6. MASTERING
B-83155EN/04
6
MASTERING
Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute
Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for
obtaining the pulse count value; corresponding to the zero position.
6.1
OVERVIEW
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering becomes necessary after:






Motor replacement
Pulsecoder replacement
Reducer replacement
Link B, Driveshaft, and Wrist unit replacement
Cable replacement
Batteries for pulse count backup in the mechanical unit have gone dead
CAUTION
Robot data (including mastering data) and Pulsecoder data are backed up by
their respective backup batteries. Data will be lost if the batteries die. Replace
the batteries in the controller and mechanical units periodically. An alarm will
alert you when battery voltage is low.
Types of Mastering
Table 6.1 describes the following mastering methods. Note that "Quick Mastering for Single Axis" is not
supported in software version 7DC2(V8.20P) or earlier.
Table 6.1 Type of mastering
Fixture position
mastering
Zero-position
mastering (witness
mark mastering)
Quick mastering
Quick mastering
For single axis
Single-axis mastering
Mastering data entry
Mastering performs with mastering fixture before shipping.
This is performed with all axes set at the 0-degree position. A zero-position mark (witness
mark) is attached to each robot axis. This mastering is performed with all axes aligned to
their respective witness marks.
This is used for a quick recovery of mastering when pulse count is reset due to battery
run-out etc. In order to use this, you need to set a reference position in advance.
(all axes at the same time)
This is used for a quick recovery of mastering for single axis when pulse count is reset
due to battery run-out etc. In order to use this, you need to set a reference position in
advance.
This is performed for one axis at a time. The mastering position for each axis can be
specified by the user. This is useful in performing mastering on a specific axis.
Enter the Mastering date directly.
This MAINTENANCE MANUAL describes fixture position mastering that is mainly required during
replacement of parts. For other mastering methods, refer to OPERATOR'S MANUAL.
Once performing the mastering, the positioning (calibration) is indispensable. The Positioning is an
operation which recognizes the robot current position loading the pulse count value.
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6. MASTERING
B-83155EN/04
CAUTION
1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. For this reason, the Master/Cal screen is designed to appear
only when the $MASTER_ENB system variable is 1 or 2. After performing
positioning, press F5, ([DONE]) on the Master/Cal screen. The $MASTER_ENB
system variable is reset to 0 automatically, and the Master/Cal screen will
disappear.
2 It is recommended that the current mastering data be backed up before
mastering is performed.
Mastering procedure for M-3iA/12H is common to other FANUC robot.
But mastering procedure for M-3iA/6S/6A is different from other FANUC robot because it has special
structure. You can perform mastering in an interactive method as below.
1
2
3
4
Master major axis (J1 to J3).
Move major axis to make the universal joint straight. (This motion is automatically done.)
Master wrist axis (J4 to J6).
Calibrate the phase of universal joint one by one.
You must move J1, J2, J3 to 27.0320º before you master wrist axis on Fixture position mastering,
Zero-position mastering and Single-axis mastering. This motion is automatically done.
6.2
RESETTING ALARMS AND PREPARING FOR
MASTERING
Before performing mastering because a motor is replaced, it is necessary to release the relevant alarm and
display the positioning menu.
Alarm displayed
“SRVO 062 BZAL” or “SRVO 075 Pulse not established”
Procedure
1
Display the positioning menu by following the steps 1 to 6.
1
Press the [MENU] key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press the F1 ([TYPE]), and select [Variable] from the menu.
4
Place the cursor on $MASTER_ENB, then key in “1” and press the [ENTER] key.
5
Press the F1 ([TYPE]), and select [Master/Cal] from the menu.
6
Select the desired mastering type from the [Master/Cal] menu.
2
To reset the “SRVO 062 BZAL” alarm, follow steps 1 to 5.
1
Press the [MENU] key.
2
Press [0 NEXT] and select [6 SYSTEM].
3
Press the F1 ([TYPE]), and select [Master/Cal] from the menu.
4
Place the cursor on the F3 ([RES_PCA]), then press the F4 ([YES]).
5
Cycle power of the controller.
3
To reset the “SRVO 075 Pulse not established” alarm, follow the steps 1 to 2.
1
After cycle power of the controller, the message “SRVO 075 Pulse not established” appears
again.
2
Move the axis for which the message mentioned above has appeared till alarm disappears when
press [FAULT RESET] in either direction.
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6. MASTERING
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6.3
FIXTURE POSITION MASTERING
Fixture position mastering is performed using a mastering fixture. This mastering is carried out in the
predetermined fixture position. Fixture position mastering is accurate because a dedicated mastering
fixture is used.
When mastering the robot, arrange the robot to meet the following conditions.
Make the robot mounting base horizontal.
(The overall levelness of the robot mounting surface shall be 1 mm or less.)
Remove the hand and other parts from the wrist.
Set the robot in the condition protected from an external force.
For the M-3iA/6S/6A
Assembling the fixture
1
Assemble the fixture to robot referring to Fig. 6.3 (a) to (e).
The fixture of wrist axis is needed on procedure 9 of Fixture position master. Don't assemble the
fixture of wrist axis until procedure 9 of Fixture position master.
Clamp
クランプ
A290-7523-X913
A290-7523-X913
Bolt
ボルト
M5x12
M5X12
Block
ブロック
A290-7523-X912
A290-7523-X912
ボルト
Bolt
M5X12 (2)
(2)
M5x12
Fig. 6.3 (a) Assembling the fixture (major axis side)
Plate
プレート
A290-7523-X915
A290-7523-X915
ボルト
Bolt
M6X16(2)
(2)
M6x16
Plate
プレート
A290-7523-X914
A290-7523-X914
ボルト
Bolt
M6X16 (4)
(4)
M6x16
ピン
Pin
A290-7523-X916
A290-7523-X916
Fig. 6.3 (b) Assembling the fixture (wrist axis side of M-3iA/6S (A05B-1523-B201))
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6. MASTERING
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Plate
プレート
A290-7523-X925
A290-7523-X925
Plate
プレート
A290-7523-X918
A290-7523-X918
Bolt
ボルト
M5x16
M5X16(2)
(2)
Bolt
ボルト
M5X16(3)
(3)
M5x16
Plate
プレート
A290-7523-X920
A290-7523-X920
Bolt
ボルト
M5X16 (2)
(2)
M5x16
Pin
ピン(2)
(2)
JB-PH-H7A-4X8S45C
JB-PH-H7A-4X8S45C
Plate
プレート
A290-7523-X919
A290-7523-X919
Fig. 6.3 (c) Assembling the fixture (wrist axis side of M-3iA/6A)
Bolt
ボルト
M6x16
M6X16 (2)
(2)
Plate
プレート
A290-7523-X917
A290-7523-X917
ボルト
Bolt
M6X16(4)
(4)
M6x16
Pin
ピン
A290-7523-X916
A290-7523-X916
Fig. 6.3 (d) Assembling the fixture (wrist axis side of M-3iA/6A)
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6. MASTERING
B-83155EN/04
プレート
Plate
A290-7523-X928
A290-7523-X928
プレート
Plate
A290-7523-X927
A290-7523-X927
Bolt
ボルト
M6X16 (2)
M6x16
(2)
Bolt
ボルト
M6X16 (4)
(4)
M6x16
Pin
ピン
A290-7523-X916
A290-7523-X916
Fig. 6.3 (e) Assembling the fixture (wrist axis side of M-3iA/6S (A05B-1523-B203))
2
Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M5 bolt as shown
in Fig 6.3 (f). (Do not tighten the bolt too strongly, or the dial gauge will be broken.)
The dial gauge of wrist axis is needed on procedure 9 of Fixture position master. Don't assemble the
dial gauge of wrist axis until procedure 9 of Fixture position master.
20
Gauge block
A290-7018-X087
All dial gauge indicates 3mm in calibration.
Major axis
M-3iA/6S wrist axis
M-3iA/6A wrist axis
Fig. 6.3 (f) Mounting dial gauge
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6. MASTERING
B-83155EN/04
Procedure of Fixture position mastering
1
2
3
Press the [MENU] key to show screen menu.
Press [0 NEXT] and select [6 SYSTEM].
Press F1 [TYPE] and select [Master/Cal] from the menu.
NOTE
If RUNNING or PAUSED program exists, ABORT it beforehand.
Otherwise, you can not proceed to the following step.
4
Select [FIXTURE POSITION MASTER] and press F4 [Yes].
SYSTEM Master/Cal
1
2
3
4
5
6
7
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
QUICK MASTER FOR SINGLE AXIS
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ‘ENTER’ or number key to select.
5
The interactive mastering starts from here. First, start with the major axis mastering. Assemble the
mastering fixture of major axis and dial gauge referring to Fig. 6.3 (a), (b), (e) and (f). Let dial gauge
of major axis touch face of Fig.6.3 (g) to (i), and adjust until all the dial gauges of major axis
indicate 3 mm. The robot will take the posture shown in Fig. 6.3 (g) to (i). See this figure for
reference.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 1: Major Axis Master *********
JOG J1,J2,J3
to the mastering position.
If TP program is running, abort the TP
program. and reset all alarms.
If OK. please enter [1]:
NOTE
If you use a LEGACY (monochrome) teach pendant, the title lines (“M-3iA
Master” to “Step n: xxxxx”) are not displayed.
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6. MASTERING
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A
B
A
0.5 to 1.5
Detail B
C
View C
Face to put
dial gauge
Face to put
dial gauge
Section A-A
Mastering position
J1：0°
J2：0°
J3：0°
J4：0°
Fig. 6.3 (g) Fixture position master (M-3iA/6S (A05B-1523-B201))
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6. MASTERING
B-83155EN/04
A
B
0.5 to 1.5
A
Detail B
C
Face to put
dial gauge
Face to put
dial gauge
Section A-A
Mastering position
View C
J1：0°
J2：0°
J3：0°
J4：-90°
J5：-90°
J6：0°
Fig. 6.3 (h) Fixture position master (M-3iA/6A)
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6. MASTERING
B-83155EN/04
A
B
A
0.5 to 1.5
Detail B
C
Face to put
dial gauge
Section A-A
Mastering position
View C
J1：0°
J2：0°
J3：0°
J4：-90°
J5：-90°
J6：0°
Face to put
dial gauge
Fig. 6.3 (i) Fixture position master (M-3iA/6S (A05B-1523-B203))
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6. MASTERING
6
B-83155EN/04
Enter [1], then major axes are mastered.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 1: Major Axis Master **********
Major axes are mastered!
Mastering Data:
J1: 123456
J2: 7890123
J3: -45678
Please press [ENTER]:
_
7
Before performing the wrist axis mastering, major axes are automatically moved to make the upper
and lower universal joints straight. Enter [1] to proceed.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 2: Major Axis Motion **********
In this step, J1~J3 will move to the
position: J1~J3 =
27.0320[deg]
Uninstall all mastering fixtures, and
ensure that no obstacle exists on the
motion path.
Enter [1] to proceed:
_
8
Turn off AUTO mode and TP, reset all alarms and enter [1].
Then, major axes automatically move.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 2: Major Axis Motion **********
Turn to AUTO mode, TP off, abort all TP
programs, and reset all alarms.
If OK, please enter [1].
!!!!!!!!! CAUTION !!!!!!!!!
Robot will move just after
you enter [1].
_
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6. MASTERING
B-83155EN/04
9
Assemble the mastering fixture of wrist axis and dial gauge referring to Fig. 6.3 (c), (d), (e), and
perform wrist axis mastering. Turn on T1/T2 mode and TP. Jog wrist axis to the mastering position.
Let dial gauge of wrist axis touch face of Fig.6.3 (f), (g) and make adjustments so that all the dial
gauges of wrist axis indicate 3 mm. A posture as shown in Fig. 6.3 (f), (g) should be taken. See this
figure for reference.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 3: Wrist Axis Master **********
Turn to T1 or T2 mode and TP on,
then JOG wrist axes to adjust J4
to the mastering position.
If OK, please enter [1]:
_
10
Enter [1], then wrist axes are mastered.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 3: Wrist Axis Master **********
Wrist axes are mastered!
Mastering Data:
J4: 498623
J5: -913124
J6: 8993789
Please press [ENTER]:
_
11
Perform phase matching of universal joint. Jog J4-axis to the posture for universal joint phase
matching. (See Fig.6.3 (j))
Straight bar
Keep these faces parallel
to each other using straight bar.
(Roughly matching without
any accurate fixtures is OK)
Fig. 6.3 (j) Universal joint phase matching
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6. MASTERING
12
B-83155EN/04
Enter [1], then J4-axis universal joint phase matching is performed.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 4: U/J Phase Calibration *********
JOG J4 to the universal joint phase
Calibration position.
!!!!!!!!!!CAUTION !!!!!!!!!
JOG J4. J5 and J6 move automatically.
If OK. please enter [1]:
13
Next, perform universal joint phase matching for J5 and J6 axes. (Only in case of M-3iA/6A)
When universal joint phases matching is performed for all the wrist axes, phase matching data is
displayed.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 4: U/J Phase Calibration ******
Universal joint phases are calibrated!
Calibration Data:
J4: 622490
J5: -853742
J6: 8711359
Please press [ENTER]:
_
14
Then, you finish the mastering procedures.
M-3iA Master
*** Group 1 FIXTURE POSITION MASTER ***
*** Step 5: End ************************
All mastering procedures have done!
Please press [ENTER]:
_
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6. MASTERING
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15
Press the [ENTER] key to return to [Master/Cal] Menu.
SYSTEM Master/Cal
1
2
3
4
5
6
FIXTURE POSITION MASTER
ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ‘ENTER’ or number key to select.
16
Select [CALIBRATE] then press [ENTER] to calibrate the robot.
For the M-3iA/12H
Installing the fixture
1
2
Assemble fixture to robot referring to Fig.6.3 (a).
Adjust the dial gauge to 3.00 mm using the calibration block, and tighten it with M5 bolt as shown
in Fig 6.3 (f). (Do not tighten the bolt too strongly or the dial gauge will be broken.)
Mastering
1
2
3
4
Press the [MENU] key to show screen menu.
Press [0 NEXT] and select [6 SYSTEM].
Press F1 [TYPE] to show screen switching menu.
Select [Master/Cal]. [Master/Cal] screen appears.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.
[ TYPE ]
5
LOAD
RES_PCA
DONE
Release brake control, and jog the robot into a posture for mastering.
Assemble the fixture of major axis and dial gauge referring to Fig. 6.3 (a). Let dial gauge of major
axis touch face of Fig.6.3 (k), and make adjustments so that all the dial gauges of major axis indicate
3 mm. A posture as shown in Fig. 6.3 (k) should be taken. See this figure for reference.
NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.$SV_OFF_ALL
: FALSE
$PARAM_GROUP.$SV_OFF_ENB[*] : FALSE (for all axes)
After changing the system variables, turn the controller power off and on again.
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6. MASTERING
6
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Select “1 FIXTURE POSITION MASTER” and Press F4 [YES].
"MASTER POSITION" shown in Fig. 6.3 (k) is set in this position.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <12200039> <2000319>
[ TYPE ] LOAD RES_PCA
DONE
7
Select “7 CALIBRATE“ and press F4 [YES]. Position arrangement will be performed.
Alternatively, cycle power of the controller to perform position arrangement.
SYSTEM Master/Cal
AUTO JOINT 10 %
TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<
0.0000> <
0.0000> <
0.0000>
<
0.0000> <
0.0000> <
0.0000>
8
After position arrangement is completed, press F5 [DONE].
DONE
F5
9
Return brake control to original setting, and cycle power of the controller.
CAUTION
No check is made on the axis movable range during mastering. Be very careful
when running the robot. Continuing axis movement may bump into the
mechanical stopper.
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6. MASTERING
B-83155EN/04
A
0.5 to 1.5
B
A
Detail B
Mastering position
Section A-A
J1：0°
J2：0°
J3：0°
Fig. 6.3 (k) Fixture position master (M-3iA/12H)
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6. MASTERING
6.4
B-83155EN/04
Q&A (M-3iA/6S/6A)
Q
A
Can I change the screen from the interactive mastering dialog to other display?
Yes. You can come back to the mastering dialog display by pressing [MENU] and [9 User].
Although display of title lines (“M-3iA Master” to “Step n: xxxxx”) will disappear, you can proceed
with no problem.
Q
A
How to abort the interactive mastering dialog.
You can abort it by selecting [FCTN] > [1.ABORT (ALL)].
Be sure to perform mastering again from the first step. If you do not perform it, the robot will fall to
a wrong mastering status.
Q
The interactive mastering is stopped by error during [Step 2: Major Axis Motion] and cannot be
resumed. What should we do?
Q The interactive mastering is stopped by [HOLD] command during [Step 2: Major Axis Motion] and
cannot be resumed. What should we do?
A In this case, you cannot resume the interactive mastering.
- If software version is 7DA7/07 or later, a message “Mastering procedure will be aborted” will be
shown. Press [ENTER] to return to [Master/Cal] menu. The wrist axis will not be mastered due to
the interruption during mastering process. Perform mastering procedure again to complete
mastering.
- If software version is 7DA7/06 or before, no message will be displayed. You must select [Function]
> [1.ABORT (ALL)], then perform mastering again from the first step. If you do not perform it, the
robot will fall to a wrong mastering status.
Q
A
What needs to be done in case a major axis was moved by mistake when performing wrist axis
mastering or universal joint phase matching?
Jog the robot back to its original position by manual operation. The original position is
J1, J2, J3=27.032º.
Note: This operation has an acceptable positional tolerance of ±0.1 deg.
Q
A
Message “Robot Not Mastered!” is displayed and interactive mastering dialog does not start.
Select [FCTN] > [1. ABORT (ALL)] and try mastering again.
Q
A
Warning “SRVO-421 Jnt Phs not calibrated (G1)” is displayed.
On 7DA7/09 or later software version, if you try to set $DMR_GRP.$MASTER_DONE = TRUE
when $DMR_M3_GRP.$MASTER2_ENB = FALSE, this warning is posted. On 7DA7/09 or later
software version, for direct Mastering data entry, set $DMR_M3_GRP.$MASTER2_ENB = TRUE
first. After that, set $DMR_GRP.$MASTER_DONE = TRUE
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6. MASTERING
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6.5
1
2
VERIFYING MASTERING
How to verify that the robot is mastered properly:
Usually, positioning is performed automatically when the power is turned on. To check whether
mastering has been performed correctly, examine if the current displayed position meets the actual
robot position by using the procedure described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0 rad) positions. Check that the zero-degree position
marks indicated in Section 7.3 of OPERATOR’S MANUAL are aligned. There is no need to
use a visual aid.
(3) Using fixtures, set the robot to the mastering position in the same way as when performing
mastering. Check that the displayed current position agrees with the actual mastering
position.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have been
invalidated as a result of an alarm described in 6.2. Alternatively, the mastering data in system
variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation
error or some other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the value of
the system variable on the data sheet.
Alarm type displayed during mastering and their solution method:
(1) BZAL alarm
This alarm is displayed if the Pulsecoder's backup battery voltage decreases to 0 V while the
power to the controller is disconnected. Furthermore, if the Pulsecoder connector is removed
for cable replacement, etc. this alarm is displayed as the voltage decreases to 0. Confirm if the
alarm will disappear by performing a pulse reset (See Section 6.2.). Then, cycle power of the
controller to check if the alarm disappears or not.
The battery may be drained if the alarm is still displayed. Perform a pulse reset, and turn off
and on the controller power after replacing the battery. Note that, if this alarm is displayed, all
the original data held by the Pulsecoder will be lost. Mastering is required.
(2) BLAL alarm
This alarm is displayed if the voltage of the Pulsecoder's backup battery has fallen to a level
where backup is no longer possible. If this alarm is displayed, replace the battery with a new
one immediately while keeping the power turned on. Check whether the current position data is
valid, using the procedure described in 1.
(3) Alarm notification like CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and
SPHAL may have trouble with Pulsecoder, contact your local FANUC representative.
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