Download Section 16: Troubleshooting
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Fadal Maintenance Manual Section 16: Troubleshooting Error Messages Absolute Mode Required at N = The CNC must be in the G90 (absolute) mode during all probe functions. Probe function L9101 is programmed in the G91 (incremental) mode. Amplifier Fault on Axis This occurs at power on if the control does not detect an axis that should be operational. This is often seen when the A axis is not in use and the dummy termination plug has been installed. If the dummy termination plug is installed, this message can be disregarded. If this message appears for any of the other axes (X, Y, or Z), then power off to check the motor overload relays. Power on and if the message appears again, call the service department, noting the error message number. Power off the machine before checking fuses, relays, and circuit breakers. The motor overload relays can be recognized by their white reset buttons. They are located in both control enclosures. The white button must be pressed to reset a relay. This message also appears when the EMERGENCY STOP button has been pressed. The operator must release the EMERGENCY STOP button and press the JOG button to reset the amplifiers. (Pressing in the EMERGENCY STOP button disconnects the axis amplifiers. This is why this message appears when the button is pressed.) Arm Must Be Left Before a pallet change can occur, the arm must be completely to the left with the pallet on the table. The feed back on the arm is being read at this time. Array Exceeds Allowable Number This message will appear when the number on the array exceeds the expected amount. This amount varies from variable to variable. For example, H(99) is acceptable, H(102) is not. March 2003 Section 16: Troubleshooting 509 Fadal Maintenance Manual ATC Failure Check to see if the Z axis alignment was properly set at cold start. The automatic tool changer has failed to respond to an M6 or the TC,1 command. Try a power off and power on. If this does not help check the fuses. The fuses F5, F6, F7, and F8 should be checked to see if they are burned out. Circuit breakers 1 and 2 (if they are present) should be pressed to see if they have been tripped. Power off the machine before checking fuses, relays, and circuit breakers. If this does not help, call the service department. If this message appears with the turret in the extended position, it may be an indication that the sensor for turret extension is faulty. Call the service department. ATC Turret Failure Check to see if the Z axis alignment was properly set at cold start. Then check to see if anything is caught between the sheet metal guard and the turret. If not, this could be an indication that the sensor for turret rotation is faulty. The fuses F5 and F6 should be checked to see if they are burned out. Circuit breaker 2 (if it is present) should be pressed to see if it has been tripped. Power off the machine before checking fuses, relays, and circuit breakers. ATC Will Not Move to Position Check to see if the Z axis alignment was properly set at cold start. An attempt is made to make a tool change and something prevents the turret from going all the way out to the spindle. Check the tracks that allow the turret to slide out to the spindle. Sometimes chips stick to the track and prevent the rollers from rolling on the track. When this message appears use the command SETCS then the command HO which will bring the tool to the Cold Start position. It is important to visually check the axis indicator markers to see if they are aligned; if not, jog the table until the markers are aligned. Use the command CS, then answer Yes (Y) to the “move to home?” question. This will bring the tool to the part’s home position and enable the operator to begin running the program in AUTO again. It is also possible that the turret extended sensor is faulty. Fuses F5, F6, F7, and F8 should be checked to see if they are burned out. Circuit breakers 1 and 2 (if present) should be pressed to see if they have been tripped. 510 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Power off the machine before checking fuses, relays, and circuit breakers. Attempted Division by Zero In a macro statement, a division by zero was attempted. Attempted SQR of a Negative Number In a macro statement, a square of a negative number was attempted. Attempt to Change CRC Side Without G40 at N = This message will occur when attempting to switch from G41 to G42, or vice versa, on a linear move. However, switching from one to the other is permitted during circular interpolation. Attempt to Change Tool While in CRC Mode, N = This message occurs if a G41 or G42 is used in the program and a G40 code does not appear before an M6 code. The G40 cannot be on the same line with M6. An M6 will not cancel CRC. Attempt to Switch Plane During CRC G40 must be in effect (CRC must not be on) when changing planes. The default plane selection is G17. If CRC is in effect and a code to change to another plane (G17, G18, G19) is used, this message will appear in the block where the plane selection was called. G40 must be in effect (CRC must not be on) when changing planes. Axis Controller Does Not Respond During Power Up Sequence This an indication that there is a communication problem between the CPU (1400) board and the axis controller (1010). Note error number and call the service department. Axis Controller Does Not Respond to NC This an indication that there is a communication problem between the CPU (1400) board and the axis controller (1010). Note error number and call the service department. Axis Data Transfer is Stalled This message is the result of a data transfer problem between the 1030 card and a 1010 card. This message does not represent a serious problem and should only be reported to the service department if it is persistent. Please note error number. Axis Does Not Respond This is possibly a problem with the 1010 card for the stated axis. Try a power off and a power on. If this does not help, call the service department. March 2003 Section 16: Troubleshooting 511 Fadal Maintenance Manual Axis Fault(s) as Follows This appears when the EMERGENCY STOP button is pressed, a motor overload relay is tripped, or the machine places itself into the Emergency Stop mode. If any message or error number is presented on the screen, record this message and number and report them, if needed, to the service department. Release the EMERGENCY STOP button if necessary, then press the JOG button which will reset the machine. If the machine does not reset, call the service department. If the EMERGENCY STOP button is not depressed, then power off the machine and press the reset buttons of the motor overload relays to see if they are tripped. The motor overload relays can be recognized by their white reset buttons. They are located in both control enclosures. The white button must be pressed to reset a relay. If the machine stalls for one reason or another, the control places itself into the Emergency Stop mode. Press the JOG button and jog the tool out of the stalled position. An axis fault also occurs during an emergency stop because the control removes the power to each of the axis servo amplifiers as a safety feature. The control then analyzes the situation and, as a part of the report, shows a servo amplifier fault, a result of having removed power to the amplifiers. Axis Overflow The axis controller detected an overflow situation. Power off the machine at the main power switch wait ten seconds, and turn the power on again. If this problem is persistent, call the service department. Bad Circle OR Missing G at N This can indicate an incorrect starting position for the circle, an incorrect ending position, or an incorrect description of the arc center location relative to the starting position of the circle. This can also indicate that the circle is programmed in absolute or incremental and the G90 or G91 codes are incorrect. Bad Data or No Tool Dia. This occurs when an H word (in format 1) or the D word (in format 2) is missing in the program. When a program uses cutter radius compensation (CRC) or a fixed subroutine, an H word or D word must be specified. 512 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual This also occurs when no diameter value is placed in the tool table when using Fixed subroutines L94NN, L95NN,L9601, L9701, L9801, L9901. A DIAMETER VALUE MUST BE USED. When the fixed subroutine for engraving (L9201) is used, the Z depth and the R2 variable must be included in the line. See the Users Manual for the correct format. If the R0 variable is not specified, it is assumed as R0+0. If the R1 variable is not specified, it is assumed as R1+1. Bad Fixture No. Fixtures are numbered E1-E48. This message is displayed when a fixture offset is programmed with a value greater than 48. Format 2: G54-G59 and E6-E48 are used. Bad Interpolation Type at N Check to see what type of move is intended for this block. G1, G2, and G3 are the interpolation codes; G1 is for linear moves and G2 and G3 are for circular moves. Bad R Field This occurs during input from the keyboard or through the RS-232 port (from an offline computer) when the R0 was typed incorrectly. Example: If RO is typed (R with the letter O) or R with no zero (0) is typed (R-.05 is accepted but not R.05 or R+.05). Correct the line in the CNC; or correct the line in the text editor and send the program again. Bad R1 Using L91 at N = The R1 parameter is not present in the block containing L9101, or it is present with an improper value. L9101 has 9 possible functions that are defined by the R1 parameter; R1+1. through R1+9. Bad T Word at N = This message occurs during a SUM command. It indicates that the T word value is larger than the tool changer capacity. Bad Z or R0 in Canned Cycle Call, N = This is a programming error due to the position of the R plane relative to the Z axis position when initializing a fixed (canned) cycle. Problem: 1) The R plane is described to be above the I plane. March 2003 Section 16: Troubleshooting 513 Fadal Maintenance Manual 2) The R plane is described to be below the final Z depth. 3) The final Z depth is described to end above the I or R planes. Solution: Check to see if the program has the correct positioning mode (G90 or G91), and check for correct signs and decimal point placement. Note: The H code might not be in the program. Calculated Radius Error Of This is a programming error possibly due to a G90 or G91 code missing, or being in the wrong place. (EXAMPLE: Giving absolute positions while still in incremental). Also, check the end point description, the beginning position, and the arc center description (I, J, and K), or radius designation. This message does not appear during the Auto mode. It appears when using the SUM command (SU). Cancel CRC Before G50.1 OR G51.1 AT N = Before using CRC (G41, G42), mirror the desired axes (G51.1). Also, turn CRC off (G40) before canceling mirror image (G50.1). Cancel CRC Before N = The control requires the G40 code to cancel cutter radius compensation before the line number listed. See the cutter radius compensation section for suggestions. Cancel Z Axis Mirror Before Tool Change at N The G50.1 code must appear on a separate line before the M6. Cannot Return from Subprogram or Subroutine Calling Line Cannot Be Found This is a background editing error message. The line that called the subprogram or subroutine was deleted or cannot be found. Cannot Start Directly in a Subprog. A mid program start must begin from the main program. If it is necessary to start the program in a subroutine, the COPY command can be used to copy the subroutine to the main program as many times as the subroutine will be repeated. The programmer or operator can now do a mid program start to where the subroutine was copied into the main program. After the part is complete, delete the copied portion and run the program as before. 514 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Another method to start the program in a subroutine is to use the AUTO command. Enter AU,# (see AUTO command in the Operators Manual), where # is a sequence number in the subroutine. The control will process the program from the beginning of the program up to the number specified then start execution of the program. Char. Size or Depth Exceeds 2.5 In. Characters that are higher than 2.5 inches cannot be engraved using the Engraving mode (L9201). Check Emergency Stop Switch and Motor Overload Relays If the EMERGENCY STOP button (switch) is not pressed, it is necessary to check the motor overload relays. Power off the machine before checking fuses, relays, and circuit breakers. The motor overload relays can be recognized by their white reset buttons. They are located in both control enclosures. The white button must be pressed to reset a relay. Also, check the brake relay fuse (F17) to see if it is burned out. It is advised to power off the machine when checking the fuses or motor overload relays. Check Spindle Lube, Way Lube and Air Pressure When this message is displayed, it is necessary to check the way lube level, spindle oiler level, and the air pressure gauge. It is advised to check these oil levels at least once a day. Clear an Emergency Stop Condition An emergency stop condition was invoked. To clear, press the JOG key. Wait 2 seconds for the amplifiers to be reset, then continue. Command Error This occurs because a SET (parameter) command was typed in improperly. Refer to the Users Manual or use the menu of the control to help with any command format. The following is a list of available SET commands: SETH, SETX, SETY, SETZ, SETA, SETB, SETCS, SETTO, SETP. Command Prohibited by the Key Lock With the key lock in the horizontal position, editing commands (CH, CO, DE, IN) cannot be used. CRC Called With No Tool Assigned at N = This happens when the programmer has turned CRC on without an H word in the program. March 2003 Section 16: Troubleshooting 515 Fadal EXAMPLE: Maintenance Manual Format 1: N1 G41 N2 H1 N1 H1 N2 G41 Format 2: N1 H1 N2 G41 N1 H1 D1 N2 G41 This is incorrect. This is correct for Format 1 only. This is incorrect. Diameter must be for Format 2 programming and is acceptable for Format 1 programming. This is a common error in one tool programs when the Z axis is set with the tool at the gauge point. Assign an H word with no tool length offset (only a tool diameter) in the tool table. D or H Too Large The control maintains a table of 99 tool diameters and 99 length offsets. The control will only accept H words and D words up to 99. Data Transfer Fault For this error, it is important to note which axis the transfer fault is on and report it to the service department. Please note the error message number. There is a data transfer problem between the 1030 card (slot 8) and the 1010 card for the stated axis. DNC Mode This message appears after DNC is typed at the control. The VMC is then ready for DNC operation and is waiting for CNC code from the RS-232 port. Door Began to Close While Arm was Moving This message will occur if the door begins to close during a pallet change. The feedback of the door may need adjustment or there may have been a drop in air pressure. Do You Want to Move to the Last Home Position? This is not an error message but it appears each time the operator uses the CS command and a home position is established (SETH) in memory. Do You Want to Reinitialize Memory? This prompt is accessed by reinitializing the memory via the RI command. A ‘Y’ response zeroes the memory of the CNC. WARNING 516 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual ! March 2003 All program data is deleted from memory. After the memory is reinitialized, a cold start must be performed. Section 16: Troubleshooting 517 Fadal Maintenance Manual Do You Want to Zero Tool Table? This prompt is accessed by reinitializing the memory via the RI command. A ‘Y’ response zeroes the tool offset table. ! WARNING All tool diameter and length offsets are deleted from memory. Do You Want to Zero Fixture Offsets? This prompt is accessed by reinitializing the memory via the RI command. A ‘Y’ response zeroes the fixture offset table. ! WARNING All fixture offsets are deleted from memory. Dry Run Option ___ is in Effect The selected dry run option (1, 2, or 3) is displayed prior to automatic execution. See the Users Manual or the Run Time Menu for the appropriate option definition. Duplicate Name No two programs in the library can be identified by the same number. When copying an existing program assign an unused number to the new, or copied program. Use option 2 (display program numbers) of the PR menu to determine which numbers have been used. Duplicate or Bad Prog. Name This will occur if a program is being input through the RS-232 port and the program has an O word in the first line that is a duplicate of an existing number in the program library. Use option 2 (display program numbers) of the PR menu to determine which numbers have been used. Change the O word to one not being used, or remove it. Then send the program out to the control again. If the program currently active in memory has an O word in the first line, the program will be moved into the program library when the new program is transferred through the RS-232 port. If the program currently active does not have an O word in the first line, the program will be deleted when the new program is transferred. Dwell, Hit Start to Interrupt This message is displayed when a G04 (dwell) is executed by the CNC. You can interrupt the dwell time and continue program execution by pressing the START key. 518 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual E Word May Only Be Used With G0 or G1 N = Fixture offsets cannot be on the same line with a circular move (G2, G3). Emergency Stop - Take Appropriate Action An emergency stop has occurred. If the emergency stop button is depressed, turn it clockwise until it returns to its normal position. Press the JOG button and the message WAIT 2 SECONDS, THE AXES ARE BEING RESET. If this message persists, call the service department. The appropriate action to take: 1) Release the EMERGENCY STOP button if it has been pressed. 4) Press the JOG button which resets the amplifiers if the problem has been resolved. 5) Type HO and press ENTER, then after the waiting message appears press START (see note). 6) The operator may now resume the running of the part. Note: It is not necessary to move the axes to their Cold Start position or establish the part home again unless the message, JOG AXES TO HOME POSITIONS, THEN ENTER THE CS COMMAND appears. Enter Again or Hit Manual to Exit This message comes up when inserting program coding at the keyboard (using the IN command) or when in Manual Data (MD) and Change (CH) mode. It is referring to the line just typed. Something was not acceptable, for example the letter O for the number zero (0) or anything else not correct. The control is still on the line with the problem, so retype the entire line. Enter Command SETP and Set the Machine Parameters The SETP procedure will ask questions regarding the machine and certain preferences. If any of the questions are not clear, call the service department for help. Enter Command MU to See the Menu This happens when a command is typed incorrectly. Either it is an unrecognizable command or a comma was omitted. This message is only a suggestion. It is not necessary to go to the menu to use a command. The menu is there to remind the operator of the command format. March 2003 Section 16: Troubleshooting 519 Fadal Maintenance Manual Error This message is a program input error. It is displayed when a program block containing an error is transmitted to the CNC via the RS-232. It appears at the time the error is received. Therefore, list the program at the control to display the last block of code received. The following block of code in the program, which was not received, is in error. This normally is caused by back to back alpha characters, which must be separated by numeric characters. Also, a 0 could be typed as an O. Error in User Program, ‘SUM’ to See Message See the Operator Manual for instructions on using the SUM (SU) command. This message will occur when the control lists an error message in the Auto mode, and the operator persists in running the program by pressing the START or AUTO button. This message will appear when the line in which the error exists is at the top of the stack of lines to be executed. Error N Word Exceeds 99999 This error occurs when the sequence number is larger than 99999. The sequence number must be between .001 and 99999. Error While Processing Block This is an indication that there may be a problem with the CPU board. 1) Send the machine back to cold start alignment markers. 7) Power off the machine’s main power, wait 15 seconds and power on the machine. 8) Cold start then run the program again. If this error repeats: 1) Save all the programs and offset information currently in memory. Write down the present home position. 9) Send the machine back to cold start alignment markers. 10) Use the command RI and answer Yes (Y) to all the questions. If the above does not work please call the Service representative in your area. Error(s) Reading Tape While the control is inputting a tape or program with the TA command, error option 2, this message appears after input is complete. If the TA command and error option 1 is used (TA,0,1 or TA,1,1) the input of the program would have been stopped if an error in the program is detected. 520 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual If errors are detected, list the program and look for missing line numbers to find which lines the control did not accept. Use the IN command to insert the missing lines where needed. File Overflow This message could mean that the program has too many G codes and M codes on the same line. It could also mean that during CRC, there were too many blocks that the control had to look beyond for the next compensated move (comment lines, Z moves, G code and M code lines, and dwells). This message may also appear if a fixed cycle is in effect when attempting to initiate cutter radius compensation. Fixture Offset Out of Range This message occurs when an E word value in the program exceeds 48 or in Format 2 exceeds G54 - G59 or exceeds E1 - E48. Fixture Offset Must Be Applied With G0 or G1 Fixture offsets cannot be applied on lines with circular interpolation (G2 or G3). G28 and G29 Used With Cutter Radius COMP at SEQ Before the control can execute the codes G28 or G29, the program must turn CRC off (G40). G31 Used With an Incompatible Word or Mode Only G1, P and F are allowed with a G31. No other codes are supported. CRC, mirror image, rotation and drill cycles are not allowed during the execution of a G31 code. G45-G48 & G52 are Not Allowed With Rotation. N = Codes G45-G48 and G52 are incremental offsets. Rotation can only be used in the Absolute mode. Therefore, these codes are not allowed. G91.2 is Not Allowed in Format 1 The machine is in format 1 with the G91.2 code in the program. The G91.2 code can only be used in format 2. In format 1 you must remain in the Incremental mode when G91.1 is coded. G92 Cannot Be Used in CRC Mode. N = The G92 code should be used in a line before CRC is turned on. The code G92 can only be used after a G40 (G40 is a default code). March 2003 Section 16: Troubleshooting 521 Fadal Maintenance Manual G92 Must Be Only G Code in Block There can be no other G codes in the line with a G92. The program does not need to be in absolute (G90) to use the G92 code. GNN is an Unsupported G Code At N The G code displayed is not a supported code of the FADAL CNC 88. Helical Move Too Short, N = (See error message HELICAL RISE TOO STEEP) Helical Radius Too Small, N = (See error message HELICAL RISE TOO STEEP) Helical Rise Too Steep, N = The radius of the circle and the helical rise are radically different in length (usually the rise is much longer in comparison to the radius). Also, depending on the programmed feed rate, the control may or may not be able to handle the situation. Reducing the feed rate in the program usually helps. I, J or K Must Be Specified at N = This message is displayed when an X, Y, or Z is used with an R0 without a G2 or G3. Full circles must use the direction around the circle and either the I, J, or K. See the circular interpolation section for more details. Illegal O Word This error occurs during program input via. the RS-232. The O word must have a value of 1 through 9999. No other character or symbol is allowed. Illegal G Code During G91.1 Mode at N = This message appears when an illegal G code is programmed while in G91.1. See the Users Manual for acceptable G codes. Improper Use of Canned Subr. This message may appear for the following reasons: 1) No tool diameter in the tool table. 11) The programmer omits a required R word from the subroutine. 12) The programmer does not cancel a fixed cycle with a G80, G28, G29, M6, G49, or H0 before using a fixed subroutine, except for L93 (bolt hole). 13) Using L96 - L99, if R1 variable is equal to the radius of the tool. The R1 variable is used for the radius on the corner of the tool (fillet radius), not the 522 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual tool radius. For example, a 1.0 diameter end mill with a .125 corner radius, the R1 variable will be R1+.125, and the tool diameter entered in the tool table will be 1.0. 14) The G41 or the G42 code has not been canceled with a G40 before using a fixed subroutine. Inches Mode Required - Operator Must Set The CNC is in the Metric mode (SETME), and the program has a G20 or G70 code to verify that the control is in the Inches mode. To run this program, the operator must set the CNC to the Inches mode by entering the SETIN command. Incompatible G Codes at SEQ Some codes, even though they are modal and from different groups (families), are incompatible with one another. Break up the grouping of G codes on the line by moving some of them to the line just before or after the line they are presently on. This message is also displayed when any G code is on the line with a G53. EXAMPLE: N20 G1 F20. N21 G8 G41 X.5 The G41 and the G8 are incompatible. Move the G8 to the line with the G1. N20 G1 G8 F20. This is correct. N21 G41 X.5 Increment Divided By Two If renumbering causes a line in the program to be greater than 99999, the increment for renumbering is divided by two and renumbering is resumed. All the lines or program blocks must have sequence numbers. The NU command is used to renumber the lines in the program by the increment specified in the first parameter. For example, entering NU,5 will renumber the lines, incremented by five. If program is large, renumber by 1. Increment Too Large This occurs when the increment parameter of the program input (IN) command causes the sequence numbers to exceed 99999 or a typing error in the program has given a value too large. Example: X-123456789. Increment Too Small This alarm occurs when the increment parameter of the program input (IN) command is less than .001 Example: IN, 0.00001 March 2003 Section 16: Troubleshooting 523 Fadal Maintenance Manual Input Xmodem Transmit Block Missed Error This occurs when a packet has been missed or came out of order during XModem transmission. Jog Axes to Home Positions, Then Enter the CS Command This message appears at power on. If the axes are at the Cold Start position (machine home), enter the CS command. The operator needs only to jog the axes if they are not at the Cold Start position. This message also appears when the tool changer crashes and the AUTO button is pushed or the MD command is used. However, the operator does not have to jog to Cold Start. Use the SETCS command to reference the Cold Start position, then enter HO to return the axes to home, and when the axes are back at the Cold Start position, visually check, and enter the CS command. SETP will also make this message appear. If the operator used the SETP command at the part home, handle the situation in the same way as suggested for a tool changer crash (see above). Look Ahead Was Canceled By Operator This indicates the NO LOOK AHEAD buffer option of the Run Time Menu has been selected. The CNC processes only one block at a time, while displaying only two blocks of the program on the screen. This option can be selected or canceled using the Run Time Menu by typing MU in the Automatic mode. M, S, T Lockout is in Effect This message indicates the M function, Spindle, and Tool change lockout option of the Run Time Menu has been selected. In this mode, M function, Spindle or Tool Change commands will not be performed during Dry Run. This option can be selected or canceled using the Run Time Menu by typing MU in the Automatic mode. M Function Too Large at N = M functions cannot exceed a 2 digit value. See the Users Manual or the menu (MU) for a list of the accepted M functions. Main Prog. Not Found This is a programming error. There are subroutines written in the beginning of the program without an M30. M30 is used to separate the subroutines from the main program. Insert the M30 in the proper place. See the Users Manual for the accepted format for subroutines. The M30 code on the first line of the program and a subroutine heading (L100) on the next line will also cause this error message to appear. 524 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual N1 O1 (START OF PROGRAM N2 (ACCEPTABLE PROGRAM EXAMPLE) N3 L100 (SUB #1) N4 X1. N5 * N6 L200(SUB #2) N7 L105 N8 M46 N9 X-5.Y-1. N10 M47 N11 * N12 L300 (SUB #3) N13 G91 N14 L204 N15 L104 N16 G90 N17 * N18 M17 ——— This ends the last subroutine. N19 M30 ——— This separates the subsection from the main program. N20 * N21 (MAIN PROGRAM) Memory Error, Reload Program This is a memory error. Turn the machine’s main power off. Then power on and reload the program. If this does not work, save all the programs in the memory (PU,3) and use the RI command, answering Yes (Y) to all the questions. After using the RI command, load the programs back into the control. Memory Error, Respond With Y to Delete Bad Blocks There is a possible hardware problem when this message appears. If the operator answers Yes (Y) to this question, the control may delete some of the program in memory. Answer Yes (Y) only if the program in memory can be replaced (if the program is stored on paper tape or on computer disk). Answer No (N) if the program needs to be saved. Turn the machine’s main power off. Then power on and reload the program. If this does not work, save all the programs in the memory (PU,3) and use the RI command, answering Yes (Y) to all the questions. After using the RI command, load the programs back into the control. If this does not help, call the service department. March 2003 Section 16: Troubleshooting 525 Fadal Maintenance Manual Metric Mode Required - Operator Must Set The control, at power on, is in the Inches mode. The Metric mode must be turned on by using the SETME command. This message will appear if the G21 or G71 code is present in the program to verify that the Metric mode has been turned on by the operator. Motor Overload This is an indication that something has stalled or overheated a motor, and is associated with an emergency stop (see EMERGENCY STOP). Move Exceeds Axis Limit at N = Check Program and Tool or Fixture Offsets The most common reason this message appears is because of either a missing or an extra G90 or G91 code. This message will appear only when the control is in the Auto mode or Manual Data (MD) mode. This message will not appear in the Sum mode (SU). When the control is executing the program, processing of the program is ahead of the current line that is being executed. If, while processing the program, the control detects an over travel situation, execution of the program will stop immediately. The setup person may have to consider moving the fixture to another location on the table. The program may be correct but the fixture is set up incorrectly. The programmer can provide information to the setup person, indicating how close to the axis limits the fixture can be located. Move Turret to Tool 1 and Enter SETTO Command When this happens, the head will be above the tools in the turret, with the turret ready for loading. Move the turret using the turret CW or CCW buttons so that the tool designated to be tool #1 is under the spindle, and remove tool #1 from the turret. Press the JOG button. The head will stay where it is (4” above the Z axis CS position), and the turret will move back to its home position. Now use the command SETTO to establish this turret position as #1. Use the HO command or jog the head down to the Z axis CS position. Next use the command TC,1 to reopen the turret. Replace tool #1 in the turret and press the MANUAL button to bring the head down over tool #1. Next Entry is Out of Range This message is displayed by entering pitch error compensation for the ball screw when an entry exceeds the maximum allowable difference of 9 (See Survey command in the Axis Drive Systems Section). For example, if an entry is 15 and the next consecutive entry is 0, the difference is greater than 9. 526 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual No Angle, the Points Are the Same The calculated angle, of either function 3 or 4 of L9101, is the same as the expected angle. No Memory Available for New Program When this occurs, the operator will have to remove (delete) as many programs as necessary from the program library to input another program from the RS232 port. The standard memory capacity is an equivalent of 277 feet of paper tape. FADAL distributors have a memory expansion board available that increases the memory capacity to 1205 feet of paper tape. No Other Words Allowed With O Word If program coding is used on the first line of the program along with the O word, this message appears. A comment is allowed with an O word and is used to identify each program in the library. The first sixteen characters of this comment are shown when the program library menu displays the programs in memory. EXAMPLE: N1 O1 G0 G90 (P/N 1234) — This line is incorrect. N1 O1 (P/N 1234) — This line is correct. N2 G0 G90 No Parameters or Parameters Corrupted Machine Defaults Used This message occurs most commonly after the memory has been zeroed from the DI diagnostics mode. This will also occur if there is a memory error. Enter the machine parameters with the SETP command. The parameters to use are usually found recorded on a check off sheet on the inside door of the pendant. No Response From Axis This happens when powering on the machine and the CPU (1400) does not get a response from the axis controller (1010). If this message appears for the X, Y, Z, A, or B axes, power the machine’s main power off and then on again. If this does not help, call the service department. No Touch or Incompleted Point at N = The move that causes the probe to touch the part was completed without a touch. Increase the length of the move so that the probe touches. Also, you must activate the selected probe by coding an M64 for an MP8 probe, or an M65 for a TS20. Note Error Then Hit Manual March 2003 Section 16: Troubleshooting 527 Fadal Maintenance Manual When the programmer is inputting a program through the RS-232 port (using the command TA,1,0 or TA,1,1), the input will be terminated if the control detects a bad programming word (EXAMPLE: O for 0, or double letters (XX1.5), etc.). The programmer will have to edit the program at the computer or Teletype before inputting the program again. The control will ignore all errors in the program and continue input by using the error option 2, with the TA command (EXAMPLE: TA,1,2). An error count is given at the end of transmission. If there were errors detected, list the program to find missing line numbers. If the lines are numbered in sequence before transmission of the program, look for the numbers that are out of sequence. After the numbers have been located use the IN command to insert the missing lines. Number Out of Range This message appears when a number of twelve digits or greater is typed in. This error may be detected by the machine after making a calculation. The calculated number may be out of range. Macro calculation less than .0001. Offset Entry Error This message is displayed using the Utility (UT) command, by pressing the MANUAL key when the CNC prompts you for a tool diameter. It is also displayed by entering a diameter value that is too large. Only Block Skip Allowed With Macro The only non macro command allowed with a macro line is the block skip character. Only M3, M4 & M5 Are Allowed With M6 at N = This message appears when the M6 is coded with an M function other than an M3, M4 or M5. The unacceptable M function must be moved to another line. Only Z, L, R & F Words Allowed This message appears when the programmer uses the fixed subroutine L9201 for engraving, and has programmed other words in the line with the L9201 other than Z, L, R, and F. Orientation Failure Visually check the air pressure, it must be between 80 and 90 PSI. If this problem persists call the service department. 528 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Out of File Space, a File Compression is Being Tried This message informs the programmer that the memory of the control is almost full. It usually is displayed when editing the active program in memory, or during program input via the RS-232. This does not destroy any portion of the program. A file compression organizes the memory so that unused portions are made available. The NE command will perform a file compression before prompting you with a (Y or N) to delete the current program. Also, a file compression is performed by deleting the current program using option 5 from the PR menu. It is always best to retry the command that caused this message to appear. After the compression, the command will often work the second time. If unwanted programs are stored in the program library, remove them to create more room in memory. If there is only one program in memory, try to reduce the size of the program by removing unnecessary comments and making full use of all modal codes. Create subroutines for repetitive portions of the program wherever possible. The program may have to be broken up into separate operations. The standard memory capacity is an equivalent of 277 feet of paper tape. FADAL distributors have a memory expansion board available that increases the memory capacity to 1205 feet of paper tape. O Word Out of Range This occurs using the program input (IN) command when typing an O word greater than 4 digits. O words must be an integer of 1 through 9999. Pallet Disabled in Parameters This message occurs when a pallet changer command or code is used and the SETP parameters indicate no pallet changer exists on the machine. Pallet in Storage This message occurs when there is an attempt to store a pallet where a pallet already is stored. Pallet Not Fully Stored This message occurs when the time to store a pallet exceeds the allotted time. The feedback on the arm may need to be adjusted. Call the service department for assistance. March 2003 Section 16: Troubleshooting 529 Fadal Maintenance Manual Pallet Must Be Clamped This message occurs when both pallets are in storage and a command is give to make a pallet change. One of the pallets must be loaded and clamped on the table before a pallet change can occur. The feedbacks for pallet loaded and pallet stored are being read at this time. Parameter Error After a command is entered and a comma is typed, the control is expecting a parameter. If a parameter is not typed before pressing the ENTER button, this error message appears. EXAMPLE: AU, — This is a parameter error. Note: If the operator is not using a parameter, for instance, the second and third out of a possible four, the parameters can be omitted when the fourth parameter is typed in. EXAMPLE: AU,50,,,1 — This is acceptable. Also if the DE command is used to delete a line that does not exist, or the CO command is used to copy lines that do not exist, this message appears. Parity Error This message appears during input through the RS-232 port and is caused by several factors. 1) Unshielded cable is used, and the cable is subject to electrical noise. 15) The baud rate is too fast for the length of cable used. 16) There is a failure in the RS-232 port (hardware problem). 17) There may be a problem with the computer that is sending the program. Parity Error During DNC This occurs during DNC transmission of data. (See the error message PARITY ERROR) 530 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Please Put an O Word at the First of the Current Program The Following Programs Are in Memory To use the PR command, the active program must have an O word and a number in the first line. The number must be different than the other numbers in the program library. This is why it lists the other programs in memory. EXAMPLE: N.1 O43 (P/N 34-765) N1 G0 G90 S10000 M3 Here, a line was inserted before N1 using the command: IN,.1 A comment can be added to the line with the O word. These comments help identify the program. Points Are on Same Line at N = The 3 touch points of L9101 function 1, are on the same line. Check the program for positioning errors. Possible Probe Over Travel During the UT command, this error occurs for two cases. The first is when the Z axis home position is set below the Cold Start position and the tool change is made to the Probe. The second is when there is a positive offset value used, and the tool change is made to the Probe. Position Limit This message will occur when the program has instructed the tool to move out beyond the axis limits. When the tool moves beyond the axis limit the CNC issues an emergency stop. The machine will stop at the line which caused the over travel. Press Y to Keep This Position Press N to Return to Last Position These messages appear after jogging while in Slide Hold or Single Step modes. See the Users Manual for the proper application of the Jog Away feature. Probe Test = Failure Testing the probe by using the Utility (UT) command failed. Verify that the probe was properly interfaced. If an MP8 or MP9 is being tested, be sure the 9 volt battery has a charge. Also remove any obstructions between the probe (transmitter) and the collector unit (receiver). Problem Positioning Slides to Zero This error only occurs during Cold Start. When the Glass Slides are not aligned close enough to the indicators during Cold Start. Place the machine in Jog and manually align the Cold Start indicators more accurately. March 2003 Section 16: Troubleshooting 531 Fadal Maintenance Manual Program Does Not Exist Retry or Hit Manual to Exit This happens when the selected program number does not exist in the program library. Enter a program number that does exist, or press the MANUAL button, and then use the PR command again to display the programs that are stored in memory (option 2). The programmer may have put an O-1 or an O.1 as a program number. The number will show up when the programs are displayed in the library but the control will not be able to retrieve the program. If the operator uses the PU,3 command and presses the EMERGENCY STOP button when the lost program is being displayed on the screen, that program is now active in memory and can be edited. Delete the bad O word, from O-1 or O.1 (which appears as 1000 when it is listed in PR) to O1. Program Not Found This message is displayed when the PA command is used to display the active program, and no program is active. Use the PR command to activate the desired program stored in memory. Program Block Not Found This message is displayed when the LI command is used to list selected blocks of the active program, and the selected blocks are not found or the program is not active. View the program by using the PA command. P Word Too Large The P word for referencing a line number using M99 is too large of a value. Line numbers can not exceed 99,999. Reset the Emergency Stop Switch The EMERGENCY STOP button has been pushed. Turn the button clockwise until it is released and then push JOG. Resolver Fault or Scale Error This message may occur in three cases as follows: 1) A failure of the resolver. 18) An axis runaway during power on. 19) A large Scale or Motor error, indicating a possible scale failure. ! 532 IMPORTANT Report this to the service department when this message appears. Do not run the machine when this message appears. Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Rails Not Aligned This message occurs when the rails for the pallet changer are not aligned or the feedback switches need adjustment. Call service department for adjustment. Return Pallet to the Load Position This message occurs when a pallet change is attempted and the other pallet is away from the load position. The operator must slide the pallet into the load position before the other pallet on the table can be changed. The feedback from the pallet loaded and pallet stored are being read at this time. Rotary Axis Move Too Long. N = The maximum incremental rotary move for one block is 1080.00 degrees. If it is necessary to go further, break up the move into several blocks. RS-232 Error During DNC This error only occurs during DNC operations. It may occur while using 9600 baud to DNC. Slow the baud rate. It may also indicate line noise or the possibility of dropped characters. These would indicate a possible problem with the RS-232 cable or the communications port. Check the cable and communications port and retry DNC. A failure of the CPU may cause this error also. If the above corrections are unsuccessful, contact the maintenance department. Scale Error A scale error has been detected. The LEDs in the scale interface box in the back of the machine will indicate which axis gave the error. Call the service department. See Menu for New CD Format The CD command is different for some versions of software. See the menu for these changes. Sequence Number Too Large This occurs using the Program Input (IN) command when the ‘From’ parameter is specified greater than the maximum allowable number. Sequence numbers can not exceed 99,999. Sequence Number Too Small This occurs using the Program Input (IN) command when the ‘From’ parameter is less than the minimum allowable number. Sequence numbers can not be less than .001. March 2003 Section 16: Troubleshooting 533 Fadal Maintenance Manual Servo Amplifier Fault This message appears when the EMERGENCY STOP button is pressed. The operator must pull the button out (for ‘85 and older models) or turn it clockwise (for ‘86 to present models) and then press the JOG button to reset the amplifiers. If the amplifiers do not reset, call the service department. Single Step This message identifies the control is in the Single Step mode. Should the green START button be pressed when in this mode, the following program block is executed. The feed rate potentiometer affects all axis motion. At the end of each block, the operator can press the JOG button and jog away from the current position without aborting the operation. Program execution can be continued at the new location, or the axes can be returned to the position at which the Jog function was initiated. To exit single step, press the AUTO button for continuous block execution. Slide Hold Pressing the SLIDE HOLD button stops all axis motion. The distance to finish the move is presented under the blinking SLIDE HOLD message. It is possible to press the JOG button and jog away from the current position while in the Slide Hold mode without aborting the operation. Program execution can be continued at the new location, or the axes can be returned to the position at which the Jog function was initiated. To exit from the Slide Hold mode, the operator must press the START button, if in single step, or press the AUTO button for continuous block execution. Spindle Controller Does Not Respond Please note error number and see list at the end of this chapter. This simply could be a problem that occurs when the operator is powering on the machine. Turn the machine’s main power off. Press the motor overload relay button, and then power on again. If this does not help call the service department with the error message and number. The motor overload relays can be recognized by their white reset buttons. They are located in both control enclosures. The white button must be pressed to reset a relay. Call service department first. 534 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Spindle Controller or Driver Fault Please note error number and see list of Emergency Stop Error Messages at the end of this chapter. This message is displayed if the spindle was commanded to turn on after an emergency stop without pressing the JOG button to reset the amplifiers. If this message appears when not in the Emergency Stop mode, please take these steps to help the service department analyze the problem: 1) Look at the air pressure gauge and write down the current air pressure (do not change it at the machine!) 20) Check to see if the belts are on the pulleys. 21) Do not turn the power off. 22) Call the service department and report this problem (while the machine is on). Spindle Controller Software Update is Required The current software module (1610) detected spindle software that was not compatible. Call the service department. Spindle Driver Fault This is the result of the air pressure being too low while the spindle is on. Air pressure should be set between 80 and 90 PSI. Visually check the air pressure and start the program over again. If the air pressure is not the problem, power off the machine and check the motor overload relays to see if they have been tripped. The motor overload relays can be recognized by their white reset buttons. They are located in both control enclosures. The white button must be pressed to reset a relay. Spindle Failure While Tapping If the spindle stops while in G74, G75 or G84 modes, this message will appear. Problems such as a dull tap, undersized hole, poor tapping lubricant or a shallow hole must be eliminated. The programmer may want to consider thread milling as an alternative to tapping. Call the service department if this is persistent. March 2003 Section 16: Troubleshooting 535 Fadal Maintenance Manual Spindle Failure During Reversal This will occur when an M3 and an M4 are in the same line. If the spindle stops while in G74, G75 or G84 modes, this message will appear. Problems such as a dull tap, undersized hole, poor tapping lubricant or a shallow hole must be eliminated. The programmer may want to consider thread milling as an alternative to tapping. Call the service department if this is persistent. Spindle Has Failed to Turn On Either the Hall Effect Switch on top of the spindle pulley has not recognized that the spindle is turning, or the spindle actually has not turned on and there is another problem. Call the service department. Spindle Fault Line The spindle inverter has detected a fault. See the fault number on the inverter and report this to the service department. Spindle Motor Temperature Fault Check to see if the spindle fan is on. If it is not, turn machine’s main power off and check the fuse for the spindle fan (F24). Allow time for the spindle motor to cool down and attempt to run the machine again. If this message persists, call the service department. Spindle Would Not Stop The spindle would not stop in the designated amount of time (12 seconds). If this message is persistent, call the service department. Stack Overflow This message should be reported to the service department. It is caused by excessive stacking of keyboard commands. Subr. Does Not Exist This message indicates that a subroutine was called that is not in the subroutine section of the program. Check to make sure that the subroutines were numbered properly. This message also appears if the G66 code is used on a line that does not have a subroutine call on it. 536 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Subr. Nesting Error This is a message that occurs when a subroutine heading (L0100) is entered after the M30 code. This message will also occur if a Fixed Cycle is still active (use a G80 to cancel) or G68 (rotation) is still active when a tool change or end of program is coded (use a G69 to cancel). EXAMPLE: N20 M17 N21 M30 N22 L200 This is not permitted after an M30. Tape Input Terminated This message reports to the operator that the tape or program input process is complete. Tape is Good When verifying a punched tape, this message appears if the tape is accepted. This message also appears if no errors are detected in transmission when the TA command is used. Temperature Fault For any temperature fault, the operator must check the cooling fans; if they are not operational, turn the machine’s main power off and check the fan fuses (F23, F24, F27, and F28). If this message is persistent, call the service department. Temporary Conflict With Auto This message occurs when background editing is being used. The edit just made is in the area where auto is currently executing from. The change will be made when auto is out of that area. The Axis Controller is Not a 1010-4 (See Survey in the Axis Drive Systems Section) The Survey Contains Errors, Please Review (See Survey in the Axis Drive Systems Section) The Survey Was Not Written to the Axis Controller (See Survey in the Axis Drive Systems Section) There is No Survey (See Survey in the Axis Drive Systems Section) March 2003 Section 16: Troubleshooting 537 Fadal Maintenance Manual Thread Lead Not Specified at N = Fixed cycles G74, G75 and G84 need a Q word in the line that represents the decimal thread lead of the tap (see the Users Manual for the proper format). If the Q word is omitted this message will appear. If the programmer uses the fixed cycles G74, G75 or G84 and does not cancel the cycle with any of the following codes: M6, G28, G29, G49, G80, H0, this message will appear at the next Z move. Too Many Blocks For Gap This happens when the CO (copy) command is used and there are too many lines being copied between existing lines in the program. Use the NU (renumber) command and copy again, now that the program is renumbered. Too Many M Functions at N = This error occurs when another M function is coded with the M17 or M30. These two codes must be the only M function on the line. Too Many Consecutive Non Motion Blocks This error message appears if a program contains over sixteen consecutive comment blocks (with no program coding in the lines). A solution to this is to put coding between the comment lines or put comments on lines with program coding. This way the program can have comments on every line. Comment blocks in the beginning of the program can be placed in an unused subroutine. This way the control never reads the lines when executing the program, but the operator can list the program and read the comment lines. Too Many Parameters Commands have associated with them a certain number of parameters. If more parameters are typed in than allowed, this message appears. EXAMPLE: AU,50,,,1, or AU,50,,,3,1 Refer to the Users Manual, or the Menu (MU) on the control for the correct format of each command. Too Many Subr. Calls Nesting can only be seven deep. If the program goes further than seven deep, this message appears. 538 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Tool Breakage Detection = Failure at N = When the TS-20 touch probe is used for tool breakage detection, this error indicates the program line that the broken tool is detected at. Replace the tool and continue the program. Tool Diameter Too Large at N = This is displayed in cutter radius compensation when the programmed move is smaller than the radius of the cutter. 1) Check the tool diameter entered in the tool table to see if it was entered correctly. 23) Check the program to see if it contains any typographical errors. 24) If the intention was to make a rough pass using a larger tool diameter than the finish pass tool diameter, the smallest programmed inside radius, on the part, should be as big as the tool radius (half the tool diameter) entered for the roughing pass. 25) Check the math work to see if it is correct, and was transferred correctly to the program. When debugging a program that uses cutter radius compensation use a zero diameter in the tool table when running the program or when using the SUM command for the first time. Then put the tool diameter in the tool table and try it again. This will make the debugging process easier. Tool Offset Not Allowed During Z Mirror If mirroring the Z axis is desired, first call up the tool length offset, then code the G51.1 Z0. The H word must be on a line in the program before the G51.1 Z0. Tool NN is in the Spindle Identifies the current tool that is in the spindle. This is displayed when entering the program execution (AU) and the Manual Data Input (MD) modes, and is also listed in the tool table display (DT). Tool Number Too High The starting tool number of the utility (UT) tool setting cycle must not exceed that of the tool changer capacity. Tool Turret Location is Not Set Rotate the tool turret so that tool #1 is adjacent to the spindle and then type SETTO. Transfer Error, Please Retry March 2003 Section 16: Troubleshooting 539 Fadal Maintenance Manual (See Survey command in Maintenance Manual) Trouble Reading the External Slide Hold Switch The feedback from the external slide hold switches is erratic or inconsistent. This is an indication that the external slide hold switch system is faulty. Call the service department. Type A Y To Ignore, Or Turn Power Off And Then On Again This error message appears only after the message AXIS CONTROLLER DOES NOT RESPOND DURING POWER UP SEQUENCE. This is an indication that there is a communication problem between the CPU and the axis controller. Call the service department. Undefined Macro Error This message will appear when situations during a macro execution cause the system to fail, but there is no specific error or message associated to the situation. Wait 2 Sec., The Axis Drivers Are Being Reset This message occurs when the JOG key is pressed after an axis fault. The control returns to the Command mode after 2 seconds. The axis drivers are reset and the machine can continue normal operation. Waiting In the Waiting mode, the operator has the choice of pressing either the START or AUTO button to execute automatic motion. Or, the operator can press the MANUAL button to exit to the Command mode. Waiting On Air Valve When this occurs, the control is waiting on a signal from one of the air valves indicating that the valve has completed its job - usually air pressure to the machine has dropped below 80 PSI. If this message persists, call the service department. Warning Possible Gouge at N = Generally caused by math errors in the program. The CNC has processed a move that possibly could cause the cutting tool to damage the part. The error usually is not large enough to make any noticeable difference on the machined part. Therefore, only a warning is displayed. If there is a noticeable difference, review your program math. Way Lube Pressure Switch Failure Check the way lube oil level if this message appears. 540 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Writing Error, Wait 2 Min. and Retry (See Survey in the Axis Drive Systems Section.) X, Y, or Z Move Must Be Specified at N = Probe function #1 (L9101) has been programmed without an axis specified for the given plane. For example, if probing is to be used in the XY plane (G17), X and/or Y must be programmed in the same block as L9101 R1+1. Z can be used if in the ZX (G18) or YZ (G19) plane. You Cannot Delete the Program That is Currently Active To delete a program in memory, it must be in the library. Use the PR command and switch the program currently in memory with a program in the library. The program can then be deleted. If there are not any programs in the library, use option 3 to start a new program. This will put the currently active program in the library and the program can then be deleted. Or just simply use the DE command and delete starting from the first block in the program to the last. You Have a Version Upgrade or Memory Has Been Corrupted Memory Needs to Be Zeroed This occurs when the control detects that a new module has been inserted. See the Maintenance Manual for proper zeroing procedures. This may also occur because of a memory error and the memory needs zeroing. You Must Enter the Backlash Table The CNC does not have a valid backlash table. Enter the backlash for each axis by using the BL command. The backlash set at the factory is documented on the inside surface of the pendant door. The backlash information is retained by the battery backed memory card. If this message appears again, after the BL command has been used, call the service department. Your Version of CNCMAIN Needs to Be Updated The control has detected an incompatibility with the CNC memory manager software on the 32MP pendant. Call the service department for an update. Z, Q, or F Missing in Canned Cycle Call, N = See the Users Manual in the fixed cycle section for the proper format for each fixed cycle. March 2003 Section 16: Troubleshooting 541 Fadal Maintenance Manual Z & M6 Lockout is in Effect This message indicates the Z axis and Tool Change Lockout option of the Run Time Menu has been selected. In this mode, Z axis movement and tool change commands will not be performed during Dry Run. This option can be selected or canceled by using the Run Time Menu. Z Axis Must Be at Cold Start for TC,1 Check to see if the Z axis alignment was properly set at cold start. The operator cannot use the TC,1 command unless the Z axis is at the Z axis CS position. Use the HO command or jog the axis to the Cold Start (Z0). If the SETZ command has been used, first use the HO command to bring all axes home, then enter the SETCS command. Jog the Z axis to Z0 and then use the command SETH so the X and Y home position is not lost. The TC,1 command can now be used to open the tool changer. If necessary return the Z axis to the previous setting and use the SETZ command. (See the error message JOG AXES TO HOME POSITIONS if the tool changer crashes). Emergency Error Codes Error Numbers From the Axis or Spindle Controller Error numbers help discern the location of the problem the axis or spindle is reporting. The error number will follow a message to call the service department and report the error number on the screen to correct the problem. [ 1 ] NO MOTOR FEEDBACK This error appears during power up, when no motor feedback (either resolver or encoder) is detected by the axis controller. [ 2 ] ENCODER NOT RESPONDING This error appears during the rigid tap operation. If the encoder feedback is interrupted during the spindle operation then the spindle operation is halted. [ 3 ] LOGIC JUMPER INCORRECT OR COMMAND SIGNAL MISSING OR MOTOR-TACH CONNECTION INCORRECT This error appears during power up. An incorrect motor—tach—jumper configuration or failed component may cause the axis to run away in the opposite direction of the command signal. Axis operation is halted. [ 4 ] ENCODER IS NOT 1024 LINE This error appears during power up, and only applies to axes with encoder(1024 line) as motor feedback. The axis controller will count the encoder lines in one revolution of the screw and compare it to the expected count of 1024 542 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual [ 5 ] NO INDEX MARK DETECTED This error appears during the cold start process, if the index mark of the axis primary feedback device, encoder or scale, is not detected. [ 6 ] SWITCH 1 DISABLED Currently not used. [ 7 ] RIGID TAP PRECYCLE ENCODER COUNT PROBLEM This error appears during the rigid tap precycle process, when the spindle feedback is not within tolerance. [ 8 ] SPINDLE MAGNET NOT DETECTED OR SPINDLE NOT TURNING This error appears during spindle operation if the spindle magnet is not detected for any period longer than 3 seconds. [ 9 ] SPINDLE FAULT LINE DOWN This error appears any time the axis card no longer detects the fault line signal from the inverter, or the signal strength has dropped below 10V, indicating a possible inverter fault. [ 10 ] ENCODER AND MAGNET NOT RESPONDING OR SPINDLE NOT TURNING This error appears during spindle operation if both the encoder feedback and the spindle magnet are not detected for any period longer than 3 seconds. [ 11 ] FOLLOWING ERROR CANNOT BE SCALED FOR COMMAND SIGNAL This error appears when the signal strength of the following error, after scaling, exceeds the maximum allowable command signal. [ 12 ] MOTOR OVERLOAD — STEP COMMAND CHECKSUM ERROR This error appears at the completion of a move, when the actual move by the axis controller is not equal to the move commanded by the CPU. [ 13 ] MOTOR OVERLOAD — FOLLOWING ERROR > OVERLOAD FACTOR This error appears when the following error exceeds the overload factor, which is a user-defined parameter that sets, in motor turns, the maximum allowable following error for the axis operation. [ 14 ] MOVE TRANSFER FAULT — BUFFER INDICATOR NOT SET This error appears prior to executing the first step command of a move command, if the flag indicating completion of the move transfer process is not set. March 2003 Section 16: Troubleshooting 543 Fadal Maintenance Manual [ 15 ] TIME OUT ERROR — RIGID TAP PRECYCLE TEST This error appears during the rigid tap precycle process, if the spindle rotation is interrupted or the spindle magnet is not detected within the allowable time. [ 16 ] TIME OUT ERROR — RESOLVER RESPONSE This error appears any time the resolver “zero-crossing” pulse is not detected within the allowable time (4-10 milliseconds). This pulse is hardwaregenerated every 1 millisecond. [ 17 ] BAD READING ON RESOLVER PORT This error appears if the value of resolver “counts”, read from the resolver port when the “zero-crossing” pulse is detected, is too large, indicating possible failure of the resolver cables, 1010-4 card, or the resolver itself. Also caused by severe motor vibrations. [ 18 ] AMPLIFIER FAULT LINE DOWN This error appears any time the axis card no longer detects the fault line signal from the amplifier, or the signal strength has dropped below 10V, at least 5V indicating a possible amplifier fault. [ 19 ] STACK OVERFLOW — OVERLOADED WITH STEP COMMAND This error appears if the stack on the axis card, used to store CPU commands until they have been serviced, overflows. [ 20 ] MOVE TRANSFER FAULT — MOVE SETUP INCOMPLETE This error appears when an axis move command is not properly transferred to the axis card, as indicated by a checksum comparison between what the CPU sent and what the axis card received. [ 21 ] UNEXPECTED INTERRUPT This error appears if the interrupt currently being processed is not an expected interrupt, and therefore cannot be serviced, indicating possible failure of the 1010-4, 1030, or main CPU. [ 22 ] BAD SCALE READING This error appears if the feedback from the scale port is outside allowable limits, indicating possible failure of the EXE box, scales, cables, or 1010-4 card. Also caused by severe motor vibrations. [ 23 ] MOTOR OVERLOAD DURING STAND-BY MODE SEE ERROR CODE 13 ABOVE [ 24 ] MOTOR OVERLOAD DURING RAPID MODE SEE ERROR CODE 13 ABOVE 544 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual [ 25 ] MOTOR OVERLOAD DURING CONTOURING MODE SEE ERROR CODE 13 ABOVE [ 26 ] MOTOR OVERLOAD DURING JOG MODE SEE ERROR CODE 13 ABOVE Troubleshooting Checklist RS-232 Commmunications Use this procedure to determine which device or cable is not functioning properly. At the end of each step check to see if communications are possible. If no communications occur: 1. If a switch box is used, determine that the switch is in the proper position. • Turn the switch handle back and forth a few times. Sometimes the connections are corroded and turning the handle will TEMPORARILY correct the problem. 2. Check to see if all cable connections are firmly connected. • Loose cable connections are the MOST COMMON cause of communications failures. 3. Check to see that the phone modem cable on the inside of the control cabinet is disconnected from the back of the phone modem in the modem sleeve. Some machines do not have a phone modem in the sleeve. • The phone modem WILL interfere with communications through the RS-232 port. 4. The machine must be properly grounded. Follow the grounding instructions on the green label inside the main disconnect box to confirm the grounding connections. 5. Check to see if the communication parameter settings in the software of the computer are set properly. a. Baud rate - This is variable, depending on the default setting at the machine established in SETP or with a CD,# command • Sometimes a computer can communicate at the lower baud rates (600 or 1200) and not at the higher baud rates (2400 - 9600). The customer should try a lower baud rate as a temporary solution. b. Parity - Even March 2003 Section 16: Troubleshooting 545 Fadal Maintenance Manual c. Data Bits - Seven d. Stop Bits - One e. EOB (End Of Byte) - CR,LF (ASCII 13,10) f. Starting and ending character - % (ASCII 37) g. Xon/Xoff (Software handshaking) - disabled for TA or PU, enabled for DNC h. Hardware handshaking - disabled i. The IO port number (RS-232 or serial port) on the computer must be identified (i.e.,COM 1, COM2. COM3 or COM4). 6. Determine that the IO port on the machine is functioning properly. Exercise the port by putting a mirror plug in the port and sending a character out. which should then be received back again. • The mirror plug, found in the control cabinet of the machine, is a DB-25 plug with pins 2 and 3 crossed, and is usually shipped with the machine. or can be ordered from our parts department. a. Put the mirror plug in the RS-232 port of the machine. b. Move to the cold start position and go into the diagnostics mode. c. From the command mode type DI then press the enter button. Then type GO 3000 (G zero, space, three thousand) then press the enter button. A menu will appear, then select number four by pressing the 4 button. A second selection will appear. Select the baud rate that is desired for the test by pressing one of the numbers. d. Numbers next to the word TESTING should be changing constantly. e. The numbers at the end of the other sentences should all be zero. If any numbers appear at the end of these sentences an error on the 10 port has occurred and indicates a problem with the port. • If this test fails the S100 board is bad or the cable on the inside of the control cabinet is faulty or it is not plugged in properly. Change the S100 board and cable if needed. Note: It is our experience that the S100 board and inside cable rarely need to be changed. f. This test can be repeated with each section of cable plugged into the machine leading up to the computer. This will test the integrity 546 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual of each section. A gender changer may be needed to plug in the mirror plug in some sections. • If a switch box is used in the chain of cables, it must be checked also. Check it in the same manner that the cables were checked. 7) After thoroughly checking the machine and the cables it can be safely concluded that something in the computer is at fault. • Introducing another computer into the line of communication is a quick way to determine if the computer in question is faulty. a. A mouse or network board. screen savers, and other software running concurrently in the host computer, may interfere with communications. Check the IRQ and DMA settings in the computer for conflicts with the values assigned to the IO port. b. The output voltage of the IO board across pins 7 and 12; when transmitting a program, should be between 10 and 12 VAC. c. The file being sent may have something wrong with it. Incorrect syntax in a line of code may interrupt transmission. March 2003 Section 16: Troubleshooting 547 Fadal Troubleshooting Charts 548 Maintenance Manual Chart 1 Chart 2 Chart 3 Chart 4 Chart 5 Chart 6 Chart 7 Chart 8 Chart 9 Chart 10 Chart 11 Chart 12 Chart 13 Chart 14 Chart 15 Chart 16 Chart 17 Chart 18 Chart 19 Chart 20 Chart 21 Chart 22 Chart 23 Chart 24 Quick Checkout Automatic Tool Changer Spindle Driver Axis Control Repeatability Computer Axis Motor Runaways Baldor SWEO Spindle Drive Z200/Z300 Spindle Drive Keyboard Finish Problems Bad Power / Bad Voltage Rotary Heads A Axis FADAL TR65 Rotary Heads A & B Axis Tsudakoma 301 Rotary Heads A & B Axis Servo Coolant Control Circle Roundness Error Codes Reported by Axis Card Serial Port Communications FADAL Servo Indexer Positioning Problems Scale Problems Rigid Tap M-Function Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 1 Q U IC K C H E C K O U T P R O C E D U R E DA S H ED S YM B O L S AP PL Y TO C E N OR M EU R O P EA N M AC H IN E S ONLY 9- 2 0 -9 5 Q U IC K C H EC K OU T DIF FIC UL T T O D IA GN O S E P RO B LE M S C A N O C CU R IF M AC H INE IS N O T P R OP E RL Y G R O UN D ED . TH ER E MU S T B E A CO N TIN U O US G RO U N DIN G CO N D UC TO R (AS S PE CIF IED O N T H E G R OU N D IN G LA B EL IN TH E M AC H INE 'S D IS CO N N EC T B O X) F RO M TH E VM C 'S GR O U ND BU S TO TH E GR O U ND B US IN T HE BU ILD ING 'S P OW E R DIS TR IB UT IO N P AN E L. IS TH ER E NO AIR PR E SS U R E? (8 0 P SI )) YE S 1. 1 PR OP ER AIR PR E SS U R E AN D A D EQ U ATE A IR V O L U M E IS C RI TIC A L FO R TO O L C HA N G E S. AIR PR E SS U R E RE G U L A TOR O N MA C H IN E M US T BE S ET AS L A BE L ED (8 0 - 9 0 PS I A N D 12 0 PS I F OR TOO L O U T R EG U L A TO R ) . AIR SU P PL Y TO MA C H IN E S HO U L D BE 1 2 0 P SI . AIR HO SE TO M AC H IN E M US T BE 3 /8 " AN D A S S HO R T A S PO S S IBL E . AIR DI ST RI BU T IO N P IP E IN B UI L D IN G S H O U L D B E A M IN IM U M OF 3/ 4 ". TH E PR E SS U R E DR O P A T TH E MA C H IN E D UR I N G A TOO L C H AN G E S H O U L D B E A MA XI MU M O F 3 -5 P S I. CO R R EC T AIR PR E SS U R E 1. 1 .1 SE T M ET ER F O R VA C AN D CH E C K FO R AC R IP P L E O N +5 V , + 1 2 V A N D - 1 2 V D C CH E C K + 5 V, +1 2 V , -1 2 V , AN D 1 1 0 V AC AT PO W ER S U P PL Y ( 12 2 0 ) (U S E O SC IL L O SC O P E IF A VA IL A BL E ) (0 .01 5V AC R IP P LE M AX O N + /-12 V, 0.00 5V AC R IP P LE M AX O N + 5V ) 1. 2 1. 3 1. 5 YE S YE S YE S RE P EA TA BI LI TY PR O B L EM ? 1. 6 1. 7 YE S 1. 7 .1 NO KE YB O A R D PR O B L EM ? 1. 8 YE S 1. 3 .5 CH E C K FU S ES F5 , F6 , F7 , F8 , F 19 , F2 0 AN D C IR C U IT B RE A KE R S CB 1 & C B 2 O N 1 1 0 0 -2 1. 4 .2 1. 4 .3 TO O L D U L L ? OR TO O L AR G E A C U T? 1. 5 .2 CH E C K CI R C UI T BR E AK ER S (C E MA C H IN ES ) 1. 3 .6 SE E CH A R T NO . 4 1. 3 .7 SE E CH A R T NO . 2 1. 4 .4 SE E CH A R T NO . 3 1. 5 .3 CH E C K TO OL I S TIG H T CH E C K FO R FIX TU R E MO V E ME N T 1. 6 .2 CH E C K PU L S E L E D 's ON A LL BO AR D S . AR E TH E Y B L IN K IN G . CH E C K MO T O R O VE R L OA D RE L A YS 1. 3 .4 CH E C K TH AT R E LA Y S K5 , K6 , K3 3 , K1 1 , K1 2 , K 1 3 , & K 1 4 AR E FIR M L Y SE AT ED O N 1 1 0 0 -2 B O A R D VE R IFY PU L S E L E D 's O N A LL AX IS BO AR D S AR E BL I N KIN G CH E C K FO R CH I PS IN SP IN D L E CH E C K D OO R S . (C E MA C H IN E S L IM IT M O V EM E NT W H EN D O O R S AR E O P EN .) MA KE S U R E FEE D R A TE IS N O T AT 0 % 1. 3 .3 CH E C K CO L D ST AR T PO S ITI O N OF Z AX IS 1. 6 .1 NO CO N TR O L PR O B L EM ? CH E C K EM ER G E N C Y STO P BU TT O N 1. 3 .2 . 1. 5 .1 NO 1. 2 .3 YE S 1. 4 .1 NO IS IT A S P IN D L E PR O B L EM ? VE R IFY PU L S E L E D 's O N A LL AX IS BO AR D S AR E BL I N KIN G 1. 3 .1 NO IS IT A T OOL CH A N G E R PR O B L EM ? 1. 4 YE S SE E CH A R T NO . 1 2 1. 2 .2 1. 2 .1 IS IT A N A XI S PR O B L EM ? NO IS PO W ER O K? 1. 6 .3 CH E C K LE V EL N E SS OF MA C H IN E AD J U ST PO S ITI ON L O O P G AI N AN D FEE D R AT E C L O C K 1. 6 .4 1. 6 .5 SE E CH A R T NO . 5 1. 6 .7 SE E CH A R T NO . 6 1. 7 .2 SE E CH A R T NO . 1 0 1. 8 .1 GO T O PA G E 2 O F CH A R T 1 Figure 16-1 Quick Checkout Procedure March 2003 Section 16: Troubleshooting 549 Fadal Maintenance Manual CO N T IN U E D FROM CH A R T 1 PA G E 1 C H A R T 1 c o ntin u e d (p a ge 2 ) Q U IC K C H E C K O U T P R O C E D U R E 9- 2 0 -9 5 IS IT A F IN IS H PROBLEM ? 1A .1 YES 1A .1 .1 NO IS IT A RO TAR Y HE AD PROBLEM ? 1A .2 YES YE S IS IT A SE R VO C OO LA N T PROBLEM ? 1A .4 YES MAKE SURE P O S IT I O N O V E R R I D E P O T IS CE N TE R ED V E R IF Y SE R VO C OO LA N T A X IS IS S E T T O C O O L A N T IN S E T P 1A .3 .2 CH E C K SIN/C O S S IG N A L S U S I N G S E R V IC E T O O L S T 4 8 . A D J U S T IF V A R IA N C E > 0 . 00 1 V CHE C K BA LAN CE O F A X IS A M P L IF IE R S 1A .4 .1 NO ERROR CO D E? 1A .1 .3 SEE CHA RT 13, 14 . 0 R 1 5 1A .3 .1 NO IS IT A RO U N DN E S S PROBLEM ? 1A .1 .2 SEE CHA RT NO . 11 1A .2 .1 NO 1A .3 CHE C K SIN/C OS S IG N A L S U S I N G S E R VIC E T O O L S T 4 8 . A D J U S T IF V A R IA N C E > 0.001 V CHE CK BA LAN CE O F A X IS A M P L IF IE R S YES 1A .5 1A .4 .2 SEE CHA RT NO . 16 1A .3 .3 SEE CHA RT NO . 17 1A .4 .3 SEE CHA RT NO . 18 1A .5 .1 NO IS IT A C O M M U N IC A T IO N PROBLEM ? YES 1A .6 V E R IF Y BAUD RATE AND C O M M U N IC A T IO N PA RAM ET ER S V E R IF Y CO N N EC TIO N OF R S 232 C AB LES 1A .6 .2 1A. 6.1 SEE CHA RT NO . 19 1A .6 .3 NO IS IT A N IN D E X E R PROBLEM ? YES 1A .7 YES 1A .7 .1 NO IS IT A N M -F U N C T IO N PROBLEM ? 1A .8 IS IT A FAD A L IN D EX E R ? SEE CHA RT NO . 20 1A .7 .2 NO YE S NO SEE CHA RT NO . 24 1A .8 .1 GO TO PAGE 3 OF CH A R T 1 Figure 16-2 Quick Checkout Procedure (Continued) 550 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 1 continued (page 3) QUICK CHECKOUT PROCEDURE CONTINUED FROM CHART 1 PAGE 2 IS IT A POSITIONING PROBLEM? 1B.1 9-20-95 YES NO DOES MACHINE HAVE SCALES? 1B.1.1 NO SEE CHART NO. 21 1B.1.2 YES, START WITH SCALE CHART IS IT A SCALE PROBLEM? YES 1B.2 1B.3 SEE CHART NO. 22 1B.2.1 NO IS IT A RIGID TAPPING PROBLEM? REMOVE COVER FROM SCALE BOX ON OUTSIDE OF CONTROL BOX AND CHECK FOR ERROR LED YES 1B.2.2 SPINDLE INVERTER MUST BE LABELED "RIGID TAPPING" SPINDLE SOFTWARE (IN 1010-S) MUST BE RIGID TAP 1B.3.1 NO 1B.3.2 FOUNDATION IS IMPORTANT IS IT A VIBRATION PROBLEM? 1B.4 YES SEE CHART NO. 23 1B.3.3 SEE MAINTENANCE MANUAL FOR DETAILS MOVE ONE AXIS AT A TIME TO DETERMINE WHICH AXIS HAS VIBRATION PROBLEM CHECK ALIGNMENT OF MOTOR MOUNTS AND BALLSCREW MOUNTS 1B.4.1 1B.4.2 1B.4.3 MACHINE MUST BE POSITIONED ON A SINGLE SLAB OF CONCRETE WITHOUT CRACKS CONSULT CHART 3, CHART 22, CHART 23 1B.4.4 Figure 16-3 Quick Checkout Procedure (Continued) March 2003 Section 16: Troubleshooting 551 Fadal Maintenance Manual CH AR T 2 A UT OM A T IC T OO L CH AN G E R TOOL CH A N GE R 10-18-95 PROP ER AIR PR E SS U RE AN D A D EQ UATE A IR V OLU M E IS C RI TIC A L FOR TOOL CHA N GE S. AIR PR E SS U RE RE GU LA TOR O N MA C H IN E M US T BE S ET AS LA BE LED (80-90 PS I A N D 120 PS I F OR TOO L OU T R EGU LA TOR ). AIR SUP PLY TO MA CH IN E S HO ULD BE 120 P SI . AIR HO SE TO M AC H IN E M US T BE 3/8" AN D A S S HO R T A S POS S IBLE . AIR DI ST RI BU T ION P IP E IN B UI LD IN G S HOULD B E A M IN IM U M OF 3/ 4". TH E PR E SS U RE DR O P A T THE MA C HIN E DURI N G A TOO L C H ANG E S H OU LD B E A MA XI MU M OF 3-5 P S I. US E T OOL IN/ OU T TO IN S ER T /R E MO VE TOOL F RO M S PI N D LE 2. 1 DO ES TOOL I N/OUT W OR K ? 2. 2 CH E C K AI R PR E SS U R E (80P SI AN D 120P SI ) (M AX 3-5 PS I DR O P DU R I NG TOO L CH A N GE ) NO 2. 2.1 YE S PRE SS TUR R ET CW AN D TUR R ET C C W MA N U ALLY AC T IVA TE DR A W B AR SOLE N OID AT MA C A IR VA LVE A SS Y. CH E C K F20 AN D K24 ON 1100-2. 2. 2.2 2. 2.3 (IF A T OOL IS IN TH E S PIN D LE , HA VE H EL PE R HO LD O N TO IT.) EUROP EAN CE N ORM MACH INES M UST HAVE DOOR S CLOSED FOR ATC TO WORK PROPER LY DO ES DR A WB AR W OR K W H EN M A NUA LLY OPE R AT ED ? 2. 2.4 NO CH E C K AI R DE LIV ERY TO DRA WB AR CY LIN D E R . 2. 2.6 YE S CHE CK 1040 AN D W IR ING (S EE D R A WIN G 1002 AN D K EY B OAR D TR OU BLE S HO OTI NG DI AG RA M ) CH E C K D RAW B A R CY LIND E R FOR BA D SE A LS O R BR OK EN PI STO N 2. 2.7 2. 2.5 2. 3 DI D TU R RET MOV E C ORR E C TLY? 2. 4 EM ER GE NC Y ST OP MUS T B E RE LE AS ED AN D AM PLIF IE RS R E SE T NO 2. 4.1 C2 ON 1100-2 MU S T BE B YP AS S ED . 2. 4.3 GEN E VA 2. 5 2. 4.2b 2. 4.2a DI D SP IN DLE OR IE NT ? CH E C K TUR R ET FA CTOR I N SE TP . CH E C K GE NE V A M EC H A N ISM . CH E C K TUR R E T M OTOR WIR IN G. CH E C K FU SE S F5 & F6 & CB 2 AN D RE LAY S K5, K33, K11, & K 12 ON 1100-2. K12 M U ST BE R A TE D FOR 3 AM P OU TP U T (BLA C K) . IN M DI E N TE R M19 NO DI D SP IN D LE TU RN ? 2. 6.1 YE S YE S DI D OR IE NT AT ION AR M SW IN G IN ? 2. 6.2 GO T O CHA RT NO . 3 SP IN D LE DRI VE R NO ADJ UST OR IE NT AT ION FAC T OR IN S ETP 2. 6.2a NO 2. 4.4 C H ECK S ER V O T U RRE T ME C HAN IS M FOR B IN D ING OR E XC E SS IV E PLA Y. CH E C K TU R R ET MO TOR W IR IN G. CH E C K TU R RET MO TOR E N C OD E R AND W I R IN G. 2. 4.5 IF T UR R E T A M PLIF IER FUSE I S BLOW N OR O VE R-C UR R E N T LE D IS O N, C H ECK M OTO R WIR E S F OR S H OR T T O C H AS S IS. (WI R ES TO MO TOR AR E SH I ELD E D ; SH IE LD M US T BE S TR IP PE D BA C K F ROM C ON D UC TOR). 2. 6.1a YE S CH E C K FU SE S F5 & F6 & CB 2 AN D R E LAY S K5, K33, K11, & K 12 ON 1100-2. K12 M UST BE LOW LE A KA GE (GREE N ). CH E C K F4 A N D SE R VO TUR R ET FUS ES . TU R RET FAC T OR IN S ETP M U ST BE 1 FOR S E R VO TU RR ET . SE R VO 2. 4.2 YE S GO TO C S PO SI TI ON. (I F N O T C O LD S TA R T ED , DO A C OLD ST A RT.) 2. 6 GE NE V A OR S E RVO TU RR ET ? GO T O CH A R T NO . 3 SP IN D LE DR I VE R 2. 4.6 IF T UR RE T M OV ES CO R REC TLY E XC E PT FOR D IR E C TIO N, CHA NGE D IR E C TION CO N TR OL FR O M TB1- 7 TO TB 1-5 ON 1100-2 (OR VICE V ER S A) 2. 6.2b CH E C K F19 & K23 ON 1100-2 2. 4.7 2. 6.3 IF TU R RE T R U NS A WAY : 1 .RE V ER SE MO TOR LE AD S , 2 .CH E CK EN C O DE R WIRIN G, 3 .RE P LA CE EN C ODE R , 4 .RE P LA CE TU R RE T C ONT RO L MOD U LE . RE M OV E TO OL FR OM S PI N D LE AND MAN U A L LY A CTI VA T E OR IE N TA TI ON A IR S OL EN O ID AT M A C AI R V A LV E ASS Y . 2. 4.8 2. 6.4 DI D OR IE NT AT ION ARM SW IN G IN? 2. 6.5 GO T O PA GE 2 OF CH A R T 2 2. 7 YE S NO CH E C K AI R PR E SS U R E. CH E C K AN D RE P AIR OR IE NT M EC H A N ISM AN D A IR LIN E S . IF V ERY HE AV Y TOO LS AR E U N EV E NLY DI ST RI BU TE D, RE D IS TR IB UTE TOO LS ON TUR R E T CHE CK WIR I NG. TR Y KN OW N GOOD 1040. 2. 6.6 2. 4.9 D IP S W ITC H SE TT ING S SP EE D SW 1 S W2 F AS T OP E N OP E N M E DF A ST C LO S E D O PE N M E DS LO W O P EN C L OS E D S LO W C LO S E D C LO S ED MO T OR T YP E: S W3 & SW 4 O PE N C O N SU LT FA CT ORY A BO U T O TH E R MO T OR S ET TIN GS. CO N SU LT FACT OR Y SE RVIC E D E PT . AB OU T D I P S WI TC H SE TTIN G S F OR SP EE D A N D PI D 2. 4.10 2. 6.5a Figure 16-4 Automatic Tool Changer 552 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual C H A R T 2 c o nti nu e d (p a ge 2 ) A U T OM A T IC T OO L C H A N G E R CO N TIN U E D FR OM PA GE 1 OF CH A R T 2 1 0 -1 8 - 9 5 MA N U A LL Y MO VE A T C TO EX TE N D E D P OS ITI ON (G R AS P A N D SW IN G UP P ER GE N E VA A R M) 2A .1 NO DI D ME C H AN IS M MO VE SM OOTH L Y ? 2A .2 2A .2 .2 2A .2 .1 YE S IS TOOL C A R R IE R PR OP ER L Y A L IGN E D W ITH S P IN D L E? RE P L AC E ME C H AN IS M IF D A MA GE D CL E A N, A DJ U S T, AN D L U B R IC AT E ME C H AN IS M NO CH E C K AN D A D J US T TU R R ET FAC T OR CH E C K IF T OOL CA R R IE R IS OU T OF P OS ITIO N OR S KE W E D DU E TO A C R AS H (T U RR E T FA C TO R MU S T B E 1 FO R SE RV O TU R RE T.) 2A .3 2A .3 .1 2A .3 .2 AD J U ST TU R R ET AL IG N ME N T AN D /O R CO L D ST AR T PO SIT ION 2A .3 .3 (S E RV O TU R RE T M U S T MA K E A M OV E BE FO R E TU RR E T A LIG N ME N T IS AD JU ST E D.) YE S RE TU R N A TC T O RE TR A C T ED PO SI TI ON . TH EN IN MD I E N TE R M6 T2 (IF TO O L 2 IS IN T H E SP IND LE , U SE M 6T 1.) 2A .4 DI D ATC SL ID E CO ME IN ? NO 2A .5 YE S AR E FU SE S F7 , F8 , & C B1 AN D R E L AY S K6 , K1 3 & K 1 4 OKA Y ? 2A .5 .1 YE S CH E C K AT C H OME S W IT C H . CH E C K A TC FA U L T S W IT CH . CH E C K C ON TR OL V OL TA GE A T K 1 4 . CH E C K SL I DE M OTO R & W I R IN G. CH E C K AT C AL IG NM E N T 2A .5 .2 NO 2A .5 .3 CH E C K SL I DE M OTO R BE L T TE N SI ON AN D A D JU S TM EN T O F G EN E VA S L OT 2A .5 .4 RE S ET C B1 O R RE P L AC E F7 , F8 , K 6, K 13 , K 14 AS N EE D E D 2A .5 .1 a DI D YE S TOOL C A R R IE R CR A S H IN TO SP IN D L E? 2A .6 TU R R ET MU S T B E AT AN E M PTY POC K ET (A D JU S T S ET TO) 2A .6 .1 NO AD J U ST CO L D ST AR T PO SIT ION , AN D TU R R E T A L IGN M EN T 2A .6 .2 (S E RV O TU R RE T M U S T MA K E A M OV E BE FO R E TU RR E T A LIG N ME N T IS AD JU ST E D.) CH E C K TU R R ET FA C TOR FOR GE N E VA . CH E C K EN C OD E R A N D EN C OD E R W IR I NG FOR S E R VO TU R R ET . 2A .6 .3 (T U RR E T FA C TO R M US T BE 1 FO R SE R VO T UR R ET .) GO T O PA GE 3 OF CH A R T 2 2A .7 Figure 16-5 Automatic Tool Changer (Continued) March 2003 Section 16: Troubleshooting 553 Fadal Maintenance Manual C H A R T 2 continu ed (page 3) AUTOM A TIC TOO L CHA NG E R 10 - 1 8 -9 5 C O N T IN U E D FROM PA GE 2 OF CH A R T 2 P R O P E R A IR P R E S S U R E A N D A D E Q U A T E A IR V O L U M E IS C R I T IC A L F O R T O O L C H A N G E S . A IR P R E S S U R E R E G U L A T O R O N M A C H IN E M U S T B E S E T A S L A B E L E D (8 0 - 9 0 P S I A N D 12 0 P S I F O R T O O L O U T R E G U L A T O R ) . A IR S U P P L Y T O M A C H IN E S H O U L D B E 1 2 0 P S I . A IR H O S E T O M A C H IN E M U S T B E 3 /8 " A N D A S S H O R T A S P O S S IB L E . A IR D I S T R I B U T IO N P IP E IN B U I L D IN G S H O U L D B E A M IN IM U M O F 3/ 4 " . T H E P R E S S U R E D R O P A T T H E M A C H IN E D U R I N G A T O O L C H A N G E S H O U L D B E A M A X I M U M O F 3 -5 P S I. DI D Z A X IS GO UP? IS TOOL STUCK IN S P IN D L E ? NO 2B .1 IS DR A W B A R FU SE OK A Y? (F 2 0 ) YE S 2B .1 .1 2B .1 .2 CH E C K CH E C K CH E C K CH E C K S L I D E E X T E N D E D S W IT C H . A T C F A U LT S W IT C H . D R A W B A R S W IT C H . Z A XIS SE R VO. NO CH E C K DR A W B AR SW I TC H (A N D A D J U S T M E N T ) , AN D D R A W BA R C Y L IN D E R A S S Y RE P LAC E FU SE F20 2B .1 .1 a YE S A IR P R E S S U R E M U S T B E 80 P S I A N D 1 2 0 P S I (M A X 3 - 5 P S I D R O P DU R I NG TO O L C H AN G E) 2B .1 .3 NO NO YE S IS M A C H IN E IN A T A P -T A P CY C L E? YE S 2B .1 .2 a 2B .1 .4 CH E C K K24 AN D C O N T RO L VOLT AGE TO K 24 2B .1 .5 2B .1 .3 a DI D TURRET IN D E X ? 2B .2 NO YES DI D TURRET STO P? GO B AC K TO S TA RT OF CH A R T 2 2B .1 .6 2B .2 .1 NO IF O V E R S H O O T / UN D E R SH O OT CH E C K/ AD J U ST TU R R ET FAC T OR CH E C K TU R R ET F E E D B A C K S W IT C H 2B .3 2B .3 .1 YE S DI D Z A X IS C O M E DO W N ? NO YES YE S NO CH E C K AT C A L IG N M E N T & BE LT TE N SION 2B .5 .1 a DI D S L ID E M O T O R STO P? 2B .6 NO D I D S P IN D L E DR O P T OO L ? 2B .7 NO CH E C K AT C S L ID E H O M E SW ITC H 2B .6 .1 YE S YE S CH E C K CO L D ST AR T P O S IT I O N . 2B .7 .1 (T U R R E T F A C T O R MU S T B E 1 FO R SE RV O TU R RE T.) 2B .3 .3 2B .4 .2 DI D Z A X IS G O UP ? 2B .5 .1 GO BACK TO S TA RT OF CH A R T 2 CH E C K AT C SA FE TY SW ITCH 2B .4 .1 YE S 2B .5 2B .3 .2 CH E C K Z A X IS SE R VO NO 2B .4 DI D SL I D E PU LL B AC K ? TO O L H O L DE R S MU S T B E CLE A N . CH E C K D R AW BA R VA LVE FU S E F20 . CH E C K Z A XI S FOLLOW ING ER R OR , IS IT E X C E S S I V E ? C H E C K K 2 4 A N D IT S CO N TR O L V OL TA G E . 2B .5 .2 CH E C K FU SE S F7 & F8 & CB1. CH E C K R EL A YS K6, K13, & K 14 2B .5 .1 b 2B .5 .3 CH E C K: S L I D E E X T E N D E D S W IT C H , A T C F A U LT S W IT C H , D R A W B A R S W IT C H , SL I DE M O TO R 2B .5 .1 c CH E C K AIR PR E SS U R E (8 0 P S I ) A N D 1 2 0 P S I (N O T T O E X C E E D 3- 5 P S I D R O P D U R IN G TOOL CHA NGE ) 2B .5 .4 SE E TOOL CHA NGE R AD J U STM E NT S IN M A IN T E N A N C E MA N U AL 2B .5 .5 CH E C K AD J U STM E NT O F GEN E VA S LOT 2B .6 .2 MAKE SURE T OOL HA S PR O PE R PULL STUD. 2B .7 .2 ATC SY ST EM S OK END 2B .8 Figure 16-6 Automatic Tool Changer (Continued) 554 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual DA SHED SYM BOLS APPLY TO CE NORM EUROPEAN M ACHINES ONLY CHART 3 SPIND LE DRIVE R SPINDLE DRI VER 10-20-95 DIF FICUL T T O D IA GN OS E P ROB LE MS CA N OCCU R IF MAC HINE IS NOT P R OP E RL Y GROUN DED . TH ERE MU ST B E A CONTINUOUS GROUNDIN G CON DUCTOR (AS S PE CIF IED ON T H E GROUND ING LA B EL IN THE MACHINE 'S D IS CON NECT B OX) F ROM THE VMC'S GR OU ND BUS TO THE GROUND B US IN T HE BUILDING'S P OWE R DIS TR IB UT ION P AN E L. NOT E: SPINDLE WILL NOT RUN ON A CE M ACHINE WITH THE DO ORS OPEN CHE CK ERROR MESS AGES ON INV ERTE R DISPLAY (M ITSUBI SHI INVE RTERS REQUIRE INSTA LLAT ION OF PARAM ETER UNIT ) CO RRECT FAULT AND RESET I NVERTER 3. 1 NO DO ES SP INDLE RUN? 3. 2 WILL SP INDLE TURN BY HAND? 3. 2.1 NO 3. 2.2 YES YES IS SP INDLE POT AT 0? 3. 2.1a SP INDLE MA Y BE FROZE N CHECK BELTS 3. 2.3 CHA NGE SPINDLE POT SETTING YES NO 3. 2.1a.1 VERIFY LE D ON SPINDLE 1010 (S LOT 14) IS BLINKING CHECK AND RESET OVERLOA D RELA Y 3. 2.1b 3. 2.1b.1 CHECK AIR PRE SS URE (80-90 PS I) 3. 2.1b.2 CHECK AND RE SE T CE CIRCUIT BREAKERS A12, B12, C12 CHECK 3-PHASE AC POW ER T O INVERTER 3. 2.1b.3 3. 2.1b.4 CHECK ERROR MESSAGES ON INVERTER DISP LAY (M ITS UBI SHI INVERTE RS RE QUIRE INS TALLAT ION OF P ARAM ETER UNIT ) AFT ER F AULT IS CORRECTE D PRESS RESET O N INVERTER 3. 2.1b.5 RUNS 3 SECONDS AND STOPS? (ERROR #8) YE S NO 3. 3 CHECK SPINDLE HALL EFFECT SWIT CH AND WI RING (USE DI DS TO S EE I F SWI TCH IS B EI NG READ) ON 1100-2: CHECK F1 & F3. CHE CK K7, K9, K3, & K4. 3. 3.1 3. 2.1b.6 MOT OR TURNS B UT SP INDLE DO ES NO T OR SLIP S? 3. 4 YES YES NO 3. 5 YE S SPINDLE TAKES A LONG TIM E T O STO P? NO 3. 6 SP INDLE SP EE D VARIES ? 3. 7 NO CO NTINUED ON PAGE 2 SPINDLE DRI VER (CHA RT 3) 3. 8 DO NOT OVE R TIGHTE N BE LT S 3. 4.1 NO SP INDLE RUNS IN ONE DI RECTI ON ONLY? INSPECT BELTS AND BELT TENSIO N CHECK AIR PRE SS URE (SHOULD BE 80-90 P SI ) CHECK F3, K 9, & K4 ON 1100-2 3. 5.1 3. 5.2 CHECK REGEN RESIST OR OR EXTE RNAL BRAK E 3. 6.1 YES CHECK/ ADJ UST J1 CONNECTOR * ON SPINDLE CARD 3. 7.1 3. 4.3 3. 4.2 CHECK FOR LO OS E W IRES OR TERMI NALS * 3. 6.2 VE RIFY THA T 1010S /J 1, J2, & J 3 * AND 1100-1/ J2 & J3 ARE PLUG GED IN 3. 2.1b.7 *GOL D COAX C ONNE CT OR M US T FIR MLY GRIP CE N TE R P IN (US E S ERV ICE TOOL S T4 4 T O T ES T A N D A DJUST ), M US T B E S OLIDLY CRIM PE D T O CEN TE R WIRE , M US T MAK E FIRM C ONTA CT WITH JA CK. US E OHM METER TO CHECK REGEN RESISTO R (CHE CK DRA WING 1002 FOR VALUE) IF SPI NDLE STILL DO ES NOT RUN, CHECK FUSES IN I NVERTE R, THEN T ES T I NVE RTER USING BATTERY BO X (SERV ICE TOO L ST 03) 3. 2.1b.8 SPINDLE RUNS WI TH BATTERY BOX ? CHECK FUSES IN INVERTE R YES SP INDLE CARD MAY BE BAD. SWAP IN KNOWN GOOD 1010-S 3. 2.1b.9 NO 3. 2.1b.10 3. 6.3 CHECK MO TOR WI TH OHMM ET ER LE G TO LEG ABOUT 0. 6 OHM . LEG TO G ND O.L. 3. 7.2 INSPECT HI /LOW RANGE MECHANIS M CHECK SP INDLE ENCODER WITH ENCODE R TESTER CHECK FOR VOLTAGE AT OVERLOAD RELAY TO DE CIDE IF M OT OR OR INV ERTER I S BAD 3. 2.1b.11 3. 7.3 TY PICAL SYM PTOMS O F A CO NSULT FACT ORY BAD ENC ODER : SERVICE DEPT . BALDOR SWEO : BE FORE REP LACING SPINS SLOWLY, SIN KS LOTS OF CU RREN T, MOT OR OR THEN FAULTS O UT (OC ). MITSUBIS HI: INVERTER NO VISIB LE S YMPTOM S MITSUBIS HI DOE S NOT RE QUIRE ENCO DER 3. 2.1b.12 FEEDBACK TO RUN . PERFOR MANC E SUFFERS ( BUT NO T OBVIOU SLY). Figure 16-7 Spindle Driver March 2003 Section 16: Troubleshooting 555 Fadal Maintenance Manual CHART 3 continued (page 2) SPINDLE DRIVER CONTINUED FROM PAGE 1 SPINDLE DRIVER (CHART 3) SPINDLE IDLERS WILL NOT SWITCH? 3A.1 10-20-95 YES USE DI DS TO CHECK HALL SWITCHES CHECK 0-5V SWITCHING AT K27 AND K10 ON 1100-1 (IDLER WILL NOT SWITCH UNLESS OTHER IDLER IS IN 01=OUT 00=IN) (5V PULL-UP IS SUPPLIED THRU THE RELAY, SO RELAY MUST BE IN PLACE) 3A.1.1 NO ORIENTATION FAILURE? CHECK SPINDLE TYPE IN SETP (CPU WILL NOT SWITCH IDLERS IF IT IS NOT A HI/LOW SPINDLE TYPE) YES 3A.2 BUZZ WIRING FROM 1060 J10-8 TO SLOT 14 J2 USE DI DS TO CHECK ORIENTATION MAGNET 3A.2.1 3A.3 YES YES 3A.2.4 USE ENCODER TESTER TO TEST AT EACH CONNECTOR FROM ENCODER TO INVERTER 3A.3.2 REMOVE BELTS, RUN SPINDLE AT MAXIMUM SPEED AND CUT POWER (MOTOR COASTS TO STOP) DOES SPINDLE MOTOR SHAKE WHILE COASTING? YES DOES VIBRATION OCCUR WHILE COASTING? 3A.5.2 CONSULT FACTORY SERVICE DEPT. BEFORE REPLACING SPINDLE MOTOR CONSULT FACTORY SERVICE DEPT. ABOUT BALANCING SPINDLE MOTOR 3A.4.3 NO BRING SPINDLE TO MAXIMUM RPM AND SHUT OFF POWER 3A.5.1 YES 3A.4.2 3A.4.1 NO 3A.5 CHECK THAT TERMINALS ON GREEN CONNECTOR ON INVERTER ARE TIGHT AND CLAMPED ON WIRE (NOT INSULATION) 3A.3.1 3A.4 SPINDLE VIBRATION? 3A.2.3 ORIENTATION MAGNET IS READ BY CPU THROUGH 1060 J10 PIN 8 BUT THE SPINDLE CARD READS IT THROUGH J2. IF WIRING IS BAD, CPU MAY BE ABLE TO READ MAGNET, BUT THE SPINDLE CARD MAY NOT BE ABLE TO READ IT. NO SPINDLE MOTOR SHAKES? IF ORIENTATION SOLENOID IS NOT ACTIVATING CHECK F19 AND K23 ON 1100-2 ADJUST ORIENTATION FACTOR IN SETP 3A.2.2 NO "BAD ENCODER" ON BALDOR-SWEO INVERTER? 3A.1.3 3A.1.2 3A.4.4 RUN AN EXTERNAL CABLE BETWEEN ENCODER ON MOTOR AND INVERTER NO 3A.5.3 YES POSSIBILITIES: BELTS, PULLEY OUT OF ROUND, MOTOR SHAFT BENT, BAD SPINDLE. NO DOES SHAKING/VIBRATION STOP? CONSULT FACTORY. 3A.5.4 3A.5.5 YES 3A.5.2a ENCODER CABLE IS BAD, INCORRECTLY ROUTED, OR INCORRECTLY SHIELDED. CONSULT FACTORY. 3A.5.4b POSSIBILITIES: INVERTER SOFTWARE, BENT ENCODER PIN, ENCODER DISK RUNOUT, BAD ENCODER, CONSULT FACTORY SERVICE DEPT. ABOUT INSTALLING SOLID MOTOR MOUNTS 3A.5.6 CONSULT FACTORY SERVICE DEPT. BEFORE REPLACING INVERTER 3A.5.7 Figure 16-8 Spindle Driver (Continued) 556 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 4 A XIS C O N T R O L AX IS C ON TR OL DA S H ED S YM B OL S AP PL Y TO C E N OR M EU R OP EA N M AC H IN E S ON L Y 10 - 2 0 -9 5 IS AX IS AT LI MI T? YE S 4. 2 4. 2 .1 NO IS IT A RUNAWAY PR OB LEM ? DIF FIC UL T T O D IA GN O S E P RO B LE M S C A N O C CU R IF M AC H INE IS N O T P R OP E RL Y G R O UN D ED . TH ER E MU S T B E A CO N TIN U O US G RO U N DIN G CO N D UC TO R (AS S PE CIF IED O N T H E G R OU N D IN G LA B EL IN TH E M AC H INE 'S D IS CO N N EC T B O X) F RO M TH E VMC 'S GR O U ND BU S TO TH E GR O U ND B US IN T HE BU ILD ING 'S P OW E R DIS TR IB UT IO N P AN E L. MOV E OFF LI MI T POS ITI ON W AS MOT OR RE P L AC E D ? YE S 4. 1 4. 1 .1 NO 4. 1 .2 YE S NO AR E AL L 3 A X ES RU N N IN G AW A Y ? GO T O CH A R T 7 CH E C K VO L TAG ES : +5 V , + 12 V, - 12V & 1 1 0V AC A T 122 0 YE S IF V OL TA GE S AR E OU T OF TOL E R AN C E , CH A N GE L OGI C POW ER S U PP L Y (A L SO C HE C K F OR A C RIP PL E O N DC V OL TA G ES : 0.01 5V AC MAX O N +/-1 2V 0.00 5V AC MAX O N +5 V) NO 4. 1 .4 4. 1 .3 DO ES TH E AX IS R U N TO A LIM IT? YE S 4. 1 .1 a 4. 1 .2 a IS AX IS CO MP L ET EL Y IN OP ER A TIV E? YE S 4. 3 4. 3.1 NO IS TH ER E AN A MP L IFI ER FAU LT? 4. 4 CH E C K C E CI R C UI T BR E AK ER S (A 1 0 ,B1 0, C1 0 OR 1 4 ) CH E C K MOT OR OVE R L OA D RE L A Y YE S 4. 3.2 NO DI D PR OB L EM FOL LOW TH E AM PL IF IE R CA R D ? SW A P SE R VO AM PL IF IE R CA R D 4. 3 .4 4. 3 .3 SW A P TH E AX IS CO N TR OL L ER CA RD S (1010) (R E ME MB E R TO CH A N GE J UM P ER BL OC K ON J 4) NO YE S 4. 3 .5 DI D YE S PR OB LEM FOL L OW TH E AX IS CA R D ? RE P LAC E SE R VO AM PL IF IE R CA R D CH E C K EM ER GE N C Y ST OP AN D MOT OR OV ER L O AD RE L A YS 4. 3 .6 4. 3 .4 a 4. 4.1 RE P LAC E AX IS CO N TR OL L ER CA R D 4. 3 .7 NO NO CH E C K C E CI R C UI T BR E AK ER S (A 1 0, B 1 0 , C 10 OR 1 4 ) W AS TH E PR OB L EM RU N A W A Y? 4. 3 .6 a YE S RE P LAC E RE S OL VE R 4. 3 .6 a .1 NO 4. 4 .2 WAS MOT OR RE C E NT L Y RE P L AC E D OR RE W I RE D ? 4. 4.3 YE S 4. 4 .4 NO A OR B AX IS W H IC H A R E NO T IN U SE ? 4. 4 .3a YE S YE S NO IF A OR B A X IS AR E NO T U S ED T H EY MU S T B E IN AC T IVE IN P AR A ME TE R S O R DU M M Y P L U G M U ST BE IN P L A CE . 4. 4 .3 a .1 NO IS IT Z-A X IS? AR E MOT OR W I RE S SH OR TE D TO CH A S SIS ? MOT OR W I RE S AR E SH I EL D E D . VE R IFY TH A T S H IE L D IS STR I PP ED BA C K FR OM C ON D U C TOR . VE R IFY TH A T DU M M Y P L U G SH OR TS PIN S H & G W ITH P OW ER O N AN D D U M MY P L U G IN ST AL LE D , V ER IF Y TH AT 11 0 0 -1 T B1 PIN 1 TO P IN 6 IS 0 V 4. 4 .3 a .2 4. 4 .3 a .3 DO ES IT M OV E FR EE L Y? TR Y TO M OV E Z-A X IS BY H A N D . 4. 4 .3 b GO T O PA FE 2 OF CH A R T 4 PR E SS J OG. DO A MP L IFIE R S STA Y ON ? 4. 4 .3c 4. 4 .3 b .1 NO NO CH E C K K1 , K2 ,K 18 ,K 2 0, F1 2 , & F1 4 ON 1 1 0 0-1 . CH E C K OV ER L OA D RE L A YS 4. 4 .3 c. 1 4. 3 .6 b 4. 4 .5 DO N O T M OV E Z-A X IS ! PR E SS EM E R GE N CY ST OP . YE S CO N SU L T FAC T OR Y SE R VIC E D E PT . BE FOR E R EP L A C IN G SE R VO MO TOR 4. 4 .3 b .2 W ITH P OW ER O N AN D D U M MY P L U G IN ST AL LE D , V ER IF Y TH AT 1 0 6 0 J5 - 6 A N D J4 - 6 AR E 0V 4. 4.3 a .4 NO CO N SU L T FAC T OR Y BE FOR E R E PLA C IN G BA L LSC R E W 4. 4 .3 b .3 YE S JU M PE R EM ER GE N C Y STO P C I R CU I T (J U MP F1 6 T O F12 ON 1 1 00 -1 ) CH A N GE A MP IN D IC AT ED B Y FAU LT LIGH T 4. 4.3 c. 2 4. 4.3 c. 3 Figure 16-9 Axis Control March 2003 Section 16: Troubleshooting 557 Fadal Maintenance Manual CHART 4 continued (page 2) AXIS CONTROL CONTINUED FROM PAGE 1 OF CHART 4 MOTOR OVERLOADS? 10-20-95 4A.1 4A.2 TEMPERATURE SNAP SWITCH WILL SHORT COS SIGNAL TO GND ON RESOLVER BOARD IN MOTOR IF MOTOR OVERHEATS. CHECK COS OUTPUT TO RESOLVER (PIN 8 OF J1-J6 ON 1060) FOR SHORT TO GND. LET COOL. CHECK AND ADJUST RESOLVER CONNECTOR AT AXIS CARD J2 WITH SERVICE TOOL ST44 * 4A.2.2 4A.2.1 NO 4A.2.3 RESOLVER FAULTS ON MULTIPLE AXES? 4A.2.4 RUNS ROUGH? YES ALL 3 AXES RUN ROUGH? YES 4A.3.1 4A.3 * GOLD COAX CONNECTOR : MUST FIRMLY GRASP CENTER PIN (USE SERVICE TOOL ST44 TO TEST AND ADJUST), MUST BE SOLIDLY CRIMPED TO CENTER WIRE, MUST MAKE FIRM CONTACT WITH JACK. 4A.1.3 4A.1.2 ISOLATE WHICH AXIS USING 201060-0-1 RESOLVER TESTBOARD YES GO TO PAGE 3 OF CHART 4 (SHOULD BE APPROX. 130-165VDC DEPENDING ON MODEL) CONSULT FACTORY IF DIFFERENT 4A.1.1 NO RESOLVER FAULTS? CHECK BUS VOLTAGE AT BLUE CAPACITOR ON AMPLIFIER CHASSIS. CHECK AND ADJUST COMMAND CONNECTOR AT AXIS CARD J1 WITH SERVICE TOOL ST44 * YES NO NO CHECK AND ADJUST RESOLVER CONNECTOR AT AXIS CARD J2 WITH SERVICE TOOL ST44 * CHECK RESOLVER 4A.3.1a CHECK SINE & COSINE OUTPUT OF CLOCK CARD (1020) USING SERVICE TOOL ST48 4A.3.2 CHECK WAYLUBE 4A.3.1a.1 CHECK RESOLVER CABLE. REPLACE RESOLVER. NO 4A.2.5 YES CHECK +12V & -12V ON 1220 CHECK J14 ON 1060 4A.2.4a 4A.2.4b CHECK 1060-0-1 OR JUMPER PCB IN J14 OF 1060 4A.3.1a.2 4A.2.4b CHANGE CLOCK CARD (1020) 4A.3.3 SWAP AMPLIFIERS AS ABOVE CHECK SINE & COSINE OUTPUT OF CLOCK CARD (1020) USING SERVICE TOOL ST48 4A.3.4 CHECK MOTOR COUPLER AND BALLSCREW FOR LOOSENESS. CHECK MOTOR THRU-BOLTS ARE TIGHT. 4A.3.1a.3 4A.3.1a.4 CHECK GROUNDING 4A.4 CONSULT FACTORY 4A.5 Figure 16-10 Axis Control (Continued) 558 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual C H A R T 4 c o n tin u e d (p a g e A X IS C O N T R O L 3) 6-1 5 -9 5 MOTOR OVERLOADS C O N T IN U E D FROM PAGE 2 OF CHART 4 IS T H E F A U L T DU R ING P R O G R A M EX EC U TIO N ? NO GO TO PAGE 4 OF CHART 4 4 B .1 YES 4 B .1 .1 IS T H E PROG RAM U S IN G M 9 0 - M 9 3 P R O G R A M M A B L E G A IN S E T T IN G S ? NO M90 = U M91 = N M 9 2= IN M93 = H 4 B .2 S E S E T P G A IN O R M A L G A IN T E R M E D IA T E G A IN IG H G A IN YES IN S E R T A N M 9 1 A T B E G IN N IN G OF PROGRAM. 4 B .3 R E M O V E A L L G 8 's . DO ES STILL DU R ING EXEC ERROR OCCUR PRO GRAM U TIO N ? YES SLOW DOW N THE FEE D R A TES IN THE PROG RAM 4 B .4 .1 4 B .4 NO NO PROBLEM SHOULD BE RESOLVED 4 B .5 IS T H E R E S T IL L A PROBLEM ? YES 4 B .4 .1 a IF N O T G O T O PAGE 4 OF CHART 4 4 B .6 END Figure 16-11 Axis Control (Continued) March 2003 Section 16: Troubleshooting 559 Fadal Maintenance Manual MOTOR OV ERLOA DS C H A R T 4 c o nt in u e d ( p a ge AXIS CO NTRO L CO N T IN U E D FROM PA G E 3 O F CH A R T 4 OVE RLOA D O C C U RS A T SLOW SP E E D ? 4C . 1 6- 1 5 -9 5 YE S 4C . 1 .1 NO 4C . 2 YE S CH E C K B A L L SC R E W AL IG NM E N T 4C . 1 .2 CH E C K AN D A D J US T M E C H A N IC A L A XIS LI M I T S T O P 4C . 2 .1 NO OCCUR W H IL E S T O P P E D O R IN G 0 ? 4C . 3 CHE C K W A YLU B E CH E C K AN D A D J US T G IB S A N D S T R A P S O VE R L O A D O C C U RS N E AR P O S IT I O N LI M I T ? 4) YE S LO O P G A IN P O T O N A M P L IF IE R SH O U L D B E M O S T L Y C W . (T U R N F U LL Y C W F O R T E S T A N D RE - AD J U ST L O O P G A IN IF T HI S CO R R E C T S P R O B LE M ) CU R R E N T L IM IT P O T O N A M P L IF IE R MUS T BE FULLY CW (E X C E P T F O R VH 6 5 ) 4C . 3 .1 NO 4C . 3 .2 M A K E A D JU S T M EN T S IN T H E F O L L O W IN G O RD E R : M AS T E R F E ED R A T E C L O C K , P O S I T IO N L O O P G A IN , B AL A N C E A D J US T M EN T . 4C . 4 PR O B L E M RE S O L V E D ? SW I T C H T O S E R V IC E P R O G R A M "P R ,5 8 1 1 " CH A N G E G 1 's T O G 0 's . RU N PR O G R A M . 4C . 5 YE S EN D 4C . 6 NO 4C . 5 .1 W AS FOLLOWING E R R O R C O RR E C T * THROUGHOUT MOVE? 4C . 5 .2 * G0 FOLLOWING ERRO R: INCH - 1840 +/-20 METRIC - X/Y 1630 + /-20 Z 1380 + /-20 YE S IS M A C H IN E W IR E D F O R 20 8 V A C ? 4C . 5 .3 YE S NO CH E C K SE T P PA R AM ET ER : "3 PH A S E > 5 % L O W " SH O U L D B E Y E S CH E C K BU S V O L T A G E AT BL U E C AP A C IT O R O N A M P L IF IE R CH A S SIS . SH O U L D B E 1 1 5 V A C 4C . 5 .4 4C . 5 .5 NO DO E S 20 " M O VE NO AT 1 00 IP M T AK E 12 . 2 -1 2 .5 SE C? 4C . 5 .3 a CH A N G E T H E G 0 's BA C K T O G 1 ' s AN D R U N P R O G R A M AG A IN YE S AD J U ST M A S T ER F EE D R A T E C L O C K 4C . 5 .3 a .1 SW A P Q U E ST I O N AB L E AM PL IF IE R W IT H O N E O F T H E O T H E R A X E S. 4C . 5 .2 a AD J U ST PO S IT IO N LO O P G A IN 4C . 5 .3 a .2 DID P R O B L EM S T A Y W IT H A X IS? YE S RU N P R O G RA M AG A I N 4C . 5 .3 b W AS FOLLOWING E R R O R C O RR E C T * THROUGHOUT MOVE? 4C . 5 .3 b .1 NO , ST A YE D W ITH A M P LI F IE R NO RE P L A C E AM P L IF IE R CH A N G E MOT OR 4C . 5 .2 b * G1 FO LL O W ING E R R O R : I N CH - 59 5 + / -1 M E TR IC - 30 2 + / -1 YE S 4C . 5 .3 b .3 CO N SU L T F AC T O R Y 4C . 5 .3 b .2 A D J U ST P O S IT I O N LO O P G A IN 4C . 5 .2 b .1 4C . 5 .2 c Figure 16-12 Axis Control (Continued) 560 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 5 R EP EAT A B IL ITY RE P E A T A B I LI T Y 9- 2 0 -9 5 F O R A D D IT IO N A L P R E C I SIO N IN L E V E L IN G , P E R F O R M SQ U A R E N E S S T E ST O N X & Y , T H E N S Q U A R N ES S T E S T O N C O L U M N , T H E N S P IN D L E T R A M T E S T . (C O N S U L T F A D A L S E R V I C E D E P T F O R P R O C E D U R E) V E R IF Y M A C H IN E IS L EV EL (S E E M A I NT E N A N C E M A N U AL ) DI F F IC U L T T O D I A G NO S E P R O B L E M S C AN O C C UR IF M A C H I NE I S N O T P R O P E R L Y G R O U N D E D. T H E R E M U ST B E A C O N T I NU O U S G R O U N D IN G CO N D UC T O R ( A S S P E C IF I ED O N T H E G R O U N D IN G L A B E L IN T H E M A C H IN E 'S D IS CO N N E C T BO X ) F R O M T H E V M C 'S G R O U N D B US T O T H E G R O UN D BU S IN T H E B U IL D IN G ' S POW ER DISTR IBU TION P AN E L. 5. 1 RE M O VE S U B P L A T E O R F I X T U R I NG . IS T H E R E A S U BP LA TE O R L A R G E H EA VY F IX T U R IN G ? 5. 2 MA C HI N E MU S T B E T ES TE D W I TH O UT FI X TU R I NG . SU BP LA T ES O R F IXT UR IN G C A N IN D UC E P O S IT I O NIN G PR O BL EM S TH A T A RE NO T INH E RE N T IN T H E M A CH IN E. PO S IT IO NIN G PR O B LE MS I N DU C ED BY FI X TU R I NG MU S T B E D E AL T W IT H S EP A RA TE LY FR O M PR O BL EM S IN TH E M AC H I NE ITS EL F. YE S NO 5. 2 .1 CH E C K A N D A D J US T : B AC K LAS H , B A L A N C E O N A X IS A M P S , L O O P G AIN O N A M P S N1 N2 N3 N4 N5 N6 N7 N8 N9 5. 3 IN S E R T P R O G R A M A T R IG H T . S E T U P IN D IC A T O R F O R P R O B LE M A X IS L 01 0 0 G1 F20. X 4 .0 X - 4 .0 G 4 P 1 0 00 M17 M30 L 01 9 9 M2 5. 4 * GO L D C O AX CO N N EC TO R (J1 , J 2 & J3 O N 101 0): M U ST FI R M LY GR A SP C EN TE R PIN (US E SE RV IC E T O O L S T4 4 TO T ES T A N D A D JU ST ), M U ST BE SO L I DL Y C R IMP E D T O C E NT E R W IR E , M U ST M AK E F IRM C O NT A CT W ITH JA CK . RU N PR O G RA M 5. 5 RE PE A T A BIL I TY CA N BE AF FE C TE D IF CO N NE C TO R IS LO O S E. DO ES T H E AX IS RE P EA T ? IN S P E C T M O T O R C O U P L ER AN D B A L L S C R E W FOR LOO SE N ES S . NO CH E C K F O R L O O SE RE S O L V E R O R C O U P L IN G . 5. 6 YE S 5. 6 .1 YE S DO E S A XI S HA V E A B A CK L A S H PR OB LEM ? 5. 7 CH E C K G O L D C O AX CO N N EC T O RS (J 1 , J 2 O N 1 0 1 0 ) W IT H S E R V IC E TOOL S T44 * 5. 6 .2 AD JU ST BA C KLA SH 5. 6 .3 CH E C K A N D A D J US T G IB S AN D S T R A PS CH E C K BA L L SC R E W A L IG NM E N T 5. 6 .4 CH E C K S I NE & CO S I NE O UT P U T O F C L O C K C AR D (1 0 2 0 ) U S IN G S E R V IC E T O O L S T 4 8 IF B A C K L A S H I S E X C E S S I VE , CH E C K F O R LO O S E N E S S IN M O T O R C O U P L E R , W O R N B A L L S C R E W , A ND BA L L S C R E W A L IG N M E N T 5. 7.1 NO A D J U S T G A I N A ND CO M P E N S A T IO N O N A XIS A M P L IF I E R 5. 6 .5 5. 7 .2 CH A N G E RE S O L V E R RE - IN S T A L L S U B P L A T E AN D F IX T U R IN G A N D R E PE AT T E S T 5. 6 .6 RE P EA T A B I LI T Y P R O BL E M S M A Y A L S O BE C AU S E D BY T E M P E R AT U RE G RO W T H O F B AL L S C R E W S O R S P IN D L E . 5. 8 CH E C K S U R V E Y T A BL E 5. 6 .7 DO ES T H E AX IS RE P EA T O N X & Y? 5. 9 A X IS R E P E AT S W I T H O U T S U B P L A T E A ND F IX T U R IN G B U T DO ES N O T R EP E A T W IT H S U B P L A T E A ND F IX T U R IN G . T H E R E F O R E F I XT U R I NG O R S U B P L A T E IS D IS T O R T I NG T A BL E O R C R E A T IN G A M E C H AN I CA L B IN D . O R A M A C H IN IN G PR O C E D U R E IS C A U S IN G N O N -R E P E A T AB IL IT Y. NO 5. 9 .1 YE S IS Z A XIS O F F S E T CH A N G IN G ? 5. 1 0 NO EN D A L L A XE S R E P E A T 5. 1 1 YE S 5. 9 .2 IS S P IN D L E CO O L ER RU N N IN G ? 5. 1 0 .2 CO R R EC T M E C H A N IC A L B IN D OR C H AN G E M A C H IN IN G P R O C E D U RE NO YE S IS C O O L A NT F L O W IN G IN RE S E R V O IR ? 5. 1 0 .3 NO CH E C K F O R A C R IP P LE ON THE DC V OLTAGE S (0 .01 5V AC M AX O N + / -1 2V , 0. 00 5V AC M AX O N + 5 V) 5. 1 0 .4 S E R V IC E T H E SP IN D L E CO O L E R A S SE M B L Y A N D P U M P A SS E M B L Y 5. 1 0 .5 Figure 16-13 Repeatability March 2003 Section 16: Troubleshooting 561 Fadal Maintenance Manual CO M P U T E R CHART 6 COMPUTE R PO W ER O N 9- 2 0 -9 5 (W A IT A F EW SE C O N D S AN D P R E S S CN C PO W ER S W IT C H ) 6. 1 A R E L ED S ON B OARDS F L AS H IN G ? NO PRE SS A ND HOLD CN C PO W E R S W IT C H 6. 2 6. 2 .1 YE S NO IS T H E R E 5V O N T H E 10 6 0 ? RE S ET BO AR D S TH A T A R E N O T F L A S H IN G GO T O CH A R T 1 2 6. 2 .2 6. 2 .3 G O I NT O D IA G N O S T I CS (IF C O N T R O L IS " D EA D " T R Y PO W ER IN G U P W ITH JU M P E R A T J 2 O N 1 4 0 0 6. 3 CA N YO U G ET IN TO DI AG NO ST IC S? 6. 4 YE S 6. 4 .1 NO IS T H ER E YE S G AR B AG E O N T H E SCRE EN? 6. 5 6. 4 .2 EP R O M M O DU L E ( 1 6 1 0) , EX PA N D ED M E M O RY ( 1 4 6 0 ), AN D B U S B R ID G E ( 1 7 3 0 ) M U S T B E F IR M L Y S E A TE D IN T H E IR C O N N E C TO R S . CH E C K FO R B E N T P IN S. CH E C K 5 V O LT S (5 .0 5 V ), +/- 1 2 V O L T S YE S 6. 5 .2 CH E C K VI DE O SWITCH ON F R O N T P A NE L CH E C K B R IG H TN E S S A N D C O N T RA S T P O T S O N M O N IT O R 6. 6 CH A N G E VID E O B O A R D ( 14 2 0 ) , CO M P U T E R IN T E R F A C E ( 1 0 3 0 ), CP U ( 1 4 0 0 ), E X P A N D ED M E M O RY ( 1 4 5 0 ) (A L SO S ET M E TE R FO R VA C AN D C H EC K FO R AC RIP P LE ON + 5V , + 12 V A ND -12 V D C ) 6. 5 .1 NO DI D SCRE EN G O D E AD ? IF M EM O R Y W A S RE P L A C E D O R A D D ED O R E PR O M M O D U L E W A S C H A N G ED , ZE R O M E M O R Y AN D RE S E T P A R A M E T E R S RU N DI AG NO S T IC S O N M EM O R Y , V ID EO , CL O C KS , M IL L IN T E R F A C E , ETC . IS V ID E O M O N I T O R A L IV E ? (C H E CK F O R GLOW) 6. 6 .2 YE S CH E C K V I DE O C AB L E. CH E C K F U S E F 2 5 O N 1 1 0 0 -1 . CH E C K V I DE O C AR D . IF 3 2 M P, CH E C K CN C / DO S SW I T C H 6. 6 .4 6. 6 .3 NO 6. 6 .1 NO 6. 5 .3 CH A N G E VID E O MONITOR 6. 6 .5 PO W E R O F F AND CHE CK FUSE S ON MONITOR 6. 6 .2 a IS M E M O RY L O S IN G PR O G R AM S? 6. 7 6. 9 YE S YE S CO N SU L T F AC T O R Y 6. 7 .2 SUM PRO GRAM TO F IN D A N D CO R R E C T A N Y ER R O RS P R O B L EM CO R R EC T E D ? 6. 8 .1 NO "ME MO RY E R R O R "? T E S T B A T T E R Y BA C KU P O N C PU B O A R D . RE P L A C E C PU B O A R D IF B A T TE RY T ES T FAILS. 6. 7 .1 YE S "E R R O R W H IL E P R O C E SS IN G BL O C K "? 6. 8 NO NO CH A N G E CP U /M EM O R Y BOA RD 6. 8 .3 6. 8 .2 Z ER O M E M O R Y. RU N RA M T E S T S IN D IA G N O S T IC S . IF T E S T F A IL S RE P L A C E C PU O R M E M O RY E XP A N SIO N IF P R O B L EM R E CU R S RE P L A C E C P U O R RA M E X P AN S IO N . 6. 9 .1 6. 9 .2 M E M O RY L O C A T I O N S : O N C P U ( 1 4 0 0) 4 0 0 0 0 -5 F F F F, 80 0 0 0 - 8 F F F F O N R A M EX P AN S IO N ( 1 4 6 0 -2 ) 9 0 0 0 0 - EF F F F Figure 16-14 Computer 562 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 7 A X IS M O T O R R U N A W A Y S A X IS M O T O R RU N A W A YS 6- 1 5 -9 5 W H E N R E P LA C IN G M O T O R S , C O N N E C T A L L W IR I N G A N D V E R IF Y C O R R E C T O P E R A T IO N B E F O R E IN S T A LL I N G M O T O R IN V M C . T H IS W IL L P R E V E N T D A M A G E T O M A C H IN E D U E T O R U N A W A Y S . A X IS M O T O R RUNS AW AY AFTER R E P L A C IN G T H E MOTOR 7.1 P O W E R D O W N M A C H IN E . PRE SS EMERGE NCY S TOP . C H E C K W IR IN G A T A M P AND J4 J U M P E R O N C O N T RO LLER C A R D . 7.2 POW ER O N. RELEAS E EM E RGENCY STO P. RES ET AM PS BY P R E S S IN G J O G . 7.3 DO ES T H E A X IS RUN AW AY? 7.4 YE S W AS M OTO R W IR E D E X A C T L Y THE SAME AS OLD MOTOR? NO 7. 4 .1 7.4 .2 YES NO C O R R E C T W IR IN G AND RE TE ST CH E C K RES OLV ER C O UP LE R . CHECK AND A DJUST RE SO LVE R CONNECTO R W I T H S E R V IC E T O O L S T 4 4 . CH E C K TA CH C ON N EC TION S. RETEST. 7. 4 .1 a RE V ER S E MOT OR W IRE S AND RE TE ST 7. 4 .1 b DO ES IT S T IL L RU N AW A Y ? YE S 7. 4 .1 c NO IS T H E M O T O R T U R N IN G IN T H E C O R R E C T DIR EC TION ? 7. 4 .1 d T H E R E A R E 4 P O S S IB LE M O T O R W I R E /T A C H W I R E C O M B IN A T IO N S . RE V ER S E MOT OR W IR ES A ND R ETE S T. IF S T IL L R U N N IN G A W A Y , R E V E R S E T A C H W IR E S A N D R E T E S T . IF S T IL L R U N N IN G A W A Y , P U T W IR E S B A C K I N O R IG I N A L C O N F IG U R A T IO N . GO TO CH A R T 4 7. 4 .1 c.2 7. 4 .1 c.1 NO PU T MOT OR W IRE S B A C K A S W IR E D BE FORE A ND S W I T C H T A C H W IR E S 7. 4 .1 d .1 RETEST 7. 4 .1 d .2 YES END 7.5 Figure 16-15 Axis Motor Runways March 2003 Section 16: Troubleshooting 563 Fadal Maintenance Manual Table 1: Baldor SWEO Spindle Drive Error Messages DESCRIPTION ALARM DISPLAY This fault occurs when the main bus supply voltage has gone too low, even momentarily. DCLO This fault occurs when the main bus supply voltage has gone too high, even momentarily. DCHI These faults are usually the result of an excessive load on the drive output. The fault condition can be permanent, occurring when the drive is enabled, or intermittent, occurring randomly during normal operation. PH-1 PH-2 PH-3 Motor is over temperature. OH E Baldor SWEO drive is over temperature. OH C Overspeed on the motor has been detected. OSP The Baldor SWEO power supply has momentarily experienced a reduction of the +/- 15 volts below allowable levels. 15DC Spindle motor has overloaded. OL Spindle motor is not properly connected, to torque. I LO Drive cannot follow the speed command within the error band setting. F. ERR Parameters need to be reloaded. PAR Power has been interrupted. UP EPROMs have faulted. PROG Table 2: Z200/Z300 Spindle Drive Error Messages 564 DESCRIPTION ALARM DISPLAY Inverter output current exceeded the overcurrent limit during acceleration. EOC1 Inverter output current exceeded the overcurrent limit during constant speed operation. EOC2 Inverter output current exceeded the overcurrent limit during deceleration. E0C3 Braking regenerative power from motor exceeded the regenerative overvoltage limit. EOVT Electronic thermal relay in the inverter was activated (current is below 150% of preset current). ETHM Electronic thermal relay in the inverter was activated (current is over 150% of preset current). ETHT Instantaneous power failure protective function was activated. EIPF Temperature of transistor heatsink exceeded the specified limit. EFIN Brake transistor fault detection. E BE Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Table 2: Z200/Z300 Spindle Drive Error Messages March 2003 DESCRIPTION ALARM DISPLAY Stall preventative function was activated during constant speed operation and stopped the motor. EOLT Memory in the inverter is corrupted. E PE Inverter input voltage fell below the specified limit. EUVT Overcurrent due to earth fault on the inverter output side. E GF Externally installed thermal relay activated (overheat). EOHT Built-in optional unit connection failure during operation EOPT Section 16: Troubleshooting 565 Fadal Maintenance Manual CHART 10 KEYBO ARD KE YB OA RD 10-18-95 YE S IS ENTI RE KE YB OA RD LO CKE D UP? 10. 1.2 10.1.1 WILL NOT CO NTINUE TO JOG WHEN JOG BUTT ON IS HE LD DO WN? 10. 2 IS MILL WAI TING FOR DO OR TO BE ACTUATED? TES T F OR 5V AT KE YB OA RD (1090) NO 10.1 DA S HED S YM B OLS AP PLY TO CE NORM EUROPEA N M ACHINES ONLY POSS IBLE CAUSES: KE Y BOA RD ( 1090) 1030 1040 YE S 10. 1.2a NO 10.1.2a.1 DO ES DISP LAY CHA NGE ? 10. 1.2a.2 CHECK WIRING TO SWITCHES. YE S SOM E KE YS DO NO T WORK ? NO YE S PROB LEM SOLV ED? POS S IBLE P ROB LE M S: TOO LIGHT A TOUCH KE Y PA D KE Y BOA RD (1090) CAB LE TO 1060 1040 BO ARD 10. 1.2a.2b NO YE S YE S NO UP DA TE TO LA TE ST 1090 SOF TWA RE 10. 1.2a.6 POSS IBLE PROB LE M S: KE Y PA D KE Y BOA RD ( 1090) CAB LE TO 1060 1040 BO ARD IF PROB LEM RECURS, RE P LACE K EY BO ARD LO GIC (1090) 10. 1.2a.7 MA KE SURE J OG WAS P RES SE D A ND JOG SW ITCHE S PROP ERLY S ET CHECK CABLE CO NNECTI ONS TO MP G. 10. 7.1 10. 7.2 THE FIRST TIME JOG I S P RESSED, THE KEYBOA RD LO GIC S E NDS "-J ", THE A XI S ("X ", " Y", "Z", "A" , "B " OR "C"), A ND THE RES OLUTION ("H", "M ", OR "L"). WHEN JOG IS P RE S SE D A GAIN, THE K EY B OARD SE NDS "-J " ONLY . WHEN T HE M P G IS T URNE D, T HE K E YB OA RD LO GIC S E NDS "-P " FOR A P OS ITIVE TURN O R "-Q" FOR A NE GA TIV E TURN. "-J ", " -P ", A ND "-Q" ARE SI NG LE CHARACT ERS, NOT "-" AND "J ". THEY A RE DI SP LAY E D IN THE DIA GNOS TI CS W ITH THE "-" TO DIFFE RENTI ATE T HE M FROM THE LE TT ERS "J ", "P " A ND "Q". YE S CHE CK ALL P OW ER CO NNECTI ONS TO KE YB OA RD (1090) . POW ER O FF M ILL AND RE ST ART. 10. 1.2a.5 10.6.1 10.7 POSSIBLE CAUSES: 1030 MP G 10.8 NO 10. 1.2a.4 10. 1.2a.2a 10.5.1 NO MIS S ES JOG PULS ES FROM MP G? MA KE SURE LE D ON 1030 IS BLINK ING. IF NOT , P RES S EM ERGE NCY ST OP AND RE SE T CP U (1400 B OA RD). CHE CK CAB LE TO 1060. CHE CK 1040 BO ARD. CHE CK 1030 BO ARD. RE P LACE CONTACTS . NO MP G DO ES NOT WORK ? NO DI SCONNE CT SE RIAL PO RT FROM 1090 TO P C (J15) 10. 4.1 10.4 10.6 YE S 10. 1.2a.3 ARE STA RT, SLIDE YE S HO LD, OR E S TOP BUTT ONS (NOT KE Y S) ERRA TIC? WRONG KE YS DI SP LAYED? 10. 1.4 YE S 10. 3 10.5 CHE CK THAT DOOR SWI TCHES A RE CO NNECTE D (1060 J13) AND WO RKING NO CHANGE POSITION OF CNC/DOS SWIT CH GO TO KE YBOARD T ES T IN DI AGNOS TI CS MA KE S URE ALL DO ORS ARE CLOS ED, THEN O PE N AND CLOSE FRONT DO OR 10.1.3 NO 32M P ? 10. 2.1 YE S 10. 8.1 GO T O PA GE 2 OF CHA RT 10 RE P LACE MP G 10. 7.3 RE P L ACE KE YB OA RD LOGI C (1090) 10. 7.4 IN THE K EYBO ARD DIA GNO STI CS NO N-PRINTA BLE CHARACTE RS ARE DIS PLA YE D WI TH A "- ". T HE TAB LE SHO WS THE KE Y AND THE CHA RACT ER T HAT WILL B E DIS PLA YE D. STA RT "- B" AUTO "-D" MA NUAL NO DIS PLA Y, EX IT S T ES T SING LE S TE P "-H" JOG "-J " SP INDLE ON/OF F "-L" SHIF T-S P INDLE O N/OFF "-O " SLIDE HOLD "-A " CO OLANT 1 "-C" CO OLANT 2 "-E " TOOL I N/OUT "-G " TURRET CCW "-I" TURRET CW " -M " BA CKS PA CE "_" DE LE TE "& " ENTE R "-N" RA P ID TRAVEL SWIT CH NOT DI SP LAYABLE, SCREEN WILL SHOW " " KE YLO CK S ENT WHEN ES TOP P RES S ED. ~ = LOCKE D OPT IONA L ST OP ON = '"' O FF = " " EM ERGE NCY ST OP GENE RALLY NOT DIS PLA YA B LE . ES TO P S E NDS S TA TUS OF K E YLOCK A ND ES TOP , STA TUS O F OP TIO NAL S TO P S WITCH, S TA TUS OF B LOCK S KIP S WIT CH, A ND STA TUS OF RAP ID T RAV EL SWI TCH. A NY COM BINA TIO N OF ' ' OR '~" ' M AY A PP E AR. MP G + "-P " MP G "-Q" Figure 16-16 Keyboard 566 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CONTINUED FROM PAGE 1 OF CHART 10 CHART 10 continued (page 2) KEYBOARD 10-18-95 RETURN TO CNC MODE 10.9 MISSES KEYSTROKES YES OR JOG PULSES IN CNC MODE BUT NOT IN DIAGNOSTICS? 10.10 DISCONNECT RS232 CABLE AND TRY AGAIN (MILL LISTENS FOR KEYBOARD AND RS232 INPUT IN MILL MODE. NOISE ON THE RS232 CAN MASK KEYSTROKES.) 10.10.1 NO YES KEYBOARD (BUT NOT SCREEN) DROPS OUT OF JOG? 10.11 (THIS MAY HAPPEN ONLY IN CNC MODE AND NOT IN DIAGNOSTICS) 10.11.1 CHECK +5V AND GND WIRING FROM POWER SUPPLY TO 1090 (RUN EXTERIOR +5V AND GND FOR TEST) 10.11.2 OTHER POSSIBLE CAUSES: KEYPAD KEYBOARD (1090) ESTOP (OR REMOTE ESTOPS) REMOTE TOOL IN/OUT 10.11.3 NO CNC YES (AND KEYBOARD) DROPS OUT OF JOG? 10.12 10.13 10.12.1 NO ATC CHANGES DIRECTIONS WHEN TURRETCCW IS HELD DOWN? NO IF THIS ONLY HAPPENS IN CNC MODE AND NOT IN DIAGNOSTICS IT IS PROBABLY A PROBLEM WITH ONE OF THE CARDS IN THE CARD CAGE YES RUN AXIS CARD DIAGNOSTICS 10.12.2 COULD BE: 1030 1400 AXIS CARD OR ??? 10.12.3 VERIFY THAT 1090 AND 1040 ARE LATEST VERSIONS WITH UPDATES 10.13.1 CONSULT FACTORY 10.14 Figure 16-17 Keyboard (Continued) March 2003 Section 16: Troubleshooting 567 Fadal Maintenance Manual DIFFICULT TO DIAGNOSE PROBLEMS CAN OCCUR IF MACHINE IS NOT PROPERL Y GROUNDED. THERE MUST BE A CONTINUOUS GROUNDING CONDUCTOR (AS SPECIFIED ON THE GROUNDING LABEL IN THE MACHINE'S DISCONNECT BOX) FROM THE VMC'S GROUND BUS TO THE GROUND BUS IN THE BUILDING'S POW ER DISTRIBUTION PANEL. CHART 11 FINISH PROBLEMS FINISH PROBLEMS 10-20-95 IF PROBLEM IS NOT RESOLVED QUICKLY, AND BEFORE DOING ANY MAJO R WORK LIKE CHANGING SPINDLE, BALL SCREW S, MO TORS ETC.. DO FADAL STANDARD TEST CUT. SEND SAMPLE PART CUT WITH TEST CUT TOOL SUPPLIED BY FACTORY. CO NTACT FACTORY FOR TEST CUT KIT. CHECK +5V,+12V,-12V. ALSO SET METER FO R VAC AND CHECK FOR AC RIPPLE ON +5V, +12V AND -12V DC (0 .015VAC RIPPLE MAX ON +/-12V, 0.00 5VAC RIPPLE MAX ON +5V) 11.0 FOR ADDITIO NAL PRECISIO N IN LEVELING, PERFORM SQUARENESS TEST ON X & Y, THEN SQUARNESS TEST ON COLUMN, THEN SPINDLE TRAM TEST. (CONSULT FADAL SERVICE DEPT FOR PROCEDURE) VERIFY MACHINE IS LEVEL (SEE MAINTENANCE MANUAL) 11.1 WAVY FINISH ON STRAIGHT CUTS? 11.2 YES 11.2.1 NO CHECK FOR SPINDLE VIBRATIONS CHECK SPINDLE MOTOR TENSION CABLE AND MOTO R MO UNTS 11.2.4 11.2.5 11.3.2 11.3.3 CHECK SIN/COS SIG NALS USING SERVICE TO OL ST48. ADJUST IF VARIANCE > 0.001V 11.3.4 CHECK AXIS AMPLIFIER COMPENSATION SETTING ON X & Y YES 11.4.1 NO YES 11.5 CHECK BELTS AND BELT TENSION DO ES A BAD CUT YES CO RRESPOND TO A PARTICULAR PLACE ON THE BALL SCREW? CHECK SURVEY TABLE AND BACKLASH 11.6.1 CO NSULT FACTORY SERVICE DEPT BEFORE REPLACING SPINDLE 11.5.2 11.5.1 NO 11.6 CHECK AXIS AMPLIFIER CO MPENSATION SETTING ON X & Y MATCH X & Y FOLLOWING ERROR 11.3.1 11.4 DO CUT S HAVE A CRISS-CROSS APPEARANCE? (ESP X) 11.2.3 11.2.2 CHECK BACKLASH NO DO ANGLES HAVE STAIR-STEP FINISH? CHECK BELTS DO NOT OVERTIGHTEN BELTS. DO YES CIRCLES HAVE STEPS AT 90 & 45 DEGREES? 11.3 CHECK SIN/COS SIG NALS USING SERVICE TOOL ST48. ADJUST IF VARIANCE > 0.001V CHECK BALANCE ON AXES CO NSULT FACTORY SERVICE DEPT BEFORE CHANGING BALLSCREW 11.6.2 NO CO NSULT FACTORY 11.7 Figure 16-18 Finish Problems 568 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 12 BAD POWER/BAD VOLTAGE BAD POWER/ BAD VOLTAGE DASHED SYMBOLS APPLY TO CE NORM EUROPEAN MACHINES ONLY 6-16-95 CHECK INCOMING VOLTAGE AT MAIN DISCONNECT AND AT INPUTS TO TRANSFORMER 12.1 INCOMING VOLTAGE GOOD? 12.2 CHECK FUSES IN MAIN POW ER DISCONNECT NO 12.2.1 YES CONSULT ELECTRICIAN FOR WIRING FAULTS IN BUILDING CHECK 1170 SURGE SUPPRESSOR BOARD 12.2.2 12.2.3 A12, B12, C12 SHOULD BE 230-245 VAC LEG TO LEG. 15 & 16 SHOULD BE 120 VAC. *A10, B10, C10 SHOULD BE 95 VAC LEG TO LEG. *13 & 14 SHOULD BE 120 VAC WITH T817E OR T818E TRANSFORMER. CHECK OUTPUT VOLTAGES OF TRANSFORMER *TRANSFORMER WILL HAVE A10,B10,C10 OR 13 & 14, BUT NOT BOTH. 12.3 OUTPUT VOLTAGES GOOD? 12.4 NO 12.4.1 USE CLAMP-ON AMMETER TO CHECK FOR EXCESSIVE CURRENT DRAW 12.4.2 VERIFY THAT TRANSFORMER IS PROPERLY CONFIGURED FOR INPUT VOLTAGE TYPICAL CURRENT WITH MACHINE AT REST: A12,B12,C12 - 0.3A 15 & 16 - 1.5A A10,B10,C10 OR 13 & 14 - 0.4A YES CHECK INPUT VOLTAGE TO AMPLIFIER CHASSIS AND BUS VOLTAGE ON LARGE BLUE CAPACITOR THESE ARE TYPICAL VALUES. ACTUAL VALUES MAY VARY. EXCESSIVE VALUES WOULD BE OVER 5A HIGHER WITH MACHINE AT REST. INPUT VOLTAGE SHOULD BE 95 VAC AND CAPACITOR VOLTAGE 133 VDC WITH T816 TRANSFORMER. INPUT VOLTAGE SHOULD BE 120 VAC AND CAPACITOR VOLTAGE 165VDC WITH T817E OR T818E TRANSFORMER. 12.5 INPUT VOLTAGE GOOD? 12.6 YES CHECK FOR LOOSE TERMINALS 12.6.1 YES BUS VOLTAGE GOOD? 12.7 NO NO 12.6.2 EMERGENCY STOP MUST BE OUT AND AMPLIFIERS RESET BY PRESSING JOG 12.7.1 ON CE MACHINE CHECK CIRCUIT BREAKERS ON SUPPLY TO AXIS AMP CHASSIS CHECK K2 AND F17 ON 1100-1 (110VAC CONTROL VOLTAGE FOR SSR ON AMP CHASSIS) VERIFY OVERLOAD RELAYS ARE RESET. CHECK K1, K18, K20, F12, F14, AND F16 ON 1100-1. 12.7.2 12.7.3 GO TO PAGE 2 OF CHART 12 12.8 Figure 16-19 Bad Power/Bad Voltage March 2003 Section 16: Troubleshooting 569 Fadal Maintenance Manual CO N TIN U E D FR OM PA G E 1 O F CH A R T 1 2 C H A R T 1 2 c o nti nu e d (p a ge B A D D C VO L T A G E 2) 6- 1 6 -9 5 CH E C K IN PU T VOL T AGE TO DC POW ER S U P PL Y (1 2 2 0 ) SH O U L D B E 1 2 0 VA C 12 A .1 12 A .2 CH E C K FOR LO OS E TER M IN A L S O N 1 2 0 VA C L I NE S NO IN PU T VOL T AGE GOO D ? US E C L AM P -ON AM ME TE R TO C H E C K F OR E XC E SS IV E CU R R E N T D R A W ON 12 0 VA C L IN E S FR O M TR AN S FOR M ER 12 A .2 .2 12 A .2 .1 YE S CH E C K D C PO W ER SU P PL Y OU TP U TS : +5 V & C OM , +1 2 V & C O M, -1 2 V & C OM TYP IC A L C U R R EN T TO 1 2 2 0 I S 1 . 5 A. O TH E R BO AR D S (1 1 0 0 - 1 , 1 1 0 0 - 2, C H IL L E R, E TC .) MA Y BE P UL L I N G D OW N L IN E VOL T AG E. AL S O C H E CK F OR A C R IP PL E ON T H E D C VOL T AGE . SE T M ET ER F OR V AC A N D C H E C K + 5 V , + 1 2V , AN D - 1 2 V; ME TE R SH O U L D SE TTL E TO L ES S TH AN 0 .0 1 V AC . IF A C R IP PL E IS P R ES E N T R E PL A C E 1 2 2 0 P OW ER S U PP L Y . 12 A .3 AL L VOL T AGE S BA D ? YE S CH E C K BR OW N OU T RE L A Y ( K 1 ) ON 1 220 CH E C K FU SE ON POW ER S U PP L Y (1 2 2 0 ) BR O W NO U T R E LA Y M U ST BE W HIT E 1 40 2-1 (7 0Y Y2 108 4) 12 A .4 .2 12 A .4 NO +/- 1 2 V GOO D ? 12 A .4 .1 NO 12 A .5 .1 12 A .5 12 A .6 DI SC ON N E C T + /- 1 2 V O U TP UT S FR OM 1 2 2 0 AN D T ES T A GA IN . IF N O W GOO D , L OO K F OR B AD BOA R D P U LL I N G TO O M U C H 1 2 V. NO 12 A .5 .2 YE S TU R N OFF MA C H IN E . PR E SS E ME R GE N CY S TOP . RE M OVE A L L C A RD S FR OM C AR D C A GE. UN P L U G J 9 -J 1 3 FR O M 1 0 6 0 . PO W ER O N MA C H IN E . 12 A .6 .1 EN D PO W ER G OO D U N D E R STA TIC C O N D ITIO N S 12 A .7 RE P L AC E 1 2 2 0 DC POW ER S U P PL Y IF + / -12V I S B A D IT C A N E FF E CT CH ILL ER C O NT RO L , R S 232 , CL O CK S, S I NE /C O SIN E, A N D A XIS CO N T RO L. +/ -1 2V M AY RE A D O K ON A DC M ET ER A ND S TI LL BE BA D ; AN O SC ILL OS C O PE IS N E ED E D T O F UL LY TE S T + /-12 V, BU T A C R IP PL E M A Y S H OW U P W HE N M ET ER IS S E T FO R VA C . YE S +5 V GOO D ? (5 .0 1 - 5 .1 0 V) BR O W NO U T R E LA Y (K 1) O N 1 22 0 W ILL NO T LA TC H A T L ES S TH AN 4.5 V AN D W IL L R EL E AS E IF +5V D R O PS BE LO W 4 .5V . IS +5 V NO W GO OD ? 12 A .6 .2 NO 12 A .6 .3 YE S DI SC ON N E C T + 5 V O U TP UT S FR O M 1 2 2 0 . ATT AC H 1 0 O H M 5 W RE S IST OR B E TW E EN +5 V AN D C OM. +5 V GOO D ? 12 A .6 .4 SW I T CH IN G P O W E R S UP P LIE S R EQ U IR E A LO A D T O W O RK PR O P ER LY . YE S LO OK FO R I N D IVI D U AL C A R D TH AT MA Y BE P U L L IN G T OO MU C H + 5 V RE C ON N E C T +5 V O U TP U TS TO 1 2 2 0 . (R E PL AC E CA R DS O NE A T A T IM E.) (R E PL AC E J9-J 13 O N E AT A T IM E . ) 12 A .6 .2 a NO 12 A .6 .4 a (C A RD S SH O U LD NE VE R BE RE M O VE D O R R EP LA CE D W ITH TH E P O W ER O N .) PU T AL L C A R D S BA C K I N C AR D C A GE 12 A .6 .4 b 12 A .6 .2 b US E C L AM P -ON AM ME TE R TO L OO K FOR EX C ES SI VE CU R R E N T D R A W TYP IC A L C U R R EN TS W ITH M A C HI N E A T R ES T: 1 0 6 0 - 5 .5 A 1 1 0 0 -1 - 0 A 1 1 0 0 -2 - 0 A P EN D A N T - 0 .5 A RE P L AC E 1 2 2 0 DC PO W ER S U P PL Y 12 A .6 .5 TH ES E A R E T YP I C AL VA LU ES . AC TU A L V AL UE S M A Y V A RY . EX CE S SIV E V A LU ES W O UL D B E 2-5A H IG H E R. Figure 16-20 Bad DC Voltage (Continued) 570 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 13 RO TAR Y HE ADS A A XIS RO T A RY H E A D S A A X IS SO M E H E AD S HA VE T E M P ER A T U RE SW I T C H E S I N ST EA D O F ( O R I N AD D IT I O N T O ) F U SE S T O PR O T E CT T H E M O T O R F R O M O V E RH E AT I NG . T H ES E A U T O M A T I C AL LY RE S ET W HE N TH E M O TO R C O O L S. 7- 4 - 95 YE S CH E C K OVE R LO A D RE L A Y S A X IS D E A D ? NO 13 . 1 13 . 1 .1 T E M P E RA T UR E S N AP S W I TC H W I L L S H OR T C O S SI G N AL T O G ND O N R ES O LV ER B O A R D I N M O TO R IF M O T O R O V ER H E AT S. CH E CK CO S O UT PU T T O RE S O L VE R (P I N 8 O F J 5 O N 1 06 0 ) FO R S H O RT T O G ND . LE T C OO L . CH E C K RO T A RY H E A D FU SE 13 . 1 .2 GO TO CH A R T 4 A X IS CO N T R O L 13 . 1 .4 13 . 1 .3 HE A D O VE RH EA TS ? YE S NO 13 . 3 HE A D KE EP S B L O W IN G FU SE S? 13 . 4 13 . 4 .1 NO LE A K IN G O IL ? 13 . 5 YE S 13 . 4 .2 RE P L A C E S E A L T H A T IS L E A K IN G CH E C K O IL L E V E L IN H E A D YE S DO E S A X IS H A V E LI M I T E D M O T IO N ? (W I L L N O T D O F U L L RO T A T IO N ) CU R R E N T E X C E S S I V E IN ON E SP OT? 13 . 4 .4 YE S 13 . 4 .4 a C H ECK A X IS J U M P E R ON 1010 CA RD. IT M U S T B E A N A - A X IS J U M P E R. W AS CA P A C IT Y O F T HE H E A D EX CEE D ED ? 13 . 4 .4 b CH E C K R A T I O IN S E T P YE S YE S YE S 13 . 4 .4 c CH A N G E P R O G RA M T O G IV E M O T O R T IM E T O C O O L 13 . 4 .4 c. 1 NO ARE M O T O R W IR E S SH OR TE D TO CH A S S IS ? DO N O T E X C E E D LO A D C A P A C IT Y 13 . 4 .4 b .1 13 . 7 .2 13 . 9 RE A D JU S T BA C KLA SH AN D GE A R ME S H 13 . 4 .4 a .1 NO IS DUTY CYCLE E X C E S S IV E ? G E A R IS D A M A G E D BY A C R AS H. RE T U R N H E A D T O F A C T O RY F O R R E P A IR S 13 . 4 .5 NO NO GO TO C H ART 4 A X IS C O N T R O L YE S NO BA CKLA SH OR GE AR ME SH A D J U S T M E NT T O O T IG H T ? AD J U ST GEA R M ES H 13 . 6 .2 13 . 6 .1 13 . 7 .1 13 . 7 US E C L A M P -O N AM ME TE R TO CH E C K F O R EX C ES SI VE CU R R E N T D R A W 13 . 5 .1 NO 13 . 6 CH E C K F O R W AT ER IN FU SE HO LD E R OR M OTOR HO U S IN G 13 . 4 .3 NO AR E TH E GEA R S NO IS Y ? CH E C K FOR M E C H A N IC A L B IN D YE S YE S 13 . 4 .4 d M O T O R W I RE S AR E SH IELD E D . V E R IF Y T H A T S H IE L D IS S T R I P P E D B A C K FR OM COND UC TOR. 13 . 4 .4 d .1 IS S H O R T IN MOT OR OR CA B L E ? 13 . 4 .4 d .2 CA B L E MOT OR RE P L A C E MOT OR 13 . 4 .4 d .3 RE P A IR / RE P L A C E CA B L E 13 . 4 .4 d .4 Figure 16-21 Rotary Heads A Axis March 2003 Section 16: Troubleshooting 571 Fadal Maintenance Manual C H A R T 14 FA D A L T R 65 R O TA R Y H E A D S A & B A XIS TR 6 5 R OTA R Y H EA D S A & B A XI S SO M E H E AD S HA VE TE M P ER A TU RE SW IT CH E S I N ST EA D O F (O R IN AD D IT I O N T O ) F U SE S T O PR O TE CT TH E M O TO R FR O M OV E RH E AT ING . TH ES E A U TO M A TIC AL LY RE S ET W HE N TH E M O TO R C OO L S. 6- 15-95 YE S CH E C K OVE R LOA D RE LA YS AX IS D EA D ? 14. 1 NO CH E C K RO TA RY H E AD FU SE 14. 1.1 14. 1 .2 TE MP E RA T UR E S N AP S W ITC H W ILL S H OR T C O S SIG N AL TO G ND ON R ES O LV ER B OA R D IN M O TO R IF M O TO R O V ER H E AT S. CH E CK CO S O UT PU T T O RE S OL VE R (P IN 8 O F J4 0R J5 O N 10 60 ) FO R S H O RT TO G ND . LE T C OO L . 14. 1.3 DO ES YE S B- AX IS FAU L T D U RI N G RA P ID ? 14. 2 14. 3 NO HE A D KE EP S BL OW IN G FU SE S? YE S TR 65 B- AX IS ? YE S 14. 3.1 YE S B- AX IS IN H IBI T R E LAY TU R N S O FF A M P WH EN B R A KE IS ON ? 14. 3.2 YE S NO 14. 1.4 RE P L AC E R ELA Y * O R C O R R E CT W IR IN G *A U GA T R D I R ELA Y IN C ON TR OL C AB IN E T 14. 3.3 YE S CH E C K FOR WAT ER I N FU S E H OL D ER O R M OTOR HO U SIN G CH E C K FOR ME C H AN I CA L BIN D 14. 4.1 NO GO T O CH A R T 4 AX IS CO N TR OL *W HE N AD JU S TIN G B -A XIS AM P : S ET PA R AM E TE R S F OR 90 : 1 D I SC O N NE C T S CA LE NO 14. 4 LE A KIN G OIL? B A XI S SE TS FO L LO W IN G E R RO R DIF FE RE N TL Y F RO M O TH E R A XE S .* 14. 2.1 NO HE A D OVE R H EA TS ? FOLLOW I N G E R RO R IMP R OP ER LY AD J U STE D US E C L AM P -ON AM ME TE R TO CH E C K FOR EX C ES SI VE CU R R E N T D R A W 14. 4.2 14. 4.3 CU R R E N T EX C ES SI VE IN ON E SP O T? 14. 4 .4 GEA R IS D A MA GE D BY A C R AS H . RE TU R N H E AD TO F AC TO RY FOR R E PA IR S 14. 4.5 NO BA C KLA SH OR GE AR ME SH AD J U STM E NT TO O TIGH T? RE P LAC E S EA L TH AT IS LEA K IN G YE S YE S RE A D JU S T BA C KLA SH AN D GE A R ME S H 14. 5 14. 5.1 NO AR E TH E GEA R S NO IS Y? 14. 6 CH E C K OIL LE VE L IN H EA D 14. 6.1 NO TR 65 B- AX IS LO SI NG POS ITI ON ? 14. 7 YE S YE S B A X IS C LUT C H MA Y BE LOOS E 14. 4.4a AD J U ST GEA R M ES H W AS CA P AC IT Y OF T HE H E AD E XC E ED E D ? GO TO C H AR T 4 AX IS C ON TR O L YE S 14. 4.4b.1 NO BR A KE M AY B E DE FE C TIV E IS D U TY C YC LE EX C ES S IV E? YE S CH E C K AI R SO LEN OI D 14. 7.1 DO N OT EX C EE D LO AD C A P AC IT Y 14. 4.4b 14. 6.2 14. 4.4 c NO 14. 4.4a.1 NO 14. 7.2 14. 4.4c. 1 NO AR E MO TOR W IR ES SH OR TE D TO CH A S SIS ? 14. 4.4 d 14. 8 CH A N GE PR O G RA M TO G IVE M OTO R TIM E T O C O O L YE S MOT OR W I RE S AR E SH I ELD E D . VE R IFY TH A T S H IE L D IS STR I PP ED BA C K FR OM C ON D U C TOR . 14. 4.4d.1 IS SH OR T IN MOT OR OR CA B L E? 14. 4.4d .2 MOT OR CA B L E RE P LAC E MOT OR 14. 4.4d.3 RE P AIR / RE P L AC E CA B LE 14. 4.4d.4 Figure 16-22 TR65 Rotary Heads A & B Axes 572 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 15 TS UDAKO M A 301 ROTAR Y HEADS A & B AXIS TSU D A KO MA 301 A & B A XIS SO M E H E AD S HA VE TE M P ER A TU RE SW I T CH E S IN ST EA D O F (O R I N AD D IT IO N T O ) F U SE S T O PR O TE CT TH E M O TO R FR O M OV E RH E AT I NG . TH ES E A U TO M A T IC AL LY RE S ET W HE N T H E M O TO R C OO L S. 6- 1 5 -9 5 YE S A X IS D E A D ? 15 . 1 CH E C K OVE R LOA D RE L A Y S CH E C K RO T A RY H E A D FU SE 15 . 1 .1 NO 15 . 1 .2 TE MP E RA T UR E S N AP S W I TC H W ILL S H OR T C O S SI G N AL TO G ND ON R ES O LV ER B OA R D I N M O TO R IF M O TO R O V ER H E AT S. CH E CK CO S O UT PU T T O RE S OL VE R (P I N 8 O F J4 O R J 5 O N 1 06 0) FO R S H O RT TO G ND . L E T C OO L . 15 . 1 .3 DO E S YE S B- A X IS F A U L T D U RI N G RA P ID ? 15 . 2 15 . 3 B A XI S SE TS FO L LO W IN G E R RO R DI F FE RE N TL Y F RO M O T H E R A XE S .* 15 . 2 .1 NO HE A D OVE R H EA TS ? F O L L O W I N G E R RO R IM P R O P E R L Y A D J U ST E D GO T O CH A R T 4 AX IS CO N T R O L * W HE N AD JU S TIN G B -A XIS AM P : S ET PA R AM E TE R S F OR 90 :1 D I SC O N NE C T S CA LE 15 . 1 .4 YE S NO HE A D KE E P S B L O W IN G FU SE S? YE S CH E C K F O R W AT ER I N FU SE H OLD E R OR M OTOR HO U S IN G CH E C K FOR M E C H A N I CA L B IN D 15 . 4 15 . 4 .1 NO LE A K IN G O IL ? 15 . 5 15 . 4 .3 15 . 5 .1 15 . 6 GO TO C H AR T 4 A X IS C O N T R O L 15 . 4 .4 15 . 4 .4 a YE S CH E C K O IL L E V E L IN H E A D 15 . 6 .1 NO CU R R E N T E X C E S S I V E IN ON E SP OT? AD J U ST G EA R M E S H 15 . 6 .2 YE S YE S DO N O T E X C E E D LO A D C A P A C IT Y 15 . 4 .4 b .1 CH A N G E P R O G RA M T O G IV E M O T O R T IM E T O C O O L YE S NO AR E M O T O R W IR E S SH OR TE D TO CH A S S IS ? 15 . 4 .4 d RE A D JU S T BA C KLA SH AN D GE A R ME S H 15 . 4 .4 a .1 NO IS DU T Y C Y C L E EX C ES SIVE ? 15 . 4 .4 c 15 . 4 .5 NO W AS CA P A C IT Y O F T HE H E A D E X C EE D E D ? 15 . 4 .4 b G EA R IS D A M A G E D BY A C R AS H . RE T U R N H E A D T O F A C T O RY F O R R E P A IR S YE S NO BA C KLA SH OR GE AR ME SH A D J U ST M E NT T O O T IG H T ? RE P L A C E S E A L T H A T IS L E A K IN G NO AR E TH E GEA R S NO IS Y ? 15 . 8 YE S 15 . 4 .2 US E C L A M P -O N AM ME TE R TO CH E C K F O R EX C ES SIVE CU R R E N T D R A W 15 . 4 .4 c. 1 M O T O R W I RE S A R E S H I EL D E D . V E R IF Y T H A T S H IE L D IS S T R I P P E D B A C K FROM CONDUCTOR. YE S 15 . 4 .4 d .1 IS S H O R T IN MOT OR OR CA B L E ? 15 . 4 .4 d .2 CA B L E MOT OR RE P L AC E MOT OR 15 . 4 .4 d .3 RE P AIR / RE P L A C E CA B L E 15 . 4 .4 d .4 Figure 16-23 Tsudakoma 301RotaryHeads A & B Axes March 2003 Section 16: Troubleshooting 573 Fadal Maintenance Manual CHART 16 SERVO COOLANT CONTROL 12-5-95 SERVO COOLANT THE COOLANT AXIS MUST BE SET TO COOLANT IN SETP. IF AXIS IS SET TO 90:1, THE MILL WILL NOT COLD START. AXIS CARD MUST HAVE SERVO COOLANT SOFTWARE. COOLANT NOZZLE WILL NOT MOVE 16.1 NO NOZZLE POSITIONING IS WRONG 16.2 YES POSITION OVERRIDE POT MUST BE: CENTERED, PLUGGED INTO J3 OF APPROPRIATE 1010 CARD, CONNECTED TO GND AND +12V. 16.1.1 YES ADJUST POSITION OVERRIDE POT TO NEUTRAL (VERTICAL) POSITION ENCODER MUST BE CONNECTED (J5 OF 1010, J2 & J3 OF 1890-0, AND 9-PIN MOLEX AT MOTOR) 16.1.2 16.1.3 CHECK PARAMETERS IN SETP AMPLIFIER MAY BE UNPLUGGED OR DEAD. CHECK AMPLIFIER FUSE. (AMPLIFIER IS ALIVE IF GREEN LED IS LIT.) 16.1.4 AMPLIFIER FUSE HOLDER IS PART OF POWER RECEPTACLE ON AMPLIFIER. OVERTEMP SWITCH ON MOTOR MAY HAVE TRIPPED AMPLIFIER MAY BE MISADJUSTED. 16.1.5 16.2.1 NO COMMAND SIGNAL MUST BE CONNECTED AT AMPLIFIER AND J1 OF 1010 16.2.2 16.2.3 AXIS MUST BE ACTIVE IN SETP AND SET TO "COOLANT" NOZZLE RUNS AWAY 16.3 MOTOR LEADS REVERSED AT AMPLIFIER SIGNAL UNPLUGGED FROM AMPLIFIER OR J1 OF 1010 16.3.1 NO RESPONSE IS MUSHY 16.4 YES YES 16.3.2 AMPLIFIER DIP SWITCHES ARE SET WRONG 16.3.3 AMPLIFIER IS MISADJUSTED 16.4.1 NO ENCODER CABLE DISCONNECTED OR ENCODER BAD 16.4.2 ENCODER IS UNPLUGGED FROM AMPLIFIER 16.1.6 AMC BE25A20-AC-FD2 DIP SWITCH SETTINGS: 1- OUT (OFF) TEST/OFFSET 2- IN (ON) DECREASE CURRENT LOOP GAIN 3- IN (ON) 100% CURRENT SCALING 4- OUT (OFF) LOOP INTEGRATOR 5- OUT (OFF) DUTY CYCLE FEEDBACK 6- IN (ON) VELOCITY FEEDBACK 7 IN (ON) VELOCITY DIRECTION 8- IN (ON) CURRENT REDUCTION 9- IN (ON) INCREASE INTEGRATOR CAP 10- OUT (OFF) 120/60 PHASING POT PRESETS: LOOP GAIN FULLY CCW, THEN 5 TURNS CW. CURRENT LIMIT FULLY CW. REF IN GAIN FULLY CW. 16.4.3 AMP ADJUSTMENTS: REMOVE NOZZLE. DISCONNECT COMMAND SIGNAL. ADJUST OFFSET POT TO STOP AXIS. NO COOLANT 16.5 YES 16.5.1 NO RESPONSE YES OF OVERRIDE POT IS REVERSED 16.6 16.7 YES "UP" DIRECTS NOZZLE UP THE TOOL. "DOWN" DIRECTS NOZZLE DOWN THE TOOL. USE PROGRAM 5815 TO ADJUST AXIS: SET FEEDRATE TO 2000. ADJUST REF IN GAIN AND OFFSET FOR FOLLOWING ERROR OF +/-680. PRESS SLIDE HOLD AND ADJUST LOOP GAIN TO REDUCE OVERSHOOT AND MINIMIZE VIBRATION. (VIBRATION IS THE MORE SERIOUS PROBLEM, OVERSHOOT IS OK.) WHEN AMP IS ADJUSTED, SET COOLANT AXIS RATIO TO COOLANT IN SETP. POT IS MISWIRED OR J4 ON 1890-0 IS MISWIRED * 16.6.2 AMP MAY BE INHIBITED BY EMERGENCY STOP OR OVERTEMP OF MOTOR 16.7.1 CONNECT COMMAND SIGNAL. IN SETP SET COOLANT AXIS RATIO TO COOLANT. COLD START. IN SETP SET COOLANT AXIS RATIO TO 90:1. 16.5.2 16.6.1 NO RED LED ON AMPLIFIER CHECK COOLANT VALVE FOR SERVO NOZZLE. VERIFY FLOOD COOLANT IS WORKING * VMC MUST BE OFF WHEN WIRING IS BEING CHANGED. DISCONNECT J4 FROM 1890-0 BEFORE REWIRING POT OR 1890-0 MAY BE DAMAGED. AMPLIFIER DIP SWITCH FOR PHASING MAY BE MIS-SET WIRES TO MOTOR ARE SHIELDED. SHIELD MUST BE STRIPPED BACK FROM CONDUCTOR OR A SHORT TO GROUND WILL OCCUR. 16.7.2 16.7.3 Figure 16-24 Servo Coolant Control 574 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 17 C IR C L E R O U N D N ESS C I R C LE RO U N D N E S S 1 0 -3 - 9 5 F O R A D D IT IO N AL P R E C I S IO N IN L E V E L IN G , P E R F O R M S Q U A R E N ES S T E ST O N X & Y , T H EN S Q U A R N E S S T E S T O N C O L U M N , T H EN S P IN D L E T R A M T E S T . (C O N S U L T F A D A L S E R V I C E D E P T F O R PR O C E D U R E) V E R IF Y M A C H IN E IS L EV EL (S E E M A I NT EN A N C E MA NUAL) DI F F IC U L T T O D I A G NO SE P R O B L E M S C A N O C C UR IF M A C H I N E I S N O T P R O PE R L Y G R O U N D E D. T H E R E M U ST BE A C O N T I NU O U S G R O U N D IN G CO N D UC T O R ( AS S PE C IF I ED O N T H E G R O U N D IN G L AB E L IN T H E M A C H IN E 'S D IS C O N N E C T BO X ) F R O M T H E V M C 'S G R O U N D B US T O T H E G R O U N D B U S IN T H E B U IL D IN G ' S PO W E R D I S T R I BU T I O N P AN E L . 17 . 1 TES T B A LAN C E OF S IN / C O S S IG N A L S US IN G F A D A L S IN /C O S T E S T ER (S ER V IC E T O O L ST 4 8 ) IF SI N A ND C OS A RE NO T B A LA NC E D W I T H IN 0 . 0 0 1 V, B A LA NC E S I N AN D CO S A N D R U N T ES T C U T A G A I N . 17 . 2 PR O CE D UR E F O R A D J U ST I N G L O OP G AI N A N D B A LA N CE I S I N T H E MA I N T E NA N C E M A NU A L . US I NG T HE F O L L O W I N G E R RO R DI S P L A Y I S MO R E AC C UR A T E T H A N A M E T E R . ON C E T HE L O O P GA I N AN D B A L A NC E AR E A D JU ST E D, R ED U CE TH E F E ED R AT E T O F2 0 . AN D FI N E T UN E T H E L OO P G A I N AN D BA L A N CE A DJ US TM E N T S . CH E C K A N D A D J U S T P O S IT I O N L O O P G A I N AN D B A L A N C E F O R X A N D Y AX E S. 17 . 3 CH E C K B A C KL A SH O F X & Y AX E S (T H E S CR E W P I T CH C O M P E NS A TI O N TA B L E S CA N AL SO A FF E C T CI R CL E R O U ND N E S S W HE N CU T T I NG L AR G ER D I A M E TE RS . ) 17 . 4 CH E C K F O R LO O S EN E S S IN M O T O R C O U P L ER S AND WO RN OR LOO SE BA L L S C R E W S 17 . 5 CH E C K W A Y L U B E AN D V ER I F Y W A Y L U B E IS B E IN G DE L IV ER E D T O A L L A X E S. (L U B RI C AT E L I NE A R W A Y S .) 17 . 6 IS PA R T IN S P EC T ED O N O R O F F M A C H IN E ? 17 . 7 IN SP E C T E D O F F M A C H IN E IN S P EC T ED O N M A C H IN E E N T E R T H E T E S T P R O G R AM AT R I G H T T O C U T A 1 IN C H IN S ID E D IA H O L E 0 .2 5 D E E P IN A L U M I N U M . T E S T C IR C L E W IL L B E RO U GH C U T A N D T H EN F IN I SH C U T . 17 . 8 PL A C E D I A L I N DI C A T O R IN S P IN D L E (A D J U S T X A N D Y S O S P I N DL E I S AT EX AC T C E NT E R O F H O LE A C C OR D I NG T O I N D IC A T O R ) PA R T M U S T B E IN S P E C T E D O N M A C H IN E B E F O R E A NY C L A M P IN G IS R E M O V ED . CL A M P I NG A ND FI X T U R I NG C A N D I S T O RT TH E P A RT . IF TH I S H A PP E NS , TH E P A RT W I L L B E RO U N D W H E N C U T B U T W H E N P AR T IS R EL E A S ED F R O M T H E C L A M P IN G TH E C U T W I L L BE D IS T OR T ED . T O F I N D T H E S O UR C E O F D I S T O R TI O N, P A RT MU S T B E I NS P EC T E D O N M AC H I NE B EF O RE I T I S R E L E AS E D. 17 . 7 .1 N 1 (C IR C L E R O U N D N E S S T E S T N 2 (0 .5 0 0 D I A E N D M IL L , T O O L D IA M E T E R M U S T B E IN T O O L T AB L E , T O ,1 ,.5 N 3 (H O M E IS C EN T ER O F P A R T N 4 (S E T T O O L AT T O P O F P AR T N 5 G 0 G 1 7 G 4 0 G 8 0 G 9 0 E0 N 6 X 0 Y 0 M 3 S 1 00 0 0 N 7 H 1 D 1 Z 0 .1 M 8 N 8 G 1 Z - 0 .2 5 F 4 . N9 G8 N 1 0 L9 4 0 2 R 0 + 1 5 . R 1 + 0 .9 8 0 N 1 1 L9 4 0 2 R 0 + 1 5 . R 1 + 1 . N12 M5 M 9 N13 G0 H 0 Z0 N14 X0 Y 0 E 0 N15 M2 17 . 9 RO T A T E SP IN D L E MA N U ALLY TO CH E C K R O U N D N E S S O F C IR C L E SP EC IF IC A T IO N S F O R C IR C L E RO U N D N E S S : M A XI M U M D E VIA T I O N V M C 8 0 30 , VM C 6 0 3 0 < .0 0 0 6 - .0 0 1 2 V M C 5 0 20 A , 4 0 2 0 A , 4 0 2 0 , 3 01 6 , 2 2 1 6 , 1 5 < .0 0 0 4 -.0 0 0 8 17 . 1 0 CO N T IN U E D O N P AG E 2 OF CHART 17 Figure 16-25 Circle Roundness March 2003 Section 16: Troubleshooting 575 Fadal Maintenance Manual CHART 17 continued (page 2) CIRCLE ROUNDNESS CONTINUED FROM PAGE 1 OF CHART 17 IS CIRCLE ROUND? NOTE 1: IF A MEASUREMENT TEST FAILS, ALWAYS 10-3-95 IS CIRCLE ROUND? REMOVE PART FROM FIXTURING AND INSPECT OFF MACHINE YES (SEE NOTE 1) 17A.1.1 17A.1.2 CHECK AND ADJUST GIBS AND STRAPS ON BOX WAY MACHINES YES (SEE NOTE 1) 17A.1 NO MEASURE AGAIN USING A DIFFERENT TOOL OR DIFFERENT MEASURING PROCEDURE. THE FAULT MIGHT BE IN THE MEASURING TOOL OR PROCEDURE INSTEAD OF THE MACHINE. NO CLAMPING IS DISTORTING PART. CHANGE CLAMPING METHODS AND RETEST CHECK FOR TIGHT SLIDES ON LINEAR WAY MACHINES 17A.2 17A.1.3 DO ANOTHER CIRCLE TEST CUT 17A.3 IS CIRCLE ROUND? YES (SEE NOTE 1) 17A.4 NO FINISHED REMOVE SUBPLATE OR FIXTURING. MACHINE MUST BE TESTED WITHOUT FIXTURING. SUBPLATES OR FIXTURING CAN INDUCE POSITIONING PROBLEMS THAT ARE NOT INHERENT IN THE MACHINE. POSITIONING PROBLEMS INDUCED BY FIXTURING MUST BE DEALT WITH SEPARATELY FROM PROBLEMS IN THE MACHINE ITSELF. IS THERE YES A SUBPLATE OR LARGE HEAVY FIXTURING? 17A.5 IS CIRCLE ROUND? (SEE NOTE 1) YES REINSTALL FIXTURING AND SUBPLATE 17A.5.3 NO IF MACHINE PASSES CIRCLE ROUNDNESS TEST, BUT HAS ROUNDNESS PROBLEMS FOR FEEDRATES ABOVE F30., USE M92 IN PROGRAM AND TRY AGAIN. REPEATABLITY MAY ALSO BE AFFECTED BY TEMPERATURE GROWTH. 17A.5.2 17A.5.1 NO 17.7.4a.1 DO ANOTHER CIRCLE TEST CUT 17A.5.4 DO ANOTHER CIRCLE TEST CUT 17A.5.5 IS CIRCLE ROUND? YES (SEE NOTE 1) 17A.5.6 NO FIXTURING OR SUBPLATE IS DISTORTING MACHINE WHICH WILL CREATE A MECHANICAL BIND. 17A.5.7 CONSULT FACTORY 17A.6 Figure 16-26 Circle Roundness (Continued) 576 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 18 ERROR CODES ER R O R C O DE S ER R OR NU M B ER # R EP O RT E D B Y AX IS D IA GN O S IS PR O CE D U R ES ME A NI N G 8- 18 -95 #1 NO M OTOR FEE D BA C K 18. 1 #2 EN C OD E R N O T RE S PON D I NG 18. 2 #3 LO GIC J U MP E R IN C OR R EC T O R SIG N AL M IS SI N G OR MOT O R -T AC H IN C OR R EC T NO M OTO R F EE D BA C K (E ITH E R R ES OL V ER OR EN C OD E R ) DE TE C TE D AT POW ER - U P CH E C K TH AT FEE D BA C K D EV IC E (S ) AR E PL U G GED IN TO 10 1 0 CA R D J 2 (J 5 , J6 ) US E FA D AL EN C OD E R TE ST ER OR S CA L E TE ST ER TO T ES T E N C OD ER S RE S OL VE R IN P U T AT J2 O F 1 0 10 SH OU L D B E AB OU T 1. 7 VA C 18. 1 .3 18. 1 .4 18 . 1 .5 18 . 1 .2 EN C O D E R F EE D BA C K ON S PIN D L E FAI L ED D U R IN G RI GID T AP 18 . 2 .1 18 . 2 .2 18 . 1 .6 SW A P SP IN D L E CO N TR OL LER C AR D W ITH K N OW N GOOD CA R D 18 . 2 .3 MA C H IN E CH E C K S F O R RU N A W A Y AT POW ER - U P. ME SS AG E IN D IC AT ES A N IN C O R R EC T MO TOR - TAC H JU M PE R C O N F I GU R AT ION OR FA ILE D C OM PO N EN T. IN ST AL L J U MP E R AT A1 O N AX IS C A RD TO B YP A SS FEE D BA C K TE ST O N P O W E R -U P . 18 . 3 .1 18 . 3 US E F A D AL EN C O D E R TE ST ER O R S CA L E TE ST ER T O T ES T S PI N D LE EN C OD E R VE R IFY CO N N EC TI ON OF E N C OD ER CA B LES CH E C K C AR D IN J 14 O F 10 6 0 18 . 3 .2 DI SC ON N E C T J1 O N AX IS C AR D . DO ES AX IS R U N AW A Y ? M OT OR W IR E S OR TA C H W IR E S A R E RE V ER S ED YE S POW ER O N . 18 . 3 .4 18 . 3 .3 NO 18 . 3 .5 J4 J U MP E RS O N AX IS CA R D A R E W R ON G OR AX IS C AR D I S BA D 18 . 3 .4a #5 NO IN D E X M A R K DE T E C T E D 18 . 5 #7 RI GID T AP PR E C YC LE EN C OD E R C OU N T PR O BL E M 18 . 7 #8 SP IN D L E MA GN E T NO T D E TE CT ED O R SP IN D LE N O T TU R N IN G 18 . 8 IN D EX ER MA R K OF EN C OD E R OR S C AL E NO T D E TE CT ED DU R I NG C OL D S T A R T 18 . 5 .1 VE R IFY C ON N E C T ION OF E N C OD ER OR SC A LE C A B LE S US E FA D AL EN C OD E R TE ST ER OR S CA L E T E ST ER T O T ES T E N C OD ER OR S CA L E 18 . 5.2 18 . 5 .3 EN C OD E R C OU N TS N OT W ITH IN TOLE RA N C E DU R I NG R IG I D TA P PR E C YC L E TE ST STO P S P IN D L E AN D U S E DI D S T O C H E C K M A GN ET (TU R N S P IN D L E BY H AN D ) US E FA D AL EN C OD E R TE ST ER OR S CA L E T E ST ER T O T ES T E N C OD ER AT AX IS C AR D (J 5 ) 18 . 7 .1 18. 7 .2 18. 7.3 SP IN D L E MA GN E T W A S NO T D E TE CT ED F OR O VE R 3 S E CO N D S W H EN S P IN D L E SH O U L D HA V E B E EN T U R NI N G IS SP IN D L E TU R N IN G? 18 . 8 .2 18. 8.1 YE S NO G O TO CH A R T 3 SP IN D L E 18. 8 .2a DR I VE R #9 SP IN D L E FAU L T LI N E D O W N 18 . 9 SP IN D LE FAU L T L IN E IS N OT D E T E C T ED OR H AS F ALL E N BE LO W 1 0V 18 . 9 .1 CH E C K IN VE R T E R F OR FA U LT 18 . 9 .2 STO P S P IN D LE AN D U S E DI D S TO C H E C K M A G N ET (T U R N S P IN D LE BY H AN D ) 18 . 8 .3 VE R IFY M AG N E T IS C ON N EC TE D AN D C H E C K AD J U STM E NT 18 . 8 .4 US E KN O W N GO OD H ALL E FF E C T SW I TC H AN D TE S T W I T H A M A GN ET US IN G D I D S 18. 8 .5 OR IE NT AT IO N M A G NE T IS RE A D B Y C P U T HR O U GH 10 60 J10 PIN 8 BU T T HE SP IN DL E C A RD R EA D S IT T H RO U G H J 2. IF W IRIN G IS B A D, C PU M AY B E A BL E T O RE AD M A GN E T, BU T T HE SP IN DL E C A RD M AY N O T B E A BL E T O R E AD IT. CH E C K O VE R L OA D RE L A Y 18 . 9 .3 CH E C K F A UL T L IN E CA B LIN G F R O M IN VE R TE R (J 6 -6 ) 18. 9.4 CH E C K OPE R AT ION OF K 2 ON 1 100 - 1 18 . 9.5 CO N TIN U E D ON N EX T PA GE Figure 16-27 Error Codes March 2003 Section 16: Troubleshooting 577 Fadal Maintenance Manual CH ART 1 8 continued (page ERROR CODE S CO NTINUE D FROM PRE VIO US PA GE 2) ERROR NUM B ER # REPORTED BY AXIS ME A NI NG DIA GNOS IS PRO CE DURES 8-18-95 #10 ENCODE R AND M AG NET NOT RE S PONDI NG OR SP INDLE NOT TURNING 18. 10 OCCURS DURING SP INDLE OPE RA TION IF BOTH E NCODER F EE DBA CK AND SPI NDLE M AG NET ARE NOT DE TE CTE D FOR LO NGER THAN 3 SE CONDS IS SP INDLE TURNING? NO 18. 10.2 18. 10.1 #13 MOT OR OVE RLOA D FOLLOWI NG E RRO R > OVE RLOA D FACT OR 18. 13 #14 MOV E TRA NS FE R FAULT - MOVE SE TUP INCOMP LE TE ERROR O CCURS A T E ND OF M OV E WHEN NUM B ER OF P ULSE S COUNTE D BY A XIS CONT ROLLER DO ES NOT EQ UAL NUM B ER S ENT B Y CP U #15 TIM E O UT E RROR RI GID T AP PRE CYCLE TES T 18. 15 18. 12.2 18. 12.3 FOLLOWI NG E RRO R EX CEE DS THE OVE RLOA D FA CTOR PA RAM ET ER CHE CK OVE RLOAD FA CTOR PA RAMET ER. IS IT T OO LO W? 18. 13.1 18. 13.2 AX IS MO VE COMMA ND WAS NOT PRO PE RLY TRANS FE RRE D TO AX IS CARD (CHE CK S UM F AI LE D) SP INDLE MA GNE T WAS NOT DET ECTE D WITHIN THE ALLOWA B LE T IM E GOTO CHA RT 4 AX IS CO NTROL 18. 13.3 18. 13.4 RUN DI AG NO ST ICS ON CPU AND A X IS: IF O NE A XI S FAI LS, REP LACE THAT AX IS CA RD AND RE TE ST . IF M ULTIP LE CARDS FA IL, RE PLA CE 1030 OR 1400 AND RETE ST 18. 14.2 18. 14.3 IS SP INDLE TURNING? YE S NO GO TO CHA RT 3 SP INDLE DRI VE R 18. 16 CHE CK PO WER GOTO CHART 12 BA D PO WE R/ BA D VO LTA GE CHE CK +5V , + 12V, & -12V VOLT AGE S FROM POW ER S UPP LY SE E CHART 12A 18. 15.2 18. 15.1 #16 TIM E O UT E RROR RE S OLVE R RE SP ONS E OR M OTOR O VE R TEM P RUN DI AG NO ST ICS ON CPU AND A X IS: IF O NE A XI S FAI LS, REP LACE THAT AXIS CA RD AND RE TE ST . IF M ULTIP LE CARDS FA IL, RE PLA CE 1030 OR 1400 A ND RETE S T CHE CK +5V , + 12V, & -12V VOLT AGE S FROM POW ER S UPPLY SE E CHA RT 12A 18. 12.1 18. 14.1 18. 14 18. 10.3 GO TO CHA RT 3 SP INDLE DRI VE R 18. 10.2a #12 MOT OR OVERLOA D STEP COM MA ND CHE CKS UM ERROR 18. 12 CHE CK SP INDLE ENCODE R AND MA GNET A ND THEI R CAB LING YE S RES OLVE R ZE ROCROSS ING WA S NO T DE TECT ED BY A XIS CA RD WIT HIN THE ALLOWA B LE T IM E 18. 16.1 STO P S P INDLE AND US E DI DS TO CHE CK M A GNET (TURN S P INDLE BY HAND) VE RIFY M AGNE T IS CONNECTE D AND CHE CK ADJUSTM E NT 18. 15.4 18. 15.3 US E KNO WN GO OD HALL E FFE CT SWI TCH AND TE S T WI TH A M A GNET US ING DI DS 18. 15.5 ORIENT AT ION MAG NE T IS RE AD B Y CP U T HRO UGH 10 60 J10 PIN 8 BUT T HE SP INDL E CARD REA DS IT T HROUG H J 2. IF WIRING IS B AD, CPU MAY B E A BL E T O RE AD MA GNET, BUT T HE SP INDL E CARD MAY NOT B E A BL E T O RE AD IT. VERIFY RES OLV ER IS PLUGG ED I NTO J2 O F 1010 CA RD 18. 16.2 TE MP ERAT URE SNAP S WITCH WILL S HORT COS SIG NAL TO G ND ON R ESO LV ER B OARD IN MO TO R IF MO TO R OV ERHE AT S. CHE CK IF MO TO R IS HO T OR CHE CK COS OUT PUT T O RES OL VER (PIN 8 OF J1 -J6 ON 10 60 ) FO R S HO RT TO GND . LET MO TO R CO OL. GO T O CHART 4A AX IS CONTROL (RESOLV E R FAULTS ) 18. 16.4 18. 16.3 #17 BA D REA DING ON RE S OLVER P ORT 18. 17 RE A DING FRO M T HE RE S OLVE R P ORT INDICAT ES A S PINDLE SP EE D G RE A TE R THAN P OS SIBLE 18. 17.1 MA KE S URE CA B LE S A RE PROP ERLY ATTACHED (S PI NDLE "RE SO LVER" I S THE SPINDLE ORIE NTAT ION HA LL E FFECT S ENS OR) 18. 17.2 CHA NGE SP INDLE CA RD 18. 17.3 CO NTINUE D ON NEX T PA GE Figure 16-28 Error Codes (Continued) 578 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHA RT 1 8 con tin ued (pag e 3) ER RO R CO DE S CO NTIN UE D FROM PRE VIO US PA GE ERROR NUM B ER # REP ORT E D BY AX IS 8-2 3-95 #18 AM PLIF IE R FAULT LINE DO WN 18. 18 AX IS C ARD DO ES N OT DE TE CT F AULT LI NE OR SIG NAL HA S FA LLE N BE L OW 1 0V 18. 1 8.1 #19 STA CK OVE RFL OW OVE RLOA DED W ITH STE P COM MA ND 18. 1 9 CHE CK CAB LING AND A MP LIFI ER IF THE LS E CB I S LI T, CHE CK FOR ME CH ANICA L B IND 18. 1 8.2 18. 18 .3 THE STA CK ON THE A XI S CA RD (US ED T O S TORE C P U COMM A NDS UNT IL TH E Y ARE S ERV ICE D) HA S OV ERFLO WE D 18. 20 THE MOV E TRA NSFE R PR OCE SS WA S NOT CO MP LET ED (A COM MUNICA TIO N FAI LURE B ET WE EN AX IS C ARD A ND CP U) 18. 2 1 AN UNK NOWN OR ILLE GA L INTE RRUP T HA S OCCURR ED 18. 2 2 FEE DBA CK FROM SC A LE P OR T IS OUTS ID E ALLOW AB LE LI MI TS RE P LACE AX IS CARD 18. 2 1.3 CHE C K CA B LING CH E CK ALIG NM E NT OF S CALE TES T S CA LE FOLLOWI NG E RRO R EX CEE DS THE USE RDE FI NE D OV E RLOAD FAC T OR 18. 23.2 18 . 27 18 . 27.1 18 . 27.2 #28 ORIE NT AT ION TIM EOUT OR T AP PI NG CA LIB RAT ION ERROR 10 SE COND TI ME OUT.DI D NOT ORIE NT OR DI D NOT ARR IV E AT 5TH MA GNET DURING CA L IB RAT ION 18 . 28 18 . 28.1 GOTO CHART 12 BA D PO WE R/ BA D VO L TA GE IS SP INDL E TURNING? 18 . 28.3 18. 23.4 YE S NO (CO U LD BE 1-25 5) 18 . 48 AX IS DAT A T R ANS FE R HA S ST AL LE D. 18 . 48.1 VE RIFY THA T ALL A XI S CA RDS ARE BLI NKING 18. 48.2 STO P S P INDLE AN D U S E DI DS TO C HE CK M A GNET (TURN S P INDLE BY HAND ) VE RIFY M AGNE T IS CONNECTE D AND CHE CK ADJ USTM E NT 18. 28.4 18. 28 .5 OR IE NT AT IO N M A G NE T IS RE A D B Y C P U T HR O U GH 10 60 J10 PIN 8 BU T T HE SP IN DL E C A RD R EA D S IT T H RO U G H J 2. IF WIRIN G IS B A D, C PU M AY B E A BL E T O RE AD MA GN E T, BU T T HE SP IN DL E C A RD M AY N O T B E A BL E T O RE AD IT. GO TO CHA RT 3 SP INDLE DRI VE R THIS E RR O R IS R EP O RT E D B Y THE C P U N O T THE AX IS C A RD . IT IS N O T A N E R RO R #. GOTO CHA RT 4A AX IS CONTR OL (M OTOR OVE RL OA D) 18. 23.3 ORIE NT AT ION SP EE D M AY BE TOO LOW 18 . 28.2 18. 2 2. 4 CHE CK PO WER CHE CK OVE RLOA D FA CTOR PA RAM ET ER. IS IT T OO L O W? ORIE NT AT ION SP EE D M AY B E TOO LO W SP INDLE CO NTROLLER DO ES NOT R ES P ON D #48 CHE CK BO ARDS IN S CA LE BO X 18. 2 2. 3 18. 2 2. 2 CO ULD NOT F IND MA GNET A FTE R TAP P ING HO LE. 5 SE COND TI ME OUT. (DURING RI GID T AP PI NG) #27 RE TURN TO M AG NET TIM EOUT 18. 20.3 18. 21.2 18 . 23.1 18. 23 RU N DI AG NO ST ICS ON CPU AND A X IS: IF O NE A XI S FAI LS, REP LACE THAT AX IS CA RD AND RE TE ST . IF M ULTIP L E CARDS FA IL, RE PLA CE 1030 OR 1 400 A ND RETE S T CHE CK +5V , + 12V, & -1 2V VOLT AGE S FROM POW ER S UPP LY SE E CH A RT 12A FAUL TY CON NE CTIO N CA N CA USE NOI SE 18. 22.1 #23, #24 , #25 #26 MOT OR OV ERLO AD FOLLOWI NG E RRO R > OVE RLOA D FAC T OR 18. 18.4 CHE CK CONNECTI ONS 18. 21.1 #22 BA D SCA LE RE A DING GO T O CHA RT 4 (A MP LIFI ER FAULT) PROB LEM COULD B E AX IS CARD (1010), CP U CA RD (1400 ), OR 1 030 18. 20.2 18. 20.1 #21 SP URIOUS INTE RRUP T - NOT SE RVICE A BLE DIA GNOS IS PRO CE DURES 18. 19.2 18. 1 9.1 #20 MOV E TRAN S FE R FAULT - BUF FER IN DIC AT OR NO T S ET ME A NI NG PROB LEM COULD B E AN A XI S CARD (N O T NE CES SA R ILY THE SP INDLE C ARD ) , THE 1030, OR THE 14 00 18 . 48.3 Figure 16-29 Error Codes March 2003 Section 16: Troubleshooting 579 Fadal Maintenance Manual CHART 19 S E R IA L P O R T C O M M U N I C A T IO N S S E R IA L CO M M U N IC AT IO N S 6 -1 4 - 9 5 IS PROB LEM W ITH A LL C O M M U N IC A T IO N S O R O N L Y A S IN G L E FILE ? S IN G LE F IL E 19 . 1 LO O K F O R HID DEN CH A R AC T ER S IN T H E F I L E F IL E M U S T B E SA VE D IN A T E X T ONLY F ORMAT 1 9 . 1 .1 1 9 . 1 .2 IS IT A S Y N T A X ER R OR ? (D O E S P A R T O F F I L E TRAN S MIT?) 1 9 . 1 .3 NO YE S S E N D F IL E U S IN G T A ,1 ,1 SO C ON TR OL S TOP S AT SYN TA X E R ROR 1 9 . 1 .4 ALL C OM M UNIC ATIO N CHE C K BA UD R A TE AN D O T H ER C O M M U N IC AT IO N P A R A M E T E R S A T M A C H IN E A N D AT C OMP U TE R LO O K F O R I L L EG A L CHA R AC T ERS B EFO RE T H E IN IT IA L P E R C E N T SIG N 19 . 2 1 9 . 1 .3 a V E R IF Y T H A T A L L R S 2 3 2 C A B L E S A R E P L U G G E D IN (A T 1 0 3 0 , B A C K O F C A B I N E T , CO MP U TE R) 19 . 3 IS A NU LL M OD E M B E IN G U S E D ? 19 . 4 YE S CHE C K S W I T C H P O S I T IO N O F NU LL M OD E M, T R Y A G A IN I N O T H E R P O S I T IO N 19 . 4 . 1 NO CH E C K G R O U N D IN G O F M A CH IN E. G R O U N D M U S T B E A C O N T IN U O U S W IR E T O T H E P O W E R D IS T R IB U T IO N P A N E L O F T H E B U IL D IN G . G RO UN D RO DS AR E N OT A CC E P TAB LE A S T H E P R I M A R Y G R O U N D IN G M E T H O D . 19 . 5 T H E G R O U N D W IR E O F TH E RS 232 D B 25 PLUG IN T H E M A IN C A B IN E T MUS T B E ATT AC HE D TO T HE CA BIN ET. P A IN T M U ST B E R E M O VE D FOR GO OD CONTA CT. DIFF IC U LT T O D IA GN O SE P RO B LEM S C AN OC C U R IF M A C H I N E I S N O T P R O P E R L Y G R O U N D E D . TH E R E M U ST BE A C ON T IN U O U S G R O U N DIN G C O N D U C T O R ( A S S P E C I F IE D O N T H E G R O U N D IN G L A B E L IN T H E M A C H I N E ' S D IS C O N N E C T B O X ) F R O M T H E V M C 'S G R O U N D B U S T O T H E G R O U N D B U S I N T H E B U I L D I N G 'S P O W E R D IS T R IB U T IO N P A N E L . TH E C O M P U TE R BEIN G U S ED M U ST AL SO BE P R OP ER LY G R O U N D ED (U N LE SS IT IS A B AT T E R Y O P E R A TE D LA P T O P ). 19 . 6 IF M A C H I N E H A S A P H O N E M O D E M , M A K E S U R E I T IS D IS C O N N E C T E D FROM TH E RS232 P OR T 19 . 7 PLU G R S 232 TE ST P LUG IN T O R S 2 3 2 P O R T O N C A B IN E T . FROM COM MA ND MO D E, T Y P E " D I" , P R E S S E N T E R , T YP E "G 0 3 0 0 0 ", P R E SS E N T ER , SE LEC T TH E RS232 TES T. 19 . 8 YE S DO ES RS 232 TE S T P AS S W IT H O U T ER R OR S? 19 . 9 PL U G R S 2 3 2 C A BL E IN TO PO R T AN D M OV E T ES T P LU G TO C OM P UTER EN D O F C A BLE . RE R U N TE ST . 19 . 9 . 1 NO EIT H ER T HE 1 0 3 0 C A R D OR TH E RS232 CA B LE FROM THE 1030 T O T HE D B 2 5 P LU G IS B A D DO ES RS 2 32 TE S T P AS S W IT H O U T ER RORS ? 1 9 . 9 .2 YE S NO M A C H IN E P A S S E S D I A G N O S T I C S AN D IS N O T A T FA U L T I N C O M M U N IC A T IO N P R O B L E M . A N U L L M O D E M M IG H T B E N E E D E D . 19 . 9 . 3 CA B LE M A Y B E D E F E C T IV E , T O O LO N G , O R R O U T E D IN A N O IS Y E N V IR O N M E N T 1 9 . 9 .2 a 19 . 1 0 IF P R O B L E M S P E R S I S T , G O T O C O M M U N IC A T IO N S T R O U B L E S H O O T IN G S E C T IO N O F M A IN T E N A N C E M A N U A L F O R A D D IT IO N A L I N F O R M A T I O N 19 . 1 1 Figure 16-30 Serial Port Communications 580 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 20 FA D A L S E R V O IN D E X ER SE R VO IN D EX ER W ILL IN D EX ER POW ER -U P? 10- 20 -95 NO CH E C K FU SE ON B AC K OF CO N TR O L B OX 20 . 1.1 20 . 1 YE S W ITH MOT OR C A BLE DI SC ON N E C TE D , W ILL IN D E XE R POW ER UP ? 20 . 1.2 YE S IS PU LS E L E D ON 181 0-0 BLIN K IN G? NO 20 . 1.3 CH E C K FOR S H OR T OF 5V TO GR OU N D IN C AB L E OR E NC O D ER 20 . 1.4 YE S CH E C K CO N N EC TO R TO D IS P LAY 20 . 1.2 a 5V BE TW E EN PIN 1 AN D P IN 6 OF J 11 ON 18 10- 0? NO YE S CH E C K CO N N EC TI ON S OF 5V R E GU L A TOR O N P O W E R SU P P LY (1 818-0 -2 ) 20. 1 .4a 20 . 1.3 a NO CH E C K FOR 12 0V A C AT PIN S 1 & 2 OF J 1 ON P OW E R SU P P LY (181 0-0- 2) 20 . 1.5 CH E CK FO R BA D S O LD E R J OIN TS A T AL L FO U R V O LT AG E RE G U LA TO R S. W ILL HE A D MO VE ? 20 . 2 NO DO ES DI SP LAY I ND I C ATE MOT ION ? 20 . 2.1 20 . 2.2 NO YE S 20. 2 .3 TU R N OFF AN D UN P LU G U N IT . CH E C K FOR S H OR TE D (B LOW N ) IGB T'S ON A M PLIF IER CH E C K FU SE S ON M OTOR , ON 181 0-0- 1 A ND ON 181 0- 0-2 20. 2 .1a LI ST EN C A R EF U LL Y TO U N IT. IF M OTO R IS TU R N IN G AN D H E AD I S N OT, A C O UP LE R IS LOOS E IN SI DE H E AD . CH E C K PA R AM ET ER S (R A TIO AN D EN C OD E R C OU N TS ) VE R IFY FEE D R A TE PO T IS N OT S ET A T 0 YE S 20. 2.1b 20 . 2.4 IF A MP LIFI ER IS BLOW N , LO OK FOR C A U S E. AR E MO TOR L E A DS SH OR TE D TO C H AS S IS? 20 . 2.1c W IRE S T O MO T O R A R E SH IEL DE D . S H IEL D M U S T BE ST RIP P ED BA C K F RO M CO N DU C TO R . DO ES HE A D R U N AW A Y ? DO ES DI SP LAY IN D IC AT E MOT ION ? YE S 20 . 3 20. 3.1 NO YE S IF M OTO R W A S RE P LAC E D , MOT OR L E AD S MA Y BE R EV E R SE D CH E C K C ON N EC TO R S ON MOT OR C A BL E A ND BOX FOR P U SH E D IN O R DA M AGE D PIN S O R SO C K E TS 20. 3 .1a 20 . 2.1 d RE S ET PA R AM E TER S TO F AC TO RY D E FA U L TS (M IS C/ PA R AM /FA C S ET) AN D R E TR Y 20. 2 .1e 20 . 3.2 NO CH E C K VO LTAG ES 181 0-0- 1 J3 : P IN 1 +5 V & P IN 2 GN D P IN 5 +1 2V & PI N 6 C O M 181 0-0 J11: P IN 1& 2 + 5V P IN 3 +12V P IN 4 -1 2V P IN 5& 6 GN D CH E C K C AB LE AN D SOC K ET FOR D AM AG ED PIN S OR SOC K E TS EN C OD E R C AB LE O R E N C OD E R MA Y BE B A D: 20. 2.1f CH E C K ALL E N C OD E R C ON N EC T ION S . CH E C K FOR C O NT IN U ITY OF A L L EN C OD E R LIN ES F RO M EN C OD E R TO U 4 ON 181 0-0 . CH E C K FOR 5V A T E N C OD ER . 20. 3.1b DO ES HE A D JO G IN BOT H DI R EC TI ON S? 20 . 4 20 . 4.1 YE S MOT OR OVE R LOA D S? 20. 5 NO NO MOT OR OV ER L O AD OR OV ER C U R R E NT FAU LTS I ND I C ATE A BL OW N IGB T ON A MP LIFIE R YE S 20 . 4.2 IF AM P LIF IER IS B LO W N , FIN D C AU S E B E FO R E R EP LA C ING . RE SIS TA N CE A CR O SS M O TO R LE AD S S H O UL D B E 4 -6 O H M S. RE SIS TA N CE FR O M M O TO R L EA D TO C HA S SIS S H O UL D B E IN F IN IT E. W IRE S T O MO T O R A R E S HIE LD E D. S HIE LD M US T B E ST RIP P ED BA C K FR O M C O N DU C TO R . CH E C K BR A KE AIR LI N ES (1 I S O U TPU T TO H EA D , 2 IS IN P U T FR O M AIR SU P PL Y ) 20. 5.1 IF H E AD MO V E S BU T POS ITI ON D IS P LA Y DO ES N 'T C H A N GE TH ER E IS A N E NC O D ER FEE D BA C K PR O BLE M DI SC ON N E C T AIR 20 . 5.2 CH E C K C AB LE AN D S OC K ET FOR D A MA GE D PIN S OR SOC K E TS 20. 5.3 IS L OAD TOO HE A VY ? 20. 5.4 YE S NO TR Y RU N N IN G IN D EX ER W ITH NO FIX TU R IN G , AU X ILIA R Y C H U C K , OR P AR T 20. 5 .5 RE D U C E FEE D R AT E GO T O PA GE 2 OF CH A R T 20 20A .5.6 CO N SU LT FAC T OR Y AB OU T M OTO R TY PE JU M PE R S ETT IN GS 20. 5 .6 Figure 16-31 Servo Indexer March 2003 Section 16: Troubleshooting 581 Fadal Maintenance Manual CO N TIN UE D FR OM PA GE 1 OF CHA RT 20 CHART 20 conti nued (page 2) FAD AL S ERV O IN DEX ER 10- 20-95 IN DEX ER MIS POSITION S, LO SE S POS ITI ON ( MAY ALS O MOT OR OV ER LO AD ) YE S 20.6 ENC ODE R C AB LE MAY BE B AD , VER IFY C ONTI NUI TY OF ENCOD E R SI GN ALS IN C AB LE TES T E N COD E R WITH F ADA L ENC ODE R TE ST ER (E NC ODER M A Y B E B AD) 20.6.1 ENC ODE R MA Y B E SLIP PI N G ON MOT OR SHA FT, 20. 6.2 20. 6.3 NO HE AD MIS SES STA RT PU LS ES ? 20. 7 YE S AR E YOU US IN G SIM ULTA N EOUS MOV E ME N T? 20. 7.1 NO HEA D MUS T F INIS H MOV E BE FOR E NEX T STA RT IS S ENT. ADD DWE LL TO VM C PROG RA M . YE S 20. 7.2 NO DI SCON NE CT I NDE XER IN TE RF ACE C A BLE AND RU N P R OGRA M USING TH E STAR T B U TTO N . DO ES PROG RA M R UN PROP ER LY ? 20.7.1b 20. 7.1a WILL NOT C OLD S TART ? 20. 8 YES FEE D RATE POT D O ES NO T R ESP ON D PROP ER LY ? 20. 8.2 CHE CK PA RAM ET ER S TO S EE I F BR AK E IS ACTI VE 20. 9.1 NO YES 20. 10 20. 7.1c CHE CK C ONN ECTO R S ON MOT OR CA BLE A ND BOX FOR PU SHE D IN O R DA M AGE D PINS OR SOCK E TS FIR ST M AKE SU RE UN I T J OGS IN BOT H DI REC TI ONS AND CO R REC TLY DISPLA Y S POSITI ON 20. 8.1 NO BRA KE DO ES N'T WOR K ? 20. 9 YE S MILL M A Y NE ED 0. 001uF CAP A CITOR AC ROS S FINIS H TERM INA LS O F MILL. CHE CK C OMM UN ICA TION PROT OC OL BETWE EN IND EX ER AN D M ILL YES 20. 7.1d ENC ODE R C AB LE OR E NCO DER MAY BE B AD . CH E C K ALL E N COD E R C ONNECT ION S . CH EC K CON TIN UIT Y OF E NC ODER LINE S. 20. 8.3 CH E CK AI R SUP PLY AND AIR LIN E CO NN ECTO RS (A IR PR ES SUR E SHOU LD B E 80 PSI) TEST I N MD I (M 60 BRA K E O N, M61 BRA KE OF F) 20. 9.2 20. 9.3 CH EC K SOLI D ST ATE RE LA Y (K 1) ON 1810- 0-2) 20. 9.4 AIR SOLE NOID PORT S AR E 1 & 2. 2 IS AI R IN. 1 IS AI R OU T TO HE AD . REC A LI BRA TE FEEDRAT E POT IN DIA GN OSTICS 20.9.5 20.10.1 NO RS 232 DO ES N OT WORK ? 20. 11 YES IN SE RT DU M MY PLU G IN TO R S232 DB 25 CONNEC TO R (P IN S 2 & 3 J UMP E RED ) RU N RS232 TE S T IN DIA GNOS TICS 20. 11.1 DO ES RS 232 TE ST WOR K ? 20. 11.2 INDEXE R HA S CTS, DT R , & DSR JUMP E RE D INT ER NAL LY. YE S NO CHE C K CAB LING, BA UD RAT E, AND P ROTOCO L (IN DEX E R IS 7 D AT A B ITS , EV EN P ARITY, 1 S TOP B IT) 20. 11.3 CHE C K VO LTAG ES 1810-0 J11: P IN 1& 2 + 5V P IN 3 +12V P IN 4 -12V P IN 5& 6 GN D 20. 11.2a Figure 16-32 Servo Indexer (Continued) 582 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual C H A R T 2 1 c o nti nu e d (p a ge 2 ) P O S IT IO N IN G P R O B L E M S CO N T IN U E D FR O M PA G E 1 OF C H A R T 2 1 10 - 2 0 -9 5 IF B AL L S C R EW HA S BE E N R EP L AC E D A N E W S U R VE Y M U S T B E DO N E SU R VE Y F O R S CA L ES IS N O T TH E S AM E AS S UR V EY FO R RE SO L VE R . F O R P O SIT ION IN G TO BE C OR R EC T , S U RV E Y F OR RE SO L VE R MU S T B E E N TE RE D W HE N SC AL E S A RE U NP LU G G ED AN D S U RV E Y F O R S CA LE S MU S T BE EN TE R ED W H EN S CA LE S AR E RE C ON N EC T ED . SU R VE YS A RE BA LL SC R EW D E PE N DE N T. CH A NG IN G T H E B AL LS CR E W INV A LID AT ES TH E SU R VE Y. 21 A .1 O VE R SH O O T IN G PO S IT I ON ? 21 A .2 YE S YE S IS PA R T SL IP PI N G IN F IX T U R E O R IS F IX TU R E MO V IN G ? YE S NO 21 A .3 .2 PO W ER OF F M A C H IN E . DI S C O N N EC T S C A L E S. PO W ER ON M A C H I N E. 21 A .2 .3 NO IF O VE R SH O O TIN G DO ES N O T O C C U R W ITH OU T SC A L ES CO N TAC T F A C TO R Y AB O U T S O FT W A RE CH A N G E 21 A .2 .4 DO ES MA C H IN E POS IT I O N C O R R E C T L Y W IT H O U T SC A L ES ? 21 A .3 .3 SU R VE Y F O R S CA L ES IS N O T TH E SA M E A S SU R VE Y F O R R ES O LV E R. FO R P OS ITIO N ING TO BE C OR R EC T , S U RV E Y F OR R ES O LV ER MU S T B E E N TE RE D W HE N SC A LE S A RE UN P LU GG E D AN D S U RV E Y F O R S CA LE S MU S T B E E N TE RE D W HE N SC A LE S A RE RE C ON N EC T ED . SU R VE Y F O R S CA L ES AN D SU R VE Y F O R RE SO L VE R CA N B E FO U ND IN M A C HIN E RE C OR D S. YE S NO GO TO CH A R T 2 2 SC A L ES 21 A .3 .4 EN S U RE T HA T PA R T AN D F I XT UR E AR E AD E Q U A TE L Y SE C U RE D 21 A .4 .1 NO IS D NC BE IN G U S E D? 21 A .5 DI S C O N N EC T S C A LE S, PO W ER D O W N MA C H I N E AN D R ES T A R T TH E S C AL E E RR O R IN P UT IS O N J13 SO IT IS CR ITIC A L TO S CA LE S TH AT J13 BE PL UG G E D IN . HO W V E R, PO S IT IO NIN G ER R O RS CA N AL SO OC C UR W ITH R ES O LV E RS IF J1 3 IS N OT PL U GG E D IN . FO R SC A LE S AN D R E SO L VE R S IT IS IM PO R TA N T TH AT J13 BE PL U GG E D IN A ND D OO R IN T ER LO C KS FU N C TIO N P R OP E RL Y. NO 21 A .4 J1 3 ON 1 0 60 MU S T BE P LU G G E D IN FO R S C AL E S T O W OR K R EL IA B L Y 21 A .3 .1 21 A .3 DO ES YE S MA C H IN E HA V E SC A L ES ? 21 A .2 .2 21 A .2 .1 NO DO ES M A C H IN E HA V E SC A L ES ? IF O VE R SH O O T IN G O C C U R S W IT H A H E AV Y PA R T O R F IX TU R E , BU T DO ES N O T O C C U R W I TH OU T I T : US E G 5 1 R 0 - # W IT H A VA L U E >1 F O R X A N D Y TO L E N G T H E N F EE D R AM P S YE S DO ES TH E MA C H IN E M IS P O SI T IO N W H EN NO T U S IN G DN C ? 21 A .5 .1 NO CO N SU L T CH A R T 1 9 SE R IAL CO MM U N IC AT IO N S 21 A .5 .2 TR Y DN C X , SH O R T E N TH E C A BL E , US E A SL O W ER BA U D R AT E, TR Y AN O T HE R C O M P U T ER AN D C A BL E 21 A .5 .3 YE S PO W ER O F F MA C H IN E AN D IN SP EC T W IR I N G 21 A .6 CH E C K F OR L O O SE OR B RO KE N W I RE S OR B AD C R IM P S 21 A .7 T ES T A L L GOLD COAX CO N N EC TO RS US IN G ST 44 SE R VIC E T O O L 21 A .8 CO N T IN U E D O N P AG E 3 OF CHART 21 Figure 16-33 Positioning Problems March 2003 Section 16: Troubleshooting 583 Fadal Maintenance Manual CHART 21 conti nued (page 3) POSIT IO NING P RO BL EM S CO NTINUE D FROM PA GE 2 OF CHA RT 21 10-20-95 CHE CK RES OLV ER CO NNECTO RS A T MOT ORS 21B .1 CHE CK LEV EL AND TRA M 21B .2 CHE CK FOR BROK EN OR LOO SE RE S OLVE R CO UPLING S 21B .3 CHE CK BA LLSCRE W ALIG NM E NT 21B .4 US E CLAM P -ON AM ME TE R TO CHE CK EA CH AX IS . AM P DRA WS M UST BE IN S PE C A ND CONSI STE NT 21B .5 CHE CK ST RA P ADJUSTM E NT S (C HECK AM P DR AWS AG AIN A FT ER ADJUST ING S TR APS ) 21B .6 IS POS ITI ONING ERROR RE VE A LED B Y OFF-MA CHINE PA RT INS PE CTION? 21B .7 YE S INS PE CT PART ON M ACHINE BE FO RE REM OV I NG CL AMP S OR RE LE AS ING V IS E 21B .7.1 NO DO ES P ART INSP ECT GOO D ON M ACHINE ? 21B .7.2 YE S NO CLA M PING MA Y BE DI ST ORTING PA RT 21B .7.3 WHEN MAT ERIAL IS CUT THE ST RES SE S IN TH E MATER IAL CHANG E SO THE DIM ENS IO NS MAY MO VE W HE N IT IS UNCL AMPED . SING LE S TE P THRU THE PROG RA M TO FIND P OS SIB LE PROG RA M MING E RRO RS OFF-MA CHINE ME AS URING M A Y B E OUT OF CALI BRA TIO N 21B .7.4 THERM AL CHA NGE S BE TWE EN MA CHINING AND INS P ECTI ON M AY BE A FFE CTING PA RT 21B .7.5 21B .8 HAV E AN APP LI CATIO N ENGI NE ER REV IE W THE P RO GRAM AND FIX TURI NG 21B .9 ARE ALL POS ITI ONS CHA NGING ? 21B .10 YE S NO THERM AL EX PA NSI ON MA Y BE THE P ROBLE M 21B .10.1 TRY RE S ETT ING HO ME A T RE GULAR INTE RV A LS THERMAL GRO WT H IS A NATURA L E F FECT OF H IGH S PEED MA CHIN ING . IT CA N BE LIMITE D, BUT NOT T OT A LLY EL IM INA TE D. IT O CCURS IN T HE BA LL SCREWS , THE HEAD, TH E SP INDL E, A ND EV EN T HE COLU MN, SADD LE AND T ABL E WHEN T HER E A RE TE MP ERAT U RE SW ING S . 21B .10.2 INSP ECT AND FLUSH THE LUB E SY S TEM . VE RIFY E NT IRE SY S TEM IS WORK ING P ROP ERLY 21B .11 Figure 16-34 Positioning Problems 584 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 22 SCALE PROBLEMS SCALE PROBLEMS SCAL E PROBLEMS CAN SHOW UP AS SCALE ERRORS (AN ERROR CODE), MISPOSITIONING, REPEATABILITY PROBLEMS, ROUNDNESS PROBL EMS OR UNEXPECTED POSITION SHIFTS. 10-20-95 IS IT AN ERROR MESSAGE? 22. 1 DIFFICULT TO DIAGNOSE PROBLEMS CAN OCCUR IF MACHINE IS NOT PROPERLY GROUNDED. THERE MUST BE A CONTINUOUS GROUNDING CONDUCTOR (AS SPECIFIED ON THE GROUNDING LABEL IN THE MACHINE'S DISCONNECT BOX) FROM THE VMC'S GROUND BUS TO THE GROUND BUS IN THE BUILDING'S POWER DISTRIBUTION PANEL. CO NSULT CHART 18 ERROR CO DES YES 22.1.1 NO SCALE ERROR MESSAGE? (AND LED IN SCALE BOX LIT) YES 22. 2 WILL SCALE BOARD RESET? 22. 2.1 YES, AND ERROR IS NO T EASILY RECREATED CO NNECT SCALE ENCODER TESTER (ST40) BETWEEN SCALE BOX AND AXIS CARD NO, OR 22.2.2 ERROR REOCCURS EASILY NO SWITCH EXE BOARDS IN SCALE BOX 22.2.1a EXE ERROR STAYS W ITH BOARD EXE BOARD OR SCALE? 22. 2.1b REPLACE EXE BOARD 22.2.1b.1 SCALE CONTINUED ON PAGE 2 COLUMN 2 OF CHART 22 22.2.1c IS IT A POSITI ONING PROBLEM? 22. 3 NO YES DO ES PROBLEM G O AWAY WITH NO SCALES? POWER OF F MACHINE. DI SCONNECT SCALE FROM 1010 CARD. PO WER ON MACHINE. YES 22.3.2 22.3.1 SURVEY FOR SCAL ES IS NOT THE SAME AS SURVEY FOR RESOLVER. FOR POSITIONING TO BE CORRECT, SURVEY FOR RESOLVER MUST BE ENTERED WHEN SCALES ARE UNPLUGGED AND SURVEY FOR SCALES MUST BE ENTERED WHEN SCALES ARE RECONNECTED. SURVEY FOR SCAL ES AND SURVEY FOR RESOL VER CAN BE FOUND IN MACHINE RECORDS. NO RECONNECT SCALES ALSO J13 ON 1 060 (SCALE ERROR LINE) MUST BE PLUGGED IN) AXIS CO LD STARTS TO CORRECT POSITION? 22.3.4 22. 3.3 22. 3.2a 22. 3.5 IF Y-AXIS, THE SCALE MOUNTING MAY BE DEF LECTED BY SCALE CABLE 22.3.4a VERIFY SCALE CABLING IS CORRECT AND PLUGGED INTO CO RRECT INPUT OF 1010 CARD (J6) CO NTINUED ON PAGE 2 CO LUMN 1 OF CHART 22 22.3.4b VERIFY THAT SURVEY IS CORRECT FOR SCALE 22.4 ZERO OFF SET IN SV F OR AXI S MAY BE SET WRO NG YES REMEMBER TO RE-ENTER THE SURVEY FOR SCAL ES. NOT A SCALE PROBLEM. GO T O CHART 21 POSITIONING PROBLEMS NO RUN AN EXTERNAL CABLE TO THE SCALES 22.3.6 USE SCALE T ESTER (1710-0) OR ENCODER TESTER (ST40) AND CHECK FOR INDEX FROM SCALES 22.3.7 SURVEY FOR SCALES IS NOT THE SAME AS SURVEY FOR RESOLVER FEEDBACK. 22.3.4c CO NTINUED ON PAGE 2 CO LUMN 5 OF CHART 22 22.3.4d Figure 16-35 Scale Problems March 2003 Section 16: Troubleshooting 585 Fadal Maintenance Manual CHART 22 conti nued (page SCALE PROBLEMS CONTINUED FROM PAGE 1 CO LUMN 2 OF CHART 22 CO NTINUED FROM PAGE 1 CO LUMN 1 OF CHART 22 CO NTINUED FROM PAGE 1 CO LUMN 5 OF CHART 22 2) 10-20-95 22A.3 22A.2 22A.1 CO NNECT SCALE ENCODER TESTER (ST40) BETW EEN SCALE BO X AND AXIS CARD PO WER DOWN MACHINE AND DISCO NNECT SCALES F RO M AXIS CARDS 22A.3.1 22A.2.1 YES SCALE TESTER SHO WS ERROR? PUT X SCALE CABLE INTO Y JACK O F SCALE BO X, ETC. 22A.3.2 PO WER ON MACHINE 22A.2.2 NO SWAP A KNOW N GOOD CABLE BETWEEN SCALE BOX AND AXI S CARD AND RETEST 22A.3.2a SWAP AXI S CARDS ERROR STAYS W ITH EXE BOARD OR SCALE? EXE BOARD 22A.2.3 22A.3.3 REPLACE 1580-1A BOARD (SCALE BOX MOT HERBOARD) PROBLEM STAYS W ITH AXIS CARD? 22A.3.4 22A.2.3a SCALE YES REPLACE AXIS CARD 22A.3.4a NO CHECK GIBS AND STRAPS SCALE CABL E MAY BE DAMAGED. RUN A NEW CABL E OUTSIDE O F MACHINE TO TEST . 22A.3.5 GO TO CHART 21 PO SIT IONING , CHART 5 REPEATABI LITY 22A.2.4 ERROR STI LL OCCURS? (LED LITES) 22A.2.5 YES DISCONNECT READER HEAD FROM BRACKET AND INSTALL SHIPPING M OUNT S ON READER HEAD. MOVE HEAD BY HAND. CHECK ALIGNMENT OF SCALE MOUNTI NG 22A.2.5a NO 22A.2.5b CABLE DAMAGED, REPLACE 22A.2.5c 22A..2.6 OVERSHO OTING? 22A.1.1 SCALE IS GOOD. ERROR STI LL OCCURS NO WHEN SCALE M OVED BY HAND? (LED LITES) RETURN BAD CABLE TO F ADAL FOR FAILURE ANALYSIS YES 22A.3.6 22A.2.5c.1 YES REPLACE SCALE CO NSULT FACT ORY ABOUT AXIS SOF TWARE UPDATE PROBLEM IS ALIG NMENT OF SCALE OR OF READER HEAD AND BRACKET WHEN SCAL E IS REPLACED A NEW SURVEY MUST BE DONE. 22A.2.5d 22A.1.1a NO CAVITATION OR VIBRATIO N? YES 22A.1.2 DO ES IT GO AWAY WHEN SCALES ARE DISCONNECTED? 22A.1.2a NO CROSSOVER PROBLEM ? (BUMP AT QUADRANT S) YES CHECK ADJUSTMENT OF GIBS AND STRAPS 22A.1.2b CHECK BACKLASH WIT H SCALES DISCONNECT ED. 22A.1.2c BACKLASH >20? 22A.1.2d YES MECHANICAL BACKLASH MUST BE CO RRECTED. 22A.1.2e NO YES CO NSULT FACT ORY 22A.1.3a NO T A SCALE PROBLEM GO T O CHART 1 22A.1.2a. 1 22A.1.3 Figure 16-36 Scale Problems (Continued) 586 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual CHART 23 R IGID TA P R I G ID T A P D I F F I C UL T T O D I A GN O S E P R O B L E M S C A N O C C U R IF M AC H I N E I S N O T P R O P E RL Y G R O U N D ED . T H ER E MU S T B E A C O N T I N U O U S G RO U N D I N G C O N D U C T O R ( AS SP E C I F I E D O N T H E G R OU N D I N G LA BE L I N T H E M A C H I N E' S D I S C O N N E C T B OX ) F R O M T H E V MC 'S G RO U N D B U S T O T H E G R O U N D BU S I N TH E BU I L D I N G 'S P OW ER D I S T R I B U T I O N P AN E L . 10 - 2 0 -9 5 TAP P ED H OLE IS B A D ( NO G O )? IS T H E C O R R E C T G O /N O G O G A G E B E IN G U S E D ? YE S IS T H E P R O P E R G R A D E O F T A P B E IN G U S E D ? 23 . 1 TAP BR E AK S? 23 . 2 TAP M U ST BE 2 F L U T E S P IR A L P O IN T (O R R O L L P O IN T ) IF L E S S T H A N 5 /1 6 " YE S 23 . 2 .1 NO FAILS R I G ID T A P TES T? A C L A SS 3 H O L E I S U SU A L L Y TA P P E D W I T H A G H - 1 T A P. PI T C H D I A M E T E R O F T A P I N C R E A S E S 0 . 0 0 0 5 " F O R E V E R Y G H N U M B E R. 23 . 1 .1 NO IS T H E D R I L L E D HO LE T H E C O R RE C T S IZ E F O R T H E T A P ? 23 . 2 .2 B E F O R E D O I N G R I G ID T A P T E ST , Z - A XI S GA I N AN D BA C K L A S H M U S T B E V E R I F I ED A N D / O R A D JU ST E D A S D ES C R I B E D IN M A IN T EN A NC E M A N U A L . YE S 23 . 3 IS C O O L A N T A N D / O R T A P P IN G C O M P O U N D TH E CO R R EC T TYP E A N D M IX T U R E ? RU N R IG ID T A P T E S T A S D E S C R IB E D I N M A I NT E N A N C E M A N U A L 23 . 2 .3 23 . 2 .4 IN D IC A T O R YE S OVE R SH O OTS A T T O P O F T A P P IN G CY C LE? 23 . 3 .1 PA SS ES RI G ID T A P T E S T BU T TAP P ED HO LES A R E N O T GOOD? YE S 23 . 4 NO B E L T S M A Y B E S L IP P IN G D U R I NG A CT U A L T A P P I N G . CH E C K B E L T T E N S IO N A N D ID L E R A S S E M B L Y . C H E C K F O R O IL O R C O O L A N T O N B E LT S O R E X C E S S IV E A IR IN H Y D R A U L I C H I/L O A C T U A T O R . IN D IC A T O R YE S OVE R SH O OTS A T B O T T O M O F T A P P IN G CY C LE? 23 . 3 a. 1 23 . 4 .1 IS T H E C O R R E C T G O /N O G O G A G E B E IN G U S E D? IS T H E C O R R E C T G R A D E O F T A P B E IN G U S E D ? 23 . 3 b .1 A C L A SS 3 H O L E I S U S U A L L Y TA PP ED W I T H A G H - 1 T A P. . P I TC H D I A M E T E R O F T A P I N CR E AS E S 0 . 0 0 0 5 " F O R EV E RY G H N U MB E R . TAP M U ST BE 2 F L U T E S P IR A L P O IN T (O R R O L L P O IN T ) IF L E S S T H A N 5 /1 6 " 23 . 3 c.1 23 . 4 .4 IS T H E D RI L L T H E C O R R E C T S IZ E ? IS C O O L A NT A N D / O R T A P P IN G C O M P O U N D T H E CO R R E C T T Y P E A N D M IX T U R E ? 23 . 3 d .1 23 . 4 .6 23 . 5 YE S NO IS A BU M P F ELT W H E N S P IN D L E STA R TS OR RE V ER S ES ? HA S Z E R O O F F S E T B E E N S E T IN IN V E R T E R ? CO N S U L T F A C T O R Y A P P L IC A T I O N E N G I NE E R 23 . 4 .7 23 . 4 .8 CO N S U L T F A C T O R Y S E R V IC E D E P T . A B O U T P O S S I B I LI T Y O F EN C O D E R R U N O U T A N D IN S T A L L IN G SOLID MO TOR M OU N TS 23 . 5 .1 YE S S P IN D L E IS T U R N IN G TOO SLOW , IN C R E A S E T H E GAIN PA RAM E TE R IN S E T P 23 . 3 c.2 YE S R E M O V E IN D I C A T O R . DO A 1 0 IN C H R I G ID T A P . CH E C K F OLL O W IN G E R R OR O N Z -A X IS U P A N D D O W N . IS Z - A X IS B A L A N C E D ? 23 . 3 d .2 CH E C K F O L L O W IN G E R R O R O N C -A X I S UP A N D D O W N . IS IT T H E S A M E ? 23 . 3 d .3 B E L T S M A Y B E S L IP P IN G . CH E C K B E L T T E N S IO N A N D ID L E R A S S E M B L Y . CH E C K F O R O IL O R C O O L A N T O N B E LT S O R E X C E S S IV E A IR IN H Y D R A U L I C H I/L O A C T U A T O R . GO TO CH A R T 3 S P IN D L E DR IVE R 23 . 5 .2 23 . 3 d .4 YE S CH E C K + 5 V ,+ 1 2 V ,- 1 2 V . ALS O S ET ME TE R FO R VA C A N D C H E C K F O R A C R IP P L E O N + 5V , + 1 2 V A ND -1 2 V D C CH E C K R IG ID T A P P A R A M E T E R S IN S E T P (E S P E C I A L L Y R A M P ) (0 . 0 1 5 V AC R IP P L E M AX O N + / - 1 2 V , 0 . 0 0 5 V AC R IP P L E M AX O N + 5 V ) 23 . 6 .1 23 . 6 S P IN D L E IS T U R N IN G TOO FAS T, DE C R EA S E T H E GAIN PA RAM E TE R IN S E T P 23 . 3 b .2 NO IN D IC A T O R RE A D IN G M O V IN G UP D O E S N O T M A T C H RE A D IN G M O V IN G DO W N ? 23 . 4 .5 YE S NO N E G A T IV E IN D IC A T O R R E A D IN G W H I L E M O V IN G DO W N ? 23 . 4 .3 AD JU ST R AM P IN S E T P 23 . 3 a. 2 NO P O S IT I V E IN D IC A T O R R E A D IN G W H I L E M O V IN G DO W N ? 23 . 4 .2 S P IN D L E MOT OR SH A KE S? 23 . 3 .2 NO NO T H IS IS IR R E L E V A N T . T A P IS N O T IN T H E HO LE A T TH E TO P O F T H E T A P P IN G C Y C L E . NO CO N SU LT FAC T O R Y S E R V IC E D E P T . 23 . 3 d .5 23 . 7 Figure 16-37 Rigid Tap March 2003 Section 16: Troubleshooting 587 Fadal Maintenance Manual TH I S C HA R T C O VE R S M -FU N C TI O NS C O NT RO L LE D T HR O U GH T HE 10 50 B O AR D . M0 - 19 , M 3 0-M 4 9 , M 60 -6 9, A ND M 90 -9 9 A R E S PE C I FI C FU NC T IO N S TH AT AR E CO N TR O LL ED TH R OU G H TH E 1 04 0 BO A R D O R AX IS C A RD S . TH EY AR E NO T CO V ER E D H E RE .. M-F U NC TI O N SE TT I N GS A ND TE R MI N A LS AR E L I ST E D I N CH A P T ER 7 O F T H E MA IN TE NA N CE M AN U AL . BE SU R E Y O U A R E U S IN G TH E TA BL E F O R T HE 1 0 5 0 BO A RD YO U H AV E . CHART 24 M - F U N C T IO N M ,- F U N C T IO N 9- 1 9 -9 5 M - F U N C T IO N DO E S N O T A C T IV A T E ? CH E C K D E C A D E SE L EC T I O N JU M P E R S / SW I T C H E S ON 1050 B OAR D YE S 24 . 1 1 0 5 0 -3 A D E C A D E S DE C AD E A - M 20- 2 9 DE C AD E B - M 80- 8 9 10 5 0 - 3 A HA S 2 M - F UN CT I O N S (A O R B ) W H IC H A N Y N U M B ER I N TH A T D EC A DE W IL L AC T IV A TE . 24 . 1 .1 2 3 4 5 6 7 8 9 W IT H U S E R D EV IC E A T T A CH E D M E AS U R E V O L T A G E A C R O S S A P P R O P R IA T E T ER M IN A L S O F T B 1 O R T B 2 O N 1 0 6 0 W H IL E M - F U N C T IO N IS A C T IVA T E D . NO A B 1050-0 D E C A D E SE LE C TION DO N OT SE T 1 05 0- 0 F O R D EC A DE S 0, 1, 3 ,4 ,6 O R 9 B EC A US E T H E S E D E CA D ES AL R E A DY H AV E S P EC I FI C FU N CT I O NS AS S IG N E D T O TH E M . DO N OT SE T D E CA D E A A N D DE C AD E B T O T HE S AM E VA LU E . TH E A C TI VE D EC A DE S O N TH E 1 05 0-0 AR E A S SI G N ED U SI N G D I P S W I TC H ES LA B EL ED A1 , A 2 , A 3, A 4 , B 1, B 2, B3 , AN D B4 . TO SE T D E CA D E A FO R : M 20 -29 : A 1-C L OS E D, A 2-O P EN , A 4-C LO S E D, A 8 -C LO S ED . M 50 -59 : A 1-O P E N, A2 -CL O SE D , A 4-O P EN , A8 -CL O S E D. M 70 -79 : A 1-O P E N, A2 -O P E N, A 4-O P E N , A 8-C LO S ED . M 80 -89 : A 1-C L OS E D, A 2-C LO S ED , A4 -C LO S E D , A8 -O P E N. FO R D E CA D E B , US E SW I T CH E S B 1, B 2 , B4 , B 8 . 24 . 1 .2 M - F U N C T IO N DO E S N O T R E L E A S E? YE S 24 . 2 24 . 1 .3 NO M - F U N C T IO N RE L E A S E S PR E MA TU R ELY ? YE S NO CH E C K S E T T I N G S OF 1A 2A OR 1B 2B DIP SW ITC H ES ON 1050 B OAR D 24 . 1 .5 CH E C K V O L T A G E A T TB3-2 (M-FU N CTION R E SE T) ON 1060. S H O U L D B E 5 V W H EN R E L E A S E D , 0V W HE N C L O S E D. RE S ET MU S T B E R ELE AS E D BE FO R E NE X T M -F UN C T IO N O C C U R S . CHE C K SE TTIN GS OF 1A 2A OR 1B 2B DI P S W I T C H E S ON 1050 B OAR D 24 . 2 .1 NO 24 . 1 .4 24 . 1 .3 a YE S 24 . 2 b TE RM I N AL S W IL L B E 0 W HE N CO N TA C TS CL O S E ) NO AR E YO U SU R E ? RE LA YS P R OVID E A CO N TAC T C LOS UR E , NO T A V O L T A G E . VO L T AG E O R C U R R E N T TH R OU G H R E LAY C O N TA C TS M U S T B E S U P PL IE D B Y US E R D E V IC E . 24 . 2 a C N C IS H U N G U P? 10 5 0 B O A R D IS A C T I V A T IN G M - F U N C T IO N . CH E C K C A B L IN G A N D U S E R D E V IC E. YE S DID RELA Y CO N TAC T S (V O LT A G E AC R O SS CL O S E ? US ER D E V I C E A ND M-F U NC TIO N BO A R D MU S T B E S ET FO R TH E S AM E PR O TO C O L . 24 . 2 .2 AL L M - FU N CT I ON S O N T HE 10 50 SH AR E TH E S A M E R E S E T LI N E . M -FU N C TIO N T E R M I N A LS UN ITS D E C A DE DI G IT A B T B1 TB 2 0 * 7+ 1 3 1 1+ 10 1 9 15 13 12 2 2 4 19 20 3 5 6 14 1 4 8 10 2 3 5 11 16 16 15 6 19 20 18 17 7 17 18 9 8 8 1 3 7 6 9 12 14 5 4 * FO R 1 05 0- 3 A ( P O L A R I T Y IM P OR T AN T F O R B O AR D S U S IN G O PT O -I SO L A TO R S ) US ER D E V I C E A ND M-F U NC TIO N BO A R D MU S T B E S ET FO R TH E S AM E PR O TO C O L . DISC ON N E C T U S ER DE V IC E F R O M 1 0 6 0 T B 1 / T B 2 A N D T B3 24 . 2 .3 CO N N E C T O H M M E T E R O R SP IN D L E/ M - F U N C T IO N T E ST E R ( ST 0 3) T O S E L E C T E D M -F U N C T I O N T E R M IN A L S O F T B 1 O R T B 2 . 24 . 2 .4 R E L A Y A C T I O N / R E S E T C O N D IT IO N D IP S W I T C H E S TH E R E LA Y A CT IO N A N D R ES E T C O ND I TIO N S A R E S E L E C T E D BY D IP S W ITC H ES L A B E LE D 1A ,2 A , 1 B ,2 B , W HE R E A AN D B A R E T HE DE C AD E S . O N TH E 1 05 0-0 A T HI R D D I G IT I N DIC A TE S T HE M -FU N CT IO N W I T HI N TH E DE C AD E . FO R D E CA D E A , TH E S E TT IN G S A R E: 1 A-O P EN 2A -O P E N = RE L A Y GI V E S A 0. 1 S E C P UL S E , C N C P R OC E ED S A F TE R P U LS E. 1 A-C LO S ED 2A -O P EN = R E LA Y G IV E S A 0 .1 S E C P U LS E , C N C P R OC E ED S A F TE R R E SE T R E LE AS E. 1 A-O P EN 2A -CL O SE D = R E LA Y H E L D U N TI L RE SE T C L OS E S, C N C P R OC E ED S A F TE R R E SE T R E LE AS E. 1 A-C LO S ED 2A -C LO S E D = RE LA Y HE LD U NT IL R ES E T C L O S E S AN D IS R EL EA S ED , C N C P R OC E ED S A F TE R R E SE T R E LE AS E. FO R D E CA D E B , TH E D I P S W I T CH E S A RE 1B A ND 2 B . FO R M -F UN C TIO N 9 O F D EC A DE A (e. g. M 29 ) O N T HE 10 50-0 , TH E D I P S W IT CH E S W OU L D B E 1 A 9 AN D 2A 9. US U A L L Y T H E S ET TI N G S A R E F OR A 0 .1 S E C P UL S E A ND TH E CN C P R O CE E DS A F TE R R E SE T R E LE AS E: S O TH E S E TTI N G S W OU L D B E 1 A-C L O S E D , 2A -O P E N , 1 B -C L O S E D, 2 B- O P E N . EX E C U T E M -F U N C T IO N FROM MDI. RE L A Y T ER M IN A LS SH OU LD C LOS E . * (O H M M E T E R W I LL S H O W 0 O H M O R S T 0 3 L ED W IL L L IG H T ) 24 . 2 .5 * RE LA Y T ER M I N AL S W IL L C L O S E OR C LO SE FO R 0. 1 S E C. A N D T HE N O P E N DE P E N DIN G O N T HE O PT IO N S E L EC T E D BY TH E D I P S W I T CH E S. S H O R T T B 3- 2 ( R E S E T ) T O T B 3 - 1 . (O R P R E S S B U T T O N O N S T 0 3 ) RE L A Y W IL L O P E N A N D CN C W IL L P R O C EE D A C C O R D IN G T O T H E O P T IO N SE L E C T E D B Y T H E D IP SW IT C H E S . 24 . 2 .6 CN C W I LL N O T P RO C E ED U NT I L CO N DIT IO N F OR R ES E T I S S A TI S FI E D. IF 1 0 5 0 B O A R D O P E R A T E S C O R RE C T L Y DI SC O N N E C T E D F R O M U S E R D E V IC E , RE FE R TO C H AP TE R 7 O F M A IN T E N A N C E M AN U A L A N D MA N UAL F OR U S ER D E VIC E F OR P R O P E R C O N F IG U R A T IO N S . 24 . 2 .7 CO N S U L T F A C T O R Y S E R V IC E D E PT . 24 . 3 Figure 16-38 M-Function 588 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual INDEXER WIRING DIAGRAM 10- 20-95 U1 SOLID S TATE R ELAY FOR AIR S OLENOID (1 2 VOLT REGULATORS) U2 U3 AIR SOLENOID IGBT's Q2 Q3 Q4 J2 J4 120VAC 1 FU SE (A GC 10 ) BLACK WHITE 1 2 BLACK 3 6 5 4 3 2 1 - COM FOR 165VDC 4 1810-0-1 WHITE AMPLIFIER K1 POWER SUPPLY 165VDC U4 1810-0-2 Q1 J2 (5 VOLT REGULATOR) GND (isolated) +12V (isol ated) NC NC GND +5V FU SE (A GC 10 ) 1 1 1 J3 J3 J1 J1 1 1 2 3 4 WHITE BLACK 1 7 ELECTROCUB E SNUB BER 3 6 4 POWER SWI TCH FUSE (A GC10) 9 8 10 13 12 11 16 15 MOV130LA20A 19 1 4 O N W R 2 ED O R AN SHIE LD BR 1 G J11 J1-1 J1-2 J1-4 J1-6 J1-8 J1-10 P WM* DIR OVERCURRENT OVERTEMP S TOP/ GO* RES ET* 1 ENCODER J10-1 T O U4 J10-2 T O U4 J10-3 T O U4 J10-4 T O U4 J10-5 T O U4 J10-6 T O U4 J10-7&8 J10-9&10 N POWER CORD CONNECTOR J15 FINIS H BLACK J10 L E VI OLET J1 3 BLACK GREEN W O L L EN YE RE E G U BL WHITE 2 RED 17 PIN PIN PIN PIN PIN PIN 7 A6 A+ 1 B2 B+ 14 Z 15 Z + +5V GND GRAY WHITE 1&2 3 4 5&6 8 - + 5V +12V -12V GND BRAK E 1 START 1 IN DEXER IN TE RFACE J3 1 RS -232 J3-3 J3-5 J3-7 J3-9 J3-11 J3-13 J3-14 CONTROL BOARD TXD RXD RTS CTS DSR GND DTR DB25-2 DB25- 3 DB25-4 DB25-5 DB25- 6 DB25-7 DB25- 20 CTS IS JUMPERED TO D TR AND DSR IS JUMPERED TO DTR. 1 J2 DISPLA Y J6 1 1 J4 J5 1 1810-0 KEYPAD RED EMERGENCY STOP BLACK RED FEED RATE BLACK WHITE WHITE START GREEN Figure 16-39 Indexer Wiring Diagram March 2003 Section 16: Troubleshooting 589 Fadal Maintenance Manual 9-PIN CONNECTOR TO ENCODER ON MOTO R 19- PIN CONNECTOR ON MOT OR CABLE MOTOR WHITE 3 1 GRAY 14 GA. SHIELDED B LACK BROWN 4 6 9 8 14 GA. GREEN 7 YELLOW RED 11 10 12 16 15 ORANGE 14 GA. SHIELDED R ED 19 17 Z- 8 A+ 7 A- GREEN BLUE 13 9 VI OLET 6 Z+ 5 B+ 4 B- BLACK MOTOR WI RES ARE SH IELDED. SHIELD MUST NOT TOUCH CONDUCTOR!!! SHIE LD 3 COM 2 +5V 1 SHIE LD MOTOR CABLE WIRING FOR VH-5C INDEXER 4-6-95 8-PIN CONNECTOR TO ENCODER ON MOTOR 19- PIN CONNECTOR ON MOT OR CABLE MOTOR WHITE 3 1 +5V 2 COM 3 B- 4 B+ 5 Z- GREEN 6 Z+ BLUE 7 A- ORANGE 8 A+ YELLOW 14 GA. SHIELDED B LACK 4 6 9 8 14 GA. GREEN 1 GRAY 7 RED 11 10 13 BROWN 12 16 15 14 GA. SHIELDED R ED 19 17 VI OLET BLACK MO TOR WI RES ARE SH IELDED. SHIELD MUST NOT TOUCH CO NDUCTO R!!! SHIE LD MOTOR CABLE WIRING FOR VH-65 INDEXER 4-6-95 BULKHEAD CONNECTOR WIRING FOR CLOCKWISE POSITIVE MOTION 6-20-95 WHITE 1 3 7 6 4 9 8 BLACK 10 13 16 17 R N EE YE LL 19 W O U BL BR O 2 E N W R ED O R AN SHIE LD G 12 11 15 G E VI OLET BLACK J1 0 1 ENCODER GRAY WHITE Figure 16-40 Motor Cable Wiring & Bulkhead Connector Wiring 590 Section 16: Troubleshooting March 2003 Fadal Maintenance Manual Figure 16-41 Servo Coolant Wiring March 2003 Section 16: Troubleshooting 591 Fadal Maintenance Manual Figure 16-42 Servo Turret Wiring 592 Section 16: Troubleshooting March 2003