Fanuc Renishaw Inspection Plus

Renishaw Inspection Plus is a suite of probing macros installed on Fanuc CNC controls. Cycles are called via G65 P98xx and handle protected positioning, measurement, calibration, and tool offset updates. Results are stored in common variables #135–#149; calibration data lives in #500–#541.

Cycle Quick Reference

Cycle	Name	Format
Calibration
`O9801`	Probe Length Calibration	`G65 P9801 Zz Tt`
`O9802`	Stylus X/Y Offset Calibration	`G65 P9802 Dd [Zz]`
`O9803`	Stylus Ball Radius Calibration	`G65 P9803 Dd [Zz Ss]`
`O9804`	Vector Ball Radius Calibration	`G65 P9804 Dd [Zz Ss]`
Positioning
`O9810`	Protected Positioning	`G65 P9810 Xx Yy Zz [Ff Mm]`
Standard Measuring
`O9811`	Single Surface (X, Y, or Z)	`G65 P9811 Xx\|Yy\|Zz [opts]`
`O9812`	Web / Pocket	`G65 P9812 Xx\|Yy [Zz] [opts]`
`O9814`	Bore / Boss	`G65 P9814 Dd [Zz] [opts]`
`O9815`	Internal Corner	`G65 P9815 Xx Yy [opts]`
`O9816`	External Corner	`G65 P9816 Xx Yy [opts]`
Vector Measuring (requires O9804)
`O9821`	Angle Single Surface	`G65 P9821 Aa Dd [opts]`
`O9822`	Angle Web / Pocket	`G65 P9822 Aa Dd [Zz] [opts]`
`O9823`	3-Point Bore / Boss	`G65 P9823 Aa Bb Cc Dd [Zz] [opts]`
Additional Cycles
`O9817`	4th Axis X Measurement	`G65 P9817 Xx Zz [opts]`
`O9818`	4th Axis Y Measurement	`G65 P9818 Yy Zz [opts]`
`O9819`	Bore/Boss on PCD	`G65 P9819 Cc Dd Zz\|Kk [opts]`
`O9820`	Stock Allowance	`G65 P9820 Xx\|Yy\|Zz Ii Jj Kk [opts]`
`O9834`	Feature-to-Feature	`G65 P9834 [Xx Yy Zz Aa Dd] [opts]`
`O9835`	SPC Tool Offset Update	`G65 P9835 Tt Mm [opts]`
`O9843`	XY Plane Angle Measure	`G65 P9843 Xx\|Yy Dd [opts]`

Common Optional Inputs

Most measuring cycles accept these optional letter-address inputs:

Input	Description	Notes
`H h`	Tolerance on feature dimension	Exceeding triggers `#3006` alarm
`M m`	True position tolerance (cylindrical zone)	Evaluated as radial error
`Q q`	Overtravel distance	Default: 4 mm (Z), 10 mm (X/Y)
`S s`	Work offset number to update	S1–S6 = G54–G59; S7–S48 = extended
`T t`	Tool offset number to update	Adjusts wear offset register
`W w`	Print data (DPRNT)	W1. = feature #; W2. = component #
`E e`	Experience value	Spare tool offset # storing adjustment
`F f`	Percent feedback	0–1 fraction for tool offset update
`U u`	Upper tolerance limit	No offset update if exceeded
`V v`	Null band	Dead zone—no offset if error within this range
`R r`	Radial clearance (external features)	Default 5 mm. `R-r` = force internal

Cycle Input Arguments

O9810 — Protected Positioning

Monitors probe trigger signal during positioning moves. If the probe trips (collision), machine stops immediately with #3000 = 86(PATH OBSTRUCTED).

Input	Req?	Description
`X x`	Yes	Target X position
`Y y`	Yes	Target Y position
`Z z`	Yes	Target Z position
`F f`	Modal	Feedrate for all protected moves (stays set until changed)
`M m`	Opt	M1. = flag mode: sets `#148 = 7` on trigger instead of alarm

O9811 — Single Surface Measurement

Measures one surface in X, Y, or Z. Only one axis per call.

Input	Req?	Description
`X x` / `Y y` / `Z z`	One required	Nominal surface position
Plus common optional inputs: H, M, Q, S, T, W, E, F, U, V

O9812 — Web / Pocket Measurement

Measures a web (external) or pocket (internal) in X or Y. Omit Z for pocket; include Z for web.

Input	Req?	Description
`X x` / `Y y`	One required	Nominal feature size in X or Y
`Z z`	Opt	Absolute Z for web (external). Omit = pocket.
`R r`	Opt	Radial clearance for external. R-r = force internal.
Plus common optional inputs: H, M, Q, S, T, W, E, F, U, V

O9814 — Bore / Boss Measurement

Four-touch measurement (X+, X−, Y+, Y−). Omit Z for bore; include Z for boss.

Input	Req?	Description
`D d`	Yes	Nominal diameter of feature
`Z z`	Opt	Absolute Z for boss (external). Omit = bore.
`R r`	Opt	Radial clearance for boss. R-r = force internal.
Plus common optional inputs: H, M, Q, S, T, W, E, F, U, V

What a bore measurement touches: O9814 probes X+, X−, Y+, Y− from the bore center — the touch positions give the center (#135, #136), their spread gives the size (#138).

Calibration Cycles

Cycle	Required Inputs	Purpose
`O9801`	`Z z` (ref surface), `T t` (tool offset #)	Calibrate probe length
`O9802`	`D d` (bore diameter), opt `Z z` for external	Calibrate X/Y stylus offsets → `#502`, `#503`
`O9803`	`D d` (gauge diameter), opt `Z z`, `S s`	Standard ball radius → `#500`, `#501`
`O9804`	`D d` (gauge diameter), opt `Z z`, `S s`	Vector ball radius → `#500`–`#501` + `#510`–`#517`

Calibration order: O9801 (length) → O9802 (X/Y offsets) → O9803 or O9804 (ball radius). Use O9804 if you will use vector cycles (O9821/O9822/O9823).

Calibration Variables

Stored in persistent common variables #500–#541. These survive power-off.

Variable	Name	Description
`#500`	XRAD	X calibration ball radius
`#501`	YRAD	Y calibration ball radius
`#502`	XOFF	X-axis stylus offset
`#503`	YOFF	Y-axis stylus offset
`#506`	BMCF	Back-off distance (basic move control factor)
`#509`	—	Active vector radius (for O9821/O9822/O9823)
`#510`–`#517`	VRAD	Vector calibration radii at 30° intervals (30°, 60°, 120°, 150°, 210°, 240°, 300°, 330°)
`#518`–`#521`	K1	Multi-stylus K1 store (XRAD, YRAD, XOFF, YOFF)
`#522`–`#525`	K2	Multi-stylus K2 store
`#526`–`#533`	K11	Vector multi-stylus K11 store
`#534`–`#541`	K12	Vector multi-stylus K12 store

Skip Signal & Internal Variables

Renishaw macros use G31 (skip signal) internally. When the probe contacts the workpiece, the position is captured in system variables:

Variable	Description
`#5061`	Skip signal X position (machine coords at probe contact)
`#5062`	Skip signal Y position
`#5063`	Skip signal Z position

Standard two-touch measuring: fast approach → back-off → slow gauge move at 100 mm/min. Measuring uncertainty ≈ 0.002 mm at 4 ms PLC scan time.

Error & Alarm Handling

`#148` — Out-of-Tolerance Flag

Value	Meaning	Offset Update?
0	No error	—
1	OUT OF TOL / OUT OF POS / ANGLE OUT OF TOL	Yes (after cycle start)
2	OUT OF POS	Yes (after cycle start)
3	UPPER TOL EXCEEDED	No
4	ANGLE OUT OF TOL	Yes (after cycle start)
5	DIA OFFSET TOO LARGE	Yes (after cycle start)
6	EXCESS STOCK	No
7	Probe triggered (O9810 flag mode)	—

`#3000` Reset Alarms (Program Stop)

Alarm #	Message	Cause
86	PATH OBSTRUCTED	Probe triggered during O9810 move
88	NO FEED RATE	O9810 called without F input
89	NO TOOL LENGTH ACTIVE	G43/G44 not active before probe cycle
91	FORMAT ERROR / INPUT MISSING	Required input not supplied or conflicting inputs
92	PROBE OPEN	Probe already triggered before move (stylus in contact)
93	PROBE FAIL	Probe did not trigger during move (surface not found)

`#3006` Cycle-Start-to-Continue Alarms

These pause execution; press cycle start to continue:

Message	Condition
OUT OF TOL	Feature size outside H tolerance
OUT OF POS	Position outside M true position tolerance
ANGLE OUT OF TOL	Angle outside B tolerance
UPPER TOL EXCEEDED	Exceeds U upper tolerance (no offset update)
EXCESS STOCK	Stock exceeds U limit (no offset update)

Output Variables by Cycle

All measuring cycles write results to #135–#149. Variables #148 (out-of-tolerance flag) and #149 (probe error flag) are set by every cycle.

O9811 — Single Surface

Var	Output
`#135`	X position
`#136`	Y position
`#137`	Z position
`#140`	X error
`#141`	Y error
`#142`	Z error
`#145`	True position error
`#146`	Metal condition
`#147`	Direction indicator

O9812 — Web / Pocket

Var	Output
`#135`	X position
`#136`	Y position
`#138`	Size
`#140`	X error
`#141`	Y error
`#143`	Size error
`#145`	True position error
`#146`	Metal condition

O9814 — Bore / Boss

Var	Output
`#135`	X position
`#136`	Y position
`#138`	Size (diameter)
`#140`	X error
`#141`	Y error
`#143`	Size error
`#145`	True position error
`#146`	Metal condition

O9815 — Internal Corner

Var	Output
`#135`	X position
`#136`	Y position
`#138`	Size
`#139`	X surface angle
`#140`	X error
`#141`	Y error
`#142`	Y surface angle
`#143`	Y angle error
`#144`	X angle error
`#145`	True position error

O9816 — External Corner

Var	Output
`#135`	X position
`#136`	Y position
`#139`	X surface angle
`#140`	X error
`#141`	Y error
`#142`	Y surface angle
`#143`	Y angle error
`#144`	X angle error
`#145`	True position error

O9817/O9818 — 4th Axis

Var	Output
`#135`	X position (O9817)
`#136`	Y position (O9818)
`#139`	4th axis angle
`#143`	Height error (Z1−Z2)
`#144`	Angle correction

O9819 — PCD Bore/Boss

Var	Output
`#135`	X position
`#136`	Y position
`#137`	PCD
`#138`	Size (diameter)
`#139`	Angle
`#140`	X error
`#141`	Y error
`#142`	PCD error
`#143`	Size error
`#145`	True position error
`#146`	Metal condition
`#147`	Hole number

O9820 — Stock Allowance

Var	Output
`#144`	Maximum value (metal)
`#145`	Minimum value (metal)
`#146`	Variation (stock allowance)

O9821 — Angle Single Surface

Var	Output
`#135`	X position
`#136`	Y position
`#140`	X error
`#141`	Y error
`#143`	Size error
`#145`	True position error
`#146`	Metal condition

O9822 — Angle Web / Pocket

Var	Output
`#135`	X position
`#136`	Y position
`#138`	Size
`#140`	X error
`#141`	Y error
`#143`	Size error
`#145`	True position error
`#146`	Metal condition
`#147`	Direction indicator

O9823 — 3-Point Bore / Boss

Var	Output
`#135`	X position
`#136`	Y position
`#138`	Size (diameter)
`#140`	X error
`#141`	Y error
`#143`	Size error
`#145`	True position error
`#146`	Metal condition

O9834 — Feature to Feature

Var	Output
`#135`	X incremental distance
`#136`	Y incremental distance
`#137`	Z incremental distance
`#138`	Minimum distance
`#139`	Angle
`#140`	X error
`#141`	Y error
`#142`	Z error
`#143`	Min distance error
`#144`	Angle error
`#145`	True position error
`#146`	Metal condition

O9843 — XY Angle Measure

Var	Output
`#139`	Measured angle
`#143`	Height error
`#144`	Angle error

Worked Example: Measure a Bore and Act on the Result

This program probes a 25 mm bore with O9814, copies the outputs into user common variables before the next cycle overwrites #135–#149, and stops the machine with a #3000 alarm if the diameter is out of tolerance. The manual branch shown here is the DIY alternative to passing an H tolerance input, which would raise the #3006 OUT OF TOL alarm for you.

O0100 (MEASURE 25MM BORE AND ACT ON RESULT)
(ASSUMES PROBE IS CALIBRATED - O9801, O9802, O9803 COMPLETE)
T20 M6                            (LOAD THE SPINDLE PROBE)
G54 G90 G0 X0 Y0                  (RAPID OVER NOMINAL BORE CENTER)
G43 H20 Z100.                     (TOOL LENGTH ACTIVE - ALARM 89 IF OMITTED)

(PROTECTED POSITIONING - A PROBE TRIP RAISES 86 PATH OBSTRUCTED)
G65 P9810 X0 Y0 Z10. F3000.       (PROTECTED MOVE TO CLEARANCE - F IS MODAL, ALARM 88 IF NEVER SET)
G65 P9810 X0 Y0 Z-8.              (PROTECTED PLUNGE TO MEASURING DEPTH INSIDE THE BORE)

(FOUR-TOUCH BORE MEASUREMENT - NO Z WORD, SO THE FEATURE IS A BORE)
G65 P9814 D25.                    (MEASURE 25.0 MM NOMINAL BORE)

(COPY OUTPUTS BEFORE THE NEXT CYCLE OVERWRITES #135-#149)
#101 = #138                       (MEASURED DIAMETER)
#102 = #135                       (MEASURED CENTER X)
#103 = #136                       (MEASURED CENTER Y)
#104 = #143                       (SIZE ERROR = MEASURED - NOMINAL)

(TOLERANCE BRANCH - ACCEPT +/- 0.05 MM ON DIAMETER)
IF [ABS[#104] LE 0.05] GOTO 100   (IN TOLERANCE - CARRY ON)
#3000 = 100 (BORE DIA OUT OF TOL) (HARD STOP - OPERATOR MUST INVESTIGATE)

N100 (MEASUREMENT ACCEPTED)
G65 P9810 X0 Y0 Z100.             (PROTECTED RETRACT TO CLEARANCE)
M30

To also correct a work offset from the same measurement, add S to the O9814 call (e.g. S1 updates G54 with the measured center error) — and check #148 afterwards if you run with alarms suppressed.

References

Renishaw, Inspection Plus Programming Manual, Renishaw plc.
Fanuc, Operator’s Manual / Parameter Manual, FANUC Corporation.