Maintenance
Replacing a Robot Teach Pendant
Swap a damaged or failed FANUC iPendant for a compatible replacement on an R-30iB or R-30iB Mate controller, following the powered-down procedure in the maintenance manual. The job covers matching the pendant specification, detaching and attaching the cable at the connector retaining ring, updating the TP firmware when it lags the controller software, and verifying the emergency stop, deadman, and enable switches. Every safety device on the new pendant gets tested before the robot moves under power.
- Step 1.
Confirm the replacement pendant matches the specification
The maintenance manual warns that teach pendant specifications vary with the application, so check the replacement carefully before you install it. Confirm the part number, the controller type, and the display: the R-30iB pendant uses a 640 x 480 screen and the R-30iB Plus uses 1024 x 768. A mismatched pendant may not communicate correctly or may lack the option the cell depends on.
- Step 2.
Record the controller software and TP firmware version
While the old pendant still displays, press MENU, then 0 NEXT, then select 4 STATUS and 2 Version ID. The line labeled TP Core Firmware shows the current teach pendant firmware version, and the software version screen shows the controller series. Write both down so you can decide later whether the new pendant needs a firmware update.
- Step 3.
Bring the robot to a safe, stopped state
Ensure no program is running and the robot is fully stopped before you touch the pendant connection. Confirm there is no queued motion and that servo power is off. Keep clear of the work envelope while you prepare the swap.
- Step 4.
Power off the controller and apply lockout/tagout
The replacement procedure requires that controller power is off before the cable is detached, so turn the controller off at the main disconnect. Apply lockout/tagout so the controller cannot be re-energized while you work. This is the sanctioned method for this controller; do not attempt a live swap it does not document.
- Step 5.
Detach the cable from the old pendant
Release the pendant cable by rotating the connector retaining ring, as the maintenance manual specifies. Support the connector as it frees so the pins are not stressed. Note the orientation so the replacement seats the same way.
- Step 6.
Inspect the pendant cable before reuse
With the cable free, inspect it for chafing, kinks, or damaged connector pins. FANUC troubleshooting steps for pendant faults call for replacing the teach pendant cable (CRS36) when it is inferior, so fit a new cable now if this one is suspect. A marginal cable can mimic a failed pendant after the swap and send you chasing the wrong part.
- Step 7.
Fit the replacement pendant
Put on the anti-static wrist strap before handling the replacement unit. Position the new pendant on its hook or holder and route the cable so it will not be pinched or walked on. Keep the connector clean and free of debris.
- Step 8.
Attach the cable to the new pendant
Mate the connector in the noted orientation and secure it by rotating the retaining ring until it is firmly seated. A loose ring is a common cause of intermittent communication and nuisance faults. Confirm the cable is dressed with strain relief so the connector is not loaded.
- Step 9.
Power on and watch the pendant LEDs
Remove the lockout/tagout and restore controller power. The POWER LED confirms the controller is on, and the FAULT LED indicates an alarm is present. Confirm the display comes up and the status window shows its eight software LEDs, the alarm line, and the override value.
- Step 10.
Clear expected startup e-stop alarms at the cause
A fresh pendant commonly powers up with an emergency stop alarm asserted, such as SRVO-002 Teach pendant E-stop if its button is latched, or SRVO-001 Operator panel E-stop from the operator panel button. Twist the pressed button clockwise to release it, then press RESET. Correct the actual cause and never bypass or force past a latched e-stop.
- Step 11.
Check the TP firmware version against the controller
Open MENU, 0 NEXT, 4 STATUS, 2 Version ID again and read TP Core Firmware on the new pendant. A firmware update is needed when the TP firmware is older than the controller software or from a different software series. If the software version is 7DC1/06 (V8.10P/06) or earlier, or the FROM is smaller than 64MB, this update method does not apply and you contact your FANUC representative.
- Step 12.
Update the TP firmware if it lags the controller
Hold the PREV and NEXT keys together and turn the controller on to reach the configuration menu, then select 3 Controlled start. Press FCTN and choose 1 START (COLD) to launch the update, which the firmware version is checked against during the controlled start and cold start. The update takes a few minutes; do not turn the controller off while it runs, and a cold start completes automatically when it finishes.
- Step 13.
Test the emergency stop button
Press the pendant emergency stop button and confirm the robot loses servo power and an alarm such as SRVO-002 Teach pendant E-stop posts, regardless of the enable switch position. Twist the button clockwise to release it, then press RESET to clear. If the alarm will not clear after release, the maintenance manual points back to replacing the pendant, so recheck the unit rather than forcing the fault.
- Step 14.
Test the three-position deadman switch
With the mode switch in T1 and the pendant enabled, press the deadman to its midpoint to allow motion, then confirm that releasing it or squeezing it hard stops the robot immediately and posts SRVO-003 Deadman switch released. Press the switch back to the middle position to release the condition, then press RESET. Verify this at reduced speed with everyone clear of the envelope.
- Step 15.
Verify the enable switch and mode behavior
Confirm that jogging is possible only when the pendant enable switch is on and the deadman is gripped, which matches the pendant enabled state. Check that the mode switch and enable switch sit at the correct positions for the task; enabling the pendant in AUTO mode posts a warning that you clear with RESET. Keep the switches in the right positions rather than working around the warning.
- Step 16.
Check the touch panel and run a reduced-speed jog test
If the touch panel option is fitted, confirm it registers single touches at the correct locations; a broken panel can report the wrong position, so do not use touch for any operation that affects safety. Confirm the software LEDs and status window read correctly, then jog each axis a short distance in T1 at low override. Only return the robot to production once every safety device and motion check passes.
Common questions
- How long does Replacing a Robot Teach Pendant take?
- Replacing a Robot Teach Pendant is rated Basic and takes about 45 minutes across 16 steps.
- What tools do I need?
- You will need Replacement teach pendant (matching part number, controller type, and software series), Anti static wrist strap, Replacement teach pendant cable (CRS36), used only if the existing cable is worn or damaged, Lockout/tagout hardware for the controller disconnect.
- What should I do before starting?
- Replacement pendant confirmed compatible with the controller model (R-30iB or R-30iB Plus) and its software series. Controller software version and current TP firmware version recorded before removal, so you can tell whether a firmware update is needed. Robot program stopped and the cell secured before the controller is powered off. Access to a controlled start and a cold start, which the firmware update step requires.
- What is the first step?
- Confirm the replacement pendant matches the specification. The maintenance manual warns that teach pendant specifications vary with the application, so check the replacement carefully before you install it. Confirm the part number, the controller type, and the display: the R-30iB pendant uses a 640 x 480 screen and the R-30iB Plus uses 1024 x 768. A mismatched pendant may not communicate correctly or may lack the option the cell depends on.