Operation of Machine
7. Operation of Machine (HMI Screens)
1.Instructions
1.1 Operator Duties.
The Operator will:
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Maintain an overview of the entire machine.
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Monitor machine performance and investigate any alarms that occur and resolve or call maintenance.
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Ensure all the mechanical setpoints (Hard_Variables) are correctly set to their values.
1.2 HMI Navigation
Every page on the HMI has the same Top Banner on it.
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Press to navigate to the Main Control Screen.
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Displays the current logged in User
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Press to navigate to the Overview Screen.
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Press to navigate to the Safety screen.
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Displays an Active Alarms popup. Press to navigate to the Alarm Page
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Press to navigate to the Interface Screen.
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Press to navigate to the Menu screen.
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Press to navigate to the User Management Screen.
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Press to navigate to the Recipe Screen.
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Alarm Acknowledge button.
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1.3 Control Buttons
Operational Control Buttons on RML Machines use symbols that comply with the IEC-60417 standard. The colours do not comply with any standard, however we have implemented industry standards as a guideline.
Reference and Symbol
IEC Title
BRML Title
IEC Function
BRML Function
IEC 60417-5008
“OFF” (Power)
“Off”
(Not Ready for Safety Reset)
To indicate disconnection from the mains, at least for mains switches or their positions, and all those cases where safety is involved.
To indicate the machine is De-Energized and that there is a safety device preventing the machine from being Powered ON
IEC 60417-5009
Standby
Reset
To identify the switch or switch position by means of which part of the equipment is switched on in order to bring it into the Standby condition.
To indicate the machine is powered on but requires a Reset to bring it to an Idle State.
IEC 60417-5011
“ON/OFF” (Push button)
“Off”
(Ready for Safety Reset)
To indicate connection to the mains, at least for mains switches or their positions, and all those cases where safety is involved. "OFF" is a stable position, whilst the "ON" position only remains during the time the button is de-pressed.
To indicate the machine is De-Energized and that it is in a state where it can be powered ON
IEC 60417-5104
Start
Start
To identify the Start Button.
To identify the Start Button.
IEC 60417-5110A
Stop
Stop
To identify the control or the indicator to stop the active function.
To identify the Stop Button. Stop will terminate all Sequences immediately, bringing the machine to a Rapid Stop.
IEC 60417-5111A
Pause, interruption
Hold
To identify the control or the indicator which stops operation intermittently and keeps the equipment in Operating Mode.
To identify the Hold Button. Hold will transition the machine to a Held State, allowing all the sequences to complete their current function
1.4 Side Control Bar
The Side Control Bar provides access to common machine functions. I.e., Start, Stop and Off buttons may be accessed from any display.
Pressing the RML logo in the Top Banner opens and closes the Side Control Bar.
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1. Start Push Button - Press to issue a start command to the machine. When in the Execute state, this button will change to the Hold icon.
2. Stop Push Button - Press to terminate all sequences immediately, bringing the machine to a rapid stop.
3. Off (Not Ready for Safety Reset) Push Button - This is shown when the machine is in the Aborted state and the E-Stop is pressed. When the E-Stop is released, the icon becomes the Off – Ready for Safety Reset button. If the machine enters the Stopped state, the icon becomes the Reset button.
4. Machine Home Button - Press to home the machine.
1.5 HMI Main Control Screen
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1. Machine State Model. Displays the current State of the Machine
2. Machine Status Bar. Provides information on the current machine state
3. Shows the currently selected recipe (SKU).
4. The Machine Home Button is pressed to home the machine or reset all of the Sequences back to Step 0.
5. Machine Statistics: Press to launch the dedicated Statistics Display.
1.6 Machine State Control
PackML Machine State Model has been implemented for the overall control of this machine. There are three machine state types that define the current condition of the machine:
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Acting State – represents a processing activity, i.e., Aborting, Clearing, Stopping, Resetting Un-holding, Holding, Un-Suspend, Suspending and Completing.
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Wait State – identifies that a machine has achieved a defined set of conditions, i.e., Aborted, Stopped, Idle, Held, Suspended and Completed.
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Dual State – a Wait State that is causing the machine to appear as an Acting State. There is only one Dual State: Execute.
The image above shows the 17 Machine States and transition paths between states. The operator uses the control buttons on the main overview page to transition from state to state.
PackML Machine State Model States
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Aborting: An E-Stop has been pressed or a door has been opened while in a running or Holding state. All power and air is being removed from the zone. The machine will be brought to a rapid, controlled, safe stop.
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Aborted: All power and air have been removed from the zone. The machine maintains relevant information about the abort condition. A Safety Reset command will force a transition to the Clearing state.
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Clearing: The machine is to clear faults that may have occurred when aborting and that are present in the Aborted state before proceeding to a Stopped state.
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Stopping: The machine executes a controlled and safe stop.
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Stopped: Machine is powered and stationary.
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Resetting: The machine enters an energized state awaiting a start command. The machine will be homed in this state if necessary.
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Idle: Machine resetting is complete and ready to start up.
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Starting: Machines perform steps required to enter the Execute state.
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Execute: The machine is operating and producing product.
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Holding: The machine is being brought to a controlled stop when executing.
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Held: The machine is paused either by the operator or a fault occurs in the Execute state.
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Un-Holding: The machine is being prepared to re-enter the Execute state.
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Suspending: Machine is being prepared to enter the suspended state.
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Suspended: The machine enters this state due to a request from out/in-feed.
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Un-suspending: The Machine is being prepared to re-enter the Execute state.
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Completing: Machine has run product to completion. Used at the end of a production run to drain any remaining product from all machines within this zone. I.e., processing of the product at the infeed will stop.
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Complete: The machine is waiting for a stop command that will bring the machine into the stopped state.
Restart after an Emergency Stop or Monitored Guard being opened
Check the machine to see if the reason for the E-Stop activation or guard door opening has been cleared.
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If an E-Stop was activated, release all E-Stop buttons (Twist to release)
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If a guard door was opened, close any guard doors that are open.
Once the E-Stop has been released and guard doors are closed, press the RESET button on the Side Control Bar or Main Control Display. This will reset the safety system and bring the machine into the idle state.
1.7 Machine Restart from Held or Suspended State
From Machine Fault:
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Check machine fault
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Carry out necessary actions to resolve the fault
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Once the fault has been cleared, press the START button on the Side Control Bar or Main Control Display.
From Line Fault:
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Check line fault
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Carry out necessary actions to resolve the fault.
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Once the fault has been cleared, the machine should automatically restart.
Ensure the safety system is reset, Press the Start push button on the Side Control Bar to start the machine
2. Menu Layout and Screens
2.1 Main Menu
Press the buttons on the menu screen to open the particular screen.
Maintenance info: Press to launch the manual, electrical drawingand pneumatic drawing screen
2.2 User Login
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1. Enter username
2. Enter Password
3. Click to Login
4. Click to Logout
5. Click to Change Password
Following is a matrix of the level access for each user, please note the Level 1-4 passwords are able to be altered for customer preference.
Level 5 are set aside for RML Engineering access only to enable machine setup.
2.3 User Management
User Creation/Deletion
Refer the below steps to create the new User ID
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1. Press the Create button to add a new user.
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2. Enter the name of the new user
3. Enter the user's password. The password must comply with the password policy
4. Select the user group for the new user.
5. Click the Apply button to save the new user.
Refer the below steps to delete the User ID
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1. Select the user to be deleted.
2. Click on the delete button to delete the user.
2.4 Mimic - Overview Display
The Overview Display provides an overview of the machine layout. Specific areas of the machine can be navigated to by using the Arrow buttons.
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1. Pressing this button in the navigation panel will launch the Mimic Overview Screen. This can be accessed from a display on the HMI
2. These icons around the display will launch the Mimic indicated in the Arrow box when pressed. E.g. pressing the “Pallet Locator” button will launch a mimic for that area of the machine.Press on Sub-assembly area for manual operation for Example: -solenoid valve, motor, photo eye etc.…
2.5 Mimic Overview – Device Legend
2.6 Mimic - Safety Screen
The Safety Mimic provides an overview of the machine. The safety devices are shown in their approximate locations around the machine and have the following color indication.
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Green is ready for Reset.
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Grey is Open.
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Red is in Fault.
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1. This area displays Safety Devices that are in the Main Control cabinet or are in fields mounted on the machine.
2. This is an indicator for an Estop Switch.
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Green is Closed
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Grey is Open
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Red is in Fault.
Pressing this Icon will launch a face plate for this device.
3. This is an indicator for a Door Switch..
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Green is Released
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Grey is Pressed
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Red is in Fault.
Pressing this Icon will launch a face plate for this device.
2.7 Mimic – Machine Module
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1. Device Indicator. These are.
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Green when on or running.
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Grey when off
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Red when in fault.
Pressing a device icon will launch a popup for that object.
2.8 Sequences
Clicking on the Sequences button in the Menu launches this display.
Example: -
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1. Sequence Status. This displays the Sequence Name, Current Step and description of the current action that is taking place. 2. Pressing this button launches another faceplate with more detail on that Sequence. That faceplate can be seen below.
2.9 Interface
1. Input: It indicates the Digital Input
2. Output: It indiactes the Digital Outputs.
3. LED Indication:
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Red: It indicates the Alarm in the System.
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Green: It indicates the system is in Idle state.
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Amber: It indicates the system is in Alert State.
2.10 Current Alarms
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Current Alarms: Current Alarm screen shows the current alarms that are active and can be access through the Menu Screen (as mentioned in 2.1), or by clicking in the Top bar (as mentioned in 1.2)
1. TimeStamp: The date and time the Alarm has occurred.
2.SourceName: Refers to the type of Alarm
3. Message: The current alarm message to be displayed in the page.
4. Acknowledge: to acknowledge the alarm once the issue is resolved.
2.11 Alarm History
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Alarm History: Alarm History screen shows the record of alarm that have occured in the past and can be access through the Menu Screen (as mentioned in 2.1).
1. ConditionName: Shows the Condition name for that particular alarm
2. SourceName: Shows the source name for that particular alarm
3. Message: Message displayed for that alarm
4. Severity: The severity rate for that alarm (Severity 1 and 2, where severity 1 being the highest)
5. DateTime: The Date and time when thaat particular alarm occured
2.12 Diagnostic
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Diagnostic: Used by BCRML to diagnos the application and can be access through the Menu Screen (as mentioned in 2.1).
1. Message_en-US: Shows the Diagostic message for that event.
2. ModuleName: Shows the module of application that generated the event.
3. Time: The date and time they were executed in the application
4. Level: This shows the severity or importance of the diagnostic entry.
3. Recipe
3.1 Recipe Settings
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Click the drop-down menu to select the saved recipes.
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Entry Box to enter the recipe values
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Current Setpoints.
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Save button is used to save the new recipe. The load button is used to load the PLC values to the recipe settings values. The Delete button is used to delete the existing recipe.
4. Face Plates
4.1 Mimic – Device Legend
4.2 Cylinder
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Tag name and description for the selected cylinder.
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Number of times the cylinder has been actuated.
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Cylinder status flags showing Output State, Reed Status, Alarm and Manual state.
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Timer pre-sets for the cylinder alarms. If the cylinder is setup as having no reed switches, these timers become extend and retract times for the cylinder.
4.3 Miscellaneous Input
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Tag name and description for the selected device.
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Current status of the device with de-bounce times applied
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Device Status
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De-bounce and Fault Times.
4.4 Miscellaneous Output
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Tag name and description for the selected device.
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Current State of the device.
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Current Status of the device.
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Fault timer and cycle counter.
4.5 Motors
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Tag name and description for the selected motor.
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Frequency feedback and current target frequency.
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Current state of the motor.
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Status of the motor.
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Fault timer and run hours for the motor.
4.6 Servo Motor
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Tag name and description for the selected servo.
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Display Velocity and Position feedback and current target position.
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Current drive status
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Pressing here will launch the servo settings display.
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Pressing here will launch a home selection screen. This will provide information about the homing of the axis.
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Manual Controls. You must be logged in as a technician to gain access to these controls.
4.7 Servo Setting
This display is launched from the servo faceplate and show the setpoints for the servo control. You must be logged in as a technician to gain access to these controls.
4.8 Service
5. Stack Light Indication
5.1 Green Stack Light
5.2 Amber Stack Light
5.3 Red Stack Light
SOP (Standard Operation Procedure)
1. SOP for Startup
1.1 Power On the system:
1. Power on the Main control Panel and ON the Transformer of the Robot (HMI Screen will turn on)
2. Ensure there is no emergency stop push button pressed and all Guard doors are closed.
3. Ensure that the Robot Pendant Switch is in OFF Mode and Controller is in Auto Mode
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Auto
1.2 Start the system:
1. Press the safety reset button to energize the system.
Safety Rest
2. Navigate to Recipe Screen Select the Recipe and Load the Recipe and Confirm it.
Select Recipe from Listed
Load Recipe
3. Do Home to load appropriate recipe.
Select Home
Select Yes
Rest
4. After Home Done start the System.
Select Start
FANUC Robot Teach Pendant – Complete Operation & Key Manual
This document describes all major keys of the FANUC Robot Teach Pendant, including jogging keys, function keys (F1–F5), and the procedure for selecting coordinate systems for robot movement.
1. Teach Pendant Overview
2. Emergency Stop (E-STOP)
• Immediately stops robot motion.
• Cuts servo power.
• Twist clockwise to release.
• Used during unsafe or emergency conditions.
3. Deadman Switch (Enable Switch)
• Located at the back of the teach pendant.
• Three-position safety switch: - Released: Robot disabled
4. Function Keys (F1–F5)
F1 – Soft Key 1:• Executes first soft menu option shown at bottom of screen.• Common uses: TYPE, YES, SELECT.
F2 – Soft Key
2:• Executes second soft menu option.• Common uses: DETAIL, OPTION.
F3 – Soft Key
3:• Often used for NEXT page or UTILITIES.• May act as INSERT or MODIFY in program editing.
F4 – Soft Key
4:• Used for system or parameter-related selections.• Can be CHOICE or PARAM depending on screen.
F5 – Soft Key
5:• Accesses extended functions like NEXT, PREV, or MORE.• Used to navigate additional menu pages.NOTE: The actual function of F1–F5 depends on the active screen. The function label is displayed directly above each key on the LCD.
5. Cursor / Navigation Keys
• VUsed to move cursor in program editing.
• Works with ENTER and SHIFT keys.
• Used for navigating menus and data fields.
• Blue keys control robot movement.
• Includes Joint keys (J1–J6) and Cartesian keys (X/Y/Z).
• Must hold SHIFT + Axis Key + Enable Switch (Deadman).
• Speed depends on T1/T2 mode.
7. How to Select Coordinate System
The robot movement depends on the selected coordinate system. Coordinate selection changes how the jogging keys move the robot.
Available Coordinate Systems
1. JOINT:
• Moves individual robot axes (J1–J6).
• Each key rotates one joint.
• Used for mechanical alignment and troubleshooting.
2. WORLD:
• Moves robot relative to world reference frame.
• X, Y, Z directions are fixed to cell layout.
3. TOOL:
• Movement relative to tool center point (TCP).
• Used for straight-line tool approach.
4. USER:
• Movement relative to user-defined frame.
• Commonly used in fixture-based applications.Procedure to Select Coordinate System:
Step
1: Press the COORD key on the teach pendant.
Step 2: The coordinate selection window appears on the screen.
Step 3: Use F1–F5 or arrow keys to select JOINT, WORLD, TOOL, or USER.
Step 4: Press ENTER to confirm.
Step 5: Jog robot using SHIFT + Axis key.
NOTE: Always ensure the correct coordinate system is selected before jogging to avoid unexpected robot motion.
8. Numeric Keypad
• Used for entering position values and data.
• Keys 0–9 with decimal input.
• Used in registers, offsets, and program editing.
FANUC Robot Teach Pendant BACKUP
2. Procedure
2.1. Plug in the USB-stick on the Teach Pendant
Power on the robot.
Plug the USB-stick in the USB-port of the Teach Pendant.
2.2. Go to file menu
Press Menu, select 7 File, press arrow RIGHT to select 1 File and press ENTER.
Press F5 (UTIL), select 1 Set Device and press ENTER. Then arrow RIGHT and select 1 USB on TP (UT1:) and press enter. Now the USB directory on the Teach Pendant is selected.
Verify the correct memory device is active in the top left corner.
Verify the root folder of the USB-stick is selected.If this is not the case, select 1 .. (Up one Level) <DIR> and press ENTER.
2.3. Backup all of abovePress
F4 [BACKUP], select 8 All of above and press ENTER.
If the robot asks to create a backup directory press F4 YES to confirm.
If the robot asks to not delete, but create backup in backup directory press F4 YES to confirm.
Wait while the robot is making the backup. This may take a few minutes.
After the backup is finished the USB-stick can be removed.