Software Instalation R-J2

FANUC Robotics
SYSTEM R-J2 Controller

HandlingTool Software
Installation Manual
Version 4.31-1
MARF2HD4307701E
This publication contains proprietary information of FANUC Robotics
North America, Inc. furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics
North America, Inc.
FANUC Robotics North America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
The descriptions and specifications contained in this manual were in effect

at the time this manual was approved for printing. FANUC Robotics
North America, Inc, hereinafter referred to as FANUC Robotics, reserves
the right to discontinue models at any time or to change specifications or
design without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,
schematics, bills of material, parts, connections and/or procedures for
installing, disassembling, connecting, operating and programming FANUC
Robotics products and/or systems. Such systems consist of robots,
extended axes, robot controllers, application software, the KARELR
programming language, INSIGHTR vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in
one or more approved FANUC Robotics Training Course(s) be permitted
to install, operate, use, perform procedures on, repair, and/or maintain
FANUC Robotics products and/or systems and their respective
components. Approved training necessitates that the courses selected be
relevant to the type of system installed and application performed at the
customer site.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
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 such
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 whatever
measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a
regularly scheduled basis at the companys world headquarters in
Rochester Hills, Michigan. For additional information contact
FANUC Robotics North America, Inc.
Training and Documentation Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
Tel: (248)377-7234
FAX: (248)377-7367 or (248)377-7362
Copyright E1997 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 part
in any way without the prior written consent of FANUC Robotics North
America, Inc.
AccuStatR, ArcToolR, DispenseToolR, FANUC LASER DRILLR,
KARELR, INSIGHTR, INSIGHT IIR, PaintToolR, PaintWorksR,
PalletToolR, SOCKETSR, SOFT PARTSR SpotToolR,
TorchMateR, and YagToolR 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:
AccuFlowT
ARC MateT
ARC Mate Sr.T
IntelliTrakT
LaserToolT
MotionPartsT
PaintWorks IIT
PalletMateT
SureWeldT
TurboMoveT
MARF2HD4307701E
Purpose of this Manual
Preface
vii
This manual describes FANUC Robotics SYSTEM R-J2 Software

Installation:
D Package contents
D Requirements
D Procedures
D Troubleshooting and error recovery
Required Manuals
You must have access to these manuals to use all the information in this
manual effectively.
Related Manuals
The entire manual set for this product includes manuals you can use when
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 areas
of the robot, controller, and application system.
How to Use this

Manual
Use this table to locate specific information in the manual.

If you want to
Refer to
Find information about a specific topic
Table of Contents
Determine the installation requirements for

your application
Chapter 1, Overview
Set up and check memory requirements
Chapter 2, Setting Up
Controller Memory
Check and install EPROM chips
Chapter 3, EPROM
Installation
Install core, application, robot library, motion

groups and extended axis software
Chapter 4, Software
Installation
Master the robot
Chapter 5, Mastering
Perform troubleshooting and error recovery
Chapter 6, Troubleshooting
and Error Messages
Use BootROM
Appendix A, BootROM
Operations
Identify robot configuration information before

you begin loading the software.
Appendix B, Configuration
Tables
Back up or load teach pendant programs or

system files.
Appendix C, Backing Up and

Restoring Files
Copy software to a PC or memory card.
Appendix D, Copying
Software to a PC or memory
card
Determine the version of software on your

controller.
Appendix E, Displaying
Version Information
viii
Conventions Used in
this Manual
PREFACE
MARF2HD4307701E
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.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set
it apart from other text.
CAUTION
Information appearing under CAUTION concerns the protection
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.
MARF2HD4307701E
Safety
xv
FANUC Robotics is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your company
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 in
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 professionals
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 system
to recognize and respond to known hazards associated with your robotic
system and to be aware of the recommended operating procedures for your
particular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be trained in
an approved FANUC Robotics training course and become familiar with
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 recommended
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of
safety in the workplace.
xvi
SAFETY
MARF2HD4307701E
CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION
Safety is essential whenever robots are used. Keep in mind the following
factors with regard to safety:
D The safety of people and equipment
D Use of safety enhancing devices
D Techniques for safe teaching and manual operation of the robot(s)
D Techniques for safe automatic operation of the robot(s)
D Regular scheduled inspection of the robot and workcell
D Proper maintenance of the robot
Keeping People and

Equipment Safe
The safety of people is always of primary importance in any

situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider
D People
D External devices
D Robot(s)
D Tooling
D Workpiece
Using Safety
Enhancing Devices
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:
D Safety fences, barriers, or chains
D Light curtains
D Interlocks
D Pressure mats
D Floor markings
D Warning lights
D Mechanical stops
D EMERGENCY STOP buttons
D DEADMAN switches
Setting Up a Safe
Workcell
A safe workcell is essential to protect people and equipment. Observe the

following guidelines to ensure that the workcell is set up safely. These
suggestions are intended to supplement and not replace existing federal,
state, and local laws, regulations, and guidelines that pertain to safety.
D
Sponsor your personnel for training in approved FANUC Robotics

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 prevent

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

measures.
Arrange the workcell so the operator faces the workcell and can see
what is going on inside the cell.
MARF2HD4307701E
SAFETY
xvii
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 or

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

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

entry by personnel into the work envelope.
Install special guarding that prevents the operator from reaching into
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 be

optionally installed between the robot wrist flange and tooling. If the
tooling strikes an object, these devices dislodge, remove power from
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 frequency
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 could
get trapped between a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to teach

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 appropriate

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

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

Teaching or Manually
Operating the Robot
SAFETY
MARF2HD4307701E
Advise all personnel who must teach the robot or otherwise manually
operate the robot to observe the following rules:
D
Know whether or not you are using an intrinsically safe teach pendant
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 extends
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 of

a robot that is on. However, if you must enter the work envelope, be
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 work
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 motion
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 program
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 continuously

for at least one full cycle.
Make sure all personnel are outside the work envelope before running
production.
MARF2HD4307701E
Staying Safe During

Production Operation
Staying Safe During

Inspection
SAFETY
xix
Advise all personnel who operate the robot during production to observe
the following rules:
D
Know the entire workcell area. The workcell includes the robot and its
work envelope, plus the area occupied by all external devices and
other equipment with which the robot interacts.
Understand the complete task the robot is programmed to perform

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 the
robot control and external control devices. Be prepared to press these
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 to
continue activity.
If the robot is running in a pattern, do not assume it will continue to

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 an
EMERGENCY STOP button located on the controller panel, teach
pendant, or emergency stop stations around the workcell.
When inspecting the robot, be sure to

D
Turn off power at the controller.
Lock out and tag out the power source at the controller according to
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, be

prepared to press the EMERGENCY STOP button, in an emergency.
xx
Staying Safe During

Maintenance
SAFETY
MARF2HD4307701E
When performing maintenance on your robot system, observe the

following rules:
D
Never enter the work envelope while the robot or a program is in

operation.
Before entering the work envelope, visually inspect the workcell to

make sure no potentially hazardous conditions exist.
Consider all or any overlapping work envelopes of adjoining robots

when standing in a work envelope.
Test the teach pendant for proper operation before entering the work
envelope.
If it is necessary for you to enter the robot work envelope while power
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 DEADMAN
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 IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
Turning the disconnect or circuit breaker to the OFF
position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.
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 work
envelope has sole control of the robot. The teach pendant must be
held by this person.
Make sure personnel cannot get trapped between the moving robot and
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 hazardous

movement by the robot. Make sure that such devices do not create
pinch points that could trap personnel.
MARF2HD4307701E
SAFETY
xxi
WARNING
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result
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 do

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 operating
normally.
KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE
Certain programming and mechanical measures are useful in keeping the

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

to machine tools and other external devices.
Mechanical Safety
Precautions
Back-check limit switches in the workcell to make sure they do not

fail.
Implement failure routines in programs that will provide appropriate

robot actions if an external device or another robot in the workcell
fails.
Use handshaking protocol to synchronize robot and external device

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

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

prevent undesired movement of the robot into the work area of
machine tools and external devices.
xxii
SAFETY
MARF2HD4307701E
KEEPING THE
ROBOT SAFE
Observe the following operating and programming guidelines to prevent

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

during operation.
Programming Safety
Precautions
Use a low override speed to increase your control over the robot when
jogging the robot.
Visualize the movement the robot will make before you press the jog
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.
The following safety measures are designed to prevent damage to the robot
during programming:
D
Establish interference zones to prevent collisions when two or more

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

tooling resulting in personal injury or equipment damage.
NOTE Any deviation from the methods and safety practices described in
this manual must conform to the approved standards of your company. If
you have questions, see your supervisor.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch
is released on a bypassed robot.
WARNING
Observe all safety rules and guidelines to avoid injury.
MARF2HD4307701E
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix
vii
xv
Chapter 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.1 INSTALLATION TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 PACKAGE CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1 Software Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2 System EPROM Chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Storage and Load Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Controller Hardware Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1--2
1--2
1--3
1--4
1--4
1--5
1--7
Chapter 2
SETTING UP CONTROLLER MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--1
2.1 IDENTIFYING KINDS OF MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Controller Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Flash ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.3 C-MOS RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.4 D-RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 CHECKING CONTROLLER MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 INSTALLING FLASH ROM, C-MOS RAM AND D-RAM CHIPS . . . . . . . . . . . . . . . . . . . .
2--2
2--2
2--2
2--3
2--3
2--4
2--5
Chapter 3
EPROM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--1
3.1 INSTALLING BOOTROM EPROM CHIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 INSTALLING TEACH PENDANT EPROM CHIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3--2
3--9
Chapter 4
SOFTWARE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--1
4.1 SOFTWARE INSTALLATION THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 SETTING UP LOAD DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Using a PS-100 Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Using a Memory Card Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Using KFLOPPY PS-100 Floppy Disk Drive Emulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 INSTALLING HANDLINGTOOL APPLICATION SOFTWARE . . . . . . . . . . . . . . . . . . . . . .
4.4 INSTALLING HANDLINGTOOL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 QUICK/FULL PASSWORD SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 MODIFYING AND INSTALLING ADDITIONAL EXTENDED AXES . . . . . . . . . . . . . . . . .
4.7 INSTALLING MOTION GROUP SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 INSTALLING SOFTWARE UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--2
4--5
4--5
4--8
4--16
4--17
4--26
4--35
4--38
4--53
4--67
TABLE OF CONTENTS
MARF2HD4307701E
Chapter 5
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5.1 RESETTING ALARMS AND PREPARING FOR MASTERING . . . . . . . . . . . . . . . . . . . . . .

5.2 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER) . . . . . . . . . . . . . . . . . . . . .
5.3 ZERO DEGREE MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 SINGLE AXIS MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 QUICK MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--3
5--6
5--8
5--10
5--13
Chapter 6
TROUBLESHOOTING AND ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--1
6.1 TROUBLESHOOTING USING SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 TROUBLESHOOTING USING ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 CHECKING MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--2
6--4
6--5
Appendix A
BOOTROM OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--1
A.1 STARTUP METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1.1 INIT Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1.2 Controlled Start (START CTRL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1.3 Controlled 2 Start (START CTRL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1.4 Cold Start (START COLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1.5 Semi Hot Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1.6 Re-Init Start (CMOSINIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 BOOTROM UTILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.1 Extended Boot Monitor (EMON>) Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.2 Diagnostic Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.3 INSTALL Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.4 Flash ROM Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.5 Memory Card Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--2
A--2
A--3
A--7
A--9
A--11
A--12
A--14
A--17
A--18
A--20
A--23
A--24
Appendix B
CONFIGURATION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--1
TABLE OF CONTENTS
MARF2HD4307701E
xi
Appendix C
BACKING UP AND RESTORING FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C--1
C.1 SETTING THE DEFAULT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.2 BACKING UP FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.3 LOADING OR RESTORING FILES FROM DISK TO CONTROLLER MEMORY . . . . . . .
C.4 CONTROLLER BACKUP AND RESTORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.4.1 Backing up a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.4.2 Restoring a Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C--2
C--4
C--8
C--14
C--14
C--20
Appendix D
COPYING SOFTWARE TO A PC OR MEMORY CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D--1
D.1 COPYING HANDLINGTOOL SOFTWARE TO A PERSONAL COMPUTER . . . . . . . . . . .

D.2 COPYING HANDLINGTOOL SOFTWARE TO MEMORY CARD . . . . . . . . . . . . . . . . . . .
D--2
D--3
Appendix E
DISPLAYING VERSION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E--1
Index-1
List of Procedures
Procedure 2--1
Procedure 2--2
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 4--9
Procedure 4--10
Procedure 5--1
Procedure 5--2
Procedure 5--3
Procedure 5--4
Procedure 5--5
Procedure 5--6
Verifying Controller Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing a Flash ROM, C-MOS RAM or D-RAM Module . . . . . . . . . . . . . . . . .
Checking the BootROM Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing New BootROM EPROM Chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Teach Pendant EPROM Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing A New Teach Pendant EPROM Chip . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting a PS-100 Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Memory Card Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using KFLOPPY to Install Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing HandlingTool Software and Firmware . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customizing the Menu Display using Quick/Full Password . . . . . . . . . . . . . . . . .
Modifying Extended Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Extended Axis Setting Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Motion Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Software Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing the Robot for Mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering to a Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering to Zero Degrees (for all robots except S-420iR) . . . . . . . . . . . . . . . . . .
Mastering a Single Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording the Quick Master Reference Position . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Mastering the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--4
2--5
3--2
3--3
3--9
3--10
4--7
4--10
4--16
4--17
4--27
4--35
4--38
4--40
4--53
4--67
5--3
5--6
5--8
5--10
5--14
5--16
TABLE OF CONTENTS
xii
MARF2HD4307701E
Procedure 6--1 Displaying Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure A--1 Performing a Controlled Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--2 Performing a CTRL2 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--3 Performing a Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--4 Performing a Semi Hot Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--5 Performing a Re-Init Start using CMOSINIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--6 Using BootROM Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--7 Using EMON> Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--8 Using DIAG> Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--9 Using INSTALL Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--10 Using FROM Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure A--11 Using MCARD Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure C--1 Setting the Default Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure C--2 Backing Up System Files, Teach Pendant Programs, and
Application Files to Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure C--3 Loading Selected Files Using the FILE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure C--4 Restoring BACKUP Files Using the FILE Menu . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure C--5 Backing up a Controller to a Floppy or Memory Card Device . . . . . . . . . . . . . . .
Procedure C--6 Restoring a Controller after a Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure D--1 Copying HandlingTool Software to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure D--2 Copying HandlingTool Software to Memory Card . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure E--1 Displaying the Software Version and Installed Option List During a
CONTROLLED START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--5
A--5
A--7
A--9
A--11
A--12
A--16
A--17
A--19
A--22
A--23
A--24
C--2
C--5
C--10
C--12
C--15
C--20
D--2
D--3
E--1
List of Figures
Figure 1--1.
Figure 1--2.
Figure 1--3.
Figure 1--4.
Figure 1--5.
Figure 1--6.
Figure 2--1.
Figure 2--2.
Figure 2--3.
Figure 2--4.
Figure 2--5.
Figure 2--6.
Figure 3--1.
Figure 3--2.
Figure 3--3.
Figure 3--4.
Figure 3--5.
Figure 3--6.
Figure 3--7.
Disk Label Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PS-100 Connected to the i-size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PS-100 Connected to the B-size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory Card Interface and Memory Card Connected to the i-size Controller . . . . . .
Memory Card Interface and Memory Card Connected to the B-size Controller . . . . .
R-J2 Controller Disconnect Handle and Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN CPU Board Location in the i-size Controller . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN CPU Board Location in the B-size Controller . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the MAIN CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main CPU PC board module locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Flash ROM, C-MOS RAM or D-RAM Module . . . . . . . . . . . . . . . . . .
R-J2 Controller Disconnect Handle and Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN CPU Board Location in the i-size Controller . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN CPU Board Location in the B-size Controller . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the MAIN CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main CPU PC Board Module Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locating the BootROM Chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Back Cover of the Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1--4
1--5
1--5
1--6
1--7
2--6
2--6
2--7
2--8
2--9
2--10
3--4
3--5
3--5
3--6
3--7
3--8
3--11
MARF2HD4307701E
TABLE OF CONTENTS
Figure 3--8. Locating the Teach Pendant EPROM Chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3--9. EPROM Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--1. PS-100 Connected to an i-size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--2. PS-100 Disk Drive Connected to the B-size Controller . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--3. Memory Card Interface and Memory Card Connected to the i-size Controller . . . . . .
Figure 4--4. Memory Card Interface and Memory Card Connected to the B-Size Controller . . . . .
Figure 4--5. R-J2 Controller Disconnect Handle and Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--6. Memory Card Interface Location on an i-size Controller . . . . . . . . . . . . . . . . . . . . . . .
Figure 4--7. Memory Card Interface Location on a B-Size Controller . . . . . . . . . . . . . . . . . . . . . .
Figure 4--8. Inserting a Memory Card with the ER-2 Printed Circuit Board . . . . . . . . . . . . . . . . . .
Figure 4--9. Inserting a Memory Card without an ER-2 Printed Circuit Board . . . . . . . . . . . . . . . .
Figure 4--10. R-J2 Controller Disconnect Handle and Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xiii
3--11
3--12
4--5
4--6
4--8
4--9
4--11
4--11
4--12
4--13
4--14
4--18
List of Tables
Table
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Table
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Table
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2--1. Minimum Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4--1. Robot Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--2. Option Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--3. Completing the Option Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--4. SVU Servo Amplifier Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--5. C-Series Servo Amplifier Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4--6. Typical Robot Model Servo Amplifier Configurations . . . . . . . . . . . . . . . . . . . . . . . .
6--1. Troubleshooting Symptoms and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--2. Software Option Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6--3. Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--1. Controlled Start Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--2. BootROM Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--3. BootROM Extended Monitor Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--4. BootROM Diagnostic Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--5. INSTALL Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--6. Flash ROM Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--7. Memory Card Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--1. A-520i Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--2. M-6i Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--3. M-16i Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--4. M-16iL/ARCMATE-120iL Robot Configuration Information . . . . . . . . . . . . . . . . .
B--5. M-400 Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--6. M-410i Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--7. M-410iW Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--8. M-410iWx Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--9. M-500 Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B--10. M-710i and M-710iW Robot Configuration Information . . . . . . . . . . . . . . . . . . . .
B--11. S-6 Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--4
4--22
4--26
4--32
4--43
4--43
4--48
6--2
6--4
6--5
A--3
A--14
A--17
A--18
A--20
A--23
A--24
B--2
B--2
B--3
B--4
B--4
B--5
B--5
B--6
B--7
B--7
B--8
TABLE OF CONTENTS
xiv
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
Table
B--12.
B--13.
B--14.
B--15.
B--16.
B--17.
B--18.
B--19.
B--20.
B--21.
B--22.
B--23.
MARF2HD4307701E
S-12 Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S-420iF Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iL Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iR Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iS Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iW Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-450 Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Offset Wrist S-700 Robot Configuration Information . . . . . . . . . . . . . . . . . . . . . . .
B--9
B--9
B--10
B--10
B--11
B--11
B--12
B--12
B--12
B--13
B--14
B--14
MARF2HD4307701E
OVERVIEW
1--1
Topics In This Chapter
Page
Installation Tasks
This section lists the tasks you need to perform to install your software.
1--1
Package Contents
The R-J2 software installation package consists of.

D Software disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
D Erasable Programmable Read-Only Memory (EPROM) chips . . . . . . . . . . . 1--3
D This manual
Installation Requirements
In order to install a new SYSTEM R-J2 Application Software Package,

you need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D A teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D A storage/load device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D Controller hardware tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--4
1--4
1--5
1--7
This chapter describes the SYSTEM R-J2 Software Installation Package.

This manual includes information on
D What you must do to set up and install the components of this
package in your system
D What you have in your SYSTEM R-J2 Software Installation Package
D What you need to set up and install the components of this package
1.1
INSTALLATION TASKS
Verify controller
memory. Adjust if
necessary
See Chapter 2
Are you
replacing,
upgrading or
updating
controller
software?
The first time you install your SYSTEM R-J2 software, and whenever you
update your controller with components in this package, you must do the
following:
NO Verify EPROM chips

and install if
necessary
See Chapter 3
Fill out
configuration
tables
Install all software

for your system
Master the robot
See Appendix B
See Chapter 4
See Chapter 5
YES
Back up all
system files
See Appendix C
Troubleshoot
See Chapter 6
You must satisfy controller memory and EPROM

requirements before you can install the SYSTEM
R-J2 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
MARF2HD4307701E
1--2
1.2
PACKAGE CONTENTS
The SYSTEM R-J2 controller design utilizes a features-based design. A

feature is a high-level building block which uses SOCKETS and SOFT
PARTS in the application software structure. An application is constructed
from standard features and can be enhanced using optional features.
The R-J2 software installation package consists of
D Software disks
D Erasable Programmable Read-Only Memory (EPROM) chips
1.2.1
Software Disks
Your R-J2 software installation package contains the disk set that can be
used for your robot.
The software package delivered to you is delivered under
the terms and conditions of the FANUC Robotics North
America, INC. Software License Agreement (SLA). A
copy of the SLA was previously delivered to you. Your use
of this software constitutes your consent to the applicability
of the terms and conditions of the SLA to such use.
Your disk set consists of the following kinds of disks:

D Application
D Robot Library
D Options
Your package can also contain Updates
Figure 1--1. Disk Label Example
Disk Type
Product Name
APx
R-J2 DISK # OF #
ProductTool Name
4.3x-x
Controller and Disk

Number
Product Version
FANUC Robotics N.A., Inc.

Copyright(C) 199x
Part Number
SFTxxxxxxxxxxxx
Serial # 000000
Software Serial
Number
1. OVERVIEW
1--3
MARF2HD4307701E
A disk label contains the following information:

Disk Type identifies when the disk is used in the installation process.
Controller and Disk Number identify on which controller this disk can
be used (R-J2, for example), and the number of the disk in a series of
disks.
Product Name is the name of the product stored on the disk.
Product Version is the released version number of the software product.
Part Number is the part number of the disk.
Software Serial Number identifies the serial number of the software,
which is normally the same as the R-J2 controller F number.
NOTE Software part numbers and actual disk information is included in
an ASCII file called readme.txt and is stored on the AP1 disk.
1.2.2
System EPROM Chips
The following system EPROM chips are already installed on your

controller:
D Bootstrap ROM (BootROM) EPROM Chip -- One EPROM chip
that is installed on the MAIN CPU board inside the controller.
D Teach Pendant EPROM Chip -- One EPROM chip that is installed
on the teach pendant PCB inside the teach pendant.
You must check the version of EPROM chip in your controller to be sure
that it is compatible with the version of software you are loading. Refer to
Chapter 3 for information on checking EPROM chips.
1. OVERVIEW
1--4
1.3
INSTALLATION
REQUIREMENTS
1.3.1
Teach Pendant
MARF2HD4307701E
In order to install a new SYSTEM R-J2 Application Software Package,

you need
D
D
D
A teach pendant
A storage/load device
Controller hardware tools
The FANUC Robotics teach pendant is an operator interface device that

displays the SYSTEM R-J2 software. The teach pendant 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.
The teach pendant is the device you use to load software.
The teach pendant provides
D
A 16 line x 40 character teach pendant screen
Eleven status indicators including three indicators dedicated to the

SYSTEM R-J2 software application.
Teach pendant keys, including keys specific to the SYSTEM R-J2

software application.
Figure 1--2 shows the standard teach pendant.

Figure 1--2. Standard Teach Pendant
Indicators
ON/OFF
Switch
Screen
EMERGENCY
STOP
BUTTON
1. OVERVIEW
1--5
MARF2HD4307701E
1.3.2
Storage and Load
Devices
PS-100 Disk Drive
To perform a software installation, you must have one of the following

devices available:
D FANUC Robotics PS-100 disk drive unit
D Memory card interface
D PC emulator
The FANUC Robotics PS-100 disk drive, shown in Figure 1--4, is used
with 720 KB double-density, 3 inch disks. The PS-100 connects to the
P2 port (FLPY:). The P2 port is an RS-232-C interface. Refer to
Section 4.2.1 for more information.
Figure 1--3. PS-100 Connected to the i-size Controller
Operator box
(option)
Teach
pendant
R-J2
Controller
PS-100
Disk
Drive
Figure 1--4. PS-100 Connected to the B-size Controller
Teach
pendant
R-J2
Controller
PS-100
Disk Drive
PS-100
Disk
Drive
1. OVERVIEW
1--6
MARF2HD4307701E
NOTE Loading from a memory card is not available as a standard

product.
Refer to Section 4.2.2 for more information.
CAUTION
Be sure to insert the memory card into the interface as shown
in Figure 1--5. Otherwise, you could damage the memory card
or the memory card interface.
Figure 1--5. Memory Card Interface and Memory Card Connected to the i-size
Controller
Memory Card
Power Supply Unit
1. OVERVIEW
1--7
MARF2HD4307701E
Figure 1--6. Memory Card Interface and Memory Card Connected to the B-size
Controller
Power Supply Unit

Memory Card
KFLOPPY Disk Drive

Emulator
You can use the KFLOPPY disk drive emulator to install software by
loading all the files from each FANUC Robotics-supplied disk to your PC.
Refer to Section 4.2.3 for more information.
1.3.3
To perform the EPROM installation, you must have a

D Flat-tip screwdriver to open the controller door.
D Cross-tip screwdriver to remove the teach pendant cover.
D Dual-inline-pin (DIP) chip removal tool and installation tool to
remove and install EPROM chips.
D Anti-static pad with wrist strap to prevent static damage to the
EPROM chips.
Controller Hardware
Tools
MARF2HD4307701E
SETTING UP CONTROLLER MEMORY
2--1
Page
Identifying Kinds of
Memory
The following kinds of memory exist in the controller: . . . . . . . . . . . . . . . . . . . . . . .

D Controller Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D Flash ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D C-MOS RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D D-RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2--2
2--2
2--2
2--3
2--3
Checking Controller
Memory
Checking controller memory allows you to determine the amount of

Flash ROM, D-RAM and C-MOS RAM memory available in your system. . . . . . 2--4
Installing FLASH ROM,

C-MOS RAM and D-RAM
Chips
Flash ROM, C-MOS RAM and D-RAM EPROM chips are installed on
the MAIN CPU board inside the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--5
2. SETTING UP CONTROLLER MEMORY
2--2
2.1
IDENTIFYING KINDS
OF MEMORY
MARF2HD4307701E
The following kinds of memory exist in the controller:

D Controller memory
D Flash ROM (F-ROM or FROM)
D C-MOS RAM
D D-RAM (or DRAM)
To set up controller memory you must
D
D
2.1.1
Controller Memory
2.1.2
Flash ROM
Check system memory allocation to be sure you have enough to load

software (Section 2.2).
Install the D-RAM, C-MOS RAM and Flash ROM modules on the
main CPU board inside the controller (Section 2.3).
Controller memory consists of Flash Read Only Memory (Flash ROM),

Complementary Metal Oxide Semiconductor Random Access Memory
(C-MOS RAM), and Dynamic Random Access Memory (D-RAM).
C-MOS RAM memory stores some robot system software, some
application software, and some user programs. Flash ROM stores the
majority of the robot system software such as core, and application
software.
Most of the SYSTEM R-J2 system software executes from D-RAM.
When the controller is turned on, the system software is loaded from Flash
ROM to D-RAM and then is executed. Teach pendant programs are stored
and are executed from C-MOS RAM.
Flash ROM (F-ROM or FROM disk) is not battery-backed but is

non-volatile. Non-volatile means that all data in Flash ROM is saved even
after you turn off and turn on the controller. Flash ROM has three parts: a
system memory section, an image memory section, and a flash file section.
The system memory section contains the software that executes all system
software. Image memory contains software options. The flash file system
section contains space for backing up user programs and robot
configuration information. It also holds hidden files required for Re-INIT
start (CMOSINIT).
2--3
MARF2HD4307701E
2.1.3
C-MOS RAM
C-MOS RAM is battery-backed. C-MOS RAM is non-volatile only while

the batteries are working. If the batteries are faulty or removed, C-MOS
RAM is lost. C-MOS RAM has two parts: the TPP memory pool, and the
permanent (PERM) memory pool.
D
D
2.1.4
D-RAM
The TPP memory pool contains the teach pendant programs. The
PERM memory pool contains system variables.
PERM can also contain system software and options.
D-RAM is volatile, but it is loaded from Flash ROM when the controller is
turned on. D-RAM also has three parts: a SYSTEM memory pool, an
IMAGE memory pool, and a TEMP memory pool. The SYSTEM
memory pool contains the software that executes all system software. The
IMAGE memory pool contains all HandlingTool programs and software
options. The TEMP memory pool contains the read/write scratch space for
the system.
CAUTION
Data in C-MOS RAM can be lost if the battery is removed or
loses its charge, or if new core software is loaded on the
controller. The C-MOS RAM memory will last for 30 minutes
without the battery when power is off. To prevent loss of data,
back up or copy all files for permanent storage.
CAUTION
To transport or store the contents of the MAIN CPU, you can
plug the battery into the VBAT connector in the MAIN CPU.
However, do not plug it into the RESET connector; otherwise
you could damage equipment.
2--4
MARF2HD4307701E
2.2
Checking controller memory allows you to determine the amount of Flash

ROM, D-RAM and C-MOS RAM memory available in your system. Use
Procedure 2--1 to verify the amount of controller memory you have.
CHECKING
CONTROLLER
MEMORY
Procedure 2--1
Condition
Step
Verifying Controller Memory

H
The controller is turned off.
1 Press and hold the PREV and NEXT keys on the teach pendant, then
press the ON button.
The boot monitor prompt, BMON>, is displayed. You will see a
screen similar to the following.
*** BOOT MONITOR
Version 4.22P
F-ROM/D-RAM/C-MOS
TP Version
Current TIME
Slot
0
1
D
ID
9B
6A
6A
BMON>
COLD
CTRL
for R-J2 CONTROLLER ***

01-JAN-199x
:
8.0/8.0/1.0 MB
:
I
:
01-JAN-199x 22:52:53
FC
0
0
0
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
NOLOAD
INIT
START
Available
Controller
Memory
Optional
Optional
>
CAUTION
The minimum controller memory configuration required to
install HandlingTool software is shown in Table 2--1. If your
controller has less than this requirement of F-ROM, D-RAM,
and C-MOS RAM, you must contact your FANUC Robotics
representative for information on increasing the memory in your
controller.
Table 2--1.
Minimum Requirements
Memory Device
Flash ROM
Minimum Amount of
Memory Required
4.0 MB
D-RAM
4.0 MB
C-MOS RAM
0.5 MB
2--5
MARF2HD4307701E
2.3
INSTALLING FLASH
ROM, C-MOS RAM
AND D-RAM CHIPS
Procedure 2--2
Condition
A maximum of 1 (one) Flash ROM module can be used in the R-J2

controller. A maximum of 1 (one) C-MOS RAM module can be used in
the R-J2 controller. A maximum of 1 (one) D-RAM module can be used
in the R-J2 controller. Flash ROM, C-MOS RAM and D-RAM are
installed on the MAIN CPU board inside the controller. Use
Procedure 2--2 to remove or add a Flash ROM, C-MOS RAM or D-RAM
module.
Installing a Flash ROM, C-MOS RAM or D-RAM Module
H

WARNING
Disconnect electrical power from the controller before you
remove or replace components, or you could be injured
seriously.
CAUTION
Use anti-static devices and observe anti-static safety
precautions when handling any electronic material, otherwise
you could damage the equipment.
H
Step
You are wearing a wrist strap to prevent static discharge to the C-MOS
circuits.
1 Disconnect electrical power from the controller.

D
If your controller is equipped with a disconnect handle at the upper

right front corner, pull it to the OFF (down) position.
OR
D If your controller is equipped with a circuit breaker handle, turn
the handle to the OFF (open) position.
See Figure 2--1.
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 remove
all power from the controller.

MARF2HD4307701E
2--6
2 Open the front door of the controller using a flat-tip screwdriver to

turn the latch. See Figure 2--1.
Figure 2--1. R-J2 Controller Disconnect Handle and Latch
Circuit breaker
i-size controller
Locked
ON
OFF
ON
Unlocked
OFF
Circuit breaker
B-Size controller
3 Locate the MAIN CPU board inside the controller. See Figure 2--2
and Figure 2--3.
Figure 2--2. MAIN CPU Board Location in the i-size Controller
2--7
MARF2HD4307701E
Figure 2--3. MAIN CPU Board Location in the B-size Controller
4 Disconnect the cables from the MAIN CPU board.

5 Press and hold both latches of the MAIN CPU board and remove the
board from the backplane. See Figure 2--4.

MARF2HD4307701E
2--8
Figure 2--4. Removing the MAIN CPU Board
6 Install the Flash ROM, C-MOS RAM or D-RAM modules on the

MAIN CPU board in the appropriate memory slots. See Figure 2--5
and Figure 2--6.
2--9
MARF2HD4307701E
Figure 2--5. Main CPU PC board module locations
LED display
Axis module (J5, J6)
DRAM module
SRAM module
Bat
VBAT
JRV1 & JRV2

Connections
BootROM
Flash ROM module
Line
JF21
Ex-op
JM10
I/O - LK
(master)
JD1A
RS232/485
JD17
PDI/O
JRM3
CAUTION
This is RESET.
Connecting the battery
here can damage the CPU.
CRM10 & CR51

MARF2HD4307701E
2--10
Figure 2--6. Installing the Flash ROM, C-MOS RAM or D-RAM Module
Pin 1
Step a
Fit the recess on

the module over
the tab in the
module socket.
CAUTION:
It is possible to
force the module in
backward despite
the keytab.
Step b
Step c
Main CPU PC board

*All modules tilt out toward
back of board.
CAUTION
Be gentle with the
spring tabs because
they can break easily.
Step d
7 Insert the MAIN CPU board into the proper slot on the controller
backplane. See Figure 2--4.
8 Connect the cables to the MAIN CPU board.
9 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 C-MOS RAM memory will be initialized automatically when the
software is installed.
MARF2HD4307701E
EPROM INSTALLATION
3--1
The SYSTEM R-J2 controller uses Erasable Programmable Read-Only
Memory (EPROM) chips that contain special setup software. They are
located on the MAIN CPU board and on the teach pendant PCB. Your
controller must contain the EPROM chips that are compatible with the
version of system software you are installing.
NOTE Software version information is included in an ASCII file called
readme.txt and is stored on the AP1 disk.
Page
Installing the BootROM

chip
FANUC Robotics requires you to have the version of BootROM EPROM chip
that is compatible with the version of R-J2 software you are using. . . . . . . . . . . . 3--2
Checking and installing

the teach pendant
EPROM chip
You must have the teach pendant EPROM version that corresponds to the
version of software you are using. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
3. EPROM INSTALLATION
MARF2HD4307701E
3--2
3.1
FANUC Robotics requires you to have the version of BootROM EPROM

chip that is compatible with the version of R-J2 software you are using.
The BootROM EPROM chip is located on the MAIN CPU board inside
the controller.
INSTALLING
BOOTROM EPROM
CHIPS
Use the procedures in this section when you

D Check the version of BootROM EPROM you have.
D Install Application software, and BootROMs for the first time.
D Update Application software and must check the current BootROM
version.
Use Procedure 3--1 to check the BootROM version you have. Use
Procedure 3--2 to install a new BootROM EPROM.
NOTE BootROM version information is included in an ASCII file called
Procedure 3--1
Checking the BootROM Version
WARNING
seriously.
CAUTION
Step
1 If the controller is turned on, turn it off.

2 Press and hold the PREV and NEXT keys on the teach pendant.
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.
3--3
MARF2HD4307701E
3 Release these buttons. You will see a screen similar to the following.
*** BOOT MONITOR for R-J2 CONTROLLER ***

Version 4.22P
01-JAN-199x
F-ROM/D-RAM/C-MOS :
TP Version
:
Current TIME
:
Slot
0
1
D
BMON>
COLD
ID
9B
6A
6A
CTRL
FC
0
0
0
INIT
4.0/4.0/1.0 MB
I
01-JAN-199x 22:52:53
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
NOLOAD
START
BootROM
Version
Number
optional
optional
>
4 Compare the BootROM version with the version required for your
software.
NOTE Refer to the readme.txt ASCII file on the AP1 disk to determine
the BootROM version that is compatible with the version of software you
have.
Procedure 3--2
If the BootROM version is correct for the version of software

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

software you have, you must install new BootROMs. Use
Procedure 3--2 to install a new BootROM EPROM.
Installing New BootROM EPROM Chips
WARNING
seriously.
CAUTION
Data in C-MOS RAM will be lost if the main CPU board is
removed from the backplane without a battery back-up. To
prevent loss of data, back up or copy all files for permanent
storage.
MARF2HD4307701E
3--4
CAUTION
Condition
Step
circuits.
1 Turn off the controller.

D
If your controller is equipped with a disconnect handle at the upper

OR
WARNING
3 Use a flat-tip screwdriver to turn the latch on the front door of the
controller to the UNLOCKED position. See Figure 3--1.
Circuit breaker
i-size controller
Locked
ON
OFF
Circuit breaker
B-size controller
OFF
ON
Unlocked
3--5
MARF2HD4307701E
4 Locate the MAIN CPU Board. See Figure 3--2 and Figure 3--3.
Figure 3--2. MAIN CPU Board Location in the i-size Controller
Figure 3--3. MAIN CPU Board Location in the B-size Controller
The MAIN CPU Board is on the backplane of the controller, to the left
of the power supply unit, and the vision engine PCBs (if the vision
option has been installed).
MARF2HD4307701E
3--6
5 Disconnect the cables from the MAIN CPU board.
6 Press and hold both latches of the MAIN CPU board and remove the
board from the backplane. See Figure 3--4.
Figure 3--4. Removing the MAIN CPU Board
3--7
MARF2HD4307701E
7 Find the location of the BootROM chips. See Figure 3--5 and
Figure 3--6.
Figure 3--5. Main CPU PC Board Module Locations
LED display
DRAM module
SRAM module
Bat
VBAT
JRV1 & JRV2

Connections
Flash ROM module
Line
JF21
Boot ROM
Boot ROM Chip
Ex-op
JM10
I/O - LK
(master)
JD1B
RS232/485
JD17
PDI/O
JRM3
CAUTION
This is RESET.
Connecting the battery
here can damage the CPU.
CRM10 & CR51
MARF2HD4307701E
3--8
Figure 3--6. Locating the BootROM Chips
BootRom Chip
have.
CAUTION
The pins on the BootROM EPROM chip are fragile. When
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-pin
(DIP) chip installation tool to install each BootROM chip. Be sure to
orient the notch as shown in Figure 3--6.
10 Plug in the MAIN CPU Board. Be sure the connector seats properly
with the backplane connector.
11 Reconnect the cables to the MAIN CPU Board. See Figure 3--5 for a
diagram of where each cable must be connected.
12 Close the controller door and set the circuit breaker handle or
disconnect handle to ON.
3--9
MARF2HD4307701E
3.2
INSTALLING TEACH
PENDANT EPROM
CHIPS
You must have the teach pendant EPROM version that corresponds to the
version of software you are using. Procedure 3--3 describes how to check
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
D Check the version of teach pendant EPROM you have.
D Install software and a teach pendant EPROM for the first time.
D Update software and check the current version of teach pendant EPROM.
Use Procedure 3--3 to check the teach pendant EPROM version you have.
Use Procedure 3--4 to install a new teach pendant EPROM.
NOTE EPROM version information is included in an ASCII file called
Procedure 3--3
Step
Checking Teach Pendant EPROM Versions

2 Hold the teach pendant and look at the screen. The screen shown in
Step 4 is displayed very quickly. Be sure you are looking for this
screen otherwise you could miss seeing it.
3 Press and hold the ON button on the controller.
4 Quickly view the teach pendant display. You will see a screen similar
to the following.
R-J2 Teach Pendant

7D01 / 09I
[199207-21]
VRAM, CGRAM CLEAR
INTERNAL RAM TESTING
EXTERNAL RAM TESTING
: COMPLETE
: OK
: OK
Teach Pendant Ready
5 If you miss seeing the screen, repeat Steps 1 through 4.
Teach
Pendant
Version
Number
MARF2HD4307701E
3--10
have.
6 Compare the EPROM version with the one required for your software.
Procedure 3--4
If the teach pendant EPROM version is correct for the version of

software you have, do not install a new teach pendant EPROM.
If the teach pendant EPROM version is NOT correct for the

version of software you have, you must install a new teach
pendant EPROM. Use Procedure 3--4 to install a new teach
pendant EPROM.
Installing A New Teach Pendant EPROM Chip
WARNING
seriously.
CAUTION
Condition
Step
You are wearing a wrist wrap to prevent static discharge to the C-MOS
circuits.

2 Hold the teach pendant so the back of the teach pendant is facing you.
See Figure 3--7.
3 Using a cross-tip screwdriver, remove the seven screws on the back
cover of the teach pendant. See Figure 3--7.
NOTE These screws are two different lengths. Mark the holes that
require the shorter screws for later reassembly.
CAUTION
Do not remove or disconnect any cables connected inside the
teach pendant or damage to equipment could occur.
3--11
MARF2HD4307701E
Figure 3--7. Removing the Back Cover of the Teach Pendant
4 Find the location of the teach pendant EPROM. See Figure 3--8.
Figure 3--8. Locating the Teach Pendant EPROM Chip
EPROM
Chip
the EPROM version that is compatible with the version of software you
have.
MARF2HD4307701E
3--12
See Figure 3--9 for a description of how the EPROMs are labeled.
Figure 3--9. EPROM Labels
R-J2
09
I
012345
TP
Product Category
Product Version
Product Revision
Software Serial Number
Blank
Product Name
CAUTION
The pins on the teach pendant EPROM chip are fragile. When
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, reinstall the seven screws on the back
cover.
MARF2HD4307701E
SOFTWARE INSTALLATION
4--1
Page
Setting up Load Devices
You can set up the following load devices to load software: . . . . . . . . . . . . . . . . . 4--5
D PS-100 disk drive with floppy disks
D Memory card interface with a memory card (not a standard product)
D PC emulator
Installing Software
The software allows you to run your application using your robot
and controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--5
Installing Options
Software options are additional features that can be used with your
application software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--26
Quick/Full Password
Setup
After the HandlingTool software is installed, you can change the QUICK/FULL
menu display for the Operator-level user when you use the Password
option.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--35
Installing Extended Axes
Extended axis software must be installed only in systems that use

extended axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--38
Installing Motion Groups
Motion groups provide the ability to have multiple devices on a single

controller, each with their own control program for independent operation.
Motion group software must be installed only in systems that use multiple
motion groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--53
Installing Updates
Software updates are disks that contain updated information to your

application and robot library software. Installing software updates is optional
and should only be performed if you have a disk labeled Update and it is
consistent with the software version you have loaded in the controller. . . . . . . . . 4--67
4. SOFTWARE INSTALLATION
4--2
4.1
SOFTWARE
INSTALLATION
THEORY
MARF2HD4307701E
Installing software involves loading the software from floppy disks into
controller memory (Flash ROM, D-RAM and C-MOS RAM) and might
also involve loading the software from floppy disks into the local memory
of optional hardware. You install software when you first install a new
system or when you update an existing system. You must install:
D Application software
D Robot libraries
When you have finished installing the application software and robot
libraries, you must set up information specific to your application.
You can also install:
D Software options
D Software updates
Installation Components
The SYSTEM R-J2 software is modular. The kinds of components you

will be loading are:
D Application software disks
D Robot LIBRARY disks
D OPTION disks
D UPDATE disks
CAUTION
You must load the software components in the correct order,
otherwise your system will operate incorrectly.
Installation Disk Order
The installation procedure begins with the first disk of the application (AP)
set. All of the decisions you must make during installation will occur at
the end of the installation procedure.
CAUTION
Your disk set includes all of the software options supported by
HandlingTool. Your disk set has been pre-authorized to install
only the options you have purchased. You will be unable to
install any options that have not been purchased and
authorized by FANUC Robotics.
To install an option that has not been pre-authorized for this
disk set, you must purchase the option and receive a Product
Authorization Code (PAC) from FANUC Robotics. Contact your
FANUC Robotics spare parts department for more information.
Each disk is installed in ascending order. If you have any software
options, they can be loaded after the application has been set up.
Refer to the readme.txt ASCII file on the AP1 disk for specific software
version information.
MARF2HD4307701E
4--3
CAUTION
A 3-volt battery pack supplies C-MOS RAM memory with power
when the controller power is off. Make sure the output voltage
of the battery pack is at least 2.5 volts, otherwise the
information stored in C-MOS RAM memory could be lost when
controller power is off.
CAUTION
Loading software erases all controller Flash ROM, D-RAM and
C-MOS RAM memory, as well as the RAM disk. Back up to
floppy disk all system variables, programs, and files stored on
the controller before you load software. Refer to Appendix C
for more information.
CAUTION
File access problems will result if your disk and disk drive are
misaligned. Try using a different disk drive. If file access
problems still occur, contact FANUC Robotics to receive a new
disk. Do not continue with the load procedure if file access
problems occur; otherwise, your controller memory will operate
incorrectly.
CAUTION
Do not turn off the controller during software installation. If the
controller is turned off, you will have to restart the entire
software installation procedure from the beginning.
4--4
MARF2HD4307701E
Installation Procedure
Overview
To install software, you must perform the following general steps:
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Quick/Full
Password
Setup
Section 4.2
Section 4.3
Section 4.4
Section 4.5
Install or
modify
extended
axes
(optional)
Section 4.4
and
Section 4.6
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.7
Section 4.8
Refer to the readme.txt ASCII file on the AP1 disk for information on the
options available with the HandlingTool software.
Robot Configuration
When you are installing software on a FANUC robot, you will be asked a
series of questions regarding your system configuration. Before you
begin the installation procedure, refer to Appendix B and fill in all the
information for your robot model.
Timetable
approximately 1 hours
If you are installing from floppy disks, the entire installation procedure
will take approximately one and one-half hours. Be sure you have the
entire disk set and all other information you need (refer to Appendix B)
before you begin this installation process or you might have to begin the
process over from the beginning.
If you are installing from a memory card (not supported as a standard
product), the entire installation procedure will take approximately 10
minutes. Be sure you have the memory card and all other information
you need (refer to Appendix B) before you begin this installation process
or you might have to begin the process over from the beginning.
Troubleshooting
If at any time during the installation procedure you make a mistake,

refer to the boxes within the procedure that are similar to the following.
g These boxes identify the problem in boldface type, then
provide a solution to the problem.
4--5
MARF2HD4307701E
4.2
SETTING UP LOAD
DEVICES
The following load devices can be used to install software:

D PS-100 disk drive with floppy disks
D Memory card interface with a memory card (not a standard product)
D PC emulator
NOTE Only one load device can be connected to the R-J2 controller
during software installation. Disconnect the load devices you are not
using before you begin installing software.
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Quick/Full
Password
Setup
Section 4.2
Section 4.3
Section 4.4
Section 4.5
4.2.1
Using a PS-100 Disk
Drive
Install or
modify
extended
axes
(optional)
Section 4.4
and
Section 4.6
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.7
Section 4.8
The PS-100 disk drive connects to the P2: port. The P2: port is an
RS-232-C interface.
Figure 4--1 and Figure 4--2 show the PS-100 attached to the controller.
Use Procedure 4--1 to connect a PS-100 disk drive to a controller or
operator box.
Figure 4--1. PS-100 Connected to an i-size Controller
PS-100
Disk Drive
To Controller
4--6
MARF2HD4307701E
Figure 4--2. PS-100 Disk Drive Connected to the B-size Controller

Teach
pendant
Operator panel
PS-100
Disk Drive
4--7
MARF2HD4307701E
Procedure 4--1
Connecting a PS-100 Disk Drive

CAUTION
If devices such as a printer, or floppy disk drive are connected
to the controller, always turn on the robot first, then turn on
these devices; otherwise, equipment could be damaged.
Step
1 Connect the RS-232-C cable from the disk drive to the P2: port.
2 Turn on the controller.
3 Turn on the power switch located under the disk drive cover. The
LED next to the power switch will turn on.
NOTE If the LED does not turn on, the disk drive could be faulty.
Replace the disk drive and repeat Steps 1 through 3.
4 To insert a disk, hold the disk with the label toward you and insert it
into the disk drive.
5 To install software, go to Section 4.3.
4--8
4.2.2
Using a Memory Card
Interface
MARF2HD4307701E
The memory card interface is installed in either the ER-2 board if you have
one, or in the PSU B1 slot which connects to the R-J2 controller
backplane.
Figure 4--3 and Figure 4--4 show the memory card interface module on the
ER-2 board inserted into the controller. Use Procedure 4--2 to install a
memory card in a controller.
product.
CAUTION
Be sure that the version of Main CPU BootROM you have is
version 4.20 or later. If not, DO NOT load the optional A-B RIO
software from memory card while the memory card interface is
in the ER-2 printed circuit board. Otherwise, you could erase
all the information on the memory card and destroy the ER-2
board. Instead, if the BootROM version is not 4.20 or later,
load the A-B RIO software using the FANUC Robotics-supplied
disks.
Figure 4--3. Memory Card Interface and Memory Card Connected to the i-size
Controller
Memory Card
Power Supply Unit
4--9
MARF2HD4307701E
Figure 4--4. Memory Card Interface and Memory Card Connected to the B-Size
Controller
Power Supply Unit

Memory Card
NOTE If you do not have an ER-2 printed circuit board, you will need to
remove the plastic slot cover on the PSU B1 slot. Align the memory card
interface adapter in the left hand slot.
4--10
MARF2HD4307701E
Procedure 4--2
Using the Memory Card Interface

product.
CAUTION
If devices such as a printer, or floppy disk drive are connected
to the controller, always turn on the robot first, then turn on
these devices; otherwise, equipment could be damaged.
Condition
You have a memory card interface module and memory card that
contains the software you want to load.
You are using memory cards that are based on one of the following
standards:
- JEIDA IC Memory Card Guideline Version 4.0

- PCMCIA PC Card Standard R. 2.0
- 2 MB SRAM card (no Flash ROM cards)
NOTE Refer to the maintenance manual specific to your controller for
information on changing the batteries in a memory card.
WARNING
seriously.
CAUTION
H
Step
circuits.

D If your controller is equipped with a disconnect handle at the upper
OR
See Figure 4--5.
4--11
MARF2HD4307701E
WARNING
2 Open the front door of the controller using a flat-tip screwdriver to
turn the latch. See Figure 4--5.
Circuit breaker
i-size controller
Locked
OFF
ON
Unlocked
ON
OFF
Circuit breaker
B-Size controller
3 Identify the memory card interface module location inside the

controller. See Figure 4--6.
Figure 4--6. Memory Card Interface Location on an i-size Controller
Memory Card
Power Supply Unit
4--12
MARF2HD4307701E
Figure 4--7. Memory Card Interface Location on a B-Size Controller
Memory Card
4--13
MARF2HD4307701E
4 To insert a memory card, hold the memory card with the label facing
the left and the write protect switch on the top.
D
If you have an ER-2 printed circuit board, see Figure 4--8.
Figure 4--8. Inserting a Memory Card with the ER-2 Printed Circuit Board
PSU B1
ER-2 Board
Memory Card Interface
Write protect
switch
ER-2 Board
Memory Card
AI6B-1212-0871/--- ---
Power Supply Unit PCB
4--14
MARF2HD4307701E
If you do not have an ER-2 printed circuit board, insert the

memory card interface in the module located in the 1/2 slot next to
the power supply unit. The interface will only fit in the left slot.
See Figure 4--9.
Figure 4--9. Inserting a Memory Card without an ER-2 Printed Circuit Board
Memory Card Interface
Write protect
switch
Memory Card
AI6B-1212-0871/--- ---
Power Supply Unit PCB
4--15
MARF2HD4307701E

product.
CAUTION
Do not close the i-size controller door when the memory card is
in the interface. Otherwise, you could damage the memory
card.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock when the controller door is open.
Do not leave an open controller unattended.
Turning the disconnect or circuit breaker to the OFF
position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.
5 If you are using a B-size controller, close and latch the controller
door. Otherwise, an error will occur. If an error occurs, close and
latch the controller door, and press RESET.
4--16
MARF2HD4307701E
4.2.3
You can use the KFLOPPY PS-100 disk drive emulator to install software.
You can do this by loading all the files from each FANUC
Robotics-supplied disk to one directory on your PC. Use Procedure 4--3
to install HandlingTool software using KFLOPPY.
Using KFLOPPY
PS-100 Floppy Disk
Drive Emulator
Procedure 4--3
Condition
Step
Using KFLOPPY to Install Software

H
You have KFLOPPY installed on your PC and it is configured

correctly. Refer to the KFLOPPY DOS PS-100/200 Floppy Disk Drive
Emulator Manual for more information.
You are using DOS. Refer to your DOS users manual for more
information on using DOS commands.
1 Create a directory on your PC hard drive that will contain the

HandlingTool files. Name the directory for the version of software
you have; for example, HDL43xx for HandlingTool V4.3x-x.
2 Make the directory, created in Step 1, the current directory.
3 Copy all the files from the robot library disks to the HDL43xx
directory.
4 Copy all the files from the OPTION disks to the HDL43xx directory.
CAUTION
Be sure to copy the AP disks to the directory last. Otherwise,
you might not retain the most recent version of all the files.
5 Copy all the files from the AP1-AP3 disks to the HDL43xx directory.
CAUTION
Do not copy any UPDATE disk information to the same
directory as all the other FANUC Robotics-supplied software.
Otherwise, you might not retain the most recent version of all
the files.
6 If you have any UPDATE disks, either use only the FANUC
Robotics-supplied 3.5 disk, or copy each UPDATE disk to a separate
subdirectory.
7 Start KFLOPPY on your PC.
4--17
MARF2HD4307701E
4.3
INSTALLING
HANDLINGTOOL
APPLICATION
SOFTWARE
This section contains information for installing HandlingTool software and

firmware.
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Quick/Full
Password
Setup
Section 4.2
Section 4.3
Section 4.4
Section 4.5
Install or
modify
extended
axes
(optional)
Section 4.4
and
Section 4.6
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.7
Section 4.8
Use Procedure 4--4 to install HandlingTool software and firmware.
Procedure 4--4
Condition
Installing HandlingTool Software and Firmware

H
You have filled in the HandlingTool configuration table specific to

your robot model in Appendix B.
The R-J2 controller is plugged in and is working properly.
Enough system memory is available to install all application software.

Refer to the readme.txt ASCII file on the AP1 disk for information on
the amount of memory available for your application and required by
each option.
The teach pendant ON/OFF switch is OFF and the DEADMAN switch
is released.
The REMOTE/LOCAL keyswitch on the operator panel is set to

LOCAL.
You have obtained a PS-100 disk drive, a memory card interface, or a

PC compatible computer to load software.
If you are updating controller software, you have backed up

everything that you want to use on this controller. Refer to
Appendix C for more information on backing up system, programs
and application files.
You have the R-J2 software disks or memory cards and any additional
option disks that you need to install. (Refer to readme.txt ASCII file
on the AP1 disk for the number of disks you should have.) Refer to
Appendix D for information on copying software to memory card.
The PS-100, memory card interface or PC compatible computer is

connected to the controller and is turned on. (Refer to Section 4.2)
If you are reloading software and do not want to reload and resetup
existing communications firmware, refer to Appendix A,
Section A.2.3, for a list of the command files that you can run to
install software without reinstalling firmware.
4--18
MARF2HD4307701E
CAUTION
This procedure erases all controller Flash ROM and C-MOS
RAM memory, as well as the RAM disk. Be sure that any
programs or files you want permanently saved are backed up
to a floppy disk. Refer to the FANUC Robotics SYSTEM R-J2
Controller HandlingTool Setup and Operations Manual for more
information.
Step

2 Turn on the disconnect. See Figure 4--10.
Circuit breaker
i-size Controller
Locked
OFF
ON
ON Unlocked
OFF
Circuit breaker
B-Size controller
3 Insert the first disk into the disk drive:

D If you are using floppy disks, insert the disk labeled AP1.
D If you are using a memory card, insert the card labeled AP1 into
the memory card interface.
4 Press and hold the PREV and NEXT keys on the teach pendant. While
holding these keys, turn the controller ON. You will see a screen
similar to the following.
Version 4.22P
01-JAN-199x
F-ROM/D-RAM/C-MOS :
TP Version
:
Current TIME
:
Slot
0
1
D
BMON>
COLD
ID
9B
6A
6A
CTRL
FC
0
0
0
INIT
6.0/8.0/1.0 MB
I
01-JAN-199x 22:52:53
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
NOLOAD
START
>
optional
optional
4--19
MARF2HD4307701E
5 Press NEXT, >, until F2, INSTALL is displayed.

6 Press F2, INSTALL, and then press ENTER.
7 Press NEXT, >, until F3, RUN is displayed.
8 Press F3, RUN.
9 Press F4, FROMINIT and then press ENTER. You will see a screen
Slot
0
1
D
ID
9B
6A
6A
FC
0
0
0
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
BMON> INSTALL
INSTALL> RUN FROMINIT
Run file FROMINIT.CF
Are you sure ? (Y=1/N=0) :
10 If you do not want to continue, press 0, and then press ENTER. The
BMON> prompt will be displayed.
If you are ready to continue, press 1, and then press ENTER. A
series of screens, similar to the following, will be displayed on the
teach pendant.
Clearing .. done
- Initialize entire F-ROM Clearing chip no 1 .. done
Clearing chip no 2 .. done
Opening SYSTEM1.LDC
4--20
MARF2HD4307701E
Memory Card
time: 3 minutes
If you are loading from a memory card, the files will take
approximately three minutes to load. Go to Step 16 to select a robot.
Using KFLOPPY on a PC
time: 45 minutes
If you have copied the files from floppy disks and are using
KFLOPPY (Procedure 4--3 ), you can load all the files from the
floppy disks to one directory on the computer and begin the load from
that directory. Go to Step 16 to select a robot.
Floppy Disks and a PS-100

Disk Drive
time: approximately
20 minutes per disk
If you are loading from floppy disks, (after approximately 20

minutes), you will see a screen similar to the following.
- Initialize entire F-ROM Clearing chip no 1 .. done
Clearing chip no 2 .. done
Opening SYSTEM1.LDC
read size is 348184 bytes
expand size is 630611 bytes
Opening SYSTEM2.LDC
Insert disk AP2.
Press ENTER to continue._
11 Insert the disk labeled AP2 and press ENTER.

When all the files on AP2 have been loaded, you will see a screen
UCBLK 00010000 00220000 00000000 00220000
CHECKSUM E496463A
Set TPE size to 600 kbytes.
Done!
Opening FLASH01.LDC
WARNING: block address is near 0
Insert disk AP3
Press ENTER to continue.
12 Insert the disk labeled AP3 and press ENTER. When all the files on
AP3 have been loaded, you will be prompted to load firmware if it is
needed.
If you do not have the hardware required for these options installed in
your controller, go to Step 15. The following firmware will be loaded as
needed:
4--21
MARF2HD4307701E
For A-B RIO, Genius,

ECBR, FTP and MOTET
you will see this screen.
Controlled Start Initialization

Insert disk COMMPKG1.
13 Insert the disk labeled COMMPKG1 or HTOOLPKG1 and press

ENTER.
For VISION boards you will
see this screen.

Insert disk VISNPKG1/MIGEYEPKG1
14 Insert the disk labeled VISNPKG1 and press ENTER.

15 When you are finished loading firmware, (or if you are not loading
firmware), you will see a screen similar to the following.
You will see a screen similar to the following.
*****
Load Group 1 Robot Library
1 A-520i Robot Library
2 M-6i (ARCMATE-100i)
4 M-16iL/ARCMATE-120iL
5 M-400 Robot Library
6 M-410i Robot Library
7 M-410iW Robot Library
10 NEXT MENU
*****
Enter robot selection
To display the next screen type 10, and press ENTER. You will see a

*****
0 PREV MENU
11 M-410iWx Robot Lib
13 M710i Robot Library
15 S-6 (ARCMATE-100) Lib
16 S-12 (ARCMATE120) Lib
17 S-420iF Floor Mnt Lib
20 NEXT MENU
*****
D
D
To display the previous screen type 0, and press ENTER.

4--22
MARF2HD4307701E

*****
0 PREV MENU
21 S-420iL Long Arm Lib
22 S-420iR Rack Mnt Lib
23 S-420iS Hi Force Lib
24 S-420iW H Payload Lib
25 S-420A Angle Mnt Lib
26 S-450 Robot Library
30 NEXT MENU
*****
D
D


*****
0 PREV MENU
32 Ofset Wrist S-700 Lib
35 Coord Nobot Library
36 Nobot Library
*****
NOTE The teach pendant might beep to notify you when some files are
being loaded.
16 Insert the appropriate disk for your robot model. Refer to Table 4--1.
Table 4--1.
Robot Disks
Robot Model
Disk Name
A-520i
OLIB1
M-6i (ARCMATE-100i)
OLIB2
M-16i (ARCMATE-120i)
M-16iL/ARCMATE-120iL
M-400 Robot Library
M-410i Robot Library
OLIB3
OLIB1
M-410iW Robot Library

M-410iWx Robot Lib
OLIB2
M-500 Robot Library

M710i Robot Library
M710iW Robot Library
OLIB3
S-6 (ARCMATE-100)
S-12 (ARCMATE-120) Lib
S-410iF Floor Mnt Lib
SLIB1
4--23
MARF2HD4307701E
Table 4--1. (Contd) Robot Disks

Robot Model
Disk Name
S-420iL Long Arm Lib

S-420iR Rack Mnt Lib
SLIB2
S-420iS Hi Force Lib

S-420iW H Payload Lib
SLIB3
S-420A Angle Mnt Lib
SLIB4
S-450 Robot Library

S-500 Robot Library
SLIB3
S-700 Robot Library

Offset Wrist S-700 Lib
S-800 Robot Library
S-900 Robot Library
Coord Nobot Library
Nobot Library
SLIB2
SLIB4
MOTNPKG1
CAUTION
Be sure to select the correct robot model from the list of
available robot models. If you select the wrong robot model
you will not be notified by the system and your software will
operate incorrectly.
17 Select the robot model you are using and press ENTER. The model
number should be on the robot plate as FANUC Robot S-420iF, for
example.
g If you choose the wrong robot, you must run CMOSINIT to
perform a RE-INIT start. Refer to Section A.1.6 to perform a
RE-INIT start (CMOSINIT).
18 The following set of screens requires you to specify information

specific to your robot and wrist type. Set each item appropriately.
Refer to the configuration tables in Appendix B for more information.
CAUTION
Be sure to answer the robot configuration questions correctly.
If you answer a question incorrectly you will not be notified by
the system and your software will operate incorrectly. Refer to
the configuration tables you have completed in Appendix B.
4--24
MARF2HD4307701E
g If you choose the right robot but answer the robot configuration
questions incorrectly, you must
a
b
Perform a controlled start. (Refer to Appendix A)

If you are changing the CARTESIAN motion option, insert the
disk labeled SLIB1.
c Select MOTION SYSVAR SETUP.

d Press F4, YES.
e
f
g
h
i
Select INITIALIZE SYSTEM VARIABLE.

Press F4, YES.
Select INITIALIZE GROUP1 VARIABLES.
Press F4, YES.
Answer the payload and CARTESIAN motion option question
again.
NOTE If you are loading from floppy disks and the robot library disk
is not in the disk drive, insert the disk (refer to Table 4--1) now and press
ENTER.
When the robot library files have been loaded, (after a few minutes), you
will see a screen similar to the following.
***** Load Group 1 Robot Library *****
Loading PATH:\RLSV42IF.PC, please wait..
-- Payload setting -enter Payload (0..120[kg])?
Application Setup
19 If you are updating the controller from 4.10 to 4.30, you might see
a screen similar to the following when you finish setting up the
configuration items.
Note V4.10 compatible servo parameters loaded
Press ENTER to continue!
This message notifies you that the V4.10 parameters were automatically
loaded for you. If you have newer DSP Vs, you will not see this message.
20 Press ENTER. You will see a screen similar to the following.
S/W INSTALL
CONTROLLED START MENUS

1/3
Appl/Tool: HandlingTool
1 Setup Application
2 Install Option
3 Install Update
[TYPE]
4--25
MARF2HD4307701E
21 Select 1 and press ENTER. The application will be set up

automatically and the S/W INSTALL screen will be displayed again.
22 If you want to install a software option or update,
a To install options, go to Procedure 4--5 .
b To install updates, go to Procedure 4--10 .
Restoring *.SV, *.VR or
*.IO Files
23 If you want to restore saved *.SV, *.VR, or *.IO files, refer to

Appendix C.
NOTE During a controlled start, teach pendant programs can only be
loaded or restored after a CTRL2 START has been performed. Refer to
Appendix A for more information on a CTRL2 START.
Restoring *.TP Files
24 If you want to restore saved teach pendant files (*.tp),

a Press FCTN.
b Select START (CTRL2). After a few minutes you will see a
S/W INSTALL
CONTROLLED 2 START MENUS

1/3
1 Setup Application
2 Install Option
3 Install Update
[TYPE]
c Press MENUS.
d Select File.
e Refer to Appendix C for file operation information.
25 If you are finished setting up your application and do not want to
install options or updates, cold start your controller.
a Press FCTN.
b Select START (COLD) and press ENTER. You will see a screen
UTILITIES Hints
JOINT 10 %
HandlingTOOL (TM)
V4.31-x
Copyright 1997, FANUC Robotics
North America, Inc.
All Rights Reserved
[ TYPE ]
HELP
4--26
MARF2HD4307701E
4.4
Software options are additional features that can be used with your
application software. To install software options you must have already
installed the HandlingTool software and set up the HandlingTool
application.
INSTALLING
HANDLINGTOOL
OPTIONS
Installing Authorized
Options
Procedure 4--5
Your disk set includes all of the software options available with
HandlingTool. FANUC Robotics has authorized only those options you
have purchased. Use Procedure 4--5 to install these options.
NOTE You will be unable to install any options that have not been
purchased.
To authorize more options for this disk set, you must purchase the option
and receive a Product Authorization Code (PAC) from FANUC Robotics.
Contact the FANUC Robotics Spare Parts department at 248-377-PART
Using a PAC to
Authorize and Install
More Options
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Quick/Full
Password
Setup
Section 4.2
Section 4.3
Section 4.4
Section 4.5
Install or
modify
extended
axes
(optional)
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.4
and
Section 4.6
Section 4.7
Section 4.8
NOTE Even though you have all of the available option disks, you will
only be able to install the options that you have purchased.
Refer to Table 4--2.
Table 4--2.
Option Disks
To Install this Software Option

Multi-Group Motion
Insert this Disk in

the Floppy Drive
MOTNPKG1
Extended Axes
MOTNPKG1
PLC I/O (A-B/GENIUS)
COMMPKG1
Continuous Turn
MOTNPKG1
TPP Line Tracking
MOTNPKG1
Tool CRT/KB Manager
UTILSPKG1
Palletizing
HTOOLPKG1
Coordinated Motion
MOTNPKG1
Soft Float
MOTNPKG1
Controller backup
UTILSPKG1
AccuPath
MOTNPKG2
Space Check
UTILSPKG1
Collision Guard
MOTNPKG2
Small Circle Accuracy
MOTNPKG1
Error Recovery
UTILSPKG2
FTP Interface
COMMPKG1
Ethernet CBR
COMMPKG1
Quick/Full Password
HTOOLPKG1
Duty Diagnosis
MOTNPKG2
4--27
MARF2HD4307701E
Table 4--2. (Contd) Option Disks

V-400i Vision
Procedure 4--5
VISNPKG2
Visual tracking
VISNPKG1
Control Reliable
UTILSPKG2
DeviceNet Interface
COMMPKG2
Shape Generation
HTOOLPKG1
Installing Options
g If you make a mistake in Procedure 4--5 , you cannot start
the procedure over again from the beginning. The software will
not let you load an option twice on the same controller.
Condition
Enough system memory is available to install the software option.

Refer to the readme.txt ASCII file on the AP1 disk for more
information. Refer to Section 2.2 for information on checking the
amount of system memory you have.
You have purchased the option from FANUC Robotics. If the option
did not come with your application software then you will have
received a Product Authorization Code (PAC). If you have not
purchased the option and received a PAC, contact the FANUC
Robotics Spare Parts department at 248-377-PART.
You have finished Procedure 4--4 .
NOTE If you have JUST completed Procedure 4--4 , and the Install
Optional Features screen is displayed, go to Step 10. Otherwise, continue
with Step 1.
You have the R-J2 software option disks that you want to install.
The PS-100, memory card interface (not a standard product), or PC is
connected to the controller and is turned on. (Procedure 4--1 or
Procedure 4--2 )
H
H
Step
CAUTION
Be sure to install all option disks before you install any update
disks or your system will operate incorrectly.
4--28
MARF2HD4307701E
Performing a Controlled
Start
3 While still holding these buttons, press the ON button on the
teach pendant.
4 Release these buttons.
BMON>
5 At the BMON> prompt press F2, CTRL, and press ENTER.
BMON> CTRL
6 Now press F5, START, and press ENTER. This performs a controlled
start of the controller. After the controlled start is complete, you will
see a screen similar to the following.
1
2
3
4
MOTION SYSVAR SETUP

PROGRAM INIT
MOTION DEVELOPMENT
EXIT
Press enter or number key to select.
7 Type 4, then press ENTER.

Exit? [NO]
YES
NO
8 Press F4, YES. You will see a screen similar to the following.
S/W INSTALL
Appl/Tool:

HandlingTool
1/3
1 Setup Application
2 Install Option
3 Install Update
[TYPE]
9 Insert the option disk in the disk drive. Refer to Table 4--2.
10 Use the down arrow key to select Install Option and then press
ENTER. You will see a screen similar to the following.
*** Install Optional Features ***
1 Multi Group Motion
2 Extended Axes
3 PLC I/O (A-B/GENIUS)
4 Continuous Turn
5 TPP Line Tracking
6 Tool CRT/KB Manager
7 Palletizing
10 NEXT MENU
Feature code (-1 to EXIT)
4--29
MARF2HD4307701E
D
D
To exit option loading, type --1 and press ENTER.

To display the next menu, type 10 and press ENTER. You will see a
0
11
12
13
14
15
16
17
20
PREV MENU
Coordinated Motion
SoftFloat
Controller Backup
AccuPath
Space Check
Collision Guard
NEXT MENU
D
D
To display the previous menu, type 0, press ENTER.

0 PREV MENU
21 Error Recovery
22 FTP Interface
23 Ethernet CBR
24 Quick/Full Password
25 Duty Diagnosis
26 V-400i Vision
27 Visual Tracking
30 NEXT MENU
D
D
To display the previous menu, type 0, press ENTER.

0 PREV MENU
31 Control Reliable
32 DeviceNet Interface
33 Shape Generation
4--30
Checking configuration...
MARF2HD4307701E
11 Type the number of the option you want to install and press ENTER.
g If the option is not valid for your configuration, it is
because the option is already installed, it is not compatible
with another installed option, or the option has not been
purchased.
If the option is already installed, you cannot install it twice on the
same controller. Choose another option.
If the option is not compatible with another option, you cannot
install the option. Contact the FANUC Robotics Spare Parts
department for more information at 248-377-PART.
If the option has not been purchased, contact the FANUC Robotics
Spare Parts department to receive the Product Authorization Code
(PAC) for the option you want to install. You can install only the
options that have been purchased and authorized by FANUC
Robotics. After you have received the PAC, go to Step 12.
Checking authorization ...
CRT/Keyboard Manager
is NOT authorized for this configuration.
If you do NOT have an

authorized option you will
see this screen. Go to
Step 12.
Do you want to authorize it? YES

Please supply the PAC?
is authorized for this configuration.
If you have an authorized

option you will see this screen.
Go to Step 13.
Do you want to continue?

YES
NO
12 If the option is NOT authorized, the Product Authorization Code

(PAC) for the option you want to install is required. You must have
the PAC number to install the option. If you do not have the PAC for
the option, contact the FANUC Robotics Spare Parts department. To
install the option using the PAC, type the PAC number and press
ENTER.
13 If the option is authorized and you want to continue installing it,
press F4, YES. You will see a screen similar to the following.
is authorized for this configuration.
Do you want to continue?
YES
D
D
NO
To continue, press F4, YES.

If you do not want to install the authorized option, press F5, NO.
4--31
MARF2HD4307701E
g If you do not have the correct disk in the disk drive, you
will see a message similar to the following.
Insert disk COMMPKG1.
The option configuration information will be checked.

14 To finish loading the option, refer to Table 4--3 to determine the next
step.
CAUTION
To load Extended Axis Control and FANUC Multi-Group, you
must perform a cold start before you turn off the controller and
do a controlled start. Otherwise, the option software will not be
loaded properly.
4--32
MARF2HD4307701E
Table 4--3.
To finish loading this option
Multi-Group Motion
Extended Axes
Completing the Option Installation
Perform these steps
Use this Disk
Comments
Select multi-group motion. When

the loading is complete, press FCTN
and select START (COLD). Then,
go to Procedure 4--9 to finish setting
up and installing the extended axes.
MOTNPKG1
Refer to the Extended Axis and

Group Motion Setup and Operations
Manual for more information.
Select extended axes. When the

loading is complete, press FCTN
and select START (COLD). Then,
go to Procedure 4--7 to finish setting
up and installing the extended axes.
MOTNPKG1
PLC I/O (A-B/GENIUS)
COMMPKG1
Continuous Turn
TPP Line Tracking
MOTNPKG1
Excludes:
D TPP Line Tracking
MOTNPKG1
Excludes:
D Continuous Turn
Tool CRT/KB Manager
UTILSPKG1
Palletizing
HTOOLPKG1
Coordinated Motion
MOTNPKG1
Soft Float
MOTNPKG1
Controller Backup
AccuPath
Go to Step 15 of this procedure.
UTILSPKG1
Refer to Appendix C to perform a

controller backup.
MOTNPKG2
Refer to the KAREL Setup and

Operations Manual for more
information.
Space Check
UTILSPKG1
Collision Guard
MOTNPKG2
MOTNPKG1
Error Recovery
UTILSPKG2
FTP Interface
COMMPKG1
Includes:
D Host Communications
D TCP/IP Interface
COMMPKG1
Includes:
D Host Communications
D Controller Backup
Refer to the Ethernet Controller
Backup/Restore -- FTP Setup and
information.
Ethernet CBR
Quick/Full Password
Go to Procedure 4--6 .
HTOOLPKG1
Duty Diagnosis
MOTNPKG2
Allows you to change the way the

QUICK menus are accessed when
you use the Password Option.
4--33
MARF2HD4307701E
Table 4--3. (Contd) Completing the Option Installation

To finish loading this option
V-400i Vision
Perform these steps
Use this Disk
Comments
VISNPKG2
Refer to the installation information

in the SYSTEM R-J2 Controller
V-400i Vision System Setup and
information.
Visual Tracking
VISNPKG1
Includes:
D V-400i Vision
D TPP Line Tracking
Control Reliable
UTILSPKG2
Excludes:
D CE Mark
DeviceNet Interface
COMMPKG2
Shape Generation
After you load Shape Generation,

the controller is in CTRL-2 Start
mode. Go to Step 18 of this
procedure. After the COLD START
is complete, you can load more
options by starting Procedure 4--5
again at Step 1.
HTOOLPKG1
Includes:
D AccuPath
15 Remove the disk from the disk drive.

16 Repeat Steps 11 through 15 for each option you want to install.
17 When you are finished installing options, type --1 to exit and press
ENTER.
18 Perform a COLD START:
a Press FCTN.
b Select START (COLD). When it is finished, you will see a screen
UTILITIES Hints
JOINT 10 %
HandlingTOOL (TM)
V4.31-x
North America, Inc.
All Rights Reserved
[ TYPE ]
HELP
4--34
MARF2HD4307701E
CAUTION
If you have an S-12 robot and you have loaded the AccuPath and
Small Circle options, you must load the AccuPath option before you
load the Small Circle option. If you loaded the Small Circle option first,
then you must do the following:
2 Perform a controlled start. (Refer to Appendix A)
3 Select 1, MOTION SYSVAR SETUP.
4 Select 1, INITIALIZE SYSTEM VARIABLE.
5 Select INITIALIZE GROUP n VARIABLES.
Typically, this will be 1 for the first motion group.
6 Select Exit three times until the S/W Install screen is displayed.
7 Press FCTN and select START (COLD).
19 To display a list of all the standard and installed options on the

controller, display the Version Id screen.
a Press MENUS.
b Select STATUS.
c Press F1, [TYPE].
d Select Version Id. The Version Id screen will be displayed.
NOTE Refer to Appendix E to display the Version Id screen after a
controlled start.
CAUTION
If the software fails to load completely, or if you do not perform
a COLD START after you install software options or update
information, your system will not operate correctly. If this
occurs, perform a RE-INIT start (CMOSINIT) then reinstall the
options and updates. Refer to Section A.1.6.
4--35
MARF2HD4307701E
4.5
QUICK/FULL
PASSWORD SETUP
After the HandlingTool software is installed, you can change the

QUICK/FULL menu display for the Operator-level user when you use the
Password option.
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Quick/Full
Password
Setup
Section 4.2
Section 4.5
Section 4.4
Section 4.5
Install or
modify
extended
axes
(optional)
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.4
and
Section 4.6
Section 4.7
Section 4.8
Use Procedure 4--6 to modify the menu display.

Procedure 4--6
Condition
Step
Customizing the Menu Display using Quick/Full Password

H
You have enabled the Password option by setting up the first user and
password. Refer to the SYSTEM R-J2 Controller HandlingTool Setup
and Operations Manual for more information.
You have just installed the Quick/Full Password Setup option from
Procedure 4--5 .
1 You will see a screen similar to the following.

NOTE If you do not see the following screen, go to Procedure 4--5 and
be sure the Quick/Full Password option has been installed.
Changing the Password Operator
Level handling is now allowed.
Please select 1. Setup Application
at the controlled start S/W INSTALL
menu and answer the password setup
questions to set the desired Operator
Level handling.
Press 1, ENTER to continue.
4--36
MARF2HD4307701E
2 Press ENTER to continue. You will see a screen similar to the

following.
S/W INSTALL

1/3
1 Setup Application
2 Install Option
3 Install Update
[TYPE]
3 Type 1 and press ENTER. You will see a screen similar to the
following.
S/W INSTALL

1/3
Do you want to change the Password

Option Operator-level handling?
Enter 1 = YES
2=NO
Operator uses Quick menu
Operator uses Full menu
4 If you do not want to change the password handling, press 2, NO,

and go to Step 6.
If you want the operator-level user to use the FULL menus,
press 1, YES. You will see a screen similar to the following.
S/W INSTALL

1/3
Enter 1 if you want the operator level

to use the Full menus.
Enter 2 if you want the operator level
to use only the Quick menu.
Enter other to not change the Password
Setup.
NOTE You can change the way the QUICK/FULL menus are displayed
by repeating Steps 2 and 4.
5 To use Full menus, type 1. To use the Quick menu, type 2.
Type any other key if you do not want to change the Password setup.
4--37
MARF2HD4307701E
6 Perform a cold start.

a Press FCTN.
b Select START (COLD). When it is finished, you will see a screen
UTILITIES Hints
JOINT 10 %
HandlingTOOL (TM)
V4.31-x

North America, Inc.
All Rights Reserved
[ TYPE ]
HELP
4--38
MARF2HD4307701E
4.6
MODIFYING AND
INSTALLING
ADDITIONAL
EXTENDED AXES
The first time you install extended axes, you must use the option
installation procedure (Procedure 4--5 ). When you have finished
Procedure 4--5 , go to Procedure 4--8 .
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Section 4.2
Section 4.3
Section 4.4 Section 4.5
Quick/Full
Password
Install or
modify
extended
axes
(optional)
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.4
and
Section 4.6
Section 4.7
Section 4.8
NOTE Refer to the Extended Axis Operations Manual for extended axis
troubleshooting information.
To modify your extended axes setup, use Procedure 4--7 and then
Procedure 4--8 .
NOTE You can also use Procedure 4--7 as an alternate method for
installing additional extended axes. However, to install extended axes the
first time, go to Procedure 4--8 .
Procedure 4--7
Condition
Step
Start
Modifying Extended Axes

H
If the controller is turned on, turn it off.
1 Connect the PS-100 disk drive cable to the RS-232-C port on the
operator panel or operator box.
teach pendant.
BMON>
5 At the BMON> prompt press F2, CTRL and press ENTER.
BMON> CTRL
6 Now press F2, START and press ENTER. This performs a controlled
start of the controller. You will see a screen similar to the following.
1. MOTION SYSVAR SETUP
2. PROGRAM INIT
3. MOTION DEVELOPMENT
4. EXIT
Enter selection --Press enter or number key to select.
4--39
MARF2HD4307701E
7 Type 1 and press ENTER.

Perform sysvar setup? [NO]
YES
NO
1.
2.
3.
4.
5.
Initialize System Variables

Add/Delete Group
Extended Axis Setup/Init
Display System Setup Status
Exit
9 Type 3 and press ENTER.

Extended axes setup/init [NO]
YES
NO
10 Press F4, YES.

11 Go to Step NO TAG of Procedure 4--8 .
4--40
MARF2HD4307701E
Procedure 4--8
Condition
Using the Extended Axis Setting Program

H
The extended axis setting program is running. Perform Procedure 4--5

or Procedure 4--7 .
**** EXTENDED AXIS SETTING PROGRAM ****
SELECT GROUP
Enter Group Number to Add
Extended Axes to (1->3)
Step
1 Type the group number to which the extended axis hardware is to be

installed and press ENTER. For example, if you are adding a rail to a
six-axis robot, the group number is 1. The hardware specific
information will be added later. You will see a screen similar to the
following.
SELECT HARDWARE
Enter hardware start number for the
extended axes
2 Type the starting number of the extended axis hardware and press
ENTER. The hardware start number is the next axis number in the
robot series. For example, if you are adding a rail to a six-axis robot,
the starting number is 7. You will see a screen similar to the
following.
NOTE The starting number can vary depending on how the hardware is
set up for your system.
****
**** EXTENDED
EXTENDED AXIS
AXIS SETTING
SETTING PROGRAM
PROGRAM
E1 E2
*** Group 1 Total Ext Axis = * *
1. Display/Modify Ext_axis 1~3
2. Add Ext_axes
3. Delete Ext_axes
4. Exit
Select?
****
****
E3
*
NOTE Extended axes can be added out of order. For example, you can
add extended axis 2 before you add extended axis 1.
3 To add an extended axis, type 2.
To delete an extended axis, type 3. You will see a screen similar to
the following.
4--41
MARF2HD4307701E
NOTE If an I is displayed in place of an * under the extended axis

name in the following screen, the axis is initialized.

E1 E2 E3
*** Group 1 Total Ext Axis = * * *
1. Display/Modify Ext_axis 1~3
2. Add Ext_axes
3. Delete Ext_axes
4. Exit
Select?2
Enter axis to add (1 ->3)
NOTE If you choose to install axis 2, and the hardware start number is 7,
the extended axis 2 will be connected to hardware port number 8.
4 Type the extended axis number you are adding (1, 2, or 3) and press
Controlled
Start
Initialization
**** EXTENDED
AXIS
SETTING PROGRAM ****
**** Ext Axis 1 Initialization
****
33.
34.
35.
36.
37.
0.
ALPHA MOTOR SIZE

ACa0.5
38. ACa12
49. ACaM3
ACa1
39. ACa22
50. ACaM6
ACa2
40. ACa30
51. ACaM9
ACa3
41. ACa40
ACa6
42. ACa0.5B
Next page
Select?
NOTE Select ACa0.5 for the 0.5 motor.

5 To display more choices, type 0 and press ENTER. You will see a
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
65.
66.
67.
68.
69.
0.
ALPHA
ACaL3
81.
ACaL6
82.
ACaL9
83.
ACaL25
84.
ACaL50
97.
Next page
Select?
MOTOR SIZE
ACaC3
98. ACaHV22
ACaC6
99. ACaHV30
ACaC12
ACaC22
ACaHV12
4--42
MARF2HD4307701E
6 Select the size of the motor for your extended axis. The motor size
can be found on the motor name plate on your robot. You will see a
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
MOTOR TYPE
1. /2000
6. F/3000
2. /3000
7. F/2500
3. S/2000
8. L/3000
4. S/3000
9. /1200
5. F/2000
10. /1500
Select?
7 Select the motor type for your robot and press ENTER. You will see a
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
CURRENT LIMIT FOR AMPLIFIER
1.
2A
6. 60A
2.
4A
7. 80A
3. 12A
8. 100A
4. 32A
9. 130A
5. 40A
10. 20A
Select?
4--43
MARF2HD4307701E
Refer to Table 4--4 and Table 4--5 for information on specifying servo
amplifier information.
Table 4--4.
Amplifier Type
Single Axis Amplifier
Dual Axis Amplifier
SVU1-12
A06B-6089-H101
Current Limit
L Axis (A)
12
SVU1-20
A06B-6089-H102
20
SVU1-40
A06B-6089-H104
40
SVU1-80
A06B-6089-H105
80
SVU1-130
A06B-6089-H106
130
SVU2-12/12
A06B-6089-H201
12
12
SVU2-12/20
A06B-6089-H202
12
20
SVU2-20/20
A06B-6089-H203
20
20
SVU2-12/40
A06B-6089-H204
12
40
SVU2-20/40
A06B-6089-H205
20
40
SVU2-40/40
A06B-6089-H206
40
40
SVU2-40/80
A06B-6089-H207
40
80
SVU2-80/80
A06B-6089-H208
80
80
SVU2-12/80
A06B-6089-H209
12
80
SVU2-20/80
A06B-6089-H210
20
80
Name
Part Number
Table 4--5.
Amplifier Type
Single Axis Amplifier
Dual Axis Amplifier
SVU Servo Amplifier Specification

Current Limit
M Axis (A)
-
C-Series Servo Amplifier Specification
C-series 1-4
A06B-6066-H002
Current Limit
L Axis (A)
4
C-series 1-12
A06B-6066-H003
12
C-series 1-40
A06B-6066-H004
40
C-series 1-60
A06B-6066-H005
60
C-series 1-80
A06B-6066-H006
80
C-series 1-130
A06B-6066-H007
130
C-series 1-80
A06B-6066-H011
80
C-series 1-60
A06B-6066-H012
60
C-series 4/4
A06B-6066-H211
C-series 4/4
A06B-6066-H222
C-series 4/40
A06B-6066-H223
12
C-series 4/40
A06B-6066-H224
40
C-series 12/12
A06B-6066-H233
12
12
C-series 12/40
A06B-6066-H234
12
40
C-series 12/60
A06B-6066-H235
12
60
C-series 12/40
A06B-6066-H244
40
40
C-series 80/80
A06B-6066-H266
80
80
C-series 12/12
A06B-6066-H281
12
12
C-series 80/80
A06B-6066-H291
80
80
Name
Part Number
Current Limit
M Axis (A)
-
8 Select the amplifier current limit for your extended axis. Refer to the
FANUC AC Servo Motor Digital Series Descriptions Manual for more
information. You will see a screen similar to the following.
4--44
MARF2HD4307701E
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
EXTENDED AXIS TYPE
1. Integrated Rail (Linear axis)
2. Integrated Arm (Rotary axis)
3. Auxiliary Linear axis
4. Auxiliary Rotary axis
Select?
9 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) is
added to the robot position. You will see a screen similar to the following
if integrated rail or integrated arm is selected.
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
EXTENDED AXIS TYPE
1. Integrated Rail (Linear axis)
2. Integrated Arm (Rotary axis)
3. Auxiliary Linear axis
4. Auxiliary Rotary axis
Select? 1
Direction
1:X
2:Y
3:Z
Enter Direction (1~3)?
Select?
10 Type the direction of the extended axis alignment and press ENTER.
D For integrated rail, the rail alignment is usually with respect to the
user frame axes of the robot.
D For integrated arm, arm specific information is required. Typically,
the offset length is 0 except for cases where the first axis of the robot
is replaced by an extension arm. The direction defines about which
world axis the arm rotates.
D For auxiliary linear or rotary axes, the extended axis is not added
into the robot position.
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
GEAR RATIO
For a linear axis it is the number of
mms traveled for one rotation of the
motor.
Enter Gear Ratio?
4--45
MARF2HD4307701E
11 Type the gear ratio for the extended axis and press ENTER.
D For linear axes, the gear ratio is in millimeters of travel per
revolution of motor.
D For rotary axes, the gear ratio is in motor turns per single
rotations of the rotary axes, which is 24.
NOTE This number will be used to calculate acceleration variables.
Gear ratio values from 80 -- 100 are most common.
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
MAX JOINT SPEED SETTING
Suggested Speed = 1000.000(mm/s)
(Calculated with Max motor speed)
Enter (1:Change, 2:No Change)?
Select?
12 Type the motor speed if you want it to be lower than the suggested
speed.
D For rotational axes you will be prompted to enter the
Max Joint Speed Setting. If you have entered a gear ratio of 80 -100, the default speed should not need to be changed. However
you might want to change this number if it seems too fast or slow
for your application.
D For linear axes you will be prompted to enter the
Suggested Speed. If you have entered a gear ratio of 80, for
example, your suggested speed will be 2667 mm/sec. If this
seems high, you can slow it down to the 1500 -- 2000 mm/sec
range.
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
MOTOR DIRECTION
Ext_axs 1 Motion Sign = TRUE
Enter (1:TRUE, 2:FALSE)?
Select?
13 Type the extended axis motion sign and press ENTER. The direction
determines which way the motor turns when the positive jog key is
pressed, and should be consistent with axis alignment. You will see a
NOTE If the rotation is incorrect, you can modify it by performing a
controlled start and by performing Procedure 4--7 . Refer to Appendix A.
4--46
MARF2HD4307701E
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
UPPER LIMITS
Enter Upper Limit (mm)?
NOTE Upper and lower limits will be displayed in millimeters (mm) if a

linear axis is used, and in degrees (deg) if a rotational axis is used.
14 Type the upper limit of the extended axis and press ENTER. You will
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
LOWER LIMITS
Enter Lower Limit (mm)?
15 Type the lower limit of the extended axis and press ENTER. You will
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
MASTER POSITION
Enter Master Position (mm)?
16 Type the Master Position of the extended axis and press ENTER. You
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
ACC/DEC TIME
Default acc_time1 = 360(ms)
17 Type the appropriate acceleration constant and press ENTER. You

Controlled
****
EXTENDED
Start
AXIS
Initialization
****
Enter (1:Change, 2:No Change)? 2
4--47
MARF2HD4307701E

****
EXTENDED
AXIS
Controlled
Start
Initialization
****
EXP_ACCEL TIME
Default exp_accel time = 0(ms)
Enter (1:change, 2:No Change)?
19 Type the exponential acceleration time and press ENTER. You will
****
EXTENDED
AXIS
Controlled
Start
Initialization
****
MIN_ACCEL TIME
Default min_acctime = 256(ms)
20 Type the appropriate minimum acceleration constant and press

****
EXTENDED
AXIS
Controlled
Start
Initialization
****
LOAD RATIO
Load Ratio is
Load Inertia (Kg*cm*s**2)
-------------------------Motor Inertia (Kg*cm*s**2)
Enter Load ratio? (0:None 1-5:Valid)
4--48
MARF2HD4307701E
21 Type the load ratio and press ENTER.

The load ratio adjusts the gain of the axis based on the load inertia and the
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.

Refer to the FANUC AC Servo Motor Digital Series Descriptions Manual
for more information. You will see a screen similar to the following.
****
SELECT AMP NUMBER
Enter amplifier number (1-16)?
NOTE The amplifier number is the number of the amplifier that is

connected to the extended axis you are adding. Amplifiers are numbered
sequentially.
For example, a standard S-420i, 6-axis robot with one additional extended axis
has two amplifiers; one for the 6-axis robot (#1) and one for the extended axis
(#2). In this case, you will enter the number 2 in Step 22 as the number of the
amplifier that is connected to the extended axis you are adding. Refer to
Table 4--6 for typical robot model servo amplifier configurations.
Table 4--6.
Robot
Model
Axis 1
Axis 2
Axis 3
Typical Robot Model Servo Amplifier Configurations

Axis 4
Arc Mate
100
Amplifier #1
Arc Mate
120
Amplifier #1
Arc Mate
100i (M-6i)
Amplifier #1
Arc Mate
120i (M-16i)
Amplifier #1
S-6
Amplifier #1
S-12
Amplifier #1
S420i
S-450
Axis 5
Axis 6
Amplifier #2
Axis n
Optional extended axes

used on these robot
models are numbered
starting with amplifier #2.

used on these robot
models are numbered
Amplifier #1
Amplifier #1
Axis 7
Amplifier #3
Amplifier #4
Optional
extended
axes used
on this
robot model
are
numbered
starting with
amplifier
#5.
4--49
MARF2HD4307701E
Table 4--6. (Contd) Typical Robot Model Servo Amplifier Configurations

Robot
Model
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
S-500
A-520i
Axis n

used on these robot
models are numbered
Amplifier #1
M-400i
Axis 7
S-700
S-800
Amplifier #1
Amplifier #2
Amplifier #3
S-900
Amplifier #1
Amplifier #3
Amplifier #5
Amplifier #2
Amplifier #4
M410i
Amplifier #1
Amplifier #2
Amplifier #3
Amplifier #4
Optional extended axes used on this robot model are

numbered starting with amplifier #5.
M-500
Amplifier #1
Amplifier #3
Amplifier #2
Amplifier #3
Amplifier #4
M-710i
Amplifier #4
Amplifier #1
Amplifier #5

used on this robot model
are numbered starting
with amplifier #6.
Amplifier #6

with amplifier #7.
Optional extended axes used on this

robot model are numbered starting with
amplifier #5.
with amplifier #2.
22 Type the number of the amplifier for the axis. You will see a screen
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
SELECT AMP TYPE
1. A06B-6076 series 6 axes amplifier
2. A06B-6089 Alpha C series
3. A06B-6079 Alpha series
4. A06B-6066 C series
Select?
23 Type the number of the kind of amplifier you are using. Typically this
is C Series.
****
EXTENDED
AXIS
Controlled
Start
Initialization
****
BRAKE SETTING
Enter Brake Number (0-4)?
CAUTION
Make sure that the brake number is assigned and is connected
correctly; otherwise, improper operation will result.
4--50
MARF2HD4307701E
24 Type the brake connection point and press ENTER.

NOTE The above brake number represents the brake control that the
extended axes are on.
- Typically, you will use brake 2.
- A zero (0) means no brake is used.
- Brakes 3 and 4 require a special cable, from JD20 on the
Additional Axis Control Board to CRR16 on the E-stop Board.
(Refer to the Extended Axis and Group Motion Setup and
Operations Manual for more information.)
- In a B cabinet, if the extended axis has brakes, they should be
connected in the controller. Brake 1 is reserved for the robot
(special connector), brake 2 is available for extra axes. Brake 2 is
located on the EMG CONT printed circuit board (BKP4-BKM4,
BKP5-BKM5). Each brake requires 0.6A or 0.8A, depending on
the specification, and each brake output is fused at 2.0A.
Additional brakes 3 and 4 are available, but require additional
hardware (cable) and setup to install.
- Never use brake control 1 for extended axis. Brake control 1 is for
the robot axes only.
WARNING
Never use brake control 1 for extended axis brakes. Brake
control 1 is for the robot axes only. Using brake control 1
for extended axis brakes could cause unexpected results
and injure personnel or damage equipment.
****
EXTENDED
AXIS
Controlled
Start
Initialization
****
SERVO TIMEOUT
Servo Off is Enable
Enter (1: Enable 2: Disable)
Select?
25 Select whether to enable or disable SERVO OFF and press ENTER.

If enabled, SERVO OFF allows the brakes to hold the axis and drop
servo power after the specified time.
You will see a screen similar to the following
****
EXTENDED
AXIS
Controlled
Start
Initialization
****
SERVO TIMEOUT VALUE
Enter Servo Off Time? (0.0~30.0 Sec)
4--51
MARF2HD4307701E
26 Type the servo off time and press ENTER.

If you used Procedure 4--5 to begin installing extended axes, you will
Controlled
****
EXTENDED
Start
AXIS
Initialization
E1 E2 E3
*** Group 1 Total Ext Axis = I * *
1. Display/Modify ext axis 1->3
2. Add Ext_axis
3. Delete Ext_axis
4. Exit
select?
If you used the controlled start menus to begin installing extended

axes, you will see a screen similar to the following.
1.
2.
3.
4.
5.

Add/Delete Group
Exit
Press ENTER or number key to select.
27 Repeat Steps 3 through 26 for each extended axis you are adding.
28 When you have finished type 4, Exit, and press ENTER. You will
S/W INSTALL
Appl/Tool:

HandlingTool
1 Setup Application
2 Install Option
3 Install Update
[TYPE]
1/3
4--52
Performing a Cold Start
MARF2HD4307701E
1 Press FCTN.
2 Select START (COLD).
NOTE If the application is not set up, the cold start procedure will abort,
and the following warning will be displayed:
Setup
Application prior to START (COLD).
NOTE If the application is not set up, the cold start procedure will abort,
and the following warning will be displayed:
Procedure 4--5
Setup
3 When the controller is turned on, you should master and calibrate
the robot. Refer to Chapter 5.
If you want to load more options, go to Procedure 4--5 .
4--53
MARF2HD4307701E
4.7
INSTALLING MOTION
GROUP SOFTWARE
Motion groups provide the ability to have multiple devices on a single

controller, each with their own control program for independent operation.
The first time you install motion groups, you must use the option
installation procedure (Procedure 4--5 ). When you have finished
Procedure 4--5 , go to Procedure 4--9 to install and set up the motion
group hardware. You can also use Procedure 4--9 to delete motion groups.
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Section 4.2
Section 4.3
Section 4.4
Procedure 4--9
Condition
Step
Start
Quick/Full
Password
Section 4.5
Install or
modify
extended
axes
(optional)
Section 4.4
and
Section 4.6
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.7
Section 4.8
Installing Motion Groups

H
If the controller is turned on, turn it off.
You have completed Procedure 4--4 and Procedure 4--5 .
1 Connect the PS-100 disk drive cable to the RS-232-C port on the
operator panel.
operator panel or operator box until you see the BMON> prompt on
the teach pendant.
BMON>
BMON> CTRL
6 Press F5, START and press ENTER. This performs a controlled start
of the controller.
1.
2.
3.
4.
MOTION SYSVAR SETUP

PROGRAM INIT
MOTION DEVELOPMENT
EXIT
7 Type 1.
4--54
MARF2HD4307701E
Perform sysvar setup? [NO]

YES
NO
1.
2.
3.
4.
5.

Add/Delete Group
Exit
9 Type 2, and press ENTER.

Add/Delete Group? [NO]
YES
NO

1. Add Motion Group(s)
2. Delete Motion Group(s)
3. Exit
Adding or Deleting
Motion Groups
11 To add motion groups, type 1.

To delete motion groups, type 2.
Add Motion Group(s)? [NO]

YES
NO

Current $NUM_GROUP=1
Enter number of groups to add
NOTE Type the total number of groups to be added or deleted. Do not

type the number of the motion group.
13 Type the total number of motion groups you are adding, and press
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.
NOTE Motion groups are deleted sequentially starting at the highest
numbered group.
4--55
MARF2HD4307701E

1. Add Motion Group(s)
2. Delete Motion Group(s)
3. Exit
14 Type 3.
Exit?
YES
NO
Number of Motion Groups are modified
Please Exit Karel Startup program
and CTRL start sequence will be run
again (automatically) to update (add/del
new sysvars). Press CONT to continue
Press CONT func key to continue
CONT
16 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 displayed
when you are adding a motion group. You will see this sequence of
screens each time you add a motion group.

*****
1 A-520i Robot Library
4 M-16iL/ARCMATE-120iL
6 M-410i Robot Library
10 NEXT MENU
*****
4--56
MARF2HD4307701E

*****
0 PREV MENU
11 M-410iWx Robot Lib
13 M710i Robot Library
15 S-6 (ARCMATE-100) Lib
16 S-12 (ARCMATE120) Lib
17 S-420iF Floor Mnt Lib
20 NEXT MENU
*****
D
D


*****
0 PREV MENU
21 S-420iL Long Arm Lib
22 S-420iR Rack Mnt Lib
23 S-420iS Hi Force Lib
24 S-420iW H Payload Lib
30 NEXT MENU
*****
D
D


*****
0 PREV MENU
31 Ofset Wrist S-700 Lib
34 Coord Nobot Library
35 Nobot Library
*****
D
D

4--57
MARF2HD4307701E
17 Type the number that corresponds to the library for the new group
(typically Nobot is used), then press ENTER.
CAUTION
You can only set up coordinated motion nobot, C-100, an
opener, or a nobot as motion group 2 or 3. Do not set up any
other robot model or your system will operate incorrectly.
If you add the wrong device, delete the motion group (Step
11 of this procedure) then add it again and select the correct
robot model.
SELECT HARDWARE
Enter hardware start number for the
extended axes
18 Type the starting number of the motion group hardware and press
ENTER. For example, if you are adding a nobot to a six-axis robot,
the starting number is 7. The hardware specific information will be
added automatically.
Loading Servo Parameters
19 Answer the remaining prompts according to the type of multi-group

device you have selected. This information is similar to the
information you must specify in Procedure 4--8 .
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 the
following:
D
D
D
D
D
Link length information

Motor parameters
Limit parameters
Acceleration parameters
Mastering information

*** Group 1 Nobot Axis Setup Program ***
*** Group 1 Total Nobot Axes = 1 ***
1. Display/Modify Nobot Axes 1~6
2. Add Nobot Axis
3. Delete Nobot Axis
4. EXIT
Select?
4--58
MARF2HD4307701E
20 Type 1, and press ENTER. You will see a screen similar to the
following.
Controlled
****
Group 2Start
NobotInitialization
Axis Setup Program ****
**** Nobot Axis 1 Initialization
****
33.
34.
35.
36.
37.
0.
ALPHA MOTOR SIZE

ACa0.5
38. ACa12
49. ACaM3
ACa1
39. ACa22
50. ACaM6
ACa2
40. ACa30
51. ACaM9
ACa3
41. ACa40
ACa6
42. ACa0.5B
Next page
Select?
21 To display more choices, type 0 and press ENTER. You will see a
**** Group 2 Nobot Axis Setup Program ****
****
ALPHA
65. ACaL3
81.
66. ACaL6
82.
67. ACaL9
83.
68. ACaL25
84.
69. ACaL50
97.
0. Next page
Select?
Motor Parameters
MOTOR SIZE
ACaC3
98. ACaHV22
ACaC6
99. ACaHV30
ACaC12
ACaC22
ACaHV12
22 Select the size of the motor for your nobot. The motor size can be
found on the motor name plate on your robot. You will see a screen
****
Controlled
Group 2Start
NobotInitialization
Axis Setup Program ****
****
MOTOR TYPE
1. /2000
6. F/3000
2. /3000
7. F/2500
3. S/2000
8. L/3000
4. S/3000
9. /1200
5. F/2000
10. /1500
Select?
4--59
MARF2HD4307701E
23 Select the motor type for your nobot.

NOTE All motor combinations might not be supported by the FANUC
Robotics parts department.
*** Nobot Axis 1 Initialization
***
Controlled
Start
Initialization
CURRENT
LIMIT
FOR AMPLIFIER
6. 60A
7. 80A
8. 100A
9. 130A
10. 20A
1. 2A
2. 4A
3. 12A
4. 32A
5. 40A
Select?
24 Select the amplifier current limit for your extended axis. Refer to the
FANUC AC Servo Motor Digital Series Descriptions Manual for more
information. You will see a screen similar to the following.
***
NOBOT AXIS TYPE
1. Linear Axis
2. Rotary Axis
Select?
NOTE If the motor combination you specified in the previous steps is not
supported, the message, Motor type not found, will be displayed. The
system will ask for the motor information again. Type a valid motor
combination and repeat Steps 22 through 41.
25 If you have a linear axis, type 1.
If you have a rotary axis, type 2.
***
GEAR RATIO
Enter Gear Ratio?
26 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 is
25mm, the gear ratio is 2(pi)(25) = 157.08.
4--60
MARF2HD4307701E
If the axis has a gear box between the motor and pinion, divide the
number by the gear ratio. For example, if the motor is connected to a
5:1 gear box and a 50mm pinion, the gear ratio is
(2)(pi)(25)/5 = 31.416.
The gear ratio for rotary axes is in motor turns per single rotation of
the rotary axes. The ratio is ng2:ng1, where ng is the number of teeth
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 ratio
would be 2:1.
***
MAX JOINT SPEED SETTING
Suggested Speed = 200.040(deg/s)
(Calculated with Max Motor Speed)
Select?
Enter Max Speed (deg/s)?
27 Type 1 to change the maximum joint speed and press ENTER.

NOTE The maximum joint velocity is automatically calculated, based on
the gear ratio and the maximum RPM of the motor chosen. This value can
be used or it can be lowered.
CAUTION
Do not increase the value of the maximum joint velocity,
otherwise the maximum motor RPM will be exceeded, possibly
damaging equipment and causing unexpected results.
28 Type the motor speed. You will see a screen similar to the following.
***
MOTOR DIRECTION
NOBOT 1 Motion Sign = TRUE
Enter (1: TRUE, 2: FALSE)
Select?
4--61
MARF2HD4307701E
29 Type the nobot axis motion sign and press ENTER.

The direction determines which way the motor turns when the positive
jog key is pressed, and should be consistent with axis alignment.
TRUE indicates that the motor will turn counterclockwise when
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. Go to Step 14.
***
UPPER LIMITS
Enter Upper Limit ( deg)?
Limit Parameters
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.
***
LOWER LIMITS
Enter Lower Limit (deg )?
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 hard
stop. This is usually 0 or a negative number.
***
MASTER POSITION
Enter Master Position ( deg)?
Master Position
32 Type the Master Position of the nobot and press ENTER. You will see
a screen similar to the following.
***
ACC/DEC TIME
Default Value of acc_time1 = 360(ms)
4--62
Acceleration Constant
MARF2HD4307701E
33 Type 1 to change the acceleration constant and press ENTER. You

***
ACC/DEC TIME
Enter Accel Time1 (ms)?
34 Type the appropriate acceleration constant and press ENTER.

The sum of acc_time_1 and acc_time_2 is the time, in milliseconds, it
will take for the axis to reach full joint speed. The min_acctime value
is used for acceleration/deceleration if the distance between the two
points is short enough that the axis cannot reach full speed.
***
ACC/DEC TIME
Enter Accel Time1 (ms)? 360
35 Type 1 to change the acceleration constant and press ENTER. You

***
ACC/DEC TIME
Enter Accel Time1 (ms)? 360
Enter Accel Time2 (ms)?
4--63
MARF2HD4307701E

***
MIN_ACCEL TIME
Default Value of min_acctime = 256(ms)
37 Type 1 to change the minimum acceleration time and press ENTER.

***
MIN_ACCEL TIME
Default Value of min_acctime = 256(ms)
Enter Minimum Accel Time (ms)?

***
LOAD RATIO
Load Ratio is
Load Inertia (Kg*cm*s**2)
-------------------------Motor Inertia (Kg*cm*s**2)
Enter Load ratio? (0:None 1~5:Valid)
4--64
Load Ratio
MARF2HD4307701E
39 Type the load ratio and press ENTER.

The load ratio adjusts the gain of the axis based on the load inertia and the
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.

**** Group 2 Nobot Axis Setup Program ****
****
SELECT AMP NUMBER
Enter amplifier number (1-16)?
40 Type the number of the amplifier for the axis. You will see a screen
Controlled
****
EXTENDED
Start
AXIS
Initialization
****
SELECT AMP TYPE
1. A06B-6076 series 6 axes amplifier
2. A06B-6089 Alpha C series
3. A06B-6079 Alpha series
4. A06B-6066 C series
Select?
41 Type the number of the kind of amplifier you are using. Typically this
is C Series. You will see a screen similar to the following.
***
BRAKE SETTING
Enter Brake Number (0~4)?
CAUTION
Make sure that the brake number is assigned and is connected
correctly, otherwise, improper operation will result.
4--65
MARF2HD4307701E
42 Type the brake connection point and press ENTER.

If the nobot axis has brakes, they should be connected in the controller.
Brake 1 is reserved for the robot (special connector), brakes 2 through
4 are available for nobot axes. Brakes 2 through 4 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 at 2.0A.
***
SERVO TIMEOUT
Servo Off is Disable
Enter (1: Enable 2: Disable)?
Select?
43 Select whether to enable or disable SERVO OFF press ENTER.

If enabled, SERVO OFF allows the brakes to hold the axis and drop
servo power after the specified time.
***
SERVO TIMEOUT VALUE
Enter Servo Off Time? (0.0~30.0)
44 Type the servo off time and press ENTER. You will see a screen
***
*** Group 1 Total Nobot Axes = 1
1. Display/Modify Nobot Axis 1~6
2. Add Nobot Axes
3. Delete Nobot Axes
4. Exit
Select? 1
Enter Axis to Display/Modify(1~6)?
4--66
MARF2HD4307701E
45 You can either continue adding axes, or exit.

If you want to add/delete other axes, type 2, Add/delete Nobot Axes
and repeat Steps 20 through 44.
If you are finished, type 4, Exit. You will see a screen similar to the
following.
S/W INSTALL
Appl/Tool:

HandlingTool
1/3
1 Setup Application
2 Install Option
3 Install Update
[TYPE]
1 Press FCTN.
3 When the controller is turned on, master and calibrate the robot.
Refer to Chapter 5.
4--67
MARF2HD4307701E
4.8
INSTALLING
SOFTWARE UPDATES
Software updates are disks that contain updated information to your

application and robot library software. Installing software updates is
optional and should only be performed if you have a disk labeled Update
and it is consistent with the software version you have loaded in the
controller.
Set up the
Load
Device
Install
HandlingTool
Software and
Firmware
Install
software
options
(optional)
Quick/Full
Password
Section 4.2
Section 4.3
Section 4.4
Section 4.5
Install or
modify
extended
axes
(optional)
Section 4.4
and
Section 4.6
Install
motion
groups
(optional)
Install
software
updates
(optional)
Section 4.7
Section 4.8
Use Procedure 4--10 to install software updates.

Procedure 4--10 Installing Software Updates
CAUTION
Be sure to install all option disks before you install any update
disks or the system could become corrupted.
Condition
Step
Start
You have completed Procedure 4--4 and Procedure 4--5 .
You have obtained a PS-100 disk drive.
You have the R-J2 software update disks that you want to install.
The PS-100, memory card interface or PC compatible computer is

connected to the controller and is turned on. (Refer to Section 4.2)

teach pendant.
5 At the BMON> prompt press F3, RUN.
6 Press F2, UPDATE and then press ENTER.
BMON>
4--68
MARF2HD4307701E
8 Now press F5, START and press ENTER. This performs a controlled
start of the controller. You will see a screen similar to the following.
BMON> CTRL

1
2
3
4
MOTION SYSVAR SETUP

PROGRAM INIT
MOTION DEVELOPMENT
EXIT

Exit? [NO]
YES
NO
9 Type 4, then press ENTER.

S/W INSTALL
Appl/Tool:

HandlingTool
1/3
1 Setup Application
2 Install Option
3 Install Update
[TYPE]
11 Use the arrow keys to select 3 Install Update.

12 Insert the update disk in the disk drive.
13 Press ENTER.
Checking configuration...
The maintenance update will begin to install. Steps 14 and 15 will be

repeated automatically for each update on the update disk.
4--69
MARF2HD4307701E
14 If the update is mismatched with the current robot configuration,

then a message similar to the following will be displayed:
Update
is not valid for this configuration.
Press ENTER to return to the previous menu.

15 If the update is appropriate for the current robot configuration,
then a message similar to the following will be displayed:
Update
is valid for this configuration.
16 If you need to install additional updates, go to Step 12.

17 When the update has finished loading, remove the update disk from
the disk drive.
1 Press FCTN.
NOTE If the application is not set up, the cold start procedure will
abort, and the following warning will be displayed:
Setup
To set up the application, go to Procedure 4--4 .
MARF2HD4307701E
MASTERING
5--1
When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robots positional
information. A robot must be mastered to operate properly. Robots are
usually mastered before they leave FANUC Robotics. However, it is
possible that a robot might lose its mastering data and require to be
remastered.
Topics In This
Chapter
Robots
Resetting Alarms and

Preparing for Mastering
All except
P-200
Mastering to a fixture
(Fixture Position Master)
All except
P-200
When to Use
When you power up the robot after disconnecting the

pulsecoder backup batteries you might see a
SRVO--062 BZAL or SRVO--038 Pulse mismatch alarm.
Before mastering the robot you must reset the alarm
and rotate the motor of each axis that lost battery power
to prepare the robot for mastering. . . . . . . . . . . . . . . . . . . . . . 5--3
D
D
D
D
D
Mastering to zero degrees
M-series
S-series
P-series
D
D
D
Single axis mastering
S-series
M-series
P-series
Page
When mastery was lost due to mechanical

disassembly or repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
When a quick master reference position was not
previously set.
Method of choice for P- and A-series robots.
Method of choice for A-series robots.
Used for S-series and M-Series robots when
extreme precision is required.
When mastery was lost due to mechanical
disassembly or repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
When a quick master reference position was not
previously set.
Method of choice for S- and M-series robots when
extreme precision is not required.
When mastery was lost due to mechanical disassembly

or repair of a single axis (usually due to
motor replacement). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--10
Quick mastering
All
To retrieve mastering data that has been stored as a

quick master reference position when mastery is lost
due to an electrical or software problem. Do not use if
mastery was lost due to mechanical disassembly
or repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--13
Recording the quick

master reference position
All
To record mastering data as a reference for future

quick mastering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--14
5. MASTERING
5--2
MARF2HD4307701E
Before you master the robot, you must clear any faults that prevent
servo power from being restored or that prevent mastering completion.
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 more
information on mastering using a fixture.
Quick mastering is a convenient way to master an M-series or S-series
robot after you have recorded a reference position. You cannot quick
master a robot unless the reference position was taught before mastering
was lost.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
Use Procedure 5--1 to clear common faults related to mastering and to
prepare the robot for mastering. For more detailed information on fault
recovery, refer to the SYSTEM R-J2 Controller Series Electrical
Connection and Maintenance Manual.
5. MASTERING
5--3
MARF2HD4307701E
5.1
RESETTING ALARMS
AND PREPARING FOR
MASTERING
When you power up the robot after disconnecting the pulsecoder backup
batteries you might see a SRVO--062 BZAL or SRVO--038 Pulse
mismatch alarm. Before mastering the robot you must reset the alarm and
rotate the motor of each axis that lost battery power to prepare the robot
for mastering.
Use Procedure 5--1 to reset these alarms and prepare the robot for
mastering.
NOTE These SRVO errors will also appear after you have performed a
full load of the robot.
Procedure 5--1
Condition
Step
Preparing the Robot for Mastering

H
You see a SRVO--062 BZAL or SRVO--038 Servo mismatch alarm.
1 If you receive a SRVO-062 alarm, replace the robot batteries with four
new 1.5 volt alkaline batteries, size D. Observe the direction arrows in
the battery box for proper orientation of the batteries.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
5. MASTERING
MARF2HD4307701E
5--4
e Select Master/Cal. You will see a screen similar to the following.

WARNING
For M-6i (ARC Mate 100i), an M-16i (ARCMate 120i), S-6
(ARC Mate 100), and S-12 (ARC Mate 120) robots, the
TORQUE function key on the SYSTEM Master/Cal screen
releases the robot brakes. When the brakes are released,
the robot arm will drop suddenly. DO NOT use this
function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%
FIXTURE POSITION MASTER

ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE

[ TYPE ]
LOAD
DONE
RES_PCA
6 Press F3, RES_PCA. You will see a screen similar to the following.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE

Reset pulse coder alarm? [NO]
[ TYPE ]
YES
NO
5. MASTERING
5--5
MARF2HD4307701E
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
Pulse coder alarm reset!
[ TYPE ]
LOAD
RES_PCA
TORQUE
DONE
8 If the SRVO--062 alarm is still present; there is a battery, cable or

pulsecoder problem. Refer to the SYSTEM R-J2 Controller Series
Electrical Connection and Maintenance Manual for further
information.
9 If a SRVO--038 alarm is present at this time, repeat steps 1 through 6
to reset it. It is not necessary to cold start the robot after resetting to
clear this alarm.
10 Rotate each axis that lost battery power by at least one motor
revolution in either direction.
a Jog each rotary axis at least twenty degrees.
b Jog each linear axis at least thirty millimeters.
11 Perform any of the mastering procedures from the MASTER/CAL
menu.
5. MASTERING
MARF2HD4307701E
5--6
5.2
MASTERING TO A
FIXTURE (FIXTURE
POSITION MASTER)
When you master to a fixture, you use a mastering fixture to align the
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.
NOTE If you have an M-6i (ARCMate 100i), an M-16i (ARCMate 120i),
an S-12 (ARCMate 120), or an S-6 (ARCMate 100), robot, do not use the
following procedure. These robots require that servo power be removed
and brakes released in order to use the fixture. Refer to the Mechanical
Service Manual or Mechanical Connection and Maintenance Manual for
detailed procedures on mastering these robots to a fixture.
Use Procedure 5--2 to master to a fixture.
Procedure 5--2
Condition
Step
Mastering to a Fixture
H
You have the appropriate mastering fixture for your robot.
You have cleared any servo faults that prevent you from jogging the
robot.
You have jogged each axis that has lost mastery at least one motor
turn. (Procedure 5--1 ).
1 Install the mastering fixture on the robot and jog the robot into
mastering position. Refer to the Mechanical Service Manual or
Mechanical Connection and Maintenance Manual specific to your
robot model for the procedures on how to set up and use a mastering
fixture.
2 Press MENUS
3 Press SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
5. MASTERING
5--7
MARF2HD4307701E

WARNING
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE

[ TYPE ]
LOAD
RES_PCA
DONE
6 Select Fixture Position Master.

7 Press F4, YES. Mastering will be performed automatically.
8 Select Calibrate.
9 Press F4, YES.
5. MASTERING
MARF2HD4307701E
5--8
5.3
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.
ZERO DEGREE
MASTERING
Use Procedure 5--3 to master to zero degrees.
Procedure 5--3
Condition
Step
Mastering to Zero Degrees (for all robots except S-420iR)

H
robot.
1 Using the joint coordinate system, jog each axis of the robot to the
zero degree witness mark. Refer to the Mechanical Service Manual or
Mechanical Connection and Maintenance Manual specific to your
robot model for the location of the witness marks.
2 Press MENUS.
3 Press SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
5. MASTERING
5--9
MARF2HD4307701E

WARNING
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
RES_PCA
DONE
6 Select Zero Position Master.

7 Press F4, YES. Mastering will be performed automatically.
8 Select Calibrate.
9 Press F4, YES.
5. MASTERING
MARF2HD4307701E
5--10
5.4
You can master a single axis of an S-series robot when mastery was lost
due to mechanical disassembly or repair of a single axis, usually due to
motor replacement.
SINGLE AXIS
MASTERING
Use Procedure 5--4 to master a single axis.
Procedure 5--4
Condition
Step
Mastering a Single Axis

H
robot.
1 Using the joint coordinate system, jog the unmastered axis of the robot
to the zero degree witness mark. Refer to the Mechanical Service
Manual or Mechanical Connection and Maintenance Manual specific
to your robot model for the location of the witness marks.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
5. MASTERING
5--11
MARF2HD4307701E

WARNING
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
RES_PCA
6 Select 4, Single Axis Master. You will see a screen similar to the
following.
SINGLE AXIS MASTER

ACTUAL POS
J1
0.000
J2
3.514
J3
-7.164
J4 -357.366
J5
-1.275
J6
4.571
E1
0.000
E2
0.000
E3
0.000
[ TYPE ]
(MSTR POS)
(
0.000)
( 35.000)
(-100.000)
(
0.000)
( -80.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
JOINT 10%
1/9
(SEL) [ST]
(0)
[2]
(0)
[0]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
GROUP
EXEC
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.
5. MASTERING
MARF2HD4307701E
5--12
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.
12 Press PREV.
13 Select Calibrate.
14 Press F4, YES.
5. MASTERING
5--13
MARF2HD4307701E
5.5
QUICK MASTERING
Quick mastering allows you to minimize the time required to remaster the
robot using a reference position you established when the robot was
properly mastered. You cannot quick master the robot unless you have
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properly
mastered. The best time to record the quick master reference position is
when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can use
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--5 to record the quick master reference position. Use
Procedure 5--6 to quick master the robot.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
5. MASTERING
MARF2HD4307701E
5--14
Procedure 5--5
Condition
Step
Recording the Quick Master Reference Position

H
The robot is properly mastered.
1 Align the witness marks on the robot. This is the zero position, which
will be the quick master reference position. Refer to the Mechanical
Service Manual or Mechanical Connection and Maintenance Manual
specific to your robot model for the location of the witness marks.
If you have an A-series robot, jog all robot axes to zero degrees and
scribe witness marks on each axis.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
WARNING
5. MASTERING
5--15
MARF2HD4307701E
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
RES_PCA
DONE
6 Move the cursor to SET QUICK MASTER REF and press ENTER.
Set quick master ref? [NO]
7 Press F4, YES.
5. MASTERING
MARF2HD4307701E
5--16
Procedure 5--6
Condition
Quick Mastering the Robot

H
The robot has lost mastery due to an electrical or software problem.
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.
Step
The quick master reference position was recorded before the robot lost
mastery.
robot.
1 Jog the robot to the quick master reference position (zero degree
position).
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
5. MASTERING
5--17
MARF2HD4307701E

WARNING
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE

[ TYPE ]
LOAD
RES_PCA
DONE
6 Move the cursor to QUICK MASTER and press ENTER.

Quick master? [NO]
7 Press F4, YES.

8 Move the cursor to CALIBRATE and press ENTER
9 Press F4, YES.
MARF2HD4307701E
TROUBLESHOOTING AND ERROR

MESSAGES
6--1
This chapter contains information on how to solve problems that occur
during setup and installation of the R-J2 Software and EPROM Package.
Page
Troubleshooting Using
Symptoms
Use this when you have a problem with the system but do not see an error
message on the screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
Troubleshooting Using
Error Messages
Use this when you have a problem with the system and see an error message
on the screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
Checking Memory
Use this when you have to check the amount and allocation of memory in
your controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
6. TROUBLESHOOTING AND ERROR MESSAGES

MARF2HD4307701E
6--2
6.1
Refer to Table 6--1 to determine the cause of a problem and to solve it.
TROUBLESHOOTING
USING SYMPTOMS
Table 6--1.
Symptom
The controller will not turn on.
Troubleshooting Symptoms and Solutions
Possible Cause
Solution
The controller disconnect or circuit

breaker is turned off.
Turn on the controller disconnect or circuit

breaker.
The power ON button on the controller

has not been pressed.
Press the power ON button.
Internal hardware is not operating

properly.
Check the Mechanical Unit Connection and

Maintenance Manual for your specific robot
model for specific troubleshooting procedures.
The controller is not receiving the proper

power, or the front panel cable is not
plugged in.

Maintenance Manual for your robot model for
specific troubleshooting procedures.
The EX-OP JRM10 cable is not

connected to the CPU.
Check the cable connection to the MAIN CPU

PCB.
The controller will turn on but the

Boot Monitor prompt (BMON>) is
not displayed when the PREV
and NEXT keys on the teach
pendant are pressed while the
controller is turned on.

properly.


properly, or the BootROM is installed
upside down.

The controller will turn on (Boot

Monitor is running) but the R-J2
software will not start running.
The MAIN CPU is not operating properly. Replace defective memory boards as
necessary and reload R-J2 software.
A file will not load.
The PS-100 disk drive is not functioning

properly.
y
Turn off the power to the disk drive then turn

the power on again.
Check the disk using BMON>TEST DISK.
Refer to Appendix A, BootROM Operations,
Extensions can cause communication

problems.
RS-232-C serial communication calling is

limited to 25 meters. The PS-100 disk drive
uses PIN 25 for 24VDC and PIN1 for 0VDC.
Some RS-232-C cables are made up as a Null
Modem cable.
Remove the extension cable and retest the
disk drive using only the cable supplied with
your disk drive.
6--3
MARF2HD4307701E
Table 6--1. (Contd) Troubleshooting Symptoms and Solutions

Symptom
A file will not load.
Possible Cause
Solution
The PS-100 disk drive is not functioning

properly.
Try using a different or new disk drive.
The disk is corrupted.
Check the disk using BMON>TEST DISK.

Refer to Appendix A, BootROM Operations,
If the disk is ok but file access problems still
occur, try using a different or new disk.
Contact FANUC Robotics to receive a new
disk.
A file was omitted from the disk.
Contact FANUC Robotics to receive a new

disk.
The proper device was not selected

in the Port Init menu. Set the
device to PS-100/200
The controller will not turn on.
If a VT-220 terminal is being used, the

cable is configured incorrectly or is
broken/intermittent.
Configure the cable as follows:
R-J2 Controller
Pin
2
3
4
5
6
8
20
7
VT-220
Pin
2
3
4
5
6
8
20
7

MARF2HD4307701E
6--4
6.2
TROUBLESHOOTING
USING ERROR
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 controller
hardware to load ROS software disk. After the ROS has been loaded, it
directs the remaining software installation.
Table 6--2 lists the software option messages, their possible cause, and a
typical solution.
Table 6--2.
ROS Error Message
Software Option Messages

Possible Cause
Solution
Too many options installed
The maximum number of software

options is installed.
None
Installed: %s
Installation of software option or update

has finished successfully.
None
Skipped: %s
Software option was not authorized and

was skipped.
Do not install software options of the

same name and version twice.
Not Installed: %s
Software option or update was not

installed.
None
Unauthorized: %s
Software option or update was not

authorized for the configuration.
Contact the FANUC Robotics Spare

Parts Department to purchase and
authorize the option.
Requires: %s
To load this option or update, you must

also have the specified option or update
installed.
Install the specified option or update. If

you do not have the specified option or
update, contact the FANUC Robotics
Spare Parts Department to purchase
and authorize the option.
Authorized: %s
You have performed a successful field

authorization.
None required.
10
Start (COLD) Disallowed
You must set up your application before

you can perform a COLD start.
Set up your application. Refer to

Section 4.3.
11
Start (CTRL2) Disallowed
You must set up your application before

you can perform a CTRL2 start.
Set up your application. Refer to

Section A.1.3.
12
ID/File is Missing/Corrupt
Your software was installed improperly

or the F-ROM in your controller is
damaged.
Reinstall the software from the

beginning.
13
Invalid PAC
You have typed an invalid PAC code.
Retry typing the PAC code again. If you

are still unsuccessful, contact the
FANUC Robotics Spare Parts
Department.
6--5
MARF2HD4307701E
6.3
This section describes how to check the amount of memory in your

system.
CHECKING MEMORY
Table 6--3 lists and describes each memory status item. Use
Procedure 6--1 to check system memory.
Table 6--3. Memory Status
MEMORY STATUS
DESCRIPTION
Pools
Indicates the amount of memory for

D TPP contains teach pendant programs. TPP memory is stored in permanent
memory. Therefore, to determine the amount of memory available for teach pendant
programs, you must subtract the total amount of TPP C-MOS memory shown from
the total amount of permanent memory shown.
D PERM contains system variables, options, and the operating system
D SYSTEM contains the operating system
D IMAGE contains KAREL programs and options
D TEMP contains temporary memory used for system operations
Hardware
Indicates the total amount of memory for

D FROM Flash ROM
D DRAM D-RAM
D CMOS C-MOS RAM
Procedure 6--1
Step
Displaying Memory Status

1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Memory. You will see a screen similar to the following.
STATUS Memory
JOINT
10 %
Total
Available
Pools----------------------------------TPP CMOS
300.0 KB
287.0 KB
PERM CMOS
999.8 KB
275.8 KB
TEMP DRAM
1054.9 KB
340.4 KB
Description:
TPP
Used by .TP, .MR, .JB, .PR
PERM
Used by .VR, RD:, Options
TEMP:
Used by .PC, .VR, Options
[ TYPE ]
DETAIL
HELP

MARF2HD4307701E
6--6
5 To display the DETAIL screen press F2, DETAIL. You will see a
STATUS Memory
Pools
TPP
PERM
SYSTEM
IMAGE
TEMP
Hardware
FROM
DRAM
CMOS
[ TYPE ]
JOINT
10 %
Total Free
Lrgst Free
------------------------------300.0 KB
287.0 KB
287.0 KB
999.8 KB
275.8 KB
274.9 KB
1010.4 KB
188.9 KB
188.9 KB
1023.9 KB
202.9 KB
189.9 KB
1054.9 KB
340.4 KB
331.6 KB
------------------------------4.0 MB
4.0 MB
1.0 MB
BASIC
6 To display the first screen, press F2, BASIC.
HELP
MARF2HD4307701E
BOOTROM OPERATIONS
A--1
The BootROM is a startup program you can use to turn on the robot using
different methods and accessing specific system utilities. The BootROM
hardware consists of the BootROM EPROM chip, located on the Main
CPU PCB.
This appendix describes how to
D
Start up the robot and controller using one of the start methods:
Init start
Controlled start/Controlled 2 start
Cold start
Semi hot start
Re-init start
Access the BootROM prompt, BMON>, and perform operations at the

prompt:
Extended monitor utilities (EMON)

Diagnostic utilities (DIAG)
Install utilities (INSTALL)
Flash ROM utilities (FROM)
Memory Card utilities (MCARD)
A. BOOTROM OPERATIONS
A--2
A.1
STARTUP METHODS
MARF2HD4307701E
BootROM provides the following startup methods:

D INIT start
D Controlled start/Controlled 2 start
D Cold start - standard start method (approximately 30 seconds)
D Semi Hot start - standard start method (approximately 15 seconds)
D Re-Init start
WARNING
DO NOT turn on the robot if you discover any problems or
potential hazards. Report them immediately. Turning on a
robot that does not pass inspection could result in serious
injury.
A.1.1
INIT Start
An initialized (INIT) start occurs automatically as the first phase of

software installation.
CAUTION
Do not use init start to start the controller. An INIT start
erases all information stored in the D-RAM memory pools.
CMOS must be manually cleared before you can perform an
INIT start. Instead, use re-init start (CMOSINIT) to start the
controller. Refer to Section A.1.6.
A--3
MARF2HD4307701E
A.1.2
A controlled start (START CTRL) turns on power to the robot and

controller and allows you to do the following:
D Set robot motion parameters
D Install options and updates
D Load or set system variables
Controlled Start
(START CTRL)
CAUTION
The items that appear on the controlled start screen
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 the
robot and controller.
Table A--1.
ITEM
Motion System Variable
Setup
DESCRIPTION
D
D
D
D
D
Program Initialization
Motion Development
Controlled Start Options
Initialize System Variable Reruns the robot library setup program for the selected
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.
Process Axes Setup/Init Initializes any softparts attached to motion that have not yet
been initialized.
Display System Setup Status Displays the current robot library and whether it is
initialized.
Allows you to set the maximum number of tasks, number of registers, and number of
position registers in the controller.
D
D
D
D
Disable Digital Servo Program Start When FALSE, activates the servo system; TRUE
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.
A--4
MARF2HD4307701E
Table A--1. (Contd) Controlled Start Options

ITEM
Exit
DESCRIPTION
Displays the Configuration screen. Refer to Appendix B for more information on setting
these items. Press FCTN and select START (COLD) when you are done.
D
D
D
D
MENUS key
-- S/W INSTALL
-- S/W VERSION
-- Variables
-- File
-- ALARM
-- Port Init
-- MEMORY
-- CLOCK
FCTN key
-- START (COLD)
-- START (CTRL2)
-- SAVE
-- PRINT SCREEN
Used to install software.

Displays the STATUS:VERSION ID screen.
Displays the SYSTEM Variables screen.
Displays the FILE screen.
Displays the ALARM screen.
Displays the FILE:Port Init screen
Displays the STATUS:MEMORY screen
Displays the SYSTEM:CLOCK screen
Performs a COLD START. Refer to Section A.1.4.

Performs a CTRL2 START. Refer to Section A.1.3.
Saves current data.
Prints the current screen to a serial printer or, if a PC is
connected to the P3 port, to a file called TPSCRN.LS.
-- PRINT CONFIG Prints softpart configuration information to a serial printer or, if a
PC is connected to the P3 port, to a file called CONFIG.LS.
-- UNSIM ALL I/O Unsimulates all I/O settings.
Application Setup
- Performs application-specific setup and initialization.

Install Option
- Used to install standard software options.
Install Update
-
Used to install update software.
Use Procedure A--1 to perform a controlled start.
A--5
MARF2HD4307701E
Procedure A--1 Performing a Controlled Start

Condition
All personnel and unnecessary equipment are out of the workcell.

WARNING
injury.
Step
1 On the teach pendant, press and hold the PREV and NEXT keys.
BMON>
After the BMON> prompt appears on the teach pendant screen, release
the PREV and NEXT keys.
BMON> CTRL
Press F2, CTRL, and press ENTER.
BMON> START
Press F5, START, and press ENTER. This begins the controlled start.
1
2
3
4
MOTION SYSVAR SETUP

PROGRAM INIT
MOTION DEVELOPMENT
EXIT
Select the kind of setup or initialization you want to perform and

continue as directed by the prompts on the screen and the information
specific to your installation.
CAUTION
Never turn off the robot after a START (COLD) or START
(CTRL2) has been selected (when the message, System save
in progress is displayed on the teach pendant). Otherwise,
you will corrupt the controller and all software will have to be
reloaded.
A--6
MARF2HD4307701E
When you are finished with the Controlled Start Initialization:

a
Press 4, EXIT.
If you want to set configuration items, Refer to Chapter 4 for

more information. When you are finished setting these items,
press FCTN and select START (COLD).
If you want to operate the robot, perform a cold start. Press

FCTN and select START (COLD).
If you want to load system variable files, press MENUS, select

FILE and load .SV or .VR files. Refer to Appendix C.
If you want to load teach pendant programs at this time, you

must perform a Controlled 2 Start. You cannot load teach pendant
files at a Controlled Start. Refer to Section A.1.2.
A--7
MARF2HD4307701E
A.1.3
A controlled 2 start (START CTRL2) updates memory and enables you to

load teach pendant programs. It is also the mode the controller must be in
to perform a full controller backup. Refer to Appendix C. Controlled 2
start is the second phase of a controlled start.
Controlled 2 Start
(START CTRL2)
NOTE You cannot load system variable files (.SV), or install options or
updates during a CTRL2 START.
Use Procedure A--2 to perform a Controlled 2 Start.
Procedure A--2 Performing a CTRL2 Start
Condition

WARNING
injury.
Step
1 Perform a controlled start. Refer to Procedure A--1 , Steps 1 through 4.

2 On the teach pendant, you will see a screen similar to the following.
3
Select 4, EXIT and press ENTER.
Press F4, YES.
Press FCTN.
CAUTION
The CTRL2 start takes a few minutes to finish. Do not turn off
the controller until the CTRL2 start has completed. Otherwise,
you will lose the software loaded on your controller and will
have to reload it. The CTRL2 start is finished when the FCTN
menu disappears and you can display it again by pressing the
FCTN key.
Select START (CTRL2) and press ENTER. The CTRL2 start will be
performed immediately. When it is finished, you will see a title line
on the screen similar to the following.
HANDLING CONFIG
CONTROL 2 START MENUS

1/20
When the CTRL2 start has completed, press FCTN.
A--8
MARF2HD4307701E
NOTE After a CTRL2 START is performed, item 2 on the FCTN menu

will be blank.
8
Load teach pendant programs if necessary. Press MENUS and

select FILE.
When you have finished, select START (COLD). A cold start will be
performed.
10 To restore files, refer to Appendix C.
A--9
MARF2HD4307701E
A.1.4
A cold start (START COLD) is the standard method for turning on power
to the robot and controller. A cold start does the following:
Cold Start
(START COLD)
D Initializes changes to system variables

D Initializes changes to I/O setup
D Displays the UTILITIES Hints screen
A cold start will be complete in approximately 30 seconds.
Use Procedure A--3 to perform a cold start.
Procedure A--3 Performing a Cold Start

Condition

WARNING
injury.
Step
ON
OFF
CIRCUIT
BREAKER
1 Visually inspect the robot, controller, workcell, and the surrounding

area. During the inspection make sure all safeguards are in place and
the work envelope is clear of personnel.
2
Turn the power disconnect circuit breaker on the operator box or

operator panel to ON.
3 On the teach pendant, press and hold the PREV and NEXT keys.
A--10
MARF2HD4307701E
BMON>
After the BMON> prompt appears on the teach pendant screen, release
the PREV and NEXT keys.
BMON> COLD
Press F1, COLD, and press ENTER.
BMON> START
Press F5, START, and press ENTER.

D
On the teach pendant screen, you will see a screen similar to the
following.
UTILITIES Hints
JOINT 10 %
HandlingTOOL (TM)
V4.31-x
North America, Inc.
All Rights Reserved
[ TYPE ]
HELP
A--11
MARF2HD4307701E
A.1.5
Semi hot start is the standard method for turning on power to the robot and
controller without using BootROM. Semi hot start is active when the
system variable $SEMIPOWERFL is set to TRUE. You perform a semi
hot start by pressing the ON button. The screen that was displayed before
power was turned off is displayed.
Semi Hot Start
When $SEMIPOWERFL is set to TRUE, after the first cold start the
controller is put into semi hot start mode automatically. This means that
the next time you turn on the controller (by pressing the ON button), a
semi hot start will be performed. A semi hot start will be complete in
approximately half the time of a cold start.
If a program was running at the time power was turned off, the program
will be paused when power is turned on. Use the standard methods of
resuming a paused program. If $SEMIPOWERFL is set to FALSE and
power is turned off while a program is running, when power is turned on,
the program will be ABORTED and cannot be resumed.
The semi hot start procedure is the same as the procedure for turning on
the robot. Use Procedure A--4 to perform a semi hot start.
Procedure A--4 Performing a Semi Hot Start
Condition
Step
ON
OFF
1 Visually inspect the robot, controller, workcell, and the surrounding

area. During the inspection make sure all safeguards are in place and
the work envelope is clear of personnel.
2
CIRCUIT
BREAKER
Turn the power disconnect circuit breaker on the operator panel or

operator box to ON.
WARNING
injury.
ON
OFF
3
i-size controller operator box
Press the ON button on the operator panel.

D
On the operator panel or operator box, the ON button will be

illuminated, indicating robot power is on.
On the teach pendant screen, you will see the screen displayed
when the robot was last turned off.
ON
OFF
B-size controller operator panel
A--12
MARF2HD4307701E
A.1.6
A re-init start will cause all CMOS resident softparts to be reloaded. This
is useful when some portion of CMOS or D-RAM memory has become
fragmented, or accidentally overwritten.
Re-Init Start
(CMOSINIT)
Performing a re-init start -- Use this when the TPP, PERM, or

IMAGE memory pools have become fragmented, or accidentally
overwritten. A re-init start can also be performed if the robot library
information was installed incorrectly.
The file, CMOSINIT.CF, located on the disk labeled AP1, executes all of
the proper steps needed to perform a re-init start. A re-init start
D Clears CMOS memory
D Loads the TPE memory pool configuration
D INIT starts the controller
Use Procedure A--5 to perform a re-init start.
Procedure A--5 Performing a Re-Init Start using CMOSINIT
Condition
Step
A portion of CMOS memory is overwritten or otherwise corrupted,

IMAGE memory has been depleted, or you have installed the wrong
robot library during software installation.
You have obtained a PS-100 disk drive, memory card interface, or a

PC compatible computer.
You have backed up all your teach pendant programs and other files
you want to save. Refer to Appendix C.
You have the R-J2 software disks that you want to install.
The PS-100 disk drive, memory card interface, or PC compatible

computer is connected to the controller and is turned on.
(Refer to Section 4.2.)

2
Insert the disk labeled AP1 in the disk drive.
Press and hold the PREV and NEXT keys on the teach pendant.
A--13
MARF2HD4307701E
Turn on the controller. You will see a screen similar to the following.
Version 4.22
01-JAN-9x
F-ROM/D-RAM/C-MOS :
TP Version
:
Current TIME
:
Slot
0
1
D
ID
9B
6A
6A
BMON>
COLD
FC
0
0
0
CTRL
6.0/8.0/1.0 MB
I
01-JAN-199x 22:52:53
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
NOLOAD
INIT
START
Turn on the disk drive.
Press NEXT, >, until F2, INSTALL is displayed.
Press F2, INSTALL, and then press ENTER.
Press NEXT, >, until F2, RUN is displayed.
Press F2, RUN.
optional
optional
>
10 Press F3, CMOSINIT and then press ENTER. You will see a screen
Slot
0
1
D
ID
9B
6A
6A
FC
0
0
0
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
BMON> INSTALL
INSTALL> RUN CMOSINIT
Run file CMOSINIT.CF
11 If you do not want to continue, press 0. The BMON> prompt will

be displayed.
If you are ready to continue, press 1.
12 Go to Procedure 4--4 , Step 16, to set up your robot model.
13 Go to Procedure 4--4 , Step 21, to set up your application.
14 Re-install all options and updates. Refer to Procedure 4--5 and
Procedure 4--10 .
A--14
MARF2HD4307701E
A.2
BOOTROM UTILITIES
You can perform operations from the BootROM prompt, BMON>.

Table A--2 lists and describes the utilities you can use from the BMON>
prompt.
D The EMON utility provides access to BootROM extended monitor
utilities. Refer to Section A.2.1.
D The DIAG utility provides access to BootROM diagnostic utilities.
Refer to Section A.2.2.
D The INSTALL utility provides access to installation utilities. Refer to
Section A.2.3.
D The FROM utility provides access to Flash ROM memory utilities.
Refer to Section A.2.4
Use Procedure A--6 to access BootROM and use BootROM utilities.
Table A--2.
BootROM Utilities
DESCRIPTION
UTILITY
COLD
Performs a cold start. Refer to Section A.1.4.
CTRL
Performs a controlled start. Refer to Section A.1.2.
INIT
Performs an initialized start.

CAUTION An initialized start should only be used for a full software load. Controller
memory is altered, and software that is currently on the controller is lost and cannot
be recovered. Use Re-init start instead. Refer to Section A.1.6.
NOLOAD
Prevents automatic loading of the system memory area from Flash ROM to D-RAM.
IMAGE is always loaded.
START
When the controller is powered up, START begins whatever kind of start (COLD, CTRL, or
INIT) has been chosen. Semi Hot start cannot be selected.
A--15
MARF2HD4307701E
Table A--2. (Contd) BootROM Utilities

UTILITY
CLEAR
DESCRIPTION
Clears C-MOS RAM, D-RAM, Flash ROM or MCARD memory.
CAUTION This can destroy the contents of C-MOS RAM memory, D-RAM
memory, Flash ROM memory and MCARD. This includes all programs and files.
Clear CMOS
Clears the entire CMOS memory with zeros. You are

prompted to confirm the execution of the file; answer
YES to confirm, NO to cancel.
Clear DRAM
Clears the entire DRAM system code area with zeros.

You are prompted to confirm the execution of the file;
answer YES to confirm, NO to cancel.
Clear DRAM FFFFFFFF
Clears the entire CMOS memory with FFFFFFFF.

For FANUC Robotics use only.
Clear FROM ALL
Clears the entire FROM memory.
Clear FROM CHIP n
Clears the entire FROM memory where n is 1 for the

first 2 megabyte area; 2 for the second 2 megabyte
area, and so forth.
Clear FROM Block
(SYST, IMAG, SYSR) CLears the FROM memory save

block. You are prompted to confirm the execution of
the file; answer YES to confirm, NO to cancel.
Clear MCARD
Clears the memory card with zeros. You are prompted

to confirm the execution of the file; answer YES to
confirm, NO to cancel.
EMON
Provides access to the extended monitor utilities. Refer to Section A.2.1.
CRT
Causes all screen information to be displayed on the CRT/KB. Pressing TP SELECT key
causes the display to toggle between the teach pendant and the RS-232-C port. The
SELECT key toggles between the teach pendant screen and the CRT device.
DIAG
Provides access to the diagnostics utilities. Refer to Section A.2.2.
INSTALL
Provides access to BMON software installation utilities. Refer to Section A.2.3.
FROM
Provides access to Flash ROM utilities. Refer to Section A.2.4.
MCARD
Provides access to memory card software installation utilities. Refer to Section A.2.5.
A--16
MARF2HD4307701E
Procedure A--6 Using BootROM Utilities
WARNING
injury.
Condition
Step
H The controller is turned off.

Version 4.22P
01-JAN-199x
F-ROM/D-RAM/C-MOS :
TP Version
:
Current TIME
:
Slot
0
1
D
BMON>
COLD
ID
9B
6A
6A
CTRL
FC
0
0
0
INIT
6.0/8.0/1.0 MB
I
01-JAN-199x 22:52:53
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
NOLOAD
START
optional
optional
>
To display more commands, press NEXT, >.

CAUTION
The INIT utility deletes some of the current software in the
controller. Do not use the INIT utility unless you want to reload
the software; otherwise, a loss of data will occur.
To execute a command, press the appropriate function key and press

ENTER.
4 To enter data manually,
D Press the down arrow to display the alphabet from beginning to end
D Press the up arrow to display the alphabet from end to beginning
D Enter a character by pressing the right arrow
A--17
MARF2HD4307701E
A.2.1
Extended Boot Monitor
(EMON>) Utilities
The extended boot monitor utility (EMON) is used to load and clear
memory on sub CPUs such as Vision (VISN), or Ethernet/RIO (ENAB) CPU.
You can access extended boot monitor utilities from BootROM.
Table A--3 lists and describes the extended boot monitor utilities. Use
Procedure A--7 to access extended boot monitor utilities.
Table A--3. BootROM Extended Monitor Utilities
DESCRIPTION
UTILITY
EXIT
Returns to BMON>
ECLEAR FROM mid
Clears the Flash ROM or C-MOS on other boards in the backplane. mid = Module ID such
as VISN, ENAB, or RISC.
ECLEAR CMOS mid
CAUTION This can destroy the contents of C-MOS RAM memory, D-RAM memory,
Flash ROM memory and MCARD. This includes all programs and files.
ELOAD filename mid
load_address (opt)
Loads software from the specified file to hardware specified by mid. mid = Module ID for
modules such as VISN, ENAB, or RISC.
ELOAD filename RISC
Load filename file into RISC DRAM.
ELOAD filename RISC 0
Load filename file into main DRAM.
Procedure A--7 Using EMON> Utilities

Condition
Step
The BMON> prompt is displayed. Refer to Procedure A--6 .
1 On the teach pendant, press NEXT, >, until F3, EMON, is displayed.
2
Press F3, EMON.
Press ENTER. You will see a screen similar to the following.
BMON >
EMON>
EXIT
ECLEAR
ELOAD
>
To display more utilities, press NEXT, >.

CAUTION
The EMON utilities invalidate the current vision software in the
controller. Do not use these utilities unless you want to reload
the software; otherwise, a loss of data will occur.
To execute a utility, press the appropriate function key and press

ENTER.
To exit EMON, type ENTER at the EMON> prompt and press

ENTER. The BMON> prompt will be displayed.
A--18
MARF2HD4307701E
A.2.2
Diagnostic Utilities
The boot monitor diagnostic utilities are used to maintain and diagnose
controller setup and hardware.
You can access diagnostic utilities from BootROM. Table A--4 lists and
describes the diagnostic utilities. Use Procedure A--8 to access diagnostic
utilities.
Table A--4. BootROM Diagnostic Utilities
DESCRIPTION
UTILITY
EXIT
Returns to BMON>.
GOFF
Used to shut down any GFS/KFLOPPY process running on a remote PC device.
DB hex_addr
DW hex_addr
Displays the memory, in byte/word/long word format, after you provide the hexadecimal
starting memory location.
DL hex_addr
SHOW CONF
Shows the configuration of FROM as:

NAME:
FRCONF:
DRCONF:
TPESIZE:
Allocated Blocks:
Free Memory:
SHOW TIME
Shows the controller time.
SHOW MODULE
Shows the hardware modules, which also are displayed on the first BMON screen.
SHOW ENETADDR
Shows the Ethernet address. This will display an error message unless the Ethernet
software is loaded on the Ethernet board and the Ethernet board is installed. Refer to the
SYSTEM R-J2 Ethernet Controller Backup and Restore -- FTP Setup and Operations
Manual manual for more information.
SHOW MEMORY
Shows the BMON memory usage. For FANUC Robotics use only.
SET PORTn SPEED value
Sets the speed of the specified port n (n=2,3,4): 19200, 9600, 4800, 2400
SET PORTn DEVICE value
Sets the device of the specified port n (n=2,3,4): Greco (FLPY:), CRT
SET TIME
Sets controller time.
SET ENETADDR
Sets the Ethernet hardware address. This will display an error message unless the
Ethernet software is loaded on the Ethernet board and the Ethernet board is installed.
Refer to the SYSTEM R-J2 Ethernet Controller Backup and Restore -- FTP Setup and
Operations Manual for more information.
MB hex_addr value*
MW hex_addr value*
Allows you to modify the memory, by byte/word/long format.
ML hex_addr value*
FRCONF value*
For FANUC Robotics internal use only.
DRCONF value*
BALLOC name value*
A--19
MARF2HD4307701E
UTILITY
DESCRIPTION
SYSNAME char string*
CONFIG*
TPESIZE value*
CHGPATH char string*
TEST CMOS*
Tests the memory by writing and reading.
TEST DRAM*
You are prompted to confirm the execution of the file; answer YES to confirm, NO to
cancel.
TEST FROM*
This displays the addresses as they are tested.
CAUTION
All functions marked with an asterisk (*) can modify controller
memory. If they are used incorrectly they will corrupt your
controller.
Procedure A--8 Using DIAG> Utilities

Condition
Step
1 On the teach pendant, press NEXT, >, until F2, DIAG, is displayed.
2
Press F2, DIAG.
Press ENTER. You will see a screen similar to the following.
DIAG>
EXIT
GOFF
DB
DW
DL
>
To display more utilities, press NEXT, >.

ENTER.
To exit EMON, type ENTER at the DIAG> prompt and press

ENTER. The BMON> prompt will be displayed.
A--20
MARF2HD4307701E
A.2.3
INSTALL Utilities
You can access the INSTALL utilities from BootROM to install software.
Table A--5 lists the items you can install using the INSTALL utilities. Use
Procedure A--9 to access INSTALL utilities.
The BMON INSTALL utilities use three file devices at once. First BMON
looks for memory card (MC:), then ENET (if loaded and installed on the
Ethernet board), then P2: (FLPY:).
Table A--5.
INSTALL Utilities
DESCRIPTION
UTILITY
EXIT
Exits to BMON>.
SHD
Displays the current directory.
CHD char string
Change directory to the specified character string.
DIR
Performs a directory of the files on the first device found:
NOTE If the CHD function has not been executed, the directory is performed in
the following order: MCARD, ENET, then FLPY. Otherwise, the directory is
performed on the device that was specified in the CHD command.
LOAD filename *
Loads the specified file into DRAM or C-MOS RAM. filename is the name of the file
to be loaded. You will be prompted to confirm the load; answer YES to confirm, NO
to cancel.
FS LOAD filename *
Loads the file directly to FROM. For FANUC Robotics use only.
ENET
This will display an error message unless the Ethernet software is loaded on the
Ethernet board and the Ethernet board is installed. Refer to the SYSTEM R-J2
Ethernet Controller Backup and Restore manual for more information. This starts
the BOOTP client looking for the BOOTP server.
(optional)
NOTE You must have already performed the SET ENETADDR function to set
the Ethernet address before you can execute ENET.
RUN filename
Runs the specified command file. The following command files (.CF) can be run:
D AUTOLOAD -- Clears all the memory pools on the F-ROM, D-RAM, and
CMOS devices. Does not set the TPP size.
D UPDATE -- Found only on a maintenance update disk. This is used to load
software that cannot be loaded at a controlled start.
D CMOSINIT -- Clears all the memory pools on the D-RAM and CMOS RAM
devices. It also causes these memory pools to be reloaded from the F-ROM
device.
D FROMINIT -- Clears all the memory pools on the F-ROM, D-RAM, and CMOS
devices. It causes them to be reloaded from the ENET (if installed), floppy, or
MCARD device.
D AUTO -- Clears all the memory pools on the F-ROM, D-RAM, and CMOS
devices. Does not load VISN, ENAB, or RISC firmware.
You are prompted to confirm the execution of the file; answer YES to confirm, NO to
cancel.
A--21
MARF2HD4307701E
Table A--5. (Contd) INSTALL Utilities

UTILITY
DESCRIPTION
FTEST filename prompt string
For auto loading, tests for the presence of the specified file, filename. If the file is
not there, it prompts the user with the prompt string. For FANUC Robotics use
only.
RESTORE*
Executes the restore.cf file to restore a backup set of software. You are prompted to
confirm the execution of the file; answer YES to confirm, NO to cancel.
ORD LOAD*
For FANUC Robotics use only.
ORD EDIT*
CAUTION
controller.
A--22
MARF2HD4307701E
Procedure A--9 Using INSTALL Utilities

Condition

WARNING
injury.
H
Step
BMON> INSTALL

2
Press F2, INSTALL and press ENTER. You will see a screen similar
to the following.
INSTALL>
EXIT
SHD
CHD
DIR
>
INSTALL>
At the INSTALL> prompt, press NEXT, >, until F2, RUN is

displayed.
INSTALL> RUN
Press F2, RUN. You will see a screen similar to the following.
INSTALL> RUN
AUTOLOAD UPDATE CMOSINIT FROMINIT
AUTO
Refer to Table A--5 for a description of each of these files.

5
To reload software,
a
Press F4, FROMINIT and press ENTER. You will see a screen
Slot ID
FC
0
9B
1
1
AF
1
D
6A
0
E
8A
0
BMON> INSTALL
INSTALL> FROMINIT
OP
0
0
0
0
R-J2 Main CPU

R4600 Sub-CPU V4.20
MCARD I/F
AB/Ether I/F
RUN FILE FROMINIT.CF

If you do not want to continue, press 0. The BMON> prompt

will be displayed.
If you are ready to continue, press 1.
Re-install all options or updates.
A--23
MARF2HD4307701E
A.2.4
You can access the Flash ROM (F-ROM or FROM disk) utilities from
BootROM. Table A--6 lists the FROM items you can use. Use
Procedure A--10 to access the FROM utilities.
Flash ROM Utilities
Table A--6.
Flash ROM Items

DESCRIPTION
ITEM
Exits to BMON>.
EXIT
FRDB addr*
Displays Flash ROM memory address in byte/word/long word format. FROM addresses
start at relative 0.
FRDW addr*
FRDL addr*
FRSAVE block- name
start_addr size*RISC (opt)
Saves SYSTem, SYSRisc or IMAGe memory pools from D-RAM to Flash ROM as
SYSTEM start# size or IMAGe start# size. The start# is a hexadecimal number that
represents the start address in D-RAM. The size is the size of the memory.
FRSAVE SYSR 0 200000
Save SYST from MAIN DRAM to MAIN FROM.
FRSAVE SYSR 0 200000 RISC
Save MAIN DRAM to MAIN FROM (req. for RISC).
FRLOAD block- name

start-addr (opt)
Loads SYSTem, SYSRisc IMAGe memory pools from Flash ROM to D-RAM. The start# is
a hexadecimal number that represents the start address in D-RAM.
FRLOAD SYSR
Loads SYSR into RISC DRAM.
FRLOAD SYSR 0
Loads SYSR into Main DRAM.
LOADALL
Loads SYSTem and IMAGe memory pools from Flash ROM to D-RAM. You must verify
that you want to perform this function.
CAUTION
controller.
Procedure A--10 Using FROM Utilities

Condition
Step

2
Press NEXT, >, until F1, FROM is displayed.
Press F1, FROM and press ENTER.

ENTER.
A--24
MARF2HD4307701E
A.2.5
Memory Card Utilities
You can access the memory card (MCARD) utilities from BootROM to
use a memory card. Table A--7 lists the memory card items you can use.
Use Procedure A--11 to access the MCARD utilities.
Table A--7.
Memory Card Items

DESCRIPTION
ITEM
Exits to BMON>.
EXIT
MCDB addr
MCDW addr
Displays Memory Card memory address in byte/word/long word format.
MCDL addr
MCSAVE CMOS
Saves C-MOS RAM 0.5 MB, 1.0 MB, or 2.0 MB to memory card (MC:).
MCSAVE DRAM
Saves D-RAM, always 0 -- 2 MB, to memory card (MC:).
MCSAVE FROM start_addr size
Saves Flash ROM from start_addr (HEX) for the specified size (a maximum of 2
MB) to memory card (MC:)
MCLOAD CMOS*
Loads from memory card (MC:) to C-MOS 0.5 MB, 1.0 MB, or 2.0 MB.
MCLOAD DRAM*
Loads from memory card (MC:) to D-RAM, always 0 -- 2 MB.
MCLOAD FROM start_addr size*
Loads from memory card (MC:) to Flash ROM from start_addr (HEX) for the
specified size (a maximum of 2 MB).
NOTE The area of Flash ROM on which to load must have been cleared
before the MCLOAD FROM can be executed.
CAUTION
controller.
Procedure A--11 Using MCARD Utilities

Condition
Step
1 Press NEXT, >, until F4, MCARD is displayed.

2
Press F4, MCARD, then press ENTER.

ENTER.
MARF2HD4307701E
CONFIGURATION TABLES
B--1
Topics in this chapter

Robot Configurations
Page
During the installation process you will be required to answer questions that define
robot-specific parameters for the following robot models:
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
A-520i information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-6i information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-16i information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-16iL/ARCMATE-120iL information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-400 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-410i information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-410iW information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-410iWx information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-500 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-710i information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-710iW information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-6 (ArcMate 100) information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-12 (ArcMate 120) information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iF information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iR Rack Mount information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iS information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-420iW information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-450 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-500 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-700 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Offset Wrist S-700 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-800 information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-900 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nobot information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coordinated Nobot information Refer to the Coordinated Motion
Setup and Operations Manual.
B--2
B--2
B--3
B--4
B--4
B--5
B--5
B--5
B--7
B--7
B--7
B--8
B--9
B--9
B--10
B--11
B--11
B--12
B--12
B--12
B--13
B--14
B--14
Section 4.7
CAUTION
Be sure to set the Payload correctly for your robot. If you do
not, your system will not operate properly.
g If you choose the right robot but answer the robot configuration
questions incorrectly, you must
a
b
Perform a controlled start. (Refer to Appendix A)

If you are changing the CARTESIAN motion option, insert the
disk labeled SLIB1.
c Select MOTION SYSVAR SETUP.

d Press F4, YES.
e
f
g
h
i
Select INITIALIZE SYSTEM VARIABLE.

Press F4, YES.
Select INITIALIZE GROUP1 VARIABLES.
Press F4, YES.
Answer the payload and CARTESIAN motion option question
again.
B. CONFIGURATION TABLES
B--2
MARF2HD4307701E
Table B--1.
You Must Answer These
Questions
A-520i Robot Configuration Information
You Have These Choices
J2 Axis Limitation Type
Normal (-150 -- 150) [deg]
Type
This varies depending on the
application.
Floor Mount Type
Wash Down Type
Yes
Write Your Answer Here
Upside-Down Mount Type
No
Payload
application.
0 - 20[kg]
Cartesian Motion Option

CAUTION: Do not choose the
Cycle Time Priority option if you
are going to load the Continuous
Turn or Soft Float software
options. Otherwise, robot motion
will not work properly.
Cycle Time Priority

Path Priority
Joint Motion Option

(if Path Priority is selected for the
Cartesian motion option)
Cycle Time Priority

Path Priority
Table B--2.
Questions
M-6i Robot Configuration Information
Robot Type
This is usually M-6i Normal
Flange.
M-6i Normal Flange

M-6i Adapter Flange

This is usually Normal.
Normal (-165 -- 165) [deg]

Option (-180 -- 180) [deg]
Mount Type
Floor Mount Type

Angle Mount Type
Mount Angle Setting
(0 - 180[deg])
The mount angle setting must be

set for angle mount robots only.
Cabinet Type
This varies depending on your
cabinet size.
Controller is attached to the robot.
Auxiliary axis cabinet on

i-cabinet?
(If the controller is attached to the
robot.) This varies depending on
your cabinet location.
No
Payload
This is usually 6.
0 -- 6[kg]
Brake Type Setting

Normal (--, J2, J3, --, --, --)
Controller is remotely located.
Yes
Option-A (J1, J2, J3, J4, J5, J6)
B--3
MARF2HD4307701E
Table B--3.
Questions
Robot Type
Flange.
M-16i Normal Flange

M-16i Adapter Flange

Normal (-165 -- 165) [deg]

Option (-180 -- 180) [deg]
Mount Type
Floor Mount Type

Angle Mount Type
Mount Angle Setting
(0 - 180[deg])

Cabinet Type
cabinet size.
Controller is attached to the

robot.

i-cabinet?
No
Payload
This is usually 6.
0 -- 6[kg]
Brake Type Setting

Normal (--, J2, J3, --, --, --)

Cycle Time Priority

Path Priority
Joint Motion Option

(If Path Priority is selected for the
Cycle Time Priority

Path Priority

Yes
Option-A (J1, J2, J3, J4, J5, J6)
B--4
MARF2HD4307701E
Table B--4.
Questions
M-16iL/ARCMATE-120iL Robot Configuration Information
Robot Type
Flange.
M-16i Normal Flange

M-16i Adapter Flange

Normal (-165 -- 165) [deg]

Option (-180 -- 180) [deg]
Mount Type
Floor Mount Type
Angle Mount Type

Mount Angle Setting
(0 - 180[deg])

Cabinet Type
cabinet size.

robot.

i-cabinet?
No
Payload
This is usually 6.
0 -- 6[kg]
Brake Type Setting

Normal (--, J2, J3, --, --, --)

Cycle Time Priority

Path Priority
Joint Motion Option

(If Path Priority is selected for the
Cycle Time Priority

Path Priority

Yes
Option-A (J1, J2, J3, J4, J5, J6)
Table B--5.
Questions
M-400 Robot Configuration Information
Robot Type
application.
E Wrist (4 axes) Type

F wrist (5 axes) Type
Door-Opener (A wrist) Type
Payload
application.
0 - 50[kg]
B--5
MARF2HD4307701E
Table B--5. (Contd) M-400 Robot Configuration Information

Questions

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--6.
Questions
Frame Type
Standard Base Frame

Short Base Frame
Payload
application.
0 - 60[kg] (M-410i)

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--7.
Questions
M-410iW Robot Configuration Information
Frame Type
Standard Base Frame

Short Base Frame
Payload
application.
0 - 100[kg]
B--6
MARF2HD4307701E
Table B--7. (Contd) M-410iW Robot Configuration Information

Questions

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--8.
Questions
M-410iWx Robot Configuration Information
Frame Type
Standard Base Frame

Short Base Frame
Payload
application.
0 - 155[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
B--7
MARF2HD4307701E
Table B--9.
Questions
Robot Type
M-500 Robot Configuration Information
1. Robot Initialization
You must perform the robot

2. Wrist axes exchange
initialization first. When finished,
3. Exit
perform a CTRL start, select
Motion System Variable Setup and
set the wrist axes exchange.
Select Exit when done.
Wrist Axes Exchange
(if selected in robot type)
1. Add wrist axes

2. Remove wrist axes
3. Exit
Wrist Type
4 axes type (M500)

application.
Roll Wrist Type (M500R)
Payload
application.
0 - 60[kg]
Option Brake J1
Enable
Pitch Wrist Type (M500P)
Disable
J3 Option Brake
Enable
Disable

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--10.
Questions
M-710i and M-710iW Robot Configuration Information

Normal (-165 -- 165) [deg]

Option (-180 -- 180) [deg]
Mount Angle Setting
Floor Mount Type
This is 0 for a robot mounted on

the floor.
Upside Down Mount Type
Cabinet Type
cabinet size.

robot.
Payload
This is usually 45.
0 -- 45[kg]
B--8
MARF2HD4307701E
Table B--10. (Contd) M-710i and M-710iW Robot Configuration Information

Questions

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--11.
Questions
S-6 Robot Configuration Information
Robot Type
S-6 Normal Flange
This is usually S-6 Normal Flange. S-6 Adapter Flange
Normal (-165 -- 165) [deg]

Option (-180 -- 180) [deg]
Mount Type
Floor Mount Type

the floor.
Angle Mount Type
Mount Angle Setting
(0 - 180[deg])

Payload
This is usually 6.
0 -- 6[kg]
Motor Cover Setting
With motor cover

Without motor cover
Axis Brake Type

Normal (--,J2,J3,--,--,--)
Option-A(J1,J2,J3,J4,J5,J6)

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
B--9
MARF2HD4307701E
Table B--12.
Questions
Robot Type
This is usually S-12 Normal
Flange.
S-12 Normal Flange

S-12 Adapter Flange

Normal (-165 -- 165) [deg]

Option (-180 -- 180) [deg]
Mount Angle Setting
0 [deg]

the floor.
(0-180[deg]) -> 0
Payload
This is usually 12.
0 -- 12[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--13.
Questions
Arm Length
S-420iF Robot Configuration Information

S420iF (Standard Arm Length)
S420iF/2.85 (Middle Arm Length)
Robot Type
Standard Robot Type

Compact Robot Type
Payload
application.
0 - 120[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
B--10
MARF2HD4307701E
Table B--14.
Questions
Robot Type
S-420iL Robot Configuration Information
Standard Robot Type

Compact Robot Type
Payload
application.
0 - 75[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--15.
Questions
Robot Type
S-420iR Robot Configuration Information

S-420iR/100[kg]
(A05B-1313-B401)
S-420iR/120[kg]
(A05B-1313-B402)
Payload
application.
S420iR = 0 - 100[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
S420iRW = 0 - 120[kg]
B--11
MARF2HD4307701E
Table B--16.
Questions
Robot Type
S-420iS Robot Configuration Information
Standard Robot Type

Compact Robot Type
Payload
application.
0 - 80[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--17.
Questions
Robot Type
S-420iW Robot Configuration Information

Standard Robot Type
Compact Robot Type
Payload
application.
0 - 155[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
B--12
MARF2HD4307701E
Table B--18.
Questions
X Stroke Type
This varies depending on how
your robot is set up.
X Stroke 400 mm
X Stroke 700 mm
X Stroke 1000 mm
Payload
application.
0 - 120[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--19.
Questions
Wrist Type

Normal Speed Wrist

High Speed Wrist
Mount Angle
0 - 180
This is usually 0.
Payload
For a normal speed wrist, this is
usually 15. For a high speed
wrist, this is usually 5.
0 -- 15[kg]
Table B--20.
Questions
Flange Type
Normal Flange
Special Flange
Mount Type
Floor Mount
Upside Down Mount
Payload
application.
0 - 30[kg]
B--13
MARF2HD4307701E
Table B--20. (Contd) S-700 Robot Configuration Information

Questions

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Table B--21.
Questions
Offset Wrist S-700 Robot Configuration Information
Flange Type
Normal Flange
Special Flange
Mount Type
Floor Mount
Upside Down Mount
Payload
application.
0 - 30[kg]

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
B--14
MARF2HD4307701E
Table B--22.
Questions
Robot Type
S800
S800W

Cycle Time Priority

Path Priority
Joint Motion Option

Cycle Time Priority

Path Priority
Payload
application.
0 - 60[kg]
Robot Type

S900W High Payload Type
S900H High Speed Type
S900L Long Arm Type

Cycle Time Priority
(only displayed if the S900W robot Path Priority
is selected)
Joint Motion Option
Cycle Time Priority
(only displayed if the S900W robot Path Priority
is selected and if Path Priority is
selected for the Cartesian motion
option)
Payload
application.
0 - 80[kg]
Table B--23.
Questions
0 - 300[kg]
MARF2HD4307701E
BACKING UP AND RESTORING FILES

C--1
Page
Setting the Default Device
Setting the default device specifies which device to use when manipulating
programs and files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backing Up Files
You can back up program files, system files, and application files to the
default device using the FILE menu. When you back up a program or file you
save it from controller memory to a disk, such as a floppy disk or memory
card, so that you have a second copy of the file. . . . . . . . . . . . . . . . . . . . . . . . . . . C--4
. . . C--2
Program Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--4

Program files are ASCII files that you create. When you back up program files,
all teach pendant program files currently loaded onto controller memory (listed
on the SELECT menu) will be saved to the default device.
System Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--4
System files are binary files that store default values for system variables, servo
parameter data, and mastering data. They contain information specific to the
controller, robot, and software.
Application Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--4
Application files are program variable files.
Loading or Restoring
Files from Disk to
Controller Memory
Loading or restoring files allows you to load a file and all of its relevant
data from disk into controller memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--8
Controller Backup and

Restore
You can completely back up and restore a controller using the backup
and restore function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--14
CAUTION
If you are updating controller software you should first back
up all program, system and application files you want saved to
disks in case these files are lost during the update. If these
files are lost during the update, you can load these files back
into the controller from the disks.
NOTE FTP can be used to transfer controller memory files over an

Ethernet network. The Trivial File Transfer Protocol (TFTP) can be used
to load controller memory files onto the controller via an Ethernet
network. Refer to the SYSTEM R-J2 Ethernet Controller Backup
Restore/FTP Setup and Operations Manual for more information.
C. BACKING UP AND RESTORING FILES
C--2
MARF2HD4307701E
C.1
Setting the default device specifies which device to use when manipulating
programs and files. You must set the default device before you can
perform any program or file manipulations, including formatting a disk.
You can set the default device to
SETTING THE
DEFAULT DEVICE
D
D
D
D
D
Serial floppy disk -- A serial floppy disk drive connected to the P2 port
of the controller, such as the PS-100 or PS-200
Serial printer -- A serial printer connected to the P2 port of the
controller
Flash ROM disk (FR:)
Memory card (MC:)
Client device (C1:) -- used if the FTP option is installed
After you set the default device, the device will remain the default until
you change it or until an init start is performed.
Use Procedure C--1 to set the default device.
Procedure C--1 Setting the Default Device
CAUTION
Before you connect the floppy disk to the controller, turn on the
controller, then connect and turn on the floppy disk; otherwise,
equipment could be damaged.
Condition
Step
If you are setting the default device to FLPY:, the PS-100, PS-200,
printer, or other device is connected to the P2 port on the controller
and is turned on.
1 Press MENUS.
2
Select FILE.
Press F1, [TYPE].
C--3
MARF2HD4307701E
Select File. You will see a screen similar to the following.

FILE
JOINT
FLPY:\*.*
1
*
2
*
3
*
4
*
5
*
6
*
7
*
8
*
9
*
10
*
*
KL
CF
TX
LS
DT
PC
TP
MN
VR
(all
(all
(all
(all
(all
(all
(all
(all
(all
(all
50%
1/14
files)
KAREL source)
command files)
text files)
KAREL listings)
KAREL data files)
KAREL p-code)
TP programs)
MN programs)
variable files)
11
*
SV (all system files)
12
*
IO (I/O config data)
13
*
DF (all DEFAULT files)
14
*
ML (all part model files)
15
*
BMP all bit-map images)
16
[you enter]
Press DIR to generate directory
[ TYPE ] [DIR]
LOAD [BACKUP] [UTIL] >
DELETE
COPY
DISPLAY
>
1 Set Device
2 Format
Press F5, [UTIL].
Select Set Device.
1 Serial Floppy Disk

2 Serial Printer (text ONLY)
3 RAM Disk (RD:)
Move the cursor to the device you want to select and press ENTER.
FILE
RD:\Default Device
[TYPE]
[DIR]
LOAD
JOINT
[BACKUP]
10%
[UTIL] >
The default device is now set. The default device name is displayed on the
FILE screen, under the word FILE.
C--4
C.2
BACKING UP FILES
MARF2HD4307701E
You can back up program files, and system files to floppy disk, Flash
ROM disk, or memory card using the FILE screen. When you back up a
program you save it from controller memory to a disk, such as a floppy
disk, so that you have a second copy of the file.
Program Files
When you back up program files, all teach pendant program files currently
loaded onto controller memory (listed on the SELECT menu) will be
saved to the default device: RAM disk or floppy disk.
System Files
System files are binary files that store default values for system variables,
servo parameter data, and mastering data. They contain information
specific to the controller, robot, and software. When you backup system
files, all system variable, servo parameter, and mastering data currently on
controller memory is saved to the default device: RAM disk or floppy
disk. The following are types of system files:
Application Files
DIOCFGSV.IO - contains I/O configuration information
FRAMEVAR.SV - contains frame information
NUMREG.VR - contains register information
POSREG.VR - contains position register information
SYSVARS.SV - contains system variable default values for your

system. The $STYLE_NAME system variable, which contains style
names, is included in SYSVARS.SV. When you back up system files,
your style names will also be backed up.
SYSSERVO.SV - contains servo parameter data the robot needs to

function. The values in this file are loaded automatically when the
controller is turned on.
SYSMAST.SV - contains dynamic mastering data, which is

automatically created when the robot is mastered.
SYSMACRO.SV - contains macro command table and associated

data.
Application files are all program variable files.

Refer to the SYSTEM R-J2 Controller HandlingTool Setup and Operations
Manual for more information about each kind of file.
When you back up system files, all files are copied to the default device.
C--5
MARF2HD4307701E
Procedure C--2 Backing Up System Files, Teach Pendant Programs, and

Application Files to Disk
CAUTION
Before you connect the floppy disk drive to the controller, turn
on the controller, then connect and turn on the floppy disk
drive; otherwise, equipment could be damaged.
Condition
If you are backing up files to a floppy disk, the serial disk drive is
connected to the controller P3 port, is turned on, and contains a
formatted disk.
If you are backing up files to a memory card, the memory card is

installed properly. Refer to Section 4.2.2.
The default device is set correctly. Refer to Procedure C--1 .
H
Step
1 Press MENUS.
2
Select FILE. You will see a screen similar to the following.

FILE
JOINT
FLPY:\*.*
1
*
2
*
3
*
4
*
5
*
6
*
7
*
8
*
9
*
10
*
*
KL
CF
TX
LS
DT
PC
TP
MN
VR
(all
(all
(all
(all
(all
(all
(all
(all
(all
(all
50%
1/14
files)
KAREL source)
command files)
text files)
KAREL listings)
KAREL data files)
KAREL p-code)
TP programs)
MN programs)
variable files)
11
*
12
*
13
*
14
*
15
*
16
[you enter]
[ TYPE ] [DIR]
DELETE
COPY
DISPLAY
>
C--6
MARF2HD4307701E
1 Serial Floppy Disk

2 Serial Printer (text ONLY)
3 RAM Disk (RD:)
Move the cursor to the device you want to select and press ENTER.
FILE
P3:\Default Device
[TYPE]
4
System Files 1
1
2
3
4
System files
TP programs
Application
All of above
Teach Pendant (TP) 1

Programs
System files
TP
TP programs
programs
Application files
All of the above
LOAD
[BACKUP]
10%
[UTIL] >
Press F4, [BACKUP].

To back up system files, select System files. You will see a screen
Save FLPY:\DIOCFGSV.IO
EXIT
ALL
1
2
3
4
[DIR]
JOINT
YES
NO
Back up the specified files:

D To back up this system file only, press F4, YES.
D If you do not want to back up this system file, press F5, NO.
The next system file name on controller memory will be
displayed.
D
To back up all system files, press F3, ALL. If the file already
exists, then you will have the option to overwrite, skip or cancel.
To exit, press F2, EXIT.
To back up all teach pendant program files, select TP Programs.
The first program name on controller memory (the SELECT menu)

will be displayed.
D
To back up this program only, press F4, YES.
If you do not want to back up this program, press F5, NO. The
next program name on controller memory will be displayed.
To back up all teach pendant programs, press F3, ALL. If the

file already exists, then you will have the option to overwrite, skip
or cancel.
C--7
MARF2HD4307701E
Application Files
1
2
3
4
The first application file name on controller memory (the SELECT menu)
will be displayed.
System files
TP programs
Application
Application
All of above
All Files
1
2
3
4
To back up all Application files, select Application files.
To back up this application file only, press F4, YES.
If you do not want to back up this application file, press F5, NO.
The next application file name on controller memory will be
displayed.
To back up all application files, press F3, ALL. If the file already
exists, then you will have the option to overwrite, skip or cancel.
To back up all types of files, select All of above. You will see the
following message displayed at the bottom of the screen.
System files
TP programs
Application
All of
of above
above
All
Del, backup all files?

YES
NO
CAUTION
All the files on a floppy disk or memory card are deleted before
the All of above backup. If the destination device is network,
pre-delete does not work. Be sure you do not have any files on
the floppy disk or memory card that you want to keep.
Otherwise, if you continue with the backup, all the files on the
floppy disk or memory card will be destroyed.
If you do not want to delete the files on the default device and
then back up the files, press F5, NO. The files will not be
backed up.
If you want to delete the files on the default device and back
up the specified files press F4, YES. All files in the
$FILE_SYSBCK and $FILE_APPBCK system variables will be
backed up. All .TP and .DF files will also be backed up.
NOTE If an error occurs while the files are being saved, you will be
prompted with a message and asked if you want to proceed.
When the backup is complete, the FILE menu will be displayed and
a directory of the default device will be generated, including the newly
saved files.
Restore Backup Files 1
To restore backup files, you must load them. Refer to

Section C.3.
C--8
C.3
LOADING OR
RESTORING FILES
FROM DISK TO
CONTROLLER
MEMORY
MARF2HD4307701E
Loading or restoring files allows you to load a file and all of its relevant
data from disk into controller memory. You can load files into controller
memory from one of the following file devices:
D Floppy disk
D Flash ROM disk
D Memory card
D PC
Loading Files
Typically, you load a file from a disk when

D You want to modify a program (teach pendant program file, .MN) that
is not currently in controller memory
D You want to execute a program (teach pendant program file, .TP, or
KAREL p-code file, .PC)
D You want to load variable information the system needs to function
(system file, .SV)
D You want to load variable information required for a KAREL program
(KAREL Variable file, .VR)
D You want to load saved I/O configuration (I/O configuration file, .IO)
D You want to load saved default motion instructions (.DF file)
Loadable Files
Loadable files are those files that can be loaded into controller memory.
They are
D KAREL p-code files (.PC)
D System files (.SV)
D KAREL Variable files (.VR)
D I/O configuration files (.IO)
D Teach pendant program files (.MN)
D Variable files (.VR)
NOTE System files can be loaded only at controlled start (CTRL
START). Teach pendant files can only be loaded into controller memory
at controlled 2 start (CTRL2 START). The RESTORE procedure in
Procedure C--4 will take care of these limitations for you. Refer to
Appendix A for more information.
Only these kinds of files can be loaded into controller memory. You can
load a single file or a group of files. Use Procedure C--3 to load selected
files using the FILE menu.

MARF2HD4307701E
Restoring Files
C--9
You restore files from a disk when you have previously backed up the
files using BACKUP on the FILE screen (Section Procedure C--2 ). You
can restore the following groups of files if you have previously backed
them up using BACKUP:
D System files
D Teach pendant programs
D Application files
Use Procedure C--4 to restore BACKUP files using the FILE menu. This
procedure will restore all files on the default device that were backed up
using the BACKUP command. Refer to Section C.2 for more information
on backing up files.
C--10
MARF2HD4307701E
Procedure C--3 Loading Selected Files Using the FILE Menu
CAUTION
Condition
Step
If you are loading files from floppy disk, the serial disk drive is
connected to the controller P3 port, is turned on, and contains the
appropriate floppy disk.
The default device is set correctly. Refer to Procedure C--1 .
1 Press MENUS.
2
Select File. You will see a screen similar to the following.

FILE
JOINT
FLPY:\*.*
1
*
2
*
3
*
4
*
5
*
6
*
7
*
8
*
9
*
10
*
*
KL
CF
TX
LS
DT
PC
TP
MN
VR
(all
(all
(all
(all
(all
(all
(all
(all
(all
(all
50%
1/16
files)
KAREL source)
command files)
text files)
KAREL listings)
KAREL data files)
KAREL p-code)
TP programs)
MN programs)
variable files)
11
*
12
*
13
*
14
*
15
*
16
[you enter]
[ TYPE ] [DIR]
DELETE
COPY
DISPLAY
>
C--11
MARF2HD4307701E
To load a single file:

a Press F2, [DIR], to generate a directory of the disk that contains
the file you want to load.
b Select the subset of files you want to display and press ENTER. If
you select *.SV to display all system files, you will see a screen
FILE
FLPY:\*.SV
1
SYSVARS
2
3
4
5
6
7
8
9
0
SYSSERVO
SYSMAST
SYSMACRO
SYSSPOT
*
*
*
*
*
[TYPE]
[DIR]
JOINT
SV
10%
1/14
(system file)
SV
SV
SV
SV
KL
CF
TX
LS
DT
(system file)
(system file)
(system file)
(system file)
(all KAREL source)
(all command files)
(all text files)
(all KAREL listing)
(all KAREL data files)
LOAD
[BACKUP]
[UTIL] >
To select another subset of files, press F2, [DIR] and repeat Step b.
c Move the cursor to the name of the file you want to load and press
F3, LOAD. You will see a screen similar to the following.
FILE
FLPY:\*.*
1 PROG_1
JOINT
TP
2 PROG_2
TP
3 PROG_3
TP
4
*
*
5
*
KL
6
*
CF
7
*
TX
8
*
LS
9
*
DT
Load FLPY:\PROG1
Loading, please wait
Loaded PROG_1.TP
10%
1/14
(TP program)
(TP program)
(TP program)
(all files)
(all KAREL source)
(all command files)
(all text files)
(all KAREL listing)
(all KAREL data files)
YES
NO
Load the file(s):

D
To load the file(s) you selected, press F4, YES.
If you do not want to load the file(s) you selected, press F5, NO.
If you are loading a teach pendant program and it does not load,
you must perform a controlled 2 start. Refer to Section A.1.3 to
perform a controlled 2 start and then repeat this procedure.
C--12
MARF2HD4307701E
PROG_1.TP already exists
OVERWRITE APPEND CANCEL

F3
F4
F5
If the program already exists:

D
To overwrite, press F3, OVERWRITE.
To skip the file, press F4, SKIP.
To cancel, press F5, CANCEL.
Procedure C--4 Restoring BACKUP Files Using the FILE Menu

CAUTION
Condition
Step
If you are restoring files from floppy disk, the serial disk drive is
connected to the controller P2 port, is turned on, and contains the
appropriate floppy disk.
The device from which you want to restore files is set as the default
device. Refer to Procedure C--1 .
Normally, the files you are restoring were backed up using

Procedure C--2 .
1 Perform a controlled start as follows:

a If the controller is turned on, turn it off.
b On the teach pendant, press and hold the PREV and NEXT keys.
c While still pressing PREV and NEXT on the teach pendant, press
the ON button on the operator box or operator panel.
BMON>
d After the BMON> prompt appears on the teach pendant screen,

release the PREV and NEXT keys.
BMON> CTRL
e Press F2, CTRL, and press ENTER.
BMON> START
f Press F5, START, and press ENTER. This begins the controlled
start. You will see a screen similar to the following.
1
2
3
4
Exit? [NO]
MOTION SYSVAR SETUP

PROGRAM INIT
MOTION DEVELOPMENT
EXIT
Press 4, EXIT.
Press F4, YES.
Press MENUS.
C--13
MARF2HD4307701E
Select File.
Press F4, RESTORE. You will see a screen similar to the following.
Restore from PS-100/200 Disk(OVRWRT)?
YES
NO
CAUTION
In the next step, backed up files will be loaded and will
overwrite existing files of the same name. Be sure you want to
overwrite existing files before you restore them; otherwise, you
could lose important data.
7
Restore the files:

D To continue the restore, press F4, YES.
D
To cancel the restore, press F5, NO.
The system will load all files listed in the $FILE_SYSBCK and
$FILE_APPBCK system variables as well as *.TP and *.DF files.
You will not have to convert any variable files that have been restored.
This conversion will be performed automatically.
NOTE To cancel the restore at any time, press the PREV key.
During the restore, you will see messages similar to the following as
each file is restored. In the following example, SYSVARS.SV is the
fourth file you are attempting to restore out of a total of 15 files from
the default device.
Loading SYSVARS.SV (4/15)
If an error occurs during the restore, the restore will pause.

D
To skip the current file and continue restoring the remaining files,
press F4, SKIP.
To cancel the restore from this file on, press F5, CANCEL.
When the restore has completed,

D
You will see a message reporting the number of files restored. See
the following screen for an example.
Total 15 files restored
The label on the F4 function key will become [BACKUP].
The controller will be put into CONTROL START 2 startup mode.
10 To operate the robot, perform a cold start:

a Press FCTN.
b Select START (COLD).
C--14
C.4
CONTROLLER
BACKUP AND
RESTORE
MARF2HD4307701E
Controller backup and restore allows an R-J2 controller to back up and

restore controller memory. This capability is divided into two parts:
D Controller backup
D Controller restore
Controller backup is performed at controlled 2 start. During controller
backup, the entire contents of controller memory are copied to files on the
designated device. Refer to Section C.4.1.
Controller restore is performed from the Boot Monitor (BMON). During
controller restore, all of F-ROM and CMOS is cleared then the files
previously created using the controller backup procedure are loaded from
the default device. Refer to Section C.4.2.
NOTE FTP can be used to transfer controller memory files over an
Ethernet network. The Trivial File Transfer Protocol (TFTP) can be used
to load controller memory files onto the controller via an Ethernet
network. Refer to the SYSTEM R-J2 Ethernet Controller Backup
Restore/FTP Setup and Operations Manual for more information.
CAUTION
If you restore a controller and a file already exists on the
controller, the file is automatically overwritten.
C.4.1
Backing up a
Controller
The backup feature allows you to back up the entire contents of controller
memory. The backup procedure sets up the files so that controller memory
can be fully restored if necessary. When you restore the controller backup
to the controller, you will have a fully loaded controller.
Use Procedure C--5 to perform a controller backup using a floppy or a
memory card device. To perform a controller backup using Ethernet, refer
to the SYSTEM R-J2 Ethernet Controller Backup/FTP Setup and
Operations Manual.
Backup Files
When a controller backup is performed, the controller memory is copied

into compressed binary image files with the file extension .ldc. The
backup utility will create the number of files required for backup storage.
By default, these files will be named backup##.ldc, where ## is the file
number. For example, if the backup creates two files, the files will be
named backup01.ldc and backup02.ldc.
A minimum of two backup files will be created: one for controller FROM
and one for controller CMOS.
During the backup process, you will have the option to change the name of
the backup files from backup to the name you want. If you are doing
backups of several controllers, you might want to name the files using the
F number of the robot.
C--15
MARF2HD4307701E
In addition to creating the backup files, the backup utility creates a .cf file
for each memory card or floppy disk. The first one is called restore.cf.
The rest of the files will have unique names based on the date and time
stamp from when the backup was performed. When a controller restore is
performed, these files are used to direct the system to load all of the files
created during the backup.
CAUTION
The restore.cf file is overwritten each time a controller backup
is performed, regardless of the names of the controller backup
files. If you are backing up more than one controller, create a
separate subdirectory to contain backup files and restore.cf for
each controller. Otherwise restore.cf will be overwritten and
you will not be able to restore controller memory.
You might want to store the controller backup files in the location from
which you will load them. It is a good idea to create a separate
subdirectory for each robot. If you store backups
D
On a UNIX workstation, the load directory usually is the /usr

directory on the local hard drive of the workstation. This is due to
restrictions on file access established by some TFTP server
implementations.
On a personal computer, the load directory can be any directory you

specify.
Use Procedure C--5 to perform a controller backup to a floppy or memory

card device.
Procedure C--5 Backing up a Controller to a Floppy or Memory Card Device
NOTE If an error occurs during controller backup, correct the error and
try to continue. If the system does not allow you to continue, repeat the
entire controller backup procedure.
Step
1 Perform a controlled 2 start.

a If the controller is turned on, turn it off.
b On the teach pendant, press and hold the PREV and NEXT keys.
BMON>
c After the BMON> prompt appears on the teach pendant screen,

release the PREV and NEXT keys.
BMON> CTRL
d Press F2, CTRL, and press ENTER.
BMON> START
e Press F5, START, and press ENTER. This begins the controlled
start. You will see a screen similar to the following.
C--16
MARF2HD4307701E

1
2
3
4
MOTION SYSVAR SETUP

PROGRAM INIT
MOTION DEVELOPMENT
EXIT
f Type 4, EXIT, and press ENTER.

g Press F4, YES.
h Press FCTN.
CAUTION
The CTRL2 start takes a few minutes to finish. Do not turn off
the controller until the CTRL2 start has completed. Otherwise,
you will lose the software loaded on your controller and will
have to reload it. The CTRL2 start is finished when the FCTN
menu disappears and you can display it again by pressing the
FCTN key.
i Select START (CTRL2) and press ENTER. The CTRL2 start will
be performed immediately. When it is finished, you will see a title
line on the screen similar to the following.
CONTROL START 2 MENUS
Press MENUS.
C--17
MARF2HD4307701E
1
2
3
4
5
Floppy
Floppy disk
disk
Serial Printer
FROM Disk (FR:)
FTP (C1:)
Mem Card (MC:)
Select File.
Press F5, [UTIL].
Select Set Device and press ENTER.
Select Floppy disk or Mem Card (MC:).
Press F4, [BACKUP].

CAUTION
Backing up files to a memory card or floppy disk will erase all
the information on the card or disk before the backup is
performed. You will lose all the information currently stored on
the memory card or floppy disk.
1
2
3
4
5
System files
TP programs
Application files
All of above
Controller
Controller
Select Controller. You will see a screen similar to the following.
FILE Backup
Controller backup will backup the

controllers memory to compressed load
files on memory cards. Insert a
memory card.
If you have selected the

Memory Card Device you will
see this screen
WARNING:
be lost.
Any files on the card will
Press CONTINUE when ready.

CONTINUE
FILE Backup
CANCEL
Controller backup will backup the

controllers memory to compressed load
files on disks. Insert a disk.
WARNING:
be lost.

Floppy Device you will see
this screen
Any files on the disk will

CONTINUE
CANCEL
C--18
MARF2HD4307701E
If you do not want to continue the backup, press F5, CANCEL.

To continue, press F4, CONTINUE. You will see a screen similar to
the following.
FILE Backup
Backup may require 2 2MB memory cards

or
36666 KB of storage and will take
approximately 15 minutes per card.
WARNING:
lost.

Memory Card Device you
will see this screen
Any files on the card will be
Root name for .LDC files:

PREV to Cancel
backup
backup

CONTINUE
FILE Backup
CANCEL
Backup may require 9 720KB disks

or
5865KB of storage and will take
approximately 20 minutes per disk.
WARNING: Any files on the disks
will be lost.

this screen

PREV to Cancel
backup
backup

CONTINUE
CANCEL
10 To enter a root name other than the default (backup) for the
compressed files that will be created, do the following:
a Press ENTER. You will see a screen similar to the following.
1 Upper Case
2 Lower Case
3 Punctuation
4 Options
FILE Backup
PREV to Cancel
--Insert-backup
backup
Old Value: backup

ABCDEF GHIJKL MNOPQR STUVWX
YZ_@*.
b Use the function keys to enter the root name and press ENTER.
11 If you do not want to continue the backup, press F5, CANCEL.
To continue, press F4, CONTINUE.
C--19
MARF2HD4307701E
The system will start to write backup files.

If you want to cancel, press PREV. However, the system will not
respond until it has completed writing the current file.
12 When the system has finished writing the current .ldc files, and a
second memory card is required, you will see one of the following
messages:

Memory Device you will see
this screen
Insert a memory card for the LDC files

CONTINUE
CANCEL

this screen
Insert a disk for the LDC files

CONTINUE
CANCEL
13 Insert the next memory card or floppy disk and press F4, CONTINUE.
14 When the system has finished writing the current .ldc files, you
will see the following message:
Controller backup completed successfully
15 To exit the screen, press PREV.

NOTE To restore these files, refer to Section C.4.2.
C--20
MARF2HD4307701E
C.4.2
Restoring a Controller
The controller restore function allows you to restore controller memory on

a controller from a backed up controller. Use Procedure C--6 to restore a
controller.
CAUTION
If you restore a controller and a file already exists on the
controller, the file is automatically overwritten.
Procedure C--6 Restoring a Controller after a Backup

Condition
You have the controller backup files on memory cards or floppy disks.
(Procedure C--5 must have been performed before you can restore a
controller.)
Make sure the Ethernet card has not been started. Otherwise, the
restore process will try to access the network.
If you are restoring from memory cards, make sure the floppy is
disconnected.
CAUTION
You must use Procedure C--5 to back up a controller before
you can restore a controller using this procedure. Otherwise,
the controller restore procedure will not function properly.
Step
H The controller is turned off.

Version 4.22P
01-JAN-199x
F-ROM/D-RAM/C-MOS :
TP Version
:
Current TIME
:
Slot
0
1
D
BMON>
COLD
ID
9B
6A
6A
CTRL
FC
0
0
0
INIT
6.0/8.0/1 MB
I
01-JAN-199x 22:52:53
OP
0
0
0
R-J2 Main CPU

AB/Ether I/F
MCARD I/F
NOLOAD
START
>
optional
optional
C--21
MARF2HD4307701E
Insert the first memory card or floppy disk in the memory card
interface or floppy disk drive.
3 Press NEXT, >, until F2, INSTALL, is displayed.

4
Press F2, INSTALL, and press ENTER.
Press NEXT, >, until F5, RESTORE, is displayed.

BMON> INSTALL
INSTALL>
LOAD
FSLOAD
RUN
ENET
RESTORE >
Press F5, RESTORE, and press ENTER.

You will be asked to run restore.cf.
If you want to continue, press 1 and then press ENTER.

To cancel, press 0 and then press ENTER.
Restoring will take several minutes.
When the INSTALL prompt is displayed, a message will be displayed

stating that power must be cycled for the restore to take effect.
Turn off the controller and then turn it on. The controller will start up
in CONTROLLED START mode. A message will be displayed
stating that the Cleanup of FROM blocks is occurring.
MARF2HD4307701E
COPYING SOFTWARE TO A
PC OR MEMORY CARD
D--1
You can copy HandlingTool software from the FANUC Robotics-supplied
3.5 disks to a directory on your PC or to PCMCIA memory card(s) using
a personal computer that has the proper equipment.
Storing HandlingTool software on a PC or memory card can simplify the
disk installation procedure by eliminating the need for disk swapping. It
also allows you to install software on multiple controllers quickly, and
provides you with a means of backing up your HandlingTool software.
Page
Copying HandlingTool
Software to a Personal
Computer
Copy HandlingTool software to a personal computer. . . . . . . . . . . . . . . . . . . . D--2
Copying HandlingTool
Software to a Memory
Card
Copy HandlingTool software from the FANUC Robotics-supplied 3.5

disks to a memory card using a PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3

product.
CAUTION
Be sure that the version of Main CPU BootROM you have is
version 4.20 or later. If not, DO NOT load the optional A-B RIO
software from memory card while the memory card interface is
in the ER-2 printed circuit board. Otherwise, you could erase
all the information on the memory card and destroy the ER-2
board. Instead, if the BootROM version is not 4.20 or later,
load the A-B RIO software using the FANUC Robotics-supplied
disks.
D. COPYING SOFTWARE
TO A PC OR MEMORY CARD
D--2
MARF2HD4307701E
D.1
You can copy the HandlingTool software from FANUC Robotics-supplied

3.5 disks to a personal computer (PC) for back up purposes. When the
copy is complete, you can use these files to load a controller quickly. Use
Procedure D--1 to copy HandlingTool software to a PC.
COPYING
HANDLINGTOOL
SOFTWARE TO A
PERSONAL
COMPUTER
Procedure D--1 Copying HandlingTool Software to a PC

Condition
You have a PC with at least 3000 KB of disk space available.
You have the FANUC Robotics KFLOPPY PS-100/200 Floppy Disk

Drive Emulator installed on the PC.
You are using DOS. Refer to your DOS users manual for more
information on using DOS commands.
H
Step
1 Create a directory on your PC hard drive. Name the directory for the
version of software you have; for example, HDL43xx for
HandlingTool V43x-x.
2
Copy all the files from the each robot library disk (SLIB and OLIB) to
the HDL43xx directory.
If you have any OPTION disks, copy all the files from these disks to
the HDL43xx directory.
CAUTION
Be sure to copy the AP disks to the directory last. Otherwise,
you might not retain the most recent version of all the files.
Copy all the files from the AP1-AP3 disks to the HDL43xx directory.
CAUTION
Do not copy any UPDATE disk information to the same
directory as all the other FANUC Robotics-supplied software.
Otherwise, you might not retain the most recent version of all
the files.
If necessary, use the FANUC Robotics-supplied 3.5 disk to load any

UPDATE information.
To load a controller from the files in the HDL43xx directory, make

sure the HDL43xx directory is the current directory and start
KFLOPPY-DOS on the PC. Go to Section 4.2.3.
D. COPYING SOFTWARE
D--3
MARF2HD4307701E
D.2
You can copy HandlingTool software from the FANUC Robotics-supplied

3.5 disks to memory card to simplify the load procedure. Use
Procedure D--2 to copy HandlingTool software from the FANUC
Robotics-supplied 3.5 disks to memory card using a PC.
COPYING
HANDLINGTOOL
SOFTWARE TO
MEMORY CARD
Procedure D--2 Copying HandlingTool Software to Memory Card

Condition
H
H
Step
The PC has a FANUC Robotics Memory Card Interface Circuit Board,

part number A20B-2000-0600.
You are using memory cards that are based on one of the following
standards:
- JEIDA IC Memory Card Guideline Version 4.0
- PCMCIA PC Card Standard R. 2.0
- 2 MB SRAM card (no Flash ROM cards)
1 Format each memory card on a SYSTEM R-J2 controller. Do not

format the memory card on your PC. To format the memory card,
do the following:
a Insert the memory card in the memory card interface.
b Turn on the controller.
c Press MENUS.
d Select FILE.
e Press F5, [UTIL].
f Select Set Device.
g Select Memory Card (MC:).
h Press F5, [UTIL].
i Select Format.
j Press F4, YES.
k Type a volume name.
NOTE There is not enough space on one memory card for all the files on
all the disks. You can either:
D
Use one memory card to store the AP disk information and use
the FANUC Robotics-supplied 3.5 disks to load the SLIB, OLIB,
OPTION and UPDATE information.
Use two memory cards, one to store the AP1-AP4 and UPDATE
disk information, and one to store the SLIB, OLIB and OPTION
disk information.
D. COPYING SOFTWARE
D--4
MARF2HD4307701E
To copy the AP disk information to one memory card,

a Insert the disk into the PC 3.5 disk drive.
b Insert one formatted memory card in the PC memory card drive.
c Copy the files from the disk to the memory card. For example, if
your PC 3.5 disk drive is drive b:, and your PC memory card
drive is drive d:, then type the following at the hard drive prompt:
copy b:*.* d:
d Repeat Steps 2a through 2c for each disk you have.
To copy all the disks to two memory cards,

a Insert an AP disk into the PC 3.5 disk drive.
b Insert one formatted memory card in the PC memory card drive.
c Copy the files from the AP disk to the memory card. For
example, if your PC 3.5 disk drive is drive b:, and your PC
memory card drive is drive d:, then type the following at the hard
drive prompt:
copy b:*.* d:
d Repeat Steps 3a through 3c for each AP disk you have.
e Insert a second formatted memory card in the PC memory card
drive.
f Insert the UPDATE disk into the PC 3.5 disk drive.
g Copy the files from the UPDATE disk to the memory card.
h Insert the OLIB disk into the PC 3.5 disk drive.
i Copy the files from the OLIB disk to the memory card.
j Repeat Steps 3h and 3i for each OLIB disk.
k Insert the SLIB disk into the PC 3.5 disk drive.
l Copy the files from the SLIB disk to the memory card.
m Repeat Steps 3k and 3l for each SLIB disk.
n Insert an OPTION disk into the PC 3.5 disk drive.
o Copy the files from the OPTION disk to the memory card.
p Repeat Steps 3n through 3o for each OPTION disk you have.
To load a controller from memory card, refer to Chapter 4.
MARF2HD4307701E
DISPLAYING VERSION INFORMATION

E--1
When the installation process is complete, you might want to check the
software version listed on the controller to be sure it is correct. Use
Procedure E--1 to display the application software version. You can also
use this to determine which options are installed on the controller.

Displaying the Software
Version
Page
Display software version during a controlled start . . . . . . . . . . . . . . . . . . . . . . E--1
Procedure E--1 Displaying the Software Version and Installed Option List
During a CONTROLLED START
Step
1 Press MENUS.
2 Select S/W VERSION. You will see a screen similar to the following.
E. DISPLAYING VERSION INFORMATION
E--2
MARF2HD4307701E
STATUS Version ID
JC13.00
V1.11
V1.11
V4.22
7D01/09I
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
V4.31-1
**********
59: *********************
60: *********************
**********
**********
[ TYPE ] SOFTWARE MOT_ID
ID:
7D60
9020000
F00000
10 %
1/60
SOFTWARE:
HandlingTool
S/W Order No.
Controller F No.
A-520-FM
Servo Code
Cart. Mot. Parameter
Joint Mot. Parameter
Boot MONITOR
Teach Pendant
Software Edition No.
R-J2 Kernel
R-J2 Operating System
Test Run
Override Select
CTRL Start Menus
Option Installation
I/O Interconnect
Execution History
V-400i/MAIN Interface
V-400i/MAIN Int (2)
User Frame
FANUC New Background
Basic Menus
HandlingTool (N. A.)
Analog I/O
Servo Code for R-J2
MACROs, Skip/Offset
Incr Instruction
FANUC Floppy Conn
FANUC Print Func
Multi-Tasking
FANUC Hour Meter
Position Registers
FANUC PNS
FANUC Prog Adjust
TCP Auto Set
Condition Monitor
A-520i Robot Library
*********************
1:
1
2:
3:
4:
5:
6:
7:
8:
9:
10:
11:
12:
13:
14:
15:
16:
17:
18:
19:
20:
21:
22:
23:
24:
25:
26:
27:
28:
29;
30:
31:
32:
33:
34;
35:
36:
37:
38:
39:
JOINT
MOT_INF
SER_PAR
Verify that the software version numbers displayed are correct for your
system.
MARF2HD4307701E
Index
A
A---520i robot
Cartesian motion option setting, B---2
configuration information, B---2
J2 axis limitation type setting, B---2
joint motion option setting, B---2
payload setting, B---2
type setting, B---2
wash down type setting, B---2
accessing BootROM, A---16
alarms, resetting for mastering, 5---3
AP, disks, 1---2
application
disk, 1---2
software version disk label, 1---3
application setup, screen item, A---4
ARCMATE---120iL, configuration information, B---4
arm length setting, S---420iF robot, B---9
authorizing an, option, 4---31
aux axis cabinet on i---cabinet setting, M---6i robot,
B---2, B---3, B---4
auxiliary
linear axis, extended axis, 4---44
rotary axis, extended axis, 4---44
axes, extended, 4---38
axis brake type setting, S---6 robot, B---8
Index--1
C
cabinet type setting
M---6i robot, B---2, B---3, B---4
M---710i robot, B---7
card, inserting a memory, 4---13
Cartesian motion option setting
A---520i robot, B---2
M---400i robot, B---5
M---410i robot, B---5
M---410iW robot, B---6
M---410iWx robot, B---6
M---500 robot, B---7
M---6i robot, B---3, B---4
M---710i robot, B---8
S---12 robot, B---9, B---10, B---11, B---13
S---420iR/120kg robot, B---10
S---420iS robot, B---11
S---450 robot, B---12
S---6 robot, B---8
S---800 robot, B---14
S---900 robot, B---14
checking, memory, 6---5
chips, EPROM, 1---1, 1---2
clear, screen item, A---15
CMOS, 6---5
CMOS RAM, 2---2
storage device, 2---2
CMOSINIT, performing a, A---12
cold start, 4---33, 4---69, A---14
controller, A---9
CTRL2, A---7
performing a, A---9
components, 4---2
bootrom, using utilities, A---16
configuration, 4---4, 4---69

robot information, B---2, B---3, B---4, B---5, B---6,
B---7, B---8, B---9, B---10, B---11, B---12, B---13,
B---14
controlled 2 start, performing a, A---7
controlled start, A---14
of the controller, A---3
performing a, A---5
controller, 1---3
cold start, A---9
controlled start of the, A---3
init start, A---2
re-init start, A---12
semi hot start, A---11
crt, screen item, A---15
ctrl start, A---14
brake type setting, M---6i robot, B---2, B---3, B---4
CTRL2 start, A---7
B
backing up
files from FILE menu, C---5
program files, C---5
system files, C---5
BMON, A---14
boot monitor. See BMON
BootROM, A---1
accessing, A---16
Index--2
INDEX
D
default, device setup, C---2
device
default setup, C---2
floppy disk, C---2
FROM disk, C---2
memory card, C---2
printer, C---2
MARF2HD4307701E
FCTN key, A---4

FILE menu, C---5, C---10, C---12
files
backing up from FILE menu, C---5
loading from FILE menu, C---10
restoring from FILE menu, C---12
fixture position master, 5---6
flange type setting, S---700 robot, B---12, B---13
DIAG, A---18
using, A---19
Flash ROM, 2---2, 6---5
diag, screen item, A---15
flowchart, installation tasks, 1---1
diagnostic display. See DIAG
frame type setting

M---410i robot, B---5
disk
library. See LIB
number, 1---3
option, 1---2
part number, 1---3
software version label, 1---3
type, 1---3
update, 1---2
disk drive
formatting a, PS---100, 4---5
PS---100, 1---5, 4---5
using a PS---100, 4---5
disks
containing options, 4---26
software, 1---1, 1---2
displaying, memory status, 6---5
D-RAM, 2---2
DRAM, 6---5
dynamic mastering file, C---4
E
EMON, A---17
using, A---17
emon, screen item, A---15
EPROM, installation, 1---1, 1---2
Erasable Programmable Read---Only Memory. See
EPROM
errors. See troubleshooting
extended boot monitor. See EMON
F
F---ROM. See Flash ROM
floppy disk, C---2
FROM, 6---5
See also Flash ROM
from, screen item, A---15
FROM disk, C---2
See also Flash ROM
G
gear ratio, extended axis setup
linear axes, 4---45
rotary axes, 4---45
I
IMAGE, memory pool, 6---5
init start, A---14
controller, A---2
install, screen item, A---15
install option, screen item, 4---28, A---4
install update, screen item, 4---68, A---4
installation
disk order, 4---2
disks, 1---1, 1---2
EPROM, 1---1, 1---2
SOCKETS, 1---2
SOFT PARTS, 1---2
tasks, 1---1
theory of, 4---2
troubleshooting, 1---1
installing, extended axes, 4---38
instructions
displaying the version identification status, E---1
loading files using the FILE Menu, C---10
MARF2HD4307701E
Index--3
INDEX
setting the default device, C---2, C---5

using a floppy disk and disk drive, 4---7
interface
formatting a, memory card, 4---8
memory card, 4---1, 4---5, 4---8
using a memory card, 4---8
J
J1 axis limitation type setting
M---6i robot, B---2, B---3, B---4
M---710i robot, B---7
S---12 robot, B---9
S---6 robot, B---8
J2 axis limitation type setting, A---520i robot, B---2
J3 option brake setting, M---500 robot, B---7
joint motion option setting
A---520i robot, B---2
M---400i robot, B---5
M---410i robot, B---5
M---500 robot, B---7
M---6i robot, B---3, B---4
M---710i robot, B---8
S---12 robot, B---9, B---10, B---11, B---13
S---420iR/120kg robot, B---10
S---420iS robot, B---11
S---450 robot, B---12
S---6 roboT, B---8
S---800 robot, B---14
S---900 robot, B---14
L
LIB, disk, 1---2
library, disk, 1---2
linear
auxiliary axis, extended axis setup, 4---44
integrated axis, extended axis setup, 4---44
linear axis, gear ratio, extended axis setup, 4---45
loadable files, C---8
loading, files from FILE menu, C---10
M
M---16i robot, configuration information, B---3
M---16iL robot, configuration information, B---4
M---400 robot, configuration information, B---4
M---400i robot
robot type setting, B---4
M---400iW robot, configuration information, B---5
M---400iWX robot, configuration information, B---6
M---410i robot
frame type setting, B---5
M---410iW robot
M---410iWx robot
M---500 robot
J3 option brake setting, B---7
option brake J1 setting, B---7
wrist axes exchange setting, B---7
wrist type setting, B---7
M---6i, mastering restrictions, 5---6
M---6i robot
aux axis cabinet on i---cabinet setting, B---2, B---3,
B---4
brake type setting, B---2, B---3, B---4
cabinet type setting, B---2, B---3, B---4
Cartesian motion option setting, B---3, B---4
J1 axis limitation type setting, B---2, B---3, B---4
joint motion option setting, B---3, B---4
mount angle setting, B---2, B---3, B---4
mount type, B---2, B---3, B---4
payload setting, B---2, B---3, B---4
robot type setting, B---2, B---3, B---4
M---710i robot
cabinet type setting, B---7
Index--4
INDEX

mount angle setting, B---7
MARF2HD4307701E
S---6 robot, B---8
M---710iW robot, configuration information, B---7
mount type
M---6i robot, B---2, B---3, B---4
S---6 robot, B---8
maintenance update, 4---68
mount type setting, S---700 robot, B---12, B---13
Manipulating Files
backing up program, system, and files, C---1
loading files from disk to controller, C---1, C---8
manual data entry, BMON, A---16

mastering
definition of, 5---1
quick, 5---13, 5---16
single axis, 5---10
to a fixture, 5---6
to zero degrees, 5---8
mastering methods
fixture position master, 5---1
quick mastering, 5---1
recording the quick reference position, 5---1
single axis mastering, 5---1
zero degree mastering, 5---1
mcard, screen item, A---15
noload, screen item, A---14

number
controller F, 1---3
disk part number, 1---3
software serial, 1---3
O
option, software disk, 1---2
option brake J1 setting, M---500 robot, B---7
options
authorizing, 4---27, 4---31
disk locations, 4---26
installing, 4---27, 4---28, 4---32
memory
checking available, 6---5
CMOS RAM, 2---2
D---RAM, 2---2
Flash ROM, 2---2
memory card, 4---1, 4---5, C---2

inserting into an interface, 4---13
interface, 4---8
part number, disk label, 1---3
memory card interface, connecting a, 4---8

memory pools
IMAGE, 6---5
PERM, 6---5
SYSTEM, 6---5
TEMP, 6---5
TPP, 6---5
MENUS key, A---4
motion development, screen item, A---3
See also controlled start
motion sysvar setup, screen item, A---3
See also controlled start
motor cover setting, S---6 robot, B---8
mount angle setting
M---6i robot, B---2, B---3, B---4
M---710i robot, B---7
S---12 robot, B---9
S---500 robot, B---12
P2 port, 1---5, 4---5

PAC. See product authorization code
payload setting
A---520i robot setting, B---2
M---400i robot, B---4
M---410i robot, B---5
M---500 robot, B---7
M---6i robot, B---2, B---3, B---4
M---710i robot, B---7
S---12 robot, B---9
S---420iF robot, B---9
S---420iL robot, B---10
S---420iR/120kg robot, B---10
S---420iS robot, B---11
S---420iW robot, B---11
S---450 robot, B---12
S---500 robot, B---12
S---6 robot, B---8
S---700 robot, B---12, B---13
S---800 robot, B---14
S---900 robot, B---14
pc emulator, 4---1, 4---5
MARF2HD4307701E
PERM, memory pool, 6---5

port, P2, 4---5
printer, C---2
problems. See troubleshooting
product, name, 1---3
product authorization code, 4---27
prog init, screen item, A---3
program file, backing up, C---5
program init, screen item. See controlled start
PS---100
connecting a, 4---5
disk drive, 1---5, 4---5
Q
quick mastering, 5---13, 5---16
recording the position, 5---14
R
recording the quick reference position, 5---14
re-init start, controller, A---12
reinit start, using CMOSINIT, A---12
resetting alarms, for mastering, 5---3
restoring, files from FILE menu, C---12
RJ-2, controller, 1---3
robot, configuration, 4---69
robot library disk. See library
robot type setting
M---400i robot, B---4
M---500 robot, B---7
M---6i robot, B---2, B---3, B---4
S---12 robot, B---9
S---420iF robot, B---9
S---420iL robot, B---10
S---420iR/120kg robot, B---10
S---420iS robot, B---11
S---420iW robot, B---11
S---6 robot, B---8
S---800 robot, B---14
S---900 robot, B---14
rotary axis, gear ratio, extended axis setup, 4---45
S
S---12, mastering restrictions, 5---6
Index--5
INDEX
S---12 robot
Cartesian motion option setting, B---9, B---10, B---11,
B---13
joint motion option setting, B---9, B---10, B---11,
B---13
S---420iF robot
arm length setting, B---9
S---420iL robot
S---420iR robot, configuration information, B---10
S---420iR/120kg robot
S---420iS robot
S---420iW robot
S---450 robot
x---stroke type setting, B---12
S---500 robot
wrist type setting, B---12
S---6, mastering restrictions, 5---6
S---6 robot
axis brake type setting, B---8
Index--6
INDEX

motor cover setting, B---8
mount type, B---8
S---700 robot
configuration information, B---12, B---13
flange type setting, B---12, B---13
mount type setting, B---12, B---13
payload setting, B---12, B---13
S---800 robot
S---900 robot
controller, A---11
serial number
controller F, 1---3
for software, 1---3
servo parameter file, C---4
setup
application, A---4
default device, C---2
single axis mastering, 5---10
SOCKETS, 1---2
SOFT PARTS, 1---2
software
disk label, 1---3
disks, 1---1, 1---2
option disk, 1---2
update disk, 1---2
version disk label, 1---3
MARF2HD4307701E
performing a cold, A---9

performing a controlled, A---5
performing a controlled 2, A---7
performing a reinit, A---12
START CTRL, A---3
START CTRL2, A---7
start methods
controlled start, A---3
init start, A---2
re-init start, A---12
START CTRL2, A---7
steps, installation, 4---4
storage device
CMOS RAM, 2---2
D-RAM, 2---2
Flash ROM, 2---2
SYSMACRO.SV, C---4
SYSMAST.SV, C---4
SYSSERVO.SV, C---4
SYSTEM, memory pool, 6---5
system file, backing up, C---5
system files
backing up, C---1, C---4
SYSMACRO.SV, C---4
SYSMAST.SV, C---4
SYSSERVO.SV, C---4
SYSVARS.SV, C---4
system macro file, C---4
system variable file, C---4
SYSVARS.SV, C---4
T
tasks
installation, 1---1
installation flowchart, 1---1
teach pendant, 1---4
picture of standard, 1---4
TEMP, memory pool, 6---5
software disks. See application; library; option; update
timetable, 4---4
software serial number, 1---3
TPP
memory pool, 6---5
memory pools, 6---5
start
cold, 4---33, 4---69, A---14
controlled, A---14
ctrl, A---14
init, A---14
troubleshooting, 1---1, 4---4

using error messages, 6---1, 6---4
using symptoms, 6---1, 6---2
MARF2HD4307701E
turning on the robot, semi hot start, A---11

type setting, A---520i robot, B---2
U
update, software disk, 1---2
updates
installing, 4---68
installing additional, 4---69
installing maintenance, 4---68
using DIAG, A---19
using EMON, A---17
utilities, using bootrom, A---16
V
version id, 4---34
displaying at ctrl start, E---1
Index--7
INDEX
W
wash down type setting, A---520i robot, B---2
wrist axes exchange setting, M---500 robot, B---7
wrist type setting
M---500 robot, B---7
S---500 robot, B---12
X
x---stroke type setting, S---450 robot, B---12
Z
zero degree mastering, 5---8

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FANUC Robotics

SYSTEM R-J2 Controller

The descriptions and specifications contained in this manual were in effect

Copyright E1997 by FANUC Robotics North America, Inc.

Purpose of this Manual

This manual describes FANUC Robotics SYSTEM R-J2 Software

How to Use this

Use this table to locate specific information in the manual.

Find information about a specific topic

Determine the installation requirements for

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

Identify robot configuration information before

Back up or load teach pendant programs or

Appendix C, Backing Up and

Copy software to a PC or memory card.

Determine the version of software on your

This manual includes information essential to the safety of personnel,

NOTE Information appearing next to NOTE concerns related information

Keeping People and

The safety of people is always of primary importance in any

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

Sponsor your personnel for training in approved FANUC Robotics

Install a lockout device that uses an access code to prevent

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

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 or

Install flashing lights and/or audible warning devices that activate

Wherever possible, install safety fences to protect against unauthorized

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

Periodically check the safety joints or safety clutches that can be

Make sure all external devices are properly filtered, grounded,

Make provisions for power lockout/tagout at the controller.

Provide enough room inside the workcell to permit personnel to teach

Program the robot to load and unload material safely.

If high voltage electrostatics are present, be sure to provide appropriate

If materials are being applied at dangerously high pressure, provide

Staying Safe While

FANUC Robotics recommends that no one enter the work envelope of

- Using the programmed speed, test run the program continuously

Staying Safe During

Staying Safe During

Understand the complete task the robot is programmed to perform

Never enter or allow others to enter the work envelope during

Never assume that a program is complete if the robot is not moving.

If the robot is running in a pattern, do not assume it will continue to

When inspecting the robot, be sure to

Turn off power at the controller.

If robot motion is not needed for inspecting the electrical circuits,

If power is needed to check the robot motion or electrical circuits, be

Staying Safe During

When performing maintenance on your robot system, observe the

Never enter the work envelope while the robot or a program is in

Before entering the work envelope, visually inspect the workcell to

Consider all or any overlapping work envelopes of adjoining robots

Whenever possible, perform maintenance with the power turned off.

Release or block all stored energy. Before working on the pneumatic

Use blocks, mechanical stops, and pins to prevent hazardous

Be aware that when you remove a servomotor or brake, the associated

When replacing or installing components, make sure dirt and debris do