Robot Terminology

Axis Limit A software setting that is used to limit the movement of an axis.
(Preferably set before the hard stop)

Coordinate System Method or point of reference used to jog the robot in manual mode.
Fanuc robots have five coordinate systems: Joint, World, Tool,
JGFRM & User. Changing coordinate systems is accomplished by
pressing the “COORD” key

Cursor Designated by a highlighted line in the program or on a parameter

page. The Cursor can be used to view and edit program
instructions or change operational parameters.

Cycling To run a robot program.

Dead Man Switch The Dead Man Switches are safety switches located on the back of
the Teach Pendant. In order to move the robot in manual mode,
one of the Dead Man Switches must be held. If the Teach Pendant
Enabling key is in the ON position and the Dead Man Switch is not
depressed, the robot will be in an Emergency Stop condition.

Enabling Key The enabling key is the ON / OFF switch located on the front of
the Teach Pendant. Turning this switch ON will allow manual
operation of the robot.

Face Plate The face plate is located at the end to the 6th axis. The end of arm
tooling is bolted to the face plate. The face plate is also where the
default tool center point (tool frame 0) is located.

Frame A frame is a set of three planes at right angles to each other. The
point where all three planes intersect is the origin of the frame.
This set of planes is called a Cartesian coordinate system. In the
robot system, the intersecting edges of the planes are the x, y, and z
axes of the frame.

Hard Stop A device that physically stops the movement of an axis.

Jogging Moving the robot in manual mode.

Macro Routine A macro routine is a separate program that containing a set of

instructions to execute a specific task.

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Program A program is a set of instructions or commands given to the robot
To tell it what tasks to perform and how to perform them.

Servo System A closed loop system that consists of a motion control, amplifier,
motor and a position feedback device. The servo system is what
moves the robot.
Step Mode Mode that forces the robot to run a program one line or “step” at a
time. Step Mode is activated by pressing the “STEP” key and is
indicated by the green “Step” LED or when the “Step” box on the
I-Pendant is yellow.
Teach Pendant The Teach Pendant is the hand held programming device attached
to the robot controller. It has a display screen, numeric and
symbolic keys an enabling key and an E-stop button.

Tool Center Point Once end of arm tooling is added to the robot the tool center point
is used to tell the robot where the tooling is located. The TCP is an
XYZ offset to the measured from the faceplate of the robot.

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 Introduction

The purpose of this training is to allow operators and technicians to become familiar with
the operation of Fanuc robots using the RJ-2, RJ-3 & RJ-3Ib control. The scope of this
training will include basic robot operation, basic robot maintenance and basic robot
troubleshooting.

Safety

Always follow plant lock out / tag out procedures. Failure to do so may result in death or
serious injury.

General

Fanuc robots are capable of moving at a feed rate of 2000mm/sec (6.5 feet/sec) carrying
up to 500lbs. Always be aware of where the robot is in relation to you.
Always take the teach pendant in to the robot cell with you and place the robot into step
mode.

Pneumatic

Always depressurize air systems when working with air lines.

Electrical

The Fanuc robot controller supply voltage is 480VAC. The controller itself contains
200VAC & 24VDC use caution when working inside of a live controller.
Voltage from outside power sources may be present on the I/O modules even with the
main robot disconnect off.

3
 Robot System Overview

The robot system consists of three major components; the robot controller, the teach
pendant and the robot.

4
 Controller Overview

RJ-3 / RJ-3Ib A size cabinet

RJ-3 / RJ-3Ib B size cabinet

The robot controller contains the main processor for the robot. It also contains a power
supply, servo amplifier and a standard operator panel.

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 Controller Standard Operator Panel

RJ-3IB Standard Operator Panel

User 1& 2 Push buttons Application specific push buttons to be defined by the user.
(Not used at Inergy)

Fault Reset Push button Used to acknowledge and reset faults.

Cycle Start Push Button Used to initiate production on a robot when the robot is in
local mode. (Not used at Inergy)

Fault Light Indicates that a fault condition is present on the robot.

On / Off Push Button Used to power the robot up and down.

Emergency Stop Button Used to stop robot movement. Use of the emergency stop
will turn off power to the servos and pause program
execution.

Auto / T1 / T2 Used to control the robot speed when in manual mode.

Optional Key Switch The T1 position will limit the robot speed to 250mm/sec.
(Not Pictured) The T2 position will allow the robot to move at full speed.

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RJ-3 Standard Operator Panel

User 1& 2 Push buttons Application specific push buttons to be defined by the user.
(Not used at Inergy)

Remote / Local Used to give control of the robot to a PLC or to let

Key Switch the robot be the controlling device in a cell.

Hold Push Button Used to stop the robot in a controlled fashion. Use of the
hold push button will pause the robot program but not turn
off power to the servos.

Fault Reset Push button Used to acknowledge and reset faults.

Cycle Start Push Button Used to initiate production on a robot when the robot is in
local mode. (Not used at Inergy)

Remote Light Indicates that the Remote / Local key switch is in the
remote state.

Battery Alarm Light Indicates that the battery on the main control board is low.

Fault Light Indicates that a fault condition is present on the robot.

On Push Button Used to turn the robot on.

Off Push Button Used to turn the robot off.

Emergency Stop Button Used to stop robot movement. Use of the emergency stop
will turn off power to the servos and pause program
execution.

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RJ-2 Standard Operators Panel

Auto / T1 / T2 Used to control the robot speed when in manual mode.

Optional Key Switch The T1 position will limit the robot speed to 250mm/sec.
The T2 position will allow the robot to move at full speed.
(RJ-2 & 3 controllers at Inergy are not equipped with this
option.)

Fault Light Indicates that a fault condition is present on the robot.

Remote Light Indicates that the Remote / Local key switch is in the
remote state.

Battery Alarm Light Indicates that the battery on the main control board is low.

Fault Reset Push button Used to acknowledge and reset faults.

Remote / Local Used to give control of the robot to a PLC or to let

Key Switch the robot be the controlling device in a cell.

Cycle Start Push Button Used to Initiate production on a robot when the robot is in
local mode. (not used at Inergy)

On Push Button Used to turn the robot on.

Off Push Button Used to turn the robot off.

Emergency Stop Button Used to stop robot movement. Use of the emergency stop
will turn off power to the servos and pause program
execution.

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 Teach Pendant Overview

Monochrome Teach Pendant

The teach pendant is the HMI for the robot.

At this time, the Inergy Automotive Adrian facility has three types of teach pendants; the
I-pendant, the Monochrome dual chain pendant and the monochrome single chain
pendant.

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 Robot Overview

The robot it self has six servo motors, one for each axis, six encoders, one for each motor.
The motors are what move the robot arm and the encoders monitor the position of the
motors.

At this time, the Inergy Automotive Adrian facility has five robot types; the LR200I, the
LR200Ib the M710I, the R2000Ia and the S430I. All of these robots are 6-axis robot and
are functionally the same except for the size.

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 Turning On the Robot

*Ensure all personal and unnecessary equipment are out of the work cell and clear of the
robot.

Make sure all robot cables are properly connected.

Turn on the main disconnect on the robot controller.

Press the “ON” button on the robot controller.

The robot will run a self check as it boots up. If any faults are present the fault light on
the teach pendant and on the controller will be lit and a list of active faults can be seen in
the alarm screen.

Inergy Automotive robots start up in the cold start mode. On boot up the utilities screen
will be displayed.

Fault Recovery

Any time that a fault occurs a fault code will be displayed on the status line of the teach
pendant.

It is important to realize that the status line of the teach pendant only displays the last
fault that occurred. In order to see a full list of active alarms:

Press the “MENU” key

Move the cursor down to “Alarms” and press the “ENTER” key.
This will display a list all active alarms. In order to see the alarm history press “F3” in
this screen.

In order to clear a robot fault press the “RESET” key on the teach pendant or on the
controller.

If the fault does not reset after the “RESET” button is pressed power down the robot
controller. Certain servo faults require the robot to be powered down to reset the fault.

In the event that any faults are not cleared with power down, consult the Fanuc reference
manual for troubleshooting procedures. Pulse coder alarms and chain faults require a
special procedure to clear.

* Appendix A contains procedures to reset chain faults, pulse coder alarms and wrist
break faults.

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 Jogging the Robot

Joint Jogging

Joint jogging means to move the robot 1 axis or motor at a time. All joint movements are
arcing movements.

In order to jog the robot in joint mode, press the “COORD” key until “JOINT” is
displayed on the teach pendant screen. Turn on the teach pendant. Hold in the dead man
switch. Reset any faults. Press and hold the “SHIFT” key. Press the jog key for the joint
that you want to jog.

At this time the robot should be moving.

Joint jogging is most often used for rough positioning and must be used for mastering the
robot, avoiding singularity and jogging off of an over travel switch.

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World Jogging

The World frame is a Cartesian or X, Y, Z coordinate system with the origin located at
the center of the waist of the robot. When jogging in the world or any other Cartesian
coordinate system the robot will be capable of making both linear and arcing moves.

In order to jog the robot in world mode, press the “COORD” key until “WORLD” is
displayed on the teach pendant screen. Turn on the teach pendant. Hold in the dead man
switch. Reset any faults. Press and hold the “SHIFT” key. Press the jog key for the axis
that you want to jog.

In the world frame, the top three sets of jog keys will move the tool center point in a
straight line along the axis being jogged, along while holding the end of arm tooling in
the same orientation. The bottom three sets of jog keys will rotate the end of arm tooling
around the axis at the tool center point.
Movement in the world coordinate system can be predicted by using the right hand rule.

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Tool Jogging

The Tool frame is a Cartesian or X, Y, Z coordinate system with the origin located at the
tool center point. When jogging in the Tool or any other Cartesian coordinate system the
robot will be capable of making both linear and arcing moves.

In order to jog the robot in Tool mode, press the “COORD” key until “TOOL” is
displayed on the teach pendant screen. Turn on the teach pendant. Hold in the dead man
switch. Reset any faults. Press and hold the “SHIFT” key. Press the jog key for the axis
that you want to jog.

In the Tool frame, the top three sets of jog keys will move the tool center point in a
straight line along the axis being jogged, while holding the end of arm tooling in the same
orientation. The bottom three sets of jog keys will rotate the end of arm tooling around
the axis at the tool center point. The Tool coordinate system is fully definable.
Caution: Teaching points in the Tool frame may effect program operation.

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User Jogging

The User frame is a Cartesian or X, Y, Z coordinate system with the origin located at a
user defined position. When jogging in the User or any other Cartesian coordinate system
the robot will be capable of making both linear and arcing moves.

In order to jog the robot in the User mode, press the “COORD” key until “USER” is
displayed on the teach pendant screen. Turn on the teach pendant. Hold in the dead man
switch. Reset any faults. Press and hold the “SHIFT” key. Press the jog key for the axis
that you want to jog.

In the User frame, the top three sets of jog keys will move the tool center point in a
straight line along the axis being jogged, while holding the end of arm tooling in the same
orientation. The bottom three sets of jog keys will rotate the end of arm tooling around
the axis at the tool center point. The User coordinate system is fully definable.
Caution: Teaching points in the User frame may effect program operation.

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Jog Frame Jogging

The Jog Frame (JGFRM) is a Cartesian coordinate system defined for the purposes of
convenience of movement. Generally a Jog Frame is defined to give linear movement in
directions offset from the part or fixture. When jogging in the User or any other Cartesian
coordinate system the robot will be capable of making both linear and arcing moves.

In order to jog the robot in the Jog Frame mode, press the “COORD” key until “JGFRM”
is displayed on the teach pendant screen. Turn on the teach pendant. Hold in the dead
man switch. Reset any faults. Press and hold the “SHIFT” key. Press the jog key for the
axis that you want to jog.

In the Jog frame, the top three sets of jog keys will move the tool center point in a straight
line along the axis being jogged, while holding the end of arm tooling in the same
orientation. The bottom three sets of jog keys will rotate the end of arm tooling around
the axis at the tool center point. The Jog Frame coordinate system is fully definable.
One benefit of using the Jog Frame coordinate system is that it has no effect on the
program.

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 Program Select Screen

This screen is used to select programs, create programs, delete programs, and set the
attributes of programs.

To view the select screen, either press the “SELECT” key. You will see a screen similar
to this:

[TYPE] The type soft function key allows you to select the type of program that
you want to view. The selections are as follows:
1. All
2. T. P. Programs
3. KAREL Programs
4. Macro
5. Cond

CREATE Allows you to create a new program.

DELETE Deletes the highlighted program.

MONITOR Allows you to view the selected program.

[ATTR] Changes which program attribute is displayed on the select screen.

Program attributes that can be viewed are program comment, write protect,
Last modified date, program size and program copy source.

COPY The copy command will copy the highlighted program into a new program.

DETAIL The program detail screen will allow you to change the program type, turn
the write protect on and off and add a comment to the highlighted program.

LOAD Allows KAREL .PC files to be loaded to the controller.

SAVE Saves the highlighted program to a specified file name to the default
device.

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PRINT Allows the highlighted program to be printed to a serial printed. The print
command will also write a .TP file or .MR file to a disk as a .LS file.

SELECTING AND TEST CYCLING A PROGRAM

To select a program, simply move the cursor to the program that you want
to run and press the “ENTER” key.

The screen will change to the program screen:

When test cycling a program, you should always start in STEP mode at a slow speed and
gradually increase the robot speed as you become confident that the robot is not going to
crash.

To test cycle a program:

1. Turn “STEP” mode on.

2. Press and hold the Dead Man’s switch.

3. Turn on the teach pendant.

4. Press and hold the shift key.

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5. Press and release the “FWD” key. The robot will execute one line of the program,

6. Continue to press and release the “FWD” key until the program has completed.

After stepping through the program, take the robot out of step mode and run the program.
Once again you should start at a slow speed and gradually work your way up.

Remember that the robot will act differently at slow speeds than it will at faster speeds.

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 Program Instructions

Motion Instructions

A motion instruction is a program command that tells the robot where it is going to move
to, how fast it is going to move and what type of motion it is going to use.

There are three movement types that a motion instruction can use; Joint motion, Linear
motion and Circular motion. The two main motion types used at Inergy and Linear and
Joint. Typically at Inergy, circular motion will not be used.

Motion Position Speed Accuracy

Type Data Setting Setting

J P [1] 75% FINE

L P [2] 1000mm/sec CNT 50
J PR [7: Home] 20% FINE
L P [10: Pick] 2000mm/sec CNT100

Motion type

J = Joint The robot will move in an arcing motion from point to point.

Robot Joint Movement

L = Linear The robot will move in a straight line from point 1 to point 2 when
the motion type for point 2 is set to linear.

Robot Linear Movement

Position Data

Positional information is held in the “P[X]” field. In this field you can view and
change position data as well as enter a comment to the individual point.

Speed setting

The speed setting can be changed at any time by moving the cursor over the speed
field and pressing enter. Speeds for joint moves are listed in percentages and
speeds for linear moves are listed as a mm/sec feed rate.

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Accuracy Setting

The accuracy settings determine how close to a point the robot will come before
continuing to the next point. With an accuracy setting of fine, the robot will slow
down and stop at a point before continuing on to the next point. A CNT accuracy
setting will allow the robot to round off points and continue to the next point
without stopping. CNT accuracy settings are effected by robot speed. As the robot
moves faster, the robot will round more off of the point. CNT accuracy settings
not active in step mode.

Example 1: Position 2 accuracy setting = Fine

Example 2: Position 2 accuracy setting = CNT 10

Example 3: Position 2 accuracy setting = CNT 50

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Changing the Position of a Motion Instruction

A motion instruction or “point” can be changed or “touched up” at any time during
manual operation. You can do this by moving the cursor to the point that needs to be
touched up, moving the robot to its new position for the point, holding the shift key and
then pushing the F5 soft key while it reads touchup. At this time the position data for the
point being touched up will be changed.

Touching up a program may be necessary for several reasons: part variation, mold or
tooling changes, robot crashes, or re-mastering of the robot. You must use caution when
touching up a point because the line that the cursor is on will be the line that is modified.
It is very common to touch up the wrong point.

Instruction Commands

Instruction commands are non-motion related instructions used to control inputs / outputs,
program flow, math registers, timers, and any other program functions that may be
needed. Instruction commands can be accessed by pressing the F1 “[INST]” soft function
key. A list of instruction commands will appear at the top of the teach pendant screen.

Register Instructions

1. R[…] = … 5. R[…] = … / …
2. R[…] = … + … 6. R[…] = … DIV …
3. R[…] = … - … 7. R[…] = … MOD …
4. R[…] = … * …

Registers are used to store individual numbers. You can also perform math
functions with register instructions.
Examples:

R[1] = GI[1] This instruction will set the value of register 1 the value of
Group Input 1.

R[1] = R[1] + 1 This instruction will increment the value of register 1 by 1

every program cycle.

R[1] = R[1] – 1 This instruction will decrement the value of register 1 by 1

every program cycle.

I/O Instructions

1. AO[…] = … 5. RO[…] = …
2. DI […] = … 6. R […] = RI[…]
3. DO[…] = … 7. GO[…] = …
4. R […] = DI[…] 8. R […] = GI […]

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I/O instructions are used to turn devices on and off and to monitor the status of
external devices.

Examples:

RO[1:Open Gripper] = ON This is a robot output command turning on 1 of 2

robot outputs to open a gripper.

DO[2: Robot Clear] = OFF This is a digital output command turning off a
signal to an external piece of equipment.

Wait Instructions

1. WAIT ...(SEC) 5.
2. WAIT ...= ... 6.
3. WAIT ...<> ... 7.
4. WAIT SEMAPHORE [...] 8.

Wait instructions are used to pause the program for a set time delay or until a
condition is met.

Examples:

WAIT 1.00 sec This instruction will pause program execution for one
second. The program will resume after this period of time.

WAIT DI [1] = ON This instruction will pause program execution until digital
input one turns on.

If / Select Instructions

1. IF ... = … 5. IF …>…
2. IF ...<> ... 6. IF …>=…
3. IF ...< ... 7.
4. IF ....<=… 8. –NEXT PAGE-

NEXT PAGE

1. SELECT R[...] 5.
2. <SELECT> = ... 6.
3. <SELECT> ELSE 7.
4. 8. –NEXT PAGE-

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If instructions are used to make program decisions based on the status of inputs to the
robot, outputs from the robot, or register values. If a condition specified by the if
statement is true then the if instruction will be executed, when the if statement if not true
then the if statement will be bypassed.

Examples:

IF DI [1: Reject Part] = ON, CALL REJECT This instruction will run the REJECT
program if digital input 1 is on.

IF DI [2: Part in gripper] = OFF, JMP LBL [1] This instruction will jump to
program label 1 if digital input 2 is
off.

If instructions will only call other programs or jump to program lines. Therefore, the
action that is to be executed when the if statement is true must either be written in a
different section of the program or written in a completely different program.

Jump Instructions

1. JMP LBL [...] 5.

2. LBL [...] 6.
3. 7.
4. 8.

Jump instructions allow the robot to bypass program lines as necessary. The “JMP LBL
[…]” (JUMP LABEL) tells the program when and where to jump to, the “LBL […]”
(LABEL) is where the program is jumping to. Program labels must be unique…You can
only have one label “1” in a program you can however, jump to label “1” as many
different times as you need to. You can not have a jump instruction without a label you
can have a label without a jump instruction.

Example:

1: This example will make the program

2: skip lines 4 & 5 when the program
3: JMP LBL [1] is ran.
4:
5:
6: LBL [1]
7:
8:

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Call Instructions

1. CALL PROGRAM 5.
2. END 6.
3. 7.
4. 8.

Call instruction will run a program or a subroutine from another program.

Example:

CALL REJECT This instruction will execute the REJECT program from
whatever program is being run.

Other Commonly Used Instructions:

UFRAME = X This instruction sets the active USER frame in the program. It is
very important to use the proper USER frame when programming,
if the wrong USER frame is used you may get a UFRAME
MISMATCH alarm or unpredictable robot movement.

UTOOL = X This instruction sets the active TOOL frame in the program. It is
very important to use the proper TOOL frame when programming,
if the wrong TOOL frame is used you may get a UTOOL
MISMATCH alarm or unpredictable robot movement.

MESSAGE [xxx] This command will send a message to the user screen. It is widely
used on the KVT machines as a program status display.

!....your text This is a program comment. This is used to give description to a

program.

OVERRIDE = X This is a speed over ride command. The robot will automatically
Move at the programmed speed.

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 Appendix A

Robot Maintenance

This section contains common faults and maintenance procedures that may be required.

Common Faults

Before attempting to troubleshoot ANY robot faults first press the robot reset push
button, if the fault does not clear, power down the robot. If the fault still will not
clear then proceed with troubleshooting the robot.

Emergency Stop Faults

SRVO-001 SERVO Operator panel E-stop

Cause: The operator panel emergency stop push button is pressed.

Remedy: Twist the operator panel emergency stop push button clockwise to
release. Press RESET.

SRVO-002 SERVO Teach pendant E-stop

Cause: The teach pendant emergency stop push button is pressed.

Remedy: Twist the teach pendant emergency stop push button clockwise to
release. Press RESET.

SRVO-003 SERVO Deadman switch released

Cause: The teach pendant deadman switch is released while the teach pendant
is enabled.

Remedy: Press teach pendant deadman switch. Press RESET.

SRVO-004 SERVO Fence open

Cause: On the terminal block on the printed circuit board of the operator panel,
no connection is established between the FENCE1 and FENCE2 signals. When
a safety door is connected, it is open.

Remedy: Establish a connection between FENCE1 and FENCE2, then press the
RESET key. When a safety door is connected, close the door before starting
work.

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SRVO-006 SERVO Hand broken

Cause: A safety hand has broken. If no broken hand can be found, however, the
most likely is the HBK signal of a robot connection cable being at the 0 V level.

Remedy: 1. While holding down the SHIFT key, press the reset button to clear
the alarm. 2. While holding down the SHIFT key, position the tool to the
workplace by jogging. 1) Replace the safety hand. 2) Check the cable. 3. Check
cable RP1 for loose connection, damaged pins, or damaged cable. 4. Replace
the servo amplifier.

SRVO-007 SERVO External emergency stops

Cause: The external emergency stop push button is pressed. On the terminal
block of the printed circuit board for the operator panel, no connection is
established between EMGIN1 and EMGIN2.

Remedy: If using external emergency stop, clear the source of the fault, and
press RESET. If not using external emergency stop, check the wiring at EMGIN1
and EMGIN2.

SRVO-037 SERVO IMSTP input (Group:%d)

Cause: The *IMSTP signal, which is a peripheral device I/O signal, is applied.

Remedy: Turn on the *IMSTP signal.

Collision Related Faults

SRVO-023 SERVO Stop error excess(G:%d A:%d)

Cause: A excessive servo positional error occurred when the motor stopped.

Remedy: 1. Check whether the applied load exceeds the rating. If so, reduce the
applied load. If an excessive load is applied, the torque required for acceleration,
deceleration, and so forth exceeds the maximum available torque of the motor.
Therefore, it might prove impossible to correctly respond to an issued command,
resulting in the output of this alarm. 2. Check each interphase voltage of the
three-phase voltage (200 VAC) applied to the servo amplifier. If the voltage is
found to be 170 VAC or below, check the input power supply voltage. A sub-
standard voltage, applied to a servo amplifier, results in a lower-than-normal
torque. Therefore, it might prove impossible to correctly respond to an issued
command, thus resulting in the output of this alarm. Check phase-to-phase
voltage across the three pins of connector CRM38A or CRM38B of the servo

27
amplifier. 3. If the input power supply voltage is found to be 170 VAC or higher,
replace the servo amplifier. 4. Check the motor power cables (RM1, RM2, RM3)
for damage, to cable or pins, and that the connector is securely connected.
WARNING: By completing the next step you will be altering the positional
reference for the robot since you are replacing hardware. You must slowly verify
all positional data and touch-up any paths or points that have changed.
Otherwise, you could injure personnel or damage equipment. 5. Replace the
motor, and remaster the robot.

SRVO-024 SERVO Move error excess(G:%d A:%d)

Cause: When the robot moved, the servo positional error exceeded a previously
specified value ($PARAM_GROUP.$MOVER_OFFST or
$PARAM_GROUP.$TRKERRLIM). For example, this error will occur if the
feedrate of the robot differs from that specified.

Remedy: 1. Check whether the applied load exceeds the rating. If so, reduce the
applied load. If an excessive load is applied, the torque required for acceleration,
deceleration, and so forth exceeds the maximum available torque of the motor.
Therefore, it prove impossible to respond to an issued command correctly,
causing this alarm to occur. 2. Check each interphase voltage of the three-phase
voltage (200 VAC) applied to the servo amplifier. If the voltage is found to be 170
VAC or below, check the input power supply voltage. A sub-standard voltage,
applied to a servo amplifier, results in a lower-than-normal torque. Therefore, it
might prove impossible to correctly respond to an issued command, thus
resulting in the output of this alarm. Check the phase-to-phase voltage across the
three pins of connector CRM38A of the servo amplifier. 3. If the input power
supply voltage is found to be 170 VAC or higher, replace the servo amplifier. 4.
Check the motor power cables (RM1, RM2, RM3) for damage, to cable or pins,
and that the connector is securely connected. WARNING: By completing the next
step you will be altering the positional reference for the robot since you are
replacing hardware. You must slowly verify all positional data and touch-up any
paths or points that have changed. Failure to perform this could result in injury to
personnel, damage to equipment, or lost data. 5. Replace the motor, and
remaster the robot.

SRVO-036 SERVO Inpos time over (G:%d A:%d)

Cause: The in-position monitor time ($PARAM_GROUP.$INPOS_TIME) has

elapsed, but the in-position state ($PARAM_GROUP.$STOPTOL) h=as not yet
been set.

Remedy: 1. Check whether the applied load exceeds the rating. If so, reduce the
applied load. If an excessive load is applied, the torque required for acceleration,
deceleration, and so forth exceeds the maximum available torque of the motor.
Therefore, it might prove impossible to correctly respond to an issued command,

28
resulting in the output of this alarm. 2. Check each interphase voltage of the
three-phase voltage (200 VAC) applied to the servo amplifier. If the voltage is
found to be 170 VAC or below, check the input power supply voltage. A sub-
standard voltage, applied to a servo amplifier, results in a lower-than-normal
torque. Therefore, it might prove impossible to correctly respond to an issued
command, thus resulting in the output of this alarm. Check phase-to-phase
voltage across the three pins of connector CRM38A of the servo amplifier. 3. If
the input power supply voltage is found to be 170 VAC or higher, replace the
servo amplifier. 4. Check the motor power cables (RM1, RM2, RM3) for damage,
to cable or pins, and that the connector is securely connected. WARNING: By
completing the next step you will be altering the positional reference for the robot
since you are replacing hardware. You must slowly verify all positional data and
touch-up any paths or points that have changed. Otherwise, you could injure
personnel or damage equipment. 5. Replace the motor, and remaster the robot.

1. *If SRVO-044, SRVO-045 or SRVO-046 are present, power down the

robot before proceeding with trouble shooting.

SRVO-044 SERVO HVAL alarm(Group:%d Axis:%d)

Cause: The DC voltage (DC link voltage) of the main circuit power supply is
abnormally high. The LED indicator of the servo amplifier PSM displays '7'.

Remedy: 1. Check the three-phase input voltage applied to the servo amplifier.
When the voltage is 253 VAC or higher, check the input power supply voltage. If
the motor is abruptly accelerated or decelerated while the three-phase input
voltage exceeds 253 VAC, this alarm might be issued. 2. Check whether the
applied load is within the rated value. If the rated load is exceeded, reduce the
applied load. If a load exceeds the rated value, built-up regenerative energy
might this alarm to be issued even when the three-phase input voltage satisfies
the specifications. 3. Check the cables (CN3 and CN4) in the amplifier. Replace
them if necessary. 4. Check the cable between the main CPU printed circuit
board (JRV1) and the printed circuit board for the emergency stop control (JRV1).
5. Replace the servo amplifier.

SRVO-045 SERVO HCAL alarm(Group:%d Axis:%d)

Cause: An excessively high current flowed through the main circuit of a servo
amplifier. The LED indicator on the servo amplifier PSM displays '-'. One of the
red LEDs (HC1 to HC6) above the 7-segment LED is lit, indicating the axis for
which the HCAL alarm is detected.

Remedy: 1. Relax operating conditions if cooling down clears this problem. 2.

Disconnect the motor power line from the terminal block of the servo amplifier,
then turn on the power. If this alarm is still issued, replace the servo amplifier. 3.

29
Remove the motor power line from the terminal block of the servo amplifier, then
check the insulation between U, V, and W of the motor power line and GND. If a
short circuit is found, check the motor, robot connection cable, or robot internal
cable. If any abnormality is found, replace the faulty hardware. 4. Remove the
motor power line from the terminal block of the servo amplifier, then check the
resistance between U and V, V and W, and W and U of the motor power line
using a measuring instrument capable of detecting very low resistances. If the
measured resistances differ from each other, check the motor, robot connection
cable, or robot internal cable. If any abnormality is found, replace the faulty
hardware. 5. Replace the servo amplifier. 6. If this does not clear the alarm, verify
that all connectors are securely connected.

SRVO-046 SERVO OVC alarm (Group:%d Axis:%d)

Cause: This alarm is issued to protect the motor when there is a danger of
thermal destruction when the root-mean-square current value, calculated
internally by the servo system, exceeds the maximum permissible value.

Remedy: 1. Check the operating conditions of the robot. If the robot's ratings,
such as the rated duty cycle and load, are exceeded, modify the use of the robot
such that the rated values are not exceeded. 2. Check each interphase voltage of
the three-phase voltage (200 VAC) applied to the servo amplifier connector
CRR38A, which is 3-phase, and connector CRR39, which is single-phase. If the
applied voltage is found to be 170 VAC or less, check the input power supply
voltage. 3. Replace the servo amplifier. 4. If this does not clear the alarm, verify
that all connectors are securely connected. 5. Replace the motor

SRVO-050 SERVO Collision Detect alarm (G:%d A:%d)

Cause: An excessively large disturbance torque is estimated by the servo

software. A collision was detected.

Remedy: 1. Check whether the robot has collided with an object. If so, reset the
system, then move the robot away from the location of the collision by jogging. 2.
Check that the applied load does not exceed the maximum rating. If the rated
load is exceeded, reduce the applied load. If the robot is used with an excessive
load applied, the estimated disturbance might become excessively large,
resulting in this alarm being output. 3. Check each interphase voltage of the
three-phase voltage (200 VAC) applied to the servo amplifier. If the applied
voltage is found to be 170 VAC or less, check the input power supply voltage. 4.
Replace the servo amplifier.

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SRVO-053 WARN Disturbance excess(G:%d A:%d)

Cause: Disturbance estimated in the software exceeded the threshold value.

There is a possibility that the load held in the wrist exceeded the robot
specification.

Remedy: If operation is allowed to continue, a detection error might result. On

the status screen containing the disturbance value, specify a new value for the
acceptable disturbance limit.

Safety Chain Faults

SRVO-230 SERVO Chain 1 (+24v) abnormal

Cause: A single chain 1 (+24V) failure occurred.

Remedy: Repair the circuit of the chain 1 (+24V) on the hardware. Set CHAIN
FAILURE detection to TRUE on the SYSTEM/CONFIG screen. Press RESET on
the teach pendant.

SRVO-231 SERVO Chain 2 (0v) abnormal

Cause: A single chain 2 (0V) failure occurred.

Remedy: Repair the circuit of the chain 2 (0V) on the hardware. Set CHAIN
FAILURE detection to TRUE on the SYSTEM/CONFIG screen. Push RESET on
the teach pendant.

Chain faults can also be reset at the alarm screen:

Press the MENU key.

Move the cursor to ALARMS and press ENTER.

Press F4 “RES_1CH”

Press the RESET key.

Battery Faults

SRVO-065 WARN BLAL alarm(Group:%d Axis:%d)

Cause: The battery voltage for the pulse coder has dropped below the allowable
minimum.

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Remedy: Replace the battery. When this alarm is issued, immediately replace
the battery while the system power is turned on. If the BZAL alarm is issued be
the battery is not replaced in time, positional data will be lost, thus making it
necessary to master the robot.

Refer to the battery replacement procedure on page 17 of this manual.

SRVO-062 SERVO BZAL alarm(Group:%d Axis:%d)

Cause: This alarm is issued when the battery for backing up the absolute
position data of the pulse coder is not connected. The battery cable inside the
robot might have become disconnected.

Remedy: Correct the of the alarm, then turn on power again after setting the
system variable $MCR.$SPC_RESET to TRUE. Master the robot.

Refer to the mastering and calibration procedure on page 18 of this manual.

If you have a different fault than what is listed in this manual, consult the Fanuc reference
manual for the robot type that you are working on.

If you are working on a robot that is equipped with the I-pendant you may look the fault
up on the I-pendant using the following procedure:

1. At the teach pendant press the “MENU” key.

2. Move the cursor the “ALARM” selection.
3. Press the “ENTER” key. The active alarm screen will be displayed.
4. Press the “F3” soft key. This key will be labeled “HIST” for alarm history.
5. In the alarm history display, move the cursor to highlight the alarm that you want
a description of.
6. Press and hold the “SHIFT” key.
7. Press the “DIAG” key.

After about 1 minute the display will change to a display showing the fault text for
the highlighted alarm that is in the Fanuc reference manual. This fault text will
contain the full description of the alarm and possible remedies for the fault.

32
 Appendix B
Procedures

KVT Robots

Naming Structure

Homing program : Autohome

Main Program: Main Process
Process Program: Varies, Look for part numbers names of clips and weld
numbers.

KVT MANUAL HOMING PROCEDURE

Procedure 1
*THIS PROCEDURE SHOULD ONLY BE PERFORMED IF
PRESSING THE RESET AND BASIC PUSH BUTTONS DOES
NOT WORK AND THE ROBOTS ARE STOPPED FOR A
MACHINE RELATED FAULT SUCH AS:
 EMERGENCY STOP
 MAINTENANCE STOP
 BROKEN LIGHT CURTIAN
 GATES OPEN

IF THE MACHINE IS STOPPED DUE TO A ROBOT CRASH PERFORM

PROCEDURE #2

*DO NOT MOVE THE ROBOT MANUALY

BEFORE PERFORMING THIS
PROCEDURE.
1. At the robot controller turn the AUTO/T1/T2 key switch to the T1 position.
(This key switch is an option and some robots are not equipped with it).
2. Pick up the teach pendant.
3. Turn the teach pendant ON/OFF key switch to the ON position.
4. Press the SELECT key. The program select screen will be displayed.

33
 5. Using the UP and DOWN arrow keys, move the cursor to highlight the program
called “AUTOHOME”. The program name (left column) will be
AUTOHOME; the program comment (right column) will be “Homing routine”.
6. Press the ENTER key.
7. Press and hold the DEAD MAN’S SWITCH.
8. Press the RESET key. It will take approximately 30 seconds for the faults to
clear and the servos to turn on.
9. Press and hold the SHIFT key.
10. Press and release the FWD key.

At this point the program should be running, the Running and Busy indicators
should be green and the program status line should say “RUNNING” and the
robot should be moving. ALWAYS WATCH THE ROBOT WHEN IT IS
MOVING. IF THE ROBOT LOOKS LIKE IT IS GOING TO HIT
SOMETHING, RELEASE THE SHIFT KEY, RELEASE THE DEAD
MAN’S SWITCH, PRESS THE HOLD KEY OR PRESS THE E-STOP TO
STOP THE ROBOT.
When the robot has finished its program, motion will stop, the running and busy
indicators will be off and the program status line will read “ABORTED”
Return the robot to its operational condition.

Procedure 2

*This procedure should only be performed if:

 Procedure 1 did not work.
 The robot crashed.
 You are extremely confident in what you are doing with the
robot.
 You have assessed any damage to the robot and the tooling and
no further damage will be caused by moving the robot.

1. At the robot controller turn the AUTO/T1/T2 key switch to the T1 position.
(This key switch is an option and some robots are not equipped with it).
2. Pick up the teach pendant.
3. Turn the teach pendant ON/OFF key switch to the ON position.
4. Press and hold the DEAD MAN’S SWITCH.
5. Reset any robot faults by pressing the teach pendant RESET key or the robot
controller RESET push button. If the fault does not clear, consult the Fanuc
reference manual for specific instructions on how to clear the fault.
*If the robot has a SRVO-046 SERVO 0VC (group: x axis: x) alarm, then power
down the robot to clear the fault. If the fault does not clear, call technical support
before proceeding.

34
6. Assess which direction is best to move the robot away from any obstacles or
obstructions.
7. Press and hold the SHIFT key.
8. Move the robot away from the obstruction. Only move the robot far enough to
clear the obstructions. Do not make unnecessary moves with the robot.
9. Perform procedure #1.

* IF THIS DOES NOT WORK, OR YOU

ARE NOT ABSOLUTELY SURE ABOUT
WHAT YOU ARE DOING, CALL FOR
ASSISTANCE! DO NOT RISK CAUSING
FURTHER DAMAGE TO THE ROBOT
OR TOOLING!

35
Blow Mold Robots

To verify that a blow mold robot program matches the product line:

1. At the teach pendant, press the “SELECT” key. A list of robot programs will
appear.
2. Using the “Up Arrow” and the “Down Arrow” keys, move the cursor to
highlight the program called RSR0002.
3. Press the “ENTER” key. The program will be displayed on the screen and will
look very similar to the program listed below.
4. Read the program to find the “SELECT” instruction. The select instruction
will look like the instruction on line 3 below. The R[number] is the data
register that compares the value for the blow mold product line. This value
must be entered manually.
5. Read the select instruction to find the product line that matches the blow mold
product line. Example: = 4, CALL TJ05LOAD. This means that data register
200 must equal 4 to make the robot run the proper program for the TJ05
product line.
6. Press the “DATA” key.
7. Press the “F1” key for “TYPE”
8. Using the “Up Arrow” and the “Down Arrow” keys, move the cursor to
highlight the “REGISTERS” selection.
9. Using the “Up Arrow” and the “Down Arrow” keys, move the cursor to the
register number that matches the register number for the select instruction.
10. Verify that the value set in the data register matches the value for the product
line that the blow mold is running. If the values do not match move the cursor
over the number and change the value by typing the desired number on the
numeric keypad and then pressing the “ENTER” key.
/PROG RSR0002
COMMENT = "RUN LOAD PROGS";
1: OVERRIDE=100%;
2:
3: SELECT R [200: PART SELECT] =0, CALL KJ03LOAD;
4: =1, CALL KJ04LOAD;
5: =2, CALL KJ05LOAD;
6: =4, CALL TJ05LOAD;
7: =5, CALL KJ34LOAD;
8: ABORT;
/END

PART SELECT DATA REGISTER BY BLOW MOLD

301 R[32]
302 R[200]
303 R[200]
304 R[200]
305 R[32]
306 R[200]

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 Ring Load Verification

Ring load verification will require movement of the press. If you are unfamiliar
with blow mold operations call a process technician.

To verify that a robot is properly loading rings into the blow mold:

1. Verify that the robot program matches the product line. (See above procedure)
2. If the press has been running production, empty the screws.
3. Shuttle the press to the appropriate clamp.
4. Ensure that the clamp is opened to the proper opening distance.
5. Extend the mold core.
6. Swivel the clamp under the head to within .2mm of the swivel set point (page 412
for A, page 414 for B).
7. Press the “SELECT” key.
8. Move the cursor to the proper ring pickup program for the product line that is
running. Example: KJ_GET.
9. Press the “ENTER” key. This will select the ring pickup program.
10. Press the “STEP” key until the green “STEP” led is on.
11. Turn the “ENABLE KEY” to the ON position.
12. Press and Hold the “DEADMAN SWITCH”.
13. Press the “RESET” key to clear any faults.
14. Press and hold the “SHIFT” key.
15. Press and release the “FWD” key. This action will run one line of the ring pickup
program. Repeat this step to the completion of the ring pickup program.
16. At the blow mold robot interface panel, turn the “RINGS” selector switch to the
“WITHOUT” position.
17. Press the “SELECT” key on the teach pendant.
18. Move the cursor to the proper program for the product line AND the clamp under
the head. EXAMPLE: KJ05LD_A
19. Press the “ENTER” key. This action will select the load program.
20. Press and hold the “SHIFT” key.
21. Press and release the “FWD” key. This action will run one line of the load pickup
program. Repeat this step to the completion of the load pickup program. If the
load program does not complete properly then the robot will have to be touched
up. If do not know how to do this or are not comfortable doing this then call for
assistance.
22. Return the robot to operational condition by turning the “TEACH PENDANT
ENABLE” key to the off position and reseting any faults.
23. Return the blow mold to operational condition or call a process technician for
assistance.

Procedure complete.

37
 Fanuc Robot Battery Replacement Procedure
Perform this procedure when the robot teach pendant is displaying a “SRVO-065
WARN BLAL ALARM” message.

* THIS PROCEDURE MUST BE PERFORMED WITH THE

POWER ON. REPLACING THE ROBOT BATTERIES WITH THE
POWER ON WILL RESULT IN THE LOSS OF POSITIONAL DATA.
THE ROBOT WILL HAVE TO BE REMASTERED.

1. Press the robot emergency stop button to prevent robot

movement.
2. Remove the black battery cover.

3. Remove the (4) four D cell batteries.

4. Insert (4) four NEW D cell batteries.
5. Replace the black battery cover.
6. Release the emergency stop button.
7. Return the machine to operational condition.
Robot Mastering and Calibrating

38
Mastering the robot is the act of establishing the mechanical zero position of the encoders.
Calibrating the robot is the act of assigning a software offset to the mechanical zero
position.

Mastering and calibrating will be necessary if the robot batteries are changed with the
robot power off or if the batteries deplete while the robot is powered off. If this happens,
there will be two specific alarms that will have to be cleared before the robot is mastered.
They are “SRVO-062 BZAL ALARM” and “SRVO-075 WARN PULSE NOT
ESTABLISHED”

To clear the SRVO-062 BZAL ALARM:

*IF THIS ALARM HAS OCCURRED BECAUSE THE ROBOT
BATTERIES HAVE DEPLETED DURING A POWER DOWN STATE,
THEN YOU MUST CHANGE THE ROBOT BATTERIES BEFORE
THE ALARM WILL CLEAR.
1. At the teach pendant, push the “MENU” key.
2. Move the cursor down to the “NEXT PAGE” option and press “ENTER” or press
“0”.
3. Move the cursor down to the “SYSTEM” option and press “ENTER”
4. Press the “F1” TYPE key.
5. Move the cursor down to the “MASTER / CAL” option and press “ENTER”
6. Press the “F3” RES_PCA key. “RES_PCA” stands for reset pulse coder alarm.
7. Answer “YES” to the Reset pulse coder alarm question by pressing the “F4” key.
8. Cycle power on the robot immediately. DO NOT PRESS RESET.

After the SRVO-62 Alarm is cleared, you will be able to move the robot.

 The robot that you are working on may be password protected. If a

password exists you will need to login to the robot and toggle the full menus
option.
 If the Master / Cal option is not visible:
1. In the system screen, press “F1” type.
2. Move the cursor down to the “Variables” option and press “ENTER”.
3. Move the cursor down to the $MASTER_ENB variable and set the value
to 1.
4. Press “ENTER”
5. Press “F1” type.
The Master / Cal option should now be visible.

To clear the SRVO-075 warning:

1. Press the “COORD” key until the robot is in the Joint coordinate system. (The
robot will not move in any other coordinate system)

39
 2. Move each axis a minimum of 15 degrees in both the positive and negative
direction.
3. Cycle power on the robot.
4. The robot is now ready to be mastered.
Zero Position Mastering Procedure

1. Align all robot axis to their respective mastering marks.

2. At the teach pendant, push the “MENU” key.

3. Move the cursor down to the “NEXT PAGE” option and press “ENTER” or press
“0”.

5. Move the cursor down to the “SYSTEM” option and press “ENTER”.

6. Press the “F1” TYPE key.

7. Move the cursor down to the “MASTER / CAL” option and press “ENTER”.

8. Select option “2” for zero position master.

9. Answer “Yes” to the “Master at zero position?” prompt by pressing the “F4” key.

The teach pendant screen will give a prompt that says “Robot Mastered!” and will list
the encoder values for each axis.

After the robot is mastered it still needs to be calibrated.

To calibrate the robot:

1. In the “MASTER / CAL” screen, select option “6” for calibrate.

2. Answer “Yes” to the “Calibrate?” prompt by pressing the “F4” key.

The robot is now mastered and calibrated.

* Use caution when restoring a robot to operational condition. Re-mastering may

alter positional values and the robot may need to be touched up.

40
 Single Axis Mastering

When only a single axis needs to be mastered or when all axes can not be moved to the
zero position at the same time.

Single Axis Mastering Procedure

1. At the teach pendant, push the “MENU” key.

2. Move the cursor down to the “NEXT PAGE” option and press “ENTER” or press
“0”.

3. Move the cursor down to the “SYSTEM” option and press “ENTER”.

4. Press the “F1” TYPE key.

5. Move the cursor down to the “MASTER / CAL” option and press “ENTER”.

6. Select option “4” for single axis master. You will see a screen similar to the
following screen:

7. Move the cursor to the MSTR POS column for the unmastered axis
and press the “0” key.

8. Continuously press and hold the DEADMAN switch and turn the
teach pendant ON/OFF switch to ON.

9. Move the cursor to the SEL column for the unmastered axis and press
the numeric key “1.”

10. Press ENTER.

11. Press F5, EXEC. Mastering will be performed automatically.

41
12. Press PREV.

13. Select Calibrate.

14. Press F4, YES.

42