hirata ar-z1000 scara a-cal problem (yaskawa motors+servos)

[trucker]

hi, i purchased several arz1000 scara robots for palletising,one i got up and running quickly without problems.six months later i want to do another but probably because axis backup batterys have gone flat it wants me to perform axis calibration (a-cal),there are conflicting methods in robot manual and controller manual.the robot manual shows a plug that replaces the battery fly lead(axis encodes) for a-cal,looks as though -ve terminal connects to middle pin (rst) ?.controller manual makes no referance to this.anyway when performing a-cal the axis moves to first origin sensor,moves back slightly then goes back to sensor and stops. a-cal incomplete! msg
then gives a servo error warning (same on all axis).i had this robot working six months ago but im struggling now, any ideas?