Software Instalation R-J2

FANUC RoboticsSYSTEM R-J2 ControllerHandlingTool SoftwareInstallation ManualVersion 4.31-1

MARF2HD4307701E

This publication contains proprietary information of FANUC RoboticsNorth America, Inc. furnished for customer use only. No other uses areauthorized without the express written permission of FANUC RoboticsNorth America, Inc.

FANUC Robotics North America, Inc.3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253

The descriptions and specifications contained in this manual were in effectat the time this manual was approved for printing. FANUC RoboticsNorth America, Inc, hereinafter referred to as FANUC Robotics, reservesthe right to discontinue models at any time or to change specifications ordesign without notice and without incurring obligations.

FANUC Robotics manuals present descriptions, specifications, drawings,schematics, bills of material, parts, connections and/or procedures forinstalling, disassembling, connecting, operating and programming FANUCRobotics products and/or systems. Such systems consist of robots,extended axes, robot controllers, application software, the KARELRprogramming language, INSIGHTR vision equipment, and special tools.

FANUC Robotics recommends that only persons who have been trained inone or more approved FANUC Robotics Training Course(s) be permittedto install, operate, use, perform procedures on, repair, and/or maintainFANUC Robotics products and/or systems and their respectivecomponents. Approved training necessitates that the courses selected berelevant to the type of system installed and application performed at thecustomer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used inaccordance with the instruction manual, may causeinterference to radio communications. As temporarilypermitted by regulation, it has not been tested forcompliance with the limits for Class A computing devicespursuant to subpart J of Part 15 of FCC Rules, which aredesigned to provide reasonable protection against suchinterference. Operation of the equipment in a residentialarea is likely to cause interference, in which case the user,at his own expense, will be required to take whatevermeasure may be required to correct the interference.

FANUC Robotics conducts courses on its systems and products on aregularly scheduled basis at the companys world headquarters inRochester Hills, Michigan. For additional information contact

FANUC Robotics North America, Inc.Training and Documentation Department3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253Tel: (248)377-7234FAX: (248)377-7367 or (248)377-7362

CopyrightE1997 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 partin any way without the prior written consent of FANUC Robotics NorthAmerica, 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 FANUCRobotics.

FANUC Robotics reserves all proprietary rights, including but not limitedto trademark and trade name rights, in the following names:

AccuFlowTARC MateTARC Mate Sr.TIntelliTrakTLaserToolTMotionPartsTPaintWorks IITPalletMateTSureWeldTTurboMoveT

PrefaceMARF2HD4307701E viiThis manual describes FANUC Robotics SYSTEM R-J2 SoftwareInstallation:

D Package contents

D Requirements

D Procedures

D Troubleshooting and error recovery

You must have access to these manuals to use all the information in thismanual effectively.

The entire manual set for this product includes manuals you can use whenperforming other tasks in the system. You do not need these manuals touse this manual; they provide information that you can use in other areasof the robot, controller, and application system.

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 foryour application

Chapter 1, Overview

Set up and check memory requirements Chapter 2, Setting UpController Memory

Check and install EPROM chips Chapter 3, EPROMInstallation

Install core, application, robot library, motiongroups and extended axis software

Chapter 4, SoftwareInstallation

Master the robot Chapter 5, Mastering

Perform troubleshooting and error recovery Chapter 6, Troubleshootingand Error Messages

Use BootROM Appendix A, BootROMOperations

Identify robot configuration information beforeyou begin loading the software.

Appendix B, ConfigurationTables

Back up or load teach pendant programs orsystem files.

Appendix C, Backing Up andRestoring Files

Copy software to a PC or memory card. Appendix D, CopyingSoftware to a PC or memorycard

Determine the version of software on yourcontroller.

Appendix E, DisplayingVersion Information

Purpose of this Manual

Required Manuals

Related Manuals

How to Use thisManual

PREFACE MARF2HD4307701Eviii

This manual includes information essential to the safety of personnel,equipment, software, and data. This information is indicated by headingsand boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to setit apart from other text.

CAUTIONInformation appearing under CAUTION concerns the protectionof equipment, software, and data. It is boxed to set it apartfrom other text.

NOTE Information appearing next to NOTE concerns related informationor useful hints.

Conventions Used inthis Manual

SafetyMARF2HD4307701E xvFANUC Robotics is not and does not represent itself as an expert in safetysystems, safety equipment, or the specific safety aspects of your companyand/or its work force. It is the responsibility of the owner, employer, oruser to take all necessary steps to guarantee the safety of all personnel inthe workplace.

The appropriate level of safety for your application and installation canbest be determined by safety system professionals. FANUC Roboticstherefore, recommends that each customer consult with such professionalsin 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 yourresponsibility to arrange for the training of the operator of a robot systemto recognize and respond to known hazards associated with your roboticsystem and to be aware of the recommended operating procedures for yourparticular application and robot installation.

FANUC Robotics therefore, recommends that all personnel who intend tooperate, program, repair, or otherwise use the robotics system be trained inan approved FANUC Robotics training course and become familiar withthe proper operation of the system. Persons responsible for programmingthe system-including the design, implementation, and debugging ofapplication programs-must be familiar with the recommendedprogramming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance ofsafety in the workplace.

SAFETY MARF2HD4307701Exvi

Safety is essential whenever robots are used. Keep in mind the followingfactors with regard to safety:

D The safety of people and equipmentD Use of safety enhancing devicesD 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 workcellD Proper maintenance of the robot

The safety of people is always of primary importance in anysituation. However, equipment must be kept safe, too. Whenprioritizing how to apply safety to your robotic system, consider

D PeopleD External devicesD Robot(s)D ToolingD Workpiece

Always give appropriate attention to the work area that surrounds therobot. The safety of the work area can be enhanced by the installation ofsome or all of the following devices:

D Safety fences, barriers, or chainsD Light curtainsD InterlocksD Pressure matsD Floor markingsD Warning lightsD Mechanical stopsD EMERGENCY STOP buttonsD DEADMAN switches

A safe workcell is essential to protect people and equipment. Observe thefollowing guidelines to ensure that the workcell is set up safely. Thesesuggestions 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 Roboticstraining course(s) related to your application. Never permit untrainedpersonnel to operate the robots.

D Install a lockout device that uses an access code to preventunauthorized persons from operating the robot.

D Use anti-tie-down logic to prevent the operator from bypassing safetymeasures.

D Arrange the workcell so the operator faces the workcell and can seewhat is going on inside the cell.

CONSIDERINGSAFETY FOR YOURROBOTINSTALLATION

Keeping People andEquipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell

SAFETYMARF2HD4307701E xvii

D Clearly identify the work envelope of each robot in the system withfloor markings, signs, and special barriers. The work envelope is thearea defined by the maximum motion range of the robot, including anytooling attached to the wrist flange that extend this range.

D Position all controllers outside the robot work envelope.

D Never rely on software as the primary safety element.

D Mount an adequate number of EMERGENCY STOP buttons orswitches within easy reach of the operator and at critical points insideand around the outside of the workcell.

D Install flashing lights and/or audible warning devices that activatewhenever the robot is operating, that is, whenever power is applied tothe servo drive system.

D Wherever possible, install safety fences to protect against unauthorizedentry by personnel into the work envelope.

D Install special guarding that prevents the operator from reaching intorestricted areas of the work envelope.

D Use interlocks.

D Use presence or proximity sensing devices such as light curtains, mats,and capacitance and vision systems to enhance safety.

D Periodically check the safety joints or safety clutches that can beoptionally installed between the robot wrist flange and tooling. If thetooling strikes an object, these devices dislodge, remove power fromthe system, and help to minimize damage to the tooling and robot.

D Make sure all external devices are properly filtered, grounded,shielded, and suppressed to prevent hazardous motion due to theeffects of electro-magnetic interference (EMI), radio frequencyinterference (RFI), and electro-static discharge (ESD).

D Make provisions for power lockout/tagout at the controller.

D Eliminate pinch points. Pinch points are areas where personnel couldget trapped between a moving robot and other equipment.

D Provide enough room inside the workcell to permit personnel to teachthe robot and perform maintenance safely.

D Program the robot to load and unload material safely.

D If high voltage electrostatics are present, be sure to provide appropriateinterlocks, warning, and beacons.

D If materials are being applied at dangerously high pressure, provideelectrical interlocks for lockout of material flow and pressure.

SAFETY MARF2HD4307701Exviii

Advise all personnel who must teach the robot or otherwise manuallyoperate the robot to observe the following rules:

D Know whether or not you are using an intrinsically safe teach pendantif you are working in a hazardous environment.

D Before teaching, visually inspect the robot and work envelope to makesure that no potentially hazardous conditions exist. The workenvelope is the area defined by the maximum motion range of therobot. These include tooling attached to the wrist flange that extendsthis range.

D The area near the robot must be clean and free of oil, water, or debris.Immediately report unsafe working conditions to the supervisor orsafety department.

D FANUC Robotics recommends that no one enter the work envelope ofa robot that is on. However, if you must enter the work envelope, besure all safeguards are in place, and check the teach pendantDEADMAN switch for proper operation. Take the teach pendant withyou, turn it on, and be prepared to release the DEADMAN switch.Only the person with the teach pendant should be in the workenvelope.

D Know the path that can be used to escape from a moving robot; makesure the escape path is never blocked.

D Isolate the robot from all remote control signals that can cause motionwhile data is being taught.

D Test any program being run for the first time in the following manner:

WARNINGStay outside the robot work envelope whenever a programis being run. Failure to do so can result in injury.

-- Using a low motion speed, single step the program for at least onefull cycle.

-- Using a low motion speed, test run the program continuously forat least one full cycle.

-- Using the programmed speed, test run the program continuouslyfor at least one full cycle.

D Make sure all personnel are outside the work envelope before runningproduction.

Staying Safe WhileTeaching or ManuallyOperating the Robot

SAFETYMARF2HD4307701E xix

Advise all personnel who operate the robot during production to observethe following rules:

D Know the entire workcell area. The workcell includes the robot and itswork envelope, plus the area occupied by all external devices andother equipment with which the robot interacts.

D Understand the complete task the robot is programmed to performbefore initiating production operation.

D Make sure all personnel are outside the work envelope beforeoperating the robot.

D Never enter or allow others to enter the work envelope duringproduction operation of the robot.

D Know the location and status of all switches, sensors, and controlsignals that could cause the robot to move.

D Know where the EMERGENCY STOP buttons are located on both therobot control and external control devices. Be prepared to press thesebuttons in an emergency.

D 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 tocontinue activity.

D If the robot is running in a pattern, do not assume it will continue torun in the same pattern.

D Never try to stop the robot, or break its motion, with your body. Theonly way to stop robot motion immediately is to press anEMERGENCY STOP button located on the controller panel, teachpendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to

D Turn off power at the controller.

D Lock out and tag out the power source at the controller according tothe policies of your plant.

D Turn off the compressed air source and relieve the air pressure.

D If robot motion is not needed for inspecting the electrical circuits,press the EMERGENCY STOP button on the operator panel.

D If power is needed to check the robot motion or electrical circuits, beprepared to press the EMERGENCY STOP button, in an emergency.

Staying Safe DuringProduction Operation

Staying Safe DuringInspection

SAFETY MARF2HD4307701Exx

When performing maintenance on your robot system, observe thefollowing rules:

D Never enter the work envelope while the robot or a program is inoperation.

D Before entering the work envelope, visually inspect the workcell tomake sure no potentially hazardous conditions exist.

D Consider all or any overlapping work envelopes of adjoining robotswhen standing in a work envelope.

D Test the teach pendant for proper operation before entering the workenvelope.

D If it is necessary for you to enter the robot work envelope while poweris turned on, you must be sure that you are in control of the robot. Besure to take the teach pendant with you, press the DEADMAN switch,and turn the teach pendant on. Be prepared to release the DEADMANswitch to turn off servo power to the robot immediately.

D 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.

WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.

Turning the disconnect or circuit breaker to the OFFposition removes power from the output side of the deviceonly. High voltage is always present at the input sidewhenever the controller is connected to a power source.

D Release or block all stored energy. Before working on the pneumaticsystem, shut off the system air supply and purge the air lines.

D Isolate the robot from all remote control signals. If maintenance mustbe done when the power is on, make sure the person inside the workenvelope has sole control of the robot. The teach pendant must beheld by this person.

D Make sure personnel cannot get trapped between the moving robot andother equipment. Know the path that can be used to escape from amoving robot. Make sure the escape route is never blocked.

D Use blocks, mechanical stops, and pins to prevent hazardousmovement by the robot. Make sure that such devices do not createpinch points that could trap personnel.

Staying Safe DuringMaintenance

SAFETYMARF2HD4307701E xxi

WARNINGDo not try to remove any mechanical component from therobot before thoroughly reading and understanding theprocedures in the appropriate manual. Doing so can resultin serious personal injury and component destruction.

D Be aware that when you remove a servomotor or brake, the associatedaxis will fall if it is not supported or resting on a hard stop.

D When replacing or installing components, make sure dirt and debris donot enter the system.

D Use only specified parts for replacement. To avoid fires and damageto parts in the controller, never use nonspecified fuses.

D Before restarting a robot, make sure no one is inside the workenvelope; be sure that the robot and all external devices are operatingnormally.

Certain programming and mechanical measures are useful in keeping themachine tools and other external devices safe. These measures areoutlined below.

Implement the following programming safety measures to prevent damageto machine tools and other external devices.

D Back-check limit switches in the workcell to make sure they do notfail.

D Implement failure routines in programs that will provide appropriaterobot actions if an external device or another robot in the workcellfails.

D Use handshaking protocol to synchronize robot and external deviceoperations.

D Program the robot to check the condition of all external devices duringan operating cycle.

Implement the following mechanical safety measures to prevent damage tomachine tools and other external devices.

D Make sure the workcell is clean and free of oil, water, and debris.

D Use software limits, limit switches, and mechanical hardstops toprevent undesired movement of the robot into the work area ofmachine tools and external devices.

KEEPING MACHINETOOLS ANDEXTERNALDEVICES SAFE

Programming SafetyPrecautions

Mechanical SafetyPrecautions

SAFETY MARF2HD4307701Exxii

Observe the following operating and programming guidelines to preventdamage to the robot.

The following measures are designed to prevent damage to the robotduring operation.

D Use a low override speed to increase your control over the robot whenjogging the robot.

D Visualize the movement the robot will make before you press the jogkeys on the teach pendant.

D Make sure the work envelope is clean and free of oil, water, or debris.

D Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to the robotduring programming:

D Establish interference zones to prevent collisions when two or morerobots share a work area.

D Make sure that the program ends with the robot near or at the homeposition.

D Be aware of signals or other operations that could trigger operation oftooling resulting in personal injury or equipment damage.

NOTE Any deviation from the methods and safety practices described inthis manual must conform to the approved standards of your company. Ifyou have questions, see your supervisor.

WARNINGAn EMERGENCY STOP will occur if the DEADMAN switchis released on a bypassed robot.

WARNINGObserve all safety rules and guidelines to avoid injury.

KEEPING THEROBOT SAFE

Operating SafetyPrecautions

Programming SafetyPrecautions

Table of ContentsMARF2HD4307701E ixPreface vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety xv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1OVERVIEW 1--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 INSTALLATION TASKS 1--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 PACKAGE CONTENTS 1--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.1 Software Disks 1--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.2 System EPROM Chips 1--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 INSTALLATION REQUIREMENTS 1--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.1 Teach Pendant 1--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Storage and Load Devices 1--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.3 Controller Hardware Tools 1--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2SETTING UP CONTROLLER MEMORY 2--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 IDENTIFYING KINDS OF MEMORY 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.1 Controller Memory 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.2 Flash ROM 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.3 C-MOS RAM 2--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.4 D-RAM 2--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 CHECKING CONTROLLER MEMORY 2--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 INSTALLING FLASH ROM, C-MOS RAM AND D-RAM CHIPS 2--5. . . . . . . . . . . . . . . . . . . .

Chapter 3EPROM INSTALLATION 3--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 INSTALLING BOOTROM EPROM CHIPS 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 INSTALLING TEACH PENDANT EPROM CHIPS 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4SOFTWARE INSTALLATION 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 SOFTWARE INSTALLATION THEORY 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 SETTING UP LOAD DEVICES 4--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.1 Using a PS-100 Disk Drive 4--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.2 Using a Memory Card Interface 4--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3 Using KFLOPPY PS-100 Floppy Disk Drive Emulator 4--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 INSTALLING HANDLINGTOOL APPLICATION SOFTWARE 4--17. . . . . . . . . . . . . . . . . . . . . .4.4 INSTALLING HANDLINGTOOL OPTIONS 4--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 QUICK/FULL PASSWORD SETUP 4--35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6 MODIFYING AND INSTALLING ADDITIONAL EXTENDED AXES 4--38. . . . . . . . . . . . . . . . .4.7 INSTALLING MOTION GROUP SOFTWARE 4--53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8 INSTALLING SOFTWARE UPDATES 4--67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS MARF2HD4307701Ex

Chapter 5MASTERING 5--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 RESETTING ALARMS AND PREPARING FOR MASTERING 5--3. . . . . . . . . . . . . . . . . . . . . .5.2 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER) 5--6. . . . . . . . . . . . . . . . . . . . .5.3 ZERO DEGREE MASTERING 5--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 SINGLE AXIS MASTERING 5--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 QUICK MASTERING 5--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6TROUBLESHOOTING AND ERROR MESSAGES 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 TROUBLESHOOTING USING SYMPTOMS 6--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 TROUBLESHOOTING USING ERROR MESSAGES 6--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 CHECKING MEMORY 6--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix ABOOTROM OPERATIONS A--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 STARTUP METHODS A--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1.1 INIT Start A--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1.2 Controlled Start (START CTRL) A--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1.3 Controlled 2 Start (START CTRL2) A--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1.4 Cold Start (START COLD) A--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1.5 Semi Hot Start A--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1.6 Re-Init Start (CMOSINIT) A--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2 BOOTROM UTILITIES A--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2.1 Extended Boot Monitor (EMON>) Utilities A--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2.2 Diagnostic Utilities A--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2.3 INSTALL Utilities A--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2.4 Flash ROM Utilities A--23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2.5 Memory Card Utilities A--24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix BCONFIGURATION TABLES B--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTSMARF2HD4307701E xi

Appendix CBACKING UP AND RESTORING FILES C--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1 SETTING THE DEFAULT DEVICE C--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.2 BACKING UP FILES C--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.3 LOADING OR RESTORING FILES FROM DISK TO CONTROLLER MEMORY C--8. . . . . . .C.4 CONTROLLER BACKUP AND RESTORE C--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.4.1 Backing up a Controller C--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.4.2 Restoring a Controller C--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix DCOPYING SOFTWARE TO A PC OR MEMORY CARD D--1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.1 COPYING HANDLINGTOOL SOFTWARE TO A PERSONAL COMPUTER D--2. . . . . . . . . . .D.2 COPYING HANDLINGTOOL SOFTWARE TO MEMORY CARD D--3. . . . . . . . . . . . . . . . . . .

Appendix EDISPLAYING VERSION INFORMATION E--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index Index-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TABLE OF CONTENTS MARF2HD4307701Exii

Procedure 6--1 Displaying Memory Status 6--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--1 Performing a Controlled Start A--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--2 Performing a CTRL2 Start A--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--3 Performing a Cold Start A--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--4 Performing a Semi Hot Start A--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--5 Performing a Re-Init Start using CMOSINIT A--12. . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--6 Using BootROM Utilities A--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--7 Using EMON> Utilities A--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--8 Using DIAG> Utilities A--19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--9 Using INSTALL Utilities A--22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--10 Using FROM Utilities A--23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure A--11 Using MCARD Utilities A--24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure C--1 Setting the Default Device C--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure C--2 Backing Up System Files, Teach Pendant Programs, and

Application Files to Disk C--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure C--3 Loading Selected Files Using the FILE Menu C--10. . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure C--4 Restoring BACKUP Files Using the FILE Menu C--12. . . . . . . . . . . . . . . . . . . . . . . . .Procedure C--5 Backing up a Controller to a Floppy or Memory Card Device C--15. . . . . . . . . . . . . . .Procedure C--6 Restoring a Controller after a Backup C--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure D--1 Copying HandlingTool Software to a PC D--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure D--2 Copying HandlingTool Software to Memory Card D--3. . . . . . . . . . . . . . . . . . . . . . . . .Procedure E--1 Displaying the Software Version and Installed Option List During a

CONTROLLED START E--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TABLE OF CONTENTSMARF2HD4307701E xiii

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

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

TABLE OF CONTENTS MARF2HD4307701Exiv

Table B--12. S-12 Robot Configuration Information B--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--13. S-420iF Robot Configuration Information B--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--14. S-420iL Robot Configuration Information B--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--15. S-420iR Robot Configuration Information B--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--16. S-420iS Robot Configuration Information B--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--17. S-420iW Robot Configuration Information B--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--18. S-450 Robot Configuration Information B--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--19. S-500 Robot Configuration Information B--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--20. S-700 Robot Configuration Information B--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--21. Offset Wrist S-700 Robot Configuration Information B--13. . . . . . . . . . . . . . . . . . . . . . .Table B--22. S-800 Robot Configuration Information B--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table B--23. S-900 Robot Configuration Information B--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 OVERVIEWMARF2HD4307701E 1--1Topics 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 1--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D A teach pendant 1--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D A storage/load device 1--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D Controller hardware tools 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 thispackage in your system

D What you have in your SYSTEM R-J2 Software Installation PackageD What you need to set up and install the components of this package

The first time you install your SYSTEM R-J2 software, and whenever youupdate your controller with components in this package, you must do thefollowing:

Verify controllermemory. Adjust if

necessary

Verify EPROM chipsand install ifnecessary

Fill outconfiguration

tables

Install all softwarefor your system

Are youreplacing,

upgrading orupdatingcontrollersoftware?

YES

NO

Back up allsystem files

Master the robot

See Chapter 2 See Chapter 3 See Appendix B See Chapter 4 See Chapter 5

See Appendix C Troubleshoot

See Chapter 6

You must satisfy controller memory and EPROMrequirements before you can install the SYSTEMR-J2 software. If you perform all setup andinstallation procedures and still have a problemwith the installation, refer to Chapter 6 forinformation to help you solve the problem.

1.1INSTALLATION TASKS

MARF2HD4307701E1--2

1. OVERVIEW

The SYSTEM R-J2 controller design utilizes a features-based design. Afeature is a high-level building block which uses SOCKETS and SOFTPARTS in the application software structure. An application is constructedfrom standard features and can be enhanced using optional features.

The R-J2 software installation package consists ofD Software disksD Erasable Programmable Read-Only Memory (EPROM) chips

Your R-J2 software installation package contains the disk set that can beused for your robot.

The software package delivered to you is delivered underthe terms and conditions of the FANUC Robotics NorthAmerica, INC. Software License Agreement (SLA). Acopy of the SLA was previously delivered to you. Your useof this software constitutes your consent to the applicabilityof the terms and conditions of the SLA to such use.

Your disk set consists of the following kinds of disks:

D ApplicationD Robot LibraryD Options

Your package can also contain Updates

Figure 1--1. Disk Label Example

APx R-J2 DISK # OF #

ProductTool Name 4.3x-x

FANUC Robotics N.A., Inc.

Copyright(C) 199x

SFTxxxxxxxxxxxx Serial # 000000

Disk Type

Product Name

Part Number

Product Version

Software SerialNumber

Controller and DiskNumber

1.2PACKAGE CONTENTS

1.2.1Software Disks

MARF2HD4307701E 1--3

1. OVERVIEW

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 canbe used (R-J2, for example), and the number of the disk in a series ofdisks.

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 inan ASCII file called readme.txt and is stored on the AP1 disk.

The following system EPROM chips are already installed on yourcontroller:

D Bootstrap ROM (BootROM) EPROM Chip -- One EPROM chipthat is installed on the MAIN CPU board inside the controller.

D Teach Pendant EPROM Chip -- One EPROM chip that is installedon the teach pendant PCB inside the teach pendant.

You must check the version of EPROM chip in your controller to be surethat it is compatible with the version of software you are loading. Refer toChapter 3 for information on checking EPROM chips.

1.2.2System EPROM Chips

MARF2HD4307701E1--4

1. OVERVIEW

In order to install a new SYSTEM R-J2 Application Software Package,you need

D A teach pendantD A storage/load deviceD Controller hardware tools

The FANUC Robotics teach pendant is an operator interface device thatdisplays the SYSTEM R-J2 software. The teach pendant is connected tothe controller via a cable that plugs into either the MAIN CPU boardinside the controller or, if it is a disconnectable teach pendant, the standardoperator 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

D Eleven status indicators including three indicators dedicated to theSYSTEM R-J2 software application.

D Teach pendant keys, including keys specific to the SYSTEM R-J2software application.

Figure 1--2 shows the standard teach pendant.

Figure 1--2. Standard Teach Pendant

Screen

EMERGENCYSTOPBUTTON

Indicators

ON/OFFSwitch

1.3INSTALLATIONREQUIREMENTS

1.3.1Teach Pendant

MARF2HD4307701E 1--5

1. OVERVIEW

To perform a software installation, you must have one of the followingdevices available:D FANUC Robotics PS-100 disk drive unitD Memory card interfaceD PC emulator

The FANUC Robotics PS-100 disk drive, shown in Figure 1--4, is usedwith 720 KB double-density, 3 inch disks. The PS-100 connects to theP2 port (FLPY:). The P2 port is an RS-232-C interface. Refer toSection 4.2.1 for more information.

Figure 1--3. PS-100 Connected to the i-size Controller

Operator box(option)Teachpendant

R-J2Controller

PS-100DiskDrive

Figure 1--4. PS-100 Connected to the B-size Controller

Teachpendant

R-J2Controller

PS-100DiskDrive

PS-100Disk Drive

1.3.2Storage and LoadDevices

PS-100 Disk Drive

MARF2HD4307701E1--6

1. OVERVIEW

NOTE Loading from a memory card is not available as a standardproduct.

Refer to Section 4.2.2 for more information.

CAUTIONBe sure to insert the memory card into the interface as shownin Figure 1--5. Otherwise, you could damage the memory cardor the memory card interface.

Figure 1--5. Memory Card Interface and Memory Card Connected to the i-sizeController

Memory CardPower Supply Unit

MARF2HD4307701E 1--7

1. OVERVIEW

Figure 1--6. Memory Card Interface and Memory Card Connected to the B-sizeController

Memory Card

Power Supply Unit

You can use the KFLOPPY disk drive emulator to install software byloading all the files from each FANUC Robotics-supplied disk to your PC.Refer to Section 4.2.3 for more information.

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.

KFLOPPY Disk DriveEmulator

1.3.3Controller HardwareTools

2 SETTING UP CONTROLLER MEMORYMARF2HD4307701E 2--1Topics In This Chapter Page

Identifying Kinds ofMemory

The following kinds of memory exist in the controller: 2--2. . . . . . . . . . . . . . . . . . . . . . .D Controller Memory 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D Flash ROM 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D C-MOS RAM 2--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D D-RAM 2--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking ControllerMemory

Checking controller memory allows you to determine the amount ofFlash ROM, D-RAM and C-MOS RAM memory available in your system. 2--4. . . . .

Installing FLASH ROM,C-MOS RAM and D-RAMChips

Flash ROM, C-MOS RAM and D-RAM EPROM chips are installed onthe MAIN CPU board inside the controller. 2--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2--2

2. SETTING UP CONTROLLER MEMORY

MARF2HD4307701E

The following kinds of memory exist in the controller:

D Controller memoryD Flash ROM (F-ROM or FROM)D C-MOS RAMD D-RAM (or DRAM)

To set up controller memory you must

D Check system memory allocation to be sure you have enough to loadsoftware (Section 2.2).

D Install the D-RAM, C-MOS RAM and Flash ROM modules on themain 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, someapplication software, and some user programs. Flash ROM stores themajority of the robot system software such as core, and applicationsoftware.

Most of the SYSTEM R-J2 system software executes from D-RAM.When the controller is turned on, the system software is loaded from FlashROM to D-RAM and then is executed. Teach pendant programs are storedand are executed from C-MOS RAM.

Flash ROM (F-ROM or FROM disk) is not battery-backed but isnon-volatile. Non-volatile means that all data in Flash ROM is saved evenafter you turn off and turn on the controller. Flash ROM has three parts: asystem memory section, an image memory section, and a flash file section.

The system memory section contains the software that executes all systemsoftware. Image memory contains software options. The flash file systemsection contains space for backing up user programs and robotconfiguration information. It also holds hidden files required for Re-INITstart (CMOSINIT).

2.1IDENTIFYING KINDSOF MEMORY

2.1.1Controller Memory

2.1.2Flash ROM

MARF2HD4307701E 2--3


C-MOS RAM is battery-backed. C-MOS RAM is non-volatile only whilethe batteries are working. If the batteries are faulty or removed, C-MOSRAM is lost. C-MOS RAM has two parts: the TPP memory pool, and thepermanent (PERM) memory pool.

D The TPP memory pool contains the teach pendant programs. ThePERM memory pool contains system variables.

D PERM can also contain system software and options.

D-RAM is volatile, but it is loaded from Flash ROM when the controller isturned on. D-RAM also has three parts: a SYSTEM memory pool, anIMAGE memory pool, and a TEMP memory pool. The SYSTEMmemory pool contains the software that executes all system software. TheIMAGE memory pool contains all HandlingTool programs and softwareoptions. The TEMP memory pool contains the read/write scratch space forthe system.

CAUTIONData in C-MOS RAM can be lost if the battery is removed orloses its charge, or if new core software is loaded on thecontroller. The C-MOS RAM memory will last for 30 minuteswithout the battery when power is off. To prevent loss of data,back up or copy all files for permanent storage.

CAUTIONTo transport or store the contents of the MAIN CPU, you canplug the battery into the VBAT connector in the MAIN CPU.However, do not plug it into the RESET connector; otherwiseyou could damage equipment.

2.1.3C-MOS RAM

2.1.4D-RAM

2--4


MARF2HD4307701E

Checking controller memory allows you to determine the amount of FlashROM, D-RAM and C-MOS RAM memory available in your system. UseProcedure 2--1 to verify the amount of controller memory you have.

Procedure 2--1 Verifying Controller Memory

H The controller is turned off.

1 Press and hold the PREV and NEXT keys on the teach pendant, thenpress the ON button.

The boot monitor prompt, BMON>, is displayed. You will see ascreen similar to the following.

COLD CTRL INIT START >

*** BOOT MONITOR for R-J2 CONTROLLER ***Version 4.22P 01-JAN-199xF-ROM/D-RAM/C-MOS : 8.0/8.0/1.0 MBTP Version : ICurrent TIME : 01-JAN-199x 22:52:53

Slot ID FC OP0 9B 0 0 R-J2 Main CPU1 6A 0 0 AB/Ether I/FD 6A 0 0 MCARD I/F

BMON>NOLOAD

OptionalOptional

AvailableControllerMemory

CAUTIONThe minimum controller memory configuration required toinstall HandlingTool software is shown in Table 2--1. If yourcontroller has less than this requirement of F-ROM, D-RAM,and C-MOS RAM, you must contact your FANUC Roboticsrepresentative for information on increasing the memory in yourcontroller.

Table 2--1. Minimum Requirements

Memory Device Minimum Amount ofMemory Required

Flash ROM 4.0 MB

D-RAM 4.0 MB

C-MOS RAM 0.5 MB

2.2CHECKINGCONTROLLERMEMORY

Condition

Step

MARF2HD4307701E 2--5


A maximum of 1 (one) Flash ROM module can be used in the R-J2controller. A maximum of 1 (one) C-MOS RAM module can be used inthe R-J2 controller. A maximum of 1 (one) D-RAM module can be usedin the R-J2 controller. Flash ROM, C-MOS RAM and D-RAM areinstalled on the MAIN CPU board inside the controller. UseProcedure 2--2 to remove or add a Flash ROM, C-MOS RAM or D-RAMmodule.

Procedure 2--2 Installing a Flash ROM, C-MOS RAM or D-RAM Module


WARNINGDisconnect electrical power from the controller before youremove or replace components, or you could be injuredseriously.

CAUTIONUse anti-static devices and observe anti-static safetyprecautions when handling any electronic material, otherwiseyou could damage the equipment.

H You are wearing a wrist strap to prevent static discharge to the C-MOScircuits.

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, turnthe handle to the OFF (open) position.

See Figure 2--1.

WARNINGWhen the disconnect or circuit breaker handle is OFF,power is still present inside the controller. You mustunplug the controller from the electrical outlet to removeall power from the controller.

2.3INSTALLING FLASHROM, C-MOS RAMAND D-RAM CHIPS

Condition

Step

MARF2HD4307701E2--6


2 Open the front door of the controller using a flat-tip screwdriver toturn the latch. See Figure 2--1.

Figure 2--1. R-J2 Controller Disconnect Handle and Latch

Locked

Unlocked

Circuit breakerB-Size controller

OFF

OFF

Circuit breakeri-size controller

ONON

3 Locate the MAIN CPU board inside the controller. See Figure 2--2and Figure 2--3.

Figure 2--2. MAIN CPU Board Location in the i-size Controller

MARF2HD4307701E 2--7


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 theboard from the backplane. See Figure 2--4.

MARF2HD4307701E2--8


Figure 2--4. Removing the MAIN CPU Board

6 Install the Flash ROM, C-MOS RAM or D-RAM modules on theMAIN CPU board in the appropriate memory slots. See Figure 2--5and Figure 2--6.

MARF2HD4307701E 2--9


Figure 2--5. Main CPU PC board module locations

SRAM

mod

ule

DRAM

mod

ule

Axismod

ule(J1,

J2)

Axismod

ule(J3,

J4)

Axismod

ule(J5,

J6)

Flash

ROM

mod

ule

LED display

BatVBAT

JRV1 & JRV2Connections

LineJF21

Ex-opJM10

I/O - LK(master)JD1A

RS232/485JD17

PDI/OJRM3

CAUTIONThis is RESET.Connecting the batteryhere can damage the CPU.

CRM10 & CR51

Boo

tROM

MARF2HD4307701E2--10


Figure 2--6. Installing the Flash ROM, C-MOS RAM or D-RAM Module

Pin 1

Step a

Step b

Step c

Step d

Main CPU PC board

Fit the recess onthe module overthe tab in themodule socket.

*All modules tilt out towardback of board.

CAUTION:It is possible toforce the module inbackward despitethe keytab.

CAUTIONBe gentle with thespring tabs becausethey can break easily.

7 Insert the MAIN CPU board into the proper slot on the controllerbackplane. 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 thepower disconnect switch to the ON position.

This completes the installation of the new module.

NOTE C-MOS RAM memory will be initialized automatically when thesoftware is installed.

3 EPROM INSTALLATIONMARF2HD4307701E 3--1The SYSTEM R-J2 controller uses Erasable Programmable Read-OnlyMemory (EPROM) chips that contain special setup software. They arelocated on the MAIN CPU board and on the teach pendant PCB. Yourcontroller must contain the EPROM chips that are compatible with theversion of system software you are installing.

NOTE Software version information is included in an ASCII file calledreadme.txt and is stored on the AP1 disk.

Topics In This Chapter Page

Installing the BootROMchip

FANUC Robotics requires you to have the version of BootROM EPROM chipthat is compatible with the version of R-J2 software you are using. 3--2. . . . . . . . . . .

Checking and installingthe teach pendantEPROM chip

You must have the teach pendant EPROM version that corresponds to theversion of software you are using. 3--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MARF2HD4307701E3--2

3. EPROM INSTALLATION

FANUC Robotics requires you to have the version of BootROM EPROMchip that is compatible with the version of R-J2 software you are using.The BootROM EPROM chip is located on the MAIN CPU board insidethe controller.

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. UseProcedure 3--2 to install a new BootROM EPROM.

NOTE BootROM version information is included in an ASCII file calledreadme.txt and is stored on the AP1 disk.

Procedure 3--1 Checking the BootROM Version



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 thecontroller operator panel until you see the BMON> prompt on theCRT/KB or teach pendant screen.

3.1INSTALLINGBOOTROM EPROMCHIPS

Step

MARF2HD4307701E 3--3


3 Release these buttons. You will see a screen similar to the following.

COLD CTRL INIT START >

*** BOOT MONITOR for R-J2 CONTROLLER ***Version 4.22P 01-JAN-199x

F-ROM/D-RAM/C-MOS : 4.0/4.0/1.0 MBTP Version : ICurrent TIME : 01-JAN-199x 22:52:53

Slot ID FC OP0 9B 0 0 R-J2 Main CPU1 6A 0 0 AB/Ether I/FD 6A 0 0 MCARD I/F

BMON>NOLOAD

optional

BootROMVersionNumber

optional

4 Compare the BootROM version with the version required for yoursoftware.

NOTE Refer to the readme.txt ASCII file on the AP1 disk to determinethe BootROM version that is compatible with the version of software youhave.

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

D If the BootROM version is NOT correct for the version ofsoftware you have, you must install new BootROMs. UseProcedure 3--2 to install a new BootROM EPROM.

Procedure 3--2 Installing New BootROM EPROM Chips


CAUTIONData in C-MOS RAM will be lost if the main CPU board isremoved from the backplane without a battery back-up. Toprevent loss of data, back up or copy all files for permanentstorage.

MARF2HD4307701E3--4




1 Turn off the controller.



OR

D If your controller is equipped with a circuit breaker handle, turnthe handle to the OFF (open) position.


3 Use a flat-tip screwdriver to turn the latch on the front door of thecontroller to the UNLOCKED position. See Figure 3--1.


Locked

Unlocked

Circuit breakerB-size controller

OFF

OFF


ONON

Condition

Step

MARF2HD4307701E 3--5


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 leftof the power supply unit, and the vision engine PCBs (if the visionoption has been installed).

MARF2HD4307701E3--6


5 Disconnect the cables from the MAIN CPU board.

6 Press and hold both latches of the MAIN CPU board and remove theboard from the backplane. See Figure 3--4.

Figure 3--4. Removing the MAIN CPU Board

MARF2HD4307701E 3--7


7 Find the location of the BootROM chips. See Figure 3--5 andFigure 3--6.

Figure 3--5. Main CPU PC Board Module Locations

SRAM

mod

ule

DRAM

mod

ule

Axismod

ule(J1,

J2)

Axismod

ule(J3,

J4)

Axismod

ule(J5,

J6)

Flash

ROM

mod

ule

Boot ROM Chip

LED display

BatVBAT

JRV1 & JRV2Connections

LineJF21

Ex-opJM10

I/O - LK(master)JD1B

RS232/485JD17

PDI/OJRM3

CAUTIONThis is RESET.Connecting the batteryhere can damage the CPU.

CRM10 & CR51

Boo

tROM

MARF2HD4307701E3--8


Figure 3--6. Locating the BootROM Chips

BootRom Chip


CAUTIONThe pins on the BootROM EPROM chip are fragile. Wheninstalling an EPROM chip, do not bend any of the pins;otherwise, you will not be able to connect the EPROM chipproperly.

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 toorient the notch as shown in Figure 3--6.

10 Plug in the MAIN CPU Board. Be sure the connector seats properlywith the backplane connector.

11 Reconnect the cables to the MAIN CPU Board. See Figure 3--5 for adiagram of where each cable must be connected.

12 Close the controller door and set the circuit breaker handle ordisconnect handle to ON.

MARF2HD4307701E 3--9


You must have the teach pendant EPROM version that corresponds to theversion of software you are using. Procedure 3--3 describes how to checkthe current EPROM version. Procedure 3--4 describes how to install anew 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 calledreadme.txt and is stored on the AP1 disk.

Procedure 3--3 Checking Teach Pendant EPROM Versions


2 Hold the teach pendant and look at the screen. The screen shown inStep 4 is displayed very quickly. Be sure you are looking for thisscreen 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 similarto the following.

R-J2 Teach Pendant

7D01 / 09I[199207-21]

VRAM, CGRAM CLEARINTERNAL RAM TESTINGEXTERNAL RAM TESTING

:::

COMPLETEOKOK

Teach Pendant Ready

TeachPendantVersionNumber

5 If you miss seeing the screen, repeat Steps 1 through 4.

3.2INSTALLING TEACHPENDANT EPROMCHIPS

Step

MARF2HD4307701E3--10



6 Compare the EPROM version with the one required for your software.

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

D If the teach pendant EPROM version is NOT correct for theversion of software you have, you must install a new teachpendant EPROM. Use Procedure 3--4 to install a new teachpendant EPROM.

Procedure 3--4 Installing A New Teach Pendant EPROM Chip



H You are wearing a wrist wrap to prevent static discharge to the C-MOScircuits.


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 backcover of the teach pendant. See Figure 3--7.

NOTE These screws are two different lengths. Mark the holes thatrequire the shorter screws for later reassembly.

CAUTIONDo not remove or disconnect any cables connected inside theteach pendant or damage to equipment could occur.

Condition

Step

MARF2HD4307701E 3--11


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

EPROMChip

NOTE Refer to the readme.txt ASCII file on the AP1 disk to determinethe EPROM version that is compatible with the version of software youhave.

MARF2HD4307701E3--12


See Figure 3--9 for a description of how the EPROMs are labeled.

Figure 3--9. EPROM Labels

R-J209I012345

TP

Product CategoryProduct VersionProduct RevisionSoftware Serial NumberBlankProduct Name

CAUTIONThe pins on the teach pendant EPROM chip are fragile. Wheninstalling an EPROM chip, do not bend any of the pins,otherwise, you will not be able to connect the EPROM chipproperly.

5 If you are replacing an existing teach pendant EPROM chip, use adual-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 backcover.

4 SOFTWARE INSTALLATIONMARF2HD4307701E 4--1Topics In This Chapter 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 disksD 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 robotand controller. 4--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Options Software options are additional features that can be used with yourapplication software. 4--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick/Full PasswordSetup

After the HandlingTool software is installed, you can change the QUICK/FULLmenu display for the Operator-level user when you use the Passwordoption.. 4--35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Extended Axes Extended axis software must be installed only in systems that useextended axes. 4--38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Motion Groups Motion groups provide the ability to have multiple devices on a singlecontroller, each with their own control program for independent operation.Motion group software must be installed only in systems that use multiplemotion groups. 4--53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Updates Software updates are disks that contain updated information to yourapplication and robot library software. Installing software updates is optionaland should only be performed if you have a disk labeled Update and it isconsistent with the software version you have loaded in the controller. 4--67. . . . . . . .

MARF2HD4307701E4--2

4. SOFTWARE INSTALLATION

Installing software involves loading the software from floppy disks intocontroller memory (Flash ROM, D-RAM and C-MOS RAM) and mightalso involve loading the software from floppy disks into the local memoryof optional hardware. You install software when you first install a newsystem or when you update an existing system. You must install:D Application softwareD Robot librariesWhen you have finished installing the application software and robotlibraries, you must set up information specific to your application.

You can also install:D Software optionsD Software updates

The SYSTEM R-J2 software is modular. The kinds of components youwill be loading are:D Application software disksD Robot LIBRARY disksD OPTION disksD UPDATE disks

CAUTIONYou must load the software components in the correct order,otherwise your system will operate incorrectly.

The installation procedure begins with the first disk of the application (AP)set. All of the decisions you must make during installation will occur atthe end of the installation procedure.

CAUTIONYour disk set includes all of the software options supported byHandlingTool. Your disk set has been pre-authorized to installonly the options you have purchased. You will be unable toinstall any options that have not been purchased andauthorized by FANUC Robotics.

To install an option that has not been pre-authorized for thisdisk set, you must purchase the option and receive a ProductAuthorization Code (PAC) from FANUC Robotics. Contact yourFANUC Robotics spare parts department for more information.

Each disk is installed in ascending order. If you have any softwareoptions, they can be loaded after the application has been set up.

Refer to the readme.txt ASCII file on the AP1 disk for specific softwareversion information.

4.1SOFTWAREINSTALLATIONTHEORY

Installation Components

Installation Disk Order

MARF2HD4307701E 4--3


CAUTIONA 3-volt battery pack supplies C-MOS RAM memory with powerwhen the controller power is off. Make sure the output voltageof the battery pack is at least 2.5 volts, otherwise theinformation stored in C-MOS RAM memory could be lost whencontroller power is off.

CAUTIONLoading software erases all controller Flash ROM, D-RAM andC-MOS RAM memory, as well as the RAM disk. Back up tofloppy disk all system variables, programs, and files stored onthe controller before you load software. Refer to Appendix Cfor more information.

CAUTIONFile access problems will result if your disk and disk drive aremisaligned. Try using a different disk drive. If file accessproblems still occur, contact FANUC Robotics to receive a newdisk. Do not continue with the load procedure if file accessproblems occur; otherwise, your controller memory will operateincorrectly.

CAUTIONDo not turn off the controller during software installation. If thecontroller is turned off, you will have to restart the entiresoftware installation procedure from the beginning.

MARF2HD4307701E4--4


To install software, you must perform the following general steps:

Section 4.4

Installsoftwareoptions(optional)

Installmotiongroups

(optional)

Section 4.3 Section 4.7

Install ormodify

extendedaxes

(optional)

Section 4.4and

Section 4.6

Installsoftwareupdates(optional)

Section 4.8

InstallHandlingToolSoftware andFirmware

Section 4.2

Set up theLoadDevice

Quick/FullPasswordSetup

Section 4.5

Refer to the readme.txt ASCII file on the AP1 disk for information on theoptions available with the HandlingTool software.

When you are installing software on a FANUC robot, you will be asked aseries of questions regarding your system configuration. Before youbegin the installation procedure, refer to Appendix B and fill in all theinformation for your robot model.

If you are installing from floppy disks, the entire installation procedurewill take approximately one and one-half hours. Be sure you have theentire disk set and all other information you need (refer to Appendix B)before you begin this installation process or you might have to begin theprocess over from the beginning.

If you are installing from a memory card (not supported as a standardproduct), the entire installation procedure will take approximately 10minutes. Be sure you have the memory card and all other informationyou need (refer to Appendix B) before you begin this installation processor you might have to begin the process over from the beginning.

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, thenprovide a solution to the problem.

Installation ProcedureOverview

Robot Configuration

Timetableapproximately 1 hours

Troubleshooting

MARF2HD4307701E 4--5


The following load devices can be used to install software:

D PS-100 disk drive with floppy disksD 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 controllerduring software installation. Disconnect the load devices you are notusing before you begin installing software.

Section 4.4

Installsoftwareoptions(optional)

Section 4.3 Section 4.4and

Section 4.6

Installsoftwareupdates(optional)

Section 4.8

InstallHandlingToolSoftware andFirmware

Section 4.2

Set up theLoadDevice

Installmotiongroups

(optional)

Section 4.7

Install ormodify

extendedaxes

(optional)

Quick/FullPasswordSetup

Section 4.5

The PS-100 disk drive connects to the P2: port. The P2: port is anRS-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 oroperator box.

Figure 4--1. PS-100 Connected to an i-size Controller

PS-100Disk Drive

To Controller

4.2SETTING UP LOADDEVICES

4.2.1Using a PS-100 DiskDrive

MARF2HD4307701E4--6


Figure 4--2. PS-100 Disk Drive Connected to the B-size Controller

Operator panelTeachpendant

PS-100Disk Drive

MARF2HD4307701E 4--7


Procedure 4--1 Connecting a PS-100 Disk Drive

CAUTIONIf devices such as a printer, or floppy disk drive are connectedto the controller, always turn on the robot first, then turn onthese devices; otherwise, equipment could be damaged.

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. TheLED 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 itinto the disk drive.

5 To install software, go to Section 4.3.

Step

MARF2HD4307701E4--8


The memory card interface is installed in either the ER-2 board if you haveone, or in the PSU B1 slot which connects to the R-J2 controllerbackplane.

Figure 4--3 and Figure 4--4 show the memory card interface module on theER-2 board inserted into the controller. Use Procedure 4--2 to install amemory card in a controller.


CAUTIONBe sure that the version of Main CPU BootROM you have isversion 4.20 or later. If not, DO NOT load the optional A-B RIOsoftware from memory card while the memory card interface isin the ER-2 printed circuit board. Otherwise, you could eraseall the information on the memory card and destroy the ER-2board. Instead, if the BootROM version is not 4.20 or later,load the A-B RIO software using the FANUC Robotics-supplieddisks.

Figure 4--3. Memory Card Interface and Memory Card Connected to the i-sizeController


4.2.2Using a Memory CardInterface

MARF2HD4307701E 4--9


Figure 4--4. Memory Card Interface and Memory Card Connected to the B-SizeController

Memory Card

Power Supply Unit

NOTE If you do not have an ER-2 printed circuit board, you will need toremove the plastic slot cover on the PSU B1 slot. Align the memory cardinterface adapter in the left hand slot.

MARF2HD4307701E4--10


Procedure 4--2 Using the Memory Card Interface


CAUTIONIf devices such as a printer, or floppy disk drive are connectedto the controller, always turn on the robot first, then turn onthese devices; otherwise, equipment could be damaged.


H You have a memory card interface module and memory card thatcontains the software you want to load.

H You are using memory cards that are based on one of the followingstandards:

-- 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 forinformation on changing the batteries in a memory card.






ORD If your controller is equipped with a circuit breaker handle, turn

the handle to the OFF (open) position.

See Figure 4--5.

Condition

Step

MARF2HD4307701E 4--11



2 Open the front door of the controller using a flat-tip screwdriver toturn the latch. See Figure 4--5.


Locked

Unlocked

Circuit breakerB-Size controller

OFF

OFF


ON ON

3 Identify the memory card interface module location inside thecontroller. See Figure 4--6.

Figure 4--6. Memory Card Interface Location on an i-size Controller


MARF2HD4307701E4--12


Figure 4--7. Memory Card Interface Location on a B-Size Controller

Memory Card

MARF2HD4307701E 4--13


4 To insert a memory card, hold the memory card with the label facingthe 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

Power Supply Unit PCB

Memory Card

Write protectswitch

Memory Card Interface

ER-2 Board

AI6B-1212-0871/--- ---

ER-2 Board

PSU B1

MARF2HD4307701E4--14


D If you do not have an ER-2 printed circuit board, insert thememory card interface in the module located in the 1/2 slot next tothe 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

Power Su

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Software Instalation R-J2

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