This section details how to perform mastering using the teach pendent.

Mastering is necessary in some situations where the pulse counter batteries died, or the arm position moved while power was OFF.

Follow the steps below for mastering the cobot and resetting the pulse counter alarms.

Follow this video to connect to the virtual teach pendent on a laptop.

Go into the Navigate iPendent to check Master/Cal is enabled.

Click MENU>NEXT>SYSTEM>Master/Cal, it will pop-up in the list on the screen as shown.

Skip this step if Master/Cal is already enabled.

If it is not enabled, follow these steps:

•  Go to the System Variables screen: MENU>NEXT>SYSTEM>Variables
• Scroll down to $MASTER_ENB
• Set $MASTER_ENB to 1 by pressing 1 and pressing enter

Reset Pulsecoder Alarm

Go the the Master/Cal screen: MENU>NEXT>SYSTEM>Master/Cal

Click RES_PCA [1], the pendent will display a message asking if you want to reset pulsecoder alarms.

Click Yes [2], a message will appear as shown that says 'Pulsecoder alarm reset!' [3]

After the pulsecoder alarm has been reset, cycle power on the robot. DO NOT cycle power on the machine.

Re-establish pulse for each axis

When axes lose power, the pulse on each axis needs to be re-established. This is done by jogging each joint at least 10-20 degrees in each direction.

Follow these steps to do this:

• Enter the Jogging iPendent from the Robot Homepage.
• Click the Jog Panel button [1] to open the Jog Panel, make sure the E-Stop on the machine is released.
• Click Reset [2] to reset all faults
• Click the switch [3] to turn it on
• Click Shift [4] and then jog the joints

Note: If an alarm pops up while jogging, reset the alarm and lower the jogging rate [5] until the arm is able to be jogged again. This will happen once the arm has left the DCS zone and it will need to be jogged at a slower rate.

Copy Master Count to Reference Count & Checking the Zero Reference Position

Go back to the Navigate iPendent.

Copy the Master Count values to the Reference Count values by doing the following:

• Go to the System Variables screen: MENU>NEXT>SYSTEM>TYPE>Variables
• Scroll down to $DMR_GRP (should be number 199) and once it is highlighted, hit ENTER twice and the variables shown in [1] should be on the screen.
• Scroll to $MASTER_COUNT and click DETAIL when it is highlighted. Take note of these values.
• Press PREV to go back to the variable list and then go into the $REF_COUNT by pressing DETAIL when it is highlighted. Copy the values from the $MASTER_COUNT by typing them in and pressing enter to change the values.
• Press PREV to go back to the variable list and set $REF_DONE to TRUE

While still inside $DMR_GRP[1] System Variables, go to $REF_POS and make sure the axis values are set to a value of 0 as shown in [2].

Line Up Witness Marks

Go back to the Jogging iPendent, open the Jog Panel and turn on the switch.

Jog each joint so that the witness marks line up, use the image shown to locate the positions of the witness marks on HRP-1.

For HRP-1 witness mark locations, see page 76 of the HRP-1 Mechanical Unit Operator's Manual in the link below.

For HRP-2 witness mark locations, see page 82 of the HRP-2 Mechanical Unit Operator's Manual in the link below.

For HRP-3 witness mark locations, see page 117-118 of the HRP-3 Mechanical Unit Operator's Manual in the link below.

Note: The witness marks on Joint 6 may not be visible, remove the gripper and make sure the dowel pin hole is positioned upward.

Quick Master and Calibrate

After lining up the witness marks, the robot is at its zero position.

Go to Master/Cal screen: MENU>NEXT>SYSTEM>Master/Cal 

Note: if Master/Cal is not showing up, go back to step 2 to enable it again.

Scroll to QUICK MASTER and press ENTER to select [1].

A message will appear asking if you want to quick master, click YES [2].

A message will appear saying that the Robot has been mastered.

While still in Mast/Cal mode, scroll to CALIBRATE and press ENTER [3].

Click YES when the screen asks if you want to calibrate [4].

A message will display saying that the robot has been calibrated, then press DONE.

Apply DCS Parameters

After quick mastering and calibrating, the robot will be in a faulted state until you apply DCS parameters.

Go into the Jogging iPendent mode.

Go to the DCS menu: MENU>NEXT>SYSTEM>DCS

Scroll down to option 13 - Mastering parameters.

Click APPLY to apply the changes and press OK.

Enter 1111 for the Master Code.

Cycle power on the robot.

Verify Quick Mastering

Move all joints to zero and check to see if the lines on both sides of the joint are lined up. If they are not lined up, repeat the procedure.

The servo motors for each joint rely on battery power to keep track of their position when the cobot control box is powered OFF. 

If the batteries die, the cobot will lose track of its position and you will need to reset the zero position of the cobot when it is first powered ON after the batteries have died.

It is recommended to change out the batteries every 2 years to prevent them from dying unexpectedly.

This procedure applies to the following service kits:

• 93-5889 - BATTERY COBOT-F JOINT REPLACEMENT

Important: 93-5889 only contains 1 battery. HC20KG-F requires 2 batteries so you need to order 2x 93-5889 to replace all the batteries. 

If the batteries died unexpectedly, follow this procedure to replace the batteries and then refer to section 7.3 Mastering and Quick Mastering to remaster the joint positions.

Make sure that the control box is powered ON before you begin replacing the batteries.

The servo batteries are located behind the cover of Joint-2 [1]

Remove the 2 side screws from the lower part [2] of the Joint-2 cover.

Loosen the remaining screws [3] of the cover.

Use two pins [4] to help free the cover from the joint. Apply force down on the pins as shown in the image to loosen the cover.

Remove the remaining M4 fasteners [1] once the cover is loose.

Remove the cover and the gasket [2] to gain access to the internal components inside Joint-2 where the batteries are located.

Locate the battery cables [1] going to the right side of the connector.

Disconnect the battery connectors [2].

Loosen the screws that hold the battery cover [3].

Remove the two batteries [4] from the battery clips [5] and note the orientation of the batteries.