How long does Replacing Robot Arm Encoder Batteries take?

Replacing Robot Arm Encoder Batteries is rated Intermediate and takes about 30 minutes across 8 steps.

What tools do I need?

You will need Replacement pulsecoder battery pack (correct part number), Screwdriver.

What should I do before starting?

Controller power available so the pulsecoder count is preserved during the swap. Emergency Stop button accessible at the operator panel or teach pendant. Battery box location on the robot base identified for the model.

What is the first step?

Confirm the battery replacement interval. Check the maintenance manual for the recommended interval and any low-battery alarm in the fault log.

Maintenance

Replacing Robot Arm Encoder Batteries

For maintenance technicians performing scheduled replacement of the absolute pulsecoder backup batteries in the robot base battery box, preventing loss of mastering data.

Intermediate~30 min8 steps

Step 1.
Confirm the battery replacement interval
Check the maintenance manual for the recommended interval and any low-battery alarm in the fault log.
Step 2.
Keep controller power ON, but drop servo/motion power via E-Stop
Leave the controller powered ON so the pulsecoder count is preserved during the swap. Before approaching the robot base, press the Emergency Stop on the operator panel or teach pendant so servo power is removed and the arm cannot move. Controller power staying on is not the same as motion power being on: E-Stop drops the servo amplifiers while the CPU and encoder backup circuit remain energized.
Caution: Do NOT open the main disconnect or perform full LOTO of the controller. Killing controller power during the swap will cause loss of the encoder count and force remastering.
Step 3.
Verify the robot cannot move before approaching the base
Confirm the E-Stop is latched in and that the teach pendant or operator panel shows a servo-off / E-Stop condition. Keep clear of the arm work envelope on the approach to the base and do not place any body part under the arm or counterweight while working.
Caution: Even with E-Stop pressed, treat the arm as capable of settling under gravity on some axes. Stay clear of pinch points.
Step 4.
Locate the battery box on the robot base
Find the battery box on the robot base and remove its cover.
Step 5.
Remove the old battery pack
Disconnect the connector and take out the old battery pack.
Step 6.
Install the new battery pack
Fit the new pack into the holder and reconnect the connector securely.
Step 7.
Close the battery box
Refit the cover on the battery box.
Step 8.
Release E-Stop and verify mastering data is intact
Step clear of the robot, then release the Emergency Stop and reset any faults from the pendant. Check for a SRVO-062 BZAL or SRVO-065 BLAL alarm. If BZAL appears, set $MCR.$SPC_RESET to TRUE and remaster before returning the robot to production. Do not rely on a power cycle to clear these alarms.

Tools

Replacement pulsecoder battery pack (correct part number)
Screwdriver

Before you start

Controller power available so the pulsecoder count is preserved during the swap
Emergency Stop button accessible at the operator panel or teach pendant
Battery box location on the robot base identified for the model

Safety

!Distinguish controller power from servo/motion power. Controller power must remain ON to preserve the encoder count. Motion power must be OFF via Emergency Stop before anyone approaches the robot base.
!Press and confirm E-Stop before opening the base battery box. Never reach toward the base with servo power live.
!Do not perform main-disconnect LOTO for this task. Removing controller power will drop the pulsecoder backup and force remastering.
!Keep clear of the arm envelope and pinch points while at the base; arm segments can settle under gravity even with servo power off.
!Do not delay the battery swap once a low-battery warning appears; a delay may cause a BZAL and loss of position data.
!Dispose of old batteries per local hazardous waste regulations.
!If mastering data is lost, do not run production programs until the robot has been remastered.

fanuc diagnosing mastering loss troubleshooting mastering alarms

Common questions

How long does Replacing Robot Arm Encoder Batteries take?: Replacing Robot Arm Encoder Batteries is rated Intermediate and takes about 30 minutes across 8 steps.
What tools do I need?: You will need Replacement pulsecoder battery pack (correct part number), Screwdriver.
What should I do before starting?: Controller power available so the pulsecoder count is preserved during the swap. Emergency Stop button accessible at the operator panel or teach pendant. Battery box location on the robot base identified for the model.
What is the first step?: Confirm the battery replacement interval. Check the maintenance manual for the recommended interval and any low-battery alarm in the fault log.

Replacing Robot Arm Encoder Batteries

Confirm the battery replacement interval

Keep controller power ON, but drop servo/motion power via E-Stop

Verify the robot cannot move before approaching the base

Locate the battery box on the robot base

Remove the old battery pack

Install the new battery pack

Close the battery box

Release E-Stop and verify mastering data is intact

Common questions