Resolving FANUC Robocut M60 Alarm 078: Macro Program Reload Guide

Problem Overview

The FANUC ROBOCUT wire EDM platform (including the Alpha 1iA, C400i-B, and AC600iB series) uses custom M-code macros to drive auxiliary functions such as automatic wire threading (re-threading), flush control, and wire-cut condition sequencing. One of the most frequently encountered failures on these machines is Alarm 078, raised when the controller encounters an M60 call without a valid target sub-program identifier (P-address).

Field symptoms typically reported by operators:

• Program graphs/alarms out at the M60 block during dry-run or verify.
• No alarm raised when M60 is executed from the MDI/pendant directly (because the system bypasses sub-program resolution in some cases).
• Wire re-threading fails to initiate even when the Automatic Wire Feed (AWF) parameters are populated.
• Alarm text: "NO P IN A SUB-PROGRAM M98 OR M99" displayed on the Robocut HMI.

Affected Platforms and Firmware

The M60 macro sub-program issue has been confirmed on the following ROBOCUT controllers in the field:

FANUC operator documentation reference number B-85434EN/05 covers the C-generation ROBOCUT manuals set; B-series documentation is also distributed on CD-ROM for legacy machines.

Root Cause: Missing M60 Macro Program

The M60 code on a ROBOCUT is a macro call, not a fixed G/M-code function. It invokes a customer-macro or system-macro sub-program (designated by the P-address, e.g., M60 P9010) that contains the wire-thread sequence: tension release, reverse-jet flush, wire feed rate ramp, and cut recovery. If the target macro program file (O9010.nc or similar) is missing from the controller's program memory or from the CF card root, the M98/M99 sub-program resolver returns Alarm 078 because the P-designator cannot be resolved to an existing program number.

Common environmental causes that lead to this state:

1. PCMCIA / CF card swap or formatting that erased the \PROG\ directory containing the macro files.
2. Memory-allocation (common variable NVBUF / program-number pool) overflow that purged the system macros.
3. Control board battery replacement on an un-backed-up machine (BR-AGC / 4LR44 cell expired).
4. FACTOLINK file-transfer session that overwrote the macro directory tree.
5. Restoration from a partial backup that contained part programs but excluded the _MAC_ system folder.

Diagnostic Procedure

Confirm the root cause before reloading macros. Use this matrix to isolate the fault:

Solution: Reload the M60 Macro Programs

The corrective action is to reload the FANUC-supplied macro program files into the control. Use the procedure below, which mirrors the field-proven sequence published by Methods EDM for the C-generation machines.

Prerequisites

• Backup of all current part programs to CF card or PC.
• Source media containing the macro program set (USB, CD-ROM, or FACTOLINK repository). Original media is typically shipped as part of the ROBOCUT documentation set, document number B-85434EN/05.
• RS-232 / Ethernet FOCAS or FACTOLINK connectivity if transferring over network.
• Parameter K0.0 (write-protect) set to 0 to allow macro upload.

Step-by-Step Reload Procedure

1. Place the control in MDI mode and clear the active alarm by pressing RESET.
2. Navigate to the program directory: SYSTEM → PROGRAM → CARD (or MEM if files are already on CF card).
3. Insert the source CF card / USB drive containing the macro file set. Verify the directory shows the _MAC_ folder with files such as O9001.nc, O9002.nc, ... O9015.nc.
4. For each macro file, select the file and press READ to copy it into controller SRAM. Confirm the screen reads READ OK.
5. Repeat for all macros referenced in the alarm 078 P-code listing. Common M60 targets include:

   O9001  – Wire tension release
   O9002  – Reverse-jet flush
   O9010  – M60 main threading macro
   O9011  – Wire feed ramp
   O9012  – Cut-recovery sequence
   O9013  – AWF enable / disable

6. After loading, set the active program number to the first loaded macro (O9010) and press GRAPH to verify parsing — no alarm 078 should be raised.
7. Return to AUTO mode, run the original part program with the M60 block — alarm should be cleared and the threading sequence should execute.

Transfer via FACTOLINK (PC-Based)

For machines using FACTOLINK version 6.2 (TCP ports 9000 and 9010 by default), the macros can be pushed from the host PC:

1. Launch FACTOLINK on the Windows host (XP / legacy Windows supported; modern Windows requires the FOCAS driver set, not FACTOLINK).
2. Connect to the controller IP on port 9000.
3. Browse to \PROG\_MAC_\ and select all O9xxx.nc files.
4. Use SEND → CONTROL to push macros. The transfer window should show END for each file.
5. Cycle power on the controller to commit the macro programs to non-volatile memory.

Verification

After the macro reload, run these checks in order:

1. Alarm clear — HMI shows no active alarm; ALARM HISTORY shows the 078 event timestamped.
2. MDI threading — From MDI, execute M60 standalone. Wire re-threading should complete in the expected time (typically 8–25 s depending on wire diameter and machine class).
3. Program simulation — Run the part program with the M60 block in GRAPH mode. No alarm at the M60 line.
4. Auto-cycle test — Run a short test part on the machine with a real wire break after the start block. Confirm auto re-threading fires and resumes the cut at the correct path coordinate.
5. Backup — Once verified, immediately back up the full \PROG\ tree including the _MAC_ folder to a labeled CF card and to the network backup share.

Parameter Reference

Confirm the Automatic Wire Feed (AWF) and threading-related parameters per the B-85434EN/05 manual before assuming a hardware fault. Common parameters to verify:

Troubleshooting Matrix

Preventive Maintenance

• Schedule a quarterly backup of the full \PROG\ tree, including the _MAC_ folder, to a labeled CF card stored off-machine.
• Replace the SRAM backup battery every 2 years or per FANUC's service interval.
• Maintain a golden image of the macro program set (MD5-checked) on the maintenance network share.
• Avoid running FACTOLINK file-purge operations without first exporting macros.
• After any control-board replacement, request the full macro library from FANUC service or the machine OEM (Methods EDM is a common channel for North America).

Related FANUC ROBOCUT Resources

For additional context on the wire-re-thread architecture and the supported controller options, refer to the official FANUC ROBOCUT product page:

• FANUC ROBOCUT Wire EDM – Product Overview – describes the reliable re-threading in the wire path feature that is implemented by the M60 macro on most C-generation and later machines.

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