Bullseye Robot calibration error

Robot Controller IRC5
1

Good day all.

I am trying to set up a different length weldgun on an IRB2600. I have been told this robot has always had issues with the TCP goes and no one has been able to fix it. But I would like to try.

When I run the BEToolSetup the tool straightening always fails and I get the following error:

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I have checked the fine calibration values and they match up to the sticker on the robot. I also checked the revolution counters. all seems to look fine.

We are running a safety controller and the sync position is setup using the bullseye as the switch. When I run the bullseye I get an SC1 wrong sync position, which I understand why that warning would come up. I am wandering if this is perhaps what is causing the calibration to fail?
Has anyone else got their robot configured this way or would it be better for me to run a separate switch for the safety controller?
(As far as I have been told, ABB did the original configuration this way in 2013)

I have also tried to define the tool by teaching the 4 points and the z elongator - After doing this when I rotate the torch around the TCP it moves off the reference pointer by at least 15mm.

Thanks in advance.

2

One thing leaps to mind; Even though the control and manipulator values match the robot may not have been correctly calibrated by the ABB factory. You may wish to consider having the system calibrated by a technician.

3

Move all axis to zero and Check revolution counters.
Is robot on marks ?

4

Is there a n*360° issue on that robot type too as on 1600 or 140?
(when making a revolution counter update on these with axis 4 turned 360° from normal position, you will get a valid update, but the tcp will not go on a straight line anymore - you have to try an update 360° plus/minus from your current position)