MAINTENANCE 5. ADJUSTMENTS

NOTE
If the robot has lost mastery due to mechanical
disassembly or repair, you cannot perform this
procedure. In this case, master to a fixture or
master to zero degrees to restore robot mastery.

Procedure Quick Mastering

Step
1 Display the Master/Cal screen.

2 Release brake control, and jog the robot to the quick mastering
reference position.
3 Move the cursor to QUICK MASTER and press ENTER. Press
F4, YES. Quick mastering data is memorized.
4 Move the cursor to CALIBRATE and press ENTER. Calibration
is executed. Calibration is executed by power on again.
5 After completing the calibration, press F5 Done.

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5. ADJUSTMENTS MAINTENANCE B-81455EN/09

5.3.6 Single Axis Mastering

Single axis mastering is performed for one axis at a time. The mastering
position for each axis can be specified by the user.
Single axis mastering can be used, if mastering data for a specific axis is
lost, for example, because a low voltage has been detected on the pulse
counter backup battery or because the pulse coder has been replaced.

Table 5.3.6 Items set in single axis mastering

Item Description
Current position The current position of the robot is displayed for each
(Actual axis) axis in degree units.
Mastering position A mastering position is specified for an axis to be
(Matra pos) subjected to single axis mastering. It would be
convenient to set to it to the 0_ position.
SEL This item is set to 1 for an axis to be subjected to
single axis mastering. Usually, it is 0.
ST This item indicates whether single axis mastering has
been completed for the corresponding axis. It cannot
be changed directly by the user. The value of the item
is reflected in $EACHMST_DON (1 to 9).
0 : Mastering data has been lost. Single axis
mastering is necessary.
1 : Mastering data has been lost. (Mastering has been
performed only for the other interactive axes.)
Single axis mastering is necessary.
2 : Mastering has been completed.

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B-81455EN/09 MAINTENANCE 5. ADJUSTMENTS

Procedure Mastering a Single Axis

Step
1 Select SYSTEM.
2 Select Master/Cal.

3 Select 4, Single Axis Master. You will see a screen similar to the
following.

4 Move the cursor to the SEL column for the unmastered axis and
press the numeric key “1.” Setting of SEL is available for one or
more axes.
5 Turn off brake control as required, then jog the robot to the
mastering position.
6 Enter axis data for the mastering position.

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 5. ADJUSTMENTS MAINTENANCE B-81455EN/09

7 Press F5 [EXEC]. Mastering is performed. So, SEL is reset to 0,

and ST is re-set to 2 or 1.

NOTE:
Single Axis Mastering can only be
performed once per axis. If you
incorrectly master an axis, you can 8 When single axis mastering is completed, press the previous page
not single-axis-master it again, key to resume the previous screen.
unless you create, and then clear, a
SRVO-062 BZAL for that axis.

Alternately, you can move all other

axes to their ZERO positions,
correctly re-align the single axis,
and perform the steps listed in the
ZERO POSITION MASTERING
procedure.

9 Select [6 CALIBRATE], then press F4 [YES]. Positioning is

performed. Alternatively, switch the power off and on again.
Positioning is performed.
10 After positioning is completed, press F5 [DONE].

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5.3.7 Mastering Data Entry

This function enables mastering data values to be assigned directly to a
system variable. It can be used if mastering data has been lost but the
pulse count is preserved.

Mastering data entry method

Step
1 Press MENUS, then press NEXT and select SYSTEM.
2 Press F1, [TYPE]. Select [Variables]. The system variable screen
appears.

3 Change the mastering data.

The mastering data is saved to the $DMR_GRP.$MASTER_COUN
system variable.

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5. ADJUSTMENTS MAINTENANCE B-81455EN/09

4 Select $DMR_GRP.

5 Select $MASTER_COUN, and enter the mastering data you have

recorded.

6 Press the PREV key.

7 Set $MASTER_DONE to TRUE.

8 Display the positioning screen, and select [6 CALIBRATE], then

press F4 [YES].
9 After completing positioning, press F5 [DONE].

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