106

Identify the exact N-block number where the alarm occurred and review all macro variable calculations (#100-#999 ranges) in that block and preceding blocks.

Check for division operations where the divisor approaches zero (e.g., #100=#101/#102 where #102 is very small or zero), as this creates extremely large results.

Review all conditional statements to ensure division operations have zero-check protection (IF[#102 NE 0] THEN...).

Verify multiplication operations involving multiple large values or repeated multiplication loops that compound variable values beyond limits.

Add range-checking logic before calculations (e.g., IF[ABS[#100] GT 1000000] THEN #3000=100) or break large calculations into smaller incremental steps with intermediate validation.

Search the macro program for trigonometric functions (SIN, COS, TAN, ATAN, ASIN, ACOS) and SQRT operations near the alarm point.

Verify ASIN and ACOS input values are within -1.0 to +1.0 range; check SQRT inputs are non-negative; confirm ATAN divisor arguments don't create undefined conditions.

SQRT of negative values or inverse trig functions with out-of-range inputs will cause immediate overflow.

Review coordinate transformation calculations where angles are derived from position ratios that might produce invalid trigonometric inputs due to dimensional errors.

Add input validation before function calls (e.g., IF[#110 LT 0] THEN #110=0 before SQRT[#110]) and limit intermediate calculation results to safe ranges.

Examine macro calculations that compute X, Y, Z axis positions or G54-G59 work offset values, especially those involving scaling, rotation matrices, or polar-to-rectangular conversions.

Check for accumulated errors in loop-based calculations where position increments compound over many iterations (e.g., #100=#100+#101 repeated 1000+ times).

Floating-point accumulation errors in long loops can unexpectedly exceed limits.

Verify work coordinate system origin calculations don't place the working envelope outside allowable machine coordinate space (typically -99999.999 to +99999.999 mm/inch).

Implement boundary checking on all calculated position values before assignment to axis variables, and validate input parameters from operator macro variables (#500-#999 range) are reasonable.