E

MASTERING

MARO2HT4405801E E–1

When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robot’s positional
information. A robot must be mastered to operate properly. Robots are
usually mastered before they leave FANUC Robotics. However, it is
possible that a robot might lose its mastering data and need remastering.

Topics In This
Appendix Robots When to Use Page
Resetting Alarms and All except When you power up the robot after disconnecting the
Preparing for Mastering P-200 pulsecoder backup batteries you might see a
SRVO–062 BZAL or SRVO–038 Pulse mismatch alarm.
Before mastering the robot you must reset the alarm
and rotate the motor of each axis that lost battery power
to prepare the robot for mastering. . . . . . . . . . . . . . . . . . . . . . E–3

Mastering to a Fixture All except When mastery was lost due to mechanical
(Fixture Position Master) P-200 disassembly or repair.
When a quick master reference position was not
previously set.
Method of choice for P- and A-series robots.
Used for S- and M-series robots when extreme
precision is required.
Method of choice for A-series robots.
Used for S-series and M-Series robots when
extreme precision is required. . . . . . . . . . . . . . . . . . . . . . E–6
Zero Degree Mastering M-series When mastery was lost due to mechanical
S-series disassembly or repair.
When a quick master reference position was not
P-series previously set.
Method of choice for S- and M-series robots when
extreme precision is not required. . . . . . . . . . . . . . . . . . E–8
Single Axis Mastering S-series When mastery was lost due to mechanical disassembly
M-series or repair of a single axis (usually due to
motor replacement). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–10
P-series

Quick Mastering All To retrieve mastering data that has been stored as a
quick master reference position when mastery is lost
due to an electrical or software problem. Do not use if
mastery was lost due to mechanical disassembly
or repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–13

Before you master the robot, you must clear any faults that prevent
servo power from being restored or that prevent mastering completion.
Use Procedure E–1 to clear common faults related to mastering and to
prepare the robot for mastering. For more detailed information on fault
recovery, refer to the FANUC Robotics SYSTEM R-J2 Controller Series
Electrical Connection and Maintenance Manual.
 E. MASTERING

E–2 MARO2HT4405801E

If you are using a FANUC Robotics A-series or P-series robot you

should use a mastering fixture to master your robot. Refer to the FANUC
Robotics SYSTEM R-J2 Controller Mechanical Connection and
Maintenance Manual specific to your robot model for procedures on how
to set up and use a mastering fixture.

NOTE If you are using a FANUC Robotics P-series robot, and you have
witness marks scored onto your robot, then you can master the robot to
zero degrees. Refer to the Mechanical Service Manual specific to your
robot model for more information

If you are using a FANUC Robotics M-series or S-series robot you can
either master to a fixture or you can master to zero degrees. Refer to the
FANUC Robotics SYSTEM R-J2 Controller Mechanical Connection and
Maintenance Manual specific to your robot model for more information on
mastery using a fixture.
Quick mastering is a convenient way to master an M-series, P-series or
S-series robot after you have recorded a reference position. You cannot
quick master a robot unless the reference position was taught before
mastering was lost.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
 E. MASTERING

MARO2HT4405801E E–3

E.1 When you power up the robot after disconnecting the pulsecoder backup
batteries you might see a SRVO–062 BZAL or SRV0–038 Pulse mismatch
RESETTING ALARMS
alarm. Before mastering the robot you must reset the alarm and rotate the
AND PREPARING FOR motor of each axis that lost battery power to prepare the robot for
MASTERING mastering.
Use Procedure E–1 to reset these alarms and prepare the robot for
mastering.

Procedure E–1 Preparing the Robot for Mastering

Condition You see a SRVO–062 BZAL or SRVO–038 Servo mismatch alarm.

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

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA DONE

 E. MASTERING

E–4 MARO2HT4405801E

WARNING
For M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), M-16iL
(ARC Mate 120iL), S-6 (ARC Mate 100), and S-12 (ARC Mate
120) robots, setting TORQUE to OFF using the TORQUE
function key on the SYSTEM Master/Cal screen releases
the robot brakes. When the brakes are released, the robot
arm will drop suddenly unless it is supported. DO NOT
use this function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.

6 Press F3, RES_PCA. You will see a screen similar to the following.

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

Reset pulse coder alarm? [NO]

[ TYPE ] YES NO

7 Press F4, YES. You will see a screen similar to the following.

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Pulse coder alarm reset!

[ TYPE ] LOAD RES_PCA DONE

 E. MASTERING

MARO2HT4405801E E–5

WARNING
For M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), M-16iL
(ARC Mate 120iL), S-6 (ARC Mate 100), and S-12 (ARC Mate
120) robots, setting TORQUE to OFF using the TORQUE
function key on the SYSTEM Master/Cal screen releases
the robot brakes. When the brakes are released, the robot
arm will drop suddenly unless it is supported. DO NOT
use this function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.

8 If the SRVO–062 alarm is still present; there is a battery, cable or

pulsecoder problem. Refer to the FANUC Robotics SYSTEM R-J2
Controller Series Electrical Connection and Maintenance Manual for
further information.
9 If a SRVO–038 alarm is present at this time, repeat Step 6 to reset it.
It is not necessary to cold start the robot after resetting to clear this
alarm.
10 Rotate each axis that lost battery power by at least one motor
revolution in either direction.
a Jog each rotary axis at least twenty degrees.
b Jog each linear axis at least thirty millimeters.
11 Perform any of the mastering procedures from the MASTER/CAL
menu.
 E. MASTERING

E–6 MARO2HT4405801E

E.2 When you master to a fixture, you use a mastering fixture to align the
robot axes and then record the position. You can master any robot to a
MASTERING TO A
fixture. If you have a P-series or A-series robot, you must master it to a
FIXTURE (FIXTURE fixture.
POSITION MASTER)
NOTE If you have an M-6i (ARC Mate 100i), S-6 (ARC Mate 100), or
S-12 (ARC Mate 120) robot, do not use Procedure E–2 . These robots
require that servo power be removed and brakes released in order to use
the fixture. Refer to the FANUC Robotics SYSTEM R-J2 Controller
Mechanical Connection and Maintenance Manual for detailed procedures
on mastering these robots to a fixture.

Use Procedure E–2 to master to a fixture.

Procedure E–2 Mastering to a Fixture (for all robots except S-6 and S-12)

Condition You have the appropriate mastering fixture for your robot.
You have cleared any servo faults that prevent you from jogging the
robot.
You have jogged each axis that has lost mastery at least one motor
turn. (Procedure E–1 )
Step 1 Install the mastering fixture on the robot and jog the robot into
mastering position. Refer to the FANUC Robotics SYSTEM R-J2
Controller Mechanical Connection and Maintenance Manual specific
to your robot model for the procedures on how to set up and use a
mastering fixture.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
 E. MASTERING

MARO2HT4405801E E–7

e Select Master/Cal. You will see a screen similar to the following.

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA DONE

WARNING
For M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), M-16iL
(ARC Mate 120iL), S-6 (ARC Mate 100), and S-12 (ARC Mate
120) robots, setting TORQUE to OFF using the TORQUE
function key on the SYSTEM Master/Cal screen releases
the robot brakes. When the brakes are released, the robot
arm will drop suddenly unless it is supported. DO NOT
use this function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.

6 Select Fixture Position Master.

7 Select Calibrate.
8 Press F4, YES.
9 Perform a cold start.
SHIFT a Turn off the robot.
b Press and continue pressing the SHIFT and RESET key on the
teach pendant.
SHIFT
RESET c While still pressing SHIFT and RESET, press the ON button on
the operator panel.
 E. MASTERING

E–8 MARO2HT4405801E

E.3 When you master to zero degrees, you position all axes at their zero degree
witness marks and record the zero degree position. You can master any
ZERO DEGREE
M-series or S-series robot to zero degrees.
MASTERING
NOTE If you are mastering an S-420iR robot, you cannot use this
mastering method. Use one of the other mastering methods described in
Sections E.2, E.4, and E.5.

Use Procedure E–3 to master to zero degrees.

Procedure E–3 Mastering to Zero Degrees (for all robots except S-420iR)

Condition You have cleared any servo faults that prevent you from jogging the
robot.
You have jogged each axis that has lost mastery at least one motor
turn. (Procedure E–1 )
Step 1 Using the joint coordinate system, jog each axis of the robot to the
zero degree witness mark. Refer to the FANUC Robotics SYSTEM
R-J2 Controller Mechanical Connection and Maintenance Manual
specific to your robot model for the location of the witness marks.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
 E. MASTERING

MARO2HT4405801E E–9

e Select Master/Cal. You will see a screen similar to the following.

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA DONE

WARNING
For M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), M-16iL
(ARC Mate 120iL), S-6 (ARC Mate 100), and S-12 (ARC Mate
120) robots, setting TORQUE to OFF using the TORQUE
function key on the SYSTEM Master/Cal screen releases
the robot brakes. When the brakes are released, the robot
arm will drop suddenly unless it is supported. DO NOT
use this function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.

6 Select Zero Position Master.

7 Press F4, YES. Mastering will be performed automatically.
8 Select Calibrate.
9 Press F4, YES.
10 Perform a cold start.
SHIFT a Turn off the robot.
b Press and continue pressing the SHIFT and RESET key on the
teach pendant.
SHIFT
RESET c While still pressing SHIFT and RESET, press the ON button on
the operator panel.
 E. MASTERING

E–10 MARO2HT4405801E

E.4 You can master a single axis of an M-series or S-series robot when mastery
was lost due to mechanical disassembly or repair of a single axis, usually
SINGLE AXIS
due to motor replacement.
MASTERING
Use Procedure E–4 to master a single axis.

Procedure E–4 Mastering a Single Axis

NOTE For the S-420iR robot, when the witness marks are aligned for
axes J2 and J3, the joint angles are as follows:
J2: –15
J3: –15

Condition You have cleared any servo faults that prevent you from jogging the
robot.
You have jogged each axis that has lost mastery at least one motor
turn. (Procedure E–1 )
Step 1 Using the joint coordinate system, jog the unmastered axis of the robot
to the zero degree witness mark. Refer to the FANUC Robotics
SYSTEM R-J2 Controller Mechanical Connection and Maintenance
Manual specific to your robot model for the location of the witness
marks.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLES from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
 E. MASTERING

MARO2HT4405801E E–11

e Select Master/Cal. You will see a screen similar to the following.

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA DONE

WARNING
For M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), M-16iL
(ARC Mate 120iL), S-6 (ARC Mate 100), and S-12 (ARC Mate
120) robots, setting TORQUE to OFF using the TORQUE
function key on the SYSTEM Master/Cal screen releases
the robot brakes. When the brakes are released, the robot
arm will drop suddenly unless it is supported. DO NOT
use this function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.

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

SINGLE AXIS MASTER JOINT 10%

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 3.514 ( 35.000) (0) [0]
J3 –7.164 (–100.000) (0) [2]
J4 –357.366 ( 0.000) (0) [2]
J5 –1.275 ( –80.000) (0) [2]
J6 4.571 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]

[ TYPE ] GROUP EXEC

7 Move the cursor to the MSTR POS column for the unmastered axis
and press the “0” key.
8 Continuously press and hold the DEADMAN switch and turn the
teach pendant ON/OFF switch to ON.
 E. MASTERING

E–12 MARO2HT4405801E

9 Move the cursor to the SEL column for the unmastered axis and press
the numeric key “1.”
10 Press ENTER.
11 Press F5, EXEC. Mastering will be performed automatically.
12 Press PREV.
13 Select Calibrate.
14 Press F4, YES.
15 Perform a cold start.
SHIFT a Turn off the robot.
b Press and continue pressing the SHIFT and RESET key on the
teach pendant.
SHIFT
RESET c While still pressing SHIFT and RESET, press the ON button on
the operator panel.
 E. MASTERING

MARO2HT4405801E E–13

E.5 Quick mastering allows you to minimize the time required to remaster the
robot using a reference position you established when the robot was
QUICK MASTERING
properly mastered. You cannot quick master the robot unless you have
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properly
mastered. The best time to record the quick master reference position is
when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can use
this reference position to master the robot in a minimum amount of time.
If you lose mastery due to mechanical disassembly or repair, you must
master to a fixture or perform zero degree mastering.
You can define a quick master reference position and perform quick
mastering on any robot model.
Use Procedure E–5 to record the quick master reference position. Use
Procedure E–6 to quick master the robot.

CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.

Procedure E–5 Recording the Quick Master Reference Position

NOTE For the S-420iR robot, when the witness marks are aligned for
axes J2 and J3, the joint angles are as follows:
J2: –15
J3: –15

Condition The robot is properly mastered.

Step 1 Align the witness marks on the robot. This is the zero position, which
will be the quick master reference position. Refer to the FANUC
Robotics SYSTEM R-J2 Controller Mechanical Connection and
Maintenance Manual specific to your robot model for the location of
the witness marks.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
 E. MASTERING

E–14 MARO2HT4405801E

5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. You will see a screen similar to the following.

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA DONE

WARNING
For M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), M-16iL
(ARC Mate 120iL), S-6 (ARC Mate 100), and S-12 (ARC Mate
120) robots, setting TORQUE to OFF using the TORQUE
function key on the SYSTEM Master/Cal screen releases
the robot brakes. When the brakes are released, the robot
arm will drop suddenly unless it is supported. DO NOT
use this function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.

Set quick master ref? [NO] 6 Move the cursor to SET QUICK MASTER REF and press ENTER.
7 Press F4, YES.
8 Perform a cold start.
SHIFT
a Turn off the robot.
b Press and continue pressing the SHIFT and RESET key on the
SHIFT
RESET
teach pendant.
c While still pressing SHIFT and RESET, press the ON button on
the operator panel.
 E. MASTERING

MARO2HT4405801E E–15

Procedure E–6 Quick Mastering the Robot

Condition The robot has lost mastery due to an electrical or software problem.
NOTE If the robot has lost mastery due to mechanical disassembly or
repair, you cannot perform this procedure. In this case, master to a fixture
or master to zero degrees to restore robot mastering.
The quick master reference position was recorded before the robot lost
mastery.
You have cleared any servo faults that prevent you from jogging the
robot.
You have jogged each axis that has lost mastery at least one motor
turn. See Procedure E–1 .
Step 1 Jog the robot to the quick master reference position (zero degree
position).
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
 E. MASTERING

E–16 MARO2HT4405801E

e Select Master/Cal. You will see a screen similar to the following.

WARNING
For M-6i (ARC Mate 100i), M-16i (ARC Mate 120i), M-16iL
(ARC Mate 120iL), S-6 (ARC Mate 100), and S-12 (ARC Mate
120) robots, setting TORQUE to OFF using the TORQUE
function key on the SYSTEM Master/Cal screen releases
the robot brakes. When the brakes are released, the robot
arm will drop suddenly unless it is supported. DO NOT
use this function key unless instructed to do so, otherwise,
personnel could be injured and equipment damaged.

SYSTEM Master/Cal JOINT 10%

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA DONE

6 Move the cursor to QUICK MASTER and press ENTER.

Quick master? [NO] 7 Press F4, YES.
8 Move the cursor to CALIBRATE and press ENTER
9 Press F4, YES.
10 Perform a cold start.
SHIFT a Turn off the robot.
b Press and continue pressing the SHIFT and RESET key on the
teach pendant.
SHIFT
RESET c While still pressing SHIFT and RESET, press the ON button on
the operator panel.