Mastering & calibration
Mastering After Motor Replacement
For a maintenance technician who has just replaced an axis motor or pulsecoder and needs to restore accurate positioning before returning the robot to production. Single-axis mastering is the typical remaster path for this case.
- Step 1.
Support the arm before any brake release
Before releasing a brake for install or checks, support the arm on a solid support. The arm can fall if it is not supported.
Caution: Never release a brake on a gravity-loaded axis without a solid mechanical support in place.
- Step 2.
Power up and clear alarms
Turn on the controller and confirm the new motor communicates. Clear any initial encoder alarms and perform a pulse reset if required for the axis.
- Step 3.
Confirm the axis moves correctly
In T1 low-speed joint jog with the deadman held, verify the axis moves in the expected direction without unusual noise or resistance.
Caution: Keep the cell clear of other personnel while jogging.
- Step 4.
Jog to the mastering position
Bring the replaced axis to the mastering position appropriate for the method you'll use.
- Step 5.
Perform single-axis mastering
On the pendant, press MENU, then 0 NEXT, then 6 SYSTEM, and select Master/Cal. Choose item 5 SINGLE AXIS MASTER. The screen lists each axis with columns ACTUAL POS, MSTR POS, SEL, and ST. For the replaced axis, set SEL to 1 (if the axis has an interaction pair that must be mastered together, set SEL to 1 for both). Enter the MSTR POS for that axis, which is usually 0. Press F5 EXEC to run the single-axis master. SEL returns to 0 and ST updates when it's done.
- Step 6.
Calibrate and power-cycle
Run CALIBRATE, then restart the controller so the new mastering takes effect.
- Step 7.
Run a full range check
Jog the axis through its full range at low speed to confirm no unexpected limits or alarms.
- Step 8.
Verify against a production point
Run the robot to a known taught position and confirm it matches expected accuracy.
- Step 9.
Back up the updated mastering data
On the pendant, go to File, press F4 BACKUP, and save System files. Mastering data is stored as SYSMAST.SV.
Common questions
- How long does Mastering After Motor Replacement take?
- Mastering After Motor Replacement is rated Intermediate and takes about 45 minutes across 9 steps.
- What tools do I need?
- You will need Teach pendant, Mechanical support for the affected arm segment.
- What should I do before starting?
- New motor or pulsecoder is mechanically installed and correctly wired.. Brake and encoder cabling verified before power-up.. The affected axis has been supported so it cannot fall..
- What is the first step?
- Support the arm before any brake release. Before releasing a brake for install or checks, support the arm on a solid support. The arm can fall if it is not supported.