PS111

At the MDI panel, press SYSTEM > ALARM to identify the exact program block (O-number and N-sequence) where PS111 occurred. Note the macro variable numbers involved.

Press OFFSET/SETTING > MACRO to view current macro variable values. Check variables #100-#999 (common) and #500-#999 (system) for excessively large values exceeding ±10^12 range.

Review the macro program calculation logic at the alarm block. Look for unconstrained multiplication loops, exponential functions [#i=#j**#k], or cumulative addition without bounds checking. Insert conditional statements [IF[#i GT 999999999]GOTO...] to limit variable range.

Backup the original macro program to memory card before editing. Parameter 3202 bit 6 must be 1 to enable macro variable editing.

After correcting calculation logic, reset alarm with RESET key, verify parameter 6000-6009 (macro variable preserve settings) if variables need initialization, then re-execute the program in single block mode (SINGLE BLOCK key ON).

At the alarm screen (SYSTEM > ALARM), identify the macro program line. Press EDIT > PROGRAM to open the macro program and locate the calculation statement.

Check for division operations where denominator variables could be zero. Go to OFFSET/SETTING > MACRO and verify the values of divisor variables. Add protective logic: IF[ABS[#k]LT 0.001]THEN #k=0.001 before division.

For SQRT, SIN, COS, ATAN, LN functions, verify input variable ranges are valid. Check parameter 6004-6007 (macro variable data type settings) to confirm variable initialization state.

Empty (null) macro variables default to zero. Parameter 6008 bit settings control null variable behavior during calculations.

Add error-checking logic before mathematical operations: IF[#i LT 0]GOTO(error_handling_block). Reset alarm with RESET key and test program with known good input values.

Navigate to SYSTEM > PARAM and check parameter 3202 (macro program control). Verify bit 0=1 (custom macro enable), bit 5 setting for variable range limits. Record current settings.

Changing parameter 3202 requires power cycle (PWE parameter - set parameter 0000#7=1 for write enable).

Check parameters 6000-6009 for macro variable configuration. If values appear abnormal, restore from backup via SYSTEM > PMC > I/O > PARAMETER or reload parameter file from memory card (CF card/USB).

Initialize suspect macro variables: In MDI mode, manually reset critical common variables by entering #100=0 (etc.) or use G65 initialization macro. Check DIAGNOSIS > MACRO to verify variable states.

If corruption persists, backup all data and perform macro variable clear: Set parameter 6001 bit settings to clear ranges, power cycle the control. Re-validate macro program execution after variable initialization.

Clearing macro variables will erase all stored production data in #100-#999 range. Ensure critical values are documented before proceeding.