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RCS/System frames sanity check failed

Error ID: 2107
Platform: Process Simulate

During calibration, the Connector compares two motion sources:

  • motion generated by Process Simulate, and
  • motion simulated by the robot controller via RCS.

If the two do not align – for example, a Jump/Move test ends in a different pose (e.g. more than ~0.1 rad per joint difference) – the check concludes that:

  • the system frames used in Process Simulate and on the controller are misaligned, or
  • the RCS robot model in Process Simulate does not match the real controller configuration.

This mismatch can lead to incorrect calibration results and invalid exported operations, so Resolver gives the user the option to stop the process.

What this error means​

This error indicates that the reference frames used for the calibration path in Process Simulate are not consistent with the frames that the controller (via RCS) expects.

Typical root causes include:

  • different base / user / workobject frames between PS and the real controller,
  • offsets applied in Process Simulate but not configured on the controller (or the other way around),
  • incorrect mounting data (robot base, tool frame) in PS or in the RCS model,
  • using the wrong system frame during the calibration test.

As long as this mismatch exists, any calibration or exported operations relying on these frames may be inaccurate.

How to fix it (step-by-step)

Follow the steps below to resolve the error safely.

1. Identify which calibration step failed​

  1. Note when the message appears (e.g. during Jump/Move test, at the end of calibration, etc.).
  2. Check which robot and which calibration routine you were running.
  3. If available, capture screenshots of:
    • the Resolver popup,
    • the calibration dialog in Process Simulate.

This will help you understand which frames are involved (base, tool, workobject).

2. Verify tool and base data in Process Simulate​

  1. In Process Simulate, open the Robot Properties or the tool mounting configuration.
  2. Confirm that:
    • the robot base position/orientation matches the real cell layout,
    • the mounted tool (TCP) corresponds to what is configured on the real controller,
    • there are no additional offsets that are not present in the controller configuration.
  3. Correct any discrepancies and save the station.

3. Check controller / RCS system frames​

On the real controller (or in the virtual controller used by RCS):

  1. Review the tool frame (TCP) and user/base/workobject frames used for the calibration move.
  2. Make sure they correspond exactly to the frames you use in Process Simulate:
    • same origins and orientations,
    • same active frame numbers,
    • no extra offsets that PS is unaware of.
  3. If necessary, update:
    • the controller’s frames to match PS, or
    • the PS station to reflect the real controller data (whichever is the single source of truth in your project).

4. Confirm the correct frame is active in the calibration path​

In Process Simulate:

  1. Open the operation used for the calibration path.
  2. Check which base / workobject / user frame is active for the targets in this operation.
  3. Ensure that:
    • this is exactly the same frame you intend to use on the controller,
    • there is no mix of different frames along the path.

If needed, reassign the correct system frame to all targets in the calibration operation.

5. Re-run the calibration sanity check​

After aligning frames:

  1. Restart the RCS connection if required (to make sure it picks up any changed data).
  2. Run the Jump/Move or calibration test again from Process Simulate.
  3. Observe whether the final pose of:
    • PS-generated motion and
    • RCS-simulated motion
      now matches within the expected tolerance.

If they do, the error will no longer appear and you can safely continue with calibration and export.

When is it safe to proceed despite this warning?​

In general, you should not ignore this error for production work, because it indicates a real mismatch between PS and controller frames.

You may proceed only if:

  • you are running a one-off test in a non-production environment, and
  • you understand and accept that the calibration result may be inaccurate, and
  • you will not use the resulting motions directly on a real robot without further validation.

For any project that will be deployed on hardware, fix the frame mismatch first.

Summary​

  • The error indicates that PS-generated motion and RCS-simulated motion diverge during calibration.
  • The root cause is almost always inconsistent system frames (tool/base/user/workobject) between Process Simulate and the controller.
  • To fix it:
    • align tool and base data in PS and on the controller,
    • verify that the same system frame is active in both environments,
    • re-run the calibration sanity check.
  • Once frames are consistent, the sanity check passes and Resolver can rely on the calibration and exported operations.