I have two robots one is a very old fanuc p-120 the other is a 50ib/10L they paint parts that are on an over head conveyor which is hooked up to an encoder and trigger switch for line tracking. So the first rack hits the encoder switch and the first robot starts to track the part. After 12" it runs a tack paint program. The second robot is supposed to start tracking at 3250 mm from the switch. it tries to move to that tracking position and i get a motn-23 error that the position cant be reached.
last week everything was fine then power went out and i had to reinstall from an image and remaster the robot. At first i thought the robot mastering was off but i have a a HOME program with motions that works fine, a purge program with motions and and a simple test part program that works fine. The main job program does not though... Here is where it gets weird.
So when I'm running the controller in T2 and I step into the motions program I get a yellow screen that comes up and tells me i have to sync with the line once per teach session I hit NO and the program opens up and i step the teach pendant into the first point and It tries to touch a point 180 degrees x axis the opposite direction of what its supposed to. So i exit out of the program and go back in and on the yellow screen I hit yes this time. Then another screen asks me to stop the line to sync so I stop the line in the area Marked where it should track start the line and the motions program opens, I run the teach pendant to the first point and this time it goes the right direction But it stretches out beyond its reach to try and track the part. so i back the x axis up 100 mm and start the program again and it works i get 300 lines of motions and its good. The program loops to the beginning and i get the same error and it tries to reach a point it cannot reach. Even adjusting the points it wont touch any of them. even ones that should be in front of the robot.
So i exit the program again and re open it, Same yellow pop up that asks me to sync to the line and i say no i run to the first point in the program and the robot moves in the right direction but tries to touch a point out of its reach. and wont touch a point in the motions that's right in front of the robot that i know it should reach. close out and reopen and when i say no not to sync on the pop up window and run the program to the first point its again 180 degree mirror image off from what it should be.
Now before, I could open this motions program, the yellow screen would come up asking me to sync it and i always said no and it would open the lines of motions and i could run through them all no problem. It would even track with the parts. Even when i said yes and synced it to the line i didn't have problems. what's the deal now?
Things i have tried to fix the problem:
1. I measured the distance from the encoder switch to where the robot is to track and it is a reachable position.
2. checked mastering to make sure it was right.
3. Other programs work fine.
Is there a setting that's turned on somewhere messing with the tracking?
Is it possible my encoder is messed up somehow (it works fine for the first robot)?
Maybe my boundaries are off? if so how do i set them
Can some one help me with a step I must be missing thanks