fanuc B-82594EN-6 User Manual

4 . ERROR CODES B-82594EN-6/02

4 ERROR CODES

4.1 A

4.1.1 ACAL Alarm Code

ACAL-000 Fail to run DETECT Motn

Cause: The AccuCal2 Motn failed to run. The AccuCal2 motion cannot be started.

Remedy: Clear all the errors before executing AccuCal2.

ACAL-001 Robot is not ready.

Cause: The robot is not ready. The system cannot issue motion because it is in an error state.

Remedy: Clear all faults, then retry the operation.

ACAL-002 Fail to fit circle.

Cause: AccuCal2 cannot converge within the set threshold.

Remedy: Perform the following:

 Increase the number of iterations allowed.
 Increase the convergence threshold setting.
 Make sure the TCP has not been changed.

ACAL-003 Contact before search.

Cause: The robot is in contact with the part before starting a search motion.

Remedy: Reteach the starting position.

ACAL-004 No contact detected.

Cause: No contact was made during the AccuCal2 motion.

Remedy: Make sure the sensor and software are installed correctly.

ACAL-005 Undefined program name.

Cause: The AccuCal2 program name was not defined.

Remedy: Select an AccuCal2 teach pendant program before pressing the EXEC key.

ACAL-006 TPE operation error.

Cause: This is an internal teach pendant editor program error.

Remedy: Abort the program and run again. If this doesn't resolve the problem, cycle power and try again. If this doesn't resolve

the problem, reinstall the controller software.

ACAL-007 Calibration internal error.

Cause: This is an AccuCal2 internal error.

Remedy: Turn off the controller, and turn it on again to recover. If the problem persistes, reinstall the controller software.

ACAL-008 File open error.

Cause: The output file cannot be opened.

Remedy: Check the path, and file name to be sure they are correct.

ACAL-009 No matching Start inst.

Cause: You are trying to execute a CALIB END instruction without a matching CALIB START instruction.

Remedy: Add a CALIB START instruction before the CALIB END.

ACAL-010 Invalid schedule number.

Cause: The schedule number in CALIB, UTOOL, or UFRAME START is invalid.

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4 . ERROR CODES B-82594EN-6/02

Remedy: Provide a correct schedule number in CALIB (or UTOOL or UFRAME) START[] teach pendant instruction.

ACAL-011 Cannot access $MNUFRAME.

Cause: The current $MNUFRAMENUM[] is incorrect and cannot be accessed.

Remedy: Go to the USER FRAME menu to select a valid user frame.

ACAL-012 Cannot access $MNUTOOL.

Cause: Cannot access $MNUTOOL. The current $MNUTOOLNUM[] is incorrect.

Remedy: Display the FRAME menu to select a valid tool frame.

ACAL-013 Backward execution ignored.

Cause: Backward execution were ignored. The AccuCal2 instructions can not be executed backward.

Remedy: The backward execution of the AccuCal2 instructions is ignored. Rewrite the instructions if you do not want this to

happen.

ACAL-014 System loading error.

Cause: System loading error. The AccuCal2 is loaded incorrectly.

Remedy: Reload the controller.

ACAL-015 Not enough data.

Cause: Not enough data exists to compute the frame offset.

Remedy: Add more Detect instructions in the AccuCal2 program.

ACAL-016 No Preplan motion for Detect

Cause: The Detect instruction does not allow pre-plan motion.

Remedy: None.

ACAL-017 Wrong number of searches.

Cause: An incorrect number of searches was performed.

Remedy: Re-teach the AccuCal2 program with an appropriate number of searches. Refer to the application-specific Operator's

Manual for information on the number of searches required for each calibration type.

ACAL-018 Nonorthogonal search vector

Cause: The 3 planes method requires three search directions be normal to each other.

Remedy: Re-teach the cell finder program with three search directions that are normal to each other.

ACAL-019 Positions are too close.

Cause: Positions are too close. The taught positions are too close to each other.

Remedy: Re-teach the cell finder program so that the contact positions are at least 10mm apart.

ACAL-020 Invalid Frame number.

Cause: The current frame number setting is invalid.

Remedy: Use the SETUP/FRAME menu to set up the correct frame.

ACAL-021 Large Frame deviation.

Cause: The computed frame offset exceeds the pre-set value.

Remedy: Run the calibration program again to make sure the robot makes solid contacts with the part. Change the XYZ and

ORNT change value in the schedule if these numbers are very small.

ACAL-022 Detect without mastering

Cause: An AccuCal2 teach pendant program is running without performing mastering it first.

Remedy: Display the AccuCal2 menu, and master the program first.

ACAL-023 No EXEC at Single Step Mode.

Cause: The robot cannot execute an AccuCal2 program in Single Step Mode.

Remedy: Turn off Single Step before executing the cell finder program.

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B-82594EN-6/02 4 . ERROR CODES

ACAL-024 Master Update failed.

Cause: A failure occurred while trying to update the master data in a FIND instruction.

Remedy: Re-master the frame search teach pendant program.

ACAL-025 Large frame shift.

Cause: A very large frame shift has occurred.

Remedy: Check the UTOOL and the fixture to make sure that they are properly installed.

ACAL-026 No CALIB END instruction.

Cause: No CALIB END instruction. AccuCal2 program does not have a FIND END instruction.

Remedy: Add CALIB END instruction at the end of the frame search teach pendant program.

ACAL-027 Counts do not match.

Cause: The number of master data and number of run time data does not match each other.

Remedy: Run the finder program again.

ACAL-028 No logged frame data.

Cause: No logged frame data exists and the frame cannot be restored.

Remedy: Select a logged frame.

ACAL-029 Zero offset, No Update.

Cause: No change occurred in the offset frame.

Remedy: Run Cell Finder again to compute a new offset.

ACAL-030 Frame Log is disabled.

Cause: The Frame data log is disabled.

Remedy: Enable the frame log first.

ACAL-031 Cold start to set $USEUFRAME

Cause: $USEUFRAME is set to FALSE. AccuCal2 reset it to TRUE.

Remedy: TUrn off the controller, the turn it on again to perform a Cold start.

ACAL-032 Invalid motion group.

Cause: The motion group number is invalid.

Remedy: Use only one group in the program and make sure the group is available.

ACAL-033 Other group is running.

Cause: The other program has motion control.

Remedy: Abort the other running program.

ACAL-034 Group mismatched.

Cause: The motion group number is not right.

Remedy: Use only one group in the program, and make sure group is available.

ACAL-035 Press Shift Key.

Cause: The SHIFT key was not pressed.

Remedy: Press the SHIFT key.

ACAL-036 Failed to create TPE program

Cause: The teach pendant program could not be created.

Remedy: Check the following:

 Make sure enough memory is available.
 Make sure the program is not being edited.
 Make sure the program is not write protected.

ACAL-037 TPE Position is not recorded

Cause: The teach pendant position has not been recorded. Make sure the program is not write protected.

Remedy: Unprotect the write protected program.

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4 . ERROR CODES B-82594EN-6/02

ACAL-038 TPE Program does not exist.

Cause: The selected teach pendant program was not found and does not exist.

Remedy: Select an existing teach pendant program.

ACAL-039 Move to recorded posn failed

Cause: The robot could not move to the recorded position.

Remedy: Make sure the position is reachable and that another program does not have motion control.

ACAL-040 Invalid Detection TP program

Cause: The detection teach pendant program is not usable.

Remedy: Load a proper detection program.

ACAL-041 Override should be 100%.

Cause: The speed override is not 100%.

Remedy: Before running the program, increase the override to 100%.

ACAL-042 Large orientation change.

Cause: The found orientation is larger than the tolerance allows.

Remedy: Adjust the object so that orientation is smaller. Increase the orientation tolerance.

ACAL-043 Points & solution mismatch.

Cause: The number of search points does not match the selected solution type.

Remedy: Select a different solution type, or adjust number of detect statements.

ACAL-044 Solution type error.

Cause: An unsupported solution type error was selected.

Remedy: Choose a different solution type.

ACAL-045 Failed to set register.

Cause: The specified register was not set.

Remedy: Make sure the specified register exists.

ACAL-046 Failed to convert position.

Cause: The position failed to convert. The internal position was not set.

Remedy: Make sure the points are taught in the proper sequence and are not near limits.

ACAL-047 Too many points used.

Cause: Too many points are used.

Remedy: Reduce the number of detect points.

ACAL-048 Solution failed.

Cause: The solution failed to complete.

Remedy: Make sure the correct number of points are taught in the correct directions and orientation.

ACAL-049 Motion limit error.

Cause: This is a motion limit error. The detect motion failed due to a limit error for the destination position.

Remedy: Move the robot away from the joint limit, or reduce the search distance in the detection schedule.

ACAL-050 iRCal. TCP is not loaded.

Cause: TCP Cal is not loaded.

Remedy: Try to run the TCP Calibration instruction without the TCP Cal software. Perform a Controlled start, and load the

TCP Cal software from the option menu.

ACAL-051 iRCal. Frame is not loaded.

Cause: Cell Cal is not loaded.

Remedy: Try to run the Cell Calibration instruction without the Cell Cal software. Perform a Controlled start, and load the

Cell Cal software from the option menu.

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B-82594EN-6/02 4 . ERROR CODES

ACAL-052 iRCal. Master is not loaded.

Cause: Robot Cal is not loaded. The robot tried to run the robot Calibration instruction without the Robot Cal software.

Remedy: Perform a Controlled start, and load the Robot Cal software from the OPTION menu.

ACAL-053 No calibration software.

Cause: No calibration software. The robot tried to run a detect instruction without Calibration software.

Remedy: Perform a Controlled start, and load one of the Calibration software options from the OPTION menu.

ACAL-054 Invalid Calibration program.

Cause: Invalid Calibration program. The calibration program type does not match the calibration menu.

Remedy: Check the teach pendant program's calibration start instruction so it matches the calibration menu.

ACAL-055 Too Many Parallel Searches.

Cause: Too Many Parallel Searches have occurred. More than three parallel searches occurred when the total number of

searches is less than 7.

Remedy: Teach more searches, or change the excess parallel searches to be in a different direction.

ACAL-056 Skip Update Frame Inst.

Cause: The robot executed an UPDATE FRAME instruction in a non-Cell calibration program.

Remedy: UPDATE FRAME only works in Cell Calibration programs with Uframe Start instruction. Remove the UPDATE

FRAME instruction from the non-CellCal program.

ACAL-057 Large Calibration Error

Cause: Residual maximum calibration has exceeded the limit allowed by the specified schedule.

Remedy: Verify solid tooling and good contact is made during all searches. Increase the limit in the schedule.

ACAL-058 UFRAME Change Not Allowed

Cause: The UFRAME was changed during UTOOL calibration and this is not allowed.

Remedy: Use the same UFRAME for all points during the initial UTOOL calib.

ACAL-059 All Positions Not Recorded

Cause: All required positions are not recorded.

Remedy: Record all necessary positions, and retry the operation.

ACAL-060 Excessive Accumulated offset

Cause: The accumulated offset exceeds the tolerance specified in the schedule.

Remedy: Repair the tool so that the TCP is closer to the reference TCP, or increase Accumulated Error Threshold in the tool

calibration schedule.

ACAL-061 UFrame mismatch.

Cause: A UFrame mismatch has occurred. The current MNUFRAME number does not match the program's uframe.

Remedy: Change the current user frame number to match the program's user frame number.

ACAL-062 Too many moves in a program.

Cause: Too many moves have been attempted in a program. The Calibration porgram has too many motion lines in it.

Remedy: Limit the number of move instructionz in a calibration program to less than 256.

ACAL-063 Failed to update master data

Cause: The master data failed to update. The master count cannot be updated when the robot is in motion.

Remedy: Abort the robot motion and then press the UPDATE soft key again.

ACAL-064 UTool Mismatch.

Cause: A UTool mismatch has occurred. The current MNUTOOL number does not match the program's utool.

Remedy: Change the current tool number to match the program's utool number.

ACAL-065 TCP calibration failed

Cause: The TCP calibration failed to complete.

Remedy: Review the previous error to identify the cause.

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4 . ERROR CODES B-82594EN-6/02

ACAL-066 Frame calibration failed

Cause: Cell calibration failed to complete.

Remedy: Review the previous error to identify the cause.

ACAL-067 Circle fit error %s

Cause: The circle fit error exceeds the threshold.

Remedy: Check for a loss fixture or tool, or change the fit error tolerance in the detection schedule.

ACAL-068 Radius err %s

Cause: Circle radius error exceeds threshold.

Remedy: Check for a lost fixture or tool, or change the radius error tolerance in the detection schedule.

ACAL-069 Auto Update is ON.

Cause: Auto Update is on therefore the frame has been updated automatically.

Remedy: An update is not required.

ACAL-070 No update on record points.

Cause: No update on record points. The teach pendant program has a different number of DETECT instructions than

expected. The positions cannot automatically update in the screen.

Remedy: Manually record positions to create the calibration program.

ACAL-071 Invalid joint number.

Cause: The axis number specified in the DETECT Joint instruction is invalid.

Remedy: Change the axis number to a valid one.

ACAL-072 Invalid joint sensor type.

Cause: The Detect Joint instruction cannot use TOS WRIST sensor type for contact detection.

Remedy: Change sensor type to either IO or TOS all axes in the detection schedule.

ACAL-073 Skip Detect Joint

Cause: The Detect Joint instruction is not valid for TCP or CELL calibration.

Remedy: The Detect Joint instruction is for ROBOT calibration only. Change the calibration start instrction to CALIB START

or delete the instruction from the program.

ACAL-074 No motion before DETECT.

Cause: No motion exists before the DETECT instruction. Detect instructions require a motion line preceeding them.

Remedy: Add a MOVE instruction before the DETECT instruction.

ACAL-075 Mixed Detect instructions.

Cause: Mixed Detect instructions have occurred. The Detect Joint instruction cannot be used with other Detect instructions

within the same Calib Start - Calib End instructions.

Remedy: Delete the other DETECT instrucion from the program.

ACAL-076 More than one Detect Joint.

Cause: More than one Detect Joint instruction exists. Only one Detect Joint instruction is allowed between Calib Start and

Calib End instructions.

Remedy: Delete the extra DETECT JOINT instructions.

ACAL-077 No Detect Joint in Init. Cal

Cause: No Detect Joint should exist in Initial Calibration. The Detect Joint instruction does not apply to the initial robot

calibration.

Remedy: Run the program from the robot master recovery menu.

ACAL-078 Skip Update Tool instruction

Cause: Execute the Update Utool instruction in a non-TCPCal program.

Remedy: Update Tool only works in TCP Calibration programs with a UTool Start instruction.

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B-82594EN-6/02 4 . ERROR CODES

ACAL-079 Large approach angle error.

Cause: The search start position's appraoch vector does not align with the plate's normal vector.

Remedy: Touch up the search start position so that the position's approach vector is aligned to the plate's normal vector.

ACAL-080 Failed to update TPE program

Cause: Failed to update the teach pendant program's search start position.

Remedy: Make sure there is not system fault before pressing UPDATE. If the problem persists, perform a Cold start.

ACAL-081 Destination %s Limit Error

Cause: The recorded position is too close to the joint limit.

Remedy: Re-teach the position away from joint limit.

ACAL-082 Tool is 180 degree off in Z

Cause: The Tool approach vector is 180 degrees off in Z from the search direction.

Remedy: Change the system variable $cb_vars.$z_out to FALSE if it is set to TRUE, or vice versa.

ACAL-083 Invalid TPE instruction.

Cause: Invalid teach pendant calibratino instruction.

Remedy: The teach pendant program memory might be corrupted. Replace the instruction with a new one.

ACAL-084 Failed to access Karel vars.

Cause: Failed to access the calibration program's KAREL variables.

Remedy: Cold start the controller. If the problem persists, re-install the calibration option again.

ACAL-085 UFrame is too small

Cause: The specified UFrame is zero or small, and Calibrate UFrame is disabled.

Remedy: Set UFrame to be the precision calibration fixture location or enable UFrame calibration in the calibration schedule.

ACAL-086 UTool is too small

Cause: The specified UTool is zero or small, and the Calibrate UTool is disabled.

Remedy: Set UTool to be the precision calibration fixture location or enable UTool calibration in the calibration schedule.

ACAL-087 Joint[%s^1] rotation is small

Cause: The joint angle motion is too small.

Remedy: Modify calibration points to provide more motion on the specified axis. Or, disable calibration of one or more joints.

ACAL-088 Points are colinear

Cause: Three or more points with the same search direction are colinear or nearly colinear.

Remedy: Reteach one of the points so that the points are not colinear, or teach another non-colinear point.

ACAL-089 Not enough search direction

Cause: There must be at least three different search directions that are close to perpendicular to each other. There must also

be at least three non-colinear points in one search direction and at least two points in another search direction.

Remedy: Add more search points or reteach existing points to have sufficient search directions and a sufficient number of

points in the search directions.

ACAL-090 Large joint angle correction

Cause: Calibration joint angle correction exceeds the limit

Remedy: Identify the cause of the large correction. If the robot joint angle is actually off by that large amount, then you can

either increase the tolerance in the schedule or manually remaster the robot to reduce the error and touchup the
calibration points and rerun the calibration. If the calibration result is incorrect, then check that Calibrate UFrame is
TRUE unless you are doing calibration recovery or use a precision fixture. Check that Calibrate UTool is TRUE
unless you are doing calibration recovery or use a precision calibration tool. If you are doing recovery then check that
the calibration fixture is in the correct location and the UFrame is the same as the original UFrame from when the
calibration was run in MASTER mode. If recovering J6, then verify that UTool and the calibration tool are the same
as when the calibration was run in MASTER mode

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4 . ERROR CODES B-82594EN-6/02

ACAL-091 UFrame orienation not zero

Cause: The UFrame orientation must be zero.

Remedy: Use a UFrame with WPR values where all are set to zero.

ACAL-092 Position close to joint limit

Cause: The search destination position is too close to the joint limit.

Remedy: Re-teach the position away from joint limits.

ACAL-093 Invalid CD pair number

Cause: The Coordinate Motion Pair number is invalid.

Remedy: Check the CD pair setup to make sure the CD pair has been set up correctly.

ACAL-094 Invalid Process Sync Setup

Cause: Invalid Process Sync Set up

Remedy: Check the Process Sync setup to make sure the Process Sync has been set up correctly.

ACAL-095 No Coordinate Motion software

Cause: The CD pair calibration requires Coordinate Motion Software.

Remedy: Load the Coordinate Motion software on the controller.

ACAL-096 No Process Sync software

Cause: Robot Link calibration requires Robot Link Software.

Remedy: Load the Robot Link software on the controller.

ACAL-097 MultiCal is not loaded.

Cause: The user is trying to run the MultiCal instruction without MultiCal software.

Remedy: Perform a Control start and load the MultiCal software from option menu.

ACAL-098 Bar method is not supported

Cause: Calibration Bar is not support in the V7.20 MultiCal Release.

Remedy: The calibration bar method will be supported in future releases.

ACAL-099 Positioner is not supported

Cause: Positioner calibration is not supported in the V7.20 MultiCal release.

Remedy: The positioner calibration will be supported in future releases.

ACAL-100 Program Group Mismatch

Cause: The read in the program group does not match the current default motion group.

Remedy: Use the FCTN key to change the current motion group or select another calibration program.

ACAL-101 TCP Alignment error

Cause: The maximum alignment distance was exceeded.

Remedy: Fix the TCP Alignment and run TCPCal again.

ACAL-102 Process is not yet completed

Cause: Cannot execute current step without completing previous steps.

Remedy: Complete all steps leading to the current step.

ACAL-104 No Analog port data file

Cause: There is no asscoated Analog data file in FRS: for the specified analog port number.

Remedy: Copy the analog data file to the FRS: directory and cold start the controller.

ACAL-105 Option does not support AIN

Cause: RobotCal and MultiCal does not support analog sensor.

Remedy: Select a different sensor type in the detection schedule.

ACAL-106 No analog sensor support

Cause: The Detect Circle and Detect Joint instructions do not support an analog sensor.

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B-82594EN-6/02 4 . ERROR CODES

Remedy: Select a different sensor type in the detection schedule.

ACAL-107 Invalid AIN port number

Cause: The AIN port number is not valid.

Remedy: Select a different AIN port number that has its data file in an FRS: directory.

ACAL-108 Dynamic UFrame setup error

Cause: Dynamic Uframe seting require cd pair setting in its schedule.

Remedy: Set the cd pair number in the schedule or change the CellCal calibration mode in the setup menu

ACAL-109 Standard UFrame setup error

Cause: The schedule used by UFrame has a cd_pair set.

Remedy: Select a new schedule or change the cd_pair variable to 0 in the current schedule.

ACAL-110 Please turn off single step

Cause: Disable single step mode.

Remedy: Press the STEP key to disable single step.

4.1.2 APSH Alarm Code

APSH-000 %s

Cause: General status messages.

Remedy: None

APSH-001 %s missing

Cause: A MACRO was called without a parameter that must be entered.

Remedy: Check the MACRO call in the TP program.

APSH-002 %s Illegal type

Cause: A MACRO was called with a parameter that is illegal. The parameter has the wrong data type.

Remedy: Check the MACRO call in the TP program.

APSH-003 %s Illegal zone number

Cause: An zone number less that 1 or greater than $IZONEIO.$NO_ZONES was used.

Remedy: Use an event number from 1 to $IZONEIO.$NO_ZONES.

APSH-004 Waiting for interf. zone %s

Cause: The robot has requested an interferance zone, but has not been given permission to enter by the cell controller.

Remedy: If the cell controller does not give control of an interferance zone to the robot when it should, check the cell

controller's interferance zone programming.

APSH-005 Entering interf. zone %s

Cause: The robot has received permission to enter the interferance zone.

Remedy: Used to clear the waiting for interferance zone message only.

APSH-006 PERM memory is low

Cause: This warning indictates that the amount of free memory in the CMOS memory partition has gotten dangerously low.

If the PERM memory runs out, you will experience strange MEMO errors and possibly robot lock-ups or register
dumps.

Remedy: Warning only. Delete any unneeded data. Contact your FANUC representative with this error. You will probably have

to adjust the memory configuration in your robot controller.

APSH-007 TEMP DRAM memory is low

Cause: This warning indicates that the amount of free memory in the TEMP memory partition has gotten dangerously low. If

the TEMP memory runs out, you will experience strange MEMO errors and possibly robot lock-ups or register
dumps.

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4 . ERROR CODES B-82594EN-6/02

Remedy: Warning only. Delete any unneeded data. Contact your FANUC representative with this error. You will probably have

to adjust the memory configuration in your robot controller.

APSH-008 FAULT must be reset

Cause: A fault has ocurred, so the operation requested cannot be performed.

Remedy: Clear the source of the fault, and press FAULT RESET.

APSH-009 Program already running

Cause: The shell detected a start signal but a program is already running.

Remedy: Re-issue start request when current program is paused or aborted.

APSH-010 %s aborted

Cause: A UOP CYCLE START or DI[Initiate Style] was detected when a non-production (i.e. test cycle) program was

paused. This paused program was aborted for safety reasons.

Remedy: None is required. The next production start signal will start the current style.

APSH-012 REMOTE switch must be on LOCAL

Cause: The robot's REMOTE condition is TRUE, so the remote operating device (PLC) currently has motion control over the

robot.

Remedy: Disable the REMOTE condition by turning the REMOTE keyswitch on the SOP to LOCAL.

APSH-013 Place robot into REMOTE state

Cause: The REMOTE condition is currently false, so the robot is not under the control of the remote operating device (PLC).

Remedy: Verify that the following conditions are true in order to put the robot into the REMOTE condition: 1. UOP inputs #1

(IMSTP), #3 (SFTYSPD), and #8 (ENBL) are all HIGH. 2. SOP REMOTE/LOCAL keyswitch is set to REMOTE. 3.
Teach pendant is disabled. 4. Robot Auto/Bypass mode input is HIGH (if so assigned). 5. Make sure a user program
is not setting $RMT_MASTER = 1

APSH-014 RESET Failure

Cause: There is an active fault, which prevents the reset request from executing

Remedy: Clear the source of the fault (usually en external E-Stop) and press FAULT RESET.

APSH-015 Step mode must be disabled

Cause: Step mode is enabled, which prevents the run request from executing

Remedy: Disable step mode by pressing the STEP hardkey.

APSH-016 Robot is not under PLC control

Cause: The UOP is not the master device, which prevents the run request from executing

Remedy: Turn SOP REMOTE/LOCAL keyswitch to REMOTE. Make sure all UOP signals are correct for execution. Set

$RMT_MASTER to 0.

APSH-017 Running with process disabled

Cause: This is a warning to notify the user that a production job is running with the sealant disabled.

Remedy: None needed.

APSH-018 WARNING - Machine lock is on

Cause: This is a warning to notify the user that a production job is running with machine lock on.

Remedy: None needed.

APSH-019 Job queue is full

Cause: The job queue cannot accept the next job because it is full.

Remedy: Manually edit the job queue to delete any unneeded jobs or increase queue size.

APSH-020 Job queue is empty

Cause: A request to run the next job in the queue came in, but the queue is empty.

Remedy: Check the external device to make sure that a job number was correctly sent to the controller, or manually edit the

job queue to CREATE a job.

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B-82594EN-6/02 4 . ERROR CODES

APSH-021 Raise UOP ENBL input

Cause: Robot motion and/or program execution cannot occur unless UOP input 8 is ON.

Remedy: Check UOP I/O setup. UOP input 8 (ENBL) must be ON.

APSH-022 Safety fence is open

Cause: The safety fence input is LOW.

Remedy: The safety fence input must be ON to resume normal robot operation. Raise the safety fence input.

APSH-024 Program %s not loaded

Cause: The program name that the shell was requested to run is not loaded on the controller.

Remedy: Check PLC->Robot style communication. Verify that specified JOB name was requested by PLC. Load or create the

specified JOB program.

APSH-025 WARNING - Running at < 100%%

Cause: This is a warning to notify the user that a production job is running at less than 100% speed. override.

Remedy: None needed. Dispensetool can increase the override speed to 100% if you require it. Go to the Cell Setup menu to

access this option.

APSH-027 Press FAULT RESET button

Cause: In order to resume normal production operation, Dispensetool requires that you perform this action.

Remedy: Perform the action stated in the error message when you are ready to resume normal operation.

APSH-028 Increasing speed to 100%%

Cause: This is a warning to notify the user that Dispensetool in increasing the genoverride (speed override) to 100%.

Remedy: None needed. To disable this feature, you may change this option on the Cell Setup menu.

APSH-029 Robot must be at home

Cause: The robot must be at the HOME position in order to perform the requested operation. This error is usually posted

when the PLC sends a cycle start and the robot is not at home.

Remedy: Move the robot to the home position.

APSH-030 Style code %s is invalid

Cause: The GIN[style_in] is set to an invalid number.

Remedy: Check the GIN[style_in] value as well as the Group input configuration.

APSH-031 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Check the GIN[style_in] value as well as the Group input configuration.

APSH-032 Robot Servos Disabled

Cause: Dispensetool has detected that the robot servos have been disabled manually.

Remedy: This is a status message to make sure the user is aware that the robot cannot move. The servos must be re-enabled to

resume normal production operations.

APSH-033 PLC comm error - timeout

Cause: A communication sequence took too long to complete.

Remedy: Increase communication timeout value in PNS Cell Communication setup menu or disable communication timeout

checking.

APSH-034 No UOP output defined

Cause: The User Operator Panel output group has not been defined.

Remedy: Set up the UOP Outputs in the UOP I/O menu and restart the robot controller.

APSH-035 Robot is in Bypass mode

Cause: The MODE input is low, forcing the robot into BYPASS mode. The robot will now ignore all PLC style initiation.

Remedy: Set the MODE switch to ON. The robot will then re-enter AUTOMATIC mode and again accept PLC signals.

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4 . ERROR CODES B-82594EN-6/02

APSH-036 User JOB has been paused

Cause: The current JOB has been paused. This often happens if the HOLD input is turned ON or the UOP ENBL signal is

set to OFF.

Remedy: If the REMOTE condition is TRUE, the fault recovery menu will appear and give the user the appropriate recovery

options. If the REMOTE condition is not TRUE, recovery is up to the user. If all else fails, select FCTN (Function
hardkey) then ABORT ALL.

APSH-037 No UOP input defined

Cause: The User Operator Panel input group has not been defined.

Remedy: Set up the UOP Inputs in the UOP I/O menu.

APSH-038 No style input group defined

Cause: The group which carry the style code in to the controller has not been defined.

Remedy: Set up a STYLE SELECT group in the Cell I/O and GROUP I/O input menus and restart the robot.

APSH-039 No style ack strobe defined

Cause: The style acknowlege strobe, which is needed with the current communication configuration, has not been defined.

Remedy: Set up a Style Ack Strobe in the Cell Output I/O menu and restart the robot.

APSH-040 No backup input group defined

Cause: The backup input group, which is needed with the current communication configuration, has not been defined.

Remedy: Set up a Backup Style Select group in the Cell output I/O and GROUP I/O menus and restart the robot.

APSH-041 No style input strobe defined

Cause: The style strobe, which is needed with the current communication configuration (queue enabled), has not been

defined.

Remedy: Set up a PNS Strobe in the Cell Input I/O menu and restart the robot.

APSH-042 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Set up a PNS Strobe in the Cell Input I/O menu and restart the robot.

APSH-043 No style ack group defined

Cause: The style acknowlege group, which is needed with the current communication configuration, has not been defined.

Remedy: Set up a Style Ack Group in the Cell output I/O and GROUP I/O menus and restart the robot.

APSH-044 A user program is HELD

Cause: The current job has been held by pressing the HOLD button or setting the UOP HOLD input LOW.

Remedy: Release the HOLD button and raise the UOP HOLD input.

APSH-045 No program setup for style %s

Cause: No program number has been set up for this RSR input.

Remedy: Enter a program number for this RSR input in the RSR Cell Setup menu.

APSH-046 Robot is in Automatic mode

Cause: This is a notice that the robot is leaving BYPASS mode and entering AUTOMATIC mode, where it can respond to

PLC inputs

Remedy: None needed.

APSH-047 Shell will not run without UOPs

Cause: This is a warning, telling the user that the UOPs have not yet been set up, so the shell will wait for the UOPs to be

defined before resuming.

Remedy: The shell requires the UOPs to run. Once the UOPs have been set up, the shell will continue its initialization

sequence.

APSH-048 PLC comm error - invert check

Cause: The backup style group is not the 1's complement (inverse) of the style input group.

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B-82594EN-6/02 4 . ERROR CODES

Remedy: Verify that the PLC is sending the correct invert style to the correct group. Disable invert checking in the PNS Cell

Setup menu.

APSH-049 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Verify that the PLC is sending the correct invert style to the correct group. Disable invert checking in the PNS Cell

Setup menu.

APSH-050 Cell IO setup is invalid

Cause: Signals which are required for this cell IO configuration have not been configured.

Remedy: Check the messages posted previous to the in the error log for the names of the incorrect signals. Fix the IO setup of

these signals and cold start the controller.

APSH-051 Connect or deassign UOP inputs

Cause: The robot cannot move while the UOP inputs are in this state.

Remedy: You must either wire UOP inputs #1, #2, #3, and #8 high or deassign the UOP inputs and restart the controller.

APSH-052 Critical UOP inputs are LOW

Cause: UOP inputs #1 (IMSTP), #2 (HOLD), #3(SFTYFNC), #8 (ENBL) are all LOW. These must all be HIGH for normal

production operation.

Remedy: See remedy for APSH-051, Connect or deassign UOP inputs.

APSH-054 Release SOP E-STOP

Cause: In order to resume normal production operation, Dispensetool requires that you perform this action.

Remedy: Perform the action stated in the error message when you are ready to resume normal operation.

APSH-055 Raise UOP IMSTP input

Cause: In order to resume normal production operation, Dispensetool requires that you perform this action.

Remedy: Perform the action stated in the error message when you are ready to resume normal operation.

APSH-056 Release SOP E-STOP

Cause: In order to resume normal production operation, Dispensetool requires that you perform this action.

Remedy: Perform the action stated in the error message when you are ready to resume normal operation.

APSH-057 Release TP E-STOP

Cause: In order to resume normal production operation, Dispensetool requires that you perform this action.

Remedy: Perform the action stated in the error message when you are ready to resume normal operation.

APSH-058 Pause forced by shell

Cause: This error is posted to simulate a PAUSE error.

Remedy: This error is posted by Dispensetool during normal operation, but should not be visible to the user. If you see this

error, report it to you FANUC representative.

APSH-059 Abort forced by shell

Cause: This error is posted to simulate a ABORT error.

Remedy: This error is posted by Dispensetool during normal operation, but should not be visible to the user. If you see this

error, report it to you FANUC representative.

APSH-060 Cycle start ignored-not in AUTO

Cause: This is not a fault. This error is posted when the robot is sent a cycle start from the cell controller, but the robot is

either in BYPASS mode (set from Soft Panel menu) or in MANUAL mode, but no manual cycle start has been
initiated. Is is also possible that the robot is in the MANUAL mode and a MANUAL CYCLE was requested, but the
style sent by the PLC does not match the one specified on the SOFT PANEL.

Remedy: In most cases, this fault can be ignored. This fault was put in to assist in debugging problems with the soft panel in

Dispensetool. If you are trying to initiate a MANUAL CYCLE, make sure the MANUAL CYCLE STYLE inputted
into the Soft Panel menu is the same as what the PLC is sending.

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4 . ERROR CODES B-82594EN-6/02

APSH-061 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: In most cases, this fault can be ignored. This fault was put in to assist in debugging problems with the soft panel in

Dispensetool. If you are trying to initiate a MANUAL CYCLE, make sure the MANUAL CYCLE STYLE inputted
into the Soft Panel menu is the same as what the PLC is sending.

APSH-062 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: In most cases, this fault can be ignored. This fault was put in to assist in debugging problems with the soft panel in

Dispensetool. If you are trying to initiate a MANUAL CYCLE, make sure the MANUAL CYCLE STYLE inputted
into the Soft Panel menu is the same as what the PLC is sending.

APSH-063 A HOLD input is active

Cause: The current job has been paused by pressing the HOLD button or setting the UOP HOLD input LOW.

Remedy: Release the HOLD button and raise the UOP HOLD input.

APSH-064 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Release the HOLD button and raise the UOP HOLD input.

APSH-065 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Release the HOLD button and raise the UOP HOLD input.

APSH-066 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Release the HOLD button and raise the UOP HOLD input.

APSH-070 Failed to continue %s

Cause: The error handler was unable to continue the task named when the user requested that all tasks be continued This is

probably due to one of the E-Stops or HOLD buttons being active.

Remedy: Disable all E-Stops and release HOLD buttons. If it is not desired that the task named be continued, abort it.

APSH-071 Failed to pause robot task

Cause: A Karel PAUSE_TASK() command failed to pause a task which the error handler believes should be paused.

Remedy: The task which the error handler tried to pause was probably a system utility, and is not allowed to be paused. You

can probably ignore this fault without any problems.

APSH-072 Failed to abort robot task

Cause: A Karel ABORT_TASK() command failed.

Remedy: Cold start the robot controller, then manually restore production status.

APSH-073 Servos Locked-out, enable servos

Cause: Robot servos are locked out.

Remedy: Enable robot servos.

APSH-074 Disable Teach Pendant

Cause: In order to resume normal production operation, Dispensetool requires that you perform this action.

Remedy: Perform the action stated in the error message when you are ready to resume normal operation.

APSH-075 Error in accessing TPE:%s

Cause: The following error occured when a the data associated with a TPE program was accessed.

Remedy: Verify that this TPE program exists. Go into the DETAIL pages under the SELECT menu and hit NEXT key until

robot allows this mode to END.

APSH-076 Shell could not run:%s

Cause: The shell tried to execute a program, but was stopped by the operating system.

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B-82594EN-6/02 4 . ERROR CODES

Remedy: Make sure the program exists and it is not already running or paused. Use the PROGRAM STATUS display to make

sure you have not exceeded the maximum number of tasks. Abort all programs which do not need to be running.

APSH-077 No positions in %s

Cause: This TPE did not contain a position to represent HOME, SERVICE, or PURGE.

Remedy: If you need to use the AT PERCH, AT PURGE, or AT SERVICE outputs, teach the positons you need in the

appropriate TPEs. If you do not need these outputs to be updated ignore this warning.

APSH-078 Shell could not run program

Cause: The shell tried to execute a program, but was stopped by the operating system.

Remedy: Make sure the program exists and it is not already running or paused. Use the PROGRAM STATUS display to make

sure you have not exceeded the maximum number of tasks. Abort all programs which do not need to be running.

APSH-079 No DIN for Auto/Bypass

Cause: No Auto/Bypass input has been defined, but one was expected.

Remedy: Set a Auto/Bypass input in the Cell I/O Input menu and restart the robot.

APSH-080 Waiting for Cancel/Continue

Cause: The robot is currently waiting for Cancel or continue (Wet or Dry) or a HOME input from the PLC.

Remedy: This is a warning to inform the person at the teach pendant that the PLC has been given exclusive control over how

the robot will recover from the current error.

APSH-081 Waiting for Cancel

Cause: The robot is currently waiting for a cancel input from the PLC. The current JOB has had a fault so severe that it cannt

recover and must be aborted or recieve the HOME UOP input

Remedy: This is a warning to inform the person at the teach pendant that the PLC has been given exclusive control over how

the robot will recover from the current error.

APSH-082 No $ERROR_PROG defined

Cause: No $ERROR_PROG has been defined for this JOB. This fault will only appear if the Karel variable

[SLERROR]POST_NO_ERRP is set to TRUE (deault = FALSE).

Remedy: Use the TPE ERROR_PROG command, under Program Control, to set up a Error Program for this JOB. This will

allow the robot to move out of the work area when an error occurs.

APSH-083 No $RESUME_PROG defined

Cause: No $RESUME_PROG has been defined for this JOB.

Remedy: Use the TPE RESUME_PROG command, under Program Control, to set up a Resume Program for this JOB. This

will allow the JOB to resume the interrupted program.

APSH-084 WARNING - simulated I/O

Cause: The robot is running a style program with one or more I/O ports simulated. Unexpected motions and actions may

occur.

Remedy: Verify that all simulated I/O points should be simulated. Un-simulate all I/O ports which should not be simulated.

APSH-090 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Verify that all simulated I/O points should be simulated. Un-simulate all I/O ports which should not be simulated.

APSH-091 %s

Cause: Place holder error, used to keep documentaion for errors from Drastically changing.

Remedy: Verify that all simulated I/O points should be simulated. Un-simulate all I/O ports which should not be simulated.

APSH-092 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-093 %s

Cause: Site-specific alarm caused by changes made for customer

- 36 -

4 . ERROR CODES B-82594EN-6/02

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-094 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-095 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-096 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-097 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-098 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-099 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-100 %s

Cause: Site-specific alarm caused by changes made for customer

Remedy: Please consult FANUC regarding specific changes made for your site.

APSH-110 READ IO parm %s missing

Cause: The READ IO MACRO was called without a parameter that must be entered. READ IO(signal name string, integer

register number)

Remedy: Check the MACRO call in the TP program.

APSH-111 READ IO parm %s is wrong type

Cause: The READ IO MACRO was called with illegal parameters. READ IO(signal name string, integer register number)

Remedy: Check the MACRO call in the TP program.

APSH-112 signal %s does not exist

Cause: The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register

number)

Remedy: Check the MACRO call in the TP program.

APSH-113 can't fetch signal type

Cause: The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register

number)

Remedy: Check the MACRO call in the TP program.

APSH-114 can't fetch signal number

Cause: The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register

number)

Remedy: Check the MACRO call in the TP program.

APSH-115 can't read signal %s

Cause: The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register

number)

Remedy: Check the MACRO call in the TP program.

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B-82594EN-6/02 4 . ERROR CODES

APSH-116 Reg %s could not be set

Cause: Register operation failed

Remedy: Check if the register is defined, if it is between 1-64 and if it has the right value. Must ABORT ALL and retry

APSH-117 Register not defined %s

Cause: This is just a debug message

Remedy: None

APSH-118 WRITE IO parm %s missing

Cause: The WRITE IO MACRO was called without a parameter that must be entered. WRITE IO(signal name string, integer

value to write)

Remedy: Check the MACRO call in the TP program.

APSH-119 WRITE IO parm %s is wrong type

Cause: The WRITE IO MACRO was called with illegal parameters. WRITE IO(signal name string, integer value to write)

Remedy: Check the MACRO call in the TP program.

APSH-120 signal %s does not exist

Cause: The WRITE IO MACRO was called but the signal could not be found. WRITE IO(signal name string, integer register

number)

Remedy: Check the MACRO call in the TP program.

APSH-121 can't write signal %s

Cause: The WRITE IO MACRO was called but the signal could not be found. WRITE IO(signal name string, integer register

number)

Remedy: Check the MACRO call in the TP program.

APSH-122 GET IO PORT parm %s missing

Cause: The GET IO MACRO was called without a parameter that must be entered. GET IO(signal name string, integer port

number)

Remedy: Check the MACRO call in the TP program.

APSH-123 GET IO PORT parm %s is wrong type

Cause: The GET IO MACRO was called with illegal parameters. GET IO(signal name string, integer port number)

Remedy: Check the MACRO call in the TP program.

APSH-124 signal %s does not exist

Cause: The GET IO MACRO was called but the signal could not be found. GET IO(signal name string, integer port number)

Remedy: Check the MACRO call in the TP program.

APSH-125 Forcing Process Enabled

Cause: It was detected that the Process was DISABLED at the start of this production program. A choice (or setup selection)

has indicated that the Process should be FORCED to the enabled state.

Remedy: - Don't choose to FORCE the process enable. - Change Prog Select-Production Check Process ready setup to NOT

Force Condition. - Ensure that Process Enabled input is on at the start of the next production cycle.

APSH-126 %s

Cause: Robot is paused

Remedy: Status message

APSH-127 Repower to activate change.

Cause: The joint velocity limit has changed. This parameter change requires you to cycle controller power in order to take

effect.

Remedy: Turn off the controller, then turn it on again.

APSH-128 Tryout mode enabled

Cause: Tryout mode state has CHANGED from disabled to enabled. This is only a status message, it is not a fault. Note:

tryout mode is a test function - part thickness value is ignored, when tryout mode is enabled.

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4 . ERROR CODES B-82594EN-6/02

Remedy: Disable tryout mode, if desired.

APSH-129 Tryout mode disabled

Cause: Tryout mode state has CHANGED from enabled to disabled. This is only a status message, it is not a fault. Note:

tryout mode is a test function - part thickness value is ignored, when tryout mode is enabled.

Remedy: Enable tryout mode, if desired.

APSH-130 Cannot access FR: %s *.DT files

Cause: Error occurred while accessing the FR: device. No .dt files found.

Remedy: .DT files must exist on the FR: device.

APSH-131 I/O data error: %s

Cause: I/O port defined wrong: Illegal type, Default data is used.

Remedy: .DT file on the FR: device must be corrected.

APSH-132 Selected Prog %s not loaded

Cause: The program name that the shell was requested to run is not loaded on the controller.

Remedy: Check PLC->Robot style communication. Verify that specified Program name was requested by PLC. Load or create

the specified Program program.

APSH-133 Not in safe starting position

Cause: The robot has been jogged away from the position where the teach pendant was enabled.

Remedy: Move the robot back to the position where the teach pendant was enabled, abort the program, or continue (in linear

motion) from position where the robot is currently positioned.

APSH-141 %s

Cause: The robot has been jogged away from the position where the teach pendant was enabled.

Remedy: Move the robot back to the position where the teach pendant was enabled, abort the program, or continue (in linear

motion) from position where the robot is currently positioned.

APSH-142 WARNING - System is in dry run

Cause: This is a warning to notify you that a production job is running with the process disabled.

Remedy: None is required.

APSH-143 Robot motion is not enabled

Cause: Robot motion and/or program execution cannot occur unless UOP input 8 is ON.

Remedy: Check UOP I/O setup. UOP input 8 must be ON.

APSH-144 WARNING - Process Complete manually turned on at end of %s

Cause: A 'Force Process Complete' was performed from the Soft Panel

Remedy: This is just a warning to let the operator know that Process Complete was manually turned on.

APSH-150 Gun operation is NOSTROKE

Cause: A production job is running with the gun set to NOSTROKE.

Remedy: None.

APSH-151 Weld operation is NOWELD

Cause: A production job is running with weld set to NOWELD.

Remedy: None.

APSH-152 Robot mode must be AUTO

Cause: The robot must be in full automatic mode with the PLC before production operation can occur.

Remedy: Go to the SOFT PANEL menu and set Robot mode=AUTO.

APSH-153 Must press SHIFT key too

Cause: The shift key must be pressed when accessing this teach pendant hardkey.

Remedy: Press the shift key.

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B-82594EN-6/02 4 . ERROR CODES

APSH-154 Only one gun defined

Cause: Because the system is currently configured for one equipment with a single gun, there is no need to set the

equiopment that that GUN and BACKUP hardkeys will operate on; they will always operate on the one gun.

Remedy: None is required

APSH-155 HOME position not recorded

Cause: The HOME position has not been recorded yet. The HOME position is contained in Reference Position menu.

Remedy:

1. Go to the SETUP menu.

2. Select Reference Position from the [TYPE] menu.

3. Jog the robot to the HOME position.

4. Record your reference position, and then verify that it is a valid home position.

APSH-156 Specify Home in Ref Pos Menu

Cause: The HOME position has not been recorded yet. The HOME position is contained in Reference Position menu.

Remedy: Go to the SETUP menu, select Reference Position from the [TYPE] menu. Jog the robot to the HOME position.

Record your reference position, then specify it is a valid HOME position.

APSH-157 Teach pendant must be enabled

Cause: The teach pendant must be enabled when accessing this teach pendant hardkey.

Remedy: Enable the teach pendant.

APSH-158 No group output for weld sched

Cause: The group output that contains the weld schedule has not been configured yet.

Remedy: Go to the Weld Intface Output menu, and edit the index of the Weld Schedule I/O point. Make sure the group output

has been properly configured from the Group Output menu. You must cold start the controller when changing this
index, or redefining the group output.

APSH-159 Servos are not ready

Cause: The servos are not ready, so operation requested cannot be performed.

Remedy: When resetting a fault, wait for the servos to click on before attempting to execute a program.

APSH-160 Robot not at POUNCE position

Cause: The robot is not at the POUNCE position, so the operation requested cannot be performed.

Remedy: Re-issue this request when the robot is AT POUNCE.

APSH-161 No production program is running

Cause: The robot is not currently running a production style, so the operation requested cannot be performed.

Remedy: Re-issue the request when the robot is running a production style.

APSH-162 No group output for multi-pressure

Cause: The group output that contains the setting for the multi-pressure valving has not been configured yet.

Remedy: Go to the Spot Equipment Intface Output menu, and edit the index of the Valve pressure I/O point. Make sure the

group output has been properly configured from the Group Output menu. You must cold start the controller when
changing this index, or redefining the group output.

APSH-163 No motion allowed--gun closed

Cause: No motion can occur because the gun is closed. This prevents the user from jogging or running a program while the

gun is closed, and damaging parts and/or tooling.

Remedy: Open the gun.

APSH-164 Home I/O program %s not loaded

Cause: The HOME I/O program as specified from the Cell Setup menu does not exist and was not run.

Remedy: Go to the Cell Setup menu and either check the name of the HOME I/O macro name menu item. Make sure the file

specified exists on the controller. Either create a program by that name or change this menu item to a program that
already exists on the controller.

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4 . ERROR CODES B-82594EN-6/02

APSH-165 Invalid Studgun Selection

Cause: There I/O configuration for the proper studwelding gun has not been initialized.

Remedy: Proceed to the Spot Equipment I/O setup screen and configure the digital inputs Gun Present = On/Off, Gun in Nest

= On/Off for the 2 stud guns. Proper configuration if gun 1 is on the robot is for Gun 1 (Gun Present = ON, Gun in
Nest = OFF and for Gun 2 (Gun Present = OFF, Gun in Nest = ON. Proper configuration if gun 2 is on the robot is
for Gun 1 (Gun Present = OFF, Gun in Nest = ON and for Gun 2 (Gun Present = ON, Gun in Nest = OFF.

APSH-166 Studgun Change Unsuccessful

Cause: The robot was aborted or interrupted during the studgun change sequence.

Remedy: Manually change the stud guns and move the robot to the home position. Press cycle start to run production.

APSH-167 Move robot home & cycle start

Cause: The stud gun change program was interrupted.

Remedy: To resume production the robot must be manually returned home and cycle start must be pressed to continue.

APSH-168 No GO for EQP pressure

Cause: The group output that contains the setting for the equalization pressure has not been configured yet.

Remedy: Go to the Spot Equipment Intface Output menu, and edit the index of the Equal pressure I/O point. Make sure the

group output has been properly configured from the Group Output menu. You must cold start the controller when
changing this index, or redefining the group output.

APSH-169 Uninitialized Stud Macros

Cause: A macro program to dropoff or pickup studgun 1 or 2 has not been initialized.

Remedy: Proceed to Spot Equipment Menu under MENUS-SETUP and initialize the studwelding macros which will only

appear if STUD BACKUP is ENABLED at CONTROLLED START.

APSH-170 Check Nest/Changer Inputs

Cause: The inputs on the studwelder nest do not appear to be set up correctly.

Remedy: Verify on the Spot Equip I/O menu that the Head in Nest inputs are set up correctly.

APSH-171 HOME_IO has not completed running

Cause: HOME_IO has not completed successfully, so new program cannot be ran.

Remedy: Check HOME_IO and see if it is looping on some I/O.

APSH-174 SCR overtemp detected

Cause: An SCR overtemp signal has been received.

Remedy: Check the SCR for overheating.

APSH-175 Req. Press. Not mapped for WC:%s

Cause: The Request Pressure digital input is not mapped.

Remedy: Map request pressure input on Weld Interface Menu.

APSH-176 GIN For Weld Press. Not mapped for WC:%s

Cause: The GIN for Weld Pressure is not mapped.

Remedy: Map Weld Pressure pressure input on Weld Interface Menu.

APSH-177 Read Press. Not mapped for WC:%s

Cause: Read pressure input is not mapped on weld interface Menu.

Remedy: Map read pressure input on Weld Interface Menu.

APSH-178 Map I/O in Weld Interface Menu

Cause: There is not cause, this is a help code

Remedy: No rememdy required.

APSH-179 Upd. Press. timeout WC:%s

Cause: The weld controler did not set Read Pressure input in time.

Remedy: Check if weld controler is functioning correctly, or increase Weld Pres time-out at CTRL start menu.

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B-82594EN-6/02 4 . ERROR CODES

APSH-180 Could not communicate to WC.

Cause: Could not read any I/O from the Weld controller. Device may be offline.

Remedy: Check if weld controler is functioning correctly, or powered on.

APSH-201 Automatic Collision Recovery

Cause: Automatic Collision recovery is beginning.

Remedy: None.

APSH-202 Recovery Program not found

Cause: Automatic Collision recovery was attempting to run the recovery program.

Remedy: Make sure the program is loaded, and retry the operation.

APSH-203 Error running %s

Cause: The task could not run or continue.

Remedy: Check the associated error message for the task error and follow the recovery procedure.

APSH-204 Running recovery prog %s

Cause: Automatic Collision recovery is about to run the recovery program.

Remedy: None.

APSH-205 Running original prog %s

Cause: Automatic Collision recovery is about to run the original program.

Remedy: None.

APSH-206 Invalid Group Specified

Cause: The group specified to get_home does not exist.

Remedy: Verify the specified group number exists, and retry the operation.

APSH-207 Invalid Ref Pos Specified

Cause: The reference position specified to get_home.

Remedy: Verify the specified Reference position exists.

APSH-208 Failed to check %s

Cause: This error is related to production setup check screen. This item should not be checked on the present configuration.

Remedy: Press F6,REDO and cycle power to update items.

APSH-209 Fault Disabled: single cycle.

Cause: This is a warning message to log that the user chose to disable fault checking for one cycle.

Remedy: None.

APSH-210 Fault Disabled: multiple cycles.

Cause: This is a warning message to log that the user chose to disable fault checking for multiple cycles.

Remedy: None.

4.1.3 ARC Alarm Code

ARC-001 Illegal arc equipment config

Cause: An attempt was made to add or use more equipment than permitted.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-002 Illegal arc schedule number (%s^4,%d^5)

Cause: An arc instruction contained an illegal schedule number.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-003 No gas flow (%s^4,%d^5)

Cause: No gas flow was detected during an arc start.

Remedy: Check if weld controler is functioning correctly, or powered on.

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4 . ERROR CODES B-82594EN-6/02

ARC-004 Gas flow after weld (%s^4,%d^5)

Cause: The gas fault input was not ON after the gas output was set to OFF.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-005 Gas fault (%s^4,%d^5)

Cause: A gas fault input was detected during welding.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-006 Wire fault (%s^4,%d^5)

Cause: A wire fault input was detected during welding.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-007 Water fault (%s^4,%d^5)

Cause: A water fault input was detected during welding.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-008 Power supply fault (%s^4,%d^5)

Cause: A power fault input was detected during welding.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-010 Wire stick detected (%s^4,%d^5)

Cause: A wire stick has occured.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-011 Wire stick, not reset (%s^4,%d^5)

Cause: A wirestick was detected and wirestick reset was not performed. Wirestick reset may be disabled. Wirestick reset is

not done during TIG welding or if welding is stopped by turning weld enable off.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-012 Wire stick reset(s) failed (%s^4,%d^5)

Cause: A wirestick was detected and the automatic wirestick reset failed to break the wirestick.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-013 Arc Start failed (%s^4,%d^5)

Cause: The arc detect input did not stabilize during an arc start.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-014 Teach pendant is disabled

Cause: The weld enable or a wire inch hardkey was pressed with the teach pendant enable switch OFF.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-015 Press shift with this key

Cause: The weld enable or a wire inch hardkey was pressed without holding the shift key.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-016 Weld by Shift FWD is disabled

Cause: A program executing from the teach pendant attempted an Arc Start with welding from the teach pendant disabled.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-017 Arc Start was disabled (%s^4,%d^5)

Cause: An Arc Start instruction was executed with welding disabled.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-018 Lost arc detect (%s^4,%d^5)

Cause: The arc detect signal was lost during a weld.

Remedy: Check if weld controler is functioning correctly, or powered on.

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B-82594EN-6/02 4 . ERROR CODES

ARC-019 Can't read arc detect input (%s^4,%d^5)

Cause: The arc detect input could not be read.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-020 No plan data area available

Cause: Insufficient memory exists to plan an arc instruction.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-021 Program aborted while welding (%s^4,%d^5)

Cause: A program was aborted while welding.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-022 Weld AO scaling limit used (%s^4,%d^5)

Cause: The programmed analog output is beyond the equipment limits.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-023 Illegal arc schedule type (%s^4,%d^5)

Cause: The arc instruction register is not an integer type.

Remedy: Check if weld controler is functioning correctly, or powered on.

ARC-024 Invalid equipment range

Cause: The equipment min to max range is too small.

Remedy: Enter new min or max values for the equipment.

ARC-025 Invalid A/D or D/A range

Cause: The binary range data for the A/D or D/A is too small.

Remedy: Modify the correct system variable fields within $AWEPRR.

ARC-026 Cannot scale AIO while welding

Cause: An analog scaling limit was modified while welding. The scaling was not changed.

Remedy: Turn off the controller and turn it on again.

ARC-030 Wire stick is still detected (%s^4,%d^5)

Cause: A wire stick is still detected after a system RESET.

Remedy: Secure the robot and equipment. Cut the wire.

ARC-031 No motion while welding (%s^4,%d^5)

Cause: Motion has stopped longer than $arc_los_tim while welding.

Remedy: If no motion is needed during welding, increase the arc loss time in the Weld Equipment SETUP screen or disable arc

loss detection in the Weld System SETUP screen.

ARC-032 Weld stopped by single step (%s^4,%d^5)

Cause: Welding was stopped by entering single step mode after welding began.

Remedy: To continue welding you must exit single step mode.

ARC-033 Override must be 100%% to weld (%s^4,%d^5)

Cause: The speed override is less than 100%.

Remedy: Set the speed override to 100% to weld or disable welding to continue at a low speed.

ARC-034 Task does not control welding (%s^4,%d^5)

Cause: A task which does not have weld control attempted to execute an Arc Start or an Arc End instruction. Only one task is

permitted to have weld control.

Remedy: Allow the task which has weld control to end or abort before attempting to weld with another task.

ARC-035 Equipment number isn't set (%s^4,%d^5)

Cause: The arc instruction does not have the equipment number

Remedy: Please set the equipment number to the program attribute data or the arc instruction

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4 . ERROR CODES B-82594EN-6/02

ARC-036 Such equipment mask isn't supported (%s^4,%d^5)

Cause: An attempt was made to add or use more equipment than permitted.

Remedy: Please set the equipment number to the program attribute data or the arc instruction

ARC-037 Another equipment is inching now

Cause: Another equipment is wire inching now.

Remedy: Please stop wire inching for another equipment by releasing the shift key or user key

ARC-038 Already held another equipment (%s^4,%d^5)

Cause: This program( task ) has already held the another equipment A task can only use a equipment.

Remedy: Please control the equipment by the another task

ARC-039 %s^1 AO[%d^2] is not scaled (%s^4,%d^5)

Cause: The named weld analog output signal is not scaled properly.

Remedy: Adjust the weld analog output scaling in the Weld I/O screen using the CONFIG function key.

ARC-040 EQ%d^1 Missing I/O: %s^2

Cause: The named weld I/O signal is not detected or configured properly.

Remedy: Verify the I/O hardware is connected and the signal is assigned a port number in the Weld I/O screen. Use the

CONFIG function key if the signal is unassigned.

ARC-041 Weld EQ needs DeviceNet option

Cause: The weld equipment has been configured to use DeviceNet by setting the fields $VENDOR_ID, $DEV_TYPE, and

$PROD_CODE in the system variable $AWEPRR to non-zero values. However, the DeviceNet option is not
installed.

Remedy: Add the DeviceNet option or choose a weld equipment model which does not require DeviceNet. If the weld

equipment model is correct and does not require DeviceNet then set the $AWEPRR fields mentioned above to zero
and cycle power.

ARC-042 Weld EQ needs Expl Msg option

Cause: The weld equipment has been configured to use DeviceNet by setting the fields $VENDOR_ID, $DEV_TYPE, and

$PROD_CODE in the system variable $AWEPRR to non-zero values. However, the Explicit Messaging option is not
installed.

Remedy: Add the Explicit Messaging option or choose a weld equipment model which does not require DeviceNet. If the weld

equipment model is correct and does not require DeviceNet then set the $AWEPRR fields mentioned above to zero
and cycle power.

ARC-043 Weld EQ needs DeviceNet board

Cause: The weld equipment has been configured to use DeviceNet by setting the fields $VENDOR_ID, $DEV_TYPE, and

$PROD_CODE in the system variable $AWEPRR to non-zero values. However, DeviceNet hardware was not
detected.

Remedy: Add DeviceNet hardware or choose a weld equipment model which does not require DeviceNet. If the weld

equipment model is correct and does not require DeviceNet then set the $AWEPRR fields mentioned above to zero
and cycle power.

ARC-044 Weld EQ needs DeviceNet defn.

Cause: The weld equipment has been configured to use DeviceNet by setting the fields $VENDOR_ID, $DEV_TYPE, and

$PROD_CODE in the system variable $AWEPRR to non-zero values. A DeviceNet device definition could not be
found for that product.

Remedy: You can add a DeviceNet definition for this product or if the weld equipment you are using does not support

DeviceNet you can set the $AWEPRR fields mentioned above to zero and cycle power.

ARC-045 Weld EQ Device is OFFLINE

Cause: ArcTool attempted to communicate with the Welding Equipment using the DeviceNet network, but could not because

the link was not properly established.

Remedy: Verify the Weld Equipment is ON. Verify the DeviceNet cable is connected. Check the DeviceNet I/O screen board

status and device status.

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B-82594EN-6/02 4 . ERROR CODES

ARC-046 Weld EQ communication error

Cause: There was a communication error detected between ArcTool and the Weld Equipment.

Remedy: Verify the Weld Equipment is ON. Verify the DeviceNet cable is connected. Check the DeviceNet I/O screen board

status and device status.

ARC-047 Not allowed during a weld

Cause: An operation was attempted which is not permitted while a weld is executing or paused.

Remedy: Try the operation after the program ends or is aborted.

ARC-048 Auto AI/O setup is unsupported

Cause: Auto AI/O setup for the mounted I/O module is not supported. So parameters are not set automatically.

Remedy: Verify mounted I/O module and set system variables of $AWEPRR[] in system variable screen manually if need.

ARC-049 Process %d switch to %d failed

Cause: ArcTool failed to switch weld processes.

Remedy: The weld power supply may be OFF, unconnected, or data in the second process may be incorrect.

ARC-050 Process %d NOT found

Cause: ArcTool failed to find this process on the weld power supply.

Remedy: Enter a different number or use the SEARCH parameters and function key.

ARC-051 Weld EQ%d ONLINE: %s

Cause: ArcTool is communicating with the weld power supply. The version number of the power supply is shown.

Remedy: This message is for notification and information. It does not indicate a problem.

ARC-052 Bad %s %s Prc %d

Cause: The indicated parameter is out of range.

Remedy: Enter a number within range.

ARC-053 No ramp at process switch (%s^4,%d^5)

Cause: Ramping is not allowed when switching weld processes.

Remedy: Complete the process switch first, then ramp with another arc start instruction.

ARC-054 No motion while arc welding

Cause: A weld was automatically shutdown because motion had stopped while welding longer than the time specified in

$awsemgoff.$chk_time. This feature is intended to protect the welder from accidentally burning through a part.

Remedy: You can increase the $awsemgoff.$chk_time to allow a longer welding time without motion. You can also disable this

feature by setting $awsemgoff.$nofltr_off = FALSE. Both changes require you to turn off the controller then turn it on
again.

ARC-055 No sync Eq (%s^4,%d^5)

Cause: An Arc Start instruction specified synchronizing with an Equipment that is not also doing an Arc Start.

Remedy: Determine why the sync Equipment is not starting, or do not use synchonization.

ARC-056 Invalid sync (%s^4,%d^5)

Cause: An Arc Start instruction specified synchronizing with an Equipment that is not also synchronized.

Remedy: Check the synchronization equipment number specified in the Arc instruction or in the specified weld schedule

SYNCDT detail menu. Refer to the Arc Start Synchronization section in the FANUC ArcTool Operator's Manual.

ARC-057 Cannot ramp t1=%d > t2=%d

Cause: The Arc process ramping cannot execute because the delay (t1) to communicate with the welder is larger than the

ramping loop time (t2). This might occur with ramping or HeatWave $awwv_mode 2.

Remedy: Increase $aweramp[eq].$time_factor by 1.

ARC-058 Wire stick is still detected

Cause: A wire stick is still detected after a system RESET.

Remedy: Secure the robot and equipment. Cut the wire.

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4 . ERROR CODES B-82594EN-6/02

ARC-072 Illegal AMR packet

Cause: Internal error.

Remedy: Sometimes this error requires cycling the controller power.

ARC-084 Application process is changed during welding

Cause: Application is changed during welding.

Remedy: Please change the program.

ARC-085 Incomplete of conversion factor setup

Cause: Imcomplete the analog signal conversion factor.

Remedy: Please set it.

ARC-086 Invalid of binary data in conversion factor

Cause: The binary data($AWEPRR.$io_min/max_bin) is invalid. The difference is zero.

Remedy: Please set correct value.

ARC-087 Invalid conversion factor data

Cause: The conversion factor data is invalid. It must be filled more than 2 tables at least. But the value of the second table is

zero.

Remedy: Please set conversion factor more than 2 tables

ARC-088 Over selected AO factor No.

Cause: The selected number of AO conversion factor data is over the number of the actual data array

Remedy: Please select the correct number of AO conversion factor data

ARC-090 Weld disable by reason[%d]

Cause: In this situation, the welding is disalbled by the following reason 1: In Single step mode 2: In Machine lock mode 3:

In Dry run mode 4: No I/O board exist 5: No I/O assignment for welding 6: In Flush AMR status 7: In Application
disabled mode 8: In Arc disabled status 9: In Skip welding status 10: In disable status mode by AWDBG

Remedy: Please remove the specified reason to perform the welding.

ARC-091 Arc End cannot ramp to position (%s^4,%d^5)

Cause: An Arc End weld schedule specified a time of 99.0 seconds. This time value is sometimes used with Arc Starts to

indicate ramping during an entire motion. This type of ramping is not available for an Arc End. A time of 99.0
seconds for an Arc End craterfill time is very long and is not recommended. If a long time is needed then 98.0
seconds will work without this error.

Remedy: Use a different weld schedule for the Arc End or change the time value to a smaller value.

ARC-100 SVT: Unsupported Wire material

Cause: The selected wire material is not supported for Servo Torch.

Remedy: Please select the correct wire materal.

ARC-101 SVT: Unsupported Wire size

Cause: The selected wire size is not supported for Servo Torch.

Remedy: Please select the correct wire size.

ARC-102 SVT: Unsupported speed unit

Cause: The selected unit of inching speed is not supported for Servo Torch.

Remedy: Please select the correct unit of inching speed

ARC-103 SVT: WFS conversion failed

Cause: Failed to convert weld schedule to wire feed speed command for Servo Torch.

Remedy: If another alarm is also occured at the same time, please check it and remove the cause of the alarm. If no other alarm

is occured, some internal error is occured.

ARC-104 SVT: Invalid sequence mode

Cause: Internal error. Invalid sequence mode command is sent to Servo Torch.

Remedy: Internal error. Cycle power to recover.

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B-82594EN-6/02 4 . ERROR CODES

ARC-105 Cannot read WSTK input signal

Cause: Cannot received WSTK signal from serial communication power supply.

Remedy: Confirm which type of weld equip is used. Confirm the connection with serial communication power supply. Confirm

the setting of serial port.

ARC-106 Config of Roboweld is invalid

Cause: Configuration of Roboweld was invalid. So data for Robowelds were set inappropriately.

Remedy: Remove all Robowelds by selecting other equip in weld equip select screen. Then select and setup Roboweld again,

if you want to use Roboweld.

ARC-107 Roboweld internal Error(%d)

Cause: RoboWeld internal error.

Remedy: Cycle power to recover.

ARC-120 Enable/Disable Sim mode failed

Cause: The necessary signals for Simulation mode cannot be detected.

Remedy: Verify that AI/O and WDI/O signals are assigned appropriately.

ARC-121 Weld not performed(Sim mode)

Cause: Simulation mode is enabled. Actual welding is not performed.

Remedy: None.

ARC-122 Cannot SIM/UNSIM(%s,Id:%d)

Cause: I/O signals were not set to sim/unsim appropriately when Simulation mode was enabled/disabled.

Remedy: Verify that the AI/O and WDI/O signals are assigned appropriately.

ARC-123 Memory size is too small

Cause: The memory size is too small to get the memory area for the necessary data.

Remedy: Change the memory module into the one which has appropriate size, and perform an INIT start.

ARC-124 EQ%d E:%d %s

Cause: The weld equipment has reported an error.

Remedy: Refer to the weld equipment manual for more information.

ARC-125 Cannot start stitch in a weld

Cause: An Arc Stitch instruction was executed while welding. Stitch welds begin with an Arc Stitch and end with an Arc

End. Arc Stitch cannot execute between Arc Start and Arc End.

Remedy: Edit the program so the Arc Stitch instruction is not between an Arc Start and Arc End.

ARC-126 Bad stitch weld or pitch length

Cause: An Arc Stitch instruction could not execute because the stitch weld length or the pitch length were invalid or the

stitch weld length was larger than the pitch length.

Remedy: Modify the stitch weld length or pitch length. $aweupr[eq].$st_weld_len or $aweupr[eq].$st_ptch_len

ARC-127 Cannot change stitch schedules

Cause: An Arc Stitch instruction could not execute because a stitch weld was already executing. Stitch welds cannot include

weld schedule changes.

Remedy: Edit the program so the Arc Stitch instruction does not follow an Arc Stitch.

ARC-128 J motion during stitch weld

Cause: Joint motions are not permitted in a Stitch Weld.

Remedy: Edit the motion type.

ARC-140 MCC I/O parameter wrong(E:%d, %d)

Cause: Setup parameter for MMC I/O assignment are wrong.

Remedy: Check the parameters

- 48 -

4 . ERROR CODES B-82594EN-6/02

ARC-141 MCC stick detected(E:%d)

Cause: The MCC was stuck but has been turned ON.

Remedy: Check the MCC .

ARC-142 MCC monitor abnormal(E:%d)

Cause: MCC is OFF even though the MCC request is ON.

Remedy: Check the MCC and signal line for MCC.

ARC-143 Power supply/feeder com alarm(E:%d)

Cause: In the power supply, the communication between the operation board and the control board was disconnected.

Remedy:

1. Check the fuses [For feeder: 3A(FU2)/8A(FU3)]. If the fuses were blown, please perform the following remedy.
Change the encoder cable and fuses Change the encoder board in the wire feeder, and change fuses.

2. Change the Gabana board.

3. Change operation board in the welding power supply.

ARC-144 PS internal com-error(E:%d)

Cause: In Power supply, the communication alarm between GABANA CPU and Main CPU occured.

Remedy: Cycle power of the power supply by pressing E-STOP then pressing RESET.

ARC-145 PS internal abnormal com-data(E:%d)

Cause: In the Power supply, the communication data between GABANA CPU and Main CPU was abnormal.

Remedy: Cycle power of the power supply by pressing E-STOP then RESET.

ARC-146 Can't use Pulse in CO2(E:%d)

Cause: In CO2 setup, you cannot use Pulse mode.

Remedy: Set pulse mode to disabled in the weld schedule detail menu. If you use the direct command AS instruction, AS[20V,

200A], the pulse mode is always ON. So use the AS instruction with the weld schedule number.

ARC-147 Can't use Pulse in this setup(E:%d)

Cause: In CO2 setup, you cannot use Pulse mode.

Remedy: Set pulse mode to disabled in the weld schedule detail menu. If you use the direct command AS instruction, AS[20V,

200A], the pulse mode is always ON. So use the AS instruction with the weld schedule number.

ARC-148 Can't use Pulse in CO2

Cause: In CO2 setup, you cannot use Pulse mode.

Remedy: Set pulse mode to disabled in the weld schedule DETAIL menu. If you use the direct command AS instruction,

AS[20V, 200A], the pulse mode is always ON. Therefore, use the AS instruction with the weld schedule number.

ARC-149 Can't use Pulse in this setup

Cause: In CO2 setup, you cannot use Pulse mode.

Remedy: Set pulse mode to disabled in the weld schedule detail menu. If you use the direct command AS instruction, AS[20V,

200A], the pulse mode is always ON. So use the AS instruction with the weld schedule number.

ARC-150 Invalid op. in weld(0x%X)(E:%d)

Cause: Detect invalid signal operation in welding.

Remedy: Reset and try again after Arc OFF.

ARC-151 Invalid wire size(E:%d)

Cause: Detect invalid wire size.

Remedy: Set proper wire size.

ARC-152 Invalid weld process(E:%d)

Cause: Detect invalid welding process.

Remedy: Set proper welding process.

ARC-153 Invalid wire material(E:%d)

Cause: Detect invalid wire material.

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B-82594EN-6/02 4 . ERROR CODES

Remedy: Set proper wire material.

ARC-154 Invalid Arc Loss Time(E:%d)

Cause: Arc loss time is invalid range.

Remedy: Set proper arc loss time.

ARC-155 Comm. Timeout(E:%d)

Cause: Communication with RoboWeld power source is timeout.

Remedy: Confirm port setup and connection cable.

ARC-156 RoboWeld Error(0x%X, %d)

Cause: RoboWeld internal error.

Remedy: Please call FANUC service.

ARC-157 Receive error(0x%X)(E:%d)

Cause: Receive invalid data from Power Source.

Remedy: Confirm noise environment and cable.

ARC-158 1st currency (E:%d)

Cause: Detect 1st currency abnormal.

Remedy: Check currency.

ARC-159 2nd currency (E:%d)

Cause: Detect 2nd currency abnormal.

Remedy: Check currency.

ARC-160 Temperature alaram(E:%d)

Cause: Detect temperature abnormal.

Remedy: Check overload.

ARC-161 High voltage(E:%d)

Cause: Detect high voltage.

Remedy: Check voltage.

ARC-162 Low voltage(E:%d)

Cause: Detect low voltage.

Remedy: Check voltage.

ARC-163 Start signal error(E:%d)

Cause: Detect start signal abnormal.

Remedy: Check start signal.

ARC-164 Power source error(E:%d)

Cause: Detect 3-phase power source abnormal.

Remedy: Check 3-phase power source.

ARC-165 EQ is detached(E:%d)

Cause: RoboWeld is detached.

Remedy: Confirm port setup.

ARC-166 Comm. stopped in weld(E:%d)

Cause: Communication with RoboWeld power source stopped in welding.

Remedy: Confirm another error message and port, cable setup.

ARC-167 I/O asginment overlap(%d)(E:%d)

Cause: I/O space for RoboWeld is already in use.

Remedy: Confirm another I/O device and $IO_START in $RBWLD.

- 50 -

4 . ERROR CODES B-82594EN-6/02

ARC-168 I/O error(%d)(%d, E:%d)

Cause: I/O initialization error.

Remedy: Confirm another I/O device and $IO_START in $RBWLD.

ARC-169 Invalid wire op.(E:%d)

Cause: An invalid wire FWD/BWD operation was detected.

Remedy: Confirm the wire control sequence.

ARC-170 Detect Arc OFF(E:%d)

Cause: Detect ARC off.

Remedy: Confirm welding device and workpiece status.

ARC-171 Unified data RCV error(%d,0x%X)(E:%d)

Cause: Failed to receive unified data.

Remedy: Confirm port setup, noise environment, cable status.

ARC-172 Warning, Rcv(0x%X)(E:%d)

Cause: Receive invalid command from power source.

Remedy: Confirm noise environment, cable setting.

ARC-173 Warning, Retry(0x%X)(E:%d)

Cause: Retry to send the command to power source.

Remedy: Confirm noise environment, cable setting.

ARC-174 Warning, NAK for(0x%X)(E:%d)

Cause: Receive NAK from power source.

Remedy: Confirm noise environment, cable setting.

ARC-175 Signal change is ignored(E:%d)

Cause: Communication with power source is stopped.

Remedy: Confirm welding setup, cable connection, then reset.

ARC-176 No sysvar $RBWLD for E:%d

Cause: Sysvar $RBWLD is not setup for new EQ number.

Remedy: Confirm $RBWLD and $RBWLD_CFG setup.

ARC-177 RoboWeld(E:%d) reset complete

Cause: RoboWeld reset sequence is complete.

Remedy: Arc welding is now available.

ARC-179 Power supply com alarm(E:%d)

Cause: This alarm occurs when communication between the welding equipment control board and the robot controller stops.

Remedy:

1. If this alarm occurred with ARC-143, please perform the remedy for ARC-143.

2. If this alarm is still occurred after restarting the system, check the wiring between the controller and welding
power supply. If problem is not found, check the power supply control board.

ARC-180 Gabana alarm(E:%d)

Cause: Wire feeder motor speed is over the limited speed.

Remedy: Check the wire feeder motor. After check try the operation again. If the same alarm occurs, document the events that

led to the error and call your FANUC or FANUC Robotics technical representative.

ARC-181 Encoder alarm(E:%d)

Cause: Wire feeder motor sensor line was connected off or wire feeder motor did not rotate correctly.

Remedy: Check the wire feeder motor sensor line. After check try again. If the same alarm occurs, inform of the service.

ARC-182 Motor alarm(E:%d)

Cause: While the motor should stop, the motor rotation was detected.

- 51 -