Fanuc ACAL Alarm Codes

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Fanuc ACAL Alarm Codes

ACAL-000 WARN Fail to run DETECT Motn
Cause: The AccuCal2 Motn failed to run. The AccuCal2 motion cannot be started.
Remedy: Clear all the errors before executing AccuCal2.
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ACAL-001 WARN Robot is not ready.
Cause: The robot is not ready. The system cannot issue motion because it is in an error state.
Remedy: Clear all faults, then retry the operation.
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ACAL-002 WARN Fail to fit circle.
Cause: AccuCal2 cannot converge within the set threshold.
Remedy: Perform the following:
• Increase the number of iterations allowed.
• Increase the convergence threshold setting.
• Make sure the TCP has not been changed.
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ACAL-003 WARN Contact before search.
Cause: The robot is in contact with the part before starting a search motion.
Remedy: Reteach the starting position.
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ACAL-004 WARN No contact detected.
Cause: No contact was made during the AccuCal2 motion.
Remedy: Make sure the sensor and software are installed correctly.
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ACAL-005 WARN Undefined program name.
Cause: The AccuCal2 program name was not defined.
Remedy: Select an AccuCal2 teach pendant program before pressing the EXEC key.
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ACAL-006 WARN TPE operation error.
Cause: This is an internal teach pendant editor program error.
Remedy: Abort the program and run again. If this doesn’t resolve the problem, cycle power and try
again. If this doesn’t resolve the problem, reinstall the controller software. Refer to the Software
Installation Manual for information on installing software.
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ACAL-007 WARN Calibration internal error.
Cause: This is an AccuCal2 internal error.
Remedy: Turn off the controller, and turn it on again to recover. If the problem persistes, reinstall the
controller software. Refer to the Software Installation Manual for more information.
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ACAL-008 WARN File open error.
Cause: The output file cannot be opened.
Remedy: Check the path, and file name to be sure they are correct.
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ACAL-009 WARN No matching Start inst.
Cause: You are trying to execute a CALIB END instruction without a matching CALIB START
instruction.
Remedy: Add a CALIB START instruction before the CALIB END.
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ACAL-010 WARN Invalid schedule number.
Cause: The schedule number in CALIB, UTOOL, or UFRAME START is invalid.
Remedy: Provide a correct schedule number in CALIB (or UTOOL or UFRAME) START[] teach
pendant instruction.
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ACAL-011 WARN Cannot access $MNUFRAME.
Cause: The current $MNUFRAMENUM[] is incorrect and cannot be accessed.
Remedy: Go to the USER FRAME menu to select a valid user frame.
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ACAL-012 WARN Cannot access $MNUTOOL.
Cause: Cannot access $MNUTOOL. The current $MNUTOOLNUM[] is incorrect.
Remedy: Display the FRAME menu to select a valid tool frame.
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ACAL-013 WARN Backward execution ignored.
Cause: Backward execution were ignored. The AccuCal2 instructions can not be executed backward.
Remedy: The backward execution of the AccuCal2 instructions is ignored. Rewrite the instructions if
you do not want this to happen.
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ACAL-014 WARN System loading error.
Cause: System loading error. The AccuCal2 is loaded incorrectly.
Remedy: Reload the controller. Refer to the FANUC Robotics Software Installation Manual for
more information.
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ACAL-015 WARN Not enough data.
Cause: Not enough data exists to compute the frame offset.
Remedy: Add more Detect instructions in the AccuCal2 program.
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ACAL-016 STOP No Preplan motion for Detect
Cause: The Detect instruction does not allow pre-plan motion.
Remedy: None.
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ACAL-017 WARN Wrong number of searches.
Cause: An incorrect number of searches was performed.
Remedy: Re-teach the AccuCal2 program with an appropriate number of searches. Refer to the
application-specific Setup and Operations Manual for information on the number of searches required
for each calibration type.
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ACAL-018 WARN Nonorthogonal search vector
Cause: The 3 planes method requires three search directions be normal to each other.
Remedy: Re-teach the cell finder program with three search directions that are normal to each other.
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ACAL-019 WARN Positions are too close.
Cause: Positions are too close. The taught positions are too close to each other.
Remedy: Re-teach the cell finder program so that the contact positions are at least 10mm apart.
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ACAL-020 WARN Invalid Frame number.
Cause: The current frame number setting is invalid.
Remedy: Use the SETUP/FRAME menu to set up the correct frame.
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ACAL-021 WARN Large Frame deviation.
Cause: The computed frame offset exceeds the pre-set value.
Remedy: Run the calibration program again to make sure the robot makes solid contacts with the
part. Change the XYZ and ORNT change value in the schedule if these numbers are very small.
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ACAL-022 WARN Detect without mastering
Cause: An AccuCal2 teach pendant program is running without performing mastering it first.
Remedy: Display the AccuCal2 menu, and master the program first.
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ACAL-023 WARN No EXEC at Single Step Mode.
Cause: The robot cannot execute an AccuCal2 program in Single Step Mode.
Remedy: Turn off Single Step before executing the cell finder program.
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ACAL-024 WARN Master Update failed.
Cause: A failure occurred while trying to update the master data in a FIND instruction.
Remedy: Re-master the frame search teach pendant program.
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ACAL-025 WARN Large frame shift.
Cause: A very large frame shift has occurred.
Remedy: Check the UTOOL and the fixture to make sure that they are properly installed.
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ACAL-026 WARN No CALIB END instruction.
Cause: No CALIB END instruction. AccuCal2 program does not have a FIND END instruction.
Remedy: Add CALIB END instruction at the end of the frame search teach pendant program.
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ACAL-027 WARN Counts do not match.
Cause: The number of master data and number of run time data does not match each other.
Remedy: Run the finder program again.
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ACAL-028 WARN No logged frame data.
Cause: No logged frame data exists and the frame cannot be restored.
Remedy: Select a logged frame.
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ACAL-029 WARN Zero offset, No Update.
Cause: No change occurred in the offset frame.
Remedy: Run Cell Finder again to compute a new offset.
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ACAL-030 WARN Frame Log is disabled.
Cause: The Frame data log is disabled.
Remedy: Enable the frame log first.
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ACAL-031 WARN Cold start to set $USEUFRAME
Cause: $USEUFRAME is set to FALSE. AccuCal2 reset it to TRUE.
Remedy: TUrn off the controller, the turn it on again to perform a Cold start.
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ACAL-032 WARN Invalid motion group.
Cause: The motion group number is invalid.
Remedy: Use only one group in the program and make sure the group is available.
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ACAL-033 WARN Other group is running.
Cause: The other program has motion control.
Remedy: Abort the other running program.
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ACAL-034 WARN Group mismatched.
Cause: The motion group number is not right.
Remedy: Use only one group in the program, and make sure group is available.
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ACAL-035 WARN Press Shift Key.
Cause: The SHIFT key was not pressed.
Remedy: Press the SHIFT key.
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ACAL-036 WARN Failed to create TPE program
Cause: The teach pendant program could not be created.
Remedy: Check the following:
• Make sure enough memory is available.
• Make sure the program is not being edited.
• Make sure the program is not write protected.
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ACAL-037 WARN TPE Position is not recorded
Cause: The teach pendant position has not been recorded. Make sure the program is not write
protected.
Remedy: Unprotect the write protected program.
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ACAL-038 WARN TPE Program does not exist.
Cause: The selected teach pendant program was not found and does not exist.
Remedy: Select an existing teach pendant program.
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ACAL-039 WARN Move to recorded posn failed
Cause: The robot could not move to the recorded position.
Remedy: Make sure the position is reachable and that another program does not have motion control.
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ACAL-040 WARN Invalid Detection TP program
Cause: The detection teach pendant program is not usable.
Remedy: Load a proper detection program.
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ACAL-041 WARN Override should be 100%.
Cause: The speed override is not 100%.
Remedy: Before running the program, increase the override to 100%.
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ACAL-042 WARN Large orientation change.
Cause: The found orientation is larger than the tolerance allows.
Remedy: Adjust the object so that orientation is smaller. Increase the orientation tolerance.
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ACAL-043 WARN Points & solution mismatch.
Cause: The number of search points does not match the selected solution type.
Remedy: Select a different solution type, or adjust number of detect statements.
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ACAL-044 WARN Solution type error.
Cause: An unsupported solution type error was selected.
Remedy: Choose a different solution type.
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ACAL-045 WARN Failed to set register.
Cause: The specified register was not set.
Remedy: Make sure the specified register exists.
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ACAL-046 WARN Failed to convert position.
Cause: The position failed to convert. The internal position was not set.
Remedy: Make sure the points are taught in the proper sequence and are not near limits.
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ACAL-047 WARN Too many points used.
Cause: Too many points are used.
Remedy: Reduce the number of detect points.
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ACAL-048 WARN Solution failed.
Cause: The solution failed to complete.
Remedy: Make sure the correct number of points are taught in the correct directions and orientation.
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ACAL-049 WARN Motion limit error.
Cause: This is a motion limit error. The detect motion failed due to a limit error for the destination
position.
Remedy: Move the robot away from the joint limit, or reduce the search distance in the detection
schedule.
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ACAL-050 WARN TCP Cal is not loaded.
Cause: TCP Cal is not loaded.
Remedy: Try to run the TCP Calibration instruction without the TCP Cal software. Perform a
Controlled start, and load the TCP Cal software from the option menu.
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ACAL-051 WARN Cell Cal is not loaded.
Cause: Cell Cal is not loaded.
Remedy: Try to run the Cell Calibration instruction without the Cell Cal software. Perform a
Controlled start, and load the Cell Cal software from the option menu.
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ACAL-052 WARN Robot Cal is not loaded.
Cause: Robot Cal is not loaded. The robot tried to run the robot Calibration instruction without the
Robot Cal software.
Remedy: Perform a Controlled start, and load the Robot Cal software from the OPTION menu.
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ACAL-053 WARN No calibration software.
Cause: No calibration software. The robot tried to run a detect instruction without Calibration
software.
Remedy: Perform a Controlled start, and load one of the Calibration software options from the
OPTION menu.
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ACAL-054 WARN Invalid Calibration program.
Cause: Invalid Calibration program. The calibration program type does not match the calibration
menu.
Remedy: Check the teach pendant program’s calibration start instruction so it matches the calibration
menu.
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ACAL-055 WARN Too Many Parallel Searches.
Cause: Too Many Parallel Searches have occurred. More than three parallel searches occurred
when the total number of searches is less than 7.
Remedy: Teach more searches, or change the excess parallel searches to be in a different direction.
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ACAL-056 WARN Skip Update Frame Inst.
Cause: The robot executed an UPDATE FRAME instruction in a non-Cell calibration program.
Remedy: UPDATE FRAME only works in Cell Calibration programs with Uframe Start instruction.
Remove the UPDATE FRAME instruction from the non-CellCal program.
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ACAL-057 WARN Large Calibration Error
Cause: Residual maximum calibration has exceeded the limit allowed by the specified schedule.
Remedy: Verify solid tooling and good contact is made during all searches. Increase the limit in the
schedule.
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ACAL-058 WARN UFRAME Change Not Allowed
Cause: The UFRAME was changed during UTOOL calibration and this is not allowed.
Remedy: Use the same UFRAME for all points during the initial UTOOL calib.
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ACAL-059 WARN All Positions Not Recorded
Cause: All required positions are not recorded.
Remedy: Record all necessary positions, and retry the operation.
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ACAL-060 WARN Excessive Accumulated offset
Cause: The accumulated offset exceeds the tolerance specified in the schedule.
Remedy: Repair the tool so that the TCP is closer to the reference TCP, or increase Accumulated
Error Threshold in the tool calibration schedule.
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ACAL-061 WARN UFrame mismatch.
Cause: A UFrame mismatch has occurred. The current MNUFRAME number does not match
the program’s uframe.
Remedy: Change the current user frame number to match the program’s user frame number.
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ACAL-062 WARN Too many moves in a program.
Cause: Too many moves have been attempted in a program. The Calibration porgram has too many
motion lines in it.
Remedy: Limit the number of move instructionz in a calibration program to less than 256.
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ACAL-063 WARN Failed to update master data
Cause: The master data failed to update. The master count cannot be updated when the robot is
in motion.
Remedy: Abort the robot motion and then press the UPDATE soft key again.
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ACAL-064 WARN UTool Mismatch.
Cause: A UTool mismatch has occurred. The current MNUTOOL number does not match the
program’s utool.
Remedy: Change the current tool number to match the program’s utool number.
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ACAL-065 STOP TCP calibration failed
Cause: The TCP calibration failed to complete.
Remedy: Review the previous error to identify the cause.
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ACAL-066 STOP Cell calibration failed
Cause: Cell calibration failed to complete.
Remedy: Review the previous error to identify the cause.
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ACAL-067 WARN Circle fit error %s
Cause: The circle fit error exceeds the threshold.
Remedy: Check for a loss fixture or tool, or change the fit error tolerance in the detection schedule.
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ACAL-068 WARN Radius err %s
Cause: Circle radius error exceeds threshold.
Remedy: Check for a lost fixture or tool, or change the radius error tolerance in the detection schedule.
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ACAL-069 WARN Auto Update is ON.
Cause: Auto Update is on therefore the frame has been updated automatically.
Remedy: An update is not required.
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ACAL-070 WARN No update on record points.
Cause: No update on record points. The teach pendant program has a different number of DETECT
instructions than expected. The positions cannot automatically update in the screen.
Remedy: Manually record positions to create the calibration program.
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ACAL-071 WARN Invalid joint number.
Cause: The axis number specified in the DETECT Joint instruction is invalid.
Remedy: Change the axis number to a valid one.
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ACAL-072 WARN Invalid joint sensor type.
Cause: The Detect Joint instruction cannot use TOS WRIST sensor type for contact detection.
Remedy: Change sensor type to either IO or TOS all axes in the detection schedule.
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ACAL-073 WARN Skip Detect Joint
Cause: The Detect Joint instruction is not valid for TCP or CELL calibration.
Remedy: The Detect Joint instruction is for ROBOT calibration only. Change the calibration start
instrction to CALIB START or delete the instruction from the program.
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ACAL-074 WARN No motion before DETECT.
Cause: No motion exists before the DETECT instruction. Detect instructions require a motion
line preceeding them.
Remedy: Add a MOVE instruction before the DETECT instruction.
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ACAL-075 WARN Mixed Detect instructions.
Cause: Mixed Detect instructions have occurred. The Detect Joint instruction cannot be used with
other Detect instructions within the same Calib Start – Calib End instructions.
Remedy: Delete the other DETECT instrucion from the program.
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ACAL-076 WARN More than one Detect Joint.
Cause: More than one Detect Joint instruction exists. Only one Detect Joint instruction is allowed
between Calib Start and Calib End instructions.
Remedy: Delete the extra DETECT JOINT instructions.
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ACAL-077 WARN No Detect Joint in Init. Cal
Cause: No Detect Joint should exist in Initial Calibration. The Detect Joint instruction does not
apply to the initial robot calibration.
Remedy: Run the program from the robot master recovery menu.
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ACAL-078 WARN Skip Update Tool instruction
Cause: Execute the Update Utool instruction in a non-TCPCal program.
Remedy: Update Tool only works in TCP Calibration programs with a UTool Start instruction.
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ACAL-079 WARN Large approach angle error.
Cause: The search start position’s appraoch vector does not align with the plate’s normal vector.
Remedy: Touch up the search start position so that the position’s approach vector is aligned to the
plate’s normal vector.
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ACAL-080 WARN Failed to update TPE program
Cause: Failed to update the teach pendant program’s search start position.
Remedy: Make sure there is not system fault before pressing UPDATE. If the problem persists,
perform a Cold start.
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ACAL-081 WARN Destination %s Limit Error
Cause: The recorded position is too close to the joint limit.
Remedy: Re-teach the position away from joint limit.
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ACAL-082 WARN Tool is 180 degree off in Z
Cause: The Tool approach vector is 180 degrees off in Z from the search direction.
Remedy: Change the system variable $cb_vars.$z_out to FALSE if it is set to TRUE, or vice versa.
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ACAL-083 WARN Invalid TPE instruction.
Cause: Invalid teach pendant calibratino instruction.
Remedy: The teach pendant program memory might be corrupted. Replace the instruction with
a new one.
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ACAL-084 WARN Failed to access Karel vars.
Cause: Failed to access the calibration program’s KAREL variables.
Remedy: Cold start the controller. If the problem persists, re-install the calibration option again.
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ACAL-085 WARN UFrame is too small
Cause: The specified UFrame is zero or small, and Calibrate UFrame is disabled.
Remedy: Set UFrame to be the precision calibration fixture location or enable UFrame calibration
in the calibration schedule.
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ACAL-086 WARN UTool is too small
Cause: The specified UTool is zero or small, and the Calibrate UTool is disabled.
Remedy: Set UTool to be the precision calibration fixture location or enable UTool calibration
in the calibration schedule.
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ACAL-087 WARN Joint[%s^1] rotation is small
Cause: The joint angle motion is too small.
Remedy: Modify calibration points to provide more motion on the specified axis. Or, disable
calibration of one or more joints.
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ACAL-088 WARN Points are colinear
Cause: Three or more points with the same search direction are colinear or nearly colinear.
Remedy: Reteach one of the points so that the points are not colinear, or teach another non-colinear
point.
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ACAL-089 WARN Not enough search direction
Cause: There must be at least three different search directions that are close to perpendicular to
each other. There must also be at least three non-colinear points in one search direction and at least
two points in another search direction.
Remedy: Add more search points or reteach existing points to have sufficient search directions and a
sufficient number of points in the search directions.
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ACAL-091 WARN UFrame orienation not zero
Cause: The UFrame orientation must be zero.
Remedy: Use a UFrame with WPR values where all are set to zero.
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ACAL-092 WARN Position close to joint limit
Cause: The search destination position is too close to the joint limit.
Remedy: Re-teach the position away from joint limits.
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ACAL-093 WARN Invalid CD pair number
Cause: The Coordinate Motion Pair number is invalid.
Remedy: Check the CD pair setup to make sure the CD pair has been set up correctly.
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ACAL-094 WARN Invalid Process Sync Setup
Cause: Invalid Process Sync Set up
Remedy: Check the Process Sync setup to make sure the Process Sync has been set up correctly.
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ACAL-095 WARN No Coordinate Motion software
Cause: The CD pair calibration requires Coordinate Motion Software.
Remedy: Load the Coordinate Motion software on the controller.
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ACAL-096 WARN No Process Sync software
Cause: Robot Link calibration requires Robot Link Software.
Remedy: Load the Robot Link software on the controller.
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ACAL-097 WARN MultiCal is not loaded.
Cause: The user is trying to run the MultiCal instruction without MultiCal software.
Remedy: Perform a Control start and load the MultiCal software from option menu.
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ACAL-098 WARN Bar method is not supported
Cause: Calibration Bar is not support in the V7.20 MultiCal Release.
Remedy: The calibration bar method will be supported in future releases.
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ACAL-099 WARN Positioner is not supported
Cause: Positioner calibration is not supported in the V7.20 MultiCal release.
Remedy: The positioner calibration will be supported in future releases.
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ACAL-100 WARN Program Group Mismatch
Cause: The read in the program group does not match the current default motion group.
Remedy: Use the FCTN key to change the current motion group or select another calibration program.
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ACAL-101 WARN TCP Alignment error
Cause: The maximum alignment distance was exceeded.
Remedy: Fix the TCP Alignment and run TCPCal again