On an ABB IRB2600, repeated BEToolSetup tool-straightening failure and a taught TCP that departs from a reference pointer by at least 15 mm indicate that the problem extends beyond the new weldgun geometry. Verify the manipulator calibration state before accepting another tool definition. The reported SC1 wrong sync position may be related to the Bullseye being used as the safety-controller synchronization switch, but the available evidence does not establish it as the cause of the BEToolSetup failure.
Separate the Observed Faults
| Observation | What it establishes | What remains unknown |
|---|---|---|
| BEToolSetup tool straightening fails | The automatic setup cannot complete with the current robot and tool state. | The exact error shown in the referenced image is unavailable. |
| SC1 wrong sync position occurs during Bullseye operation | The safety controller does not accept the observed position as its configured synchronization position. | No evidence proves that SC1 causes the tool-straightening failure. |
| Four-point plus Z-elongator definition misses the pointer by at least 15 mm during rotation | The resulting TCP does not remain stationary at the reference point. | The evidence does not isolate tool teaching, revolution-count alignment, or mechanical calibration as the cause. |
Verify Robot Calibration Before Re-Teaching the Tool
- Move every robot axis to zero and compare the physical robot calibration marks. A revolution-counter check is incomplete if it confirms only that stored values appear valid.
- Confirm that the fine-calibration values in the controller match the robot sticker. This check was already completed, but matching values alone do not prove that the manipulator was physically calibrated correctly.
- Review the axis 4 revolution-counter relationship. A reported diagnostic hypothesis is an n × 360-degree offset: a revolution-counter update can appear valid while the axis is one full turn from the intended calibration relationship. Check the present position against the calibration marks before considering an update at the corresponding plus-or-minus 360-degree position.
- If the robot is not on its marks at zero, or uncertainty remains after the axis 4 check, stop tool calibration and have the manipulator calibration verified by a qualified ABB technician.
Do not change revolution counters solely to make BEToolSetup pass. Establish the physical axis-to-mark relationship first, because an incorrect update can preserve apparently valid counter data while corrupting Cartesian motion.
Evaluate the Safety Synchronization Independently
The installation uses the Bullseye as the switch for the safety-controller synchronization position, and Bullseye operation produces SC1 wrong sync position. Treat that event as a separate configuration issue until testing establishes a causal link. Record the robot position expected by the safety controller and the position at which the Bullseye switch changes state; the evidence does not provide enough information to declare the shared switch configuration valid or to require a separate switch.
Resolve or document the SC1 condition before repeating calibration so that a safety synchronization rejection cannot obscure the result. Do not bypass the safety controller or alter its synchronization configuration without the required safety validation.
Repeat Tool Definition and Verify the TCP
After confirming the robot calibration state, rerun BEToolSetup for the different-length weldgun. If automatic straightening still fails, repeat the four-point and Z-elongator tool definition, then place the calculated TCP at the reference pointer and rotate the torch around it. The TCP should remain coincident with the pointer; recurrence of the reported 15 mm-or-greater displacement means the tool result is not acceptable.
If both methods fail after the robot is confirmed on its calibration marks, escalate with the BEToolSetup error display, calibration-mark observations, fine-calibration data, revolution-counter history, SC1 event context, and measured TCP displacement. These records distinguish a tool-teaching problem from manipulator calibration or safety-synchronization issues.
FAQ
Can SC1 wrong sync position make ABB BEToolSetup fail?
The evidence confirms that SC1 occurs when the Bullseye operates, but it does not prove that SC1 causes the BEToolSetup failure. Diagnose the safety synchronization and robot/tool calibration as separate issues until a controlled retest establishes the relationship.
Why does an ABB TCP move away from the pointer during rotation?
A TCP that moves at least 15 mm after a four-point and Z-elongator definition is not acceptable. Check all axes on their zero marks, verify the fine-calibration data, and investigate a possible full-turn axis 4 revolution-counter offset before teaching the tool again.
Do matching ABB fine-calibration values prove the IRB2600 is calibrated?
No. Matching controller values and robot-sticker values confirm data consistency, but they do not prove that the manipulator is physically aligned; move all axes to zero and verify the calibration marks.