Fanuc PNT1 Alarm Codes

Home > Fanuc > Alarm Codes > PNT1 Alarm Codes

Fanuc PNT1 Alarm Codes

PNT1-001 WARN Unknown PAINTtool error
Cause: PaintTool has detected an unknown error.
Remedy: Refer to the teach pendant error log for the cause of the error.
________________________________________________________________
PNT1-002 WARN Press master reset
Cause: The system is in an error condition.
Remedy: Press RESET to clear the error.
________________________________________________________________
PNT1-003 WARN Reset failure
Cause: The reset procedure has failed.
Remedy: Correct the error, if any, and try the reset operation again.
________________________________________________________________
PNT1-004 WARN Robot Servos Disabled
Cause: The robot servo disconnect is on.
Remedy: Turn off the robot servo disconnect.
________________________________________________________________
PNT1-005 PAUS Production mode is disabled
Cause: The production mode input is off.
Remedy: None.
________________________________________________________________
PNT1-006 WARN REMOTE switch must be REMOTE
Cause: The remote switch is in the LOCAL position.
Remedy: Place the remote switch in the REMOTE position.
________________________________________________________________
PNT1-007 WARN Machine lock is ON
Cause: The machine lock is on going into production.
Remedy: Disable the machine lock on the teach pendant before entering production.
________________________________________________________________
PNT1-008 WARN Robot motion is not enabled
Cause: The UOP enable input is OFF.
Remedy: The UOP enable input must be ON.
________________________________________________________________
PNT1-009 ABRT Invalid job %s received
Cause: An invalid job number was received from the PLC.
Remedy: The PLC must initialize the robot with a valid job number.
________________________________________________________________
PNT1-010 ABRT Invalid tutone %s received
Cause: An invalid tutone option was received from the PLC.
Remedy: The PLC must initialize the robot with a valid tutone option.
________________________________________________________________
PNT1-011 ABRT Invalid repair %s received
Cause: An invalid repair option was received from the PLC.
Remedy: The PLC must initialize the robot with a valid repair option.
________________________________________________________________
PNT1-012 ABRT Invalid color %s received
Cause: An invalid color number was received from the PLC.
Remedy: The PLC must initialize the robot with a valid color number.
________________________________________________________________
PNT1-013 ABRT Job (%s) is not found
Cause: The teach pendant JOB program is not loaded, or was not created on the controller.
Remedy: A teach pendant JOB program must be created or loaded in the controller before attempting
to run it in production.
________________________________________________________________
PNT1-014 WARN Invalid job %s in queue
Cause: An invalid job number was received from the PLC. Therefore, the robot cannot put the
job into the job queue.
Remedy: At the PLC, initialize the robot with a valid job number in order to receive a job read
acknowledge from the robot.
________________________________________________________________
PNT1-015 WARN Invalid color %s in queue
Cause: An invalid color number was received from the PLC. The robot cannot put the color into
the color queue.
Remedy: The PLC must initialize the robot with a valid job number in order to receive a color read
acknowledge from the robot.
________________________________________________________________
PNT1-016 WARN Job queue is full
Cause: The job queue is full.
Remedy: Remove unneeded job(s) from the job queue before attempting to add more jobs to the
queue.
________________________________________________________________
PNT1-017 WARN Color queue is full
Cause: The color queue is full.
Remedy: Remove color(s) from the color queue before attempting to add more colors to the queue.
________________________________________________________________
PNT1-018 WARN Shell aborted or paused
Cause: Another task has detected that the main task has aborted or paused.
Remedy: Turn off the controller, then turn it on again.
________________________________________________________________
PNT1-019 WARN Wait for autoprocessing to finish
Cause: Autoprocessing of the last editted program is still in process.
Remedy: Wait for autoprocessing to complete before entering production mode.
________________________________________________________________
PNT1-020 ABRT Invalid job type (%s) received
Cause: An invalid job type was received from the PLC.
Remedy: The PLC must initialize the robot with a valid job prefix.
________________________________________________________________
PNT1-021 WARN System is in error status
Cause: There is an alarm that must be cleared before Test Cycle can be run.
Remedy: Press RESET to clear all system alarms.
________________________________________________________________
PNT1-022 WARN Sync Que-Job passed window
Cause: The job is not run and the encoder counts indicate that the part is past the Start switch (plus
tolerance). The robot deletes the job from the queue, posts this warning message and continues to
operate in production.
Remedy: None.
________________________________________________________________
PNT1-023 WARN Sync Que-Job before window
Cause: The job is not run and the encoder counts indicate that the part has not made it to the Start
switch (minus tolerance). The robot will hold onto that job for the next start signal, post this warning
message, and will continue to operate in production.
Remedy: None.
________________________________________________________________
PNT1-024 PAUS UOP’s assigned but disabled!
Cause: The User Operator Panel (UOP) inputs are assigned, but have been disabled!
Remedy: If your system requires these UOP signals, you must enable these inputs on the Teach
Pendant as follows:
1. Press MENUS.
2. Select SYSTEM.
3. Press F1 [TYPE].
4. Select Config.
5. Move the cursor to Enable UI signals, and change them from FALSE to TRUE. If your system
does not require these UOP signals, unassign these UOP signals in the I/O menu.
________________________________________________________________
PNT1-034 WARN Parm %s Value beyond limits
Cause: An attempt was made to set an applicator parameter output beyond its min/max value.
Remedy: Verify the specified parameter’s min/max output setting.
________________________________________________________________
PNT1-039 WARN I/O setup verified OK
Cause: SETUP Applicators: The I/O information is correct and complete.
Remedy: None.
________________________________________________________________
PNT1-040 WARN Error attempting to setup I/O
Cause: SETUP Applicators: The I/O information for an applicator was changed and is in error.
Remedy: Check that the output type, output number, rack and slot number, first bit location, and
number of bits are all specified correctly.
________________________________________________________________
PNT1-045 WARN Adj. colors table sizes to %s
Cause: The application is attempting to adjust the size of the color tables based on the configuration
variable setting.
Remedy: None.
________________________________________________________________
PNT1-046 WARN Adj. color valves table size to %s
Cause: The application is attempting to adjust the size of the color valve table based on the
configuration variable setting.
Remedy: None.
________________________________________________________________
PNT1-047 WARN Failed to adj. color table size
Cause: There is not enough memory available for the application to adjust the size of the color
tables to the match requested setting.
Remedy: Use a smaller setting that is within the memory constraints of the controller.
________________________________________________________________
PNT1-048 WARN Failed to adj. color valve table size
Cause: There is not enough memory available for the application to adjust the size of the color valves
table to match the requested setting.
Remedy: Use a smaller setting that is within the memory constraints of the controller.
________________________________________________________________
PNT1-053 WARN Invalid parameter indicator
Cause: An invalid parameter indicator value was sent from the PLC.
Remedy: Verfiy that the number of applicator control parameters set up in the robot matches the value
sent from the PLC. This value should be between the range of 1 to 4.
________________________________________________________________
PNT1-054 WARN No channel/parameter indicated
Cause: The PLC sent a parameter indicator value of 0.
Remedy: Correct the parameter indicator value at the PLC.
________________________________________________________________
PNT1-055 WARN Manual inputs are enabled
Cause: On manual mode entry, all PLC manual mode input functions are enabled.
Remedy: None.
________________________________________________________________
PNT1-056 WARN Manual inputs are disabled
Cause: On manual mode exit, all PLC manual mode input functions are disabled.
Remedy: None.
________________________________________________________________
PNT1-057 WARN Manual enabled during motion
Cause: Manual mode is being initiated during robot motion.
Remedy: Robot motion must complete before it enters manual mode.
________________________________________________________________
PNT1-058 WARN Manual enabled in color cycle
Cause: Manual mode is being initiated during a color change cycle.
Remedy: The color change cyle must complete before the robot enters manual mode.
________________________________________________________________
PNT1-059 ABRT TP Enabled in cycle
Cause: The teach pendant cannot be enabled when running a remote color change cycle.
Remedy: None.
________________________________________________________________
PNT1-064 ABRT Tracking que exceeded
Cause: For continuous line systems, indicates that too many parts have passed the part detect switch
within the current boundaries.
Remedy: Expand the robot boundaries, or lower the conveyor speed.
________________________________________________________________
PNT1-065 WARN Linetracking parameter undefined
Cause: For continuous line systems, a line tracking parameter is undefined and is required to run
the system.
Remedy: Ensure that all tracking parameters have been set up on the SETUP Tracking menu.
________________________________________________________________
PNT1-066 WARN Railtrack parameter undefined
Cause: For continuous line systems, a rail tracking parameter is undefined and is required to run
the system.
Remedy: Ensure that all tracking parameters have been set up on the SETUP Tracking menu.
________________________________________________________________
PNT1-067 WARN Invalid tracking frame
Cause: An attempt was made to use an invalid tracking frame number.
Remedy: The current software supports tracking frames 1-6. The tracking frame number must be
greater than 0, and less than 7.
________________________________________________________________
PNT1-068 WARN Encoder count rollover
Cause: For continuous line systems, this warning indicates that the encoder counter has detected
a rollover condition.
Remedy: None.
________________________________________________________________
PNT1-069 WARN Part Detect less than min dist
Cause: For continuous line systems, this warning indicates that the trigger distance is less than a
pre-determined value. The part detect will be ignored by the robot controller.
Remedy: Reduce the minimum distance value to less than the job spacing distance, or replace the
old part detect switch.
________________________________________________________________
PNT1-070 WARN Conveyor direction incorrect
Cause: For continuous line systems, the robot has determined the conveyor is running in the wrong
direction. Part detects will be ignored by the robot.
Remedy: Swap the leads on the encoder repeater board so that the encoder counts positive pulses
instead of negative.
________________________________________________________________
PNT1-071 WARN %s skipped-over max travel
Cause: For line tracking systems only: This is a warning that the part has tracked too far to be played
back. The previous job or color change took too long to play. The robot will ignore this job/color.
Remedy: Decrease the cycle time of the job or decrease the color change cycle.
________________________________________________________________
PNT1-072 PAUS Tracking encoder disconnected
Cause: The robot is detecting a problem with the tracking encoder cable.
Remedy: Check the encoder cable, and replace it if necessary.
________________________________________________________________
PNT1-073 WARN Right-Hand Rule only for this robot
Cause: The robot being used is not supported in PaintTool line tracking for a left hand arm type. The
robot is not a P-Series robot.
Remedy: If the robot library (setup) does not offer a selection for right or left hand robots, then no
remedy is required. If the robot has been set up as a left hand robot, change it to a right hand robot.
________________________________________________________________
PNT1-074 PAUS DAL alarm(Track encoder:1)
Cause: The tracking encoder has been disconnected, or is faulty.
Remedy: Reconnect the tracking encoder or determine if the encoder connector is faulty. The robot
controller power must be turned off, then turned on again before the system is allowed to reset.
________________________________________________________________
PNT1-075 ABRT Extreme entry position violation
Cause: The TCP (Line Tracking) or Extended Axis (Rail Tracking) has been commanded beyond the
Entry Limit defined in the System parameter, $LNCFG.$ENTRY_XTRM.
Remedy: Adjust the Entry Limit ($LNCFG.$ENTRY_XTRM), or change the Tracking Boundary to
be inside of this limit.
________________________________________________________________
PNT1-076 ABRT Extreme exit position violation
Cause: The TCP (Line Tracking) or Extended Axis (Rail Tracking) has been commanded beyond the
Exit Limit defined in the System parameter, $LNCFG.$EXIT_XTRM.
Remedy: Adjust the Exit Limit ($LNCFG.$EXIT_XTRM) or change the Tracking Boundary to
be inside of this limit.
________________________________________________________________
PNT1-085 PAUS Posn unreachable at line %s
Cause: An unreachable position is detected in the adjustment precheck
Remedy: Check the alarm log to find out at which position motion error will occur, use CLR_Adj
to clear the adj value
________________________________________________________________
PNT1-086 PAUS PLC e-stop detected
Cause: An interlock signal fault or PLC E-stop was detected.
Remedy: Correct the source of the fault, and RESET the controller.
________________________________________________________________
PNT1-087 ABRT Robot overtravel
Cause: The mechanical unit went beyond its normal travel limits and reached an overtravel limit
switch.
Remedy: Follow the overtravel recovery procedure in Electrical Connection and Maintenance
Manual.
________________________________________________________________
PNT1-088 PAUS Release SOP e-stop
Cause: The operator panel (SOP) EMERGENCY STOP has been detected.
Remedy: Release the SOP EMERGENCY STOP, and press RESET to clear the E-STOP condition.
________________________________________________________________
PNT1-089 PAUS Release TP e-stop
Cause: The teach pendant EMERGENCY STOP has been detected.
Remedy: Turn the teach pendant EMERGENCY STOP button, and press RESET to clear the
EMERGENCY STOP condition.
________________________________________________________________
PNT1-090 PAUS TP enabled during production
Cause: The teach pendant was enabled during production.
Remedy: The teach pendant cannot be enabled during production. Disable the teach pendant.
________________________________________________________________
PNT1-091 PAUS Disable teach pendant
Cause: The teach pendant is enabled.
Remedy: Disable the teach pendant to continue the program.
________________________________________________________________
PNT1-092 PAUS Stop error excess
Cause: Refer to SRVO-023 SERVO Stop error excess(G:x A:x) in the Error Code Manual.
Remedy: Refer to SRVO-023 SERVO Stop error excess(G:x A:x) in the Error Code Manual.
________________________________________________________________
PNT1-093 PAUS Move error excess
Cause: Refer to SRVO-024 SERVO Move error excess(G:x A:x) in the Error Code Manual.
Remedy: Refer to SRVO-024 SERVO Move error excess(G:x A:x) in the Error Code Manual.
________________________________________________________________
PNT1-094 PAUS DEADMAN switch RELEASED
Cause: The DEADMAN switch has been released during an operation. The operation has been
discontinued.
Remedy: Press and hold the DEADMAN switch to restart the procedure.
________________________________________________________________
PNT1-095 PAUS Fence open during production
Cause: The FENCE1 and FENCE2 circuits are open on the EMG control board.
Remedy: Determine the cause of the FENCE1 and FENCE2 open circuits, and correct the problem.
________________________________________________________________
PNT1-096 PAUS UOP immediate stop detected
Cause: The IMSTP (immediate stop) UOP input was not asserted.
Remedy: If you are using UOP signals, clear the source of the fault. If you are not using UOP signals,
press MENUS, select I/O, and map all UOP signals to zero. Then cycle power on the controller.
________________________________________________________________
PNT1-097 PAUS HOLD active
Cause: A HOLD signal, either from the UOP or the teach pendant, has been activated.
Remedy: Remove the HOLD condition, and press RESET.
________________________________________________________________
PNT1-098 ABRT Track destination gone
Cause: Destination out of window error.
Remedy: The current cycle must be aborted, and then restarted.
________________________________________________________________
PNT1-099 ABRT PC serial interface fault
Cause: The PLC interface serial link has failed.
Remedy: Check the LED status on PLC interface board. Refer to Remote I/O interface for an
Allen-Bradley PLC or Genius Network Interface for GE FANUC manual for more information.
________________________________________________________________
PNT1-100 PAUS OVC alarm
Cause: This Alarm is echoed to the PLC when &qout;SRVO-046 SERVO OVC alarm (Group:%d
Axis:%d)&qout; is posted. Refer to the Teach Pendant alarm screen for group and axis number. Refer
to SRVO-046 for the cause.
Remedy: Refer to SRVO-046 for the remedy.
________________________________________________________________
PNT1-101 ABRT Limit error
Cause: The taught position was outside the normal work envelope of the robot. One of the robot axes
could not reach the position.
Remedy: Reteach the position. Refer to the MOTN-017 alarm that was triggered before this paint
alarm for details on the specific group and axis number.
________________________________________________________________
PNT1-102 ABRT Position not reachable
Cause: This alarm is echoed to the PLC when &qout;MOTN-018 STOP Position not reachable&qout;
is posted. Refer to the MOTN-018 alarm for the cause.
Remedy: Refer to the MOTN-018 alarm for the remedy.
________________________________________________________________
PNT1-103 ABRT Configuration mismatch
Cause: This is a pause condition. The configuration (Flip/No-Flip) cannot change during a Cartesian
(linear or circular) motion.
Remedy: Either reteach the motions using the same configuration (Flip or No-Flip), or use a joint
motion to change configurations before proceeding with Cartesian motion.
________________________________________________________________
PNT1-104 PAUS Planner error
Cause: The planner encountered an error.
Remedy: Check the error message log for details.
________________________________________________________________
PNT1-105 ABRT Unitialized position
Cause: This is a system software error.
Remedy: Document the events that led to the error, record the software version number, and contact
your local distributor or the FANUC Robotics hotline. You can try to clear the error by turning
the controller off, and then on again.
________________________________________________________________
PNT1-106 ABRT Brake fuse blown
Cause: This alarm is echoed to the PLC when &qout;SRVO-008 SERVO Brake fuse blown&qout; is
posted. Refer to SRVO-008 for the cause.
Remedy: Refer to SRVO-008 for the remedy.
________________________________________________________________
PNT1-107 WARN Robot not mastered
Cause: This alarm is echoed to the PLC when &qout;SRVO-027 WARN Robot not
mastered(Group:%d)&qout; is posted. Refer to the Teach Pendant alarm screen for the group number.
Refer to the SRVO-027 alarm for the cause.
Remedy: Refer to the SRVO-027 alarm for the remedy.
________________________________________________________________
PNT1-108 ABRT MCC alarm
Cause: The servo amplifier magnetic contactor (MCC) is welded closed.
Remedy: Refer to the troubleshooting section in the Controller Series Electrical Connection and
Maintenance Manual.
________________________________________________________________
PNT1-109 PAUS Discharge current alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-043 SERVO DCAL alarm(Group:%d
Axis:%d)&qout; alarm is posted. Refer to the Teach Pendant alarm screen for the group and axis
number. Refer to SRVO-043 for the cause.
Remedy: Refer to SRVO-043 for the remedy.
________________________________________________________________
PNT1-110 ABRT High voltage alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-044 SERVO HVAL alarm(Group:%d
Axis:%d)&qout; alarm is posted. Refer to the Teach Pendant alarm screen for the group and axis
number Refer to SRVO-044 for the cause.
Remedy: Refer to SRVO-044 for the remedy.
________________________________________________________________
PNT1-111 ABRT High current alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-045 SERVO HCAL alarm(Group:%d
Axis:%d)&qout; alarm is posted. Refer to the Teach Pendant alarm screen for the group and axis
number Refer to SRVO-045 for the cause.
Remedy: Refer to SRVO-045 for the remedy.
________________________________________________________________
PNT1-112 ABRT Low voltage alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-047 SERVO LVAL alarm(Group:%d
Axis:%d)&qout; alarm is posted. Refer to the Teach Pendant alarm screen for the group and axis
number. Refer to SRVO-047 for the cause.
Remedy: Refer to SRVO-047 for the remedy.
________________________________________________________________
PNT1-113 PAUS Servo amp overheat alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-049 SERVO OHAL1 alarm (Grp:%d
Ax:%d)&qout; is posted. Refer to the Teach Pendant alarm screen for the group and axis number.
Refer to SRVO-049 for the cause.
Remedy: Refer to SRVO-049 for the remedy.
________________________________________________________________
PNT1-114 ABRT Collision alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-050 SERVO Collision Detect alarm
(G:%d A:%d)&qout; is posted. Refer to the Teach Pendant alarm screen for the group and axis
number. Refer to SRVO-050 for the cause.
Remedy: Refer to SRVO-050 for the remedy.
________________________________________________________________
PNT1-115 WARN Pulse coder battery discon alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-062 SERVO BZAL alarm(Group:%d
Axis:%d)&qout; alarm is posted. Refer to the teach pendant alarm screen for further information on
the SRVO-062 alarm. Refer to the SRVO-062 alarm for the cause.
Remedy: Refer to the SRVO-062 alarm for the remedy.
________________________________________________________________
PNT1-116 ABRT Pulse coder alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-061 SERVO CKAL alarm(Group:%d
Axis:%d)&qout;, &qout;SRVO-063 SERVO RCAL alarm(Group:%d Axis:%d)&qout;,
&qout;SRVO-064 SERVO PHAL alarm(Group:%d Axis:%d)&qout;, or &qout;SRVO-066 SERVO
CSAL alarm (Group:%d Axis:%d)&qout; is posted. Refer to the teach pendant alarm screen for
further information on the SRVO-061, SRVO-063, SRVO-064, or SRVO-066 alarm. Refer to the
SRVO-061, SRVO-063, SRVO-064, or SRVO-066 alarm for the cause.
Remedy: Refer to the SRVO-061, SRVO-063, SRVO-064, or SRVO-066 alarm for the remedy.
________________________________________________________________
PNT1-117 WARN Pulse coder battery low alarm
Cause: This alarm is echoed to the PLC when a &qout;SRVO-065 WARN BLAL alarm(Group:%d
Axis:%d)&qout; is posted. Refer to the teach pendant alarm screen for further information on the
SRVO-065 alarm. Refer to the SRVO-065 alarm for the cause.
Remedy: Refer to the SRVO-065 alarm for the remedy.
________________________________________________________________
PNT1-118 ABRT Motor overheat occurred
Cause: This alarm is echoed to the PLC when a &qout;SRVO-067 SERVO OHAL2 alarm (Grp:%d
Ax:%d)&qout; alarm is posted. Refer to the teach pendant alarm screen for further information on the
SRVO-067 alarm. Refer to the SRVO-067 alarm for the cause.
Remedy: Refer to the SRVO-067 alarm for the remedy.
________________________________________________________________
PNT1-119 ABRT Pulse coder communication error
Cause: This alarm is echoed to the PLC when a &qout;SRVO-068 SERVO DTERR alarm
(Grp:%d Ax:%d)&qout;, &qout;SRVO-069 SERVO CRCERR alarm (Grp:%d Ax:%d)&qout;, or
&qout;SRVO-070 SERVO STBERR alarm (Grp:%d Ax:%d)&qout; alarm is posted. Refer to the
teach pendant alarm screen for further information on the SRVO-068, SRVO-069, or SRVO-070
alarm. Refer to the SRVO-068, SRVO-069, or SRVO-070 alarm for the cause.
Remedy: Refer to the SRVO-068, SRVO-069, or SRVO-070 alarm for the remedy.
________________________________________________________________
PNT1-120 PAUS Pulse coder position compare error
Cause: This alarm is echoed to the PLC when a &qout;SRVO-071 SERVO SPHAL alarm (Grp:%d
Ax:%d)&qout; alarm is posted. Refer to the teach pendant alarm screen for further information on the
SRVO-071 alarm. Refer to the SRVO-071 alarm for the cause.
Remedy: Refer to the SRVO-071 alarm for the remedy.
________________________________________________________________
PNT1-121 ABRT Collision Detection (Hand Broke)
Cause: This alarm is echoed to the PLC when a &qout;SRVO-006 SERVO Hand broken&qout; alarm
is posted. Refer to the SRVO-006 alarm for the cause.
Remedy: Refer to the SRVO-006 alarm for the remedy.
________________________________________________________________
PNT1-122 PAUS TP disabled during Test Cycle
Cause: The teach pendant cannot be disabled during Test Cycle.
Remedy: Turn the teach pendant ON/OFF switch to ON, press the DEADMAN, and press RESET to
clear the error.
________________________________________________________________
PNT1-123 WARN Battery Low
Cause: The battery in the PSU or encoder is low or zero.
Remedy: Replace the old battery with a new battery.
________________________________________________________________
PNT1-124 WARN CE switch must be in AUTO
Cause: The Selector Mode Switch is not in AUTO.
Remedy: Select AUTO mode from the Selector Mode Switch.
________________________________________________________________
PNT1-125 PAUS Operation mode AUTO Selected
Cause: The Selector Mode Switch was set to AUTO.
Remedy: The system will pause when the MODE SELECT SWITCH is changed to a different mode.
You must reset the system after a mode change.
________________________________________________________________
PNT1-126 PAUS Operation mode T1 Selected
Cause: The Mode Select Switch is not in AUTO.
Remedy: The system will pause when the MODE SELECT SWITCH is change to a different mode.
You must reset the system after a mode change.
________________________________________________________________
PNT1-127 PAUS Operation mode T2 Selected
Cause: The MODE SELECT SWITCH was was set to T2.
Remedy: The system will pause when the MODE SELECT SWITCH is change to a different mode.
You must reset the system after a mode change.
________________________________________________________________
PNT1-128 PAUS adj out of limit at line %s
Cause: A limit error was detected during the Adjust Precheck process on the specified line number.
Remedy: Check the alarm log to find the position in which the limit error will occur, then use
CLR_ADJ to clear the adjustment value.
________________________________________________________________
PNT1-129 WARN I/O Hardware not installed
Cause: The I/O hardware that was selected is not physically installed.
Remedy: Make sure I/O hardware that is being selected is installed correctly.
________________________________________________________________
PNT1-130 WARN Data Error (see FR:dterrors.ls)
Cause: The I/O Auto Configurator data file contains errors.
Remedy: Press MENUS and select File. Display FR:dterrors.ls for a description of the error with the
corresponding line number.
________________________________________________________________
PNT1-131 PAUS Servo Disconnect
Cause: This alarm is echoed to the PLC when a &qout;SRVO-194 SERVO Servo disconnect&qout;
alarm is posted. Refer to the SRVO-194 alarm for the cause.
Remedy: Refer to the SRVO-194 alarm for the remedy
________________________________________________________________
PNT1-132 PAUS Chain 1 (+24v) abnormal
Cause: A single chain 1 (+24V) failure occurred.
Remedy: Repair the circuit of the chain 1 (+24V) on the hardware. Set the CHAIN FAILURE
detection to TRUE on the SYSTEM/CONFIG screen. Then, press the RESET button on the teach
pendant.
________________________________________________________________
PNT1-133 PAUS Chain 2 (0v) abnormal
Cause: A single chain 2 (0V) failure occurred.
Remedy: Repair the circuit of the chain 2 (0V) on the hardware. Set the CHAIN FAILURE detection
to TRUE on the SYSTEM/CONFIG screen. Then, press RESET on the teach pendant.
________________________________________________________________
PNT1-134 PAUS NTED input
Cause: The Non-Teacher Enabling Device has been released.
Remedy: This alarm was triggered by the SRVO-232 SERVO NTED input alarm. See this alarm
for the alarm remedy.
________________________________________________________________
PNT1-135 PAUS TP OFF in T1,T2/Door open
Cause: One of the following has occurred:
1. The teach pendant was disabled when the mode switch was in T1 or T2.
2. The controller door is open.
3. The hardware connection is mis-wired.
Remedy: Turn the teach pendant Enable/Disable switch to ON. Close the controller door. Press
RESET. If the reset is not effective, correct the hardware connection.
________________________________________________________________
PNT1-136 WARN Deadman switch released
Cause: The teach pendant DEADMAN switch is released.
Remedy: None.
________________________________________________________________
PNT1-137 PAUS Short term Chain abnormal
Cause: This alarm is echoed to the PLC when a &qout;SRVO-235 SERVO Short term Chain
abnormal&qout; alarm is posted. Refer to the SRVO-235 alarm for the cause.
Remedy: Refer to the SRVO-235 alarm for the remedy.
________________________________________________________________
PNT1-138 WARN Chain failure is repaired
Cause: A chain failure has been repaired.
Remedy: The status of the Chain Failure is changed to normal when the system checks the chain
failure again, and you press RESET.
________________________________________________________________
PNT1-139 WARN Cannot reset chain failure
Cause: Reset chain failure detection cannot be executed.
Remedy: Repair the circuit of the chain 1 (+24V) on the hardware, press the E-STOP button on the
teach pendant, and turn the teach pendant E-STOP button clockwise to release it. Then, press RESET.
________________________________________________________________
PNT1-140 PAUS Brake Release Switch On
Cause: The Brake Release switch on the Standard Operator Panel is ON.
Remedy: Turn the Brake Release switch to the OFF position to engage the brakes.
________________________________________________________________
PNT1-151 WARN Col %s range err/preset %%override
Cause: The specified system color contained percent preset override data that was outside the
pre-defined allowable range for percent overrides.
Remedy: None. The override percent value was automatically adjusted to the closest valid value.
________________________________________________________________
PNT1-152 WARN Data err :Col %s preset %%override
Cause: System color data has uninitialized percent preset override information. This happens when
color data created on a previous version of the software is loaded onto the controller.
Remedy: If the error occurs each time the system color table data is accessed, it might be necessary to
create new color table data on the controller.
________________________________________________________________
PNT1-153 WARN Eff. preset range err (%s)
Cause: The effective preset/estat values (after applying the preset %% override factor for a specified
color, gun, and parameter number) are outside the allowable range for that parameter.
Remedy: Verify that the preset/estat value in the table is within the acceptable range for the parameter.
Check the override percentages defined for that color. Examine the effective preset values to see they
are within the allowable ranges for all parameters.
________________________________________________________________
PNT1-154 WARN Color %s data access error
Cause: The controller could not access data for the specified system color. The data might not have
been created on this controller or might have been accidentally cleared.
Remedy: Create new system color data using the SETUP colors screen on the teach pendant.
________________________________________________________________
PNT1-159 WARN Illegal code in NEXT color %s
Cause: The system color number that is next in the queue is illegal.
Remedy: This error should never occur during normal PaintTool operation. The system color
numbers are being checked when they are put into to the queue.
________________________________________________________________
PNT1-160 WARN Illegal manual color %s received
Cause: For integral color change systems, the color valve selected by the PLC in manual mode
has no data defined.
Remedy: Check the color valve number sent by the PLC. If it is correct, then define the color valve
using the SETUP menus under VALVES.
________________________________________________________________
PNT1-165 WARN TP disabled – Calib. aborted
Cause: Calibration was aborted because the teach pendant was disabled during the process.
Remedy: Keep the teach pendant enabled during calibration. This will not be applicable to Control
Reliable robot controllers, as the teach pendent can not be turned on in auto/manual mode. Calibration
can not be performed from the teach pendant for Control Reliable robot controllers. Calibration
must be done from the GUI.
________________________________________________________________
PNT1-166 WARN Linear Potentiometer Unstable
Cause: During Auto Calibration, the feedback from the linear potentiometer revealed large
fluctuations in the canister position over a short period of time. If the linear potentiometer has been
improperly installed or the magnet has been misaligned, it might cause this alarm.
Remedy: Change the applicator and repair the malfunctioning linear potentiometer. Retry calibration
with a different applicator.
________________________________________________________________
PNT1-167 WARN Table not adapted, max err exceeded
Cause: While operating in hybrid mode, Accustat determined that a discrepancy between the actual
paint used during the job and the expected paint usage was too high to adapt to it. This could be
caused by:
• The color change valves are not operating properly.
• Color change solvent or air has been left in the canister.
• There might be a problem with the applicator.
• The regulator might not be opening/closing properly.
• The restrictor has changed in size.
• The maximum hybrid adaptation value has been set too low.
• The Hybrid Mode Gain is too high.
• If the TPR is below the Low Confidence Min (cc), then the Low Confidence Gain might be
too high.
Remedy: Determine the cause for the flow discrepancy. Check the following:
• Check the regulator, fluid or restrictors for a plugged or restricted passageway.
• Verify that the Hybrid Mode Gain in the AccuStat color data is not too high (default is 20).
• Verify that the Hybrid Mode Gain Factor is not set too high (default is 1.0).
• Set up the Low Confidence Min (ccs) for low TPRs.
• Make the Low Confidence Gain, lower to account for the less resolution at low flow rates.
• Use other alarms that occur during this job to help debug the problem.
• This alarm is a warning by default. No immediate action is necessary unless it has impacted
the job appearance.
• Perform an Auto Calibration on that color valve. If this alarm has faulted the robot the robot, then
reset and continue the job.
________________________________________________________________
PNT1-168 WARN Dedock required, robot at dock
Cause: An attempt was made to move the robot while it was in the docking station. This alarm occurs
when attempting to move the robot either in manual mode, or to the purge position, or to enable
special moves without first moving it out of the docking station.
Remedy: Request to de-dock before initiating robot motion. The robot is at the docking station and
must run dedock before other moves are enabled. Reset the robot, put the cell in manual mode, and
run the de-dock move from the MCP.
________________________________________________________________
PNT1-169 WARN Docking station not retracted
Cause: The position and proximity switch are not functioning properly. This could be caused by
one of the following:
• The docking station has not retracted fast enough.
• The Docking Cylinder Timeout is set too low.
• An obstruction, misalignment, or a faulty switch.
Remedy: Check the following:
• Check the position and the proximity switch.
• Repair the pneumatic or electric circuit if necessary.
• Adjust the pneumatic controls for the retract/extend.
• Increase the Docking Cylinder Timeout Value.
• Verify that the digital inputs and outputs have the proper state. By default: DIN[130, DSR] = ON;
DIN[129, DSE] = OFF; DOUT[147, RDS] = ON; DOUT[146, EDS] = OFF.
• If the dock has retracted, and the I/O has been verified, then reset and continue the robot.
________________________________________________________________
PNT1-170 WARN Docking station not extended
Cause: The position and proximity switch are not functioning properly. This could be caused by
one of the following:
• The docking station has not extended fast enough.
• The Docking Cylinder Timeout is set too low.
• An obstruction, misalignment, or a faulty switch.
Remedy: Check the following:
• Check the position and the proximity switch.
• Repair the pneumatic or electric circuit if necessary.
• Adjust the pneumatic controls for the retract/extend.
• Increase the Docking Cylinder Timeout Value.
• Verify that the digital inputs and outputs have the proper state. By default: DIN[129, DSE] = ON;
DIN[130, DSR] = OFF; DOUT[147, RDS] = OFF; DOUT[146, EDS] = ON.
• If the dock has extended, and the I/O has been verified, then reset and continue the robot.
________________________________________________________________
PNT1-171 WARN Auto Calibration aborted
Cause: The Accustat auto calibration could not continue. This is normally the result of an operation
time-out. The auto calibration can abort for several reasons. The function of this alarm is as follows:
First, the Auto Calibration Aborted alarm will post if an error has occurred. The next alarm will
contain the cause of the auto calibration to abort. Cause 1: While searching for the minimum or
maximum flow rates in the calibration table, the calibration timed out by reaching the maximum
number of attempts to establish the minimum or maximum flow rate output values. This can be a
result of improper fluid restriction selection, non-attainable calibration table flow ranges, or a bad
fluid regulator. The resulting alarms would be PNT1-251, Failed to find upper limit or PNT1-252,
Failed to find lower limit. Cause 2: Calibration resulted in non-increasing command values in the
calibration table data. The slope of the calibration table is negative. Increasing output values do
not result in increased flow rate. The result error code will be PNT1-254 Non-increasing cal table.
Cause 3: The calibration routine calculated output values that are above or below the maximum or
minimum output values defined in the Applicator Parameters for the fluid regulator. The minimum
output values in counts are low-res: 200, hi-res: 1600, and the maximum output values in counts are
low-res: 1000, and hi-res: 8000. The restrictor size is not compatible with the desired flow rate range
and the material attempting to be calibrated. The resulting error codes will be PNT1-255 Calculated
and the material attempting to be calibrated. The resulting error codes will be PNT1-255 Calculated
output > max output or PNT1-256 Calculated output < min output. Cause 4: The calibration has been
aborted by the user or has been interrupted by another fault such as an EMERGENCY STOP during
calibration. Or, the robot failed to reach the proper location in order to calibrate. See other alarms
to determine the cause of the fault.
Remedy: Remedy 1: Increase the number of Maximum Calibration Trys in the AccuStat setup.
Verify restrictor, regulator and calibration flow rate range in the AccuStat Color Data for that valve.
Remedy 2: Verify all equipment is operating properly. Check the linear potentiometer feedback
(AIN[1, DISP], the regulator operation, and that the trigger is opening and closing properly. Verify
attainable values have been set in the AccuStat Color Data for the requested minimum and maximum
flow rates. Remedy 3: Verify that the fluid regulator is functioning properly. Change the fluid
restrictor size to better accommodate the requested flow rate range. Change the requested flow rate
range in the AccuStat Color Data setup. Remedy 4: Determine the cause of the fault to the robot.
Check the alarm log to aid finding the cause of the fault. If the robot has not moved to the correct
position, verify that the proper path has been taught.
________________________________________________________________
PNT1-172 WARN Failed to find Upper limit
Cause: Accustat could not reach the upper flow limit in the number of attempts set at the calibration
screen. This can be caused by one of the following:
• The upper limit flow rate can not be achieved.
• The fluid restricter is too small.
• The flow rate or canister position feedback is unstable.
Remedy: Verify all equipment is working properly. Check the following:
• Check the Color Data upper limit.
• Check the applicator parameters to make sure that the App Parameter Max limit is not below the
AccuStat Color Data upper limit.
• Increase Auto cal hi/low tolerance or Trys for hi/low from the AccuStat SETUP screen.
• Check the potentiometer feedback at the analog input (AIN[1]:DISP). It should change smoothly
without jumps or pauses.
• Verify the air supply pressure to the robot. If the pressure drops below the normal operating
range it will decrease the maximum flow rate.
• A larger paint restrictor may be required for the desired flow rate.
• Check the operation of the fluid regulator and pressure transducer.
• Try a different applicator.
________________________________________________________________
PNT1-173 WARN Failed to find Lower limit
Cause: Accustat could not reach the low flow limit in the number of attempts set at the calibration
screen. This can be caused by:
• The low flow setting is too low to control
• The flow rate or the canister position feedback is unstable.
Remedy: Verify that all equipment is working properly. Check the following:
• Check the low flow on the Accustat Color Data screen. It may be too low to control.
• Check the applicator parameters to make sure that the App Parameter Min limit is not above the
AccuStat Color Data lower limit.
• Increase the Auto cal hi/low tolerance or Trys for high/low from the AccuStat setup screen.
• Check the potentiometer feedback at the analog intput(AIN[1]:DISP). It should move smoothly
without jumping or pausing.
• Try a smaller restrictor if it does not limit the high flow.
• Change Applicators.
________________________________________________________________
PNT1-174 WARN Beaker Timeout, Scale Cal Aborted
Cause: Not enough time has been allowed to empty the canister fully by the time specified in Beaker
Fill Timeout. The canister did not empty due to the trigger or regulator not opening. Or, there has
been a loss of canister position feedback.
Remedy: Check the following:
• Check the regulator and gun to be sure they are functioning properly.
• Increase the Beaker Fill Timeout on the AccuStat SETUP screen.
• Fix the trigger or regulator.
• Verify the canister position feedback (AIN[1, DISP]).
________________________________________________________________
PNT1-175 WARN (%s) Non-increasing cal table
Cause: One of the following events has occurred:
• After the calibration table has been shifted or a new calibration table created, a non-increasing
table of flow command values was detected.
• Unstable flow rates are encountered.
• The canister position change is not proportional to the fluid regulator command.
• The canister position feedback is unstable.
Remedy: Check the following:
• Verify that the regulator is working properly.
• Verify the fluid restrictor is suitable for the desired flow rates.
• Check proper feedback from the linear potentiometer.
• If this occurs as a result of a table shift, calibrate the color valve in which the calibration table
has become non-increasing.
________________________________________________________________
PNT1-176 WARN Calculated output > Max Output
Cause: The auto-calibration calculated the high flow output greater than the maximum output. The
cal table was saved with a lower range of flow than requested.
Remedy: Look at the calibration results to determine if the maximum flow rate is acceptable. If
you do not need a higher flow rate then no additional action is required. If you need a higher flow
rate then try the following
• Verify the range on the Accustat Color DATA screen.
• Verify the air supply pressure to the robot. If the pressure drops below the normal operating
range it will decrease the maximum flow rate.
• A larger paint restrictor might be required for the desired flow rate.
• Check the operation of the fluid regulator and pressure transducer.
• Try a different applicator.
________________________________________________________________
PNT1-177 WARN Calculated output < Min Output
Cause: One of the following events has occurred:
• The calculated command counts are below the Applicator Parameter Minimum Output value
(200 counts, or 1600 counts hi-res).
• The fluid restrictor is too large or the regulator is not working properly.
Remedy: Restrict fluid flow with a smaller restrictor. Or, check the Color Data Hi/Low flow range
settings.
________________________________________________________________
PNT1-178 WARN Failed to reach setpoint
Cause: One of the following events has occurred:
• The Tolerance Band is too narrow (low), or the regulator is not working properly.
• The adaptive gain for that color might be too low, and the flow rate is not adapting fast enough.
• The potentiometer is not operating properly.
• The trigger delay might not be set properly, if trigger events are too close together.
Remedy: Check regulator operation and Adaptive Gain settings in the AccuStat Color Data for that
color valve. Also, verify that the trigger delays are set up properly.
________________________________________________________________
PNT1-179 WARN Canister Fill Error
Cause: Prior to painting the job, the can is checked to see if enough paint has been put into the can
(cylinder position counts >= TPR counts). This can occur if the &qout;waiting for can full&qout;
condition is falsely satisfied. Possible causes are air in the canister due to faulty color change cycles,
or unstable readings from the linear potentiometer. Many times this happens because the air has not
been pushed out of the dump before the fill valve is opened.
Remedy: Make sure that paint has reached the docking station before starting the step to open the
fill valve. Try increasing the amount of time of the step to fill the paint line before opening the fill
valve. With air in the can, after the piston pressure has been reapplied the air will compress causing
the cylinder position to fall below the fill counts.
________________________________________________________________
PNT1-180 WARN Auto Calibration Successful
Cause: The Auto Calibration for the selected color valve has completed succesfully.
Remedy: None.
________________________________________________________________
PNT1-181 WARN Non-decreasing canister position
Cause: This alarm will be displayed if the gun has been on for the amount of time specified as
Canister Check Time and the amount of change in cylinder position counts has not reached the
Minimum Canister Change Counts. This can be caused by low flow rates, where it takes longer
to see this minimum cylinder position change. It could be an indicator of trouble with the linear
potentiometer or the feedback circuit.
Remedy: Lower the Minimum Canister Change Counts or increase the Canister Check Time. Check
the feedback from the linear potentiometer or repair the low voltage wire for the canister feedback
circuit.
________________________________________________________________
PNT1-182 WARN Canister Position Increasing
Cause: This alarm will be displayed if the piston moves during a color change cycle when it is
held at the bottom of the can for cleaning, and the cleaning solvent and air pressure overcome the
piston air pressure.
Remedy: Perform a scale calibration to insure that the calculated value for the Can Empty Check
Counts is valid. Increase the Fill Error Tolerance. Verify that the piston pressure is not being restricted.
________________________________________________________________
PNT1-183 WARN Intermittent Connection Detected
Cause: A reading of 0 counts on the analog input (AIN[1,DISP]) causes the intermittent connection
alarm. This is an indicator of potentiometer trouble during job playback, caused by an open/short
circuit in cylinder position feedback. This alarm only occurs during a job or color change in auto
mode. Regular, but not consistent, postings of this alarm indicate a poor electrical connection in the
feedback circuit. The electrical connector at the quick disconnect (QD) plate, when damaged or
worn, can cause this alarm. Induced noise in the feedback circuit from poor grounding leads to
this temporary condition as well. Resistors inside the robot controller set the supply voltage to the
linear potentiometer, and should be set at 10 Volts.
Remedy: Replace the electrical connector on the quick disconnect (QD) plate. Verify proper
grounding of the feedback circuit. Replace the low voltage cable in the robot arm. Check the supply
voltage to the linear potentiometer.
________________________________________________________________
PNT1-184 WARN Flow Error High, Valve: %s
Cause: If the percentage of paint left in the can exceeds the total paint required (TPR) by the Job
Total Error Tolerance, then this alarm will post. If the paint usage exceeds the TPR by the Job Total
Error Tolerance, then this alarm will be displayed. Most of the time, the can will run out of paint
before the paint usage exceeds the TPR by this percentage. This indicates that the fluid flow has
been restricted or the can has run out of paint.
Remedy: The paint needs to be calibrated or the adaptive gain for that color valve is too high. The
regulator might not be actuating properly from not running a clean out cycle before the end of the
shift. Often other error conditions will occur prior to this alarm. Check the alarm log to help detect
other symptoms leading to this alarm.
________________________________________________________________
PNT1-185 WARN Applicator Disabled during job
Cause: If the applicator is disabled at the end of the job, then the table will not adapt in hybrid mode.
Remedy: None.
________________________________________________________________
PNT1-186 WARN Scale Calibration Aborted
Cause: The scale calibration sequence did not complete. This can be caused by a timeout or
fill/empty error.
Remedy: Check the alarm log to see what conditions caused the calibration to abort. In most cases,
the scale calibration can time out from one of the following alarms: PNT1-253 Beaker timeout, scale
cal abort, PNT1-248, CC abort, can full timeout, PNT1-249 CC abort, can empty timeout. Verify
all equipment is operating properly. Refer to the Cause/Remedy information for the other alarms
for more information.
________________________________________________________________
PNT1-187 WARN Scale Calibration Successful
Cause: The scale calibration sequence has completed successfully.
Remedy: None.
________________________________________________________________
PNT1-192 WARN De-Docking program is undefined
Cause: No path data has been taught for DEDOCK.TP. Something has caused the position to
become invalid.
Remedy: Teach the robot path for the de-docking operation. The de-dock path is a special position.
After teaching, or touching up special position paths, you must turn the robot controller off and then
on again in order for the changes to take effect.
________________________________________________________________
PNT1-193 WARN Docking program is undefined
Cause: No path data has been taught for DOCK.TP. Something has caused the position to become
invalid.
Remedy: Teach the robot path for the docking operation. The dock path is a special position. After
teaching, or touching up special position paths, you must turn the robot controller off and then on in
order for the changes to take effect.
________________________________________________________________
PNT1-194 WARN Robot NOT at docking position
Cause: One of the following items has occurred:
• The request to enter the dock was given but the robot did not reach the docking position.
• The dock attempt did not complete and the docking station could not extend.
• The robot faulted on the way to the docking station.
• See the alarm history for information on other errors that might have occurred.
• The robot did not report it was at the docking station, because the dock special position was
not taught.
Remedy: Check the path data and ensure the last position in DOCK.TP has a FINE position type.
Verify that the DOCK.TP special position has been taught. The controller power must be cycled after
special positions are taught. If the Dock path did not complete its execution, then determine why
execution was halted. Reset the robot and continue the job. The robot should complete the motion
automatically. If the robot does not complete the motion, then in manual mode, move the robot home.
After the cell has been put into manual mode, the job must be reinitialized.
________________________________________________________________
PNT1-200 PAUS Door held input lost
Cause: The door held input was lost during part held scanning.
Remedy: Check the input as soon as possible. If the job can still be continued, activate the ignore part
signal to disable scanning operations.
________________________________________________________________
PNT1-201 PAUS Door detect sensor malfunction
Cause: The door held sensor was damaged or is malfunctioning.
Remedy: Check the sensor and fix it. If the job can still be continued, activate the ignore part signal
to disable scanning operations.
________________________________________________________________
PNT1-202 WARN Illegal Opener macro Called
Cause: This alarm can be posted for a robot or an opener program:
• A robot requested a second action from an opener with a &qout;RqstRmtOpnrAct&qout; macro
before waiting for the opener to finish the previous action with a &qout;WaitRmtOpnrDone&qout;
Macro.
• An opener sent a second complete status to a robot with a &qout;OpnrRmtActCmp&qout; macro
before waiting for a second request with a &qout;OpnrRmtWaitRqst&qout; Macro.
Remedy: Edit the programs so the commucation macros match. The robot program should
alternate between requesting a remote opener action with &qout;RqstRmtOpnrAct&qout;
and waiting for the remote opener to complete with &qout;WaitRmtOpnrDone&qout;. For
each &qout;RqstRmtOpnrAct&qout; in the robot program the remote opener program needs a
&qout;OpnrRmtWaitRqst&qout; macro. For each &qout;WaitRmtOpnrDone&qout; in the robot
program the remote opener program needs a &qout;OpnrRmtActCmp&qout; macro.
________________________________________________________________
PNT1-203 WARN Robot in opener path
Cause: The opener move cannot be excuted because the robot is in the opener path.
Remedy: Jog the robot so that it is clear of the opener, and then reissue the move.
________________________________________________________________
PNT1-204 WARN Opener in robot path
Cause: The robot move cannot be excuted because the opener is in the robot path.
Remedy: Jog the opener so that it is clear of the robot, and then reissue the move.
________________________________________________________________
PNT1-205 WARN Opener Bypass is undefined
Cause: The opener bypass program has not been taught (recorded).
Remedy: Teach (record) the opener bypass program (OPNBYPAS.TP).
________________________________________________________________
PNT1-206 WARN Opener Special1 program is undefined
Cause: The special1 opener program has not been taught (recorded).
Remedy: Teach (record) the special1 opener program (OPNSPC1.TP).
________________________________________________________________
PNT1-207 ABRT Opener Home program is undefined
Cause: The opener home program has not been taught (recorded).
Remedy: Teach (record) the opener home program (OPN1HOME.TP).
________________________________________________________________
PNT1-213 WARN Bad cur_color no.[%d]
Cause: The cur_color number is out of range.
Remedy: Check [PASHELL] cur_color to make sure it is between (1-MAX_VALVES(31)).
________________________________________________________________
PNT1-214 WARN Bad cal.tbl.(color[%d]-parm[%d])
Cause: The parameter calibration table does not increase.
Remedy: Check the color and parameter calibration tables.
________________________________________________________________
PNT1-215 ABRT %s group mask(%d) != tracking schedule group(%d)
Cause: This teach pendant program group mask does not match the group (robot or opener) in
the tracking schedule.
Remedy: Check each robot and opener process program to verify that the tracking schedule number
is assigned to this group.
________________________________________________________________
PNT1-216 WARN No defined color (color=[%d])
Cause: The color that has been sent with the current job has not been defined.
Remedy: You must define this color in the SETUP Color Table before initializing the robot with
this color.
________________________________________________________________
PNT1-224 WARN WAITCONV[] late for line %s
Cause: The first stroke that was late on the part for this job started at this line. The current speed of
the conveyor is too fast for the speed of this Job and Color Group.
Remedy: Decrease the speed at which the conveyor is moving. Increase the Target Speed or Fan
width, or both for the current Color Group. Decrease the Percent Overlap for the current Color Group.
________________________________________________________________
PNT1-225 WARN Data Monitor is disabled
Cause: The Data Monitor subsystem has been disabled because the limit on the data files set by
the user has been reached.
Remedy: Enable Data Monitor Operation from the UTILITIES Data Monitor screen. On the SETUP
Diagnostics screen, consider increasing Max Data Files Stored or setting Disable After Max Files to
NO, if these settings caused Data Monitor to be disabled. Refer to the FANUC Robotics PaintTool
Setup and Operations Manual Advanced Functions chapter for more information.
________________________________________________________________
PNT1-226 WARN Maximum DMON Data Files exceeded
Cause: The limit on data files that can be stored by the Data Monitor subsystem has been reached.
Remedy: On the SETUP Diagnostics screen, consider increasing the maximum files stored by setting
Max Data Files Stored to a larger number, or setting Disable After Max Files to NO. Refer to the
FANUC Robotics PaintTool Setup and Operations Manual, Advanced Functions chapter for more
information on these items.
________________________________________________________________
PNT1-227 WARN DMON in progress, item locked
Cause: A Data Monitor session is in progress during an attempt to change the setup that could
affect the current session.
Remedy: Wait until the end of the Data Monitor session. If in Automatic Sampling mode, this
happens at the end of the job. If sampling in Asynchronous mode, stop the current session by setting
SAMPLE NOW under SETUP Diagnostics to STOP.
________________________________________________________________
PNT1-228 WARN Asynchronous DataMonitor disabled
Cause: Asynchronous Data Monitoring has been disabled.
Remedy: To re-enable Asynchronous Data Monitoring, ensure that the UTILITIES Data Monitor,
Data Monitor Operation item is enabled. Also set the Auto Sample Each Job item on the SETUP
Diagnostics screen to NO.
________________________________________________________________
PNT1-229 WARN Asynchronous DataMonitor enabled
Cause: Asynchronous Data Monitor has been enabled.
Remedy: None.
________________________________________________________________
PNT1-230 WARN DMON file management disabled
Cause: File management features have been disabled because the Max Data Files item on the SETUP
Diagnostics screen is set to 0. Stored data will be over-written by subsequent sampling sessions.
Remedy: No action required. To re-enable file management features, you can set Max Data Files
to a non-zero value. Ensure that the destination data storage device has adequate space. Refer to
the Advanced Functions chapter of the FANUC Robotics PaintTool Setup and Operations Manual
for more information.
________________________________________________________________
PNT1-231 WARN DMON file management enabled
Cause: File management features have been enabled because the Max Data Files Stored item on the
SETUP Diagnostics screen has been set. The Data Monitor will store as many old data files as
indicated.
Remedy: No action required if the destination data storage device has adequate space. To disable file
management features, set Max Data Files Stored to 0. Refer to the Advanced Functions chapter in the
FANUC Robotics PaintTool Setup and Operations Manual for more information.
________________________________________________________________
PNT1-232 WARN Sample_start builtin exec failed
Cause: The KAREL built-in, SAMPLE_START, returned an unacceptable status.
Remedy: Contact your FANUC Robotics service representative.
________________________________________________________________
PNT1-233 WARN Sample_end builtin exec failed
Cause: The KAREL built-in SAMPLE_END returned an unacceptable status.
Remedy: Contact your FANUC Robotics service representative.
________________________________________________________________
PNT1-241 PAUS %sGlss Breakage Detected
Cause: During production, one of the glass strands feeding through the chopper motor was detected
to be broken by its corresponding microphone sensor.
Remedy: Jog the robot away from the fault location, and re-thread the glass strand through the
chopper motor. Jog the robot near the fault location, and continue the cycle.
________________________________________________________________
PNT1-242 PAUS %sCatalyst Flow Error
Cause: During production, the catalyst flow stopped which is causing only the resin to flow.
Remedy: This can be due to a faulty Kobold sensor, or mechanical problems with the catalyst pump.
________________________________________________________________
PNT1-243 WARN %s flow command warning
Cause: During production, an increase in command output was issued in order to maintain setpoint.
This increase surpassed the Command Warning percentage value. An additional jump in command
output might fault the robot.
Remedy: This problem might be due to a clogged gun tip, or old equipment. Clean the gun tip
and check the lines and equipment.
________________________________________________________________
PNT1-244 PAUS %s flow command alarm
Cause: During production, a significant increase in command output was issued in order to maintain
setpoint. This increase surpassed the Command Alarm percentage value which faulted the robot.
Remedy: This problem might be due to a clogged gun tip, or old equipment. Clean the gun tip,
and check the lines and equipment.
________________________________________________________________
PNT1-245 PAUS %s0 res flow rate T.O.
Cause: All of the conditions were set for resin fluid to be flowing, however a zero flow rate was
measured. This might be caused by:
• A broken applicator trigger
• A loss of resin fluid supply pressure
• A broken flow meter
• A broken cable (to the flow meter)
• A Zero fluid flow timeout value that is too short
Note: Accuchop automatically faults the robot when this alarm occurs.
Remedy: Check that the gun is properly triggering. If fluid was observed to be flowing, check and,
if necessary, replace the fluid flow meter. If necessary, increase the Zero flow timeout parameter
by about 25%.
________________________________________________________________
PNT1-246 PAUS %sMax output has flow < setpoint
Cause: With a maximum control output, the flow rate was measured to be lower than the setpoint
(requested flow). This can be caused by:
• The resin gun might be clogging.
• The resin or pilot air line might be pinched.
• The resin fluid pressure might have become too low.
• The I/P transducer might be broken.
Note: Accuchop automatically faults the robot and enters into Open Loop when this failure occurs.
Remedy: Check the following:
• Check the gun tip and the whole gun for clogging.
• Check the resin lines for pinching, especially at places where they flex.
• Check the resin supply pressure.
• Check and replace, if necessary, the I/P transducer.
________________________________________________________________
PNT1-247 PAUS %sMin output has flow > setpoint
Cause: With a minimum control output, the flow rate was measured to be higher than the flow rate
setpoint. The resin fluid pressure might have become too high. The I/P transducer or fluid regulator
might be stuck open. Or, there might be a fairly large fluid leak. Note: Accuchop automatically faults
the robot and enters into Open Loop when this failure occurs.
Remedy: Calibrating the resin will establish a new cracking pressure (minimum control output) for
a changed fluid pressure. Check the resin fluid regulator and I/P transducer, and replace them if
necessary.
________________________________________________________________
PNT1-248 PAUS %s0 gls feed rate T.O.
Cause: All of the conditions were set for glass to be feeding, however a zero feed rate was measured.
This might be caused by:
• A broken applicator trigger
• A broken chopper motor sensor
• A broken cable (to chopper motor sensor)
• A Zero glass feed timeout value that is too short.
Note: Accuchop automatically faults the robot when this alarm occurs.
Remedy: If the glass is not feeding from the chopper motor, check the items listed above or the
32 point input module. If it occurs with very low feed rates, decrease the Normal gain modifier
in Accuchop’s Glass SETUP screen.
________________________________________________________________
PNT1-249 PAUS %sMax output has feed < setpoint
Cause: With a maximum control output, the glass feed rate was measured to be lower than the
setpoint (requested feed). The chopper motor might be clogging. Note: Accuchop automatically
faults the robot and enters into Open Loop when this failure occurs.
Remedy: Check and clean the chopper motor if it is clogged. Check and replace the I/P transducer, if
necessary.
________________________________________________________________
PNT1-250 PAUS %sMin output has feed > setpoint
Cause: With a minimum control output, the glass feed rate was measured to be higher than the
feed rate setpoint. The motor (glass) RPM might have become too high. The I/P transducer might
be stuck open. Note: Accuchop automatically faults the robot and enters into Open Loop when
this failure occurs.
Remedy: Calibrating the glass will establish a new cracking pressure (minimum control output).
Check and replace the I/P transducer, if necessary.
________________________________________________________________
PNT1-255 WARN RDU Full – Proc Champ disabled
Cause: The report file generated by Process Champion has filled the RDU device to its capacity.
This forces the system to disable Process Champion auto mode so that no further auto appending is
performed on the file. The file has been copied to FR: and is deleted from RDU:.
Remedy: For R-J3 controller only. Re-enable Process Champion auto mode by setting the Set Process
Champion Mode item, in the SETUP Production screen, to Auto. To prevent FR: from filling to
capacity, remove the file from FR: to another device such as a PCMCIA card.
________________________________________________________________
PNT1-258 PAUS HIGH SpeedDock TORQUE: %s
Cause: The torque value of the SpeedDock exceeded the maximum safety limit.
Remedy: Determine the cause of the high torque reading, and resolve the problem.
________________________________________________________________
PNT1-259 WARN SpeedDock motor not ready
Cause: The servo power to the SpeedDock motor is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off for some reason, such as
E-stop condition or the machine is locked. Correct the condition, and reset the controller.
________________________________________________________________
PNT1-262 PAUS Pusher at Dock %s
Cause: An attempt was made to extend or retract the pusher at SpeedDock side A or B, but failed.
Remedy: Check the retract or extend sensor at SpeedDock side A or B. Ensure that the pusher
retracted or extended fully at SpeedDock side A or B. Ensure that sufficient air pressure is available
for this operation, and that the air lines are connected.
________________________________________________________________
PNT1-263 PAUS Valve at Dock %s
Cause: An attempt was made to extend or retract the valve at SpeedDock side A or B, but failed.
Remedy: Check the retract or extend sensor at SpeedDock side A or B. If it was an extended fault,
ensure that the pusher extended fully at SpeedDock side A or B. If it was a retracted fault, ensure that
the pusher retracted fully at SpeedDock side A or B and that the valve is not stuck in the extended state.
Ensure that sufficient air pressure is available for this operation and that the air lines are connected.
________________________________________________________________
PNT1-266 PAUS SpeedDock EXTEND Error
Cause: An attempt was made to extend the SpeedDock docking mechanism at side A or B, and failed.
Remedy: Check the sensors at SpeedDock docking mechanism. Ensure that sufficient air pressure is
available for this operation and that the air lines are connected securely.
________________________________________________________________
PNT1-267 PAUS SpeedDock RETRACT Error
Cause: An attempt was made to retract the SpeedDock docking mechanism at side A or B, and failed.
Remedy: Check the sensors at the SpeedDock docking mechanism. Ensure that sufficient air pressure
is available for this operation, and that the air lines are connected securely.
________________________________________________________________
PNT1-270 PAUS Retract Hard Stop Error
Cause: An attempt was made to Retract the hard stop from its normal state, but the operation failed.
Remedy: Determine if the hard stop physically retracted. If so, check the functionality of the sensors.
Ensure that the I/O is mapped correctly. If the hard stop did not retract, determine if the hard stop
received the RETRACT output signal.
________________________________________________________________
PNT1-271 PAUS Extend Hard Stop Error
Cause: An attempt was made to extend the hard stop to its normal state, but the operation failed.
Remedy: Determine if the hard stop physically extended. If so, check the functionality of the sensors.
Ensure that the I/O is mapped correctly. If the hard stop did not extend, determine if the hard stop
received the EXTEND output signal.
________________________________________________________________
PNT1-272 ABRT Exit Srv pos in prog is undefined
Cause: The robot ENT_SRV program is not taught.
Remedy: Teach the ENT_SRV.TP program.
________________________________________________________________
PNT1-273 ABRT Ent Srv pos in prog is undefined
Cause: The Robot EXIT_SRV program is not taught.
Remedy: Teach the EXIT_SRV.TP program.
________________________________________________________________
PNT1-276 WARN Error opening TPE program
Cause: This error should never occur during normal PaintTool operation.
Remedy: Contact FANUC Robotics service personnel.
________________________________________________________________
PNT1-277 WARN TPE Built-in error
Cause: An failed attempt was made to perform a software operation on a specific teach pendant
program. This error should never occur during normal PaintTool operation.
Remedy: Contact FANUC Robotics service personnel.
________________________________________________________________
PNT1-278 WARN TPE find/read header error
Cause: This error should never occur during normal PaintTool operation. In the event that this alarm
was posted, PaintTool was making an attempt to extract data from a specific teach pendant program,
but failed.
Remedy: Ensure that the teach pendant program is installed on the controller, or contact FANUC
Robotics service personnel.
________________________________________________________________
PNT1-279 WARN TPE error reading instruction
Cause: This error should never occur during normal PaintTool operation. In the event that this
alarm was posted, PaintTool was making an attempt to extract positional data from a specific teach
pendant program, but failed.
Remedy: Ensure that the teach pendant program is installed on the controller, or contact Fanuc
service personnel.
________________________________________________________________
PNT1-280 WARN TPE wrong type of program:%s
Cause: This error should never occur during normal PaintTool operation. In the event that this alarm
was posted, PaintTool was making an attempt to read data from a specific teach pendant program but
failed because the teach pendant program does not exist, or the file type is not a teach pendant program.
Remedy: Ensure that the teach pendant program is installed on the controller, or contact FANUC
Robotics service personnel.
________________________________________________________________
PNT1-281 WARN TPE error closing a program
Cause: This error should never occur during normal PaintTool operation. In the event that this alarm
was posted, PaintTool was making an attempt to close an opened teach pendant program, but failed.
Remedy: Contact FANUC Robotics service personnel.
________________________________________________________________
PNT1-282 WARN Selected program not found
Cause: The job that is selected for DATA ZONE EDIT or TEST RUN does not exist.
Remedy: Generate the job or select a job that exists.
________________________________________________________________
PNT1-283 WARN out of(strt,end)ext1 at line%s
Cause: The EXT1 (extended axis) of the current position is out of range of the EXT1 start to EXT1
end values.
Remedy: This will not affect the X-Rail smoothing process. Choose another smoothing range if
necessary.
________________________________________________________________
PNT1-284 WARN TPE’s motion group must be 1
Cause: The motion group of teach pendant program must be 1 when using the X-Rail Manager.
Remedy: Choose another teach pendant program that uses motion group 1.
________________________________________________________________
PNT1-285 WARN TPE Header size mismatch
Cause: The teach pendant program header size is inadequate. The program might have been created
on an older software version. Or, the program header information might not be stored correctly.
Remedy: Try selecting the program, then selecting DETAIL, then NEXT, then END. If this does not
work, create a new teach pendant program, and paste the lines from the old program into it.
________________________________________________________________
PNT1-286 PAUS Uninitialized TPE position in program %s
Cause: There was an uninitialized position found in the specified special move position. This could
have occurred if a new position was recorded in one of the special move programs when the robot
was not mastered or calibrated, causing an uninitialized position to be created. Executing a specific
operation afterwards might cause this alarm to occur.
Remedy: Ensure the robot is mastered and calibrated. Re-teach the position in the special move
program indicated by the alarm.
________________________________________________________________
PNT1-326 WARN %sRobot is bypassed
Cause: The robot not bypassed input is OFF.
Remedy: Turn on the robot not bypassed input.
________________________________________________________________
PNT1-327 ABRT %sSHELL failed to run SUBSHELL
Cause: The subtask failed to run.
Remedy: Cold start the controller.
________________________________________________________________
PNT1-328 WARN %sE-STAT unit faulted
Cause: Detected a E-STAT unit fault.
Remedy: Clear E-STAT unit fault.
________________________________________________________________
PNT1-329 WARN %sAutomatic CLNOUT on prod_entry
Cause: An automatic move from the cleanin position on production entry is enabled.
Remedy: None.
________________________________________________________________
PNT1-330 WARN %sCannot create presets
Cause: When a job is created, the presets for the job are also created. In this case, the presets for
the job could not be created.
Remedy: Check that the job name is of the form JOBXXXX, where XXXX is a number between 1
and 1024.
________________________________________________________________
PNT1-331 WARN %sCannot read presets data file
Cause: The preset data for the current job could not be found.
Remedy: Check for the existence of a file called PAPSXXXX, where XXXX is the job number. This
file is created when the job is created. This error might occur if the job was incorrectly named or
the file was deleted.
________________________________________________________________
PNT1-332 ABRT %s not calibrated
Cause: The calibration status for each control parameter must be complete before it can be used in
a program.
Remedy: Calibrate all control parameters used within the current program.
________________________________________________________________
PNT1-333 ABRT %sFailed to continue robot task
Cause: An attempt to continue the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-334 ABRT %sFailed to pause robot task
Cause: An attempt to pause the robot motion task has failed. The robot motion task has aborted.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-335 ABRT %sFailed to abort robot task
Cause: An attempt to abort the robot motion task has failed. The robot motion task might not have
been running at the time an attempt was made to abort it.
Remedy: None.
________________________________________________________________
PNT1-336 ABRT %sRobot task has faulted
Cause: The robot task has faulted, but was not detected by the main task.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-337 ABRT %sFailed to run robot task
Cause: An attempt to run the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-345 WARN %sRobot is bypassed
Cause: Robot Not Bypassed input is OFF.
Remedy: Robot Not Bypassed input must be ON.
________________________________________________________________
PNT1-346 ABRT %sSHELL failed to run SUBSHELL
Cause: The subtask failed to run.
Remedy: Cold start the controller.
________________________________________________________________
PNT1-347 WARN %sE-STAT unit faulted
Cause: An E-STAT unit fault was detected.
Remedy: Clear the E-STAT unit fault.
________________________________________________________________
PNT1-348 WARN %sAutomatic CLNOUT on prod_entry
Cause: An automatic move from the cleanin position on production entry is enabled.
Remedy: None.
________________________________________________________________
PNT1-349 WARN %sCannot create presets
Cause: When a job is created, the presets for the job are also created. In this case, the presets for
the job could not be created.
Remedy: Check that the job name is of the form JOBXXXX, where XXXX is a number between 1
and 1024.
________________________________________________________________
PNT1-350 WARN %sCannot read presets data file
Cause: The preset data for the current job could not be found.
Remedy: Check for the existence of a file PAPSXXXX, where XXXX is the job number. This
file is created when the job is created. This message might be displayed if the job was incorrectly
named, or if the file was deleted.
________________________________________________________________
PNT1-351 ABRT %s not calibrated
Cause: The calibration status for each control parameter must be complete before it can be used in
a program.
Remedy: Calibrate all control parameters used within the current program.
________________________________________________________________
PNT1-352 ABRT %sFailed to continue robot task
Cause: An attempt to continue the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-353 ABRT %sFailed to pause robot task
Cause: An attempt to pause the robot motion task has failed. The robot motion task has aborted.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-354 ABRT %sFailed to abort robot task
Cause: An attempt to abort the robot motion task has failed. The robot motion task might not have
been running at the time an attempt was made to abort it.
Remedy: None.
________________________________________________________________
PNT1-355 ABRT %sRobot task has faulted
Cause: The robot task has faulted, but was not detected by the main task.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-356 ABRT %sFailed to run robot task
Cause: An attempt to run the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT1-364 ABRT %sHome program is undefined
Cause: The robot home program has not been taught.
Remedy: Teach the robot home program (HOME.TP).
________________________________________________________________
PNT1-365 ABRT %sEnter cleaner program is undefined
Cause: The robot cleanin program has not been taught.
Remedy: Teach the robot cleanin program (CLNIN.TP).
________________________________________________________________
PNT1-366 ABRT %sExit cleaner program is undefined
Cause: The robot cleanout program has not been taught.
Remedy: Teach the robot cleanout program (CLNOUT.TP).
________________________________________________________________
PNT1-367 ABRT %sBypass program is undefined
Cause: The robot bypass program has not been taught.
Remedy: Teach the robot bypass program (BYPASS.TP).
________________________________________________________________
PNT1-368 ABRT %sPurge program is undefined
Cause: The robot purge program has not been taught.
Remedy: Teach the robot purge program (PURGE.TP).
________________________________________________________________
PNT1-369 ABRT %sMaster program is undefined
Cause: The robot master program has not been taught.
Remedy: Teach the robot master program (MASTER.TP).
________________________________________________________________
PNT1-370 ABRT %sSpecial 1 program is undefined
Cause: The robot special1 program has not been taught.
Remedy: Teach the robot special1 program (SPECIAL1.TP).
________________________________________________________________
PNT1-371 ABRT %sSpecial 2 program is undefined
Cause: The robot special2 program has not been taught.
Remedy: Teach the robot special2 program (SPECIAL2.TP).
________________________________________________________________
PNT1-372 WARN %sRobot not at home position
Cause: The robot is not at the Home position.
Remedy: Move the robot to the Home position.
________________________________________________________________
PNT1-373 WARN %sRobot at cleaner position
Cause: The robot is positioned at the cleaner.
Remedy: The robot must execute a cleanout move before continuing.
________________________________________________________________
PNT1-374 WARN %sRobot not at cleaner position
Cause: The robot is not positioned at the cleaner.
Remedy: The robot must be at the cleaner position before a move to exit the cleaner is executed.
________________________________________________________________
PNT1-375 WARN %sEnter Maintenance program is undefined
Cause: Robot maintenance in program is not taught.
Remedy: Teach robot maintenance in program (MNTIN.TP).
________________________________________________________________
PNT1-376 WARN %sExit Maintenance program is undefined
Cause: Robot maintenance out program is not taught.
Remedy: Teach robot maintenance out program (MNTOUT.TP).
________________________________________________________________
PNT1-377 WARN %sRobot not at maintenance position
Cause: Robot is not positioned at maintenance.
Remedy: Robot must be at the maintenance position before a move to exit maintenance is executed.
________________________________________________________________
PNT1-382 ABRT %sHome program is undefined
Cause: Robot home program is not taught.
Remedy: Teach robot home program (HOME.TP).
________________________________________________________________
PNT1-383 ABRT %sEnter cleaner program is undefined
Cause: Robot cleanin program is not taught.
Remedy: Teach robot cleanin program (CLNIN.TP).
________________________________________________________________
PNT1-384 ABRT %sExit cleaner program is undefined
Cause: The robot cleanout program has not been taught.
Remedy: Teach the robot cleanout program (CLNOUT.TP).
________________________________________________________________
PNT1-385 ABRT %sBypass program is undefined
Cause: Robot bypass program is not taught.
Remedy: Teach robot bypass program (BYPASS.TP).
________________________________________________________________
PNT1-386 ABRT %sPurge program is undefined
Cause: Robot purge program is not taught.
Remedy: Teach robot purge program (PURGE.TP).
________________________________________________________________
PNT1-387 ABRT %sMaster program is undefined
Cause: Robot master program is not taught.
Remedy: Teach robot master program (MASTER.TP).
________________________________________________________________
PNT1-388 ABRT %sSpecial 1 program is undefined
Cause: Robot special1 program is not taught.
Remedy: Teach robot special1 program (SPECIAL1.TP).
________________________________________________________________
PNT1-389 ABRT %sSpecial 2 program is undefined
Cause: Robot special2 program is not taught.
Remedy: Teach robot special2 program (SPECIAL1.TP).
________________________________________________________________
PNT1-390 WARN %sRobot not at home position
Cause: The robot is not at the Home position.
Remedy: Move the robot to the Home position.
________________________________________________________________
PNT1-391 WARN %sRobot at cleaner position
Cause: The robot is positioned at the cleaner.
Remedy: The robot must execute a cleanout move before continuing.
________________________________________________________________
PNT1-392 WARN %sRobot not at cleaner position
Cause: The robot is not positioned at the cleaner.
Remedy: The robot must be at the cleaner position before a move to exit the cleaner is executed.
________________________________________________________________
PNT1-393 WARN %sEnter Maintenance program is undefined
Cause: Robot maintenance in program is not taught.
Remedy: Teach robot maintenance in program (MNTIN.TP).
________________________________________________________________
PNT1-394 WARN %sExit Maintenance program is undefined
Cause: Robot maintenance out program is not taught.
Remedy: Teach robot maintenance out program (MNTOUT.TP).
________________________________________________________________
PNT1-395 WARN %sRobot not at maintenance position
Cause: Robot is not positioned at maintenance.
Remedy: Robot must be at the maintenance position before a move to exit maintenance is executed.
________________________________________________________________
PNT1-400 WARN %sApplicator enable is OFF
Cause: This message is displayed when the applicator valve enable input turns off. When this input is
off, the GUN trigger outputs are blocked from turning on.
Remedy: None.
________________________________________________________________
PNT1-401 WARN %sApplicator enable is ON
Cause: This message is displayed when the applicator valve enable input turns on.
Remedy: None.
________________________________________________________________
PNT1-406 WARN %sApplicator enable is OFF
Cause: This message is displayed when the applicator valve enable input turns off. When this input is
off, the GUN trigger outputs are blocked from turning on.
Remedy: None.
________________________________________________________________
PNT1-407 WARN %sApplicator enable is ON
Cause: This message is displayed when the applicator valve enable input turns on.
Remedy: None.
________________________________________________________________
PNT1-412 WARN %sError reading gun-on time for job
Cause: Some process or processes within a job might have something wrong with their headers.
Remedy: Display the DETAIL page for every process in the job. This should correct the problem.
________________________________________________________________
PNT1-413 WARN %sNo TPR calculated for job
Cause: The PGOT procedure was not performed on the processes used within the selected job
(style). The TPR is equal to zero. No Preset Gun On Time for the job could be found. The job has
not been test cycled.
Remedy: Perform the PGOT procedure on the desired job (style). Test cycle the job or allow it to
correct itself by running the process in production, if enough paint has been loaded into the canister.
________________________________________________________________
PNT1-414 WARN %sTPR Mismatch (%s) PGOT Required
Cause: The previous job gun on time for the current job differs from the calculated preset gun on
times used for the TPR calculation by more than the allowed tolerance. The Gun On Time stored in the
job header does not correspond to the preset on times read from the job processes. This can be a result
of process changes done on the fly. The robot will not have the proper amount of paint to run the job.
Remedy: Perform a PGOT test cycle on the job that caused the TPR mismatch alarm. If the robot has
filled sufficiently for the job, then it will automatically correct the TPR when the job is completed.
If the robot has faulted due to this alarm, then press RESET and continue the job. If this alarm
commonly occurs due to on the fly process changes, then increase the Gun On Time Error Tolerance.
Caution must be used in setting this value too high, because if the new gun on time is sufficiently
higher than the old gun on time in the header, the TPR will be too low and the gun will run out of paint.
________________________________________________________________
PNT1-415 WARN %sTPR exceeds Can Volume
Cause: The calculated TPR exceeds the volume of the can. The TPR for that job is too large. When
using Accustat, if the TPR for a job normally approaches the limit of the size of the canister, then the
adaptive fill tolerance might attempt to add additional paint beyond the limit of the canister volume.
Remedy: Set up for a re-dock. Decrease the Adaptive Fill Gain parameter in the SETUP AccuStat
screen. Reduce the size of the job if it is larger than 1550 ccs. This is the maximum volume of
the AccuStat canister.
________________________________________________________________
PNT1-420 WARN %sError reading gun-on time for job
Cause: Some process or processes within a job might have something wrong with their headers.
Remedy: Display the DETAIL page for every process in the job. This should correct the problem.
________________________________________________________________
PNT1-421 WARN %sNo TPR calculated for job
Cause: The PGOT procedure was not performed on the processes used within the selected job
(style). The TPR is equal to zero. No Preset Gun On Time for the job could be found. Also, the
job has not been test cycled.
Remedy: Perform the PGOT procedure on the desired job (style). Test cycle the job or allow it to
correct itself by running the process in production, if enough paint has been loaded into the canister.
________________________________________________________________
PNT1-422 WARN %sTPR Mismatch (%s) PGOT Required
Cause: The previous job gun on time for the current job differs from the calculated preset gun on
times used for the TPR calculation by more than the allowed tolerance. The Gun On Time stored
in the job header does not correspond to the preset on times read from the job processes. This can
be a result of process changes done on the fly. When this occurs, the robot will not have the proper
amount of paint to run the job.
Remedy: Perform a PGOT test cycle on the job that caused the TPR mismatch alarm. If the robot has
filled sufficiently for the job, then it will automatically correct the TPR when the job is completed.
If the robot has faulted due to this alarm, then press RESET and continue the job. If this alarm
commonly occurs due to on the fly process changes, then increase the Gun On Time Error Tolerance.
Caution must be used in setting this value too high, because if the new gun on time is sufficiently
higher than the old gun on time in the header, the TPR will be too low and the gun will run out of paint.
________________________________________________________________
PNT1-423 WARN %sTPR exceeds Can Volume
Cause: The calculated TPR exceeds the can volume. The TPR for that job is too large. When using
Accustat, if the TPR for a job normally approaches the limit of the size of the canister, then the
adaptive fill tolerance might attempt to add additional paint beyond the limit of the canister volume.
Remedy: Set up for a re-dock. Decrease the Adaptive Fill Gain parameter in the AccuStat setup
screen. Reduce the size of the job if it is larger than 1550 ccs which is the maximum volume of
the AccuStat canister.
________________________________________________________________
PNT1-428 WARN %sApplicator test outputs are ON
Cause: Applicator test outputs are on. These are initiated by the PLC.
Remedy: None.
________________________________________________________________
PNT1-429 WARN %sApplicator test outputs are OFF
Cause: Applicator test outputs are off. This is terminated by the PLC.
Remedy: None.
________________________________________________________________
PNT1-434 WARN %sApplicator test outputs are ON
Cause: Applicator test outputs are on. This is initiated by the PLC.
Remedy: None.
________________________________________________________________
PNT1-435 WARN %sApplicator test outputs are OFF
Cause: Applicator test outputs are off. This is terminated by the PLC.
Remedy: None.
________________________________________________________________
PNT1-440 WARN %sWaiting for part in window
Cause: For continuous line systems only. This is a warning that the robot is waiting for a part to enter
the tracking window. DO NOT ENTER THE ROBOT WORKSPACE; OTHERWISE YOU COULD
INJURE PERSONNEL OR DAMAGE EQUIPMENT.
Remedy: None.
________________________________________________________________
PNT1-441 WARN %sPart entered tracking window
Cause: For continuous line systems only. This is a warning that the part has entered the robot
tracking window.
Remedy: None.
________________________________________________________________
PNT1-446 WARN %sWaiting for part in window
Cause: For continuous line systems only. This is a warning that the robot is waiting for a part to enter
the tracking window. DO NOT ENTER THE ROBOT WORKSPACE; OTHERWISE YOU COULD
INJURE PERSONNEL OR DAMAGE EQUIPMENT.
Remedy: None.
________________________________________________________________
PNT1-447 WARN %sPart entered tracking window
Cause: For continuous line systems only. This is a warning that the part has entered the robot
tracking window.
Remedy: None.
________________________________________________________________
PNT1-452 WARN %sRobot not calibrated
Cause: The robot must be calibrated before proceeding. Only jogging in the joint coordinate system
and the calibration motion itself can be executed before the robot is calibrated.
Remedy: Calibrate the robot.
________________________________________________________________
PNT1-457 WARN %sRobot not calibrated
Cause: The robot must be calibrated before proceeding. Only jogging in the joint coordinate system
and the calibration motion itself can be executed before the robot is calibrated.
Remedy: Calibrate the robot.
________________________________________________________________
PNT1-462 WARN %sInvalid instruction argument
Cause: During program execution, a paint instruction was encountered with an out of range argument.
Remedy: Edit the current program and verify that all instruction arguments are valid.
________________________________________________________________
PNT1-463 WARN %sInvalid gun selection
Cause: The argument to the GUN SELECT instruction is outside of the range defined in the SETUP
screen.
Remedy: Modify the offending GUN SELECT argument to be within the valid range.
________________________________________________________________
PNT1-464 PAUS %sUnknown mnenomic instruction
Cause: An unknown instruction was encountered during program execution. This might happen if the
program was copied from a different robot installation.
Remedy: Delete the offending instruction.
________________________________________________________________
PNT1-465 PAUS %sCan’t set output
Cause: A Function instruction was used but the Function Instruction Option is not loaded.
Remedy: Load the Function Instruction Option in order to run and set the output correctly.
________________________________________________________________
PNT1-466 WARN %sInvalid GunSelect position
Cause: A GunSelect instruction that would change the state of the gun(s) is not positioned as an
option on a motion line. This instruction will not complete any operation. Such an instruction by
itself on a line in a program can not properly control the timing of the changes in the gun outputs.
Note that if the gun is not programmed to be ON then a Gunselect can be on a line by itself. Note
also that this alarm might not occur in all cases.
Remedy: Move the Gunselect instruction onto a motion line, and delete the stand alone instruction
line. If needed, add another motion line and record an appropriate position.
________________________________________________________________
PNT1-471 WARN %sInvalid instruction argument
Cause: During program execution, a paint instruction was encountered with an out of range argument.
Remedy: Edit the current program, and verify that all instruction arguments are valid.
________________________________________________________________
PNT1-472 WARN %sInvalid gun selection
Cause: The argument to the GUN SELECT instruction is outside of the range defined in the SETUP
screen.
Remedy: Modify the offending GUN SELECT argument to be within the valid range.
________________________________________________________________
PNT1-473 PAUS %sUnknown mnenomic instruction
Cause: An unknown instruction was encountered during program execution. This might happen if the
program was copied from a different robot installation.
Remedy: Delete the offending instruction.
________________________________________________________________
PNT1-474 PAUS %sCan’t set output
Cause: A Function instruction is used while the Option is not loaded.
Remedy: Load the Function Instruction Option in order to run and set the output correctly.
________________________________________________________________
PNT1-475 WARN %sInvalid GunSelect position
Cause: A GunSelect instruction that would change the state of the gun(s) is not positioned as an
option on a motion line. This instruction will not complete any operation. Such and instruction by
itself on a line in a program can not properly control the timing of the changes in the gun outputs.
Note that if the gun is not programmed to be ON then a Gunselect can be on a line by itself. Note that
this alarm may not occur in all cases.
Remedy: Move the Gunselect instruction onto a motion line and delete the stand alone instruction
line. If needed add another motion line and record an appropriate position.
________________________________________________________________
PNT1-480 ABRT %s not defined
Cause: For integral color change systems only: A color change cycle cannot be executed. There
are no steps defined for that color change cycle.
Remedy: Check the color change cycle for the current color and the next color. The cycle data
must have at least one step defined.
________________________________________________________________
PNT1-481 WARN %sPushout cycle cancelled
Cause: For integral color change systems only: A color change pushout cycle was executing during
production when it was aborted by an E-STOP. The paint line status is unknown.
Remedy: Reset the system and continue. The color change logic will automatically do a pushout
cycle before the next color change.
________________________________________________________________
PNT1-482 WARN %sIllegal manual cycle received
Cause: For integral color change systems only: An illegal color change cycle number was sent
by the PLC. Cycle numbers 1-8, and 21, 22, and 23 are legal cycle numbers for PaintTool version
1.30 and older.
Remedy: Make sure the PLC is sending a legal color change cycle number.
________________________________________________________________
PNT1-483 WARN %sColor cycle aborted
Cause: For integral color change systems only: A color change cycle was cancelled by an E-STOP.
Remedy: Reset the system. If in production mode, the color change cycle will be started over from
the beginning.
________________________________________________________________
PNT1-484 PAUS %sColor Valve + PrgSol both ON
Cause: For integral color change systems only: During the execution of a color change cycle, the
color enable output and the Purge Solvent output are not allowed to be on at the same time. If the
color change cycles attempt to do this, the cycle is aborted. (This is to prevent contamination of
the paint lines.)
Remedy: Check the cycle data table and make sure the color enable and Purge Solvent outputs are
never on at the same time.
________________________________________________________________
PNT1-485 WARN %sUsing default valve cycle data
Cause: For integral color change systems only: If there is no paint in the paint lines (current color =
0) and a color change cycle is executed, the color change cycle data for the first defined valve is used.
Remedy: None.
________________________________________________________________
PNT1-486 ABRT %sSelected color valve not defined
Cause: For integral color change systems only: The color valve selected has no data defined.
Remedy: Define the color valve using the SETUP menus under VALVES.
________________________________________________________________
PNT1-487 WARN %sApplication enable is OFF
Cause: This message is displayed when the application enable input turns off. When this input is off,
the gun and color change outputs are blocked from turning on.
Remedy: None.
________________________________________________________________
PNT1-488 ABRT %sAttempt to use illegal cycle number
Cause: This error should never occur during normal PaintTool operation.
Remedy: Contact Fanuc service personnel.
________________________________________________________________
PNT1-489 WARN %sManaul mode is locked at T.P.
Cause: The cell is attempting to perform manual operations while an operator is also performing
manual operations at the teach pendant.
Remedy: Wait for the operator to finish with the teach pendant, then try again.
________________________________________________________________
PNT1-490 WARN %sManual mode is locked at CRT.
Cause: The cell is attempting to perform manual operations while an operator is also performing
manual operations at the CRT.
Remedy: Wait for the operator to finish with the CRT, then try again.
________________________________________________________________
PNT1-491 WARN %sColor Valve + PrgAir both ON
Cause: For integral color change systems only: During the execution of a color change cycle, the color
enable output and the Purge Air output are not allowed to be on at the same time. If the color change
cycles attempt to do this, the cycle is aborted. (This is to prevent contamination of the paint lines.)
Remedy: Check the cycle data table and make sure the color enable and Purge Air outputs are
never on at the same time.
________________________________________________________________
PNT1-492 WARN %sCC Waiting for arm to be home
Cause: For integral color change systems only: The color change task is waiting for the robot to be at
the Home position before a color change cycle can be executed.
Remedy: Send the robot to the Home position.
________________________________________________________________
PNT1-493 WARN %sCC automatic cycles executing
Cause: For integral color change systems only: This indicates that a color change task is executing
a color change cycle.
Remedy: None.
________________________________________________________________
PNT1-494 WARN %sColorEnb + PrgSol both ON
Cause: For integral color change systems only: During the manual I/O testing of color change I/O,
the color enable output and Purge Solvent output are not allowed to be on at the same time.
Remedy: Do not attempt to turn on the outputs at the same time.
________________________________________________________________
PNT1-495 WARN %sColorEnb + PrgAir both ON
Cause: For integral color change systems only: During the manual I/O testing of color change I/O the
color enable output and the Purge Air output are not allowed to be on at the same time.
Remedy: Do not attempt to turn on the outputs at the same time.
________________________________________________________________
PNT1-496 WARN %sSelected color valve not defined
Cause: For integral color change systems only: The color valve selected has no data defined.
Remedy: Define the color valve using the SETUP menus under VALVES.
________________________________________________________________
PNT1-497 WARN %sNo system color for valve
Cause: Manual color change from teach pendant: Warning: the system changes the current system
color to match the fill color valve. No system color uses the current valve. The wrong system color
may be set – and the wrong preset data may be used in wet test cycle.
Remedy: Temporarily change the system color setup
________________________________________________________________
PNT1-498 WARN %sApplication enable is ON
Cause: This message is displayed when the application enable input turns on. When this input is on,
the GUN and color change outputs are allowed to turn on.
Remedy: None.
________________________________________________________________
PNT1-499 WARN %sInvalid Solv/Air State
Cause: An attempt to enable solvent valve was made without enabling a downstream valve.
Remedy: Verify that PD, Trigger, IWP or BWP enabled
________________________________________________________________
PNT1-500 WARN %sPurge Solvent + Air Both ON
Cause: Purge Solvent and Purge Air Valves Both ON
Remedy: Fix Color Change Cycle Data or Try Again
________________________________________________________________
PNT1-501 WARN %sMore Than One Color Valve ON
Cause: Multiple Color Valves ON
Remedy: Not Allowed
________________________________________________________________
PNT1-502 WARN %sCC Event Timeout!
Cause: The Color Change Event programmed for the current color change step did not complete
in the allocated time.
Remedy: Check the Color Change Event requests.
________________________________________________________________
PNT1-503 WARN %sCC Cycle does not end @ HOME!
Cause: The programmed Color Change Cycle does not send the robot to the HOME position at
the completion of a cycle.
Remedy: The last Color Change Cycle must send the robot to the HOME position at completion.
________________________________________________________________
PNT1-511 ABRT %s not defined
Cause: For integral color change systems, a color change cycle cannot be executed. There are no
steps defined for that color change cycle.
Remedy: Check the color change cycle for the current color and the next color. The cycle data
must have at least one step defined.
________________________________________________________________
PNT1-512 WARN %sPushout cycle cancelled
Cause: For integral color change systems only, a color change pushout cycle was executing during
production when it was aborted by an E-STOP. The paint line status is unknown.
Remedy: Reset the system and continue. The color change logic will automatically do a pushout
cycle before the next color change.
________________________________________________________________
PNT1-513 WARN %sIllegal manual cycle received
Cause: For integral color change systems only: An illegal color change cycle number was sent
by the PLC. Cycle numbers 1-8, and 21, 22, and 23 are legal cycle numbers for PaintTool version
1.30 and older.
Remedy: Make sure the PLC is sending a legal color change cycle number.
________________________________________________________________
PNT1-514 WARN %sColor cycle aborted
Cause: For integral color change systems, a color change cycle was cancelled by an E-STOP.
Remedy: Reset the system. If in production mode, the color change cycle will be started over from
the beginning.
________________________________________________________________
PNT1-515 PAUS %sColor Valve + PrgSol both ON
Cause: For integral color change systems, during the execution of a color change cycle, the color
enable output and the Purge Solvent output are not allowed to be on at the same time. If the color
change cycles attempt to do this, the cycle is aborted. (This is to prevent contamination of the paint
lines.)
Remedy: Check the cycle data table and make sure the color enable and Purge Solvent outputs are
never on at the same time.
________________________________________________________________
PNT1-516 WARN %sUsing default valve cycle data
Cause: For integral color change systems, if there is no paint in the paint lines (current color = 0) and
a color change cycle is executed, the color change cycle data for the first defined valve is used.
Remedy: None.
________________________________________________________________
PNT1-517 ABRT %sSelected color valve not defined
Cause: For integral color change systems only: The color valve selected has no data defined.
Remedy: Define the color valve using the SETUP menus under VALVES.
________________________________________________________________
PNT1-518 WARN %sApplication enable is OFF
Cause: This message is displayed when the application enable input turns off. When this input is off,
the GUN and color change outputs are blocked from turning on.
Remedy: None.
________________________________________________________________
PNT1-519 ABRT %sAttempt to use illegal cycle number
Cause: This error should never occur during normal PaintTool operation.
Remedy: Contact Fanuc service personnel.
________________________________________________________________
PNT1-520 WARN %sManaul mode is locked at T.P.
Cause: The cell is attempting to perform manual operations while an operator is also performing
manual operations at the teach pendant.
Remedy: Wait for the operator to finish with the teach pendant. Then try again.
________________________________________________________________
PNT1-521 WARN %sManual mode is locked at CRT.
Cause: The cell is attempting to perform manual operations while an operator is also performing
manual operations at the CRT.
Remedy: Wait for the operator to finish with the CRT. Then try again.
________________________________________________________________
PNT1-522 WARN %sColor Valve + PrgAir both ON
Cause: For integral color change systems, during the execution of a color change cycle, the color
enable output and the purge air output are not allowed to be on at the same time. If the color change
cycles attempt to do this, the cycle is aborted. (This is to prevent contamination of the paint lines.)
Remedy: Check the cycle data table and make sure the color enable and purge air outputs are never
on at the same time.
________________________________________________________________
PNT1-523 WARN %sCC Waiting for arm to be home
Cause: For integral color change systems, the color change task is waiting for the robot to be at the
Home position before a color change cycle can be executed.
Remedy: Send the robot to the Home position.
________________________________________________________________
PNT1-524 WARN %sCC automatic cycles executing
Cause: For integral color change systems, this is an indication of a color change task executing
a color change cycle.
Remedy: None.
________________________________________________________________
PNT1-525 WARN %sColorEnb + PrgSol both ON
Cause: For integral color change systems, during the manual I/O testing of color change I/O, the
color enable output and purge solvent output are not allowed to be on at the same time.
Remedy: Do not attempt to turn on the outputs at the same time.
________________________________________________________________
PNT1-526 WARN %sColorEnb + PrgAir both ON
Cause: For integral color change systems only, during the manual I/O testing of color change I/O, the
color enable output and the purge air output are not allowed to be on at the same time.
Remedy: Do not attempt to turn on the outputs at the same time.
________________________________________________________________
PNT1-527 WARN %sSelected color valve not defined
Cause: For integral color change systems only, the color valve selected has no data defined.
Remedy: Define the color valve using the SETUP menu under VALVES.
________________________________________________________________
PNT1-528 WARN %sNo system color for valve
Cause: WARNING: For manual color changes from teach pendant, the system changes the current
system color to match the fill color valve. No system color uses the current valve. The wrong system
color might be set – and the wrong preset data might be used in wet test cycle.
Remedy: Temporarily change the system color setup.
________________________________________________________________
PNT1-529 WARN %sApplication enable is ON
Cause: This message is displayed when the application enable input turns on. When this input is on,
the GUN and color change outputs are allowed to turn on.
Remedy: None.
________________________________________________________________
PNT1-530 WARN %sInvalid Solv/Air State
Cause: An attempt to enable solvent valve was made without enabling a downstream valve.
Remedy: Verify that PD, Trigger, IWP or BWP enabled
________________________________________________________________
PNT1-531 WARN %sPurge Solvent + Air Both ON
Cause: Purge Solvent and Purge Air Valves Both ON
Remedy: Fix Color Change Cycle Data or Try Again
________________________________________________________________
PNT1-532 WARN %sMore Than One Color Valve ON
Cause: Multiple Color Valves ON
Remedy: Not Allowed
________________________________________________________________
PNT1-534 WARN %sCC Cycle does not end @ HOME!
Cause: The programmed Color Change Cycle does not send the robot to the HOME position at
the completion of the cycle.
Remedy: The last Color Change Cycle must send the robot to the HOME position at completion.
________________________________________________________________
PNT1-542 WARN %s abort, can fill timeout
Cause: The canister position counts did not reach the fill counts before the Color Change Timeout
expired. If this occurs during a Scale Calibration, then the can was not filled before the Scale Cal Step
Time expired. This condition can exist if no paint has entered the can, or a loss of canister position
feedback from the linear potentiometer. The Color Change Timeout needs to be increased. The Full
Can counts have not been properly calculated.
Remedy: Establish the cause of the timeout. Verify the canister position feedback is operating
properly. Feedback can be verified by checking the analog input (AIN[1, DISP]). Check the paint
supply system. Check the color change valve operation. Check the color valve, if it is a color change
fault or the dock solvent if this occurs during a scale calibration. Increase the Color Change Timeout.
If the gun has been changed then a scale calibration might be required. Reset, and attempt to continue
if this occur during automatic mode. If the robot is stuck in the docking station then switch to manual
mode and run a de-dock move to move the robot to Home. If this alarm occurs during a scale
calibration then increase the Scale Cal Step Time (40 seconds by default). It could require more time
depending on the material used to scale calibrate.
________________________________________________________________
PNT1-543 WARN %s abort, can empty timeout
Cause: The canister position counts did not reach the empty canister check counts before the Color
Change Timeout expired. If this occurs during a Scale Calibration, then the can was not empty before
the Scale Cal Step Time expired. This condition can exist when no paint has exited the can, or if a loss
of canister position feedback from the linear potentiometer has occurred. The Color Change Timeout
needs to be increased. The Empty Can counts have not been properly calculated.
Remedy: Establish the cause of the timeout. Verify that the canister position feedback is operating
properly. Feedback can be verified by checking the analog input (AIN[1, DISP]). Check the color
change valve operation. Check the dump valve if the paint has not exited the canister. Increase the
Color Change Timeout. If the gun has been changed then a scale calibration might be required. Reset,
and attempt to continue if this occurs during automatic mode. If the robot is stuck in the docking
station then, switch to manual mode and run a de-dock move to move the robot to Home. If this alarm
occurs during a scale calibration then increase the Scale Cal Step Time (40 seconds by default). It
could require more time depending on the material used to scale calibrate.
________________________________________________________________
PNT1-544 WARN %s Canister Out Of Paint
Cause: The canister ran out of paint during the job.
Remedy: Check the following:
1. Verify that the TPR was calculated properly.
2. Verify the fill is completing successfully.
3. Check for other alarms that occurred during this job.
4. Make sure all equipment is operating properly, such as the trigger or regulator.
5. Check can empty timeout value (default = 1500 ms).
6. Perform Auto Calibration on that color if all parts are operating properly.
7. Increase the Flow Control Confidence parameter in the AccuStat SETUP screen to help prevent
running out of paint.
________________________________________________________________
PNT1-548 WARN %s abort, can fill timeout
Cause: The canister position counts did not reach the fill counts before the Color Change Timeout
expired. If this occurs during a Scale Calibration, then the can was not filled before the Scale Cal
Step Time expired. This condition can exist if no paint has entered the can or a loss of canister
position feedback from the linear potentiometer has occurred. The Color Change Timeout needs to be
increased. The Full Can counts have not been properly calculated.
Remedy: Establish the cause of the timeout. Verify that the canister position feedback is operating
properly. Feedback can be verified by checking the analog input (AIN[1, DISP]). Check the paint
supply system. Check the color change valve operation. Check the color valve if it is a color change
fault, or the dock solvent if this occurs during a scale calibration. Increase the Color Change Timeout.
If the gun has been changed, then a scale calibration might be required. Reset, and attempt to continue
if this occurs during automatic mode. If the robot is stuck in the docking station then switch to
manual mode and run a de-dock move to move the robot to Home. If this alarm occurs during a scale
calibration then increase the Scale Cal Step Time (40 seconds by default). It could require more time
depending on the material used to scale calibrate.
________________________________________________________________
PNT1-549 WARN %s abort, can empty timeout
Cause: The canister position counts did not reach the empty canister check counts before the Color
Change Timeout expired. If this occurs during a Scale Calibration, then the can was not empty before
the Scale Cal Step Time expired. This condition can exist if no paint has exited the can, or a loss of
canister position feedback from the linear potentiometer has occurred. The Color Change Timeout
needs to be increased. The Empty Can counts have not been properly calculated.
Remedy: Establish the cause of the timeout. Verify that the canister position feedback is operating
properly. Feedback can be verified by checking the analog input (AIN[1, DISP]). Check the color
change valve operation. Check the dump valve if the paint has not exited the canister. Increase the
Color Change Timeout. If the gun has been changed then a scale calibration might be required. Reset,
and attempt to continue if this occurs during automatic mode. If the robot is stuck in the docking
station then switch to manual mode and run a de-dock move to move the robot to Home. If this alarm
occurs during a scale calibration then increase the Scale Cal Step Time (40 seconds by default). It
could require more time depending on the material used to scale calibrate.
________________________________________________________________
PNT1-550 WARN %s Canister Out Of Paint
Cause: The canister ran out of paint during the job.
Remedy: Verify that the TPR was calculated properly. Verify the fill is completing successfully.
Check for other alarms that occurred during this job. Make sure all equipment is operating properly,
such as the trigger or regulator. Check the can empty timeout value (default = 1500 ms). Perform
an Auto Calibration on that color if all parts are operating properly. Increase the Flow Control
Confidence parameter in the AccuStat SETUP screen to help prevent running out of paint.
________________________________________________________________
PNT1-554 WARN %sCal. table adapted out tolerance
Cause: The fluid pressure or fluid viscosity for the current color has changed dramatically. This
change has occurred since the last calibration of this color. The value exceeded the Adaptive tolerance
parameter.
Remedy: Correct the fluid pressure or viscosity for the current color. If the pressure or viscosity
was purposely changed, then the color can be calibrated to eliminate this alarm. The setting for the
Adaptive tolerance can be increased if the variation shown by the calibration table for this color is
acceptable.
________________________________________________________________
PNT1-555 WARN %sCal. table adapted in tolerance
Cause: This status warning indicates that the conditions which caused a table adapted out of tolerance
alarm have been eliminated or disappeared.
Remedy: None.
________________________________________________________________
PNT1-556 WARN Dyn. yield > tolerance band (%s)
Cause: As a particular flow rate set point is being output, the yield (cc/min)/cnt) for that flow rate
was larger than the tolerance band for it. It is not likely that the set point will be reached. This might
be due to the restricters in the gun being too large.
Remedy: In some way, decrease the yield. Use smaller restricters in the gun if the high end flow rate
can still obtained. Otherwise, accept a larger tolerance band. If the value given in the alarm is equal
to the Minimum tolerance band, set the minimum tolerance band equal to the yield for that color.
Otherwise, increase the Percent tolerance band.
________________________________________________________________
PNT1-557 WARN %sFlow rate avg. error excessive
Cause: Checks for how far the flow rate is from the set point have been too high. Possible causes are:
• A sticking I/P transducer
• A bad fluid regulator
• Frequent fluid pressure changes
• A bad Accuflow Interface board
Remedy: Check and change the transducer, replace the fluid regulator, or service the surge
suppression system on the fluid supply pump. If the alarm occurs on many or all colors, then increase
the Max. error from setpoint parameter.
________________________________________________________________
PNT1-558 WARN %sCalibration successful
Cause: Used to notify the cell controller that a calibration has completed successfully.
Remedy: None.
________________________________________________________________
PNT1-559 WARN %sCalibration aborted
Cause: Accuflow calibration could not continue. This might be due to the fluid lines not being
filled. Check for other alarms in the log.
Remedy: The best remedy might be found from the previous alarm in the log. This is usually the
result of incorrect setup parameters, or incomplete hardware setup. If the flow hardware is operating
correctly, set the color parameter for the pulsing pump supply to YES.
________________________________________________________________
PNT1-560 WARN %sCal. low flow rate reset
Cause: The low flow rate could not be reached during Accuflow calibration. A new low flow rate
was established.
Remedy: Decrease the Gain modifier used for the color, if possible. The new low flow rate is shown
as point 2 in the calibration table. This value can be visually checked and accepted.
________________________________________________________________
PNT1-561 WARN %sCal. max. flow rate reset
Cause: During Accuflow calibration, the expected maximum flow rate could not be reached at the
maximum output. A new maximum flow was established.
Remedy: Try decreasing the Gain modifier used for the color. The new maximum flow rate is shown
as point 10 in the calibration table. This value can be visually checked and accepted.
________________________________________________________________
PNT1-562 WARN %sCal. time out at max. flow
Cause: Accuflow timed out trying to reach the maximum flow rate. The possible causes are:
• A high gain
• A sticking I/P transducer
• A bad fluid regulator
• Frequent fluid pressure changes.
Remedy: Try the following:
• Possibly decrease the Gain modifier used for the color.
• Retry the calibration.
• Check and change the transducer, if necessary.
• Replace the fluid regulator, or service the surge suppression system on the fluid supply pump.
• The calibration timeout parameter can be increased.
________________________________________________________________
PNT1-563 WARN %sCal. time out at low flow
Cause: Accuflow timed out trying to reach the loweset flow rate, typically 100 cc/min. Possible
causes are:
• A high gain
• A sticking I/P transducer
• A bad fluid regulator
• Frequent fluid pressure changes
Remedy: Try the following:
• If possible, decrease the Gain modifier used for the color.
• Retry the calibration.
• Check and change the transducer, if necessary.
• Replace the fluid regulator, or service the surge suppression system on the fluid supply pump.
• The calibration timeout parameter can be increased.
________________________________________________________________
PNT1-564 WARN %sZero fluid flow rate detected
Cause: All of the conditions were set for fluid to be flowing and a zero flow rate was measured. This
might be due to no fluid pressure or pilot air pressure. With a very low flow rate, the gain might be too
high. One of the following items might be broken:
• Color Valve
• Color select board
• Gun trigger
• Flow meter
• Flow meter pickup
• Accuflow interface board
• The 32 point input module
Note, Accuflow automatically changes to Open Loop when this failure occurs.
Remedy: If fluid can be seen coming from the applicator, check the following:
• Flow meter
• Flow meter pickup
• Accuflow interface
• The 32 point input module
Otherwise check the other items listed as part of the cause. If it occurs with very low flow rates,
decrease the Gain modifier.
________________________________________________________________
PNT1-565 WARN %sLower output did not lower flow
Cause: As Accuflow steps down through the 10 points in the calibration table, it expects a lower flow
for each decrease in the commanded flow value. In this case, the flow did not decrease. This can be
caused by low or pulsing fluid pressure, insufficient exhaust, or no quick exhaust on the fluid pilot air.
Remedy: Perform the following:
• Retry the calibration.
• Check that an adequate and stable flow rate is provided by the system for this color.
• Decreasing the leveling tries might help.
• Check that the fluid pilot regulator air line has adequate exhaust capability.
• Reevaluate the size of the restrictor in the gun.
________________________________________________________________
PNT1-566 WARN %sTime out during a cal. test
Cause: While measuring hysteresis, time up or time down, the Accuflow system timed out. This
indicates the high or low flow rate could not be reached.
Remedy: Retry the calibration. Check that the high flow rate can be reached consistently. If not, an
increase in the Tolerance band might be required.
________________________________________________________________
PNT1-567 WARN %sMin. output has flow > setpoint
Cause: With a minimum control output the flow rate was measured to be higher than the setpoint
(requested flow). The fluid pressure might have become too high. The I/P transducer or fluid
regulator might be stuck open. There might be a fairly large fluid leak. Note: Accuflow automatically
changes to Open Loop when this failure occurs.
Remedy: Calibrating the color will establish a new cracking pressure (minimum control output) for
a changed fluid pressure. Check and replace the fluid regulator and I/P transducer, if necessary.
See the Fluid flow leak alarms for other options.
________________________________________________________________
PNT1-568 WARN %sMax. output has flow < setpoint
Cause: With a maximum control output, the flow rate was measured to be lower than the setpoint
(requested flow). The gun might be clogging. A fluid or pilot air line might be pinched. The
fluid pressure might have become too low. The I/P transducer might be broken. Note: Accuflow
automatically changes to Open Loop when this failure occurs.
Remedy: Check the following:
• Check the gun tip and the whole gun for clogging.
• Check the fluid lines for pinching, especially at places where they flex.
• Check the fluid supply pressure.
• Check and replace the I/P transducer, if necessary.
________________________________________________________________
PNT1-569 WARN %sFlow setpoint below globals
Cause: The requested fluid flow output command is below the calibrated range of the color.
Remedy: Adjust the fluid flow output command in the preset argument to be within the calibrated
range.
________________________________________________________________
PNT1-570 WARN %sRequested flow above cal. table
Cause: The requested fluid flow output command is above the calibrated range of the color.
Remedy: Adjust the fluid flow output command in the preset argument to be within the calibrated
range. Perform the necessary steps to increase the Max. Controllable Flow obtained during
calibration. Recalibrate the color.
________________________________________________________________
PNT1-571 WARN %sSlow fluid flow leak detected
Cause: A small amount of fluid flow was detected when the gun was not turned on. This might be
caused by a loose fitting, or a leaking dump valve.
Remedy: No immediate remedy is required. The paint system will continue to function properly. The
various fluid lines and valves should be inspected and repaired.
________________________________________________________________
PNT1-572 WARN %sFast fluid flow leak detected
Cause: A large amount of fluid flow was detected when the gun was not turned on. This might be
caused by the dump valve being stuck on or a broken fitting, or a broken paint line. Note that each
time the fluid begins to leak fast, the color valve will be turned off. This will prevent the robot
from spraying the part.
Remedy: The various fluid lines and valves should be inspected and repaired immediately. Check
and repair the dump pilot valve and the dump valve, if necessary.
________________________________________________________________
PNT1-573 WARN %sFailed to reach setpoint
Cause: This might be caused by pulsing paint pressure or a broken I/P transducer. If it occurs on most
colors then the Minimum set point (ms)might be too small for the specific intallation setup, or one of
the tolerance band settings might be too small for the yield of the system.
Remedy: Increase the Minimum set point (ms). If the FLUID transducer is noisy, change it. If this
occurs on specific colors, check the surge suppression system’s fluid supply system. If the calibration
yield values are more than half of the minimum tolerance band, then increase the tolerance band.
________________________________________________________________
PNT1-574 WARN %sAccuflow softpart init failed
Cause: The Accuflow softpart is not running. The I/O assigned & used by the softpart is not available
or the softpart did not load correctly. Additional info. is available during controller power up at
the debug console (smon).
Remedy: Check and correct the assignments or hardware for the I/O used by Accuflow. Especially
the I/O points: Set Point Reached, Flow Rate GIN, and flow diag. AOUT. Reload the Accuflow
option, watch for alarms during the load. Document the events that led to the error, record the software
version number and contact your local distributor or the Fanuc hotline.
________________________________________________________________
PNT1-575 WARN %s0 fluid flow rate timeout
Cause: All of the conditions were set for fluid to be flowing and a zero flow rate was measured for
longer than the Zero flow timeout parameter. This might be caused by one of the following:
• A broken applicator trigger
• A loss of fluid supply pressure
• A broken fluid flow meter
• A broken cable (to the flow meter)
• A Zero flow timeout value that is too short.
Note: AccuFlow temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check that the gun is triggering properly. If you observe fluid to be flowing, check and
possibly replace the fluid flow meter. Icrease the Zero flow timeout parameter (by about 25%),
if possible.
________________________________________________________________
PNT1-576 WARN %sMax. flow below mid point
Cause: This alarm occurs only during calibration. The flow rate measured at the maximum control,
and one half of the maximum control output was nearly the same. Less than one half of the control
output range is useable. The system might still function even though this alarm has occurred. This
might be caused by low fluid pressure, a faulty transducer or regulator, or by having the wrong I/P
transducer installed (100 psi range instead of 50 psi range).
Remedy: Increase the fluid pressure. Check that the transducer is functioning properly and that it
has the correct pressure range. Change the range if appropriate. The system might operate, but
performance can be improved with one of the above remedies.
________________________________________________________________
PNT1-577 WARN CH1:Dyn. yield > tolerance band (%s)
Cause: As a particular flow rate set point is being output, the yield ((cc/min)/cnt) for that flow rate
was larger than the tolerance band for it. It is not likely that the set point will be reached. This might
be due to the restricters in the gun being too large.
Remedy: Decrease the yield. Use smaller restrictors in the gun if the high end flow rate can still
obtained. Otherwise, accept a larger tolerance band. If the value given in the alarm is equal to the
Minimum tolerance band, set the minimum tolerance band equal to the yield for that color. Otherwise,
increase the Percent tolerance band.
________________________________________________________________
PNT1-583 WARN %sCal. table adapted out tolerance
Cause: The fluid pressure or fluid viscosity for the current color has changed dramatically. This
change has occurred since the last calibration of this color. The change was beyond the percentage
value setting of the Adaptive tolerance parameter.
Remedy: Correct the fluid pressure or viscosity for the current color. If the pressure or viscosity
was purposely changed, then the color can be calibrated to eliminate this alarm. The setting for the
Adaptive tolerance can be increased if the variation shown by the calibration table for this color is
acceptable.
________________________________________________________________
PNT1-584 WARN %sCal. table adapted in tolerance
Cause: This status warning indicates that the conditions which caused a table adapted out of tolerance
alarm have been eliminated or disappeared.
Remedy: None.
________________________________________________________________
PNT1-585 WARN CH2:Dyn. yield > tolerance band (%s)
Cause: As a particular flow rate set point is being output, the yield ((cc/min)/cnt) for that flow rate
was larger than the tolerance band for it. It is not likely that the set point will be reached. This might
occur if the restrictors in the gun are too large.
Remedy: Decrease the yield. Use smaller restrictors in the gun if the high end flow rate can still
obtained. Otherwise, accept a larger tolerance band. If the value given in the alarm is equal to the
Minimum tolerance band, set the minimum tolerance band equal to the yield for that color. Otherwise,
increase the Percent tolerance band.
________________________________________________________________
PNT1-586 WARN %sFlow rate average error high
Cause: Checks for how far the flow rate is from the set point have been too high. Possible causes are
one of the following:
• A sticking I/P transducer
• A bad fluid regulator
• Frequent fluid pressure changes
• A bad Accuflow Interface board.
Remedy: Check and change the transducer, replace the fluid regulator, or service the surge
suppression system on the fluid supply pump. If the alarm occurs on many or all colors, then increase
the Max. error from setpoint parameter.
________________________________________________________________
PNT1-587 WARN %sCalibration successful
Cause: Used to notify the cell controller that a calibration has completed successfully.
Remedy: None.
________________________________________________________________
PNT1-588 WARN %sCalibration aborted
Cause: Accuflow calibration could not continue. This might occur if the fluid lines have not been
filled. Check for other alarms in the log.
Remedy: The best remedy might be found from the previous alarm in the log. This is usually the
result of incorrect setup parameters, or incomplete hardware setup. If the flow hardware is operating
correctly, set the color parameter for pulsing pump supply to YES.
________________________________________________________________
PNT1-589 WARN %sCal. low flow rate reset
Cause: During Accuflow calibration, the low flow rate could not be reached. A new low flow
rate was established.
Remedy: Possibly decrease the Gain modifier used for the color. The new low flow rate is shown as
point 2 in the calibration table. This value can be visually checked and accepted.
________________________________________________________________
PNT1-590 WARN %sCal. max. flow rate reset
Cause: During Accuflow calibration, the expected maximum flow rate could not be reached at the
maximum output. A new maximum flow was established.
Remedy: Decrease the Gain modifier used for the color, if possible. The new maximum flow rate is
shown as point 10 in the calibration table. This value can be visually checked and accepted.
________________________________________________________________
PNT1-591 WARN %sCal. time out at max. flow
Cause: Accuflow timed out trying to reach the maximum flow rate. Possible causes are:
• A high gain
• A sticking I/P transducer
• A bad fluid regulator
• Frequent fluid pressure changes
Remedy: Decrease the gain modifier used for the color, if possible. Then, retry the calibration. Check
and change the transducer if necessary, replace the fluid regulator, or service the surge suppression
system on the fluid supply pump. The calibration timeout parameter can also be increased.
________________________________________________________________
PNT1-592 WARN %sCal. time out at low flow
Cause: Accuflow timed out trying to reach the loweset flow rate, typically 100 cc/min. Possible
causes are one of the following:
• A high gain
• A sticking I/P transducer
• A bad fluid regulator
• Frequent fluid pressure changes.
Remedy: Decrease the gain modifier used for the color, if possible. Then, retry the calibration. Check
and change the transducer if necessary, replace the fluid regulator, or service the surge suppression
system on the fluid supply pump. The calibration timeout parameter can also be increased.
________________________________________________________________
PNT1-593 WARN %sZero fluid flow rate detected
Cause: All of the conditions were set for fluid to be flowing however, a zero flow rate was measured.
This might be due to no fluid pressure or pilot air pressure. With a very low flow rate, the gain might
be too high. One of the following items might be broken:
• Color Valve
• Color select board
• Gun trigger
• Flow meter
• Flow meter pickup
• Accuflow interface board
• The 32 point input module
Note: Accuflow automatically changes to Open Loop when this failure occurs.
Remedy: If fluid can be seen coming from the applicator, check the following:
• Flow meter
• Flow meter pickup
• Accuflow interface
• The 32 point input module.
Otherwise check the other items listed above. If it occurs with very low flow rates, decrease the
Gain modifier.
________________________________________________________________
PNT1-594 WARN %sLower output did not lower flow
Cause: As Accuflow steps down through the 10 points in the calibration table, it expects a lower flow
for each decrease in the commanded flow value. In this case, the flow did not decrease. This can be
caused by low or pulsing fluid pressure, insufficent exhaust, or no quick exhaust on the fluid pilot air.
Remedy: Retry the calibration. Check that an adequate and stable flow rate is provided by the system
for this color. Decreasing the leveling trys might help. Check that the fluid pilot regulator air line has
adequate exhaust capability. Reevaluate the size of the restrictor in the gun.
________________________________________________________________
PNT1-595 WARN %sTime out during a cal. test
Cause: While measuring hysteresis time up or time down, the Accuflow system timed out. This
indicates that the high or low flow rate could not be reached.
Remedy: Retry the calibration. Check that the high flow rate can be reached consistantly. If not, an
increase in the Tolerance band might be required.
________________________________________________________________
PNT1-596 WARN %sMin. output has flow > setpoint
Cause: With a minimum control output, the flow rate was measured to be higher than the setpoint
(requested flow). The fluid pressure might have become too high. The I/P transducer or fluid
regulator might be stuck open. There might be a fairly large fluid leak. Note: Accuflow automatically
changes to Open Loop when this failure occurs.
Remedy: Calibrating the color will establish a new cracking pressure (minimum control output) for
a changed fluid pressure. Check and replace if necessary the fluid regulator and I/P transducer.
See the Fluid flow leak alarms for other options.
________________________________________________________________
PNT1-597 WARN %sMax. output has flow < setpoint
Cause: With a maximum control output the flow rate was measured to be lower than the setpoint
(requested flow). This can be caused by:
• A clogged gun.
• A pinched fluid or pilot air line.
• The fluid pressure becoming too low.
• A broken I/P transducer.
Note: Accuflow automatically changes to Open Loop when this failure occurs.
Remedy: Check the following:
• Check the gun tip and the whole gun for clogging.
• Check the fluid lines for pinching, especially at places where they flex.
• Check the fluid supply pressure.
• Check and replace the I/P transducer if necessary.
________________________________________________________________
PNT1-598 WARN %sFlow setpoint below globals
Cause: The requested fluid flow output command is below the calibrated range of the color.
Remedy: Adjust the fluid flow output command in the preset argument to be within the calibrated
range.
________________________________________________________________
PNT1-599 WARN %sRequested flow above cal. table
Cause: The requested fluid flow output command is above the calibrated range of the color.
Remedy: Adjust the fluid flow output command in the preset argument to be within the calibrated
range. Perform the necessary steps to increase the Max. Controllable Flow obtained during
calibration. Then, recalibrate the color.
________________________________________________________________
PNT1-600 WARN %sSlow fluid flow leak detected
Cause: A small amount of fluid flow was detected when the gun was not turned on. This might be
caused by a loose fitting, or a leaking dump valve.
Remedy: No immediate remedy is required. The paint system will continue to function properly. The
various fluid lines and valves should be inspected, and repaired if necessary.
________________________________________________________________
PNT1-601 WARN %sFast fluid flow leak detected
Cause: A large amount of fluid flow was detected when the gun was not turned on. This might be
caused by the dump valve being stuck on, or a broken fitting, or a broken paint line. Note that each
time the fluid begins to leak fast, the color valve will be turned off. This will prevent the robot
from spraying the part.
Remedy: The various fluid lines and valves should be inspected and repaired immediately. Check
and repair the dump pilot valve and the dump valve, if necessary.
________________________________________________________________
PNT1-602 WARN %sFailed to reach setpoint
Cause: This might be caused by pulsing paint pressure or a broken I/P transducer. If it occurs on most
colors then there might be a small setting of the Minimum set point (ms) for the specific intallation
setup or one of the tolerance band settings might be too small for the yield of the system.
Remedy: Increase the Minimum set point (ms). If the FLUID transducer is noisy, change it. If this
occurs on specific colors, check the surge suppression system’s fluid supply system. If the calibration
yield values are more than half of the minimum tolerance band, then increase the tolerance band.
________________________________________________________________
PNT1-603 WARN %sAccuflow softpart init Failed
Cause: The Accuflow softpart is not running. The I/O assigned and used by the softpart is not
available, or the softpart did not load correctly. Additional information is available during controller
power up at the debug console (smon).
Remedy: Check and correct the assignments or hardware for the I/O used by Accuflow, especially the
I/O points: Set Point Reached, Flow Rate GIN, and flow diag. AOUT. Reload the Accuflow option.
Watch for alarms during the load. Document the events that led to the error, record the software
version number, and contact your local distributor, or the FANUC Robotics hotline.
________________________________________________________________
PNT1-604 WARN %s0 fluid flow rate timeout
Cause: All of the conditions were set for fluid to be flowing but a zero flow rate was measured for
longer than the Zero flow timeout parameter. This might be caused by:
• A broken applicator trigger
• A loss of fluid supply pressure
• A broken fluid flow meter
• A broken cable (to the flow meter)
• A Zero flow timeout value that is too short
Note: AccuFlow temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check that the gun is properly triggering. If fluid was observed to be flowing, check and
possibly replace the fluid flow meter. Possibly increase the Zero flow timeout parameter (by about
25%).
________________________________________________________________
PNT1-605 WARN %sMax. flow below mid point
Cause: This alarm occurs only during calibration. The flow rate measured at the maximum control,
and one half of the maximum control output, was nearly the same. Less than one half of the control
output range is useable. The system might still function even though this alarm has occurred. This
might be caused by low fluid pressure, a faulty transducer or regulator, or the wrong I/P transducer
being installed (100 psi range instead of 50 psi range).
Remedy: Increase the fluid pressure. Check that the transducer is functioning properly and that it has
the correct pressure range. Change it if appropriate. The system might operate, but performance can
be improved with one of the above remedies.
________________________________________________________________
PNT1-606 WARN CH2:Dyn. yield > tolerance band (%s)
Cause: As a particular flow rate set point is being output, the yield ((cc/min)/cnt) for that flow rate
was larger than the tolerance band for it. It is not likely that the set point will be reached. This might
be due to the restrictors in the gun being too large.
Remedy: Decrease the yield. Use smaller restrictors in the gun if the high end flow rate can still be
obtained. Otherwise, accept a larger tolerance band. If the value given in the alarm is equal to the
Minimum tolerance band, set the minimum tolerance band equal to the yield for that color. Otherwise,
increase the Percent tolerance band.
________________________________________________________________
PNT1-612 WARN %sCal. table adapted out,output up
Cause: The relationship of the output command to the flow rate obtained has changed significantly
since the last calibration. There is now a larger output required to get the same flow rate. This can be
caused by:
• A clogged air cap
• A clogged gun
• Pinched air lines
• Large losses of air supply pressure
Note that the system continues to close the loop and generally maintain requested flow rates even after
this alarm if there are no other alarms occurring. This alarm can provide early warnings of possible
failures. This alarm is controlled by the Adaptive tolerance parameter.
Remedy: Check and perform the following:
• Check, clean, and possibly replace the air cap.
• Check for a large loss of air supply pressure.
• Check for pinched air lines or clogged air passages in the gun.
• Recalibrate to clear the alarm immediately.
• Increase the Adaptive tolerance parameter to allow larger changes without alarming.
________________________________________________________________
PNT1-613 WARN %sCal. table adapted in tolerance
Cause: Just a notification that the calibration table has returned to the normal operating range (as
defined by the Adaptive tolerance).
Remedy: None.
________________________________________________________________
PNT1-614 WARN %sDyn. yield > %% tolerance band
Cause: As a particular flow rate set point is being output the yield (slpm/cnt) for that flow rate was
approximately larger than the percent tolerance. It is not likely that the set point will be reached
within the specified tolerances. This might be caused by the use of a flow rate setpoint that is above
the value that the air system can provide.
Remedy: Decrease the yield. Use larger diameter air lines to supply air to the cap. Use a larger
ratio booster (2:1 instead of 1:1) if the system can not supply the high flow rates provided. Use a
smaller ratio booster. Otherwise, accept a larger tolerance band. Increase the Percent tolerance
band (by about 50%).
________________________________________________________________
PNT1-615 WARN %sFlow rate avg. error excessive
Cause: Comparisons of how far the measured flow rate is from the setpoint had too large of a result.
The size of the error between measured flow and the setpoint that will cause this alarm, and is
controlled by the Max. error from setpoint parameter. Possible causes are:
• A clogged air cap
• A sticking I/P transducer
• A bad air booster
• Pinching air lines.
Remedy: Check and perform the following:
• Check, clean, and possibly replace the air cap.
• Check for oscillating air pressure on the output of the I/P transducer.
• If found, replace the transducer.
• Check for a large loss of air supply pressure or pinched air lines.
• If the alarm occurs on both Fan Air and Atomizing Air or on many robots then possibly increase
the Max. error from setpoint parameter.
________________________________________________________________
PNT1-616 WARN %sCalibration successful
Cause: Used to notify the cell controller that a calibration has been completed successfully.
Remedy: None.
________________________________________________________________
PNT1-617 WARN %sCalibration aborted
Cause: AccuAir calibration could not complete. This might be due to the air supply being off.
Check for other alarms in the log. This might be due to incorrect setup parameters, or incomplete
hardware setup.
Remedy: The best remedy might be found from the previous alarm in the log. Request proper air
flow at the cap, and check that it occurs. Check that the Sensor scale and various other parameters are
set properly. Increase the Calibration time out parameter.
________________________________________________________________
PNT1-618 WARN %sCal. low flow rate reset
Cause: This is a warning not a failure. During AccuAir calibration the low flow rate could not be
properly reached. A new flow rate was established. The target flow rate is determined by the Table
point no. 2 parameter.
Remedy: The new flow rate is shown as point 2 in the calibration table. This value can be visually
checked and accepted. Increase the yield of the system by increasing air line diameters to the
applicator. The Table point no. 2 parameter can be increased (by about 100%).
________________________________________________________________
PNT1-619 WARN %sCal. max. flow rate reset
Cause: This is a warning, not a failure. During AccuAir calibration, the expected maximum flow rate
could not be reached at the maximum output. A new maximum flow rate was established.
Remedy: The new maximum flow rate is shown as point 10 in the calibration table. This value can
be visually checked, and accepted.
________________________________________________________________
PNT1-620 WARN %sCal. time out at max. flow
Cause: The AccuAir controls timed out trying to reach the maximum flow rate. Possible causes are:
• A high gain
• A sticking I/P transducer
• Too large of a yield for the current tolerance band, or the system response is too slow for the
current setting of the Calibration time-out parameter.
Remedy: Perform the following:
• Retry the calibration.
• Try decreasing the Gain modifier parameter.
• Try increasing the Percent tolerance band parameter.
• Check and change the transducer if necessary.
• Try increasing the Calibration time-out parameter (by about 10 seconds).
________________________________________________________________
PNT1-621 WARN %sCal. time out at low flow
Cause: The AccuAir controls timed out trying to reach the minimum flow rate. This flow rate is the
Table point no. 2 parameter. Possible causes are:
• A high gain
• A sticking I/P transducer
• Too large of a yield for the current tolerance band
• Or, the system response is too slow for the current setting of the Calibration time-out parameter.
Remedy: Perform the following:
• Retry the calibration.
• Try decreasing the Gain modifier parameter.
• Try increasing the Percent tolerance band parameter.
• Check and change the transducer if necessary.
• Try increasing the Calibration time-out parameter (by about 10 seconds).
• Try increasing the Table point no. 2 parameter (by about 100%).
________________________________________________________________
PNT1-622 WARN %s0 air flow rate detected
Cause: All of the conditions were set for air to be flowing, but a zero flow rate was measured. This
might be caused by:
• A broken applicator trigger
• Pinched air lines
• A loss (or near loss) of air supply pressure
• A broken air flow sensor
• A broken cable (to the flow sensor)
• A Trigger delay that is too short
Note: AccuAir temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check and perform the following:
• Check, clean, and possibly replace the air cap.
• Check that the gun is properly triggering.
• If air was observed to be flowing, check and possibly replace the air flow sensor.
• Check for a pinched air line.
• Increase the Trigger delay parameter (by about 50%).
________________________________________________________________
PNT1-623 WARN %sLower output did not lower flow
Cause: As the AccuAir calibration steps down through the 10 points in the calibration table, it
expects a lower flow for each decrease in the command flow value. In this case the flow did not
decrease. This can be caused by:
• Insufficient exhaust
• No quick exhaust on the pilot air line
• Too large of a hysteresis in control equipment
• A system response that is too slow for the current setting of the Calibration step delay parameter.
Remedy: Check and perform the following:
• Retry the calibration.
• Check that the pilot air line to the booster has sufficient exhaust capability.
• Increase the Calibration step delay parameter (by about 100%).
• Try reducing the Leveling tries parameter.
________________________________________________________________
PNT1-624 WARN %sTime out during a cal. test
Cause: While measuring hysteresis time up or time down, the Closed loop system timed out. This
indicates that the high or low flow rate can not be reached consistently.
Remedy: Retry the calibration. Check that the high flow rate can be reached consistently. If not, an
increase in the tolerance band might be required.
________________________________________________________________
PNT1-625 WARN %sMin. output has flow > setpoint
Cause: With a minimum control output, the flow rate was measured to be higher than the setpoint
(requested flow). The Max. control out (ms) parameter affects the sensitivity of this alarm. This
might be caused by a leaking or broken air line between the flow sensor and the applicator. The I/P
transducer might be stuck open. The air booster might be stuck open or leaking. This might be caused
by a faulty air flow sensor (reading more flow than there really is). Note: AccuAir temporarily
automatically changes to Open Loop when this alarm occurs.
Remedy: Check and perform the following:
• Check and repair the various air lines.
• Check and repair the air booster.
• Check and repair the I/P transducer.
• Increase the Max. control out (ms) parameter, if possible.
________________________________________________________________
PNT1-626 WARN %sMax. output has flow < setpoint
Cause: With a maximum control output, the flow rate was measured to be lower than the setpoint
(requested flow). The Max. control out (ms) parameter affects the sensitivity of this alarm. This is
likely caused by a clogged air cap. This might also be caused by:
• Pinched air lines
• A broken I/P transducer
• A broken air flow sensor
Note: AccuAir temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check, clean, and possibly replace the air cap. If air is observed to be flowing (when
commanded), possibly replace the air flow sensor. Also check the following:
• Check for a pinched air line.
• Check and repair the I/P transducer.
• Increase the Max. control out (ms) parameter (by about 50%), if possible.
________________________________________________________________
PNT1-627 WARN %sFlow setpoint below globals
Cause: The requested air flow setpoint is below the range of the current parameter settings.
Remedy: Adjust the air flow setpoint to be within the range of controllable flows.
________________________________________________________________
PNT1-628 WARN %sRequested flow above cal. table
Cause: The requested air flow setpoint is above the calibrated range for Fan Air. The maximum value
is shown as point number 10 in the calibration table.
Remedy: Adjust the air flow setpoint to be within the calibrated range of this parameter. Perform
the necessary steps to increase the maximum flow obtained during calibration. This might involve
increasing the diameter of the air lines supplying Fan air to the applicator, or changing the type of
air booster being used.
________________________________________________________________
PNT1-629 WARN %sSlow air flow leak detected
Cause: A small amount of air flow was detected when the gun was not turned on. This might be
caused by a leaking trigger valve, leaking air line, or any other air leak between the air flow sensor
and the gun.
Remedy: No immediate remedy is required. The paint system will continue to function properly. The
applicator and various air lines should be inspected, and repaired if necessary.
________________________________________________________________
PNT1-630 WARN %sFast air flow leak detected
Cause: A large amount of air flow was detected when the gun was not turned on. This might be
caused by a leaking trigger valve, leaking air line, broken air line, broken applicator, or any other air
leak between the air flow sensor and the gun.
Remedy: The the applicator and the various air lines should be inspected and repaired immediately.
________________________________________________________________
PNT1-631 WARN %sFailed to reach setpoint
Cause: This is caused by a failure of the AccuAir system to reach the setpoint (within the tolerance
band) within the time allowed. The time that the system is allowed to take to reach the setpoint
is controlled by the Min. Setpoint reached (ms) parameter. This might be caused by a sticking
transducer, a system that is too slow for the current setting of Min. Setpoint reached, or a system yield
that is too large for the tolerance band setting.
Remedy: If the Fan Air control I/P transducer is noisy or broken, change it. If the calibration yield
values are more than half of the Minimum Tolerance band, then increase this tolerance value. If the
Flow delay parameter is large or this alarm is occurring on many robots, then increase the Minimum
setpoint reached parameter.
________________________________________________________________
PNT1-632 WARN %s0 air flow rate timeout
Cause: All of the conditions were set for air to be flowing but a zero flow rate was measured for
longer than the Zero flow timeout parameter. This might be caused by:
• A clogged air cap
• A broken applicator trigger
• Broken air lines
• A loss of air supply pressure
• A broken air flow sensor
• A broken cable (to the flow sensor)
• A Zero flow time-out value that is too short.
Note: AccuAir temporarily automatically changes to Open Loop when this alarm occurs.
Remedy: Check and perform the following:
• Check, clean, and possibly replace the air cap.
• Check that the gun is properly triggering.
• If air was observed to be flowing, check and possibly replace the air flow sensor.
• Check for a broken air line.
• Increase the Zero flow time-out parameter (by about 25%), if possible.
________________________________________________________________
PNT1-633 WARN %sWarning, learn item failed
Cause: While completing operations to measure the equipment delays, the equipment did not respond
within the expected timeout.
Remedy: Retry the operation by setting the Equipment learn to Redo, and calibrate again. Check for
other AccuAir alarms in the alarm log, then follow the remedies for those alarms. If there are no other
alarms, follow the remedies for the Failed to reach setpoint alarm.
________________________________________________________________
PNT1-634 WARN %sDyn. yield > min tolerance band
Cause: As a particular flow rate set point is being output, the yield (slpm/cnt) for that flow rate was
approximately larger than the percent tolerance. It is not likely that the set point will be reached
within the specified tolerances. This might be caused by the use of a flow rate setpoint that is below
the value that the air system can accurately provide.
Remedy: Decrease the yield. Use larger diameter air lines to supply air to the cap. Use a smaller ratio
booster. Otherwise, accept a larger tolerance band. Increase the minimum tolerance (by about 50%).
________________________________________________________________
PNT1-635 WARN %sCal. table adapted out, down
Cause: The relationship of the output command to the flow rate obtained has changed significantly
since the last calibration. There is now a smaller output required to get the same flow rate. This can be
caused by: air leaks, a loose air cap, or a significant increase of air supply pressure. Note that the
system continues to close the loop and generally maintain requested flow rates even after this alarm if
there are no other alarms occurring. This alarm can provide an early warning of the possible failures.
This alarm is controlled by the Adaptive tolerance parameter.
Remedy: Check and perform the following:
• Check that the air cap is tight on the gun.
• Check, clean, and possibly replace the air cap.
• Check for leaks in air lines or at fittings.
• Check for cracks or breaks in the gun.
• Check for a large increase of air supply pressure.
• Recalibrate to clear the alarm immediately. Increase the Adaptive tolerance parameter to allow
larger changes without causing another alarm.
________________________________________________________________
PNT1-636 WARN %sMax. flow is below midpt. output
Cause: During calibration, it was found that the maximum amount of flow occurred with the
command output at only the middle (midpoint) of the range. This indicates that there is the incorrect
equipment is installed or the equipment is faulty. This might also indicate a large air leak.
Remedy: Check that the I/P transducer is the right range. If not, replace it. Check that the booster has
the correct ratio, typcially 1 to 1. If the alarm log also has a leak alarm follow the remedies for that
alarm. If this equipment must be used, reduce the Max. control value for this parameter by about 20%.
________________________________________________________________
PNT1-637 WARN %sLeak detect when zeroing meter
Cause: When attempting to zero (tare) the air flow meter automatically, the flow reading from it
was large enough to indicate a possible leak.
Remedy: Complete the procedure to zero (tare) the air flow meter manually for this channel. With
the air lines all reconnected and the air pressure on, if the display on the air flow meter reads more
flow than the Fast leak flow parameter, then follow the cause and remedy for the Fast air flow leak
detected alarm.
________________________________________________________________
PNT1-638 WARN Tare timeout
Cause: The automatic zero tare routine took too long to complete.
Remedy: None.
________________________________________________________________
PNT1-643 WARN %sCal. table adapted out,output up
Cause: The relationship of the output command to the flow rate obtained has changed significantly
since the last calibration. There is now a larger output required to get the same flow rate. This can be
caused by: a clogged air cap, clogged gun, pinched air lines or large losses of air supply pressure.
Note that the system continues to close the loop and generally maintain requested flow rates even after
this alarm if there are no other alarms occurring. This alarm can provide early warning of the possible
failures. This alarm is controlled by the Adaptive tolerance parameter.
Remedy: Check, clean, and possibly replace the air cap. Check for a large loss of air supply pressure.
Check for pinched air lines or clogged air passages in the gun. Recalibrate to clear the alarm
immediately. Increase the Adaptive tolerance parameter to allow larger changes without causing
an alarm.
________________________________________________________________
PNT1-644 WARN %sCal. table adapted in tolerance
Cause: The calibration table has returned to the normal operating range as defined by the Adaptive
tolerance.
Remedy: None.
________________________________________________________________
PNT1-645 WARN %sDyn. yield > %% tolerance band
Cause: As a particular flow rate set point is being output, the yield (slpm/cnt) for that flow rate was
approximately larger than the percent tolerance. It is not likely that the set point will be reached
within the specified tolerances. This might be caused by the use of a flow rate setpoint that is above
the value that the air system can provide.
Remedy: Perform the following:
• Decrease the yield.
• Use larger diameter air lines to supply air to the cap.
• Use a larger ratio booster (2:1 instead of 1:1) if the system can not supply the high flow rates
provided.
• Use a smaller ratio booster.
• Otherwise, accept a larger tolerance band. Increase the Percent tolerance band by about 50%.
________________________________________________________________
PNT1-646 WARN %sFlow rate avg. error excessive
Cause: Comparisons of how far the measured flow rate is from the setpoint had too large of a result.
The size of the error between measured flow and setpoint that will cause this alarm is controlled by
the Max. error from setpoint parameter. Possible causes are:
• A clogged air cap
• A sticking I/P transducer
• A bad air booster
• Pinched air lines.
Remedy: Check, clean, and possibly replace the air cap. Check for oscillating air pressure on the
output of the I/P transducer. If found, replace the transducer. Check for a large loss of air supply
pressure or pinched air lines. If the alarm occurs on both Fan Air and Atomizing Air or many robots,
then possibly increase the Max. error from setpoint parameter.
________________________________________________________________
PNT1-647 WARN %sCalibration successful
Cause: Used to notify the cell controller that a calibration has been completed successfully.
Remedy: None.
________________________________________________________________
PNT1-648 WARN %sCalibration aborted
Cause: AccuAir calibration could not complete. This might be due to the air supply being off.
Check for other alarms in the log. This might be due to incorrect setup parameters, or incomplete
hardware setup.
Remedy: The best remedy might be found from the previous alarm in the log. Request a proper air
flow at the cap. Check that it occurs. Check that the Sensor scale and various other parameters are set
properly. Increase the Calibration time-out parameter.
________________________________________________________________
PNT1-649 WARN %sCal. low flow rate reset
Cause: This is a warning not a failure. During AccuAir calibration the low flow rate could not be
properly reached. A new flow was established. The target flow rate is determined by the Table
point no. 2 parameter.
Remedy: The new flow rate is shown as point 2 in the calibration table. This value can be visually
checked and accepted. Increase the yield of the system by increasing air line diameters to the
applicator. The Table point no. 2 parameter can be increased (by about 100%).
________________________________________________________________
PNT1-650 WARN %sCal. max. flow rate reset
Cause: This is a warning, not a failure. During AccuAir calibration the expected maximum flow rate
could not be reached at the maximum output. A new maximum flow rate was established.
Remedy: The new maximum flow rate is shown as point 10 in the calibration table. This value
can be visually checked and accepted.
________________________________________________________________
PNT1-651 WARN %sCal. time out at max. flow
Cause: The AccuAir controls timed out trying to reach the maximum flow rate. Possible causes are:
• A high gain
• A sticking I/P transducer
• Too large of a yield for the current tolerance band
• The system response is too slow for the current setting of the Calibration time out parameter.
Remedy: Perform the following:
• Retry the calibration.
• Possibly decrease the Gain modifier parameter.
• Increase the Percent tolerance band parameter.
• Check and change the transducer, if necessary.
• Increase the Calibration time out parameter by about 10 seconds, if possible.
________________________________________________________________
PNT1-652 WARN %sCal. time out at low flow
Cause: The AccuAir controls timed out trying to reach the minimum flow rate. This flow rate is the
Table point no. 2 parameter. Possible causes are:
• A high gain
• A sticking I/P transducer
• Too large of a yield for the current tolerance band
• Or, the system response is too slow for the current setting of the Calibration time-out parameter.
Remedy: Perform the following:
• Retry the calibration.
• Decrease the Gain modifier parameter, if possible.
• Increase the Percent tolerance band parameter.
• Check and change the transducer, if necessary.
• Increase the Calibration time out parameter by about 10 seconds, if possible.
• Possibly increase the Table point no. 2 parameter by about 100%.
________________________________________________________________
PNT1-653 WARN %s0 air flow rate detected
Cause: All of the conditions were set for air to be flowing, but a zero flow rate was measured. This
might be caused by:
• A broken applicator trigger
• Pinched air lines
• A loss (or near loss) of air supply pressure
• A broken air flow sensor
• A broken cable (to the flow sensor)
• A Trigger delay that is too short
Note: AccuAir temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check the following:
• Check, clean, and possibly replace the air cap.
• Check that the gun is properly triggering.
• If air was observed to be flowing, check and possibly replace the air flow sensor.
• Check for a pinched air line.
• Increase the Trigger delay parameter by about 50%.
________________________________________________________________
PNT1-654 WARN %sLower output did not lower flow
Cause: As the AccuAir calibration steps down through the 10 points in the calibration table, it
expects a lower flow for each decrease in the command flow value. In this case, the flow did not
decrease. This can be caused by insufficient exhaust, no quick exhaust on the pilot air line, too large
of a hysteresis in control equipment, or the system response is too slow for the current setting of
the Calibration step delay parameter.
Remedy: Perform the following:
• Retry the calibration.
• Check that the pilot air line to the booster has sufficient exhaust capability.
• Increase the Calibration step delay parameter by about 100%.
• Try reducing the Leveling trys parameter.
________________________________________________________________
PNT1-655 WARN %sTime out during a cal. test
Cause: While measuring hysteresis time up or time down, the Closed loop system timed out. This
indicates that the high or low flow rate can not be reached consistently.
Remedy: Retry the calibration. Check that the high flow rate can be reached consistently, if not an
increase in the tolerance band might be required.
________________________________________________________________
PNT1-656 WARN %sMin. output has flow > setpoint
Cause: With a minimum control output, the flow rate was measured to be higher than the setpoint
(requested flow). The Max. control out (ms) parameter affects the sensitivity of this alarm. This
might be caused by a leaking or broken air line between the flow sensor and the applicator. The I/P
transducer might be stuck open. The air booster might be stuck open or might be leaking. This
might be caused by a faulty air flow sensor (reading more flow than there really is). Note: AccuAir
temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check and perform the following:
• Check and repair the various air lines.
• Check and repair the air booster.
• Check and repair the I/P transducer.
• Possibly increase the Max. control out (ms) parameter.
________________________________________________________________
PNT1-657 WARN %sMax. output has flow < setpoint
Cause: With a maximum control output, the flow rate was measured to be lower than the setpoint
(requested flow). The Max. control out (ms) parameter affects the sensitivity of this alarm. This is
likely caused by a clogged air cap. This might also be caused by: pinched air lines, a broken I/P
transducer, or a broken air flow sensor. Note: AccuAir temporarily and automatically changes to
Open Loop when this alarm occurs.
Remedy: Check and perform the following:
• Check, clean, and possibly replace the air cap.
• If air is observed to be flowing (when commanded), possibly replace the air flow sensor.
• Check for a pinched air line.
• Check and repair the I/P transducer.
• Possibly increase the Max. control out (ms) parameter by about 50%.
________________________________________________________________
PNT1-658 WARN %sFlow setpoint below globals
Cause: The requested air flow setpoint is below the range of the current parameter settings.
Remedy: Adjust the air flow setpoint to be within the range of controllable flows.
________________________________________________________________
PNT1-659 WARN %sRequested flow above cal. table
Cause: The requested air flow setpoint is above the calibrated range for Fan Air. The maximum value
is shown as point number 10 in the calibration table.
Remedy: Adjust the air flow setpoint to be within the calibrated range of this parameter. Perform
the necessary steps to increase the maximum flow obtained during calibration. This might involve
increasing the diameter of the air lines, supplying Fan air to the applicator, or changing the type of
air booster used.
________________________________________________________________
PNT1-660 WARN %sSlow air flow leak detected
Cause: A small amount of air flow was detected when the gun was not turned on. This might be
caused by a leaking trigger valve, leaking air line, or any other air leak between the air flow sensor,
and the gun.
Remedy: No immediate remedy is required. The paint system will continue to function properly. The
applicator and various air lines should be inspected, and repaired if necessary.
________________________________________________________________
PNT1-661 WARN %sFast air flow leak detected
Cause: A large amount of air flow was detected when the gun was not turned on. This might be
caused by a leaking trigger valve, leaking air line, broken air line, broken applicator, or any other air
leak between the air flow sensor, and the gun.
Remedy: The applicator and the various air lines should be inspected and repaired immediately.
________________________________________________________________
PNT1-662 WARN %sFailed to reach setpoint
Cause: This is caused by a failure of the AccuAir system to reach the setpoint within the tolerance
band during the allotted time. The time that the system is allowed to take to reach setpoint is
controlled by the Min. Setpoint reached (ms) parameter. This failure might be caused by a sticking
transducer, a system that is too slow for the current setting of Min. Setpoint reached, or a system yield
that is too large for the tolerance band setting.
Remedy: If the Fan Air control I/P transducer is noisy or broken, change it. If the calibration yield
values are more than half of the min. Tolerance band, then increase this tolerance value. If the Flow
delay parameter is large, or this alarm is occurring on many robots, then increase the Minimum
setpoint reached parameter.
________________________________________________________________
PNT1-663 WARN %s0 air flow rate timeout
Cause: All of the conditions were set for air to be flowing but a zero flow rate was measured for
longer than the Zero flow timeout parameter. This might be caused by:
• A clogged air cap
• A broken applicator trigger
• Broken air lines
• A loss of air supply pressure
• A broken air flow sensor
• A broken cable to the flow sensor
• Or, a Zero flow time-out value that is too short.
Note: AccuAir temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check the following:
• Check, clean, and possibly replace the air cap.
• Check that the gun is properly triggering.
• If air was observed to be flowing, check and possibly replace the air flow sensor.
• Check for a broken air line.
• Increase the Zero flow timeout parameter by about 25%, if possible.
________________________________________________________________
PNT1-664 WARN %sWarning, learn item failed
Cause: While completing operations to measure the equipment delays, the equipment did not respond
within the expected timeout.
Remedy: Retry the operation by setting the Equipment learn to Redo and calibrate again. Check for
other AccuAir alarms in the alarm log, then follow the remedies for those alarms. If there are no other
alarms, follow the remedies for the Failed to reach setpoint alarm.
________________________________________________________________
PNT1-665 WARN %sDyn. yield > min tolerance band
Cause: As a particular flow rate set point is being output, the yield (slpm/cnt) for that flow rate was
larger than the percent tolerance. It is not likely that the set point will be reached within the specified
tolerances. This might be caused by the use of a flow rate setpoint that is below the value that the air
system can accurately provide.
Remedy: Perform the following:
• Decrease the yield.
• Use larger diameter air lines to supply air to the cap.
• Use a smaller ratio booster.
• Otherwise, accept a larger tolerance band.
• Increase the minimum tolerance by about 50%.
________________________________________________________________
PNT1-666 WARN %sCal. table adapted out, down
Cause: The relationship of the output command to the flow rate obtained has changed significantly
since the last calibration. There is now a smaller output required to get the same flow rate. This can be
caused by: air leaks, a loose air cap, or a significant increase of air supply pressure. Note that the
system continues to close the loop and generally maintain requested flow rates even after this alarm if
there are no other alarms occurring. This alarm can provide early warning of possible failures. This
alarm is controlled by the Adaptive tolerance parameter.
Remedy: Check that the air cap is tight on the gun. Check, clean, and possibly replace the air cap.
Check for leaks in air lines or at fittings. Check for cracks or breaks in the gun. Check for a large
increase of air supply pressure. Recalibrate to clear the alarm immediately. Increase the Adaptive
tolerance parameter to allow larger changes without causing another alarm.
________________________________________________________________
PNT1-667 WARN %sMax. flow is below midpt. output
Cause: During calibration it was found that the maximum amount of flow occurred with the command
output at only the middle (midpoint) of the range. This indicates that there is incorrect equipment
installed, or the equipment is faulty. This might also indicate a large air leak.
Remedy: Check that the I/P transducer is within the correct right range. If not, replace it. Check
that the booster has the correct ratio, typically 1 to 1. If the alarm log also has a leak alarm, follow
the remedies for that alarm. If this equipment must be used, reduce the Max. control value for this
parameter by about 20%.
________________________________________________________________
PNT1-668 WARN %sLeak detect when zeroing meter
Cause: When attempting to zero (tare) the air flow meter automatically, the flow reading from it
was large enough to indicate a possible leak.
Remedy: Complete the procedure to zero (tare) the air flow meter manually for this channel. With the
air lines all reconnected and air pressure on, if the display on the air flow meter reads more flow than
the Fast leak flow parameter, follow the cause and remedy for the Fast air flow leak detected alarm.
________________________________________________________________
PNT1-673 WARN %sEstat controller warning
Cause: The external E-stat controller detected a warning.
Remedy: Check the status of the external E-stat controller.
________________________________________________________________
PNT1-674 PAUS %sEstat controller fault
Cause: The external E-stat controller detected a fault.
Remedy: Check the status of the external E-stat controller.
________________________________________________________________
PNT1-675 WARN %sEstats disabled
Cause: The E-stat disconnect or enable switch is off.
Remedy: Turn on the E-stat disconnect or enable switch.
________________________________________________________________
PNT1-676 WARN %sEstat controller not in remote
Cause: The E-stat local/remote switch is set to local mode.
Remedy: Set the local/remote switch on the E-stat controller to remote mode.
________________________________________________________________
PNT1-677 WARN %sEstat HVON Failed
Cause: The robot sent the HVON signal to the E-stat controller, but did not get a HVON signal back
from the E-stat unit.
Remedy: Check the status of the external E-stat controller.
________________________________________________________________
PNT1-678 WARN %sEstat setpoint not reached
Cause: The E-stat controller did not set the set point reached output in time.
Remedy: Check the voltage and set point reached light on the E-stat controller. It might be having
trouble reaching the requested voltage. If not, adjust the set point reached timeout setting.
________________________________________________________________
PNT1-679 WARN %sEstat T.P. enable Timeout
Cause: The ESTAT enable for the teach pendant screen timed out.
Remedy: Request the ESTAT voltage again.
________________________________________________________________
PNT1-686 WARN %sEstat controller warning
Cause: The external E-stat controller detected a warning.
Remedy: Check the status of the external E-stat controller.
________________________________________________________________
PNT1-687 PAUS %sEstat controller fault
Cause: The external E-stat controller detected a fault.
Remedy: Check the status of the external E-stat controller.
________________________________________________________________
PNT1-688 WARN %sEstats disabled
Cause: The E-stat disconnect or enable switch is off.
Remedy: Turn on the E-stat disconnect or enable switch.
________________________________________________________________
PNT1-689 WARN %sEstat controller not in remote
Cause: The E-stat local/remote switch is set to local mode.
Remedy: Turn the local/remote switch on the E-stat controller to remote mode.
________________________________________________________________
PNT1-690 WARN %sEstat HVON Failed
Cause: The robot sent the HVON signal to the E-stat controller but did not get an HVON signal back
from the E-stat unit.
Remedy: Check the status of the external E-stat controller.
________________________________________________________________
PNT1-691 WARN %sEstat setpoint not reached
Cause: The E-stat controller did not set the set point reached output in time.
Remedy: Check the voltage and set point reached light on the E-stat controller. It might be having
trouble reaching the requested voltage. If not, adjust the set point reached timeout setting.
________________________________________________________________
PNT1-692 WARN %sEstat T.P. enable Timeout
Cause: The estat enable for the teach pendant screen timed out.
Remedy: Request E-stat votage again.
________________________________________________________________
PNT1-699 WARN %sTurbine Startup Test Not Complete
Cause: The Bell Speed Control Startup Test for the turbine is not complete. This test must be
performed before running the turbine.
Remedy: Check the Start Mode field on the Bell Speed SETUP menu to check the status of the
Startup Test. Then, run the test if necessary.
________________________________________________________________
PNT1-700 PAUS %sMax.dV/dT detected
Cause: A velocity change within a measured time has exceeded the maximum dV/dT setting for
this turbine
Remedy: Check the hardware to determine if the feedback signal from the turbine is consistant.
________________________________________________________________
PNT1-701 PAUS %sMax. output has speed < setpoint
Cause: With a maximum control output the speed was measured to be lower than the setpoint
(requested speed). This can occur if:
• The gun is clogged.
• The turbine air or turbine pilot air line is pinched.
• The turbine air pressure is too low.
Remedy: Check the turbine lines for pinching, especially at places where they flex. Check the turbine
air supply pressure. Check and replace the I/P transducer, if necessary.
________________________________________________________________
PNT1-702 WARN %sRequested speed over valid range
Cause: The requested turbine speed output command is above the range that is considered valid
Adjust the turbine speed command that is used in the preset table so it is within an acceptable range.
Remedy: N/A
________________________________________________________________
PNT1-703 WARN %sFailed to reach setpoint
Cause: The turbine speed failed to come within the Tolerance Band setting within the time setting of
Min. set point reached (ms) value. This can be caused by noise in the speed sensor signals, low air
supply pressure or other failures. This may occur with the alarm Max. output has speed &lt; setpoint .
If the Max. output has speed &lt; setpoint alarm is also in the alarm log follow the remedies for that
alarm. Examine the displayed turbine speed and evaluate if it is bouncing a lot. If so decrease the PID
gains. Possibly increase the Tolerance Band parameter by about 30% to 50%, for example from 1.8%
to 2.3%. Increase the Min. set point reached value by about 30% to 50%.
Remedy: N/A
________________________________________________________________
PNT1-704 PAUS %sZero turbine speed timeout
Cause: All of the conditions were set for the turbine to be spinning but a zero speed was measured
for a set time period. This might be due to no turbine air pressure or pilot air pressure. One of the
following items might be broken: the I/P transducer, speed sensor pickup, speed sensor interface.
The Zero speed timeout might be set too short.
Remedy: If the turbine can be seen spinning, check the following: the speed sensor interface and
speed sensor pickup. Otherwise, check the other items listed above. Possibly increase the Zero
speed timeout by about 50%.
________________________________________________________________
PNT1-705 PAUS %sTurbine over speed
Cause: While the turbine was operating the RPM level was above the Over speed limit . When this
error occurs, braking will be applied to bring the turbine speed to within the acceptable operating
range. Check and replace the I/P transducer if necessary. Possibly increase the Over speed limit value.
Remedy: N/A
________________________________________________________________
PNT1-706 WARN %sTurbine under speed fault
Cause: While the turbine was operating and the gun was on or enabled, the RPM level was below the
Under speed limit . Check and replace the I/P transducer if necessary. Check the supply and pilot air
pressures, if either one is low, increase it. Possibly decrease the Under speed limit value.
Remedy: N/A
________________________________________________________________
PNT1-707 WARN %sTurbine under speed warning
Cause: While the gun was off or disabled and the turbine was operating the RPM level was below
the Under speed limit, Manual . Check and replace the I/P transducer if necessary. Check the
supply and pilot air pressures, if either one is low, increase it. Possibly decrease the Under speed
limit, Manual value.
Remedy: N/A
________________________________________________________________
PNT1-708 WARN %sSpeed avg. error excessive
Cause: Checks for how far the speed is from the set point have been too high. Possible causes are:
• A sticking I/P transducer
• Low supply air pressure
• Low pilot air pressure
• PID Gains that are too large.
Remedy: Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures.
If either one is low, increase it. Possibly decrease the Max. error from setpoint parameter.
________________________________________________________________
PNT1-709 PAUS %sBearing Air NOT OK
Cause: The digital input signal indicating the Bear Air is above the minimum pressure is not ON.
Check the supply pressure to the Bearing Air or verify the digital input signal is working correctly.
Remedy: N/A
________________________________________________________________
PNT1-710 WARN %sCruise Speed not established
Cause: The Cruise Speed determined during the Bell Speed Startup Test could not be established.
Remedy: Redo the Bell Speed Startup Test to determine a new Cruise Speed, or check the turbine or
regulator.
________________________________________________________________
PNT1-716 WARN %sTurbine Startup Test Not Complete
Cause: The Bell Speed Control Startup Test for the turbine is not complete. This test must be
performed before running the turbine.
Remedy: Check the Start Mode field on the Bell Speed SETUP menu to check the status of the
Startup Test. If it has not been performed, run the Bell Speed Control Startup Test.
________________________________________________________________
PNT1-717 PAUS %sMax.dV/dT detected
Cause: A velocity change within a measured time has exceeded the maximum dV/dT setting for
this turbine.
Remedy: Check the hardware to determine if the feedback signal from the turbine is consistant.
________________________________________________________________
PNT1-718 PAUS %sMax. output has speed < setpoint
Cause: With a maximum control output the speed was measured to be lower than the setpoint
(requested speed). The gun might be clogging. The turbine air or turbine pilot air line might be
pinched. The turbine air pressure might have become too low.
Remedy: Check the turbine lines for pinching, especially at places where they flex. Check the turbine
air supply pressure. Check and replace the I/P transducer if necessary.
________________________________________________________________
PNT1-719 WARN %sRequested speed over valid range
Cause: The requested turbine speed output command is above the range that is considered valid
Adjust the turbine speed command that is used in the preset table so it is within an acceptable range.
Remedy: N/A
________________________________________________________________
PNT1-720 WARN %sFailed to reach setpoint
Cause: The turbine speed failed to come within the Tolerance Band setting within the time setting of
Min. set point reached (ms) value. This can be caused by noise in the speed sensor signals, low air
supply pressure or other failures. This might occur with the Max. output has speed < setpoint alarm.
Remedy: If the Max. output has speed < setpoint alarm is also in the alarm log, follow the remedies
for that alarm. Examine the displayed turbine speed and evaluate if it is bouncing a lot. If so, decrease
the PID gains. Possibly increase the Tolerance Band parameter by about 30% to 50%, for example
from 1.8% to 2.3%. Increase the Min. set point reached value by about 30% to 50%.
________________________________________________________________
PNT1-721 PAUS %sZero turbine speed timeout
Cause: All of the conditions were set for turbine to be spinning and a zero speed was measured
for a set time period. This may be due to no turbine air pressure or pilot air pressure. One of the
following items may be broken: the I/P transducer, speed sensor pickup, speed sensor interface.
The Zero speed timeout may be set too short. If turbine can be seen spinning, check: speed sensor
interface, speed sensor pickup. Otherwise check the other items listed above. Possibly iwncrease the
Zero speed timeout by about 50%.
Remedy: N/A
________________________________________________________________
PNT1-722 PAUS %sTurbine over speed
Cause: While the turbine was operating the RPM level was above the Over speed limit . When this
error occurs, braking will be applied to bring the turbine speed to within the acceptable operating
range. Check and replace the I/P transducer if necessary. Possibly increase the Over speed limit value.
Remedy: N/A
________________________________________________________________
PNT1-723 WARN %sTurbine under speed fault
Cause: While the turbine was operating and the gun was on or enabled, the RPM level was below the
Under speed limit . Check and replace the I/P transducer if necessary. Check the supply and pilot air
pressures, if either one is low, increase it. Possibly decrease the Under speed limit value.
Remedy: N/A
________________________________________________________________
PNT1-724 WARN %sTurbine under speed warning
Cause: While the gun was off or disabled and the turbine was operating the RPM level was below
the Under speed limit, Manual . Check and replace the I/P transducer if necessary. Check the
supply and pilot air pressures, if either one is low, increase it. Possibly decrease the Under speed
limit, Manual value.
Remedy: N/A
________________________________________________________________
PNT1-725 WARN %sSpeed avg. error excessive
Cause: Checks for how far the speed is from the set point have been too high. Possible causes are:
• A sticking I/P transducer
• Low supply air pressure
• Low pilot air pressure
• PID Gains that are too large.
Remedy: Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures.
If either value is low, increase it. Possibly decrease the Max. error from setpoint parameter.
________________________________________________________________
PNT1-726 PAUS %sBearing Air NOT OK
Cause: The digital input signal indicating the Bear Air is above the minimum pressure is not ON.
Check the supply pressure to the Bearing Air or verify the digital input signal is working correctly.
Remedy: N/A
________________________________________________________________
PNT1-727 WARN %sCruise Speed not established
Cause: The Cruise Speed determined during the Bell Speed Startup Test could not be established.
Remedy: Redo the Bell Speed Startup Test to determine a new Cruise Speed, or check the turbine or
regulator.
________________________________________________________________
PNT1-733 WARN %sPump 1 IN low pressure warning
Cause: Pump #1 inlet pressure has been below the low warning limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose, etc.) is removed or broken.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from paint kitchen.
• Check the resin inlet transducer as follows: Through the Analog I/O menu verify the transducer is
spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000
cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-734 PAUS %sPump 1 IN low pressure fault
Cause: Pump #1 inlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose, etc.) is removed or broken.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from paint kitchen.
• Check the resin inlet transducer as follows: Through the Analog I/O menu verify the transducer is
spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000
cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-735 WARN %sPump 1 IN high pressure warning
Cause: Pump #1 inlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the resin inlet transducer as follows: Through the Analog I/O menu verify the transducer is
spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the resin inlet regulator as follows: Through the Analog I/O menu verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-736 PAUS %sPump 1 IN high pressure fault
Cause: Pump #1 inlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the resin inlet transducer as follows: Through the Analog I/O menu verify the transducer is
spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000
cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-737 WARN %sPump 1 OUT low pressure warning
Cause: Pump #1 outlet pressure has been below the low warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose, etc.) is removed or broken.
• A broken coupling between the servo motor and pump.
• The resin outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the resin outlet transducer as follows: Through the Analog I/O menu verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-738 PAUS %sPump 1 OUT low pressure fault
Cause: Pump #1 outlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose, etc.) is removed or broken.
• A broken coupling between the servo motor and pump.
• The resin outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure fault limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to the resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the resin outlet transducer as follows: Through the Analog I/O menu verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-739 WARN %sPump 1 OUT high pressure warning
Cause: Pump #1 outlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipates are not setup correctly.
• Obstructed line, trigger, or check valve.
• The pilot line to mix resin valve is removed or broken.
• The mix resin valve has failed.
• The resin outlet transducer has failed.
Remedy: Check the following:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix resin valve. Verify that the mix resin valve is not faulty.
• Check the resin outlet transducer as follows: Through the Analog I/O menu verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-740 PAUS %sPump 1 OUT high pressure fault
Cause: Pump #1 outlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipates are not set up correctly.
• Obstructed line, trigger, or check valve.
• The pilot line to mix resin valve is removed or broken.
• The mix resin valve has failed.
• The resin outlet transducer has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix resin valve.
• Verify that the mix resin valve is not faulty.
• Check the resin outlet transducer as follows: Through the Analog I/O menu verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-741 WARN %sPump 1 fluid flow rate > set point
Cause: The actual flow rate out of pump #1 as measured by the fluid flow meter has been
continuously greater than a set point window (a percentage) for a user configurable period of time.
Remedy: Perform a fluid flow test on pump #1 with a beaker and verify that the beaker amount
matches the pump #1 size (cc/rev). Verify that the correct KFT factor has been entered for the fluid
flow meter per the manufacturer’s specification. Check the operation of the inlet regulator to verify
that no &qout;blow by&qout; is occurring across the pump.
________________________________________________________________
PNT1-742 WARN %sPump 1 fluid flow rate < set point
Cause: The actual flow rate out of pump #1 as measured by the fluid flow meter has been
continuously less than a set point window (a percentage) for a user configurable period of time.
Remedy: Perform a fluid flow test on pump #1 with a beaker and verify that the beaker amount
matches the pump #1 size (cc/rev). Verify that the correct KFT factor has been entered for the fluid
flow meter per the manufacturer’s specification. Check the operation of the inlet regulator to verify
that no &qout;blow by&qout; is occurring across the pump.
________________________________________________________________
PNT1-743 WARN %sPump 1 zero fluid flow rate detected
Cause: Zero fluid flow out of pump #1 is detected. This condition is usually caused by one or
more of the following:
• A loose mechanical coupling between the motor and pump.
• A broken line between the pump and trigger.
Remedy: Check the mechanical coupling between the motor and the pump. Make sure the line
from pump to trigger is ok.
________________________________________________________________
PNT1-744 WARN %sPump 1 motor velocity limit
Cause: The motor velocity for pump #1 has exceeded its operating limit. The motor speed will be
reduced to be within operating limit. The motor speed for pump #2 will be reduced to maintain a
proper fluid ratio.
Remedy: Lower the flow rate to within the motor limit.
________________________________________________________________
PNT1-745 WARN %sPump 1 motor servo not ready
Cause: The servo power to pump #1 is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off for some reason, such as
E-stop condition or if the controller is machine locked. Correct the condition, and reset the controller.
________________________________________________________________
PNT1-746 WARN %sPump 1 totals differ > tolerance
Cause: The actual total flow out of pump #1 as measured by the fluid flow meter has a value that is
different than the commanded total flow. This difference is larger than the total flow tolerance.
Remedy: Perform a fluid flow test on pump #1 with a beaker and verify that the beaker amount
matches the pump #1 size (cc/rev). Verify that the correct KFT factor has been entered for the fluid
flow meter per the manufacturer’s specification. Check the operation of the inlet regulator to verify
that no &qout;blow by&qout; is occurring across the pump. Verify that pump #1 does not have
excessive wear.
________________________________________________________________
PNT1-753 WARN %sPump 2 IN low pressure warning
Cause: Pump #2 inlet pressure has been below the low warning limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or broken.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Perform the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to verify the hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000
cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-754 PAUS %sPump 2 IN low pressure fault
Cause: Pump #2 inlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or broken.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy:
• Make sure the low pressure fault limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000
cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-755 WARN %sPump 2 IN high pressure warning
Cause: Pump #2 inlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the resin inlet regulator as follows: Through the Analog I/O menu verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-756 PAUS %sPump 2 IN high pressure fault
Cause: Pump #2 inlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the hardener inlet regulator as follows: Through the Analog I/O menu verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-757 WARN %sPump 2 OUT low pressure warning
Cause: Pump #2 outlet pressure has been below the low warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or broken.
• A coupling is broken between the servo motor and pump.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-758 PAUS %sPump 2 OUT low pressure fault
Cause: Pump #2 outlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or broken.
• A broken coupling between the servo motor and pump.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure fault limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-759 WARN %sPump 2 OUT high pressure warning
Cause: Pump #2 outlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipates are not setup correctly.
• A line, trigger, or check valve is obstructed.
• The pilot line to mix hardener valve is removed or broken.
• The mix hardener valve has failed.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix hardener valve.
• Verify that the mix hardener valve is not faulty.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-760 PAUS %sPump 2 OUT high pressure fault
Cause: Pump #2 outlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipates are not setup correctly.
• A line, trigger, or check valve is obstructed.
• The pilot line to mix hardener valve is removed or broken.
• The mix hardener valve has failed.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger or check valve are not obstructed.
• Check the pilot line to mix hardener valve.
• Verify that the mix hardener valve is not faulty.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-761 WARN %sPump 2 fluid flow rate > set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been
continuously greater than a set point window (a percentage) for a user configurable period of time.
Remedy: Perform the following:
• Perform a fluid flow test on pump #2 with a beaker and verify that the beaker amount matches
the pump #2 size (cc/rev).
• Verify that the correct KFT factor has been entered for the fluid flow meter per the manufacturer’s
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
________________________________________________________________
PNT1-762 WARN %sPump 2 fluid flow rate < set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been
continuously less than a set point window (a percentage) for a user configurable period of time.
Remedy: Perform the following:
• Perform a fluid flow test on pump #2 with a beaker and verify that the beaker amount matches
the pump #2 size (cc/rev).
• Verify that the correct KFT factor has been entered for the fluid flow meter per the manufacturer’s
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
________________________________________________________________
PNT1-763 WARN %sPump 2 zero fluid flow rate detected
Cause: Zero fluid flow out of pump #2 is detected. This condition is usually caused by one or
more of the following:
• A loose mechanical coupling between the motor and pump.
• A broken line between the pump and trigger.
Remedy: Check the mechanical coupling between the motor and the pump. Make sure the line
from pump to trigger is ok.
________________________________________________________________
PNT1-764 WARN %sPump 2 motor velocity limit
Cause: The motor velocity for pump #2 has exceeded its operating limit. The motor speed will be
reduced to be within operating limit. The motor speed for pump #1 will be reduced to maintain a
proper fluid ratio.
Remedy: Lower the flow rate to within the motor limit.
________________________________________________________________
PNT1-765 WARN %sPump 2 motor servo not ready
Cause: The servo power to pump #2 is not ready. Usually, the servo not ready occurs when servo
power is turned off during an E-stop condition, or if the machine is locked.
Remedy: Correct the condition, and reset the controller.
________________________________________________________________
PNT1-766 WARN %sPump 2 totals differ > tolerance
Cause: The actual total flow out of pump #2 as measured by the fluid flow meter has a value that is
different than the commanded total flow. This difference is larger than the total flow tolerance.
Remedy: Check the following:
• Perform a fluid flow test on pump #2 with a beaker and verify that the beaker amount matches
the pump #2 size (cc/rev).
• Verify that the correct KFT factor has been entered for the flow meter per the manufacturer’s
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
• Verify that pump #2 does not have excessive wear.
________________________________________________________________
PNT1-767 WARN %sCalibration aborted
Cause: The IPC auto calibration aborted.
Remedy: Ensure the pumps are operating correctly. Also ensure that the delay parameter is set
to a sufficient amount.
________________________________________________________________
PNT1-768 WARN (%s) Non-increasing cal table
Cause: The IPC auto calibration aborted because the calibration table is not increasing with the
commanded flow rate.
Remedy: Ensure the pumps are operating correctly. Ensure that the speed command delay (used to
allow the motor RPM to settle) is set to a sufficient amount.
________________________________________________________________
PNT1-769 WARN (%s) Zero PSI
Cause: The IPC auto calibration aborted. This can occur because zero PSI was detected while the
IPC system was determining the maximum flow rate during the auto calibration. This can also occur
while the IPC system was determining one of the calibration points.
Remedy: Ensure the pumps are operating correctly. Ensure that the speed command delay (used to
allow the motor RPM to settle) is set to a sufficient amount. If the setup parameter, ‘Max speed
cap:’, was enabled, ensure that the parameter ‘User speed cap:’, was not set too high – the pressure
will eventually plateau at higher speed commands. An alternate action is to disable ‘Max speed
cap:’ and re-calibrate.
________________________________________________________________
PNT1-770 WARN (%s) Set Color Valve
Cause: An error occurred in setting the color valve.
Remedy: None.
________________________________________________________________
PNT1-771 WARN %s Res:Hrd ratio is 0.0:0.0
Cause: The color identified in the error message has a default ratio (0.0:0.0) defined. The IPC pumps
can only run when a non-zero ratio is defined.
Remedy: Change the default ratio for this color in the SETUP Color DETAIL menu.
________________________________________________________________
PNT1-778 WARN %sPump 1 IN low pressure warning
Cause: Pump #1 inlet pressure has been below the low warning limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or broken.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Check the resin inlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-779 PAUS %sPump 1 IN low pressure fault
Cause: Pump #1 inlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so forth) is removed or broken.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Check the resin inlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-780 WARN %sPump 1 IN high pressure warning
Cause: Pump #1 inlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the resin inlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the resin inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-781 PAUS %sPump 1 IN high pressure fault
Cause: Pump #1 inlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The resin inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the resin inlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-782 WARN %sPump 1 OUT low pressure warning
Cause: Pump #1 outlet pressure has been below the low warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or is broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or is broken.
• A coupling is broken between the servo motor and pump.
• The resin outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the resin outlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-783 PAUS %sPump 1 OUT low pressure fault
Cause: Pump #1 outlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to resin color valve is removed or is broken.
• The resin color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or broken.
• A coupling is broken between the servo motor and pump.
• The resin outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure fault limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the resin outlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-784 WARN %sPump 1 OUT high pressure warning
Cause: Pump #1 outlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipates are not setup correctly.
• There is an obstructed line, trigger, or check valve.
• The pilot line to mix resin valve is removed or is broken.
• The mix resin valve has failed.
• The resin outlet transducer has failed.
Remedy:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix resin valve.
• Verify that the mix resin valve is not faulty.
• Check the resin outlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-785 PAUS %sPump 1 OUT high pressure fault
Cause: Pump #1 outlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipates are not setup correctly.
• There is an obstructed line, trigger, or check valve.
• The pilot line to mix resin valve is removed or is broken.
• The mix resin valve has failed.
• The resin outlet transducer has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix resin valve.
• Verify that the mix resin valve is not faulty.
• Check the resin outlet transducer as follows: Through the Analog I/O menu, verify the transducer
is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
________________________________________________________________
PNT1-786 WARN %sPump 1 fluid flow rate > set point
Cause: The actual flow rate out of pump #1 as measured by the fluid flow meter has been
continuously greater than a set point window (a percentage) for a user configurable period of time.
Remedy: Check the following:
• Perform a fluid flow test on pump #1 with a beaker and verify that the beaker amount matches
the pump #1 size (cc/rev).
• Verify that the correct KFT factor has been entered for the fluid flow meter per the manufacturers
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
________________________________________________________________
PNT1-787 WARN %sPump 1 fluid flow rate < set point
Cause: The actual flow rate out of pump #1 as measured by the fluid flow meter has been
continuously less than a set point window (a percentage) for a user configurable period of time.
Remedy: Check the following:
• Perform a fluid flow test on pump #1 with a beaker and verify that the beaker amount matches
the pump #1 size (cc/rev).
• Verify that the correct KFT factor has been entered for the fluid flow meter per the manufacturers
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
________________________________________________________________
PNT1-788 WARN %sPump 1 zero fluid flow rate detected
Cause: Zero fluid flow out of pump #1 is detected. This condition is usually caused by one or
more of the following:
• A loose mechanical coupling between the motor and pump.
• A broken line between the pump and trigger.
Remedy: Check the mechanical coupling between the motor and the pump. Make sure the line
from pump to trigger is ok.
________________________________________________________________
PNT1-789 WARN %sPump 1 motor velocity limit
Cause: The motor velocity for pump #1 has exceeded its operating limit. The motor speed will be
reduced to be within operating limit. The motor speed for pump #2 will be reduced to maintain a
proper fluid ratio.
Remedy: Lower the flow rate to within the motor limit.
________________________________________________________________
PNT1-790 WARN %sPump 1 motor servo not ready
Cause: The servo power to pump #1 is not ready. Usually, the servo not ready occurs when servo
power is turned off such as during an E-stop condition, or if the machine is locked.
Remedy: Correct the condition, and reset the controller.
________________________________________________________________
PNT1-791 WARN %sPump 1 totals differ > tolerance
Cause: The actual total flow out of pump #1 as measured by the fluid flow meter has a value that is
different than the commanded total flow. This difference is larger than the total flow tolerance.
Remedy: Check the following:
• Perform a fluid flow test on pump #1 with a beaker and verify that the beaker amount matches
the pump #1 size (cc/rev).
• Verify that the correct KFT factor has been entered for the fluid flow meter per the manufacturer’s
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
• Verify that pump #1 does not have excessive wear.
________________________________________________________________
PNT1-798 WARN %sPump 2 IN low pressure warning
Cause: Pump #2 inlet pressure has been below the low warning limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or is broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or is broken.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-799 PAUS %sPump 2 IN low pressure fault
Cause: Pump #2 inlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or is broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or is broken.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the low pressure fault limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-800 WARN %sPump 2 IN high pressure warning
Cause: Pump #2 inlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the resin inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-801 PAUS %sPump 2 IN high pressure fault
Cause: Pump #2 inlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The supply pressure is set too high.
• The hardener inlet transducer has failed.
• The inlet regulator has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the supply pressure is appropriate.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
• Check the hardener inlet regulator as follows: Through the Analog I/O menu, verify the command
200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
________________________________________________________________
PNT1-802 WARN %sPump 2 OUT low pressure warning
Cause: Pump #2 outlet pressure has been below the low warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The low pressure warn limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or is broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or is broken.
• A broken coupling between the servo motor and pump.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure warning limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-803 PAUS %sPump 2 OUT low pressure fault
Cause: Pump #2 outlet pressure has been below the low fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The low pressure fault limit is set too high.
• The low pressure sensitivity is set too short.
• The pilot line to hardener color valve is removed or is broken.
• The hardener color valve has failed.
• The supply pressure is too low.
• The supply line (hose and so on) is removed or is broken.
• A broken coupling between the servo motor and pump.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the low pressure fault limit is appropriate.
• Make sure the low pressure sensitivity is appropriate.
• Check the pilot line to hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is appropriate.
• Check the supply line from the paint kitchen.
• Verify that the pump is rotating with the motor.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-804 WARN %sPump 2 OUT high pressure warning
Cause: Pump #2 outlet pressure has been above the high warning limit for a user configurable period
of time. This condition is usually caused by one or more of the following:
• The high pressure warn limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipates are not setup correctly.
• There is an obstructed line, trigger, or check valve.
• The pilot line to mix hardener valve is removed or is broken.
• The mix hardener valve has failed.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the high pressure warning limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix hardener valve.
• Verify that the mix hardener valve is not faulty.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-805 PAUS %sPump 2 OUT high pressure fault
Cause: Pump #2 outlet pressure has been above the high fault limit for a user configurable period of
time. This condition is usually caused by one or more of the following:
• The high pressure fault limit is set too low.
• The high pressure sensitivity is set too short.
• The pump start/stop anticipate times are not set up correctly.
• There is an obstructed line, trigger, or check valve.
• The pilot line to mix hardener valve is removed or is broken.
• The mix hardener valve has failed.
• The hardener outlet transducer has failed.
Remedy: Check the following:
• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Make sure the pump start/stop anticipates are appropriate.
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix hardener valve.
• Verify that the mix hardener valve is not faulty.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the
transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change
cycle.
________________________________________________________________
PNT1-806 WARN %sPump 2 fluid flow rate > set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been
continuously greater than a set point window (a percentage) for a user configurable period of time.
Remedy: Do a fluid flow test on pump #2 with a beaker and verify that the beaker amount matches
the pump #2 size (cc/rev). Verify that the correct KFT factor has been entered for the fluid flow meter
per the manufacturer’s specification. Check the operation of the inlet regulator to verify that no
&qout;blow by&qout; is occurring across the pump.
________________________________________________________________
PNT1-807 WARN %sPump 2 fluid flow rate < set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been
continuously less than a set point window (a percentage) for a user configurable period of time.
Remedy: Check the following:
• Perform a fluid flow test on pump #2 with a beaker and verify that the beaker amount matches
the pump #2 size (cc/rev).
• Verify that the correct KFT factor has been entered for the fluid flow meter per the manufacturer’s
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
________________________________________________________________
PNT1-808 WARN %sPump 2 zero fluid flow rate detected
Cause: Zero fluid flow out of pump #2 is detected. This condition is usually caused by one or
more of the following:
• A loose mechanical coupling between the motor and pump.
• A broken line between the pump and trigger.
Remedy: Check the mechanical coupling between the motor and the pump. Make sure the line from
pump to trigger is working correctly.
________________________________________________________________
PNT1-809 WARN %sPump 2 motor velocity limit
Cause: The motor velocity for pump #2 has exceeded its operating limit. The motor speed will be
reduced to be within operating limit. The motor speed for pump #1 will be reduced to maintain a
proper fluid ratio.
Remedy: Lower the flow rate to within the motor limit.
________________________________________________________________
PNT1-810 WARN %sPump 2 motor servo not ready
Cause: The servo power to pump #2 is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off because of an E-stop
condition or because the machine is locked. Correct the condition, and reset the controller.
________________________________________________________________
PNT1-811 WARN %sPump 2 totals differ > tolerance
Cause: The actual total flow out of pump #2 as measured by the fluid flow meter has a value that is
different than the commanded total flow. This difference is larger than the total flow tolerance.
Remedy: Check the following:
• Perform a fluid flow test on pump #2 with a beaker and verify that the beaker amount matches
the pump #2 size (cc/rev).
• Verify that the correct KFT factor has been entered for the flow meter per the manufacturer’s
specification.
• Check the operation of the inlet regulator to verify that no &qout;blow by&qout; is occurring
across the pump.
• Verify that pump #2 does not have excessive wear.
________________________________________________________________
PNT1-812 WARN %sCalibration aborted
Cause: The IPC auto calibration aborted.
Remedy: Ensure pumps are operating correctly. Ensure that the delay parameter is set to a sufficient
amount.
________________________________________________________________
PNT1-813 WARN (%s) Non-increasing cal table
Cause: The IPC auto calibration aborted because the calibration table is not increasing with the
commanded flow rate.
Remedy: Ensure pumps are operating correctly. Ensure that the speed command delay (used to allow
the motor RPM to settle) is set to a sufficient amount.
________________________________________________________________
PNT1-814 WARN (%s) Zero PSI
Cause: The IPC auto calibration aborted because zero PSI was detected while the IPC system
was determining the maximum flow rate during the auto calibration or while the IPC system was
determining one of the calibration points.
Remedy: Ensure pumps are operating correctly. Ensure that the speed command delay (used to allow
the motor RPM to settle) is set to a sufficient amount. If the setup parameter, ‘Max speed cap:’, was
enabled, ensure that the parameter ‘User speed cap:’, was not set to high – the pressure will eventually
plateau at higher speed commands. Alternate action is to disable ‘Max speed cap:’ and re-calibrate.
________________________________________________________________
PNT1-815 WARN (%s) Set Color Valve
Cause: There was an error in setting the color valve.
Remedy: None.
________________________________________________________________
PNT1-816 WARN %s Res:Hrd ratio is 0.0:0.0
Cause: The color identified in the error message has a default ratio (0.0:0.0) defined. The IPC pumps
can only run when a non-zero ratio is defined.
Remedy: Change the default ratio for this color in the SETUP Color DETAIL menu.
________________________________________________________________
PNT1-823 PAUS %sHIGH ServoBell TORQUE
Cause: The torque value of the ServoBell exceeded the maximum safety limit.
Remedy: Determine the cause of the high torque reading, and resolve the problem.
________________________________________________________________
PNT1-824 WARN %sServoBell motor not ready
Cause: The servo power to the ServoBell motor is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off because of an E-stop
condition, or if the machine is locked. Correct the condition, and reset the controller.
________________________________________________________________
PNT1-825 WARN %sCalibration Aborted
Cause: The ServoBell auto calibration aborted.
Remedy: Slow down the Cal Empty Speed. Ensure that the trigger is not clogged and opens fully.
Ensure that the software limit does not exceed 2 mm.
________________________________________________________________
PNT1-826 WARN %sCalibration Time Out
Cause: The ServoBell auto calibration aborted due to a time out when the system was trying to
determine the empty can position.
Remedy: Ensure that all faults are cleared, and that the ServoBell motor is turning during the
calibration process.
________________________________________________________________
PNT1-827 WARN %sCanister Calibration Successful
Cause: The ServoBell auto calibration completed successfully.
Remedy: None.
________________________________________________________________
PNT1-828 ABRT %sBad Status from set_prax_spd
Cause: An attempt was made to move the ServoBell or the SpeedDock and a bad status from
set_prax_spd was detected.
Remedy: Determine the cause of the bad status, then resolve the problem.
________________________________________________________________
PNT1-829 PAUS %sHIGH SpeedDock TORQUE
Cause: The torque value of the SpeedDock exceeded the maximum safety limit.
Remedy: Determine the cause of the high torque reading and resolve the problem.
________________________________________________________________
PNT1-830 WARN %sSpeedDock motor not ready
Cause: The servo power to the SpeedDock motor is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off for some reason, such
as an Emergency stop condition, and/or the machine locked. Correct the condition, and reset the
controller.
________________________________________________________________
PNT1-832 PAUS %s
Cause: An attempt was made to extend or retract the valve at SpeedDock side A or B, but failed.
Remedy: Check the retract or extend sensor at SpeedDock side A or B. If it was an extended fault,
ensure that the pusher extended fully at the Speed Dock side A or B. If it was a retracted fault,
ensure that the pusher retracted fully at SpeedDock side A or B and that the valve is not stuck in
the extended state. Ensure that sufficient air pressure is available for this operation and that the
air lines are connected.
________________________________________________________________
PNT1-833 PAUS %sHIGH ServoBell TORQUE
Cause: Torque value of the ServoBell exceeded the maximum safety limit.
Remedy: Determine the cause of the high torque reading and resolve problem.
________________________________________________________________
PNT1-834 WARN %sServoBell motor not ready
Cause: The servo power to the ServoBell motor is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off because of an E-stop
condition, or because the machine is locked. Correct the condition, and reset the controller.
________________________________________________________________
PNT1-835 WARN %sCalibration Aborted
Cause: The servo power to the ServoBell motor is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off because of an E-stop
condition, or because the machine is locked. Correct the condition, and reset the controller.
________________________________________________________________
PNT1-836 WARN %sCalibration Time Out
Cause: The system timed out and the ServoBell auto calibration aborted when it was trying to
determine the empty can position.
Remedy: Clear all faults, and verify that the ServoBell motor is turning during the calibration process.
________________________________________________________________
PNT1-837 WARN %sCanister Calibration Successful
Cause: The ServoBell auto calibration completed successfully.
Remedy: None.
________________________________________________________________
PNT1-838 ABRT %sBad Status from set_prax_spd
Cause: An attempt was made to move the ServoBell or the SpeedDock and a bad status from
set_prax_spd was detected.
Remedy: Determine the cause of the bad status, then resolve the problem.
________________________________________________________________
PNT1-839 PAUS %sHIGH SpeedDock TORQUE
Cause: The torque value of the SpeedDock exceeded the maximum safety limit.
Remedy: Determine the cause of the high torque reading and resolve the problem.
________________________________________________________________
PNT1-840 WARN %sSpeedDock motor not ready
Cause: The servo power to the SpeedDock motor is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off for some reason, such
as Emergency stop condition, and/or the machine is locked. Correct the condition, and reset the
controller.
________________________________________________________________
PNT1-841 PAUS %s
Cause: An attempt was made to extend or retract the pusher at SpeedDock side A or B, but failed.
Remedy: Check the retract or extend sensor at SpeedDock side A or B. Ensure that the pusher
retracted or extended fully at the SpeedDock, side A or B. Ensure that sufficient air pressure is
available for this operation and that the air lines are connected.
________________________________________________________________
PNT1-842 PAUS %s
Cause: An attempt was made to extend or retract the valve at the SpeedDock, side A or B, but failed.
Remedy: Check the retract or extend sensor at SpeedDock side A or B. If it was an extended fault,
ensure that the pusher extended fully at the Speed Dock, side A or B. If it was a retracted fault,
ensure that the pusher retracted fully at the SpeedDock, side A or B and that the valve is not stuck
in the extended state. Ensure that sufficient air pressure is available for this operation and that the
air lines are connected.
________________________________________________________________
PNT1-843 WARN %sOutput Press low warning
Cause: Output pressure dropped below the warning level.
Remedy: Correct the problem if the warning occurs repeatedly, or adjust the output pressure warning
value if it is set too low.
________________________________________________________________
PNT1-844 WARN %sOutput Press high warning
Cause: The output pressure exceeded the high warning level.
Remedy: Correct the problem if the warning occurs repeatedly, or adjust the output pressure warning
value if it is too low.
________________________________________________________________
PNT1-845 WARN %sManifold Press low warning
Cause: The output pressure exceeded the high warning level.
Remedy: Correct the problem if the warning occurs repeatedly, or adjust the output pressure warning
value if it is too low.
________________________________________________________________
PNT1-846 WARN %sManifold Press high warning
Cause: The manifold pressure exceeded the high warning level.
Remedy: Correct the problem if the warning occurs repeatedly, or adjust the manifold pressure
warning value if it is too low.
________________________________________________________________
PNT1-847 PAUS %sOutput Press low alarm
Cause: Output pressure dropped below alarm level.
Remedy: Correct the problem immediately, or adjust the Output pressure alarm value if it is too low.
________________________________________________________________
PNT1-848 PAUS %sOutput Press high alarm
Cause: Output pressure exceeded high alarm level.
Remedy: Correct the problem immediately, or adjust the Output pressure alarm value if it is too low.
________________________________________________________________
PNT1-849 PAUS %sManifold Press low alarm
Cause: Output pressure dropped below alarm level.
Remedy: Correct the problem immediately, or adjust the Manifold pressure alarm value if it is too low.
________________________________________________________________
PNT1-850 PAUS %sManifold Press high alarm
Cause: Manifold pressure exceeded high alarm level.
Remedy: Correct the problem immediately, or adjust the Manifold pressure alarm value if it is too low.
________________________________________________________________
PNT1-851 WARN %sCalibration successful
Cause: Calibration successful.
Remedy: None.
________________________________________________________________
PNT1-852 WARN %sCalibration aborted
Cause: Calibration aborted.
Remedy: Determine cause for calibration to abort and correct accordingly.
________________________________________________________________
PNT1-853 WARN %sNon-incr cal table
Cause: Calibration aborted due to the Output or Manifold pressure failing to increase as the command
rate increased.
Remedy: Determine cause for the pressure not increasing and correct accordingly.
________________________________________________________________
PNT1-854 WARN %sZero Pressure
Cause: Calibration aborted due to zero Output or Manifold pressure detected after a flow command
was issued.
Remedy: Determine cause for the zero pressure and correct accordingly.
________________________________________________________________
PNT1-859 WARN %sOutput Press low warning
Cause: Output pressure dropped below warning level.
Remedy: Correct problem if warning occurs repeatedly, or adjust the Output pressure warning
value if it is too low.
________________________________________________________________
PNT1-860 WARN %sOutput Press high warning
Cause: Output pressure exceeded high warning level.
Remedy: Correct problem if warning occurs repeatedly, or adjust the Output pressure warning
value if it is too low.
________________________________________________________________
PNT1-861 WARN %sManifold Press low warning
Cause: Manifold pressure dropped below warning level.
Remedy: Correct problem if warning occurs repeatedly, or adjust the Manifold pressure warning
value if it is too low.
________________________________________________________________
PNT1-862 WARN %sManifold Press high warning
Cause: Manifold pressure exceeded high warning level.
Remedy: Correct problem if warning occurs repeatedly, or adjust the Manifold pressure warning
value if it is too low.
________________________________________________________________
PNT1-863 PAUS %sOutput Press low alarm
Cause: Output pressure dropped below alarm level.
Remedy: Correct the problem immediately, or adjust the Output pressure alarm value if it is too low.
________________________________________________________________
PNT1-864 PAUS %sOutput Press high alarm
Cause: Output pressure exceeded high alarm level.
Remedy: Correct the problem immediately, or adjust the Output pressure alarm value if it is too low.
________________________________________________________________
PNT1-865 PAUS %sManifold Press low alarm
Cause: Output pressure dropped below alarm level.
Remedy: Correct the problem immediately, or adjust the Manifold pressure alarm value if it is too low.
________________________________________________________________
PNT1-866 PAUS %sManifold Press high alarm
Cause: Manifold pressure exceeded high alarm level.
Remedy: Correct the problem immediately, or adjust the Manifold pressure alarm value if it is too low.
________________________________________________________________
PNT1-867 WARN %sCalibration successful
Cause: The calibration was successful.
Remedy: None.
________________________________________________________________
PNT1-868 WARN %sCalibration aborted
Cause: Calibration aborted.
Remedy: Determine cause for calibration to abort and correct accordingly.
________________________________________________________________
PNT1-869 WARN %sNon-incr cal table
Cause: Calibration aborted due to the output or manifold pressure failing to increase as the command
rate increased.
Remedy: Determine the cause for the pressure not increasing, and correct the problem.
________________________________________________________________
PNT1-870 WARN %sZero Pressure
Cause: The calibration aborted due to zero output or manifold pressure was detected after a flow
command was issued.
Remedy: Determine the cause for the zero pressure, and correct the problem.
________________________________________________________________
PNT1-875 WARN %sBad preset index [%d]
Cause: The preset index is out of range (1-MAX_PRESET(20)).
Remedy: Check Preset[] index and Preset[R[]] index value
________________________________________________________________
PNT1-876 WARN %sNo preset data (syscolor=[%s])
Cause: No preset data for error color was found.
Remedy: Check [PAPS1] or ([PAPS2] if Dualarm) preset_data for table entry
________________________________________________________________
PNT1-877 WARN %sNo estat data (syscolor=[%s])
Cause: No estat data for error color was found.
Remedy: Check [PAPSSCHG] preset_data for table entry
________________________________________________________________
PNT1-882 WARN %sBad preset index [%d]
Cause: The preset index is out of range (1-MAX_PRESET(20)).
Remedy: Check Preset[] index and Preset[R[]] index value
________________________________________________________________
PNT1-883 WARN %sNo preset data (syscolor=[%s])
Cause: No preset data for error color was found.
Remedy: Check [PAPS1] or ([PAPS2] if Dualarm) preset_data for table entry
________________________________________________________________
PNT1-884 WARN %sNo estat data (syscolor=[%s])
Cause: No estat data for error color was found.
Remedy: Check [PAPSSCHG] preset_data for table entry
________________________________________________________________
PNT1-889 WARN Wrong valve state in EMPTY CAN event-%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satisfied for the Empty Can event in the color change cycle.
Remedy: To correct the problem, ensure that the pDump valve OR pPE + pTRIG valves are in
the step before the Empty Can event.
________________________________________________________________
PNT1-890 WARN Wrong valve state in FAST FILL event-%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satisfied for the Fast Fill event in the color change cycle.
Remedy: To correct the problem, ensure that the pCI valve is enabled in the step before the Fast
Fill event.
________________________________________________________________
PNT1-891 WARN Wrong valve state in CAN FULL event-%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satisfied for the Can Full event in the color change cycle.
Remedy: To correct the problem, ensure that the pCI valve is enabled in the step before the Can
Full event.
________________________________________________________________
PNT1-892 WARN Wrong valve state in PRESET motion-%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satisfied for a preset motion instruction.
Remedy: Ensure that the pCI valve is enabled in the same step as the preset instruction if retracting
the canister. Ensure that the pDump valve OR pPE + pTRIG valves are enabled in the same step as
the preset instruction if extending the canister.
________________________________________________________________
PNT1-893 WARN Canister Dir – retracting: %s
Cause: An attempt was made to retract the canister, but the valve state was incorrect. This could have
been during a fill cycle or other commanded motion on the process axis.
Remedy: Ensure that the correct CC control valves are in the proper state. The pCI valve should
be ON.
________________________________________________________________
PNT1-894 WARN Low can Pressure after Fill: %s
Cause: A fill cycle was just completed, but the fluid pressure in the can was found to be lower
than the minimum expected.
Remedy: Increase the Minimum Fill Torque in the setup screen, or ensure that the canister is full
of fluid (check the in-coming fluid pressure).
________________________________________________________________
PNT1-895 WARN Canister Dir – extending: %s
Cause: An attempt was made to extend the canister but the state of the valves were incorrect. This
could have been during a cleanout cycle or other commanded motion on the process axis.
Remedy: Ensure that the correct CC control valves are in the proper state. The pDump valve should
be ON, or the pPE + TRIG valves should be ON. Ensure that the pCI valve is OFF.
________________________________________________________________
PNT1-896 WARN Zero Flow Programmed: %s
Cause: Zero Flow was programmed in the color change.
Remedy: Ensure that a flow rate is set up in the CC preset data.
________________________________________________________________
PNT1-897 PAUS %sHIGH Negative Canister TORQUE
Cause: The maximum compression force on the ball screw has been exceeded. When this occurs,
it is usually when the ball screw is extending.
Remedy: Ensure that the canister speed is not too fast when spraying the job. Ensure that the pTrig
and pCE valves are open during job execution. Ensure that the injector tip is not clogged. The nozzle
tip tapers to a smaller diameter; ensure that the paint did not dry inside the nozzle, causing it to clog.
Ensure that the pDUMP valve is operating correctly during the cleanout cycle. If the ball screw is
worn out, then it needs to be replaced.
________________________________________________________________
PNT1-898 PAUS %sHIGH Positive Canister TORQUE
Cause: The maximum tensile force on the ball screw has been exceeded. When this occurs, it s
usually when the ball screw is retracting. There might be a vacuum in the canister which is causing
excessive torque when the motor is retracting the canister’s piston.
Remedy: Ensure that the retraction speed is not too fast during the fast fill cycle. Ensure that the pCI
and pCC valves are open during the fill cycles.
________________________________________________________________
PNT1-899 PAUS %sAir in Canister detected
Cause: The piston was retracted from the fluid after the Fill sequence and torque was still detected on
the face of the piston. The torque should not exist if the canister is completely full of paint, therefore,
compressed air could Be mixed with the paint.
Remedy: Check the paint supply for the current color in the canister to verify air is not being
introduced into the paint supply.
________________________________________________________________
PNT1-900 WARN %sLow Trigger Torque
Cause: The torque threshold on the canister motor did not reach the minimum torque threshold value
during the fill through trigger step of the fill or refill cycle.
Remedy: Perform the following:
1. Check the paint supply for the current color in the canister.
2. Reduce the torque threshold value.
3. Reduce the fill through trigger timeout value.
________________________________________________________________
PNT1-901 WARN Wrong valve state in EMPTY CAN event%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satified for the Empty Can event in the color change cycle.
Remedy: To correct the problem, ensure that the pDump valve OR pPE + pTRIG valves are in
the step before the Empty Can event.
________________________________________________________________
PNT1-902 WARN Wrong valve state in FAST FILL event%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satified for the Fast Fill event in the color change cycle.
Remedy: To correct the problem, ensure that the pCI valve is enabled in the step before the Fast
Fill event.
________________________________________________________________
PNT1-903 WARN Wrong valve state in CAN FULL event%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satified for the Can Full event in the color change cycle.
Remedy: To correct the problem, ensure that the pCI valve is enabled in the step before the Can
Full event.
________________________________________________________________
PNT1-904 WARN Wrong valve state in PRESET motion%s
Cause: The wrong valve state was programmed in the color change cycle. The valve interlocking
requirements have not been satified for a preset motion instruction.
Remedy: Ensure that the pCI valve is enabled in the same step as the preset instruction if retracting
the canister. Ensure that the pDump valve OR pPE + pTRIG valves are enabled in the same step as
the preset instruction if extending the canister.
________________________________________________________________
PNT1-905 WARN Canister Dir – retracting: %s
Cause: An attempt was made to retract the canister but the valve state was incorrect. This could have
been during a fill cycle or other commanded motion on the process axis.
Remedy: Ensure that the correct CC control valves are in the proper state. The pCI valve should
be ON.
________________________________________________________________
PNT1-906 WARN Low can Pressure after Fill: %s
Cause: A fill cycle was just completed, but the fluid pressure in the can was found to be lower
than the minimum expected.
Remedy: Increase the Minimum Fill Torque in the setup screen, or ensure that the canister is full
of fluid (check the in-coming fluid pressure).
________________________________________________________________
PNT1-907 WARN Canister Dir – extending: %s
Cause: An attempt was made to extend the canister but the state of the valves were incorrect. This
could have been during a cleanout cycle or other commanded motion on the process axis.
Remedy: Ensure that the correct CC control valves are in the proper state. The pDump valve should
be ON or the pPE + TRIG valves should be ON. Ensure that the pCI valve is OFF.
________________________________________________________________
PNT1-908 WARN Zero Flow Programmed: %s
Cause: Zero Flow was programmed in the color change preset data.
Remedy: Ensure that a flow rate is set up in the color change preset data.
________________________________________________________________
PNT1-909 PAUS %sHIGH Negative Canister TORQUE
Cause: The maximum compression force on the ball screw has been exceeded. When this occurs, its
usually when the ball screw is extending.
Remedy: Ensure that the canister speed is not too fast when spraying the job. Ensure that the pTrig
and pCE valves are open during job execution. Ensure that the injector tip is not clogged. The nozzle
tip tapers to a smaller diameter; ensure that the paint did not dry inside the nozzle, causing it to clog.
Ensure that the pDUMP valve is operating correctly during the cleanout cycle. If the ball screw is
worn out, then it needs to be replaced.
________________________________________________________________
PNT1-910 PAUS %sHIGH Positive Canister TORQUE
Cause: The maximum tensile force on the ball screw has been exceeded. When this occurs, its
usually when the ball screw is retracting. There might be a vacuum in the canister which is causing
excessive torque when the motor is retracting the canister’s piston.
Remedy: Ensure that the retraction speed is not too fast during the fast fill cycle. Ensure that the pCI
and pCC valves are open during the fill cycles.
________________________________________________________________
PNT1-911 PAUS %sAir in Canister detected
Cause: The piston was retracted from the fluid after the Fill sequence and torque was still detected on
the face of the piston. The torque should not exist if the canister is completely full of paint, therefore,
compressed air could me mixed with the paint.
Remedy: Check the paint supply for the current color in the canister to verify that air is not being
introduced into the paint supply.
________________________________________________________________
PNT1-912 WARN %sLow Trigger Torque
Cause: The torque threshold on the canister motor did not reach the minimum torque threshold value
during the fill through trigger step of the fill or refill cycle.

Remedy: Perform the following:
1. Check the paint supply for the current color in the canister.
2. Reduce the torque threshold value
3. Reduce the fill through trigger timeout value.