Fanuc PNT2 Alarm Codes

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Fanuc PNT2 Alarm Codes

PNT2-001 WARN %sRobot is bypassed
Cause: PaintTool has detected an unknown error.
Remedy: See the teach pendant error log for the cause of the error.
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PNT2-002 ABRT %sSHELL failed to run SUBSHELL
Cause: the system is in an error condition.
Remedy: Press RESET to clear the error.
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PNT2-003 WARN %sE-STAT unit faulted
Cause: The reset procedure has failed.
Remedy: Correct the error, if any, and try the reset again.
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PNT2-004 WARN %sAutomatic CLNOUT on prod_entry
Cause: The servo disconnect on the robot is ON.
Remedy: Set the servo disconnect on the robot to OFF.
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PNT2-005 WARN %sCannot create presets
Cause: The production mode input is OFF.
Remedy: None.
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PNT2-007 ABRT %s not calibrated
Cause: Machine lock is ON going into production.
Remedy: Disable machine lock on the teach pendant.
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PNT2-008 ABRT %sFailed to continue robot task
Cause: The UOP enable input is OFF.
Remedy: The UOP enable input must be ON.
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PNT2-009 ABRT %sFailed to pause robot task
Cause: An invalid job number was received from the PLC.
Remedy: The PLC must init the robot with a valid job number.
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PNT2-010 ABRT %sFailed to abort robot task
Cause: An invalid tutone option was received from the PLC.
Remedy: The PLC must init the robot with a valid tutone option.
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PNT2-011 ABRT %sRobot task has faulted
Cause: An invalid repair option was received from the PLC.
Remedy: PLC must init robot with a valid repair option.
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PNT2-012 ABRT %sFailed to run robot task
Cause: An invalid color number was received from the PLC.
Remedy: The PLC must init the robot with a valid color number.
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PNT2-013 ABRT Job (%s) is not found
Cause: The production run program is not loaded.
Remedy: The program must be loaded before you can run it in production.
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PNT2-014 WARN Invalid job %s in queue
Cause: An invalid job number was received from the PLC. You cannot put the job into the job queue.
Remedy: The PLC must init the robot with a valid job number in order to receive a job read
acknowledge from the robot.
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PNT2-015 WARN Invalid color %s in queue
Cause: An invalid color number was received from the PLC. You cannot put the color into the
color queue.
Remedy: The PLC must init robot with a valid job number in order to receive a color read
acknowledge from the robot.
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PNT2-016 WARN Job queue is full
Cause: The job queue is full.
Remedy: Remove job(s) from the job queue before attempting to add more jobs to the queue.
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PNT2-017 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.
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PNT2-018 WARN Shell aborted or paused
Cause: Another task has detected the main task aborted or paused.
Remedy: Cycle power on the controller.
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PNT2-019 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.
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PNT2-020 WARN %sRobot is bypassed
Cause: An invalid job type was received from the PLC.
Remedy: The PLC must init the robot with a valid job prefix.
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PNT2-021 ABRT %sSHELL failed to run SUBSHELL
Cause: There is an alarm that must be cleared before Test Cycle can be run.
Remedy: Clear all system alarms before beginning Test Cycle.
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PNT2-024 WARN %sCannot create presets
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. F1, [TYPE].
4. Config and move cursor to Enable UI signals and change from FALSE to TRUE.
If your system does not require these UOP signals, unassign these UOP signals in the I/O menu.
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PNT2-034 WARN Parm %s Value beyond limits
Cause: An attempt to set an applicator parameter output was made which was beyond its min/max
value.
Remedy: Verify the parameter min/max output setting.
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PNT2-039 WARN %sRobot is bypassed
Cause: The I/O information is correct and complete.
Remedy: None.
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PNT2-040 ABRT %sSHELL failed to run SUBSHELL
Cause: The I/O information for an applicator was changed and is in error.
Remedy: Check the output type, output number, rack and slot number, first bit location and number
of bits.
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PNT2-045 ABRT %s not calibrated
Cause: This is a message indicating that the application is attempting to adjust the size of the colors
tables based on the configuration variable setting.
Remedy: None.
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PNT2-046 ABRT %sFailed to continue robot task
Cause: This is a message indicating that the application is attempting to adjust the size of the color
valve table based on the configuration variable setting.
Remedy: None.
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PNT2-047 ABRT %sFailed to pause robot task
Cause: The application can not adjust the size of the color tables to the requested setting because
there is not enough memory available.
Remedy: Use a smaller setting that is within the memory constraints of the controller.
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PNT2-048 ABRT %sFailed to abort robot task
Cause: The application can not adjust the size of the color valves table to the requested setting
because there is not enough memory available.
Remedy: Use a smaller setting that is within the memory constraints of the controller.
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PNT2-053 WARN Invalid parameter indicator
Cause: An invalid parameter indicator value was sent from the PLC.
Remedy: Verfiy the number of applicator control parameters set up in the robot to the value sent
from the PLC. This value should be between the range of 1 to 4.
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PNT2-054 WARN No channel/parameter indicated
Cause: The PLC sent a parameter indicator value of 0.
Remedy: Correct the problem at the PLC.
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PNT2-055 WARN Manual inputs are enabled
Cause: On manual mode entry. All PLC manual mode input functions are enabled.
Remedy: None.
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PNT2-056 WARN Manual inputs are disabled
Cause: On manual mode entry, all PLC manual mode input functions are enabled.
Remedy: None.
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PNT2-057 WARN Manual enabled during motion
Cause: Manual mode is being initiated while motion is occuring.
Remedy: Motion must complete before manual mode is entered.
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PNT2-058 WARN %sRobot is bypassed
Cause: Manual mode is being initiated during a color change cycle.
Remedy: The color change cyle must complete before manual mode is entered.
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PNT2-059 ABRT %sSHELL failed to run SUBSHELL
Cause: The teach pendant cannot be enabled when running a remote Color Change cycle.
Remedy: None.
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PNT2-064 ABRT %s not calibrated
Cause: For continuous line systems only. This 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.
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PNT2-065 ABRT %sFailed to continue robot task
Cause: For continuous line systems only. A line tracking parameter is undefined and is required to
run the system.
Remedy: Ensure that all tracking parameters have been setup in tracking setup.
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PNT2-066 ABRT %sFailed to pause robot task
Cause: For continuous line systems only. A rail tracking parameter is undefined and is required to
run the system.
Remedy: Ensure that all tracking parameters have been set up in tracking setup.
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PNT2-067 ABRT %sFailed to abort robot task
Cause: An attempt was made to use an invalid tracking frame number.
Remedy: The current software supports tracking frames 1-6. The frame must be greater than 0
and less than 7.
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PNT2-068 ABRT %sRobot task has faulted
Cause: For continuous line systems only. This is a warning that the encoder counter has detected
a rollover condition.
Remedy: None.
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PNT2-069 ABRT %sFailed to run robot task
Cause: For continuous line systems only. This is a warning that the trigger distance is less than a
pre-determined value. This 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 switch.
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PNT2-070 WARN Conveyor direction incorrect
Cause: For continuous line systems only. 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 counts
instead of negative.
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PNT2-071 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.
This is because the previous job or color change took too long to play.
Remedy: None. The robot will ignore this job/color.
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PNT2-072 PAUS Tracking encoder disconnected
Cause: The robot is detecting a problem with the tracking encoder cable.
Remedy: Check the encoder cable.
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PNT2-073 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 then no remedy is
required. If the robot has been set up as left hand, change it to right hand.
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PNT2-074 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. Controller
power must be cycled before the system is allowed to reset.
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PNT2-075 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 or change the Tracking Boundary to be inside of this limit.
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PNT2-076 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 or change the Tracking Boundary to be inside of this limit.
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PNT2-085 WARN %sRobot not at home position
Cause: An unreachable position is detected in the adjustment precheck.
Remedy: Check the alarm log to find out at which position the motion error will occur. Use CLR_Adj
to clear the adj value.
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PNT2-086 WARN %sRobot at cleaner position
Cause: An interlock signal fault or PLC E-stop was detected.
Remedy: Clear the source of the fault.
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PNT2-087 WARN %sRobot not at cleaner position
Cause: The mechanical unit went beyond its normal travel limits and reached an overtravel limit
switch.
Remedy: Follow the overtravel recovery procedure in the Electrical Connection and Maintenance
Manual.
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PNT2-088 WARN %sEnter Maintenance program is undefined
Cause: The operator panel (SOP) E-STOP has been detected.
Remedy: Turn/Release the SOP E-STOP button to clear the E-STOP condition.
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PNT2-089 WARN %sExit Maintenance program is undefined
Cause: The teach pendant E-STOP has been detected.
Remedy: Press the teach pendant E-STOP button again to clear the E-STOP condition.
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PNT2-090 WARN %sRobot not at maintenance position
Cause: The teach pendant cannot be enabled during production.
Remedy: Disable the teach pendant.
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PNT2-091 PAUS Disable teach pendant
Cause: The teach pendant is enabled.
Remedy: Disable the teach pendant to continue the program.
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PNT2-092 PAUS Stop error excess
Cause: Refer to SRVO-023.
Remedy: Refer to SRVO-023.
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PNT2-093 PAUS Move error excess
Cause: Refer to SRVO-024.
Remedy: Refer to SRVO-024.
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PNT2-094 PAUS DEADMAN switch RELEASED
Cause: The DEADMAN switch has been released during an operation. The operation has been
discontinued.
Remedy: Press the DEADMAN switch, and hold it down to restart the procedure.
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PNT2-095 ABRT %sHome program is undefined
Cause: FENCE1 and FENCE2 circuit open on EMG control board.
Remedy: Determine the cause of FENCE1 and FENCE2 open circuit and correct.
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PNT2-096 ABRT %sEnter cleaner program is undefined
Cause: The IMSTP (immediate stop) UOP input was not asserted.
Remedy: If using UOP, clear the source of the fault. If not using UOP, select the I/O menus, zero
UOP mapping, and cycle power on the controller.
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PNT2-097 ABRT %sExit cleaner program is undefined
Cause: A HOLD signal, either from the UOP or the teach pendant, has been activated.
Remedy: Remove the HOLD condition.
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PNT2-098 ABRT %sBypass program is undefined
Cause: Destination out of window error.
Remedy: The current cycle must be aborted. To prevent this from happening, reteach the necessary
positions, adjust the conveyor speed, or adjust the boundaries.
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PNT2-099 ABRT %sPurge program is undefined
Cause: The PC interface serial link has failed.
Remedy: Check the LED status on PC interface board.
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PNT2-100 ABRT %sMaster program is undefined
Cause: The average current calculated by the servo software exceeded the specification.
Remedy: Refer to troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-101 ABRT %sSpecial 1 program is undefined
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.
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PNT2-102 ABRT %sSpecial 2 program is undefined
Cause: There is no solution (conversion from a Cartesian position to joint angles) for the taught
position.
Remedy: Reteach the position.
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PNT2-103 WARN %sRobot not at home position
Cause: This is a pause condition. The configuration cannot change during a Cartesian (linear or
circular) motion.
Remedy: Either reteach the motions using the same configuration or use a joint motion to change
configurations before proceeding with Cartesian motion.
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PNT2-104 WARN %sRobot at cleaner position
Cause: An error was encountered by the planner.
Remedy: Check the error message log for details.
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PNT2-105 WARN %sRobot not at cleaner 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 your FANUC technical representative. You can try to clear the error by
powering the controller off and then on again.
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PNT2-106 WARN %sEnter Maintenance program is undefined
Cause: The brake fuse is blown on the EMG control pcb. The FALM light on the EMG control
pcb should be lit.
Remedy: Refer to troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-107 WARN %sExit Maintenance program is undefined
Cause: The robot is not mastered.
Remedy: Refer to the mastering section in the Electrical Connection and Maintenance Manual.
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PNT2-108 WARN %sRobot not at maintenance position
Cause: The servo amplifier magnetic contactor (MCC) is welded closed.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-109 PAUS Discharge current alarm
Cause: The regenerative energy produced by the motor exceeded the specifications.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-110 ABRT High voltage alarm
Cause: The DC voltage on the main power circuit of the servo amplifier exceeded the specification.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-111 ABRT High current alarm
Cause: The current in the main power circuit of the servo amplifier exceeded the specification.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-112 ABRT Low voltage alarm
Cause: The DC voltage on the main power circuit of the servo amplifier is lower than the specification
even though MCC is on.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-113 ABRT %sHome program is undefined
Cause: The servo amplifier overheated.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-114 ABRT %sEnter cleaner program is undefined
Cause: The servo software detected a disturbance torque that was too high, and tripped a collision
detection alarm.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-115 ABRT %sExit cleaner program is undefined
Cause: The battery voltage for the pulse coder is zero volts.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-116 ABRT %sBypass program is undefined
Cause: A pulse coder alarm has occurred. Go to the ALARMS screen on the teach pendant to
record the type of pulse coder alarm.
Remedy: Refer to the troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-117 ABRT %sPurge program is undefined
Cause: The pulse coder batteries are low.
Remedy: Refer to troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-118 ABRT %sMaster program is undefined
Cause: The pulse coder overheated.
Remedy: Refer to troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-119 ABRT %sSpecial 1 program is undefined
Cause: The axis control pcb sent the request signal, but did not receive serial data from the pulse coder.
Remedy: Refer to troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-120 ABRT %sSpecial 2 program is undefined
Cause: The feedback velocity exceeds specification.
Remedy: Refer to troubleshooting section in the Electrical Connection and Maintenance Manual.
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PNT2-122 WARN %sRobot at cleaner position
Cause: The teach pendant cannot be disabled during test cycle.
Remedy: Enable the teach pendant.
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PNT2-123 WARN %sRobot not at cleaner position
Cause: The battery in the PSU or encoder is low or zero.
Remedy: Replace the old battery with a new battery of same kind.
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PNT2-124 WARN %sEnter Maintenance program is undefined
Cause: The CE mode switch is not in AUTO.
Remedy: Select AUTO mode from the CE mode switch.
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PNT2-125 WARN %sExit Maintenance program is undefined
Cause: The CE mode switch was placed into AUTO.
Remedy: A mode change on the CE mode switch will pause your system. You must reset your
system after a mode change.
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PNT2-126 WARN %sRobot not at maintenance position
Cause: The CE mode switch was placed into T1.
Remedy: A mode change on the CE mode switch will pause your system. You must reset your
system after a mode change.
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PNT2-127 PAUS Operation mode T2 Selected
Cause: The CE mode switch was placed into T2.
Remedy: A mode change on the CE mode switch will pause your system. You must reset your
system after a mode change!!!
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PNT2-128 PAUS adj out of limit at line %s
Cause: Prog Adj out of limit in adj precheck.
Remedy: Check the alarm log to find out at which position motion error will occur, use CLR_Adj
to clear the adj value.
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PNT2-129 WARN I/O Hardware not installed
Cause: The I/O Hardware selected is physically not installed.
Remedy: Make sure I/O Hardware that is being selected is installed correctly.
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PNT2-130 WARN Data Error (see FR:dterrors.ls)
Cause: The I/O Auto Configurator data file contains errors.
Remedy: Go to the File menu and display FR:dterrors.ls for a description of the error with the
corresponding line number.
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PNT2-131 ABRT %sHome program is undefined
Cause: The servo is disconnected.
Remedy: Connect the servo, and then press RESET.
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PNT2-132 ABRT %sEnter cleaner program is undefined
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 and press RESET on the teach pendant.
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PNT2-133 ABRT %sExit cleaner program is undefined
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 and press RESET on the teach pendant.
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PNT2-134 ABRT %sBypass program is undefined
Cause: The non teacher enabling device is released.
Remedy: Press the non teacher enabling device and then press RESET.
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PNT2-135 ABRT %sPurge program is undefined
Cause: The teach pendant is disabled when the mode switch is in T1 or T2. Also check to see if the
controller door is opened or if a mis-wiring of a hardware connection has occurred.
Remedy: Change the teach pendant Enable/Disable switch to ON and close the controller door and
press RESET. If the reset is not effective, correct the hardware connection.
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PNT2-136 ABRT %sMaster program is undefined
Cause: The teach pendant deadman switch is released.
Remedy: None.
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PNT2-137 ABRT %sSpecial 1 program is undefined
Cause: A chain failure alarm is detected.
Remedy: If this error occurs with deadman switch release alarm, release the deadman switch again
and then repress deadman switch. Or, if this error occurs with other safety signal errors, reproduce
the same safety error, and press RESET. If SRVO-230, 231 also occurs, refer to the cause and
Remedy of SRVO-230,231.
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PNT2-138 ABRT %sSpecial 2 program is undefined
Cause: A chain failure is repaired.
Remedy: The status of the chain failure is changed to normal when the system checks the chain
failure again. Press RESET.
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PNT2-139 WARN %sRobot not at home position
Cause: The reset chain failure detection can not be executed.
Remedy: Repair the circuit of the chain 1 (+24V) on the hardware. Press the EMERGENCY STOP
button on teach pendant and twist the teach pendant emergency stop push button clockwise to
release. Press RESET.
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PNT2-140 WARN %sRobot at cleaner position
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.
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PNT2-151 WARN Col %s range err/preset %%override
Cause: The specified system color contained percent preset override data which was outside the
pre-defined allowable range for percent overrides.
Remedy: None. The override percent value was automatically adjusted to the closest valid value.
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PNT2-152 WARN Data err :Col %s preset %%override
Cause: System color data has uninitialized percent preset override information. This happens when
color data created on previous version of software is loaded into 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.
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PNT2-153 WARN Eff. preset range err (%s)
Cause: The effective preset/estat values (after applying a preset percent override factor for the
specified color, gun and parameter number) are outside the permissible 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 if
the values are within ranges for all parameters.
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PNT2-154 WARN Color %s data access error
Cause: The system could not access data on the specified system color. 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.
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PNT2-159 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 scanned when they are put into the queue.
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PNT2-160 WARN Illegal manual color %s received
Cause: For integral color change systems only: 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.
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PNT2-183 WARN Intermittent Connection Detected
Cause: A reading of 0 counts on the analog inpit (AIN[1,DISP]) causes the alarm, intermittent
connection. 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 indicates a poor electrical connection in
the feedback circuit. The electrical connector at the quick disconnect 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 it should be 10 Volts.
Remedy: Replace the electrical connector on the quick disconnect 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.
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PNT2-200 WARN %sApplicator test outputs are OFF
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.
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PNT2-201 PAUS Door detect 1 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 ignore part signal to
disable scanning operations.
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PNT2-202 WARN Illegal Opener macro Called
Cause: Two Cross-Conveyor Request macros have been called without waiting for the 1st Request
macro.
Remedy: Delete one of the Request macros or add a Wait macro between these macros.
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PNT2-203 WARN Robot in opener path
Cause: Opener move cannot be excuted as the robot is in the opener path.
Remedy: Jog the robot so that it is clear of the opener, and then reissue the move.
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PNT2-204 WARN Opener in robot path
Cause: The robot move cannot be excuted as the opener is in the robot path.
Remedy: Jog the opener so that it is clear of the robot, and then reissue the move.
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PNT2-205 WARN %sWaiting for part in window
Cause: Opener bypass program is not taught.
Remedy: Teach the Opener bypass program (OPNBYPAS.TP).
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PNT2-206 WARN %sPart entered tracking window
Cause: The opener special1 program is not taught.
Remedy: Teach the Opener special1 program (OPNSPC1.TP).
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PNT2-207 ABRT Opener Home program is undefined
Cause: The opener home program is not taught.
Remedy: Teach the Opener home program (OPN1HOME.TP).
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PNT2-213 WARN Bad cur_color no.[%d]
Cause: The cur_color number is out of range.
Remedy: Check [PASHELL] cur_color between (1-MAX_VALVES(31)).
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PNT2-214 WARN Bad cal.tbl.(color[%d]-parm[%d])
Cause: The parameter calibration table does not increase.
Remedy: Check the color and parameter calibration tables.
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PNT2-215 ABRT %s group mask(%d) != tracking schedule group(%d)
Cause: This teach pendant program group mask does not match group (robot or opener) in tracking
schedule.
Remedy: Check each robot and opener PROCESS to verify that the tracking schedule number is
assigned to this group.
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PNT2-216 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 initing the robot with this color.
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PNT2-224 WARN %sPart entered tracking window
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 wich 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.
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PNT2-225 WARN Data Monitor is disabled
Cause: Data Monitor subsystem has been disabled, by user choice or automatically because limit
on data files set by the user has been reached.
Remedy: Enable the Data Monitor Operation from the Utilities:Data Monitor screen. On the
SETUP:Diagnostics screen, consider increasing the Max Data Files Stored or setting Disable After
Max Files to NO, if these settings caused Data Monitor to to be disabled. See the PaintTool Setup and
Operations Manual, Advanced Functions chapter for more information.
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PNT2-226 WARN Maximum DMON Data Files exceeded
Cause: The limit on the data files that might be stored by the Data Monitor subsystem has been
reached.
Remedy: On the SETUP:Diagnostics screen, consider increasing the Max Data Files Stored or setting
Disable After Max Files to NO. See the PaintTool Setup and Operations manual, Advanced Functions
chapter for more information on these items.
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PNT2-227 WARN DMON in progress, item locked
Cause: The Data Monitor session is in progress and user tried to change 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 job end. If sampling in Asynchronous mode, set SAMPLE NOW, under SETUP:Diagnostics
to STOP, to stop the current session.
________________________________________________________________
PNT2-228 WARN Asynchronous DataMonitor disabled
Cause: Asynchronous Data Monitoring has been disabled.
Remedy: To re-enable, ensure that the UTILITIES:Data Monitor Data Monitor Operation is enabled.
Set SETUP:Diagnostics Auto Sample Each Job to NO.
________________________________________________________________
PNT2-230 WARN DMON file management disabled
Cause: File management features have been disabled because the user set SETUP:Diagnostics Max
Data Files Stored to 0. Stored data will be over-written by subsequent sampling sessions.
Remedy: No action required. To re-enable, you can set Max Data Files to a non-zero value. Ensure
that the destination data storage device has adequate space. See the PaintTool Setup and Operations
manual, Advanced Functions chapter for more information.
________________________________________________________________
PNT2-231 WARN DMON file management enabled
Cause: File management features have been enabled because the user set the SETUP:Diagnostics
Max Data Files Stored value. 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, set
the value to 0. Refer to the PaintTool Setup and Operations manual, Advanced Functions chapter
for more information.
________________________________________________________________
PNT2-232 WARN Sample_start builtin exec failed
Cause: The KAREL built-in SAMPLE_START returned a bad status.
Remedy: Document the events that led to the error, and contact your FANUC technical representative.
________________________________________________________________
PNT2-233 WARN Sample_end builtin exec failed
Cause: The KAREL built-in SAMPLE_END returned a bad status.
Remedy: Document the events that led to the error and contact your FANUC technical representative.
________________________________________________________________
PNT2-234 WARN %sRobot not calibrated
Cause: The Data Monitor session has not started.
Remedy: None.
________________________________________________________________
PNT2-241 PAUS %sGlss Breakage Detected
Cause: During production, one of the glass strands feeding through the chopper motor was detected
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.
________________________________________________________________
PNT2-242 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 to the catalyst pump.
________________________________________________________________
PNT2-243 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, check
the lines, and/or equipment.
________________________________________________________________
PNT2-244 WARN %sRobot not calibrated
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, check
the lines, and/or equipment.
________________________________________________________________
PNT2-245 PAUS %s0 res flow rate T.O.
Cause: All of the conditions were set for resin fluid to be flowing and 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
possibly replace the fluid flow meter. Possibly increase the Zero flow timeout parameter (by about
25%).
________________________________________________________________
PNT2-246 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). The resin gun may 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 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 the I/P
transducer if necessary.
________________________________________________________________
PNT2-247 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. There may 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 and replace the resin fluid regulator and I/P transducer if necessary.
________________________________________________________________
PNT2-248 PAUS %s0 gls feed rate T.O.
Cause: All of the conditions were set for glass to be feeding and 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), or 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.
________________________________________________________________
PNT2-249 WARN %sInvalid instruction argument
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.
________________________________________________________________
PNT2-250 WARN %sInvalid gun selection
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 may 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.
________________________________________________________________
PNT2-255 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 RJ3 controllers 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, ie PCMCIA card.
________________________________________________________________
PNT2-270 WARN %sColor cycle aborted
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.
________________________________________________________________
PNT2-271 PAUS %sColor Valve + PrgSol both ON
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.
________________________________________________________________
PNT2-272 WARN %sUsing default valve cycle data
Cause: The robot ENT_SRV program is not taught.
Remedy: Teach the robot ENT_SRV.TP program.
________________________________________________________________
PNT2-273 ABRT %sSelected color valve not defined
Cause: The robot EXIT_SRV program is not taught.
Remedy: Teach the robot EXIT_SRV.TP program.
________________________________________________________________
PNT2-276 WARN %sManaul mode is locked at T.P.
Cause: This error should never occur during normal PaintTool operation. In the event that this alarm
was posted, PaintTool was making an attempt to open a specific teach pendant program but failed.
Remedy: Ensure that the teach pendant program is loaded in the controller. If the error persists,
document the events that led to the error anc contact your FANUC technical representative.
________________________________________________________________
PNT2-277 WARN %sManual mode is locked at CRT.
Cause: This error should never occur during normal PaintTool operation.
Remedy: Document the events that led to the error and contact your FANUC technical representative.
________________________________________________________________
PNT2-278 WARN %sColor Valve + PrgAir both ON
Cause: This error should never occur during normal PaintTool operation.
Remedy: Document the events that led to the error and contact your FANUC technical representative.
________________________________________________________________
PNT2-279 WARN %sCC Waiting for arm to be home
Cause: This error should never occur during normal PaintTool operation.
Remedy: Document the events that led to the error and contact your FANUC technical representative.
________________________________________________________________
PNT2-280 WARN %sCC automatic cycles executing
Cause: This error should never occur during normal PaintTool operation.
Remedy: Document the events that led to the error and contact your FANUC technical representative.
________________________________________________________________
PNT2-281 WARN %sColorEnb + PrgSol both ON
Cause: This error should never occur during normal PaintTool operation.
Remedy: Document the events that led to the error and contact your FANUC technical representative.
________________________________________________________________
PNT2-282 WARN %sColorEnb + PrgAir both ON
Cause: A job that is selected for DATA ZONE EDIT or TEST RUN does not exist.
Remedy: Generate the job or select a job that does exist.
________________________________________________________________
PNT2-283 WARN %sSelected color valve not defined
Cause: The ext1 of the current position exceeded the out of range of start EXT1 to end EXT1.
Remedy: This will not affect the xrail smoothing process. Choose another smoothing range if you
want.
________________________________________________________________
PNT2-284 WARN %sNo system color for valve
Cause: The Motion group of the teach pendant program must be 1 when using the Xrail Manager.
Remedy: Choose another teach pendant program which uses motion Group 1.
________________________________________________________________
PNT2-285 WARN %sApplication enable is ON
Cause: The teach pendant program header size is inadequate. The program might have been created
on an older version. Header information might not be correctly stored.
Remedy: Try using the SELECT screen to select the program, go to ‘DETAILS’,’NEXT’,’END’. If this
does not work, create a new teach pendant program and paste the lines from the old program into it.
________________________________________________________________
PNT2-286 WARN %sInvalid Solv/Air State
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.
________________________________________________________________
PNT2-292 PAUS Macro motion group unknown
Cause: The macro could not identify as to which robot called the macro.
Remedy: Make sure the macro is running in production with the controller in remote.
________________________________________________________________
PNT2-293 PAUS Communication error %s
Cause: The Ethernet communication with another controller failed.
Remedy: Verify the Ethernet communication. Make sure all controllers are turned on and connected.
________________________________________________________________
PNT2-294 PAUS Arm config error %s
Cause: Another controller is configured for the same arm IDs as this Controller.
Remedy: Verify robot library setup and controller number for all arms on all controllers at a
Controlled start.
________________________________________________________________
PNT2-326 WARN %sRobot is bypassed
Cause: The robot not bypassed input is OFF.
Remedy: The robot not bypassed input must be ON.
________________________________________________________________
PNT2-327 ABRT %sSHELL failed to run SUBSHELL
Cause: The subtask failed to run.
Remedy: Cold start the controller.
________________________________________________________________
PNT2-328 WARN %sE-STAT unit faulted
Cause: An E-STAT unit fault was detected.
Remedy: Clear the E-STAT unit fault.
________________________________________________________________
PNT2-329 WARN %s abort, can fill timeout
Cause: An automatic move from the cleanin position on production entry is enabled.
Remedy: None.
________________________________________________________________
PNT2-330 WARN %s abort, can empty timeout
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.
________________________________________________________________
PNT2-331 WARN %s Canister Out Of Paint
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. If the job was incorrectly named, or the file was deleted, this
message might result.
________________________________________________________________
PNT2-332 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.
________________________________________________________________
PNT2-333 ABRT %sFailed to continue robot task
Cause: An attempt to continue the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-334 ABRT %sFailed to pause robot task
Cause: An attempt to pause the robot motion task has failed. The robot motion task presumably
has aborted.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-335 WARN %s abort, can fill timeout
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.
________________________________________________________________
PNT2-336 WARN %s abort, can empty timeout
Cause: The robot task has faulted, but was not detected by the main task.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-337 WARN %s Canister Out Of Paint
Cause: An attempt to run the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-345 WARN %sCalibration successful
Cause: The robot not bypassed input is OFF.
Remedy: The robot not bypassed input must be ON.
________________________________________________________________
PNT2-346 WARN %sCalibration aborted
Cause: The subtask failed to run.
Remedy: Cold start the controller.
________________________________________________________________
PNT2-347 WARN %sCal. low flow rate reset
Cause: An E-STAT unit fault was detected.
Remedy: Clear the E-STAT unit fault.
________________________________________________________________
PNT2-348 WARN %sCal. max. flow rate reset
Cause: Automatic move from the cleanin position on production entry is enabled.
Remedy: None.
________________________________________________________________
PNT2-349 WARN %sCal. time out at max. flow
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.
________________________________________________________________
PNT2-350 WARN %sCal. time out at low flow
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. If the job was incorrectly named, or the file was deleted, this
message might result.
________________________________________________________________
PNT2-351 WARN %sZero fluid flow rate detected
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.
________________________________________________________________
PNT2-352 WARN %sLower output did not lower flow
Cause: An attempt to continue the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-353 WARN %sTime out during a cal. test
Cause: An attempt to pause the robot motion task has failed. The robot motion task presumably
has aborted.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-354 WARN %sMin. output has flow > setpoint
Cause: An attempt to abort the robot motion task has failed. The robot motion task might not have
been running at the time the attempt was made to abort it.
Remedy: None.
________________________________________________________________
PNT2-355 WARN %sMax. output has flow < setpoint
Cause: The robot task has faulted, but was not detected by the main task.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-356 WARN %sFlow setpoint below globals
Cause: An attempt to run the robot motion task has failed.
Remedy: The current cycle must be aborted.
________________________________________________________________
PNT2-364 WARN CH2:Dyn. yield > tolerance band (%s)
Cause: The robot home program is not taught.
Remedy: Teach the robot home program (HOME.TP).
________________________________________________________________
PNT2-365 ABRT %sEnter cleaner program is undefined
Cause: The robot cleanin program is not taught.
Remedy: Teach the robot cleanin program (CLNIN.TP).
________________________________________________________________
PNT2-366 ABRT %sExit cleaner program is undefined
Cause: The robot cleanout program is not taught.
Remedy: Teach the robot cleanout program (CLNOT.TP).
________________________________________________________________
PNT2-367 ABRT %sBypass program is undefined
Cause: The robot bypass program is not taught.
Remedy: Teach the robot bypass program (BYPASS.TP).
________________________________________________________________
PNT2-368 ABRT %sPurge program is undefined
Cause: The robot purge program is not taught.
Remedy: Teach the robot purge program (PURGE.TP).
________________________________________________________________
PNT2-369 ABRT %sMaster program is undefined
Cause: The robot master program is not taught.
Remedy: Teach the robot master program (MASTER.TP).
________________________________________________________________
PNT2-370 WARN %sCal. table adapted out tolerance
Cause: The robot special1 program is not taught.
Remedy: Teach the robot special1 program (SPECIAL1.TP).
________________________________________________________________
PNT2-371 WARN %sCal. table adapted in tolerance
Cause: The robot special2 program is not taught.
Remedy: Teach the robot special2 program (SPECIAL1.TP).
________________________________________________________________
PNT2-372 WARN CH2:Dyn. yield > tolerance band (%s)
Cause: The robot is not positioned at Home.
Remedy: The robot must be moved to home.
________________________________________________________________
PNT2-373 WARN %sFlow rate average error high
Cause: The robot is positioned at the cleaner.
Remedy: You muust execute a cleanout move before continuing.
________________________________________________________________
PNT2-374 WARN %sCalibration successful
Cause: The robot is not positioned at the cleaner.
Remedy: Robot must be at the cleaner position before a move to exit cleaner is executed.
________________________________________________________________
PNT2-375 WARN %sCalibration aborted
Cause: The robot maintenance in program is not taught.
Remedy: Teach the robot maintenance in program (MNTIN.TP).
________________________________________________________________
PNT2-376 WARN %sCal. low flow rate reset
Cause: The robot maintenance out program is not taught.
Remedy: Teach the robot maintenance out program (MNTOUT.TP).
________________________________________________________________
PNT2-377 WARN %sCal. max. flow rate reset
Cause: The robot is not positioned at the maintenance position.
Remedy: The robot must be at the maintenance position before a move to the exit maintenance is
executed.
________________________________________________________________
PNT2-382 WARN %sTime out during a cal. test
Cause: The robot home program is not taught.
Remedy: Teach the robot home program (HOME.TP).
________________________________________________________________
PNT2-383 WARN %sMin. output has flow > setpoint
Cause: The robot cleanin program is not taught.
Remedy: Teach the robot cleanin program (CLNIN.TP).
________________________________________________________________
PNT2-384 WARN %sMax. output has flow < setpoint
Cause: The robot cleanout program is not taught.
Remedy: Teach the robot cleanout program (CLNOT.TP).
________________________________________________________________
PNT2-385 WARN %sFlow setpoint below globals
Cause: The robot bypass program is not taught.
Remedy: Teach the robot bypass program (BYPASS.TP).
________________________________________________________________
PNT2-386 WARN %sRequested flow above cal. table
Cause: The robot purge program is not taught.
Remedy: Teach the robot purge program (PURGE.TP).
________________________________________________________________
PNT2-387 WARN %sSlow fluid flow leak detected
Cause: The robot master program is not taught.
Remedy: Teach the robot master program (MASTER.TP).
________________________________________________________________
PNT2-388 WARN %sFast fluid flow leak detected
Cause: The robot special1 program is not taught.
Remedy: Teach the robot special1 program (SPECIAL1.TP).
________________________________________________________________
PNT2-389 WARN %sFailed to reach setpoint
Cause: The robot special2 program is not taught.
Remedy: Teach the robot special2 program (SPECIAL1.TP).
________________________________________________________________
PNT2-390 WARN %sAccuflow softpart init Failed
Cause: The robot is not positioned at Home.
Remedy: The robot must be moved to the home position.
________________________________________________________________
PNT2-391 WARN %s0 fluid flow rate timeout
Cause: The robot is positioned at the cleaner.
Remedy: You must execute a cleanout move before continuing.
________________________________________________________________
PNT2-392 WARN %sMax. flow below mid point
Cause: The robot is not positioned at the cleaner.
Remedy: The robot must be at the cleaner position before a move to the exit cleaner is executed.
________________________________________________________________
PNT2-393 WARN CH2:Dyn. yield > tolerance band (%s)
Cause: The robot maintenance in program has not been taught.
Remedy: Teach the robot maintenance in program (MNTIN.TP).
________________________________________________________________
PNT2-394 WARN %sExit Maintenance program is undefined
Cause: The robot maintenance out program has not been taught.
Remedy: Teach the robot maintenance out program (MNTOUT.TP).
________________________________________________________________
PNT2-395 WARN %sRobot not at maintenance position
Cause: The robot is not positioned at the maintenance position.
Remedy: The robot must be at the maintenance position before a move to exit maintenance is
executed.
________________________________________________________________
PNT2-400 WARN %sCal. table adapted in tolerance
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.
________________________________________________________________
PNT2-401 WARN %sDyn. yield > %% tolerance band
Cause: This message is displayed when the applicator valve enable input turns ON.
Remedy: None.
________________________________________________________________
PNT2-406 WARN %sCal. max. flow rate reset
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.
________________________________________________________________
PNT2-407 WARN %sCal. time out at max. flow
Cause: This message is displayed when the applicator valve enable input turns ON.
Remedy: None.
________________________________________________________________
PNT2-412 WARN %sMin. output has flow > setpoint
Cause: Some process(s) within a job might have something wrong with their header.
Remedy: Go to the DETAIL page for every process in the job. This should correct the problem.
________________________________________________________________
PNT2-420 WARN %sWarning, learn item failed
Cause: Some process(s) within a job might have something wrong with their header.
Remedy: Go to the DETAIL page for every process in the job. This should correct the problem.
________________________________________________________________
PNT2-428 WARN %sApplicator test outputs are ON
Cause: Applicator test outputs are ON. This is initiated by the PLC.
Remedy: None.
________________________________________________________________
PNT2-429 WARN %sCal. table adapted out,output up
Cause: Applicator test outputs are OFF. This is terminated by the PLC.
Remedy: None.
________________________________________________________________
PNT2-434 WARN %sCalibration aborted
Cause: Applicator test outputs are ON. This is initiated by the PLC.
Remedy: None.
________________________________________________________________
PNT2-435 WARN %sCal. low flow rate reset
Cause: Applicator test outputs are OFF. This is terminated by the PLC.
Remedy: None.
________________________________________________________________
PNT2-440 WARN %sLower output did not lower flow
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.
Remedy: None.
________________________________________________________________
PNT2-441 WARN %sTime out during a cal. test
Cause: For continuous line systems only. This is a warning that the part has entered the robot
tracking window.
Remedy: None.
________________________________________________________________
PNT2-446 WARN %sSlow air flow leak detected
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.
Remedy: None.
________________________________________________________________
PNT2-447 WARN %sFast air flow leak detected
Cause: For continuous line systems only. This is a warning that the part has entered the robot
tracking window.
Remedy: None.
________________________________________________________________
PNT2-452 WARN %sCal. table adapted out, down
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.
________________________________________________________________
PNT2-457 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.
________________________________________________________________
PNT2-462 WARN %sEstat controller not in remote
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.
________________________________________________________________
PNT2-463 WARN %sEstat HVON Failed
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.
________________________________________________________________
PNT2-464 WARN %sEstat setpoint not reached
Cause: An unknown instruction was encountered during program execution. This can happen if the
program was copied from a different installation.
Remedy: Delete the offending instruction.
________________________________________________________________
PNT2-465 WARN %sEstat T.P. enable Timeout
Cause: A Function instruction is used while the Function Instruction Option is not loaded.
Remedy: Load the Function Instruction Option in order to run and set the output correctly.
________________________________________________________________
PNT2-466 WARN %sEstat kV present while HVON=OFF
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 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.
________________________________________________________________
PNT2-471 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.
________________________________________________________________
PNT2-472 WARN %sEstat controller warning
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.
________________________________________________________________
PNT2-473 PAUS %sEstat controller fault
Cause: An unknown instruction was encountered during program execution. This can happen if the
program was copied from a different installation.
Remedy: Delete the offending instruction.
________________________________________________________________
PNT2-474 WARN %sEstats disabled
Cause: A Function instruction is used while the Function Instruction Option is not loaded.
Remedy: Load the Function Instruction Option in order to run and set the output correctly.
________________________________________________________________
PNT2-475 WARN %sEstat controller not in remote
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.
________________________________________________________________
PNT2-480 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.
________________________________________________________________
PNT2-481 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.
________________________________________________________________
PNT2-482 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.
________________________________________________________________
PNT2-483 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 it is in production mode, the color change cycle will be started over
from the beginning.
________________________________________________________________
PNT2-484 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.
________________________________________________________________
PNT2-485 WARN %sTurbine Startup Test Not Complete
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.
________________________________________________________________
PNT2-486 PAUS %sMax.dV/dT detected
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.
________________________________________________________________
PNT2-487 PAUS %sMax. output has speed < setpoint
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.
________________________________________________________________
PNT2-488 WARN %sRequested speed over valid range
Cause: This error should never occur during normal PaintTool operation.
Remedy: Document the events that led to the error and contact your FANUC technical service
representative.
________________________________________________________________
PNT2-489 WARN %sFailed to reach setpoint
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.
________________________________________________________________
PNT2-490 PAUS %sZero turbine speed timeout
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.
________________________________________________________________
PNT2-491 PAUS %sTurbine over speed
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.
________________________________________________________________
PNT2-492 WARN %sTurbine under speed fault
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.
________________________________________________________________
PNT2-493 WARN %sTurbine under speed warning
Cause: For integral color change systems only: This is an indication of the color change task
executing a color change cycle.
Remedy: None.
________________________________________________________________
PNT2-494 WARN %sSpeed avg. error excessive
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.
________________________________________________________________
PNT2-495 PAUS %sBearing Air NOT OK
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.
________________________________________________________________
PNT2-496 WARN %sCruise Speed not established
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.
________________________________________________________________
PNT2-497 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
might be set – and the wrong preset data might be used in the wet test cycle.
Remedy: Temporarily change the system color setup.
________________________________________________________________
PNT2-498 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.
________________________________________________________________
PNT2-499 WARN %sInvalid Solv/Air State
Cause: An attempt to enable the solvent valve was made without enabling a downstream valve.
Remedy: Verify that PD, Trigger, IWP or BWP are enabled.
________________________________________________________________
PNT2-500 WARN %sPurge Solvent + Air Both ON
Cause: The Purge Solvent and Purge Air Valves are both ON.
Remedy: Fix the Color Change Cycle Data or try again.
________________________________________________________________
PNT2-501 WARN %sMore Than One Color Valve ON
Cause: Multiple Color Valves are ON.
Remedy: This operation is not allowed.
________________________________________________________________
PNT2-502 WARN %sTurbine Startup Test Not Complete
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.
________________________________________________________________
PNT2-503 PAUS %sMax.dV/dT detected
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.
________________________________________________________________
PNT2-511 WARN %sSpeed avg. error excessive
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.
________________________________________________________________
PNT2-512 PAUS %sBearing Air NOT OK
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.
________________________________________________________________
PNT2-513 WARN %sCruise Speed not established
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.
________________________________________________________________
PNT2-514 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.
________________________________________________________________
PNT2-515 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.
________________________________________________________________
PNT2-516 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.
________________________________________________________________
PNT2-517 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.
________________________________________________________________
PNT2-518 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.
________________________________________________________________
PNT2-519 WARN %sPump 1 IN low pressure warning
Cause: This error should never occur during normal PaintTool operation.
Remedy: Document the events that led to the error and contact your FANUC technical service
representative.
________________________________________________________________
PNT2-520 PAUS %sPump 1 IN low pressure fault
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 the operation again.
________________________________________________________________
PNT2-521 WARN %sPump 1 IN high pressure warning
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 the operation again.
________________________________________________________________
PNT2-522 PAUS %sPump 1 IN high pressure fault
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.
________________________________________________________________
PNT2-523 WARN %sPump 1 OUT low pressure warning
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.
________________________________________________________________
PNT2-524 PAUS %sPump 1 OUT low pressure fault
Cause: For integral color change systems only: This is an indication of color change task executing
a color change cycle.
Remedy: None.
________________________________________________________________
PNT2-525 WARN %sPump 1 OUT high pressure warning
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.
________________________________________________________________
PNT2-526 PAUS %sPump 1 OUT high pressure fault
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.
________________________________________________________________
PNT2-527 WARN %sPump 1 fluid flow rate > set point
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.
________________________________________________________________
PNT2-528 WARN %sPump 1 fluid flow rate < set point
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
might be set – and the wrong preset data might be used in the wet test cycle.
Remedy: Temporarily change the system color setup.
________________________________________________________________
PNT2-529 WARN %sPump 1 zero fluid flow rate detected
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.
________________________________________________________________
PNT2-530 WARN %sPump 1 motor velocity limit
Cause: An attempt to enable the solvent valve was made without enabling a downstream valve.
Remedy: Verify that PD, Trigger, IWP or BWP are enabled.
________________________________________________________________
PNT2-531 WARN %sPump 1 motor servo not ready
Cause: The Purge Solvent and Purge Air Valves are both ON.
Remedy: Fix the Color Change Cycle Data or the operation again.
________________________________________________________________
PNT2-532 WARN %sPump 1 totals differ > tolerance
Cause: Multiple Color Valves are ON.
Remedy: This is not allowed.
________________________________________________________________
PNT2-533 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.
________________________________________________________________
PNT2-534 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 cycle.
Remedy: The last Color Change Cycle must send the robot to the HOME position at completion.
________________________________________________________________
PNT2-554 WARN (%s) Non-increasing cal table
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 accepatable.
________________________________________________________________
PNT2-555 WARN (%s) Zero PSI
Cause: This status warning indicates that the conditions which caused a table adapted out of tolerance
alarm have been eliminated or disappeared.
Remedy: None.
________________________________________________________________
PNT2-556 WARN (%s) Set Color Valve
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 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 minimum tolerance band equal to the yield for that color. Otherwise
increase the Percent tolerance band.
________________________________________________________________
PNT2-557 WARN %s Res:Hrd ratio is 0.0:0.0
Cause: Checks for how far the flow rate is from the set point have been too high. Possible causes
are: s sticking I/P transducer, bad fluid regulator frequent fluid pressure changes or 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.
________________________________________________________________
PNT2-558 WARN %sCalibration successful
Cause: This is used to notify the cell controller that a calibration has completed successfully.
Remedy: None.
________________________________________________________________
PNT2-559 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 pulsing pump supply to YES.
________________________________________________________________
PNT2-560 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.
________________________________________________________________
PNT2-561 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: Possibly decrease 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.
________________________________________________________________
PNT2-562 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 or frequent fluid pressure changes.
Remedy: Possibly decrease the Gain modifier used for the color. Retry the calibration. Check and
change the transducer if necessary, and replace the fluid regulator or service the surge suppression
system on the fluid supply pump. The calibration timeout parameter can be increased.
________________________________________________________________
PNT2-563 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 or frequent fluid pressure
changes.
Remedy: 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.
________________________________________________________________
PNT2-564 WARN %sPump 1 IN low pressure warning
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, or 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: flow meter, flow meter pickup,
Accuflow interface and the 32 point input module. Otherwise check the other items listed in the cause.
If it occurs with very low flow rates, decrease the Gain modifier.
________________________________________________________________
PNT2-565 PAUS %sPump 1 IN low pressure fault
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.
________________________________________________________________
PNT2-566 WARN %sPump 1 IN high pressure warning
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 consistantly. If not an
increase in the Tolerance band might be required.
________________________________________________________________
PNT2-567 PAUS %sPump 1 IN high pressure fault
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.
________________________________________________________________
PNT2-568 WARN %sPump 1 OUT low pressure warning
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 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 if necessary
the I/P transducer.
________________________________________________________________
PNT2-569 PAUS %sPump 1 OUT low pressure fault
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.
________________________________________________________________
PNT2-570 WARN %sPump 1 OUT high pressure warning
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.
________________________________________________________________
PNT2-571 PAUS %sPump 1 OUT high pressure fault
Cause: A small amount of fluid flow was detected when the gun was not turned on. This might be
caused by a loose fitting, leaking dump valve, etc.
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.
________________________________________________________________
PNT2-572 WARN %sPump 1 fluid flow rate > set point
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, broken paint line, etc. 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 if necessary the dump pilot valve and the dump valve.
________________________________________________________________
PNT2-573 WARN %sPump 1 fluid flow rate < set point
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 fluid supply system. If the calibration
yield values are more than half of the min. tolerance band then increase the tolerance band.
________________________________________________________________
PNT2-574 WARN %sPump 1 zero fluid flow rate detected
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 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 &flow diag. AOUT. Reload the Accuflow option,
and watch for alarms during the load. Document the events that led to the error, record the software
version number and contact your FANUC technical representative.
________________________________________________________________
PNT2-575 WARN %sPump 1 motor velocity limit
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: a broken applicator trigger,
a loss of fluid supply pressure, a broken fluid flow meter, a broken cable (to the flow meter), or a
Zero flow timeout value that is too short. Note, AccuFlow temporarily 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%).
________________________________________________________________
PNT2-576 WARN %sPump 1 motor servo not ready
Cause: This alarm occurs only during calibration. The flowrate 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
may 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 is
has the correct pressure range, change it if appropriate. The system might operate, but performance
can be improved with one of the above remedies.
________________________________________________________________
PNT2-577 WARN %sPump 1 totals differ > tolerance
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 minimum tolerance band equal to the yield for that color.
Otherwise increase the Percent tolerance band.
________________________________________________________________
PNT2-583 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 accepatable.
________________________________________________________________
PNT2-584 WARN %sPump 2 IN low pressure warning
Cause: This status warning indicates that the conditions which caused a table adapted out of tolerance
alarm have been eliminated or disappeared.
Remedy: None.
________________________________________________________________
PNT2-585 PAUS %sPump 2 IN low pressure fault
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 minimum tolerance band equal to the yield for that color.
Otherwise increase the Percent tolerance band.
________________________________________________________________
PNT2-586 WARN %sPump 2 IN high pressure warning
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, bad fluid regulator frequent fluid pressure changes or 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.
________________________________________________________________
PNT2-587 PAUS %sPump 2 IN high pressure fault
Cause: Used to notify the cell controller that a calibration has completed successfully.
Remedy: None.
________________________________________________________________
PNT2-588 WARN %sPump 2 OUT low pressure warning
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 pulsing pump supply to YES.
________________________________________________________________
PNT2-589 PAUS %sPump 2 OUT low pressure fault
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.
________________________________________________________________
PNT2-590 WARN %sPump 2 OUT high pressure warning
Cause: During Accuflow calibration, the expected maximum flow rate could not be reached at the
maximum output. A new maximum flow was established.
Remedy: Possibly decrease 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.
________________________________________________________________
PNT2-591 PAUS %sPump 2 OUT high pressure fault
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 or frequent fluid pressure changes.
Remedy: 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.
________________________________________________________________
PNT2-592 WARN %sPump 2 fluid flow rate > set point
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 or frequent fluid pressure
changes.
Remedy: 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.
________________________________________________________________
PNT2-593 WARN %sPump 2 fluid flow rate < set point
Cause: All of the conditions were set for fluid to be flowing and a zero flow rate was measured. This
may be due to no fluid pressure or pilot air pressure. With a very low flow rate the gain may be too
high. One of the following items may be broken: Color Valve, Color select board, gun trigger, flow
meter, flow meter pickup, Accuflow interface board, or 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: flow meter, flow meter pickup,
Accuflow interface and the 32 point input module. Other- wise check the other items listed above.
If it occurs with very low flow rates decrease the Gain modifier.
________________________________________________________________
PNT2-594 WARN %sPump 2 zero fluid flow rate detected
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 may help. Check that fluid pilot regulator air line has
adequate exhaust capability. Reevaluate the size of the restrictor in the gun.
________________________________________________________________
PNT2-595 WARN %sPump 2 motor velocity limit
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 consistantly. If not an
increase in the Tolerance band might be required.
________________________________________________________________
PNT2-596 WARN %sPump 2 motor servo not ready
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.
________________________________________________________________
PNT2-597 WARN %sPump 2 totals differ > tolerance
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 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 if necessary
the I/P transducer.
________________________________________________________________
PNT2-598 WARN %sCalibration aborted
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.
________________________________________________________________
PNT2-599 WARN (%s) Non-increasing 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.
________________________________________________________________
PNT2-600 WARN (%s) Zero PSI
Cause: A small amount of fluid flow was detected when the gun was not turned on. This might be
caused by a loose fitting, a leaking dump valve, etc.
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.
________________________________________________________________
PNT2-601 WARN (%s) Set Color Valve
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, broken paint line, etc. 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 if necessary the dump pilot valve and the dump valve.
________________________________________________________________
PNT2-602 WARN %s Res:Hrd ratio is 0.0:0.0
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 may 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 fluid supply system. If the calibration
yield values are more than half of the min. tolerance band then increase the tolerance band.
________________________________________________________________
PNT2-603 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 &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 FANUC technical representative.
________________________________________________________________
PNT2-604 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 may 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), or a
Zero flow timeout value that is too short. Note, AccuFlow temporarily 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%).
________________________________________________________________
PNT2-605 WARN %sMax. flow below mid point
Cause: This alarm occurs only during calibration. The flowrate 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 may 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 is
has the correct pressure range, change it if appropriate. The system might operate, but performance
can be improved with one of the above remedies.
________________________________________________________________
PNT2-606 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 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 minimum tolerance band equal to the yield for that color.
Otherwise increase the Percent tolerance band.
________________________________________________________________
PNT2-612 WARN %sCalibration Time Out
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 immediately clear the
alarm. Increase the Adaptive tolerance parameter to allow larger changes without alarming
________________________________________________________________
PNT2-613 WARN %sCanister Calibration Successful
Cause: This is a notification that the calibration table has returned to the normal operating range (as
defined by the Adaptive tolerance).
Remedy: None.
________________________________________________________________
PNT2-614 ABRT %sBad Status from set_prax_spd
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: In some way 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) booster (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%).
________________________________________________________________
PNT2-615 PAUS %sHIGH SpeedDock TORQUE
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 the measured flow and setpoint that will cause this alarm is controlled by
the Max. error from setpoint parameter. Possible causes are: clogged air cap, sticking I/P transducer,
bad air booster or pinching 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.
________________________________________________________________
PNT2-616 WARN %sSpeedDock motor not ready
Cause: This is used to notify the cell controller that a calibration has been completed successfully.
Remedy: None.
________________________________________________________________
PNT2-617 PAUS %s
Cause: AccuAir calibration could not complete. This might be due to the air supply being off.
Check for other alarms in the log. This may 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.
________________________________________________________________
PNT2-618 PAUS %s
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%).
________________________________________________________________
PNT2-619 PAUS %sHIGH ServoBell TORQUE
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.
________________________________________________________________
PNT2-620 WARN %sServoBell motor not ready
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: Retry the calibration. Possibly decrease the Gain modifier parameter. Possibly increase the
Percent tolerance band parameter. Check and change the transducer if necessary. Possibly increase the
Calibration time out parameter (by about 10 seconds).
________________________________________________________________
PNT2-621 WARN %sCalibration Aborted
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: Retry the calibration. Possibly decrease the Gain modifier parameter. Possibly increase the
Percent tolerance band parameter. Check and change the transducer if necessary. Possibly increase
the Calibration time out parameter (by about 10 seconds). Possibly increase the Table point no. 2
parameter (by about 100%).
________________________________________________________________
PNT2-622 WARN %sCalibration Time Out
Cause: All of the conditions were set for air to be flowing and a zero flow rate was measured. This
may 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), or a Trigger delay that is too
short. Note, AccuAir temporarily automatically changes to Open Loop when this alarm occurs.
Remedy: 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%).
________________________________________________________________
PNT2-623 WARN %sCanister Calibration Successful
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: 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%). Reducing the Leveling
tries parameter might help.
________________________________________________________________
PNT2-624 ABRT %sBad Status from set_prax_spd
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.
________________________________________________________________
PNT2-625 PAUS %sHIGH SpeedDock TORQUE
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 effects 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 may be stuck open. The air booster may 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 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.
________________________________________________________________
PNT2-626 WARN %sSpeedDock motor not ready
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 effects the sensitivity of this alarm. This is
likely caused by a clogged air cap. This might be caused by: pinched air lines, a broken I/P transducer
or a broken air flow sensor. Note, AccuAir temporarily 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. Check for a pinched air line. Check and repair the
I/P transducer. Possibly increase the Max. control out (ms) parameter (by about 50%).
________________________________________________________________
PNT2-627 PAUS %s
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.
________________________________________________________________
PNT2-628 PAUS %s
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.
________________________________________________________________
PNT2-629 WARN %sOutput Press low warning
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.
________________________________________________________________
PNT2-630 WARN %sOutput Press high warning
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.
________________________________________________________________
PNT2-631 WARN %sManifold Press low warning
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 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 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.
________________________________________________________________
PNT2-632 WARN %sManifold Press high warning
Cause: All of the conditions were set for air to be flowing and a zero flow rate was measured for
longer than the Zero flow timeout parameter. This may 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 timeout value that is too short. Note, AccuAir temporarily
automatically changes to Open Loop when this alarm occurs.
Remedy: 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. Possibly increase the Zero flow timeout parameter (by about 25%).
________________________________________________________________
PNT2-633 PAUS %sOutput Press low alarm
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.
________________________________________________________________
PNT2-634 PAUS %sOutput Press high alarm
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: In some way 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%).
________________________________________________________________
PNT2-635 PAUS %sManifold Press low alarm
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 the 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 immediately clear the alarm. Increase the Adaptive
tolerance parameter to allow larger changes without alarming
________________________________________________________________
PNT2-636 PAUS %sManifold Press high alarm
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 wrong equipment
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%.
________________________________________________________________
PNT2-637 WARN %sCalibration successful
Cause: When attempting to autmatically zero (tare) the air flow meter the flow reading from it
was large enough to indicate a possible leak.
Remedy: Complete the procedure to manually zero (tare) the air flow meter 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 then follow the cause and remedy for the Fast air flow leak detected alarm.
________________________________________________________________
PNT2-643 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 immediately clear the
alarm. Increase the Adaptive tolerance parameter to allow larger changes without alarming
________________________________________________________________
PNT2-644 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.
________________________________________________________________
PNT2-645 WARN %sOutput Press low warning
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: In some way 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) booster (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%).
________________________________________________________________
PNT2-646 WARN %sOutput Press high warning
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: clogged air cap, sticking I/P transducer,
bad air booster or pinching 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.
________________________________________________________________
PNT2-647 WARN %sManifold Press low warning
Cause: Used to notify the cell controller that a calibration has been completed successfully.
Remedy: None.
________________________________________________________________
PNT2-648 WARN %sManifold Press high warning
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.
________________________________________________________________
PNT2-649 PAUS %sOutput Press low alarm
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%).
________________________________________________________________
PNT2-650 PAUS %sOutput Press high alarm
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.
________________________________________________________________
PNT2-651 PAUS %sManifold Press low alarm
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: Retry the calibration. Possibly decrease the Gain modifier parameter. Possibly increase the
Percent tolerance band parameter. Check and change the transducer if necessary. Possibly increase the
Calibration time out parameter (by about 10 seconds).
________________________________________________________________
PNT2-652 PAUS %sManifold Press high alarm
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: Retry the calibration. Possibly decrease the Gain modifier parameter. Possibly increase the
Percent tolerance band parameter. Check and change the transducer if necessary. Possibly increase
the Calibration time out parameter (by about 10 seconds). Possibly increase the Table point no. 2
parameter (by about 100%).
________________________________________________________________
PNT2-653 WARN %sCalibration successful
Cause: All of the conditions were set for air to be flowing and 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), or a Trigger delay that is too
short. Note, AccuAir temporarily automatically changes to Open Loop when this alarm occurs.
Remedy: 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%).
________________________________________________________________
PNT2-654 WARN %sCalibration aborted
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: 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%). Reducing the Leveling
tries parameter may help.
________________________________________________________________
PNT2-655 WARN %sNon-incr cal table
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.
________________________________________________________________
PNT2-656 WARN %sZero Pressure
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 effects 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 may 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 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.
________________________________________________________________
PNT2-657 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 effects the sensitivity of this alarm. This is
likely caused by a clogged air cap. This may be caused by: pinched air lines, a broken I/P transducer
or a broken air flow sensor. Note, AccuAir temporarily 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. Check for a pinched air line. Check and repair the
I/P transducer. Possibly increase the Max. control out (ms) parameter (by about 50%).
________________________________________________________________
PNT2-658 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.
________________________________________________________________
PNT2-659 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.
________________________________________________________________
PNT2-660 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.
________________________________________________________________
PNT2-661 WARN %sBad preset index [%d]
Cause: A large amount of air flow was detected when the gun was not turned on. This may 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.
________________________________________________________________
PNT2-662 WARN %sNo preset data (syscolor=[%s])
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 setpoint is
controlled by the Min. Setpoint reached (ms) parameter. This may 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.
________________________________________________________________
PNT2-663 WARN %sNo estat data (syscolor=[%s])
Cause: All of the conditions were set for air to be flowing and a zero flow rate was measured for
longer than the Zero flow timeout parameter. This may 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 timeout value that is too short. Note, AccuAir temporarily
automatically changes to Open Loop when this alarm occurs.
Remedy: 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. Possibly increase the Zero flow timeout parameter (by about 25%).
________________________________________________________________
PNT2-664 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.
________________________________________________________________
PNT2-665 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
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: In some way 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%).
________________________________________________________________
PNT2-666 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 the 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 immediately clear the alarm. Increase the Adaptive
tolerance parameter to allow larger changes without alarming
________________________________________________________________
PNT2-667 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 wrong equipment
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%.
________________________________________________________________
PNT2-668 WARN %sBad preset index [%d]
Cause: When attempting to automatically zero (tare) the air flow meter, the flow reading from it
was large enough to indicate a possible leak.
Remedy: Complete the procedure to manually zero (tare) the air flow meter 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 then follow the cause and remedy for the Fast air flow leak detected alarm.
________________________________________________________________
PNT2-673 WARN %sEstat controller warning
Cause: The external E-stat controller detected a warning.
Remedy: Check the status of the external e-stat controller.
________________________________________________________________
PNT2-674 PAUS %sEstat controller fault
Cause: The external E-stat controller detected a fault.
Remedy: Check the status of the external E-stat controller.
________________________________________________________________
PNT2-675 WARN Wrong valve state in EMPTY CAN event%s
Cause: The E-stat disconnect or enable switch is off.
Remedy: Turn on the E-stat disconnect or enable switch.
________________________________________________________________
PNT2-676 WARN Wrong valve state in FAST FILL event%s
Cause: The E-stat local/remote switch is set to local mode.
Remedy: Put the e-stat controller in remote mode.
________________________________________________________________
PNT2-677 WARN Wrong valve state in CAN FULL event%s
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.
________________________________________________________________
PNT2-678 WARN Wrong valve state in PRESET motion%s
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
________________________________________________________________
PNT2-679 WARN Canister Dir – retracting: %s
Cause: The e-stat enable for the teach pendant screen timed out.
Remedy: Request the E-stat voltage again.
________________________________________________________________
PNT2-686 WARN %sLow Trigger Torque
Cause: The external E-stat controller detected a warning.
Remedy: Check the status of the external e-stat controller.
________________________________________________________________
PNT2-687 WARN Wrong valve state in EMPTY CAN event%s
Cause: The external E-stat controller detected a fault.
Remedy: Check the status of the external e-stat controller.
________________________________________________________________
PNT2-688 WARN Wrong valve state in FAST FILL event%s
Cause: The E-stat disconnect or enable switch is off.
Remedy: Turn on the E-stat disconnect or enable switch.
________________________________________________________________
PNT2-689 WARN Wrong valve state in CAN FULL event%s
Cause: The E-stat local/remote switch is set to local mode.
Remedy: Put the e-stat controller in remote mode.
________________________________________________________________
PNT2-690 WARN Wrong valve state in PRESET motion%s
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.
________________________________________________________________
PNT2-691 WARN Canister Dir – retracting: %s
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.
________________________________________________________________
PNT2-692 WARN Low can Pressure after Fill: %s
Cause: The estat enable for the teach pendant screen timed out.
Remedy: Request the E-stat voltage again.
________________________________________________________________
PNT2-699 PAUS %sIllegal macro argument
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.
________________________________________________________________
PNT2-700 PAUS %sMacro waiting for aborted robot
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.
________________________________________________________________
PNT2-701 PAUS %sMacro not acknowledged
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 if necessary the I/P transducer.
________________________________________________________________
PNT2-716 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.
________________________________________________________________
PNT2-717 PAUS %sDoor held input 1 lost
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.
________________________________________________________________
PNT2-718 PAUS %sDoor held input 2 lost
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 may 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 if necessary the I/P transducer.
________________________________________________________________
PNT2-733 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The resin inlet transducer has failed.
8. 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.
________________________________________________________________
PNT2-734 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The resin inlet transducer has failed.
8. 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.
________________________________________________________________
PNT2-735 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The resin inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-736 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The resin inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-737 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The resin outlet transducer 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. Verify that the pump is rotating with 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.
________________________________________________________________
PNT2-738 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The resin outlet transducer 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 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 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.
________________________________________________________________
PNT2-739 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not set up correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix resin valve is removed or broken.
6. The mix resin valve has failed.
7. 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.
________________________________________________________________
PNT2-740 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not setup correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix resin valve is removed or broken.
6. The mix resin valve has failed.
7. The resin outlet transducer has failed.
Remedy: 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.
________________________________________________________________
PNT2-741 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: Do 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
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-742 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: Do 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
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-743 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:
1. A loose mechanical coupling between the motor and pump.
2. A broken line between the pump and trigger.
Remedy: Check the mechanical coupling between the motor and the pump. Make sure the line
from the pump to trigger is ok.
________________________________________________________________
PNT2-744 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.
________________________________________________________________
PNT2-745 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, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-746 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: Do 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 (blow
by) is occurring across the pump. Verify that pump #1 does not have excessive wear.
________________________________________________________________
PNT2-753 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The hardener inlet transducer has failed.
8. 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 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 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.
________________________________________________________________
PNT2-754 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The hardener inlet transducer has failed.
8. 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 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.
________________________________________________________________
PNT2-755 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The hardener inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-756 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The hardener inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-757 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The hardener outlet transducer 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 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 paint kitchen. Verify that the pump is rotating with 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.
________________________________________________________________
PNT2-758 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The hardener outlet transducer 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 paint kitchen. Verify that the pump is rotating with 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.
________________________________________________________________
PNT2-759 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not setup correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix hardener valve is removed or broken.
6. The mix hardener valve has failed.
7. The hardener 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 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.
________________________________________________________________
PNT2-760 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not setup correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix hardener valve is removed or broken.
6. The mix hardener valve has failed.
7. The hardener outlet transducer has failed.
Remedy: 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.
________________________________________________________________
PNT2-761 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: 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 manufacturers specification. Check the operation of the inlet regulator to verify that no
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-762 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: 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 manufacturers specification. Check the operation of the inlet regulator to verify that no
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-763 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:
1. A loose mechanical coupling between the motor and pump.
2. 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.
________________________________________________________________
PNT2-764 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.
________________________________________________________________
PNT2-765 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 for some reason, such as
E-stop condition, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-766 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: 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 flow meter per
the manufacturers specification. Check the operation of the inlet regulator to verify that no (blow by)
is occurring across the pump. Verify that pump #2 does not have excessive wear.
________________________________________________________________
PNT2-767 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.
________________________________________________________________
PNT2-768 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 pumps are operating correctly. Ensure that the speed command delay (used to allow
the motor RPM to settle) is set to a sufficient amount.
________________________________________________________________
PNT2-769 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.
________________________________________________________________
PNT2-771 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.
________________________________________________________________
PNT2-778 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The resin inlet transducer has failed.
8. 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.
________________________________________________________________
PNT2-779 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The resin inlet transducer has failed.
8. 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.
________________________________________________________________
PNT2-780 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The resin inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-781 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The resin inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-782 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The resin outlet transducer 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. Verify that the pump is rotating with 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.
________________________________________________________________
PNT2-783 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to resin color valve is removed or broken.
4. The resin color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The resin outlet transducer 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 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 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.
________________________________________________________________
PNT2-784 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not setup correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix resin valve is removed or broken.
6. The mix resin valve has failed.
7. 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.
________________________________________________________________
PNT2-785 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not setup correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix resin valve is removed or broken.
6. The mix resin valve has failed.
7. The resin outlet transducer has failed.
Remedy: 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.
________________________________________________________________
PNT2-786 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: Do 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
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-787 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: Do 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
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-788 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:
1. A loose mechanical coupling between the motor and pump.
2. 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.
________________________________________________________________
PNT2-789 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.
________________________________________________________________
PNT2-790 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, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-791 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: Do 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 (blow
by) is occurring across the pump. Verify that pump #1 does not have excessive wear.
________________________________________________________________
PNT2-798 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The hardener inlet transducer has failed.
8. 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 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 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.
________________________________________________________________
PNT2-799 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. The hardener inlet transducer has failed.
8. 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 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.
________________________________________________________________
PNT2-800 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The hardener inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-801 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The supply pressure is set too high.
4. The hardener inlet transducer has failed.
5. The inlet regulator has failed.
Remedy: 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.
________________________________________________________________
PNT2-802 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:
1. The low pressure warn limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The hardener outlet transducer has failed.
Remedy: Make sure the low pressure warning limit is set to an appropriate value. Make sure the low
pressure sensitivity is set to an appropriate value. 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 paint kitchen. Verify that the pump is rotating with 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.
________________________________________________________________
PNT2-803 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:
1. The low pressure fault limit is set too high.
2. The low pressure sensitivity is set too short.
3. The pilot line to hardener color valve is removed or broken.
4. The hardener color valve has failed.
5. The supply pressure is too low.
6. The supply line (hose, etc.) is removed or broken.
7. A broken coupling between the servo motor and pump.
8. The hardener outlet transducer has failed.
Remedy: Make sure the low pressure fault limit is set to an appropriate value. Make sure the low
pressure sensitivity is set to an appropriate value. 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 paint kitchen. Verify that the pump is rotating with 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.
________________________________________________________________
PNT2-804 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:
1. The high pressure warn limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not setup correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix hardener valve is removed or broken.
6. The mix hardener valve has failed.
7. The hardener 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 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.
________________________________________________________________
PNT2-805 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:
1. The high pressure fault limit is set too low.
2. The high pressure sensitivity is set too short.
3. The pump start/stop anticipates not setup correctly.
4. Obstructed line, trigger or check valve.
5. The pilot line to mix hardener valve is removed or broken.
6. The mix hardener valve has failed.
7. The hardener outlet transducer has failed.
Remedy: 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.
________________________________________________________________
PNT2-806 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 manufacturers specification. Check the operation of the inlet regulator to verify that no
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-807 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: 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 manufacturers specification. Check the operation of the inlet regulator to verify that no
(blow by) is occurring across the pump.
________________________________________________________________
PNT2-808 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:
1. A loose mechanical coupling between the motor and pump.
2. 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.
________________________________________________________________
PNT2-809 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.
________________________________________________________________
PNT2-810 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 for some reason, such as
E-stop condition, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-811 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: 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 flow meter per
the manufacturers specification. Check the operation of the inlet regulator to verify that no (blow by)
is occurring across the pump. Verify that pump #2 does not have excessive wear.
________________________________________________________________
PNT2-812 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.
________________________________________________________________
PNT2-813 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.
________________________________________________________________
PNT2-814 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.
________________________________________________________________
PNT2-816 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.
________________________________________________________________
PNT2-823 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 the problem.
________________________________________________________________
PNT2-824 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 for some reason, such as
E-stop condition, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-825 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.
________________________________________________________________
PNT2-826 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 all faults are cleared. Ensure that the ServoBell motor is turning during the
calibration process.
________________________________________________________________
PNT2-828 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.
________________________________________________________________
PNT2-829 PAUS %sHIGH SpeedDock TORQUE
Cause: Torque value of the SpeedDock exceeded the maximum safety limit.
Remedy: Determine the cause of the high torque reading and resolve the problem.
________________________________________________________________
PNT2-830 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
E-stop condition, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-831 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 SpeedDock side A or B. Ensure that sufficient air pressure is available
for this operation and that the air lines are connected.
________________________________________________________________
PNT2-832 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 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.
________________________________________________________________
PNT2-833 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.
________________________________________________________________
PNT2-834 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 for some reason, such as
E-stop condition, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-835 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.
________________________________________________________________
PNT2-836 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 all faults are cleared. Ensure that the ServoBell motor is turning during the
calibration process.
________________________________________________________________
PNT2-838 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.
________________________________________________________________
PNT2-839 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.
________________________________________________________________
PNT2-840 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
E-stop condition, and/or machine locked. Correct the condition and reset the controller.
________________________________________________________________
PNT2-841 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 SpeedDock side A or B. Ensure that sufficient air pressure is available
for this operation and that the air lines are connected.
________________________________________________________________
PNT2-842 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 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.
________________________________________________________________
PNT2-843 WARN %sOutput Press low warning
Cause: Output pressure dropped below the warning level.
Remedy: Correct problem if warning occurs repeatedly, or adjust the Output pressure warning
value if it is too low.
________________________________________________________________
PNT2-844 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.
________________________________________________________________
PNT2-845 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.
________________________________________________________________
PNT2-846 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.
________________________________________________________________
PNT2-847 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.
________________________________________________________________
PNT2-848 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.
________________________________________________________________
PNT2-849 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.
________________________________________________________________
PNT2-850 PAUS %sManifold Press high alarm
Cause: Manifold pressure exceeded the high alarm level.
Remedy: Correct the problem immediately, or adjust the Manifold pressure alarm value if it is too low.
________________________________________________________________
PNT2-851 WARN %sCalibration successful
Cause: Calibration successful.
Remedy: None.
________________________________________________________________
PNT2-852 WARN %sCalibration aborted
Cause: Calibration aborted.
Remedy: Determine cause for calibration to abort, correct the problem, and retry the operation.
________________________________________________________________
PNT2-853 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 increasin, correct the problem, and retry the operation.
________________________________________________________________
PNT2-854 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, correct the problem, and retry the operation.
________________________________________________________________
PNT2-859 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 too low.
________________________________________________________________
PNT2-860 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.
________________________________________________________________
PNT2-861 WARN %sManifold Press low warning
Cause: The manifold pressure dropped below the warning level.
Remedy: Correct the problem if the warning occurs repeatedly, or adjust the Manifold pressure
warning value if it is too low.
________________________________________________________________
PNT2-862 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.
________________________________________________________________
PNT2-863 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.
________________________________________________________________
PNT2-864 PAUS %sOutput Press high alarm
Cause: The output pressure exceeded the high alarm level.
Remedy: Correct the problem immediately, or adjust the Output pressure alarm value if it is too low.
________________________________________________________________
PNT2-865 PAUS %sManifold Press low alarm
Cause: The output pressure dropped below the alarm level.
Remedy: Correct the problem immediately, or adjust the Manifold pressure alarm value if it is too low.
________________________________________________________________
PNT2-866 PAUS %sManifold Press high alarm
Cause: The manifold pressure exceeded the high alarm level.
Remedy: Correct the problem immediately, or adjust the Manifold pressure alarm value if it is too low.
________________________________________________________________
PNT2-867 WARN %sCalibration successful
Cause: Calibration successful.
Remedy: None.
________________________________________________________________
PNT2-868 WARN %sCalibration aborted
Cause: Calibration aborted.
Remedy: Determine cause for calibration to abort, correct the problem, and try the operation again.
________________________________________________________________
PNT2-869 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 cause for the pressure not increasing, correct the problem, and try the operation
again.
________________________________________________________________
PNT2-870 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, correct the problem, and try the operation again.
________________________________________________________________
PNT2-875 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
________________________________________________________________
PNT2-876 WARN %sNo preset data (syscolor=[%s])
Cause: No preset data for the error color was found.
Remedy: Check [PAPS1] or ([PAPS2] if Dualarm) preset_data for table entry.
________________________________________________________________
PNT2-877 WARN %sNo estat data (syscolor=[%s])
Cause: No estat data for error color was found.
Remedy: Check [PAPSSCHG] preset_data for table entry
________________________________________________________________
PNT2-882 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.
________________________________________________________________
PNT2-883 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
________________________________________________________________
PNT2-884 WARN %sNo estat data (syscolor=[%s])
Cause: No estat data for error color was found.
Remedy: Check [PAPSSCHG] preset_data for table entry
________________________________________________________________
PNT2-889 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 satified for the Empty Can event in the color change cycle.
Remedy: Ensure that the pDump valve OR pPE + pTRIG valves are in the step before the Empty Can
event to correct the problem.
________________________________________________________________
PNT2-890 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 satified for the Fast Fill event in the color change cycle.
Remedy: Ensure that the pCI valve is enabled in the step before the Fast Fill event to correct the
problem.
________________________________________________________________
PNT2-891 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 satified for the Can Full event in the color change cycle.
Remedy: Ensure that the pCI valve is enabled in the step before the Can Full event to correct the
problem.
________________________________________________________________
PNT2-892 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 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.
________________________________________________________________
PNT2-893 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. pCI valve should be ON.
________________________________________________________________
PNT2-894 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).
________________________________________________________________
PNT2-895 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.
________________________________________________________________
PNT2-896 WARN Zero Flow Programmed: %s
Cause: Zero Flow was programmed in CC.
Remedy: Ensure that a flow rate is setup in the CC preset data.
________________________________________________________________
PNT2-897 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.
________________________________________________________________
PNT2-898 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 may 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.
________________________________________________________________
PNT2-899 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 me mixed with the paint.
Remedy: Check the paint supply for the current color in the canister to verify air in not being
introduced into paint supply.
________________________________________________________________
PNT2-900 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: Check the paint supply for the current color in the canister or reduce the torque threshold
value or the fill through trigger timeout value.
________________________________________________________________
PNT2-901 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: Ensure that the pDump valve OR pPE + pTRIG valves are in the step before the Empty Can
event to correct the problem.
________________________________________________________________
PNT2-902 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: Ensure that the pCI valve is enabled in the step before the Fast Fill event to correct the
problem.
________________________________________________________________
PNT2-903 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: Ensure that the pCI valve is enabled in the step before the Can Full event to correct the
problem.
________________________________________________________________
PNT2-904 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.
________________________________________________________________
PNT2-905 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. pCI valve should be ON.
________________________________________________________________
PNT2-906 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).
________________________________________________________________
PNT2-907 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.
________________________________________________________________
PNT2-908 WARN Zero Flow Programmed: %s
Cause: Zero Flow was programmed in CC.
Remedy: Ensure that a flow rate is setup in the CC preset data.
________________________________________________________________
PNT2-909 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.
________________________________________________________________
PNT2-910 PAUS %sHIGH Positive Canister TORQUE
Cause: The maximum tensile force on the ball screw has been exceeded. When this occurs, it is
usually when the ball screw is retracting. There may 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.
________________________________________________________________
PNT2-911 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 air in not being
introduced into paint supply.
________________________________________________________________
PNT2-912 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: Check the paint supply for the current color in the canister or reduce the torque threshold
value or the fill through trigger timeout value.
________________________________________________________________
PNT2-913 PAUS %sIllegal macro argument
Cause: The macro argument selected an invalid arm ID.
Remedy: Verify the robot program calling the macro does not identify itself in the macro argument.
Make sure arguements are in the following list: Robots: R1,R2,R3,R4,R5,R6,R7,R8 Door Openers:
D1,D2,D3,D4,D5,D6 Hood/Deck Openers: H1,H2,H3,H4,H5,H6
________________________________________________________________
PNT2-914 PAUS %sMacro waiting for aborted robot
Cause: The robot program is waiting for program on another robot that is already aborted.
Remedy: Cancel the robot and send it home.
________________________________________________________________
PNT2-915 PAUS %sMacro not acknowledged
Cause: The previous macro was not acknowledged.
Remedy: Change the teach pendant program so that this waits on the other robot between release
macros.
________________________________________________________________
PNT2-917 PAUS %sIllegal macro argument
Cause: The macro argument selected an invalid arm ID.
Remedy: Verify the robot program calling the macro does not identify itself in the macro argument.
Make sure arguements are in the following list: Robots: R1,R2,R3,R4,R5,R6,R7,R8 Door Openers:
D1,D2,D3,D4,D5,D6 Hood/Deck Openers: H1,H2,H3,H4,H5,H6
________________________________________________________________
PNT2-918 PAUS %sMacro waiting for aborted robot
Cause: The robot program is waiting for a program on another robot that is already aborted.
Remedy: Cancel the robot and send it to the home position.
________________________________________________________________
PNT2-919 PAUS %sMacro not acknowledged
Cause: The previous macro was not acknowledged.
Remedy: Change the teach pendant program so that this waits on the other robot between release
macros.
________________________________________________________________
PNT2-921 WARN %sMissing Softfloat disable
Cause: A TP process/job is missing the instruction to disable softfloat for the specified group.
Remedy: Ensure to disable softfloat in a TP program that is associated with the same job that
enabled softfloat.
________________________________________________________________
PNT2-922 WARN %sInvalid Handoff Orientation
Cause: The orientation of both hooks are not within the specified tolerance for a successful handoff
operation.
Remedy: Ensure the handoff tolerance is not too tight. Determine as to why the hook(s) are not
physically correct for the hand off to occur.
________________________________________________________________
PNT2-923 WARN %sHood/Deck Opener Lost Part
Cause: The Hood/Deck opener lost the part while softfloat was enabled, resulting in the hook to
rotate to the Part lost position.
Remedy: Determine if the TP program needs to disable softfloat prior to this location. If programming
is correct, to continue, reposition the part on the hook and issue a continue on the opener. A cancel
can be initiated to cancel the job, which automatically disables Softfloat.
________________________________________________________________
PNT2-926 WARN %sMissing Softfloat disable
Cause: A teach pendant process/job is missing the instruction to disable softfloat for the specified
group.
Remedy: Ensure to disable softfloat in a teach pendant program that is associated with the same job
that enabled softfloat.
________________________________________________________________
PNT2-927 WARN %sInvalid Handoff Orientation
Cause: The orientation of both hooks are not within the specified tolerance for a successful handoff
operation.
Remedy: Ensure the handoff tolerance is not too tight. Determine as to why the hook(s) are not
physically correct for the hand off to occur.
________________________________________________________________
PNT2-928 WARN %sHood/Deck Opener Lost Part
Cause: The Hood/Deck opener lost the part while softfloat was enabled, resulting in the hook to
rotate to the Part lost position.
Remedy: Determine if the TP program needs to disable softfloat prior to this location. If programming
is correct, to continue, reposition the part on the hook and issue a continue on the opener. A cancel
can be initiated to cancel the job, which automatically disables Softfloat.
________________________________________________________________
PNT2-931 PAUS %sDoor held input 1 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 ignore part
signal to disable scanning operations.
________________________________________________________________
PNT2-932 PAUS %sDoor held input 2 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 ignore part
signal to disable scanning operations.
________________________________________________________________
PNT2-933 PAUS %sDoor detect 1 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.
________________________________________________________________
PNT2-934 PAUS %sDoor detect 2 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 ignore part signal to
disable scanning operations.
________________________________________________________________
PNT2-937 PAUS %sDoor held input 1 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 ignore part
signal to disable scanning operations.
________________________________________________________________
PNT2-938 PAUS %sDoor held input 2 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 ignore part
signal to disable scanning operations.
________________________________________________________________
PNT2-939 PAUS %sDoor detect 1 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 ignore part signal to
disable scanning operations.
________________________________________________________________
PNT2-940 PAUS %sDoor detect 2 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.