FOCAS Troubleshooting

Troubleshooting

Connection Issues

Problem: Machine won't connect or test connection fails

Diagnostic Steps:

1. Verify Physical Connection

   • Check Ethernet cable is securely plugged in
   • Verify cable is not damaged
   • Check LED lights on port (should show link/activity)

2. Verify IP Configuration

   • Confirm IP address matches what's configured in MachineMetrics
   • Ensure machine IP and Edge IP are on same subnet
   • Example: Machine 192.168.1.100, Edge 192.168.1.50 ✓
   • Example: Machine 192.168.1.100, Edge 192.168.2.50 ✗

3. Test Network Connectivity

   • From Edge device or computer on same network
   • Ping machine IP address
   • If ping fails: network/cable problem
   • If ping succeeds but FOCAS fails: protocol issue

4. Verify FOCAS Port

   • Check parameter 8193 TCP is configured
   • Not 8192, 8194, or other port
   • Verify FOCAS2 settings on control

5. Check Embedded Port Selection

   • Press SYSTEM → EMBDD → OPRT
   • Verify "AVAILABLE DEVICE" = EMBEDDED (not PCMCIA)
   • If wrong, press PCMCIA/EMBDD soft key → EXECUTE → Reboot

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Pinging from the Control (Testing Network from the CNC)

The FANUC embedded Ethernet maintenance screen lets you send a PING directly from the CNC control to any IP address on the network. This is the most reliable way to confirm whether the control can reach the Edge device — it rules out cable faults, wrong port selection, and misconfigured IPs in one step.

Procedure:

1. Press SYSTEM function key
2. Press [EMBED PORT] soft key (press the continue key if it isn't visible)
3. Press [PING] soft key, then press [(OPRT)]
4. To ping a specific IP address, enter the destination address on the PING setting screen (use page keys to switch between the address entry page and the status page)
5. Enter a repeat count (e.g., 4)
6. Press [PING] — the specified number of PING commands are sent and the result is displayed
7. To cancel a ping in progress, press [PING CANCEL]

You can also ping pre-configured FTP destinations directly:

• [PING FTP1] — pings FTP connection destination 1
• [PING FTP2] / [PING FTP3] — pings FTP destinations 2 or 3

Interpreting results:

• Successful replies → the control can reach that IP; if FOCAS still fails, the issue is the port number or protocol configuration
• No reply / timeout → network or cable problem; check the cable, switch, and IP/subnet settings
• If the control can't ping the Edge device but the Edge can ping the control → check for a one-way firewall rule on the Edge device

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Checking Communication Status (Packet Errors and Port Activity)

The COM STATE screen shows whether the embedded Ethernet port is actively sending and receiving data and whether errors are accumulating. Use this to detect packet collisions, excessive retransmits, or a dead port.

Procedure:

1. Press SYSTEM function key
2. Press [EMBED PORT] soft key
3. Press [COM STATE] soft key

The screen displays sending and receiving state. Use the page keys to switch between the send state page and the receive state page.

What to look for:

• If counters are incrementing during a known-good connection period → the port is live and passing data
• If send counters are incrementing but receive counters are zero → control is transmitting but nothing is coming back; check Edge-side connectivity
• If error counts are high relative to total frames → network quality issue (bad cable, too much traffic, or the control is on a busy factory network)

Note: FANUC recommends isolating the CNC from the factory-wide network using a router or separate subnet. A high-traffic environment can overload the CNC's communication stack even when no active communication is targeted at it.

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Checking Task State (Is FOCAS Running?)

The TASK STATE screen shows whether each embedded Ethernet service is running or waiting. Use this to confirm FOCAS2 is active and hasn't faulted.

Procedure:

1. Press SYSTEM function key
2. Press [EMBED PORT] soft key
3. Press [TASK STATUS] soft key

FOCAS2 #0 states:

Symbol	Meaning
C	Waiting for a connection from the host — normal idle state
W	Data processing in progress (phase 1)
D	Data processing in progress (phase 2)
N	FOCAS2 out of service — restart Ethernet or power cycle

• C is the healthy idle state — the control is listening for a connection on port 8193
• N means FOCAS2 has stopped; try the [RSTART] soft key (EMBED PORT → COMMON → OPRT → RSTART) to restart the embedded Ethernet without a full power cycle
• If RSTART doesn't fix it, power cycle the machine

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Viewing the Ethernet Error Log

The embedded Ethernet log screen records every communication error with a timestamp. Check this when a connection drops intermittently or was never established.

Procedure:

1. Press SYSTEM function key
2. Press [EMBED LOG] soft key (press the continue key if not visible)
3. The newest error appears at the top; timestamp format is MMM.DD hh:mm:ss
4. Filter by function using soft keys: [ALL], [COMMON], [FOCAS2], [FTP TRANS]
5. To clear the log: press [(OPRT)] → [CLEAR]

Common error codes and actions:

Error	Message	Action
E-0118 / E-0119	Error occurred while waiting for FOCAS2 PDU	Cable disconnected, Edge-side software closed connection, or network quality degraded
E-011A	All communication paths are busy	Up to 5 FOCAS2 clients can connect — check for other software holding connections
E-0A06	Network is too busy	Too much traffic on the subnet; isolate the CNC on its own switch or VLAN
E-0900 / E-0901	Cannot read MAC address	Hardware fault on the embedded Ethernet port
E-0B00	Own IP address is wrong	IP address format is invalid — re-enter in COMMON screen
E-0B01	Own IP address is not set	No IP address configured — set IP in COMMON screen
E-0B02 / E-0B03	Subnet mask wrong / not set	Configure subnet mask in COMMON screen
E-0B04	Router IP address is wrong	Class mismatch between machine IP and router IP
E-0B08	TCP port number is wrong	Port outside valid range (5001–65535); reset to 8193
E-0B19	Embedded Ethernet port isn't found	Software or hardware of embedded Ethernet cannot be recognized — check parameter 14880 and verify hardware
E-0207	Router is not found	Router IP is wrong or router is off
E-0208	FTP server is not found	FTP server IP is wrong or server is off (not relevant for FOCAS)

Alarm SR2032 ("EMBEDDED ETHERNET / DATA SERVER ERROR"): If this alarm appears during communication, open the log screen immediately to read the specific error code and timestamp before the log is overwritten.

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No Data Appearing

Problem: Connection succeeds but no data shows in MachineMetrics

Solutions:

1. Wait for Initial Sync

   • Allow 5-10 minutes for first data to appear
   • Refresh browser/app

2. Check Machine Status

   • Verify machine is powered on
   • Machine may need to be in AUTO or MDI mode
   • Some data only appears when machine is running

3. Verify Data Mapping

   • Go to Assets → Machines → [Your Machine] → Data Mapping
   • Ensure critical data items are mapped
   • Check for unmapped items in available list

4. Request Edge Device Logs

   • Edge device logs are not viewable in the app
   • Contact MachineMetrics Support to have them pulled and checked for connection errors

5. Restart Adapter

   • Edit machine configuration
   • Save (even without changes) to restart adapter
   • Wait a few minutes and check again

Part Count Issues

Problem: Part counts not incrementing or incorrect

⚠️ CRITICAL FIRST STEP: Verify Machine is Counting Parts

Before troubleshooting MachineMetrics configuration, verify the machine itself is incrementing its internal part counter.

MachineMetrics reads the machine's native part counter. If the machine isn't counting parts, MachineMetrics cannot report them. Without additional scripting or configuration, MachineMetrics relies entirely on the machine's internal part count signal.

Check Machine Part Counter:

1. Look at the machine's control screen
2. Find the part counter display (usually on main screen or program screen)
3. Run a cycle or manually execute M30/M02
4. Verify the counter increments on the machine itself

If the machine counter is NOT incrementing:

• This is a machine configuration issue, not a MachineMetrics issue
• Machine is not configured to count parts
• See steps below to configure part counting on the machine

If the machine counter IS incrementing but MachineMetrics shows zero:

• This is a MachineMetrics configuration issue
• Continue to diagnostic steps below

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Diagnostic Steps:

1. Verify Part Count Method on Machine

   • Check parameters 6700 and 6710
   • Confirm M-code configuration
   • Test manually in MDI (see Testing Part Count section)

2. Check Data Mapping in MachineMetrics

   • Ensure part count data item is mapped
   • Type should be "Part Count"
   • Check both "Actual" and "Target" if using both

3. Verify Program Has Count Command

   • Check your CNC program includes M30, M02, or custom M-code
   • For looping programs: Ensure count command before M99

4. Test Count Manually on Machine

   • Put machine in MDI
   • Set overrides to zero
   • Execute count command (M30 or your M-code)
   • Check parameter 6711 increments on the machine
   • If it increments, wait 30 seconds and check MachineMetrics

5. Macro Variable Issues (if using #3901)

   • Verify Macro B option is enabled on control
   • Check syntax: #3901=#3901+1
   • Ensure macro is configured in adapter

Network Problems

Problem: Intermittent connection or frequent disconnects

Solutions:

1. Check Cable Quality

   • Replace Ethernet cable
   • Use CAT5e or CAT6 rated cable
   • Avoid cables near high-voltage lines or motors

2. Verify Network Stability

   • Check for network congestion
   • Verify DHCP isn't reassigning IP addresses
   • Use static IP instead of DHCP if possible

3. Check Port Sharing

   • If using unmanaged switch to share port: Verify switch is powered and working
   • Ensure other devices aren't monopolizing bandwidth

4. EMI/RFI Interference

   • Machine electrical noise can affect communication
   • Use shielded Ethernet cable
   • Route cable away from motor drives and high-power equipment

5. Control Restart Issues

   • Some controls lose network config on power cycle
   • Verify settings persist after restart
   • May need to save settings to memory

Third-Party Tool Load Monitoring

Problem: Connection fails or experiences intermittent dropouts when the machine runs third-party tool load monitoring software

Some machines run third-party tool load monitoring or adaptive control software that maintains a persistent FOCAS connection to the control. This can cause connectivity conflicts with MachineMetrics if both systems are trying to use the same Ethernet interface.

Why This Happens:

The embedded Ethernet port (CD38A / CD38S) typically supports only one simultaneous FOCAS connection. If third-party software is already holding that connection, MachineMetrics will fail to connect or experience intermittent dropouts. The Fast Ethernet option board (CD38R), by contrast, supports up to 10 simultaneous connections.

Recommended Approach:

Scenario	Recommendation
Machine has a Fast Ethernet board (CD38R)	Move the third-party tool load monitoring software to the Fast Ethernet board. Use the embedded port for MachineMetrics, or run both on the Fast Ethernet board since it supports multiple connections.
Machine only has an embedded port (CD38A/CD38S)	Do not attempt to share the embedded port between MachineMetrics and the third-party software. Use a Digital I/O device for MachineMetrics data collection instead.

Important: If the third-party software is already running on the embedded port and that is the only Ethernet interface available, adding MachineMetrics to the same port can cause connectivity issues for both systems and may interfere with the third-party software's functionality. In this situation, Digital I/O is the recommended alternative for MachineMetrics connectivity.