1.
Professor Kevin Schmidt
Computer Integrated Manufacturing
Integration Project Report
CIM­251­IND
12/22/2015
By: Aviv Shazar & Petros Tabactsidis

2. Table of Contents
1. Introduction
2. Powering up the Controller, iPendant, & Robot
3. R­30iB iPendant
a. Emergency Stop
b. Teach Pendant
c. Deadman Switch
d. i​ Key Shortcuts
4. Jogging
a. Step by Step Tutorial
b. Jog Speed
5. Motion Instruction
a. Motion Type
b. Position Info
c. Speed
d. Termination Type
e. Motion Option
6. Alarm Error & Fault Recovery
a. Recovering from Common Faults
b. Displaying the Alarm Log
7. Creating a Program
a. Name Program
b. SHIFT+FWD/BWD
c. Step Mode
8. Mastering
a. Calibrating

3. Introduction
When the semester started we were tasked with learning as much as we possibly
could about the FANUC LR Mate 200id 4s robots. The primary task was to get each of
the robots to the point where they could be jogged and programs could be written.
Because Aviv had used the robots in similar fashion last semester he was able to teach
me, Petros, a lot of the basics. Aviv was able to teach me how to jog the robot closest to
the certification cart. Eventually, he was able to run programs on this robot. The issue
was that there were changes that needed to be applied in the DCS Parameters. I
discuss the process in the Mastering chapter of this report. For the other two robots I
calibrated them and applied the DCS Parameters. Around week 10 of this semester the
manuals arrived which gave us a renewed interest. We came to find just how little we
really knew about the robots. The manuals have taught us quite a bit including
correcting some of the techniques we were using for various things. Prior to getting the
books we would create programs that were cool to watch but nothing more than that.
Thanks to the manuals we were able to better understand how each instruction works.
In our report we highlighted what we felt was the most important information someone
should know. We hope you enjoy.

4. Powering Up Controller, Robot, & iPendant
When powering up the robot, there are
five startup methods but the four basic methods
are: Cold start, controlled start, hot start, and
initialized start.

5.
Cold Start
When doing a cold start a few things happen. It
initializes changes to system variables, initializes
changes to I/O setup, and displays the utilities hints
screen. To accomplish this, the procedure is as
follows: Turn the power disconnect circuit breaker or
power switch on the operator panel to ON. This is the
procedure you will follow in most cases and can be
used in place of other start options as long as it is safe.
Controlled Start
When doing a controlled start it allows you to do
many things some of which are: set up application
specific information, install options and updates, save
specific information, to print teach pendant screens
and the current robot configuration, and to un­simulate
all I/O. (This does not allow you to load teach pendent
programs) To accomplish this, the procedure is as
follows: Turn off the controller. On the teach pendant,
press and hold the PREV and NEXT keys and press
the ON/OFF button on the operator panel. After the
configuration menu screen is displayed, release the
keys. Select Controlled start and press ENTER.
Hot Start
A hot start turns on power to the robot and
controller without entering Boot Monitor. Hot start is
useful when you are in production and an error occurs requiring controller restart. The
controller will restart in the same condition it was prior to shutdown. The steps are fairly
simple to achieve this, go to MENU > SYSTEM > Config. Setup item 1 Hot Start to
TRUE.
Initialized Start
An initialized start occurs automatically as the first phase of software installation.
An initialized start erases all information stored in the saved memory pools. To do this
just press and hold F1 and F5 and press the ON/OFF button or main disconnect.

6. R­30iB iPendant
The R­30iB iPendant has a color graphics interface. You’re now given pop­up
menus with the ability to have multiple windows open at once if needed. New to the
R­30iB is an integrated help and diagnostics interface. Many options that appear on the
screen are can be selected with the physical buttons or by simply pressing the touch
screen. While the iPendant will be used for most operations involving the robot it is
important to understand that many options are only executable when the Teach
Pendant is on.

7.
Emergency Stop
The emergency stop button is located on the upper right of the iPendant. The purpose
of the emergency stop is to stop the robot immediately in case of an accident or any
type of fault or failure. It is also an extension of the stop button located on the controller
so it will work whether the teach pendant feature is on or off.
Teach Pendant
ON/OFF Teach Pendant
In the upper left corner of the iPendant there is a switch for
enabling teach pendant. When disabled, you will not be able to
jog the robot. Therefore, in order to create a program you’ll
need to enable the teach pendant.
Deadman Switch
The Deadman Switch is used as a safety precaution
while teach pendant is on as a means of interrupting
robot motion in an emergency. It removes power from
the servo motor and applies the brakes to the robot as
soon as it is released. The Deadman Switch has three
positions; releasing and apply excessive force when the
teach pendant is on will remove power and apply the
brakes to the robot. The Deadman Switch is used while
jogging the robot and must be depressed to the middle
position to jog the robot.

8.
KEY SHORTCUTS
New to the R30iB iPendant is the ​i​ ​ key which can be used in combination with
other keys as shortcuts. While it takes some doing to get used to using them they are
quite handy in terms of working more efficiently.
Here are the combinations you can utilize when pressing +
MENU Displays the top menu.
FCTN
Displays the Related View Menu if ​i ​ is displayed on the right side of the
title line.
SELECT Displays the Select menu in the left pane and 3D node map in the right
pane for the program which is highlighted by the cursor
EDIT Displays the TPP editor in the left pane and 3D nope map in the right
pane.
DATA Displays the position register data in the left pane and a 3D display
position register in the right pane.
POSN Presents a 3D display of the robot using the last selected scene.
COORD Toggle jog preview on or off.
Jog Keys Shows you the direction the robot will move when pressing any of the Jog
keys if you are already displaying the 3D screen.
DISP Switches the display to the next window if one is available.

9. Jogging
This section will cover manually jogging the robot. Jogging refers to any
movement involving the robot axes. There are different reasons to manually jog the
robot. Some examples would include the robot exceeding its positional limits, the robot
colliding with itself or another object, and most often when you’re creating a program.
Step by Step Tutorial
1. Turn power switch to the on position from the
controller.
2. Turn the key from
AUTO to <250mm/s T1

10.
3. Turn Teach Pendant to the ON position
*Note this will cause an alarm
4. The upper left is where you will see
a red block that reads “fault”. To the
right of that you can find the error or
alarm. In this case we are simply
going to “reset” the alarm.

11.
These two yellow switches are referred to as the
“Deadman Switch”
5. The next step is to hold either one or
both of the Deadman Switches but only
halfway.
(Press without excessive force)

12.
6. While holding the Deadman Switch press and
release the RESET key to clear the fault
*The Deadman Switch HAS to be held down to keep the
robot from faulting
7. Now for the last step, make sure there are no
faults/alarms and hold down the Deadman
Switch (without excessive force) and hold down
the SHIFT key while pressing the
corresponding X,Y,Z keys
● J1 corresponds to the base or waist
● J2 corresponds to the shoulder
● J3 corresponds to the elbow
● J4 corresponds to the rotation of the arm
● J5 corresponds to the pitch of the wrist
● J6 corresponds to the rotation of the face
plate
● J7 (Optional for End of Arm Tooling)
Jog Speed

13.
Some examples of jog speed. From left to right, 100%, 50%, 5%, FINE, VFINE
The percentage in the top right corner of the iPendant is the jog speed. The
possible speed values are 100, 95, 90, 85, … 20, 15, 10, 5, 4, 3, 2, 1, FINE, VFINE.
When holding the SHIFT key and pressing the up or down percentage arrows on
the bottom, you can change between 100, 50, 5, 1, FINE, VFINE.
Keep in mind to set the speed to a value that is appropriate for the conditions of
the workplace, type of work the robot will do, and personal experiences. Using a slow
jog speed until you are comfortable with the robot is important. The slower the jog
speed, the more control you have over the robot motion.

14. Motion Instruction
Motion instructions direct the robot to move in a specific way to the appointed
destination at a specific speed. All movements are made using the iPendant while
Teach Pendant is on. While creating a program most lines will be motion instructions.
Please remember that even with the following information there may be other
parameters or instructions necessary for your specific task.
1. Motion Type​ ­ This defines
how the robot will move to
the destination position. It
is specified in the program
not by how the robot was
jogged to the point.
a. Joint Motion​ ­ The robot moves all required
axes simultaneously to the destination and is
programmed at the end position.
b. Linear Motion​ ­ The robot moves the tool center
point in a straight line from the start position to
the end position and is programmed at the end
position.
c. Circular Motion​ ­ The robot moves the tool
center point in an arc from the start position
through an intermediate position. Keep in mind
that this is programmed at the intermediate
position meaning you are plotting two points for a
circular motion.
2. Positional Info​ ­ This described the location, orientation, and configuration of the
tool center point when a motion instruction is added to a program. Position
information is added when the motion instruction is added to the program.
a. Position Registers (PR)​ ­ Can be used to store global positions. Some examples might be
a user created HOME position or registering a position for when the robot is having
maintenance done. PR positions can be used by many programs unlike Teach Pendant
positions which are only available in the program they were created in.

15. 3. Speed ​­ Depending on the motion type, speed can be specified in percentage,
length (mm/sec, cm/min, inch/min), degrees of angle units, or length of time to
execute a move
a. Joint Motion Speed​ ­ Typically speed is defined as either a percentage of the maximum
robot speed or time.
b. Linear Motion Speed​ ­ Typically defined by a velocity (distance / time)
c. Circular Motion Speed​ ­ Like Linear motion, typically defined by a velocity.
4. Termination Type​ ­ The type you choose will determine how your robot ends
each motion instruction.
a. Fine Termination (FINE)​ ­ This causes the robot to stop at the destination position before
moving to the next position. The robot’s tool accelerates to the defined speed, and then
decelerates as it approaches the recorded position and comes to a complete stop before
continuing to the next recorded position.
b. Continuous Termination (CNT)​ ­ The robot will decelerate as it nears its destination but
will not come to a complete stop. This is the fastest option when speed is a priority. When
entering a CNT termination a number will follow from 0­100. The lower the number the
slower and more precise the robot is during each movement. The closer you get to 100 the
faster and less accurate the robot becomes.
5. Motion Options​ ­ Additional instruction can be given to the robot to determine
what the robot will do when it reaches its destination. These options are used to
provide information to perform specific tasks during robot motion.

16. Alarm Error & Fault Recovery
Most alarm errors and faults can be cleared by correcting the program and using
the RESET key. You can identify these alarms by looking at the top of the display. Look
for yellow or red highlighted text.
The first two pictures are examples of errors and faults. The third and lowest picture
was taken after resetting the iPendant.
1. Recovering from Common Faults
While not all faults will be easy to diagnose, when a fault occurs you should first
try to identify the type of error.
○ Hardware ​­ This could be broken cable or tooling.
○ Software ​­ This could be incorrect program data.
○ External ​­ This could be an open safety door, moving outside the limits of the robot, or an
emergency stop.

17.
2. How to Find and Display the Alarm Log
When you troubleshoot it is usually in your best interest to view active alarms in
the Alarm Log. Here is a step by step tutorial on how to display it:
○ Step 1: Press the MENU button
○ Step 2: Press Alarm on the screen
○ Step 3: Press F3, Hist.
○ Step 4: Press F1, TYPE, to view motion errors. Application­specific errors,
communication errors and password errors.
○ Step 5: To display more information about an error, move the cursor to the
error and press F5, DETAIL. The error detail screen displays information
specific to the error you selected, including the severity. If the error has a
cause code, the cause code message will be displayed.
○ Step 6: To remove all of the error messages displayed on the screen,
press and hold SHIFT and press F4, Clear.

18. *We found a website while researching that can answer most problems on any
alarm/fault. It provides the same information that the iPendant has but can be helpful
when you are not near the robot. http://www.linuxsand.info/fanuc/code/motn

19. Creating a Program
It is important to understand the different options
available when it comes time to make movements with the
robot. It is suggested that you look back at the Robot
Movements chapter to better understand your choices. When
writing a program you must first be sure to have your teach
pendant in the on position and that you are in T1 mode on the
controller.
Name the Program
1.​ ​On the teach pendant, press the button labeled SELECT
2.​ ​Press F2 (CREATE)
3.​ ​Name your program and press enter twice.
4.​ ​You are now ready to start inputting instructions
Creating a program can take a lot of time. When
instructing the robot you want to be as precise as possible with
each line of instruction. It can be helpful to name specific steps
during the process to help you better differentiate between
lines. Each line will have what is considered a motion instruction. A motion instruction is
made up of a motion type, positional information, a termination type, speed, and motion
options. All of these are better explained in the Motion Instruction chapter.
SHIFT + FWD/BWD
While creating a program or simply anytime you have teach pendant on and the
controller is in T1 mode pressing SHIFT in combination with the FWD or BWD key will
allow you to run a program step by step or completely. Like many options, this is
something that needs to be enabled in order to use. To enable this, press the FUNC key
on the iPendant and select the option that says disable FWD/BWD. While it may be
confusing, this option always reads “disable FWD/BWD” regardless of whether it is
enabled or disabled. While testing this option it appeared that you can only run a
line/program at a maximum of 50% total speed.

20.
STEP MODE
Step mode will allow you to run your program one line at a time when enabled.
This can be used while editing a program in combination with SHIFT+FWD/BWD or
when the controller is in auto mode and the TP is off. When the TP is off you and STEP
mode is enabled you press the green button on the controller after each step.

21. Mastering
When mastering a robot you are defining the physical location of the robot by
synchronizing the mechanical information with the robot's own position. Generally,
FANUC robots are mastered before being shipped and while unlike robots may lose
their mastering data and require being re­mastered.
*I was able to find a forum online that explained how to calibrate the robot. I used
this forum as my guide because at the time we did not have the manuals that we now
have. After reading from the chapter that discusses mastering I gained a much better
understanding of what mastering the robot really meant. The most important lesson was
that it is not something to mess around with. If it is determined that you need to master
something on the robot it is advised that you check the manual before proceeding.
However, when I calibrated the robot it just so happens that I used the correct
procedure. Here is what I did:
CALIBRATING
The two robot furthest left are the robot that I calibrated. Here is what I did:
1. Press MENU> and go to
NEXT>

22.
2. Then go to SYSTEM>
Move to the right and select VARIABLES
3. Scroll down until you find $DMR_GRP (its
item 193)

23.
4. Press DETAIL (F2) and at the next screen press
DETAIL again
(I didn’t have the $REF_COUNT calibrations but assuming
you did)
5. To fix a calibration error you want to go to
$REF_COUNT and press ENTER. Once there you can
enter the calibrations that are provided on the
Inspection Data Sheet. After you have entered them
press the PREV button on the teach pendant.
6. Now find
$MASTER_COUNT and
enter the provided
calibrations from the
Inspection Data Sheet. Hit
PREV to return to the
previous menu.
7. Now make sure that both $MASTER_DONE and $REF_DONE are set to TRUE.
You’re not done yet. After making changes like this you’ll want to do a cold
re­start

24.
8. Go to MENU>NEXT>SYSTEM move
to the right and select DCS
9. Check to see the status of MASTERING
PARAMETER. Since you made a change the
status should not say OK. If not, scroll down
and hit APPLY. You may need to enter the
master code. After this, restart again and you
should be done.