B81524EN/01 APPENDIX

B.2 Mastering
Mastering associates the angle of each axis of the robot with the pulse count of the absolute pulse coder (APC)
connected to the motor of each axis. More specifically, mastering is performed by obtaining the pulse count read
at the zerodegree position.
The current position of the robot is determined by the pulse counts of the absolute pulse coders (APCs) for the
axes.
Since mastering data is factoryset, mastering is unnecessary in normal operation. If one of the following events
occurs, however, mastering must be performed:
F Mastering data is lost for some reason such as a drop in the voltage of the backup battery for CMOS in
the controller or memory erasing with an initial start.
F The APC pulse counts are lost for some reason such as a drop in the voltage of the backup battery for APC
pulse counts backup in the mechanical unit or exchange of pulse coder.
F The pulse counts do not indicate the angles of the axes because the mechanical unit was hit bumped, etc.

CAUTION
The robot data including mastering data and the pulse coder data are maintained independently by
backup batteries. If the batteries go empty, data is lost. To prevent this, replace both batteries periodically.
When the battery voltage drops, an alarm BLAL notifies the user.

There are five types of mastering as listed below.

Table B1. Mastering types

Type of mastering Explanation
Jig mastering Mastering is performed using a special jig. Jig mastering is
performed at the factory.
Mastering at the zerodegree positions Mastering is performed with each axis of the robot aligned with
the zerodegree position. The zerodegree position mark
attached to each axis of the robot is referenced.
Quick mastering The mastering position can be set at any position. To do this,
reference points must be set in advance.
Single axis mastering Single axis mastering is that the mastering is performed every
one axis.
Setting mastering data Mastering data is set in mastering counters directly.

CAUTION
After the robot is installed, the quick mastering reference points should be stored in case the
factoryadjusted settings are needed in mastering in the future.

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After mastering, be sure to perform positioning (calibration). Positioning means that the controller reads the
current pulse counts and recognizes the current position.

Figure B2. Mastering

Mastering table 1
Angle of axis pulse count
1 deg 144,000

$PARAM_GROUP . $ENCSCALE
Mastering table 2
Angle of axis pulse count
90 deg 28,600,000

9 deg 16,900,000 Quick mastering

Mastering at the
0 deg 15,600,000
zerodegree positions
$DMR_GRP . $MASTER_COUN

90 deg 2,600,000 Jig mastering

The current position of the robot is determined by the following data:

F Pulse count per degree (See mastering table 1.) This value is defined in system variable
$PARAM_GROUP.$ENCSCALE.
F Pulse count at the zerodegree position (See mastering table 2.) This data is stored in
$DMR_GRP.$MASTER_COUN by mastering.
In jig mastering, the pulse count at the jig position is received and converted to mastering data.
In quick mastering, the pulse count at the quick mastering reference position defined by the user is
received and converted to mastering data.
F Current pulse count. The current pulse count is received from the by calibration.
Mastering and calibration are performed on the Master/Cal screen [6 SYSTEM, Master/Cal].
NOTE Mastering by mistake may cause the robot to move unexpectedly and it is very dangerous. Therefore,
the Master/Cal screen will be displayed only when the system variable, $MASTER_ENB, is set to 1 or 2. Press
F5,DONE,which is displayed in the Master/Cal screen after mastering. $MASTER_ENG is automatically set to
0 and then the Master/Cal screen can not be displayed. If you want to display the Master/Cal screen again, set
$MASTER_ENB to 1 in the system variable screen again.

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B.2.1 Jig mastering

Jig mastering is performed at the factory using a special jig. This mastering is performed at the mastering position
set beforehand.
With this mastering, the accurate mastering can be performed by using the special jig.
This mastering is usually unnecessary to perform it in normal operation because this is used at shipment.
For details of jig mastering, refer to the maintenance manual.

Procedure B6 Jig mastering

Condition H System variable $MASTER_ENB must be set to 1 or 2.

SYSTEM Variables JOINT 10%

57/136
57 $MASTER_ENB 1

Step 1 Press the MENUS key. The screen menu is displayed.

2 Select 0 NEXT and then select 6 SYSTEM.
3 Press F1, [TYPE]. The screen change menu is displayed.
4 Select Master/Cal on the screen change menu. The positioning screen appears.

9 USER
0 NEXT SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
MENUS
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 POSITION 5 SET QUICK MASTER REF
6 SYSTEM 6 CALIBRATE
7
Press ENTER or number key to select.
Master/Cal
[TYPE] LOAD RES_PCA DONE
TYPE

F1

5 Move the robot by jog feed to the mastering position. Release the brake on the manual brake control screen
if necessary.
6 Select 1 FIXTURE POSITION MASTER and press the F4 key (yes). Mastering data is set.

SYSTEM Master/Cal SYSTEM Master/Cal JOINT 30 %

ENTER
1 FIXTURE POSITION MASTER 1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER 2 ZERO POSITION MASTER
Master at master position? [NO] 3 QUICK MASTER
4 SINGLE AXIS MASTER
Master at master position? [NO] 5 SET QUICK MASTER REF
[ TYPE ] YES NO 6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>
F4
[ TYPE ] LOAD RES_PCA DONE

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7 Select 6 CALIBRATE and press the F4 key (yes). Calibration is performed.

5 SET QUICK MASTER REF

SYSTEM Master/Cal JOINT 30 %
6 CALIBRATE
Calibrate? [NO] ENTER
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
Calibrate? [NO] 3 QUICK MASTER
[ TYPE ] YES NO 4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
F4 Robot Calibrated! Cur Jnt Ang(deg):
<10.000> <25.000> <40.000>
<5.000> <15.000> <0.000>
[ TYPE ] LOAD RES_PCA DONE

8 Press F5 DONE, after mastering.

DONE

F5

9 Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed
whenever the power is turned on.

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B.2.2 Mastering at the zerodegree positions

Mastering at the zerodegree positions is performed for the robot with its all axes at the zerodegree positions.
On each axis of the robot, a zerodegree position mark is attached. Using these marks as a reference, move
the robot by jog feed to the zerodegree positions for all axes.
Mastering at the zerodegree positions cannot be performed as accurate by as other types of mastering
because it relies on visual adjustment. Perform mastering at the zerodegree positions only as an emergency
measure.
For details of mastering at the zerodegree positions, refer to the maintenance manual.

Procedure B7 Mastering at the zerodegree positions

Condition H System variable $MASTER_ENB must be set to 1 or 2.

Step 1 Press the MENUS key. The screen menu is displayed.
2 Select 0 NEXT and then select 6 SYSTEM.
3 Press F1, [TYPE]. The screen change menu is displayed.
4 Select Master/Cal on the screen change menu. The Master/Cal screen appears.
9 USER
0 NEXT SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
MENUS
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 POSITION 5 SET QUICK MASTER REF
6 SYSTEM 6 CALIBRATE
7
Press ENTER or number key to select.

Master/Cal [TYPE] LOAD RES_PCA DONE

TYPE

F1

5 Move the robot by jog feed to the zerodegree positions for all axes. Set brake control to off, if necessary.
6 Select 2 ZERO POSITION MASTER and press the F4 key (yes). Mastering data is set.

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER ENTER SYSTEM Master/Cal JOINT 30 %
3 QUICK MASTER
Master at zero position? [NO] 1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
YES NO 4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
F4 Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>

[ TYPE ] LOAD RES_PCA DONE

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7 Select 6 CALIBRATE and press the F4 key (yes). Calibration is performed.

5 SET QUICK MASTER REF

6 CALIBRATE SYSTEM Master/Cal JOINT 30 %
Calibrate? [NO] ENTER
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
YES NO 4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
F4 Robot Calibrated! Cur Jnt Ang(deg):
<0.000> <0.000> <0.000>
<0.000> <0.000> <0.000>

[ TYPE ] LOAD RES_PCA DONE

8 Press F5 DONE, after mastering.

DONE

F5

9 Alternatively, to perform calibration, turn the power off, then turn it on again. Calibration is performed
whenever the power is turned on.

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B.2.3 Quick mastering

Quick mastering allows mastering at any userdefined position. The pulse counts are calculated from the speed
and angular displacement within one rotation of the APCs connected to the motors. Quick mastering uses the
fact that the absolute angular displacement within one rotation is not lost.
F If mastering data is lost due to the empty of the backup battery for the pulse coder, quick mastering can be
used.
F When the pulse coder is replaced or when mastering data in the robot controller is lost, quick mastering
cannot be used.
To perform simple mastering, a reference point set after mastering is necessary ( reference point setting). The
reference point is factoryset to the zero position.

Figure B3. Quick Mastering

Angle of axis 9 deg 10 deg

Absolute pulse corder value 260,000 304,000 1 deg = 144,000

1 rotation = 520,000

Pulse count 16,900,000

Quick mastering uses the fact that the deviation of the angle of the axis from the reference point can accurately
be compensated when it is within one rotation of the APC.
For details of quick mastering, refer to the maintenance manual.

CAUTION
If the robot is installed in such a way that the robot cannot be set to the 0 position, which is the reference
point of initial simple mastering, the reference point of simple mastering should be stored after the
installation. This must be done to store the factoryset mastering setting, providing for future mastering.

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Procedure B8 Quick mastering

Condition H System variable $MASTER_ENB must be set to 1 or 2.

H Quick mastering reference position (reference position) must be set.
Step 1 Display the Master/Cal screen.

SYSTEM Master/Cal JOINT 30%

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

2 Jog the robot to the quick mastering position(reference position). If it is necessary,turn off the brake control.
3 Select 3 QUICK MASTER and press the F4 key (yes). Mastering data is set.

2 ZERO POSITION MASTER

3 QUICK MASTER
4 SINGLE AXIS MASTER ENTER

YES NO

F4

4 Select 6 CALIBRATE and press the F4 key (yes). Calibration is performed.

5 Press F5 DONE after mastering.

DONE

F5

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Procedure B9 Setting reference points for quick mastering

(If the robot is installed in such a way that the robot cannot be set to the 0 position)

CAUTION
This operation cannot be executed if the mastering data is lost because of mechanical disassembly or
maintenance. If that is the case, jig mastering or zerodegree positions mastering should be executed
to restore the mastering data.

Condition H System variable $MASTER_ENB must be set to 1 or 2.

Step 1 Select 6 SYSTEM on the screen menu.
2 Select Master/Cal on the screen change menu. The Master/Cal screen appears.

5 POSITION
6 SYSTEM SYSTEM Master/Cal JOINT 30%
7
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
MENUS
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Master/Cal
Press ENTER or number key to select.
TYPE
[TYPE] LOAD RES_PCA DONE

F1

3 Move the robot by jog feed to the quick mastering reference position. Set brake control to off, if necessary.
4 Select 5 SET QUICK MASTER REF and press the F4 key (yes). The reference points for quick mastering
are stored in memory.

4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF
6 CALIBRATE ENTER

YES NO

F4

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B.2.4 Single axis mastering

User can select the arbitrary position for the mastering of each axis.
Single axis mastering should be used when the mastering data of some axes is lost for some reason such as
the drops of the voltage of the backup battery for pulse coder or exchanging of the pulse coder.

SINGLE AXIS MASTER JOINT 30 %

1/9
ACTUAL POS (MSTR POS ) (SEL)[ST]
J1 25.255 ( 0.000) (0) [2]
J2 25.550 ( 0.000) (0) [2]
J3 50.000 ( 0.000) (0) [2]
J4 12.500 ( 0.000) (0) [2]
J5 31.250 ( 0.000) (0) [2]
J6 0.000 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [2]
E2 0.000 ( 0.000) (0) [2]
E3 0.000 ( 0.000) (0) [2]

GROUP EXEC

Table B2 Settings for single axis mastering

ITEMS DESCRIPTIONS
ACTUAL POS The current position expressed by joint (degree) of the robot is displayed.
MSTR POS Specifies the mastering position to the axis to be performed the single axis mastering. It is
usually specified 0 degree.
SEL For the axis to be performed mastering,set this item to 1. It is usually 0.
ST Display the state of completion of the single axis mastering. The value displayed at this item
can not be directly changed. The values of $EACHMST_DON[1 to 9] are displayed at this
column.
0 Specifies that the mastering data has been lost. The single axis mastering need to
be performed.
1 The mastering data has been lost.(Only other interactive axes is performed master-
ing.) This axis need to be performed mastering.
2 The mastering has been completed.
Refer to the maintenance manual for an accurate method of single axis mastering.

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Procedure B10 Single axis mastering

Condition H System variable $MASTER_ENBL must be set to 1.

Step 1 Select 6 SYSTEM on the screen menu.
2 Select Master/Cal on the screen change menu. The Master/Cal screen appears.

5 POSITION
6 SYSTEM SYSTEM Master/Cal JOINT 30%
7
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
MENUS
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Master/Cal
Press ENTER or number key to select.
TYPE
[TYPE] LOAD RES_PCA DONE

F1

3 Select 4 SINGLE AXIS MASTER. The single axis mastering screen is displayed.

In the example on the mastering SINGLE AXIS MASTER JOINT

30 %
1/9
of J2 and the J3 axis needs to be ACTUAL POS (MSTR POS ) (SEL)[ST]
executed. J1 25.255 ( 0.000) (0) [2]
J2 25.550 ( 0.000) (0) [0]
J3 50.000 ( 0.000) (0) [0]
J4 12.500 ( 0.000) (0) [2]
J5 31.250 ( 0.000) (0) [2]
J6 0.000 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [2]
E2 0.000 ( 0.000) (0) [2]
E3 0.000 ( 0.000) (0) [2]
GROUP EXEC

4 Enter 1 to SEL setting field of the axis that you want to perform the mastering. SEL can be specified every
one axis or plural axes simultaneously.

R JOINT 30 % SINGLE AXIS MASTER JOINT 30 %

2/9 3/9
( 0.000) (0) [0] J2 25.550 ( 0.000) (1) [0]
( 0.000) (0) [0] J3 50.000 ( 0.000) (1) [0]

GROUP EXEC

5 Jog the robot to the mastering position. Turn off the brake control if it is necessary.
6 Enter the axis data of the mastering position.

R JOINT 30 % SINGLE AXIS MASTER JOINT 30 %

2/9 3/9
( 0.000) (1) [0] J2 25.550 ( 0.000) (1) [0]
( 0.000) (1) [0] J3 50.000 ( 90.000) (1) [0]

GROUP EXEC

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7 Press F5 EXEC. The mastering is performed. This operation causes that SEL is set to 0 and ST is set to
2 or 1.

GROUP EXEC SINGLE AXIS MASTER JOINT

30 %
1/9
ACTUAL POS (MSTR POS ) (SEL)[ST]
F5 J1 25.255 ( 0.000) (0) [2]
J2 25.550 ( 0.000) (0) [2]
J3 50.000 ( 90.000) (0) [2]
J4 12.500 ( 0.000) (0) [2]
J5 0.000 ( 0.000) (0) [2]
J6 0.000 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [2]
E2 0.000 ( 0.000) (0) [2]
E3 0.000 ( 0.000) (0) [2]
GROUP EXEC

8 When the single axis mastering is completed, press the PREV key to display the Master/Cal screen.

PREV SYSTEM Master/Cal JOINT 30%

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

9 Select 6 CALIBRATE and press F4 YES. The calibration is performed.

10 Press F5 DONE, after calibration.

DONE

F5

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B.2.5 Setting mastering data

Mastering data can directly be set to the system variable. Setting mastering data can be performed when the
pulse counts are not changed.
F If CMOS mastering data is lost for some reason such as an initial start, set the recorded mastering data.
F Setting mastering data cannot be performed when pulse count data is lost.

Procedure B11 Directly setting mastering data

Step 1 Select 6 SYSTEM on the screen menu.

2 Select Variables on the screen change menu. The system variable screen appears.

5 POSITION
6 SYSTEM SYSTEM Variables JOINT 10%
7 1/98
1 $AP_MAXAX 536870912
2 $AP_PLUGGED 4
MENUS 3 $AP_TOTALAX 16777216
4 $AP_USENUM [12] 0f Byte
5 $AUTOINIT 2
6 $BLT 19920216
Variables [TYPE]
TYPE

F1

3 Change mastering data.

Mastering data is stored in system variable $DMR_GRP.$MASTER_COUN.

13 $DMR_GRP DMR_GRP_T
14 $ENC_STAT [2]of ENC_STAT_T

[TYPE]

4 Select $DMR_GRP.

DMR_GRP_T
[2] of ENC_STAT_T SYSTEM Variables JOINT 10%
$DMR_GRP 1/1
1 [1] DMR_GRP_T
ENTER

SYSTEM Variables JOINT 30 %

$DMR_GRP 1/8
1 $MASTER_DONE FALSE
2 $OT_MINUS [9]of Boolean
3 $OT_PLUS [9]of Boolean
4 $MASTER_COUN [9]of Integer
5 $REF_DONE FALSE
6 $REF_POS [9]of Real
7 $REF_COUNT [9]of Integer
8 $BCKLSH_SIGN [9]of Boolean
[ TYPE ] TRUE FALSE

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5 Select $MASTER_COUN and enter mastering data.

[9] of Boolean
SYSTEM Variables JOINT 10%
[9] of integer
$DMR_GRP[1].$MASTER_COUN 1/9
FALSE
1 [1] 95678329
2 [2] 10223045
3 [3] 3020442
ENTER 4 [4] 304055030
5 [5] 20497709
6 [6] 0

[TYPE]

6 Press the PREV key.

7 Set $MASTER_DONE to TRUE.

TRUE FALSE SYSTEM Valiables JOINT 10%

$DMR_GRP[1] 1/8
1 $MASTER_DONE TRUE
F4 2 $OT_MINUS [9]of Boolean

8 Display the Master/Cal screen and select 6 CALIBRATE.

9 Press F5 DONE, after calibration.

DONE

F5

590