Ahhh the days of the new 
If you open up a backup from this bot anytime after it has been placed in service you will find a file called SYSMAST... This is the file that holds the mastering data. you can reload this file at controlled start.
Have fun... Good Luck
What model robot?
What Axis is affected by the BZAL? I would start at that axis, check the connectors on the motor... If it is more than one axis I'd be more apt to check the cables going up through J1. Either case reset PCA, see if it pops back up... I have seen where maintenance pulled the battery cover off and didn't know how to recover from the BZAL...
Depending on the generation you use FrontPage to build HMI screens offline. I have a procedure somewhere... If I can find it I'll get it to you...
As I cant give you exact code... This will give you what you need to make it happen 
WAIT $MOR_GRP[2].$FILTER_EMPT=1 AND $MOR_GRP[2].$CARTFLTREMP=1 ;
$DMR_GRP[2].$MASTER_COUN[1]=0 ;
$MCR_GRP[2].$CALIBRATE=1 ;
WAIT $MCR_GRP[2].$CALIBRATE=0 ;
This is assuming you have the axis setup on its own group... if it is an integrated axis on group 1 you will need to single out this axis... Have fun...
Hi Greg,
I would set up user frames for each jig... If the number of jigs exceeds 10 I would simply put the frame data into PR's then pull it into the frame as needed... You could use PNS to call a specific program that holds jig number / frame number/ product number... Does the system get a BCD type input to know what fixture is in it?
With things varying slightly... How well does the conveyor repeat position?
You could make an incremental move, 45*... Then after so many indexes the system can re-master the aux axis... Or you could buy the continuous turn option...
Dr C... what say you?
As Background Logic is an option... I would make this happen with PMC... You have quite a bit more control over things in the PLC type world... Call FANUC with your F# and they can quote the option for you. It is quite simple to program as it is just a basic PLC that runs on the bot in the background...
Good Morning,
I know it is a lil bit of a drive for you but... http://www.autocells.com/fanuc-training-services
ACE has a few very knowlegable instructors... The guys that work on bots everyday teach classes 
Prices are quite reasonable and they can do custom classes too. You will probably want to talk to Al, I believe he is taking care of scheduling now. Tell him Burnison sent ya 
I would load the updated software... They are up to 8.10P/16 R30iB... and 8.13P/08 for the R30iB Mates...
Do you have any backgound tasks running? Any KAREL?
If you can pull the SystMast file out of a backup you could easily get going again. This file has to be loaded at controlled start. Last resort for me is doing the lining up axis thing... As long as the motors have not been moved from their original location / gearboxes changed, the original mastering data should be able to be used.
Have fun
I agree with the good Dr... One thing you could do to limp along (Part is ordered, have to run this till Monday) is increase the brake timeout value... This is not the fix but could keep production running for a little while. Remember the time the axis is sitting not moving while the servos are powered up heat is being created... Make sure there is sufficient ventilation around the controller and the bot itself. One other option is to have the robot wait in an orientation that the axis will not fall if the brakes slip.
Best of Luck
If this was one of my bots... I would pull an MD copy to make sure I had all my files... Then reload core software... As this is sounding like it is a core corruption...
Dr C what say you?
I agree with the Dr.... But, I think there is an underlying issue here.. If you are having to re-master an axis on an R2000 there are major issues with the wrist or tooling that is mounted... The only time you re-master is when you physically change out a component (Or unplug things)... Double check your tooling mount, make sure the dowel pins are in the mount. If there are no pins you will be constantly chasing the positions (This is no good... Robot guys are suposed to be lazy) 
... You may want rags to catch the grease releasing.
Dr C you may want to remind Sprinkles of this one...
I have a feeling you have an issue with mastering... Is this a top loader or side slung robot? The mastering positions for the major axis are different between the two.... If the wrist is doing funky thinks start there with the mastering. To check the wrist...
Two Pointers, One Fixed, One as close to X/Y zero on the faceplate as possible.
Teach a point with axis 4 and 6 at zero, axis 5 bent down to meet up the two pointers.
Teach a second point in the same position, go into point data change the NUT to a FUT
Jog the robot up and away from the pointer
Step the robot to the now modified second point
If the pointers line up as they did at point one your minor axis mastering is good.
If the point is off, move only one axis to line up the points, single axis master half the amount you needed to move.
Rinse and repeat, to check your work...
Have fun... these ones are fun
Advanced Find and Replace
On board no... I'll usually pull an MD backup and do a search with AFR...
What kind of "Twitch" are you referring to? Skye hit it dead on with the axis drop on motor power on / off... If the twitch is in motion all kinds of things play into it... Payload settings, tooling C/G, actual mechanical condition of the arm...
Keep an Eye on UO[4]... This is the Program Paused bit... I think you may be seeing UO[3] flickering when the robot goes into a bit of pause...
