Software Installation - fanuc

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

FANUC Robotics North America, Inc .2000 South Adams Roa dAuburn Hills, Michigan 48326-280 0

SYSTEM R-J Software

-Installation- Manual

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

1

' liOTL .1I

REFERENCE DOCUMEN T

SYSTEM R-J Software 1Installation Manua l

MARAJINST09206E

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

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

FANUC Robotics North America, Inc .2000 South Adams RoadAuburn Hills, Michigan 48326-2800

The description and specifications contained in this manual were in effec tat the time this manual was approved for printing . FANUC RoboticsNorth America, Inc, hereinafter referred to as FANUC Robotics, reserve sthe right to discontinue models at any time or to change specifications o rdesign without notice and without incurring obligations .

FANUC Robotics manuals present descriptions, specifications, drawings ,schematics, bills of material, parts, connections and/or procedures fo rinstalling, disassembling, connecting, operating and programming FANU CRobotics' products and/or systems . Such systems consist of robots ,extended axes, robot controllers, application software, the KAREL programming language, INSIGHT vision equipment, and special tools .

FANUC Robotics recommends that only persons who have been trained i none or more approved FANUC Robotics Training Course(s) be permittedto install, operate, use, perform procedures on, repair, and/or maintai nFANUC Robotics' products and/or systems and their respectiv ecomponents . Approved training necessitates that the courses selected b erelevant to the type of system installed and application performed at th ecustomer site .

A WARNINGThis equipment generates, uses, and can radiate radi ofrequency energy and if not installed and used inaccordance with the instruction manual, may causeinterference to radio communications. As temporaril ypermitted by regulation, it has not been tested fo rcompliance with the limits for Class A computing devicespursuant to subpart J of Part 15 of FCC Rules, which aredesigned to provide reasonable protection against suc hinterference . 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 whateve rmeasure may be required to correct the interference .

FANUC Robotics conducts courses on its systems and products on aregularly scheduled basis at the company's world headquarters in AuburnHills, Michigan. For additional information contact

FANUC Robotics North America, Inc.Training and Documentation Department2000 South Adams RoadAuburn Hills, Michigan 48326-2800Tel : (810)377-7234FAX: (810)377-7367 or (810)377-7362

Copyright 1992, 1993, 1994 by FANUC Robotics North America,Inc.All Rights Reserved

The information illustrated or contained herein is not to be reproduced ,copied, translated into another language, or transmitted in whole or in par tin any way without the prior written consent of FANUC Robotics NorthAmerica, Inc.

ArcTool, FANUC LASER DRILL, KAREL, INSIGHT ,INSIGHT II, PaintTool, PAINTWorks, PalletTool,SOCKETS, SOFT PARTS and SpotTool, are RegisteredTrademarks of FANUC Robotics.

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

ACCUFLOW'ACCUSTATARC MateARC Mate Sr.

DispenseToolIntelliTrakLaserTool

MotionPartsPAINTWork s IIPALLETMATESureWeld

TurboMove

BEFORE YOU CALL please have your Maintenance and Troubleshootingmanual, and the following information, ready .

INFORMATION DETAILS

Customer information

Include

your company's

phone number wherename

caller can be reached , caller's name

including area code andextension

Robot type(A, L, M, P, or S, & 3-digit number)

On the arm of the robot .

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

Ask your supervisor.

F Number On the identification tag on the robot an dcontroller, near the cable connection .

Robot serial number(if no F Number is available)

On the identification tag located near th ecable connection .

Controller serial numbe r(if no F Number is available)

On the controller tag located on the doors .

Software edition andrevision numbers

Shown on the CRT or teach pendant statusscreen during the power-up sequence .

This table is continued on the next page .

FANUC Robotics Hotline

For a PRODUCTION robot that is DOW Ncall 24 hours a day, 7 days a week

810-377-7159

For all other Troubleshooting and Technical Suppor tcontact your local distributor or call the Hotline

Monday - Friday, 8 :00 A.M . - 5:00 P.M . Eastern Time

INFORMATION DETAILS

List of error messages

include

error message number. message following error message numbe r any numbers following error messag e

List of diagnostic LEDs Note the PCB where the LED is located and th eLED name or designation.

History of problem Description of events leading up to problem .

Application software

List

any application software running on the system the line number where the program halted a description of what is happening on that line

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Preface

vi i

Purpose of this Manual

This manual describes FANUC Robotics SYSTEM R-J SoftwareInstallation :

Package content s

Requirements

Procedures

Troubleshooting and error recovery

Related Manuals

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 area sof the robot, controller, and application system.

DescriptionsManual

Includes detailed descriptions of the R-J controlle rhardware features, robot configurations andspecifications, end effector requirements, installatio nrequirements, and application software requirementsand features.

R-J ControllerConnection an dMaintenanceManual

Contains specific R-J controller electrical maintenanceand troubleshooting information and procedures fo rmaintenance operations such as replacing fuses ,checking wiring, recovering from fault conditions, andchecking and replacing controller components .

If you want to Refer to

Find information about a specific topic Table of Contents

Determine the installation requirements fo ryour application

Chapter 1, Overview

Set up and check memory requirements Chapter 2, Setting U pController Memory

Check and install EPROM chips Chapter 3, EPRO MInstallation

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

Chapter 4, SoftwareInstallation

Master the robot Chapter 5, Masterin g

Perform troubleshooting and error recovery Chapter 6, Troubleshootingand Error Messages

Use Boot Rom Appendix A , BootRomOperation s

How to Use this

Use this table to locate specific information in the manual .

Manual

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PREFACE

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Conventions Used in

This manual includes information essential to the safety of personnel,

this Manual

equipment, software, and data . This information is indicated by headingsand boxes in the text .

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

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

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

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Table of Contents

Preface viiSafety xiii

Chapter 1OVERVIEW 1-1

1 .1 PACKAGE CONTENTS 1-21 .1 .1 Software Disks 1-21 .1 .2 System EPROM Chips 1-24

1 .2 INSTALLATION REQUIREMENTS 1-2512.1 Teach Pendant 1-25

1 .2 .2 Disk Drive Unit 1-271 .2 .3 Controller Hardware Tools 1-27

Chapter 2SETTING UP CONTROLLER MEMORY 2-1

2.1 CHECKING SYSTEM MEMORY 2-2

22 INSTALLING CMOS AND FLASH ROM MEMORY 2-3

2.3 COPYING CONTROLLER MEMORY 2-7

Chapter 3EPROM INSTALLATION 3-1

3.1 INSTALLING BOOTROM EPROM CHIPS 3-2

3.2 INSTALLING TEACH PENDANT EPROM CHIPS 3-8

Chapter 4SOFTWARE INSTALLATION 4-1

Chapter 5MASTERING 5-1

5.1 MASTERING TO A FIXTURE (MASTER POSITION MASTER) 5-2

5.2 ZERO DEGREE MASTERING 5-4

5.3 SINGLE AXIS MASTERING 5-6

5.4 QUICK MASTERING 5-8

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Chapter 6TROUBLESHOOTING AND ERROR MESSAGES 6-1

6.1 TROUBLESHOOTING USING SYMPTOMS 6-2

6.2 TROUBLESHOOTING USING ERROR MESSAGES 6-3

6.3 PERFORMING A RE-INIT START 6-7

Appendix ABOOTROM OPERATIONS A-1

A.1 STARTUP METHODS A-2

A.1 .1 Hot Start A-2

A.1 .2 Cold Start A-3A.1 .3 Controlled Start A-4

A.2 BOOTROM UTILITIES A-6

A.3 DIAGNOSTIC UTILITIES (DIAG>) A-8

A.4 EXTENDED BOOT MONITOR UTILITIES (EMON>) A-10

A.5 DEVICE MONITOR UTILITIES (DEV>) A-1 1

List of Procedures

Procedure 2- 1Procedure 2-2Procedure 2-3Procedure 2-4Procedure 3- 1Procedure 3-2Procedure 3-3Procedure 3-4Procedure 4- 1Procedure 4-2Procedure 4-3Procedure 4-4Procedure 4-5Procedure 4-6Procedure 4-7Procedure 4-8Procedure 5-1Procedure 5-2Procedure 5-3Procedure 5-4Procedure 5-5Procedure 6-1Procedure A-1Procedure A-2

Displaying Memory Status 2-2Installing a CMOS RAM or Flash ROM Module 2-3Copying 3 .5MB (2+1.5) and 4MB (2+2) Controller Memory 2-7Copying 6MB (4+2) Controller Memory 2-12Checking the BootROM Version 3-2Installing New BootROM EPROM Chips 3-3Checking Teach Pendant EPROM Versions . . .

. . . .

. 3-8Installing A New Teach Pendant EPROM Chip 3-9Installing V3 .06P or V3 .06PA Core, Application and Robot Library Software 4-3Installing V3 .06PB Core, Application and Robot Library Software 4-17Installing V3 .06PC and V3.06PD Core, Application and Robot Library Software

4-29Installing R-J Software Options 4-39Installing PaintTool Software Options 4-42Installing R-J Software Updates 4-46Installing Motion Groups 4 49Installing Extended Axes 4-62Mastering to a Fixture 5-2Mastering to Zero Degrees 5-4Mastering a Single Axis 5-6Recording the Quick Master Reference Position 5-8Quick Mastering the Robot 5-10Performing a Re-Init Start (V3.06PA, V3 .06PB, V3.06PC) 6-7Performing a Hot Start A-2Performing a Cold Start A-3

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Procedure A-3 Performing a Controlled Start A-5Procedure A-4 Using BootROM Utilities A-7Procedure A-5 Using DIAG> Utilities A-9Procedure A-6 Using EMON> Utilities A-10Procedure A-7 Using DEV> Utilities A-1 1

List of FiguresFigure 1-1. Standard Teach Pendant 1-25

Figure 1-2. Intrinsically Safe Teach Pendant (ISTP) 1-26

Figure 1-3. PS-100 Connected to the Controller 1-27

Figure 2-1 . R-J Controller Disconnect Handle and Latch 2-4

Figure 2-2. MAIN CPU Board Location 2-4

Figure 2-3. Removing the MAIN CPU Board 2-5

Figure 2-4. Installing the CMOS RAM or Flash ROM Module 2-5

Figure 2-5. Plugging in the Extension Backplane 2-8

Figure 2-6. Plugging in the Extension Backplane 2-12

Figure 3-1. R-J Controller Disconnect Handle and Latch 3-4

Figure 3-2. MAIN CPU Board Location 3-5

Figure 3-3. Removing the MAIN CPU Board 3-6

Figure 3-4. Locating the BootROM Chips 3-6

Figure 3-5. Removing the Back Cover of the Teach Pendant 3-1 0Figure 3-6. Locating the Teach Pendant EPROM Chip 3-10

Figure 3-7. EPROM Labels 3-11

List of TablesTable 1-1 . Software Version Information 1-3

Table 2-1 . Memory Status 2-2

Table 4-1 . Shot Meter Configuration Items 4-9

Table 4-2 . Nordson Configuration Items 4-1 1

Table 4-3. Schucker Configuration Items 4-1 2

Table 4-4. Jesco Configuration Items 4-1 3

Table 4-5. Configuration Setup Items 4-37

Table 4-6. Motor Selection Combinations 4-65

Table 5-1 . Mastering Methods 5-1

Table 6-1 . Troubleshooting Symptoms and Solutions 6-2

Table 6-2. Software Option Messages 6-3

Table 6-3. BootROM Error Messages 6-4

Table A-i . Controlled Start Options A-4

Table A-2. BootROM Utilities A-6Table A-3. BootROM Diagnostic Utilities A-8Table A-4. BootROM Extended Monitor Utilities A-10

Table A-5. BootROM Device Monitor Utilities A-11

SafetyFANUC Robotics is not and does not represent itself as an expert in safet ysystems, safety equipment, or the specific safety aspects of your compan yand/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 i nthe 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 professional sin 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 syste mto recognize and respond to known hazards associated with your roboti csystem and to be aware of the recommended operating procedures for you rparticular application and robot installation .

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

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

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SAFETY

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

The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s ) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcel l Proper maintenance of the robot

Keeping People and

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

People External devices Robot(s) Tooling 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 :

Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning light s Mechanical stop s EMERGENCY STOP buttons DEADMAN switche s

A safe workcell is essential to protect people and equipment . Observe thefollowing guidelines to ensure that the workcell is setup safely . Thesesuggestions are intended to supplement and not replace existing federal,state, and local laws, regulations, and guidelines that pertain to safety .

Sponsor your personnel for training in approved FANUC Roboticstraining course(s) related to your application . Never permit untrainedpersonnel to operate the robots .

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

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

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

CONSIDERINGSAFETY FOR YOU RROBOTINSTALLATION

Equipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell

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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.

Position all controllers outside the robot work envelope .

Never rely on software as the primary safety element .

Mount an adequate number of EMERGENCY STOP buttons o rswitches within easy reach of the operator and at critical points insid eand around the outside of the workcell .

Install flashing lights and/or audible warning devices that activat ewhenever the robot is operating, that is, whenever power is applied t othe servo drive system.

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

Install special guarding that prevents the operator from reaching int orestricted areas of the work envelope .

Use interlocks .

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

Periodically check the safety joints or safety clutches that can b eoptionally installed between the robot wrist flange and tooling . If thetooling strikes an object, these devices dislodge, remove power fro mthe 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 theeffects of electro- magnetic interference (EMI), radio frequencyinterference (RFI), and electro-static discharge (ESD) .

Make provisions for power lockout/tagout at the controller .

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

Provide enough room inside the workcell to permit personnel to teac hthe robot and perform maintenance safely.

Program the robot to load and unload material safely.

If high voltage electrostatics are present, be sure to provide appropriat einterlocks, warning, and beacons .

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

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Staying Safe WhileTeaching or ManuallyOperating the Robot

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

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

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 extend sthis range .

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.

FANUC Robotics recommends that no one enter the work envelope o fa 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 switchOnly the person with the teach pendant should be in the wor kenvelope .

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

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

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

A WARNINGStay outside the robot work envelope whenever a progra mis 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 continuousl yfor at least one full cycle .

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

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Staying Safe During

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

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

Understand the complete task the robot is programmed to perfor mbefore initiating production operation .

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

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

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

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

Never assume that a program is complete if the robot is not moving .The robot could be waiting for an input signal that will permit it t ocontinue activity.

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

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

Staying Safe During

when inspecting the robot, be sure to

Inspection

Turn off power at the controller.

Lock out and tag out the power source at the controller according t othe policies of yourplant.

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

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

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

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Staying Safe Durin gMaintenance

When performing maintenance on your robot system, observe th efollowing rules :

Never enter the work envelope while the robot or a program is i noperation .

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

Consider all or any overlapping work envelopes of adjoining robot swhen standing in a work envelope .

Test the teach pendant for proper operation before entering the wor kenvelope.

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 .

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.

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

Turning the disconnect or circuit breaker to the OF Fposition removes power from the output side of the devic eonly. High voltage is always present at the input sid ewhenever the controller is connected to a power source.

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

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

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

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

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A WARNINGDo not try to remove any mechanical component from th erobot before thoroughly reading and understanding theprocedures in the appropriate manual . Doing so can resul tin serious personal injury and component destruction .

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 .

When replacing or installing components, make sure dirt and debris d onot enter the system.

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

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

Certain programming and mechanical measures are useful in keeping th emachine 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.

Back-check limit switches in the workcell to make sure they do no tfail .

Implement "failure routines" in programs that will provide appropriaterobot actions if an external device or another robot in the workcel lfails.

Use handshaking protocol to synchronize robot and external devic eoperations .

Program the robot to check the condition of all external devices durin gan operating cycle .

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

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

Use software limits, limit switches, and mechanical hardstops t oprevent undesired movement of the robot into the work area o fmachine tools and external devices .

KEEPING MACHIN ETOOLS AN DEXTERNALDEVICES SAFE

Programming SafetyPrecautions

Mechanical SafetyPrecautions

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KEEPING THE

ROBOT SAFE

Observe the following operating and programming guidelines to preven tdamage to the robot.

Operating Safety

The following measures are designed to prevent damage to the robo tduring operation .Precautions

Programming SafetyPrecautions

Use a low override speed to increase your control over the robot whe njogging the robot .

Visualize the movement the robot will make before you press the jo gkeys 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 robo tduring programming:

Establish interference zones to prevent collisions when two or mor erobots share a work area .

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

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

In dispensing applications, be aware of all safety guidelines wit hrespect to the dispensing materials .

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 .

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Process technicians are sometimes required to enter the paint booth, forexample, during daily or routine calibration or while teaching new paths toa robot. Maintenance personal also must work inside the paint boothperiodically.

Whenever personnel are working inside the paint booth, ventilatio nequipment must be used. Instruction on the proper use of ventilatingequipment usually is provided by the paint shop supervisor.

Although paint booth hazards have been minimized, potential dangers stil lexist. Therefore, today's highly automated paint booth requires thatprocess and maintenance personnel have full awareness of the system an dits capabilities . They must understand the interaction that occurs betweenthe vehicle moving along the conveyor and the robot(s), hood/deck anddoor opening devices, and high-voltage electrostatic tools .

Paint robots are operated in three modes :

Teach or manual mode Automatic mode, including production and exercise operatio n Diagnostic mode

During both teach and automatic modes, the robots in the paint booth willfollow a predetermined pattern of movements . In teach mode, the processtechnician teaches (programs) paint paths using the teach pendant.

In automatic mode, robot operation is initiated at the System Controlle rCenter (SCC), Manual Control Panel (MCP), if available, or Manual Pain tStation (MPS), if available, and can be monitored from outside the pain tbooth. All personnel must remain outside of the booth or in a designate dsafe area within the booth whenever automatic mode is initiated at theSCC, MCP, or MPS.

In automatic mode, the robots will execute the path movements they weretaught during teach mode, but generally at production speeds .

When process and maintenance personnel run diagnostic routines thatrequire them to remain in the paint booth, they must stay in a designatedsafe area .

ADDITIONALSAFETYCONSIDERATION SFOR PAINT ROBOTINSTALLATIONS

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Paint System Safety

Process technicians and maintenance personnel must become totally

Features familiar with the equipment and its capabilities . To minimize the risk ofinjury when working near robots and related equipment, personnel mus tcomply strictly with the procedures in the manuals .

This section provides information about the safety features that ar eincluded in the paint system and also explains the way the robot interactswith other equipment in the system.

The paint system includes the following safety features :

Most paint booths have red warning beacons that illuminate when therobots are armed and ready to paint. Your booth might have otherkinds of indicators. Learn what these are .

Some paint booths have a blue beacon that, when illuminated ,indicates that the electrostatic devices are enabled . Your booth mighthave other kinds of indicators . Learn what these are.

EMERGENCY STOP buttons are located on the Manual Contro lPanel (MCP), or Manual Paint Station (MPS) panel, if supplied, insidethe booth, or on the System Controller Center (SCC) outside thebooth. Also, EMERGENCY STOP buttons are located near theinterior corners of each booth, and on the robot controller and teachpendant. Become familiar with the locations of all E-STOP buttons .

An intrinsically safe teach pendant is used when teaching in hazardou spaint atmospheres .

A DEADMAN switch is located on each teach pendant . When thi sswitch is held in, power is applied to the robot servo system. If theengaged DEADMAN switch is released during robot operation, poweris removed from the servo system, all axis brakes are applied, and therobot comes to an EMERGENCY STOP. Safety interlocks within thesystem might also E-STOP other robots .

A WARNIN GAn EMERGENCY STOP will occur if the DEADMAN switc his released on a bypassed robot .

Overtravel by robot axes is prevented by software limits . All of themajor and minor axes are governed by software limits . Limit switchesand hardstops also limit travel by the major axes .

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SAFET Y

Staying Safe WhileOperating the PaintRobot

EMERGENCY STOP limit switches and photoelectric eyes might b epart of your system . Limit switches, located on the entrance/exit doorsof each booth, will EMERGENCY STOP all equipment in the booth i fa door is opened while the system is operating in automatic or manua lmode . For some systems,signals to these switches are bypassed whe nthe switch on the SCC is in teach mode.

When present, photoelectric eyes are sometimes used to monitorunauthorized intrusion through the entrance/exit silhouette openings.

System status is monitored by computer. Severe conditions result i nautomatic system shutdown .

When you work in or near the paint booth, observe the following rules, inaddition to all rules for safe operation that apply to all robot systems .

A WARNIN GObserve all safety rules and guidelines to avoid injury,

Know the work area of the entire paint station (workcell) .

Know the work envelope of the robot and hood/deck and door openingdevices .

s Be aware of overlapping work envelopes of adjacent robots .

Know where all red, mushroom-shaped EMERGENCY STOP button sare located .

Know the location and status of all switches, sensors, and/or contro lsignals that might cause the robot, conveyor, and opening devices t omove .

Make sure that the work area near the robot is clean and free of water ,oil, and debris . Report unsafe conditions to your supervisor .

Become familiar with the complete task the robot will performBEFORE starting automatic mode .

Make sure all personnel are outside the paint booth before turning o npower to the robot servo system .

Never enter the work envelope or paint booth before turning on powe rto the robot servo system.

Never enter the work envelope during automatic operation unless asafe area has been designated.

Never wear watches, rings, neckties, scarves, or loose clothing thatcould get caught in moving machinery .

xxiv

SAFETY

MARAJINST09205 E

Staying Safe DuringMaintenance

Remove all metallic objects, such as rings, watches, and belts, befor eentering a booth when the electrostatic devices are enabled .

Stay out of areas where you might get trapped between a movin grobot, conveyor, or opening device and another object .

Be aware of signals and/or operations that could result in the triggerin gof guns or bells .

Be aware of all safety precautions when dispensing of paint i srequired.

Follow the procedures described in this manual .

When you perform maintenance on the painter system, observe th efollowing rules, and all other maintenance safety rules that apply to allrobot installations . Only qualified, trained service or maintenanc epersonnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Usecaution when working with electric tools .

When a maintenance technician is repairing or adjusting a robot, th ework area is under the control of that technician . All personnel notparticipating in the maintenance must stay out of the area .

For some maintenance procedures, station a second person at th econtrol panel within reach of the EMERGENCY STOP button . Thisperson must understand the robot and associated potential hazards .

Be sure all covers and inspection plates are in good repair and in place .

Always return the robot to the "home" position before you disarm it.

Never use machine power to aid in removing any component from th erobot.

During robot operations, be aware of the robot's movements . Excessvibration, unusual sounds, and so forth, can alert you to potentialproblems .

Whenever possible, turn off the main electrical disconnect before yo uclean the robot .

MARAJINST09205E

SAFETY

xxv

When using vinyl resin observe the following :

- Wear eye protection and protective gloves during application andremoval

- Adequate ventilation is required . Overexposure could caus edrowsiness or skin and eye irritation.

- If there is contact with the skin, wash with water .

When using paint remover observe the following :

Eye protection, protective rubber gloves, boots, and apron ar erequired during booth cleaning .

- Adequate ventilation is required . Overexposure could caus edrowsiness.

- If there is contact with the skin or eyes, rinse with water for atleast 15 minutes.

OVERVIEW

MARAJINST09206E

1-1

This chapter describes the SYSTEM R-J Software Installation Package . Itincludes information on

What you must do to set up and install the components of thi spackage in your system

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

Installation Tasks The first time you install the SYSTEM R-J Software Installation Package ,and whenever you update your controller with components in this package ,you must do the following :

Make sure you have enough memory in your controller and adjust it i fyou need more . Refer to Chapter 2.

If you are updating your controller, back up all system files . Refer tothe Setup and Operations Manual for more information on backing upfiles .

Make sure you have the correct system EPROM chips and install themif necessary. Refer to Chapter 3.

Install the Core, Core Options, Robot Library, Application/Tool andApplication/Tool Options disks purchased for your system . Refer toChapter 4.

Perform the mastering procedures required for your robot . Refer toChapter 5 .

NOTE You must satisfy system memory and EPROM requirement sbefore you can install the SYSTEM R-J software . If you perform all setupand installation procedures and still have a problem with the installation,refer to Chapter 6 for information to help you solve the problem .

1 . OVERVIEW

1-2

MARAJINST09206E

The SYSTEM R-J controller design features SOCKET software structures ,allowing application/tool and robot library SOFT PARTS to be added tomeet your specific application requirements .

The R-J software installation package consists o f Software disks Erasable Programmable Read-Only Memory (EPROM) chips

Your R-J software installation package consists of the following kinds ofdisks : Core Application/Tool Robot Library

Your package can also contain the following kinds of disks:

Core Option s Application/Tool Option s Robot Library Options Core and Application Updates

A core is the fundamental component of the SYSTEM R-J software . Itprovides the robot operating system and SOCKETS for all other layeredsoftware components . Most systems will use the standard core software .However, other systems could use core software that i sapplication-specific . All systems must include core software .

An application/tool is a software component, containing SOFT PARTS ,which is used in addition to the core software. It provides applicationspecific functionality. All systems must include application/tool software .

A robot library is a software component, containing SOFT PARTS, whichis used with a core and an application/tool. It provides FANUC robo tmodel-specific functionality. Most systems will use the standard robo tlibrary software . However, other systems could use robot library softwarethat is application-specific . All systems must include a robot library.

An option is a software component that provides specific functionality thatcan optionally be used with core, application/tool and robot librarysoftware.

An update is a software component that adds specific functionality tha tmust be used with core, application/tool and robot library software .

The kinds of disks listed below are available on 3 -1/2" disks . Table 1-1lists the following information about each kind of software package youcan have :

Contents CMOS RAM requirements Flash ROM requirements BootROM EPROM versio n Number of 3" disks

1 .1PACKAGE CONTENTS

1 .1 .1Software Disks

L

1 . OVERVIEW

MARAJINST09206E

1-3

Table 1-1 . Software Version Information

Product Disk Contents&

Part NumberNumber of31/2" Disks

Comment

ArcTool Software ArcTool Application Software 1 Required for TAST, AVC, or Touch Sensin gPackage SFTARTLJ130A3X1SBARCTLJ130X3X1 Core Software 6 Includes V3 .06P robot operating system

SFTCOREJ306X3XX software information .Teach rsion

:

Pendant 7D01/04Dor

EPROMVersion : Libraries 1 Includes all currently supported robot models

later SFTRBLBJ306X3X2and supports group motion .

THRU-ARC Seam Tracking MP/RPM 1 Cannot be installed with AVC option orVersion: 1 .30P (option) Multi-Pass option . ArcTool only.

SFTTASTJ130X3XX

BootROM EPROM AVC with MP/RPM 1 Cannot be installed with TAST or Multi-Pas sVersion : 1.10P or later (option) option . ArcTool only.

SFTAVCXJ13OX3XXMemory Required:

Multi- ass Welding 1 Cannot be installed with TAST or AVC option.2MB Flash ROM (min)2MB CMOS RAM (min) (option)

SFTMULTJ13OX3XXArcTool only.

NOTE: Installation of Touch Sensing 1 Can be used alone or with AVC or TAST.multiple optionsmight require

(option)SFTTOSEJ13OX3XX

WS CMOS RAM Detached Jog 1 ArcTool only.(option )SFTDEJOJ130X3XX

FANUC Sensor Interface (3D offset) 1 Interface from Application/Tool to an eXterna l(option) sensor device such as a V 120 visio nSFTFASEJ306XSXX system .

PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANU C(option) Robotics Genius network I/O interfaceSFTPLCIJ306X3X1 hardware using the R-H eXtended backplan e

on the R-J controller.

Extended Axis 1 Supports independent auxiliary aXes .(option)SFTEXAXJ306X3XX

Remote Arc Enable / UOP Interface 1 Includes all Arc Enable and UOP interfac e(update) software .SFTUPDTJ306X316

1 . OVERVIEW

1-4

MARAJINST09206E

Table 1-1 . (Cont'd) Software Version Informatio n


Part NumberNumber of3-1/2" Disks

Comment

DispenseTool Core Software 6 Includes all V3 .06PA core softwar eSoftware Package SFTCOREJ306A3XX information .

TLJ120X3X1Robot Libraries 1 Includes all currently supported robotShot

Meter:Shot SFTRBLBJ306ASXX models.SBDISTLJ120X3X2

Jesco:SBDISTLJ12OX3X3 DispenseTool Software for Nordson 1 DispenseTool Application Software for useSchucker:SBDISTLJ120X3X4 Equipment with Nordson Micro Pro-Flo dispensin g

SFTDITLJ12OX3X2 equipment.Version : 1 .20P

DispenseTool Software for Shot 1 DispenseTool Application Software for useTeach Pendant Meter Equipment with Shot Meter dispensing equipment .EPROM SFTDITLJ12OX3X3Version : 7D01/04D or DispenseTool Software for Jesco 1 DispenseTool Application Software for us elater Equipment with Jesco dispensing equipment.

BootROM EPROM SFTDITLJ12OX3X 3Version : 1.10PA or later DispenseTool Software for Schucker 1 DispenseTool Application Software for us e

Equipment with Schucker dispensing equipment.Memory Required :2MB FROM2MB CMOS RAM

SFTDITLJ120X3X4

DispenseTool End-Of-Arm-Tooling 1 Includes all EOAT software information ,(option) including the 4-Position Tool ,

NOTE: Installation of SFTEOATJ120X3Xx Dispense/Material Handling Tool, and th emultiple options Disposable Too lmight require PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANU C4MB CMOS RAM (option) Robotics Genius network I/O interface

SFTPLCIJ306X3X1 hardware using the R-H extended backplan eon the R-J controller.

CRT/Keyboard Manager 1 Includes all CRT/KB information .(option )SFTCRTKJ306X3XX

KAREL Development Option 1 Includes KAREL editor/translator, fil ePackage system/RAM disk, and CRT/KB manage r(option) options. 4MB CMOS RAM recommendedSFTKADPJ306X3XX for this optional package.

KAREL Command Language 1 Includes all KCL commands for progra m(option) variable manipulation from the CRT/KB . YouSFTKCLXJ306x3XX must. have a CRT/KB installed to use thi s

option .

File System/RAM Disk 1 Includes all information for file system an d(option) RAM disk operations.SFTFSRDJ306X3XX

Serial Host Communication 1 Provides serial communication ove r(option) RS-232-C for file transfer.SFTSEHOJ306X3X1

MOTET Host Communication 1 Provides data communication over ethernet(option) for file transfer.SFTMOHCJ306A3XX

1 . OVERVIEW

MARAJINST09206E

1-5


Product Disk Contents &Part NumberNumber of31/2 " Disks

Comment

DispenseToo lSoftware Packag e

Nordson:SBDISTLJ120X3X1

Shot Meter:SBDISTLJ120X3X2Jesco:SBDISTLJ120X3X3

Schucker:SBDISTLJ120X3X4

Version : 1 .20P

Teach PendantEPRO MVersion : 7D01/04D 0 rlate r

BootROM EPRO MVersion : 1.1PA or late r

Memory Required :2MB FROM2MB CMOS RAM

NOTE: Installation ofmultiple optionsmight require4MB CMOS RAM

FANUC Sensor Interfac e(option)

SFTEXAXJ306X3XX

1 Interface from Application/Tool to an externalsensor device such as a V-120 visio nsystem.

Extended Axis (option)SFTEXAXJ306X3XX

1

Supports independent extended aXes.

1 . OVERVIEW

1-6

MARAJINST09206E


Product Disk Contents &Part NumberNumber of3-1/2" Disks

Comment

DispenseTool Core Software 6 Includes all V3 .06PA core softwareSoftware Package SFTCOREJ306A3XX information.

TLJ121X3X1Robot Libraries 1 Includesall currently supported robotShotMeter:Shot

SFTRBLBJ306A3XX models .SBDISTLJ121X3X2Jesco:SBDISTLJ121X3X3 DispenseTool Software for Nordson 1 DispenseTool ApplicationSoftware for us e

Schucker:SBDISTLJ121X3X4 Equipment with Nordson Micro Pro-Flo dispensin gSFTDITLJ121X311 equipment .

Version: 1 .21PDispenseTool Software for Shot 1 DispenseTool Application Software for us e

Teach Pendant Meter Equipment with Shot Meter dispensing equipment .EPROM SFTDITLJ121X32 1Version: 7D01/04D or DispenseTool Software for Jesco 1 DispenseTool Application Software for us elater Equipment with Jesco dispensing equipment .BootROM EPROM

SFTDITLJ121X331

Version: 1 .10PA or later DispenseTool Software for Schucker 1 DispenseTool Application Software for us eEquipment with Schucker dispensing equipment .

Memory Required :2MB FRO M2MB CMOS RAM

SFTDITLJ121X341

DispenseTool End-Of-Arm-Tooling 1 Includes all EOAT software information ,(option) including the 4-Position Tool,

NOTE: Installation of SFTEOATJ121X3XX Dispense/Material Handling Tool, and th emultiple options Disposable Tool.might require PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANU C4MB CMOS RAM (option) Robotics Genius network I/O interfac e

SFTPLCIJ306X3X1 hardware using the R-H extended backplan eon the R-J controller.

CRT/Keyboard Manager 1 Includes all CRT/KB information .(option)SFTCRTKJ306X3XX

KAREL Development Option 1 Includes KAREL editor/translator, filePackage system/RAM disk, and CRT/KB manage r(option) options. 4MB CMOS RAM recommendedSFTKADPJ306X3XX for this optional package .KAREL Command Language 1 Includes all KCL commands for program(option) variable manipulation from the CRT/KB. YouSFTKCLXJ306X3XX must have a CRT/KB installed to use thi s

option .

File System/RAM Disk 1 Includes all information for file system an d(option) RAM disk operations .SFTFSRDJ306X3X X

Serial Host Communication 1 Provides serial communication ove r(option) RS-232-C for file transfer.SFTSEHOJ306X3X 1

MOTET Host Communication 1 Provides data communication over etherne t(option) for file transfer.SFTMOHCJ306A3XX

1. OVERVIEW

JINST09206EMARAJINST09206E

Table 1-1 . (Cont'd) Software Version Information

Product Disk Contents&Part NumberNumber of31/2" Disks

Comment

DispenseToo lSoftware Packag eNordson :SBDISTLJ121X3X1

FANUC Sensor Interfac e(option)

SFTFASEJ306X3XX

1 Interface from Application/Tool to an externa lsensor device such as a V-120 visio nsystem.

Shot Meter:SBDISTLJ121X3X2

Jesco:SBDISTLJ121X3X3Schucker:SBDISTLJ121X3X4

Version : 1 .21 P

Teach Pendan tEPRO MVersion : 7D01/04D orlater

BootROM EPROMVersion : 1 .10PA or later

Memory Required :2MB FROM2MB CMOS RA M

NOTE: installation ofmultiple option smight require4MB CMOS RAM

Extended Axis (option)

SFTEXAXK306X3XX

1 Supports independent eXtended aXes.

1-7

1 . OVERVIEW

1-8

MARAJINST09206E


ProductDisk Contents &

Part NumberNumber of3-1/2 " Disks

Commen t

KAREL Run-Time KAREL Run-Time Application 1 Includes all software to allow you to createSoftware Package Software teach pendant programs and run them o nSBKARELJ306X3X1 SFTKARTJ306X3X1 the controller.

Version: 3.06P Core Software 6 Includes all V3 .06P core software

Teach Pendant EPROMSFTCOREJ306X3XX information .

Version : 7D01/04D or Robot Libraries 1 Includes all currently supported robotlater SFTRBLBJ306XSX2 models.

BootROM EPROM RSR/PNS (Remote Program Select) 1 Includes all RSR/PNS software fo rVersion : 1 .10PA or later (option)

SFTRSRXJ306X3XXproduction operations.

Memory Required :2MB Flash ROM (min) File System/RAM Disk 1 Includes all information for file system an d2MB CMOS RAM (min)

(option)SFTFSRDJ306XSXX

RAM disk operations .

NOTE: Installation ofmultiple option smight require4MB CMOS RAM

CRT/Keyboard Manage r(option)SFTCRTKJ306X3XX

1 Includes all CRT/KB information .

Serial Host Communication 1 Also referred to as KAREL Serial Link (KSL )(option )SFTSEHOJ306X3X1

option .

PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANU C(option) Robotics Genius network I/O interfaceSFTPLCL1306X3X1

hardware using the R-H extended backplan eon the R-J controller.

S-420 Turbo Move 1 Supports : FANUC Robotics S-420F,(option) S-420A, S-420W, S-420S robot model sSFTTUMOJ306X3X1 only.

Extended Axi s(option)SFTEXAXJ306X3XX

1 Supports independent eXtended axes .

1 . OVERVIEW

MARAJINST09206E

1-9


Product Disk Contents &Part NumberNumber of31/2" Disks

Comment

KAREL KAREL Development Option 1 Includes KAREL editor/translator, fil eDevelopment Package system/RAM disk, and CRT/KB manage rSoftware Package SFTKADPJ306XSXX options . 4MB CMOS RAM recommendedSBKARELJ306X3X2 for this option package.

Version: 3 .06P KAREL Run-Time Application 1 Includes all software to allow you to creat eSoftware teach pendant programs and run them o n

Teach Pendant EPROM SFTKARTJ306X3X1 the controller.Version:7D01/04D orlater Core Software 6 Includes all V3 .06P core software

SFTCOREJ306X3XX information .BootROM EPROMVersion : 1 .10PA or later Robot Libraries 1 Includes all currently supported robot

SFTRBLBJ306X3X2 models.Memory Required :2MB Flash ROM (min )2MB CMOS RAM (min)

RSR/PNS (Remote Program Select)(option)

1 Includes all RSR/PNS software fo rproduction operations.

SFTRSRXJ306X3XX

NOTE: Installation of Serial Host Communication 1 Also referred to as KAREL Serial Link (KSL )multiple options (option) option .might require4MB CMOS RAM

SFTSEHOJ306X3X1

PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANUC(option) Robotics Genius network I/O interfac e

SFTPLIJ306X3X1 hardware using the R-H eXtended backplan eon the R-J controller.

S-420 Turbo Move 1 Supports: FANUC Robotics S-420F,(option) S-420A, S-420W, S-420S robot model sSFTTUMOJ306X3X1 only.

Extended Axis 1 Supports independent extended axes .(option)SFTEXAXJ306X3XX

1 . OVERVIEW

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MARAJINST09206E



Part NumberNumber o f

3-1/2" DisksComment

TPP+ (KAREL TPP+ (KAREL Run-Time) Application 1 Includes all software to allow you to createRun-Time) Software Software TPP+ programs and run them on th ePackage SFTTPPPJ306B3X1 controller.SBKARELJ306B3X1 Core Software 6 Includes all V3.06PB core softwareVersion: 3 .06PB : SFTCOREJ306B3XX information.

Robot Libraries 2 Includes all currently supported robo tTeach Pendant EPRO MVersion: 7D01/04D or

SFTRBLBJ306B3X4 models .

later RSR/PNS (Remote Program Select) 1 Includes all RSR/PNS software fo r

BootROM EPRO MVersion : 1 .10PA or later

(option )SFTRSRXJ306X3XX

production operations .

File System/RAM Disk 1 Includes all information for file system andMemory Required :2MB Flash ROM (min )2MB CMOS RAM (min)

(option)SFTFSRDJ306X3XX

RAM disk operations.

NOTE: Installation ofmultiple options


1 Includes all CRT/KB information .

might CMOS4MB CMOS RAM IntelliTrak(option)

SFTINTRJ306A3XX

1 Includes all IntelliTrak software information .

Serial Host Communication 1 Also referred to as KAREL Serial Link (KSL )(option)SFTSEHOJ306B3XX

option.

Map Interface Includes the MAP communications protocol(option) for communications between the R-JSFTMAPXJ306B3XX controller and an external device .

PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANU C(option) Robotics Genius network I/O interfac eSFTPLCIJ306X3X1

hardware using the R-H extended backplan eon the R-J controller.

S-420 Turbo Move 1 Supports : FANUC Robotics S-420F,(option) S-420FD, S-420A, S-420W, S-420S robotSFTTUMOJ306X3X1 models only.

Extended Axi s(option )SFTEXAXJ306X3XX

1 Supports independent extended axes.

1 . OVERVIEW

MARAJINST09206E


Product Disk Contents &Part NumberNumber of3 i/2" Disks

Comment

KARELDevelopmentPackag e

SBKARELJ306B3X2

Version: 3.06P B

Teach Pendant EPROMVersion : 7D01/04D orlater

BootROM EPRO MVersion : 1.10PA or late r

Memory Required :2MB Flash ROM (min )2MB CMOS RAM (min)

NOTE: Installation ofmultiple option smight requir e4MB CMOS RAM

KAREL Development OptionPackageSFTKAPDJ306B3XX

1 Includes KAREL editor/translator, fil esystem/RAM disk, and CRT/KB manage roptions . 4MB CMOS RAM recommendedfor this option package .

TPP+ (KAREL Run-Time) ApplicationSoftwareSFTTPPPJ306B3X1

1 Includes all software to allow you to createTPP+ programs and run them on th econtroller.

Core SoftwareSFTCOREJ306B3XX

6 Includes all V3.06PB core softwareinformation .

Robot LibrariesSFTRBLBJ306B3X4

2 Includes all currently supported robo tmodels .

RSR/PNS (Remote Program Select )(option)SFTRSRXJ306X3XX

1 Includes all RSR/PNS software fo rproduction operations .

IntelliTrak(option)SFTINTRJ306A3XX

1 Includes all IntelliTrak software information.

Serial Host Communication(option)SFTSEHOJ306B3XX

1 Also referred to as KAREL Serial Link (KSL)option.

Map Interface(option)SFTMAPXJ306B3XX

Includes the MAP communications protoco lfor communications between the R-Jcontroller and an external device.

PLC I/O (ABRIO/Genius)(option)SFTPLCIJ306X3X1

1 Supports the Allen-Bradley and FANU CRobotics Genius network I/O interfac ehardware using the R-H extended backplan eon the R-J controller.

S-420 Turbo Move(option)SFTTUMOJ306X3X1

1 Supports : FANUC Robotics S-420F,S-420FD, S-420A, S-420W, S-420S robotmodels only.

Extended Axi s(option)SFTEXAXJ306X3XX

1 Supports independent eXtended axes .

1 . OVERVIEW

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MARAJINST09206 E

Table 1-1 . (Cont'd) Software Version informatio n


Part NumberNumber of31h" Disks

Comment

TPP+ with INSIGHT II TPP+ with INSIGHT II Application 2 Includes all software to allow you to creat eSoftware Package Software TPP+ and INSIGHT II programs and ru nSBKARELJ306B3X3 SFTTPINJ306B3XX them on the controller .

Version: 3.06PB Core Software 6 Includes V3.06PB core software information .SFTCOREJ306B3XX

Teach Pendant EPROM Robot Libraries 2 Includes all currently supported robotVersion : 7D01/04D or SFTRBLBJ306B3X4 models .later RSR/PNS (Remote Program Select) 1 Includes all RSR/PNS software fo r

BootROM EPROM (option) production operations .Version : 1 .10P or later SFTRSRXJ306X3XX

Memory Required :File System/RAM Disk 1 Includes all information for file system an d

1 .5MB Flash ROM (min) (option) RAM disk operations.

2MB CMOS RAM (min) SFTFSRDJ306X3XX

NOTE: Installation ofCRT/Keyboard Manager 1 Includes all CRT/KB information .

option smultiplemight require4MB CMOS RAM

(option)SFTCRTKJ306X3XX

IntelliTrak 1 Includes all IntelliTrak software information .(option)SFTINTRJ306A3X X

Serial Host Communication 1 Also referred to as KAREL Serial Link (KSL)(option) option.SFTSEHOJ306B3XX

Map Interface Includes the MAP communications protoco l(option) for communications between the R-JSFTMAPXJ306B3XX controller and an external device .

PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANU C(option) Robotics Genius network I/O interfaceSFTPLCIJ306X3X1 hardware using the R-H extended backplan e


S-420 Turbo Move 1 Supports: FANUC Robotics S-420F,(option) S-420FD, S-420A, S-420W, S-420S robotSFTTUMOJ306X3X1 models only.

Extended Axis 1 Supports independent eXtended axes .(option)SFTEXAXJ306X3XX

1 . OVERVIEW

MARAJINST09206E

1-13



Part NumberNumber of

3-1/2" DisksComment

KAREL KAREL Development Option with 2 Includes all INSIGHT II software to creat eDevelopment Option INSIGHT II Application Software and run INSIGHT II programs.with INSIGHT II SFTTPINJ306B3XXSoftware Package

KAREL Development Option 1 Includes KAREL editor/translator, fileSBKARELJ306B3X4Package system/RAM disk, and CRT/KB manage r

Version: 3.06PB SFTKADPJ306B3XX options . 4MB CMOS RAM recommendedfor this option package.

Teach Pendant EPROM Core Software 6 Includes all V3 .06PB core softwareVersion : 7D01/04D o rlater SFTCOREJ306B3XX information .

BootROM EPROMRobot Libraries 2 Includes all currently supported robo t

models .Version : 1.10PA or later SFTRBLBJ306B3X4

Memory Required:RSR/PNS (Remote Program Select)(option)

1 Includes all RSR/PNS software fo rproduction operations .

2MB Flash ROM (min )2MB CMOS RAM (min)

SFTRSRXJ306X3XX

IntelliTrak 1 Includes all IntelliTrak software information .NOTE: Installation ofmultiple optionsmight require4MB CMOS RAM

(option)SFTINTRJ306A3XX

Serial Host Communication 1 Also referred to as KAREL Serial Link (KSL )(option) option .SFTSEHOJ306B3XX

Map Interface Includes the MAP communications protoco l(option) for communications between the R-JSFTMAPXJ306B3XX controller and an external device .

PLC I/O (ABRIO/Genius) 1 Supports the Allen-Bradley and FANU C(option) Robotics Genius network I/O interfac eSFTPLCIJ306X3X1 hardware using the R-H eXtended backplan e


S-420 Turbo Move 1 Supports: FANUC Robotics S-420F,(option) S-420FD, S-420A, S-420W, S-420S robotSFTTUMOJ306X3X1 models only.

Extended Axis 1 Supports independent extended aXes.(option)SFTEXAXJ306X3XX

1 . OVERVIEW

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MARAJINST09206E


Product Disk Contents &Part NumberNumber of3%" Disks

Comment

PaintToo lStandAloneSoftware Packag eSBPAITLJ130X3X1

Version : 1 .30 P

Teach Pendan tEPROMVersion : 7D01/04D orlate r


Memory Required :2MB FRO M

OM RAM4MB CM

PaintTool Application Softwar eSFTPATLJ130X3X1

3 Includes all PaintTool software.


6 Includes all V3.06PB Core software .

Robot Librarie sSFTRBLBJ306B3X4

2 Includes all currently supported robotmodels .

StandAlone PaintTool SetupSFTSAPTJ130X3XX

1 Supports StandAlone PaintTool Option .

PaintTool Password Protectio n(option)

SFTSAPTJ130X3XX

1 Includes all password protection software .

Color Change Software (option)SFTCOCHJ130X3XX

1 Includes all color change software to be use dwith color change hardware .

CRT/Keyboard Manager(option)

SFTCRTKJ306X3XX

1 Includes all CRT/Keyboard managerinformation .

Line Tracking (TPP/PaintTool)(option)SFTLNTRJ306B3XX

1 Includes all line and rail tracking software tobe used with line tracking hardware .

Motet Host Communications(option)SFTMOHCJ306B3XX

1 Supports Ethernet communications

1 . OVERVIEW

MARAJINST09206E

1-15


Product Disk Contents &Part NumberNumber of

3-1/2" DisksCommen t

PaintToo lStandAlon eSoftware Package

SBPAITLJ130A3X1

Version : 1 .30PA

Teach PendantEPROMVersion : 7D01/04D o rlate r

BootROM EPROMVersion : 1 .10PA or late r

Memory Required :2MB FRO M4MB CMOS RAM

PaintTool Application SoftwareSFTPATLJ130A3XX

3 Includes all PaintTool software .

Core Softwar eSFTCOREJ306B3XX



2 Includes all currently supported robotmodels.

StandAlone PaintTool SetupSFTSAPTJ130A3XX

1 Supports StandAlone PaintTool Option .


SFTPAPRJ130X3XX


Color Change Software (option)SFTCOCHJ130A3XX

1 Includes all color change software to be use dwith color change hardware .


1 Includes all CRT/Keyboard manage rinformation .

Line Tracking (TPP/PaintTool )(option)SFTLNTRJ306B3X1

1 Includes all line and rail tracking software t obe used with line tracking hardware .

Motet Host Communication s(option)SFTMOHCJ306B3XX


1 . OVERVIEW

1-16

MARAJINST09206E


Product Disk Contents &Part NumberNumber of3-1/2 2" Disks

Comment

PaintTool PaintTool Application Software 3 Includes all PaintTool software.StandAloneSoftware Package

SFTPATLJ131X3X 1

Core Software 6 Includes all V3.06PB Core software .SBPAITLJ131X3X1SFTCOREJ306B3XX

Version : 1 .31P Robot Libraries 2 Includes all currently supported robotSFTRBLBJ306B3X4 models .

Teach PendantEPROM StandAlone PaintTool Setup 1 Supports StandAlone PaintTool Option .Version : 7D01/04D or SFTSAPTJ131X3XXlater PaintTool Password Protection 1 Includes all password protection software .BootROM EPROMVersion : 1 .10PA or later

(option)SFTSAPTJ130X3XX

Color Change Software (option) 1 Includes all color change software to be use dMemory Required: SFTCOCHJ131X3XX with color change hardware.2MB FROM4MB CMOS RAM CRT/Keyboard Manage r

(option)SFTCRTKJ306X3XX

1 Includes all CRT/Keyboard managerinformation .

Line Tracking (TPP/PaintTool) 1 Includes all line and rail tracking software t o(option) be used with line tracking hardware .SFTLNTRJ306B3X2

Motet Host Communications 1 Supports Ethernet communication s(option)SFTMOHCJ306B3XX

1 . OVERVIEW

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1-1 7


Product Disk Contents &Part NumberNumber of3 1/2" Disks

Commen t

PaintTool Finishing PaintTool Application Software 3 Includes all PaintTool software .Software Package SFTPATLJ130X3X 1

SBPAITLJ130X3X2Core Software 6 Includes all V3 .06PB Core software .

Version: 1 .30PSFTCOREJ306B3XX

Robot Libraries 2 Includes all currently supported robo tTeach Pendant SFTRBLBJ306B3X4 models.EPROMVersion : 7D01/04D or PaintTool Engineering Setup 1 Includes all PaintTool setup information.later SFTPTESJ130X3X X

BootROM EPROM Accuflow Software1 Includes all integrated Accuf lolow software t o

be

Accuflowused with

hardware .Version : 1 .10PA or later (option )SFTACFLJ130X3X XMemory Required : Color Change Software 1 Includes all color change software to be use d2MB FROM (option) with color change hardware .4MB CMOS RAM SFTCOCHJ130X3XX

PaintTool Password Protection 1 Includes all password protection software .(option)

SFTSAPTJ130X3XX

CRT/Keyboard Manager 1 Includes all CRT/Keyboard manager(option) information.SFTCRTKJ306X3XX

Line Tracking (TPP/PaintTool) 1 Includes all line and rail tracking software t o(option) be used with line tracking hardware.SFTLNTRJ306B3XX

Motet Host Communications 1 Supports Ethernet communication s(option)

SFTMOHCJ306B3XX

1 . OVERVIEW

1-18

MARAJINST09206E


Product Disk Contents &Part NumberNumber of3%" Disks

Commen t

PaintTool Finishin gSoftware Package

PaintTool Application SoftwareSFTPATLJ130A3XX

3 Includes all PaintTool software.

SBPAITLJ130A3X2

Version: 1.30PA



Robot Libraries 2 Includes all currently supported robo tTeach PendantEPROM

SFTRBLBJ306B3X4 models.

Version : 7D01/04D orlater

PaintTool Engineering SetupSFTPTESJ130A3XX

1 Includes all PaintTool setup information.

BootROM EPROMAccuf lo low Software 1 Includes all integrated Accuflow software to

Version : 1 .10PA or later(option)SFTACFLJ130A3XX

be used with Accuflow hardware .

Memory Required : Color Change Software 1 Includes all color change software to be used2MB FRO M4MB CMOS RAM

(option)SFTCOCHJ130A3XX

with color change hardware .


SFTSAPTJ130X3XX

1 Includes all password protection software.

CRT/Keyboard Manager 1 Includes all CRT/Keyboard manage r(option )SFTCRTKJ306X3XX

information.

Line Tracking (TPP/PaintTool) 1 Includes all line and rail tracking software t o(option )SFTLNTRJ306B3X1

be used with line tracking hardware .



1 . OVERVIEW

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1-19



Part NumberNumber of3W Disks

Comment

PaintTool Finishin gSoftware Package

SBPAITLJ131X3X2

Version : 1 .31 P

Teach Pendan tEPRO MVersion : 7D01/04D o rlater

BootROM Version: 1.10PA or EPROM late r

Memory Required :2MB FROM4MB CMOS RAM

PaintTool Application SoftwareSFTPATLJ131X3X1

3 Includes all PaintTool software .


6 Includes all V3.06PB-P Core software.


2 Includes all currently supported robotmodels .

PaintTool Engineering Setu pSFTPTESJ131X3XX

1 Includes all PaintTool setup information .

Accuflow Software(option)

SFTACFLJ131X3XX

1 Includes all integrated Accuflow software t obe used with Accuflow hardware .

Color Change Software(option)SFTCOCHJ131X3XX

1 Includes all color change software to be use dwith color change hardware . Cannot beinstalled with AccuStat or Parallel Purgeoptions .


SFTSAPTJ130X3XX


CRT/Keyboard Manager(option)SFTCRTKJ306X3XX

1 Includes all CRT/Keyboard manage rinformation.

Line Tracking (TPP/PaintTool)(option )SFTLNTRJ306B3X2

1 Includes all line and rail tracking software t obe used with line tracking hardware .



AccuStat(option)SFTACSTJ131X3XX

1 Includes AccuStat software. Cannot be use dwith Accuflow, Color Change, or Paralle lPurge options .

Parallel Purg e(option )SFTPAPUJ131X3XX

1 Includes Parallel Purge software. Cannot b eused with AccuStat or Color Change options .

1 . OVERVIEW

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Table 1-1. (Cont'd) Software Version Informatio n


Part NumberNumber o f3-1/2" Disks

Comment

PalletToolSoftware PackageSBPALTJL120X3X 1

Version: 1 .20 P

Teach Pendant EPRO MVersion : 7D01/04D o rlater


Memory Required:2MB Flash ROM (min )2MB CMOS RAM (min)


PalletTool Application SoftwareSFTPLTLJ120X3X,

2 Includes all PalletTool specific information.

Core SoftwareSFTCOREJ306X3XX 6 Includes all V3.06P core software

information.

Robot LibrariesSFTRBLBJ306X3X2

1 Includes all currently supported robo tmodels.

PalletTool Maintenance DiskSFTUPDTJ306X314

1 Includes V1 .20/01 m updated information forPalletTool

1 . OVERVIEW

MARAJINST09206E 1-2 1


Product Disk Contents &Part NumberNumber of3-1/2 " Disks

Comment

SpotTool SoftwarePackage

SBSPOTLJ210X3X1

Version: 2.10P

Teach Pendant EPRO MVersion : 7D01/04D o rlate r

BootROM EPRO MVersion : 1 .10P or late r

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

NOTE : Installation o fmultiple option smight require4MB CMOS RAM

SpotTool Application SoftwareSFTSPTLJ210X3X1

2 Includes all SpotTool information includin gS-420 TurboMove software (which supports:FANUC Robotics S-420F, S-420A, S-420W,S-420S robot models only .

Core SoftwareSFTCOREJ306X3XX

6 Includes v3.06P core software information .

Robot LibrariesSFTRBLBJ306X3X2

1 Includes all currently supported robo tmodels.

Serial Host Communication(option)SFTSEHOJ306X3X1

1 Also referred to as KAREL Serial Link (KSL)option .

PLC O (ABRIO/Genius)(option)SFTPLCIJ306X3X1

1 Supports the Allen-Bradley and FANU CRobotics Genius network I/O interfac ehardware using the R-H extended backplan eon the R-J controller.

CRT/Keyboard Manager MacroSuppor t(update)SFTUPDTJ306X3X4

1 Includes all update information. This is notan option .

1 . OVERVIEW

1-22

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Part NumberNumber of3-1/2" Disks

Comment

SpotTool SoftwarePackage

SBSPOTLJ220X3X1

Version:2.20P

Teach Pendant EPRO MVersion : 7D01/06T4 o rlate r

BootROM EPROMVersion : 1 .20P or late r

MemoryFlash

Required:(min)1 .5MB F Flash ROM (

2MB CMOS RAM (min )


SpotTool Application SoftwareSFTSPTLJ220X3XX

3 Includes all SpotTool information includingS-420 TurboMove software (which supports :FANUC Robotics S-420F, S-420FD,S-420A, S-420W, S-420S robot model sonly.

SpotTool Specific Core SoftwareSFTCOREJ306C3XS

4 Includes V3.06PC core software informationspecifically for SpotTool .

SpotTool Specific CommonSFTCOMNJ3O6C3XS

1 Includes V3.06PC core software informationspecifically for SpotTool .

Robot LibrariesSFTRBLBJ306C3X2

2 Includes all currently supported robotmodels.

KSL Interfac e(option)

SFTKSLIJ306C3XX

1 Also referred to as KAREL Serial Link (KSL)option . 2MB FROM required for thisoption.

PLC I/O (ABRIO/Genius)(option)SFTPLCIJ306C3XX

1 Supports the Allen-Bradley and FANU CRobotics Genius network I/O interfacehardware using the R-H extended backplan eon the R-J controller.

CRT/Keyboard Manager(option)SFTCRTKJ306X3XX


1 . OVERVIEW

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1-23

Table 1-1. (Cont'd) Software Version Informatio n


Part NumberNumber of

3-1/22"DisksComment

SpotTool SoftwarePackageSBSPOTLJ220A3X1

Version: 2.20PA

Teach Pendant EPRO MVersion : 7D01/06T4 o rlate r

BootROM EPROMVersion: 2 .00P or late r

1 .5MB Flash MemoryFlashRequired:

1.5MB Flash ROM (min )2MB CMOS RAM (min)


SpotTool Application SoftwareSFTSPTLJ220A3XX

3 Includes all SpotTool information includin gS-420 TurboMove software (which supports :FANUC Robotics S-420F, S-420FD ,S-420A, S-420W, S-420S robot modelsonly.

SpotTool Specific Core SoftwareSFTCOREJ306D3XS

4 Includes V3.06PD core software informatio nspecifically for SpotTool .

SpotTool Specific CommonSFTCOMNJ306D3XS

1 Includes V3.06PD core software informatio nspecifically for SpotTool .

Robot LibrariesSFTRBLBJ306D3XX

2 Includes all currently supported robo tmodels .

KSL Interfac e(option )SFTKSLIJ306D3XX

1 Also referred to as KAREL Serial Link (KSL)option . 2MB FROM required for thisoption .

PLC I/O (ABRIO/Genius)(option)SFTPLCIJ306C3XX

1 Supports the Allen-Bradley and FANU CRobotics Genius network I/O interfacehardware using the R-H extended backplaneon the R-J controller.



1 . OVERVIEW

MARAJINST09206 E

The following system EPROM chips are already installed on yourcontroller :

Bootstrap ROM (BootROM) EPROM Chip - One EPROM chipthat is installed on the CMOS RAM module on the MAIN CPU boardinside the controller.

Teach Pendant EPROM Chip - One EPROM chip that is installe don the teach pendant PCB inside the teach pendant.

You must check the version of EPROM chip in your controller to be sur ethat it is compatible with the version of software you are loading . Refer toChapter 3 for information on checking EPROM chips . Refer to Table 1- 1for information on the correct software version information.

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1-25

In order to install a new SYSTEM R-J Application Software Package, yo uneed

A teach pendant A disk drive uni t Controller hardware tools

The FANUC Robotics teach pendant is an operator interface device thatdisplays the SYSTEM R-J software . It is connected to the controller via acable 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 .

There are two types of teach pendants available :

Standard Intrinsically Safe (ISTP)

The standard teach pendant provide s

A 16 line x 40 character teach pendant scree n

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

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

Figure 1-1 shows the standard teach pendant .

Figure 1-1 . Standard Teach Pendant

1 .2INSTALLATIONREQUIREMENTS

1 .2.1Teach Pendant

1 . OVERVIEW

The ISTP, used in most hazardous paint environments, plugs into theintrinsically safe barrier (ISB) unit within the controller and consists of

A 16 line x 40 character teach pendant screen

Eleven status indicators displayed on the teach pendant screen.

Teach Pendant keys, including keys specific to the PaintTool softwar eapplication.

Figure 1-2 displays the ISTP.

Figure 1-2 . Intrinsically Safe Teach Pendant (ISTP)

1 . OVERVIEW

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1-27

To perform a software installation, you must have a FANUC Robotic sPS-100 disk drive unit. The PS-100 connects to the P3 controller port .The P3 controller port is an RS-232-C interface .

PS-100 Disk Drive

The FANUC Robotics PS-100 disk drive, shown in Figure 1-3, is use dwith 3'/4 inch disks, including 720K double-density disks .

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

To perform the EPROM installation, you must have a Flat-tip screwdriver to open the controller door. Long cross-tip screwdriver to remove the teach pendant cover. Dual-inline-pin (DIP) chip removal tool and installation tool to

remove and install EPROM chips . Anti-static pad with wrist strap to prevent static damage to the

EPROM chips .

1 .2.2Disk Drive Unit

1 .2.3Controller HardwareTools

SETTING UP CONTROLLER MEMORY

2-1MARAJINST09205E

Setting up controller memory involves checking :

Controller memory Erasable Programmable Read-Only Memory (EPROM) Chips

Controller Memory

Controller memory consists of both Flash Read Only Memory (Flas hROM) and Complementary Metal Oxide Semiconductor Random Acces sMemory (CMOS RAM). CMOS RAM memory stores some robot systemsoftware, some application software, and all user programs . Flash ROMstores the majority of the robot system software such as core, application ,and option software .

CMOS RAM is divided into three parts or memory pools . These areKAREL, TPE, and C-WORK. Flash ROM is divided into two memorypools called F-DICT and F-PROG. A teach pendant editor (WE) progra muses only the TPE memory pool . A KAREL program uses the KAREL ,WE, and C-WORK memory pools . An option could use all five memorypools .

NOTE If you change the amount of memory in the TPE pool it will affec tthe amount of memory available in the KAREL pool.

CMOS RAM is battery-backed. Flash ROM is not battery-backed but i snon-volatile. Non-volatile means that all data in Flash ROM, includin gprograms, is saved even after you turn off and turn on the controller .CMOS RAM is non-volatile only while the batteries are working . If thebatteries are faulty or removed, CMOS RAM is lost.

A CAUTIONData in CMOS RAM can be lost if the battery is removed o rloses its charge, or if new core software is loaded on th econtroller. To prevent loss of data back up, or copy, all files fo rpermanent storage .

To set up controller memory you mus t

Install the CMOS and Flash ROM modules on the main CPU boar dinside the controller.

Check system memory allocatio n

NOTE You can also format a portion of the KAREL memory poo l(CMOS RAM), as a RAM disk, which can be used as a separate storagedevice . Refer to the Setup and Operations Manual for your application fo rmore information.

Refer to Section 2.1 for more information on checking controller memory .Refer to Section 2.2 for more information on installing CMOS and Flas hROM boards.

2. SETTING UP CONTROLLER MEMOR Y

2-2

MARAJINST09205E

Checking system memory allows you to determine the amount of CMOS, 'and Flash ROM memory available in your system .

Table 2--1 lists and describes each memory status item . UseProcedure 2-1 to check system memory.

Table 2-1 . Memory Statu s

MEMORY STATUS DESCRIPTION

User Indicates the amount of memory for user programs: teach pendant programs and KARELprograms .

Total indicates the original size of the memory area . Free indicates how much memory is available . Largest Free indicates the largest contiguous segment of memory .

System Indicates the amount of memory for system information : F-DICT (dictionary files thatdefine what is displayed on the screens), F-PROG (application, operating system, an doption files), and C-WORK (temporary memory used for system operations) .

Total indicates the original size of the memory area. Free indicates how much memory is available. Largest Free indicates the largest contiguous segment

Hardware Indicates the total amount of memory in Flash ROM and CMOS RAM .

Procedure 2-1 Displaying Memory Statu s

Step 1 Press MENUS .

2 Select STATUS.

3 Press F1, [TYPE] .

4 Select Memory. See the following screen for an example .

2. 1CHECKING SYSTEMMEMORY

2 . SETTING UP CONTROLLER MEMORY

MARAJINST09205E

2-3

2.2INSTALLING CMOSAND FLASH RO MMEMORY

A maximum of four CMOS RAM modules can be used in the R-Jcontroller. A maximum of two Flash ROM modules can be used in th eR-J controller. CMOS RAM and Flash ROM are installed on the MAINCPU board inside the controller. Use Procedure 2-2 to remove or add aCMOS RAM or Flash ROM module .

Procedure 2-2 Installing a CMOS RAM or Flash ROM Module

Condition

n The controller is turned off.

A WARNINGDisconnect electrical power from the controller before yo uremove or replace components, or you could be injure dseriously.

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

n You are wearing a wrist wrap to prevent static discharge to the CMO Scircuits .

Step

1 Disconnect electrical power from the controller .

If your controller is equipped with a disconnect handle at the upperright front corner, pull it to the OFF (down) position .

OR

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

See Figure 2-1 .

A 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 remov eall power from the controller.

2 . SETTING UP CONTROLLER MEMORY

MARAJINST09205 E2-4

2 Open the front door of the controller using a flat-tip screwdriver t o

turn the latch. See Figure 2-1 .

Figure 2-1 . R-J Controller Disconnect Handle and Latc h

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

Figure 2-2 . MAIN CPU Board Locatio n

CIRCUIT BREAKE RB-SIZE CONTROLLER

POWER DISCONNECTC-SIZE CONTROLLER

2. SETTING UP CONTROLLER MEMORY

MARAJINST09205E

2-5

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

5 Press and hold both latches of the MAIN CPU board and remove th eboard from the backplane . See Figure 2-3 .

Figure 2-3 . Removing the MAIN CPU Board

6 Install the CMOS RAM or Flash ROM modules on the MAIN CPUboard in the appropriate memory slots . See Figure 2-4 .

Figure 2-4. Installing the CMOS RAM or Flash ROM Module


MARAJINST09205 E

7 Insert the MAIN CPU board into the proper slot on the controllerbackplane .

8 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 CMOS RAM memory will be initialized automatically when th esoftware is installed.


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2-7

Instead of reloading an entire controller with software using disks, you ca ncopy controller memory from one controller to another by copying theCMOS and FLASH ROM memory within the controller . You can copythe following memory configuration s

3.5MB controller memory : 2MB CMOS and 1 .5MB FROM (2+1 .5 ) 4MB controller memory : 2MB CMOS and 2MB FROM (2+2 ) 6MB controller memory : 4MB CMOS and 2MB FROM (4+2 )

NOTE The source and target MAIN CPU boards must have the samememory configuration . For example, you can copy a 2MB CMOS and1 .5MB FROM only to a MAIN CPU board with 2MB CMOS and 1 .5MBFROM.

Use Procedure 2-3 to copy 3 .5MB and 4MB controller memory. UseProcedure 2-4 to copy 6MB controller memory .

Procedure 2-3 Copying 3.5MB (2+1 .5) and 4MB (2+2) Controller Memory

Condition

n You have obtained an R-J portable processor or an R-J controller withan extension backplane (A20B-1004-0510) and two R-H CMOSmemory printed circuit boards (A16B-2200-0760 )

A CAUTIO NBoth R-H CMOS Memory printed circuit boards must b einstalled or the copy will not work .

You are using V 1 .10P-Rev. A BootROM .The controller is turned off .

The source CPU is plugged into the controller.

Any data that is currently on the target CPU that you want to save ha sbeen backed up .

Step

1 Plug the extension backplane into the R-J card rack . This board plug sinto the side of the R-J backplane on the left side. See Figure 2-5 .

2.3COPYIN GCONTROLLERMEMORY

2. SETTING UP CONTROLLER MEMORYMARAJINST09205E

2-8

Figure 2-5. Plugging in the Extension Backplan e

2 Mount the two R-H CMOS memory cards into the two right slots o fthe extension backplane . The slot names are CM0 and CM1 .

3 Press and hold the USER PB#1 and USER PB#2 buttons on thecontroller (PURGE ENABLE on a P-155 controller) while pressin gthe ON button. The BMON> prompt will be displayed. See thefollowing screen for an example .

NOTE Slots 0 and 1 on the previous screen indicate that the controlle rrecognizes the R-H CMOS boards. If this information is not displayed ,the R-H CMOS boards are not installed properly.

4 Press >, NEXT, twice.

5 Press F4, DEVICE then press ENTER. The DEV> prompt will bedisplayed .


MARAJINST09205E 2-9

6 Press F5, INIT.

7 Press Fl, CM .

8 Press 0, then press ENTER . This will initialize the R-H CMOSmemory in the first slot. The DEV> prompt will be displayed.

9 Press F5, INIT.

10 Press F1, CM.

'w prompt will be displayed .

15 Press F2, BACKUP.

16 Press Fl, CMOS and then press ENTER. See the following screen foran example .

17 To cancel the copy, type 0 .To copy the CMOS RAM contents, type 1 .

The contents of CMOS RAM memory will be copied to CM0 . Achecksum is provided for the CMOS RAM and then again as the copyis performed. This checksum verifies that CMOS RAM is intact .Record the checksum for later. The checksum performed now shouldmatch the checksum performed when CMOS RAM is restored .

When the copy is complete, the DEV> prompt will be displayed .

18 Turn off the controller.

2. SETTING UP CONTROLLER MEMORYMARAJINST09205E

2-10

NOTE The source and target MAIN CPU boards must have the samememory configuration. For example, you can copy a 2MB CMOS and1 .5MB FROM only to a MAIN CPU board with 2MB CMOS and 1 .5MBFROM.

19 Insert the target MAIN CPU in the R-J backplane .

20

21

Press and hold the USER PB #1 and USER PB#2 buttons on thecontroller (PURGE ENABLE and ON on a P-155 controller) . TheBMON> prompt will be displayed .

Press >, NEXT.

A CAUTIO NThe next step clears the data currently in CMOS memory .Cleared data cannot be retrieved. Make sure you have backedup any data you want to save to an off-line storage device suc has a floppy disk before you perform the next step, otherwise ,data will be lost .

22 Press Fl, CLEAR .

23 Press Fl, CMOS, then press ENTER.

24 Press >, NEXT.

A CAUTIONThe next step clears the data currently in FROM memory .Cleared data cannot be retrieved . Make sure you have backedup any data you want to save to an off-line storage device suchas a floppy disk before you perform the next step, otherwise ,data will be lost .

25 Press Fl, CLEAR .

26 Press F2, FROM, then press ENTER .

Press >, NEXT, twice .

Documents

Software Installation - fanuc