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Section 16: Troubleshooting

1. VERIFY MAKE SURE CHECK DOORS CHECK YES PULSE LED s uE SE FEED RATE CE MACHINES cores CIRCUIT SEE ONALL gt 18 LIMIT MOVEMENT BREAKERS CHART STOP OVERLOAD AXIS BOARDS BUTTON AT 0 WHEN DOORS EER Va CE NO 4 ARE BLINKING ARE OPEN MACHINES 1 3 1 1 3 2 1 3 3 1 3 4 1 3 5 1 3 6 1 3 7 amp CHECK THAT RELAYS CHECK FUSES K5 K11 5 F6 F7 F8 F19 F20 SEE I Ki2 amp 14 CIRCUIT BREAKERS CHART POSITION ARE FIRMLY SEATED amp CB2 NO 2 ON 1100 2 BOARD N 1100 2 1 4 1 1 4 2 1 4 3 1 4 4 VERIFY PULSE LED s TOOL DULL SEE ONALL oRTOOLARGE Y CHART AXIS BOARDS CUT NO 3 ARE BLINKING 1 5 1 1 5 2 1 5 3 YES CHECK FOR CHECK CHECK FOR CHECK ADJUST SEE CHIPS IN TOOLIS S FIxTURE gt HEVELNESS ny POSITION LOOP N CHART SPINDLE TIGHT MOVEMENT AND NO 5 CLOCK 1 6 1 1 6 2 1 6 3 1 6 4 1 6 5 1 6 7 CHECK SEE PULSE LED s ALL BOARDS ARE BLINKING 17 1 17 2 YES SEE CHART NO 10 1 8 1 Figure 16 1 Quick Checkout Procedure Section 16 Troubleshooting 549 Fadal Maintenance Manual CHART 1 continued page 2 QUICK CHECKOUT PROCEDURE 9 20 95 CHECK
2. 12 5 95 ote 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 POSITION OVERRIDE Eli COMMAND SIGNAL ENCODER MUST BE AMPLIFIER MAY BE COOLANT PLUGGED ITOS MUST BE CONNECTED UNPLUGGED OR DEAD NOZZLE WILL OF APPROPRIATE o J5 OF 1010 AMPLIFIER FUSE NOT MOVE GARR AMPLIFIER AND J2 amp J3 OF 1890 0 AND AMPLIFIER IS ALIVE CONNECTED TO GND J1 OF 1010 9 PIN MOLEX AT MOTOR IF GREEN LED IS LIT AND 12V 16 1 4 AMPLIFIER FUSE 1611 16 1 2 16 1 3 HOLDER IS PART POWER RECEPTACLE ON AMPLIFIER ADJUST OVERTEMP SWITCH POSITION OVERRIDE CHECK ON MOTOR MAY POT TO I PARAMETERS AMPLIFIER MAY HAVE TRIPPED NEUTRAL VERTICAL IN SETP POSITION 16 1 5 16 2 1 16 2 2 16 2 3 AXIS MUST BE ACTIVE IN SETP AND SET TO COOLANT NOE MOTOR LEADS SIGNAL UNPLUGGED ENCODER CABLE RUNS AWAY REVERSED FROM AMPLIFIER DISCONNECTED 16 1 6 AMPLIFIER OR J1 OF 1010 OR ENCODER BAD AMC BE25A20 AC FD2 DIP SWITCH SETTINGS 1 OUT OFF TEST OFFSET 2 IN ON DECREASE CURRENT LOOP GAIN 16 3 1 16 3 2 16 3 3 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 RESPONSE AMPLIFIER ENCODER IS 10 OUT OFF 120 60 PHASING
3. IS MILL MAKE SURE ALL CHECK THAT DOOR YES AE WAITING FOR DOORS ARE CLOSED SWITCHES ARE LOCKED UP 1090 DOOR TO BE THEN OPEN AND CLOSE CONNECTED 1060 J13 ACTUATED FRONT DOOR AND WORKING 10 1 10 1 2 10 1 3 10 1 4 10 1 1 WILL NOT CONTINUE NO YES POSSIBLE CAUSES TO JOG WHEN JOG 1090 BUTTON IS HELD 0 DOWN 10 1 2 SURE LED ON 10 2 10 2 1 1030 IS BLINKING CHANGE POSITION CNC DOS SWITCH IF NOT PRESS EMERGENCY STOP AND RESET CPU GARD leas 1400 BOARD KEYBOARD TEST IN DIAGNOSTICS 10 1 2a 3 P SESA BORE CHECK CABLE TO 1060 10 0 CHECK 1040 BOARD CHECK WIRING TO TO PC J15 CHECK 1030 SWITCHES HOLD OR ESTOP BUTTONS NOT KEYS ERRATIC 10 1 2a 2a 10 1 2 4 REPLACE CONTACTS CHECK ALL POWER CONNECTIONS TO KEYBOARD 1090 POWER OFF MILL AND RESTART 10 4 1 PROBLEM SOLVED POSSIBLE PROBLEMS TOO LIGHT A TOUCH KEYPAD KEYBOARD 1090 10 1 2a 2b 10 1 2a 5 SOME KEYS DO NOT WORK UPDATE 1040 BOARD LATEST 1090 SOFTWARE 10 81 10 1 2 6 POSSIBLE PROBLEMS WRONG KEYPAD IF PROBLEM RECURS KEYS KEYBOARD 1090 REPLACE KEYBOARD DISPLAYED CABLE TO 1060 LOGIC 1040 BOARD 1090 10 6 10 6 1 TEETE
4. CHECK ON RESOLVER BOARD IN MOTOR CHART A IF MOTOR OVERHEATS AXIS DEAD OVERLOAD gt ROTARY HEAD e COS OUTPUT TO RESOLVER axis RELAYS FUSE PIN 8 OF J5 ON 1060 CONTROL FOR SHORT TO GND LET COOL 13 1 13 1 1 13 1 2 13 1 4 13 1 3 13 3 CHECK FOR YES ane WATER IN MECHANICAL 2 FUSE HOLDER BIND 13 4 13 4 1 USE CLAMP ON GEAR IS DAMAGED AMMETER TO CURRENT BY A CRASH CHECK FOR EXCESSIVE IN RETURN HEAD REPEACE SBOE EXCESSIVE TO FACTORY THAT IS LEAKING FOR REPAIRS CURRENT DRAW 13 4 3 13 4 5 13 5 13 5 1 ARE CHECK apie READJUST THE GEARS oiL LeveL gt BACKLASH GEAR MESH ADJUSTMENT NOISY IN HEAD AND GEAR MESH 13 6 13 6 1 13 6 2 13 4 4a 13 4 4a 1 AXIS HAVE CHECK YES AXIS JUMPER CAPACITY DO NOT EXCEED ON 1010 CARD OF THE HEAD LOAD CADACHTY IT MUST BE AN EXCEEDED A AXIS JUMPER 13 7 4 13 4 4b 13 4 4b 1 13 7 CHECK RATIO IN SETP GOTO CHART 4 AXIS CONTROL CHANGE PROGRAM TO GIVE MOTOR TIME TO COOL 13 7 2 13 9 13 4 4 13 4 4 1 MOTOR WIRES ARE SHIELDED ERIFY THAT SHIELD IS STRIPPED BACK FROM CONDUCTOR 13 4 4d 13 4 4d 1 15 SHORT IN MOTOR OR CABLE 13 4 4d 2 REPLACE MOTOR 13 4 4d 3 CABLE REPAIR REPLACE CABLE 13 4 4d 4 Figure 16 21 Rotary Heads A Axis March 2003 Section 16 T
5. 11 0 VERIFY MACHINE IS LEVEL SEE MAINTENANCE MANUAL WAVY FINISH ON STRAIGHT CUTS STAIR STEP FINISH DOES A BAD CUT CORRESPOND TO A PARTICULAR PLACE ON THE BALL SCREW CONSULT FACTORY 568 YES Maintenance Manual CHART 11 FINISH PROBLEMS 10 20 95 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 FOR ADDITIONAL PRECISION IN LEVELING PERFORM SQUARENESS TEST ON X amp Y THEN SQUARNESS TEST ON COLUMN THEN SPINDLE TRAM TEST CONSULT FADAL SERVICE DEPT FOR PROCEDURE IF PROBLEM IS NOT RESOLVED QUICKLY AND BEFORE DOING ANY MAJOR WORK LIKE CHANGING SPINDLE BALL SCREWS MOTORS ETC DO FADAL STANDARD TEST CUT SEND SAMPLE PART CUT WITH TEST CUT TOOL SUPPLIED BY FACTORY CONTACT FACTORY FOR TEST CUT KIT ON AXIS AMPLIFIER COMPENSATION SETTING X amp Y 11 4 1 CHECK BELTS CONSULT FACTORY SERVICE DEPT AND i BEFORE BELT TENSION REPLACING SPINDLE 11 5 1 11 5 2 CONSULT FACTORY CHECK SERVICE DEPT SURVEY TABLE J BEFORE AND BACKLASH CHANGING BALL
6. Figure 16 41 Servo Coolant Wiring 591 Troubleshooting Section 16 March 2003 Fadal Maintenance Manual 2 42 Figure 16 42 Servo Turret Wiring 592 Section 16 Troubleshooting March 2003
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8. N 99 NON J4 K1 120VAC A POWER SUPPLY FUSE 1__ BLACK 1 1 5 gt WHITE FOR 188v00 S BLACK 3 sS WHITE 4 N U4 5 ss a AMPLIFIER NS 9 2 N 6 VOLT REGULATOR x N 6 GND isolated A 5 12V isolated FUSE x 4 NC AGC 10 3 NC 2 GND P 1 5V 1 1 1 8 0 Ji 1123 4 Z WHITE BLACK POWER if ay 6 47 FUSE SWITCH a k AGC10 3 9 z ao o K gi A EF N q 3 ZZ Jo 3 i DX Z Z x MOV130LA20A o ava 0 ZX 19 a oY x Ko Z T 4 k 2 NK i L N b POWER CORD w x N CONNECTOR amp A 4 5 a a 1 39 m J15 FINISH START 77777 182 5V 1 INDEXER Ge TENI ENG6DEB WHITE 3 Hav INTERFACE 1 2 DIR ra J3 3 TXD DB25 2 J1 4 OVERCURRENT 410 1 TOU4PIN7 A G86 GND J3 5 DB25 3 8 BRAKE Ji 6 OVERTEMP HO 2 TOURING A J3 7 RTS DB25 4 410 3 TO U4 1 B J1 8 STOP GO J3 9 CTS 0825 5 11 10 RESET HOSTOUSEIN2 B J3 11 DSR 0825 6 J10 5 TO U4 PIN 14 Z 03 13 GND 0825 7 210 6 TO U4 PIN 15 Z 13 14 DTR DB25 20 J10 7 amp 8 5V 1 2 DISPLAY 1 1 4 ig 1810 0 KEYPAD RED EMERGENCY STOP BLACK RED FEED RATE BLACK e WHITE WHITE START GREEN Figure 16 39 Indexer Wiring Diagram March 2003 Section 16 Troubleshooting 589 Fadal MOTOR 19 PIN CONNECTOR ON MOTOR CABLE 1 14 GA SHIELD
9. gt ARE MOTOR LEADS 2 BINS 112V amp PIN 6 COM 1810 0 2 GETS ON AMPLIFIER SHORTED TO CHASSIS 1810 0 J11 PIN 1 amp 2 5V 20 2 1a 20 2 1b 20 2 1 WIRES TO MOTOR ARE PIN 12V SHIELDED SHIELD MUST PIN 4 12V BE STRIPPED BACK FROM PIN 5 amp 6 GND CONDUCTOR 20 2 1d WV DOES DOES IF MOTOR WAS RESET PARAMETERS HERO RM DISPLAY YES REPLACED TO FACTORY DEFAULTS AWAY INDICATE MOTOR LEADS MISC PARAM FACSET MOTION MAY BE REVERSED AND RETRY EET 2021 P CHECK CABLE AND ENCODER CABLE SOCKET FOR DAMAGED CHECK CONNECTORS ON OR ENCODER MAY BE BAD PINS OR SOCKETS MOTOR CABLE AND BOX FOR PUSHED INOR A CHECK ALL ENCODER CONNECTIONS 20 2 1f DAMAGED CHECK FOR CONTINUITY OF ALL ENCODER PINS OR SOCKETS LINES FROM ENCODER TO U4 ON 1810 0 CHECK FOR 5V AT ENCODER 20 3 1a 20 3 1b MOTOR OVERLOAD IF HEAD MOVES DOES OR OVERCURRENT BUT POSITION DISPLAY EAD JOG IN BOTH FAULTS INDICATE gt DOESN T CHANGE DIRECTIONS A BLOWN IGBT THERE IS AN ENCODER ON AMPLIFIER FEEDBACK PROBLEM 20 4 1 20 4 2 IF AMPLIFIER IS BLOWN FIND CAUSE BEFORE REPLACING RESISTANCE ACROSS MOTOR LEADS SHOULD BE 4 6 OHMS RESISTANCE FROM MOTOR LEAD TO CHASSIS SHOULD BE INFINITE WIRES TO MOTOR ARE SHIELDED SHIELD MUST BE STRIPPED BACK FROM CONDUCTOR TRY RUNNING INDEXER WITH NO FIXTURING CHECK BRAKE AIR LINES 115 OUTPUT TO HEAD CHECK CABLE gt DISCONNECT AND SOCKET IS LOAD 2 IS INPUT FR
10. 4A 3 CHECK GROUNDING 4A 4 CONSULT FACTORY 4A 5 558 YES CHART 4 continued page 2 AXIS CONTROL 10 20 95 CHECK AND ADJUST CHECK BUS VOLTAGE COMMAND CONNECTOR AT BLUE CAPACITOR GOTO AT AXIS CARD J1 WITH ON AMPLIFIER CHASSIS PAGE 3 OF SERVICE TOOL ST44 DEPENDING SHOULD BE APPROX 130 165VDC CONSULT FACTORY IF DIFFERENT CHART 4 ON MODEL 4A 1 1 4A 1 2 4A 1 3 Maintenance Manual 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 ISOLATE WHICH AXIS USING 201060 0 1 RESOLVER TESTBOARD CHECK AND ADJUST SERVICE TOOL ST44 4A 2 1 4 2 2 RESOLVER AXIS CARD 2 WITH TEMPERATURE SNAP SWITCH IF MOTOR OVERHEATS PIN 8 OF J1 J6 ON 1060 FOR SHORT TO GND LET COOL WILL SHORT COS SIGNAL TO GND ON RESOLVER BOARD IN MOTOR gt ICHECK COS OUTPUT TO RESOLVER 4A 2 3 RESOLVER FAULTS ON MULTIPLE AXES 4A 2 4 YES N CHECK RESOLVER CABLE REPLACE RESOLVER 4A 2 5 CHECK 12V amp 12V ON 1220 LS CHECK SINE amp COSINE OUTPUT OF CLOCK CARD 1020 USING SERVICE TOOL ST48 CHECK N J14 ON 1060 4A 2 4a 4A 2 4b 4A 2 4b CHECK AND ADJUST RESOLVER CONNECTOR AT
11. The programmer may have put an 0 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 0 1 or 0 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 IMPORTANT Report this to the service department when th
12. AN ERROR MESSAGE YES AND ERROR IS WILL SCALE BOARD RESET RECREATI AND LED IN SCALE BOX LIT 22 2 NO OR NOT EASILY ERROR REOCCURS EASILY 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 CONNECT SCALE ENCODER TESTER ST40 BETWEEN SCALE BOX AND AXIS CARD ED 22 2 2 SWITCH EXE BOARDS IN SCALE BOX REPLACE EXE BOARD CONTINUED ON PAGE 2 COLUMN 2 OF CHART 22 o 22 3 1 SURVEY FOR SCALES 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 SCALES AND SURVEY FOR RESOLVER CAN BE FOUND IN MACHINE RECORDS 22 3 G CONTINUED ON PAGE 2 COLUMN 1 OF CHART 22 22 4 Figure 16 35 Sc March 2003 22 3 2 SCALE PROBLEM 22 2 1b 1 POWER OFF MACHINE DOES IS ON NO ZERO OFFSET DISCONNECT SCALE PROBLEM GO IN SV FOR AXIS A POSITIONING FROM UIO CARD SCALE ERROR LINE MAY PROBLEM POWER ON MACHINE MUST BE O SCALES PLUGGED
13. DIP SWITCHES L UNPLUGGED IS MUSHY ARE SET WRONG MISADIUSTED FROM AMPLIFIER POT PRESETS LOOP GAIN FULLY CCW THEN 5 TURNS CW CURRENT LIMIT FULLY CW REF IN GAIN FULLY CW 16 4 1 16 4 2 16 4 3 AMP ADJUSTMENTS REMOVE NOZZLE DISCONNECT COMMAND SIGNAL ADJUST OFFSET POT TO STOP AXIS CHECK VERIFY CONNECT COMMAND SIGNAL NO COOLANT FLOOD COOLANT IN SETP SET COOLANT AXIS RATIO COOLANT IS WORKING NOZZLE IN SETP SET COOLANT AXIS RATIO TO 90 1 USE PROGRAM 5815 TO ADJUST AXIS 16 5 NO 16 5 1 16 5 2 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 RESPONSE UP DIRECTS NOZZLE POT IS MISWIRED OVERSHOOT IS OK UP THE TOOL LS OR WHEN AMP IS ADJUSTED SET COOLANT AXIS RATIO IS REVERSED DOWN DIRECTS J4 ON 1890 0 IS TO COOLANT IN SETP NOZZLE DOWN THE TOOL MISWIRED 16 6 1 16 6 2 VMC MUST BE OFF WHEN WIRING IS BEING CHANGED NO DISCONNECT J4 FROM 1890 0 BEFORE REWIRING POT OR 1890 0 MAY BE DAMAGED AMPLIFIER AMP MAY BE INHIBITED WIRES TO MOTOR ARE SHIELDED SHIELD MUST BE STRIPPED BACK DIP SWITCH FOR BY EMERGENCY STOP gt FROM CONDUCTOR OR A gt PHASING OR OVERTEMP OF MOTOR SHORT TO GROUND WILL OCCUR MAY BE MIS SET RED LED ON AMPLIFIER 16 7 1 46 7 2 16 7 3 Figure 16 24 Servo Co
14. MAKE SURE JOG MPG YES CHECK CABLE REPLACE DOES NOT WAS PRESSED AND N coNNECTIONS TO S KEYBOARD LOGIC ORR JOG SWITCHES 1050 i PROPERLY SET 10 7 10 7 1 10 7 2 10 7 3 10 7 4 NO THE FIRST TIME JOG IS PRESSED THE KEYBOAR LOGIC SENDS J THE AXIS X Y u OR C AND THE RESOLUTION H M OR L IN THE KEYBOARD DIAGNOSTICS NON PRINTABLE CHARACTERS ARE DISPLAYED WITH A THE TABLE SHOWS THE KEY AND THE CHARACTER THAT WILL BE DISPLAYED WHEN JOG IS PRESSED AGAIN THE KEYBOARD START SENDS J ONLY AUTO WHEN THE MPG IS TURNED THE KEYBOARD MANUAL NO DISPLAY EXITS TEST LOGIC SENDS P FOR A POSITIVE TURN OR SINGLE STEP Q FOR A NEGATIVE TURN JOG J P AND Q ARE SINGLE CHARACTERS NOT AND J THEY ARE DISPLAYED IN THE DIAGNOSTICS WITH SPINDLE ON OFF SHIFT SPINDLE ON OFF SLIDE HOLD THE TO DIFFERENTIATE THEM FROM THE COOLANT 1 LETTERS P AND Q COOLANT 2 TOOL IN OUT TURRET CCW MISSES NYES POSSIBLE CAUSES TURRET CW JOG PULSES 1030 BACKSPACE ROM MPG MPG DELETE 10 8 ENTER 10 81 RAPID TRAVEL SWITCH DISPLAYABLE SCREEN WILL SHOW KEYLOCK SENT WHEN ESTOP PRESSED LOCKED OPTIONAL STOP EMERGENCY STOP ON OFF GENERALLY NOT DISPLAYABLE ESTOP SENDS STATUS OF KEYLOCK AND ESTOP STATUS OF OPTIONAL STOP SWITCH STATUS OF BLOCK SKIP SWITCH AND STATUS OF RAPID TRAVEL SWITCH ANY
15. Respond With Y to Delete Bad Blocks There is a possible hardware problem when this message appears lf 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 Section 16 Troubleshooting 525 Fadal 526 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 mod
16. SEE ERROR CODE 13 ABOVE Section 16 Troubleshooting March 2003 Fadal Troubleshooting Checklist RS 232 Commmunications If no communications occur March 2003 Maintenance Manual 25 MOTOR OVERLOAD DURING CONTOURING MODE SEE ERROR CODE 13 ABOVE 26 MOTOR OVERLOAD DURING JOG MODE SEE ERROR CODE 13 ABOVE 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 Ifa switch box is used determine that the switch is in the proper position the switch handle back and forth a few times Sometimes the con nections are corroded and turning the handle will TEMPORARILY correct the problem Check to see if all cable connections are firmly connected e Loose cable connections are the MOST COMMON cause of communi cations failures Check to see that the phone modem cable on the inside of the control cabi net is disconnected from the back of the phone modem in the modem sleeve Some machines do not have a phone modem in the sleeve phone modem WILL interfere with communications through the RS 232 port The machine must be properly grounded Follow the grounding instruc tions on the green label inside the main disconnect box to confirm the grounding connections Check to see if the communication parameter settings in the software of the computer are set properly a Baud rate This
17. UNPLUG J9 J13 FROM 1060 POWER ON MACHINE 12 6 12 6 1 DISCONNECT 5V OUTPUTS FROM 1220 ATTACH 10 OHM 5W RESISTOR BETWEEN 5V AND COM END POWER GOOD UNDER STATIC CONDITIONS 12A 7 IS 5V NOW GOOD 12A 6 2 12A 6 3 12A 6 4 SWITCHING POWER SUPPLIES REQUIRE YES A LOAD TO WORK PROPERLY LOOK FOR INDIVIDUAL CARD THAT MAY BE PULLING TOO RECONNECT MUCH 5V 5V OUTPUTS REPLACE CARDS ONE AT A TIME TO 1220 REPLACE J9 J13 ONE AT A TIME 12A 6 2a CARDS SHOULD NEVER BE REMOVED OR REPLACED WITH THE POWER ON 2A 6 4a sl USE CLAMP ON AMMETER PUT ALL CARDS REPLACE 1220 BACK IN CARDCAGE TORK TOR gt pc POWER SUPPLY CURRENT DRAW 12A 6 4b 12A 6 2b TYPICAL CURRENTS WITH MACHINE AT REST 1060 5 5A 1100 1 1100 2 0A PENDANT 0 5A THESE ARE TYPICAL VALUES ACTUAL VALUES MAY VARY EXCESSIVE VALUES WOULD BE 2 5A HIGHER 12 6 5 Figure 16 20 Bad DC Voltage Continued 570 Section 16 Troubleshooting March 2003 Fadal Maintenance Manual CHART 13 SOME HEADS HAVE TEMPERATURE SWITCHES INSTEAD OF OR IN ROTARY HEADS ADDITION TO FUSES TO PROTECT ROTARY HEADS THE MOTOR FROM OVERHEATING A AXIS A AXIS THESE AUTOMATICALLY RESET WHEN THE MOTOR COOLS 7 4 95 TEMPERATURE SNAP SWITCH WILL SHORT COS SIGNAL TO GND
18. AXIS CARD J2 WITH SERVICE TOOL ST44 CHECK WAYLUBE CHECK RESOLVER SWAP CHECK MOTOR COUPLER MOTOR AND BALLSCREW THRU BOLTS FOR LOOSENESS ARE TIGHT CHECK SINE amp ALL 3 COSINE OUTPUT te CHANGE AXES RUN OF CLOCK CARD J MPERECE gt CLOCK CARD ROUGH 1020 USING IN J14 OE 1060 1020 SERVICE TOOL ST48 4A 3 2 4A 3 3 4A 3 4 CHECK 4A 3 1a 1 4A 3 1a 2 4A 3 1a 3 Figure 16 10 Axis Control Continued Section 16 Troubleshooting 4A 3 1a 4 March 2003 Fadal Maintenance Manual CHART 4 continued page 3 AXIS CONTROL 6 15 95 MOTOR OVERLOADS CONTINUED FROM PAGE 2 OF CHART 4 IS THE FAULT NO DURING PROGRAM GOTO EXECUTION PAGE 4 4 4B 1 IS THE PROGRAM NO USING M90 M93 PROGRAMMABLE GAIN SETTINGS M90 USE SETP GAIN M91 NORMAL GAIN M92 INTERMEDIATE GAIN M93 HIGH GAIN 4B 2 INSERT AN M91 AT BEGINNING OF PROGRAM REMOVE ALL G8 s 4B 3 DOES ERROR STILL OCCUR DURING PROGRAM EXECUTION SLOW DOWN THE FEED RATES IN THE PROGRAM 4B 4 PROBLEM 15 SHOULD BE THERE STILLA RESOLVED PROBLEM 4B 5 IF NOT GO TO PAGE 4 OF CHART 4 4B 6 Figure 16 11 Axis Control Continued March 2003 Section 16 Troubleshooting 559 Fadal 560 MOTOR OVERLOADS CHART 4 continued page 4 CONTINUED PAGES O
19. 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 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
20. CHECK TURRET MOTOR ENCODER AND WIRING 2 4 5 L GOTO IF TURRET AMPLIFIER FUSE IS DID CHART BLOWN OR OVER CURRENT SPINDLE NO 3 ORIENT NO DiE LED IS ON CHECK MOTOR WIRES FOR SHORT TO CHASSIS DRIVER WIRES TO MOTOR 2 6 2618 ARE SHIELDED SHIELD MUST BE STRIPPED 5079 BACK FROM CONDUCTOR ADJUST CHART 2 4 6 ORIENTATION NO 3 ARM SWING FACTOR SPINDLE IF TURRET MOVES IN IN SETP DRIVER CORRECTLY EXCEPT FOR DIRECTION 2 6 2a 26 2 CHANGE DIRECTION REMOVE TOOL FROM SPINDLE CHECK TB1 7 TO TB1 5 F19 amp K23 ON 1100 2 ON 1100 2 OR VICE VERSA 2 4 7 2 7 552 PAGE 2 OF CHART 2 AND MANUALLY ACTIVATE ORIENTATION AIR SOLENOID AT MAC AIR VALVE ASSY CHECK AIR PRESSURE CHECK AND REPAIR ORIENT MECHANISM AND AIR LINES 2 6 5a CONTROL FROM Y IF TURRET RUNS AWAY 1 REVERSE MOTOR LEADS 2 CHECK ENCODER WIRING 3 REPLACE ENCODER 4 REPLACE TURRET CONTROL MODULE 2 4 8 IF VERY HEAVY TOOLS ARE UNEVENLY DID CHECK WIRING DISTRIBUTED ORIENTATION REDISTRIBUTE TOOLS ARM SWING TRY KNOWN ON TURRET IN GOOD 1040 2 4 9 2 6 5 266 DIP SWITCH SETTINGS N OREN OPEN CONSULT FACTORY MEDFAST CLOSED OPEN MEDSLOW OPEN CLOSED SLOW CLOSED CLOSED MOTOR TYPE SW3 amp SW4 OPEN CONSULT FACTORY ABOUT OTHER SERVICE DEPT ABOUT DIP SWITCH SETTINGS FOR SPEED AND PID MOTOR SETT
21. HOT OR CHECK COS OUTPUT TO RESOLVER PIN 8 OF J1 J6 ON 1060 FOR SHORT TO GND LET MOTOR COOL GOTO CHART 4A AXIS CONTROL RESOLVER FAULTS 18 16 4 18 16 1 18 16 2 18 16 3 READING FROM THE MAKE SURE CABLES ARE RESOLVER PORT PROPERLY ATTACHED CHANGE INDICATES A SPINDLE SPINDLE RESOLVER IS gt SPINDLE SPEED GREATER THE SPINDLE ORIENTATION CARD Ne THAN POSSIBLE HALL EFFECT SENSOR 18 17 1 18 17 2 18 17 3 Figure 16 28 Error Codes Continued Section 16 Troubleshooting March 2003 Fadal CHART 18 continued page 3 Maintenance Manual RREVIOUS ERROR CODES ERROR MEANING DIAGNOSIS REPORTED BY AXIS NUMBER PROCEDURES 8 23 95 18 AXIS NOT IF THE LSECB IS LIT AMPLIFIER CHECK CABLING TE FOR CHART 4 FAULT LINE SIGNAL HAS FALLEN AND AMPEIRIER MECHANICAL BIND OET EP BELOW tov 18 18 18 18 1 18 18 2 18 18 3 18 18 4 OVERFLOW THE STACK ON THE AXIS OVERLOADED WITH STEP COMMAND UNTIL THEY ARE SERVICED HAS OVERFLOWED D USED TO STORE CPU COMMANDS PROBLEM COULD BE AXIS CARD 1010 CPU CARD 1400 OR 1030 18 19 18 19 1 18 19 2 20 THE MOVE TRANSFER SREGK RUN DIAGNOSTICS MOVE PROCESS WAS NOT SSD S
22. IN SET WRONG 22 3 5 22 3 3 REMEMBER TO RE ENTER THE SURVEY FOR SCALES YES RUN AN EXTERNAL NOTA CABLE TO THE SCALES IF Y AXIS THE SCALE MOUNTING MAY BE DEFLECTED O TO CHART 21 POSITIONING BY SCALE CABLE 22 3 6 USE 22 3 4 SCALE TESTER 1710 0 OR VERIFY SCALE CABLING ENCODER IS CORRECT AND TESTER ST40 PLUGGED INTO AND CHECK CORRECT INPUT OF FOR INDEX 1010 CARD J6 FROM SCALES oa db 22 3 7 VERIFY THAT SURVEY FOR SCALES 15 NOT THE SAME AS SURVEY IS CORRECT SURVEY FOR RESOLVER FOR SCALE FEEDBACK 22 3 4c CONTINUED ON PAGE 2 COLUMN 5 OF CHART 22 22 3 4d ale Problems Section 16 Troubleshooting 585 Fadal Maintenance Manual CONTINUED CONTINUED CONTINUED CHART 22 continued page 2 FROM PAGE 1 FROM PAGE 1 FROM PAGE 1 COLUMN 1 COLUMN 2 COLUMN 5 OF CHART 22 OF CHART 22 SCALE PROBLEMS OF CHART 22 10 20 95 22A 1 22A 3 CONNECT SCALE ENCODER POWER DOWN TESTER ST40 MACHINE BETWEEN SCALE AND DISCONNECT BOX AND AXIS CARD SCALES FROM AXIS CARDS SWAP A KNOWN GOOD PUT X SCALE CABLE CABE BETYEEN INTO Y JACK OF SCALE BOX SCALE BOX ETC AND AXIS CARD AND RETEST POWER ON
23. 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 CHECK THAT BAD TERMINALS ON USE ENCODER TESTER ENCODER ON N YES GREEN CONNECTOR gt TOTESTATEACH BALDOR SWEO ON INVERTER ARE TIGHT CONNECTOR FROM INVERTER AND CLAMPED ON WIRE ENCODER TO INVERTER NOT INSULATION 3A 3 3A 3 1 3A 3 2 NO REMOVE BELTS RUN SPINDLE AT DOES yes CONSULT FACTORY CONSULT FACTORY MAXIMUM SPEED SPINDLE MOTOR SERVICE DEPT SERVICE DEPT AND CUT POWER SHAKE WHILE ABOUT BALANCING BEFORE REPLACING MOTOR COASTS SPINDLE MOTOR SPINDLE MOTOR TO STOP 3A 4 3A 4 3 3A 4 4 DOES RUN AN EXTERNAL SPINDLE SUNG BPN ANO VIBRATION CABLE BETWEEN VIBRATION OCCUR WHILE ENCODER ON MOTOR SHUT OFF POWER AND INVERTER POSSIBILITIES POSSIBILITIES INVERTER SOFTWARE BENT ENCODER PIN ENCODER DISK RUNOUT BAD ENCODER BELTS PULLEY OUT OF ROUND MOTOR SHAFT BENT BAD SPINDLE SHAKING VIBRATION 3A 5 5 CONSULT FACTORY CONSULT FACTORY 3A 5 2a ENCODER CABLE IS BAD SERVICE DEPT ABOUT INSTALLING INCORRECTLY ROUTED 8 OR INCORRECTLY SHIELDED 3A 5 6 CONSOLA OR CONSULT FACTORY 3A 5 4b SERVICE DEPT BEFORE REPLACING INVERTER 3A 5 7 Figure 16 8 Spindle Driver Continued 5
24. MACHINE 22 3 2 ERROR YN BOARD REPLACE STAYS WITH 1580 1A BOARD EXE BOARD OR SCALE BOX REPLACE SCALE MOTHERBOARD 22 2 3 22A 2 3a 22A 3 4a SCALE CABLE MAY CHECK BE DAMAGED GIBS AND RUN NEW CABLE STRAPS OUTSIDE OF MACHINE BRIS TO TEST GO TO CHART 21 POSITIONING CHART 5 DISCONNECT READER HEAD REPEATABILITY ERROR Gre NS FROM BRACKET AND STILL OCCURS Ae SALE INSTALL SHIPPING MOUNTS LED LITES READER HEAD 22A 3 6 MOVE HEAD BY HAND 22A 2 5 22A 2 5a 22A 2 5b CABLE DAMAGED fa SCALE 5 GOOD REPLACE STILL OCCURS En PROBLEM IS ALIGNMENT RETURN BAD CABLE L na OF SCALE OR TO FADAL FOR rr OF READER HEAD FAILURE ANALYSIS AND BRACKET DRAE 22 2 5 22 2 5 1 REPLACE SCALE WHEN SCALE IS REPLACED YES CONSULT FACTORY A NEW SURVEY MUST BE DONE ABOUT AXIS OVERSHOOTING pavers SATE UPDATE 22 1 1 22 1 1 DOES IT CHECK MECHANICAL CAVITATION AL OEM ADJUSTMENT CHECK BACKLASH BACKLASH YES BACKLASH SCALES ARE WITH SCALES OR VIBRATION x OF GIBS ans gt 20 MUST STRAPS CORRECTED 22A 1 2 22A 1 2b 22 1 2 2281528 22A 1 2e ROSSOVER YES PROBLEM CONSULT BUMP AT FACTORY QUADRANTS 22A 1 3a 22A 1 2a 1 22 1 3 Figure 16 36 Scale Problems Continued 586 Section 16 Troubleshooting March 2003 Fadal RIGID TAP TAPPED HOLE IS BAD NO GO IS THE CORRECT GO NOGO GAGE BEING USED IS THE PRO
25. MISSING OR INCORRECT MOTOR TACH PEE BRACE TEST gt WIRES ARE MOTOR TACH JUMPER CONFIGURATION ON BOWER UE POWERON REVERSED CORRECT OR FAILED COMPONENT 18 8 18 3 1 18 3 2 18 3 3 18 3 5 4 JUMPERS ON AXIS CARD ARE WRONG OR AXIS CARD IS BAD 18 3 4a USE FADAL 5 ENCODER RR E ERIFY CONNECTION ENCODER TESTER NO INDEX MARK SCA OF ENCODER OR Y OR SCALE TESTER DETECTED SCALE CABLES TO TEST ENCODER DURING COLD START OR SCALE 18 5 1 18 5 2 18 5 3 ENCODER COUNTS STOP SPINDLE USE FADAL NOT WITHIN AND USE DI DS ENCODER TESTER TOLERANCE TO CHECK MAGNET OR SCALE TESTER DURING RIGID TAP TURN SPINDLE TO TEST ENCODER PRECYCLE TEST BY HAND AT AXIS CARD J5 18 7 2 18 7 3 SPINDLE MAGNET WAS STOP SPINDLE USE KNOWN GOOD NOT DETECTED FOR AND USE DI DS MAGNET EFFECT SWITCH OVER 3 SECONDS TURNING TO CHECK MAGNET X S CONNECTED L AND TEST WITH WHEN SPINDLE SHOULD TURN SPINDLE MAGNET HAVE BEEN TURNING BY HAND USING DIDS 18 8 3 18 8 4 18 8 5 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 SPINDLE FAULT LINE Heer CHECK FAULT LINE CHECK IS NOT DETECTED CHECK INVERTER CABLING FROM OPERATION SINE GON OR HAS FALLEN FOR FAULT gt rr INVERTER D BELOW 10V J6 6 ON1100
26. NULL MODEM ODEM BEING USED TRY AGAIN IN OTHER POSITION 19 4 19 4 1 CHECK GROUNDING OF MACHINE IGROUND MUST BE A CONTINUOUS WIRE DOWEL BS a DIFFICULT TO DIAGNOSE PROBLEMS CAN OCCUR OF TUE BUILDING IF MACHINE IS NOT PROPERLY GROUNDED GROUND RODS ARE NOT AGCEPTABLE THERE MUST BE A CONTINUOUS GROUNDING AS THE PRIMARY GROUNDING METHOD CONDUCTOR AS SPECIFIED ON THE GROUNDING LABEL 19 5 IN THE MACHINE S DISCONNECT BOX FROM THE VMC S GROUND BUS TO THE GROUND BUS IN THE BUILDING S THE GROUND WIRE OF POWER DISTRIBUTION PANEL THE RS232 DB25 PLUG THE COMPUTER BEING USED MUST ALSO BE PROPERLY IN THE MAIN CABINET GROUNDED UNLESS IT IS A BATTERY OPERATED LAPTOP MUST BE ATTACHED TO THE CABINET PAINT MUST BE REMOVED FOR GOOD CONTACT 19 6 NZ IF MACHINE HAS A PHONE MODEM MAKE SURE IT IS DISCONNECTED FROM THE RS232 PORT 19 7 NZ PLUG RS232 TEST PLUG INTO RS232 PORT ON CABINET FROM COMMAND MODE TYPE DI PRESS ENTER TYPE GO 3000 PRESS ENTER SELECT THE RS232 TEST MACHINE PASSES DIAGNOSTICS AND IS NOT AT FAULT IN COMMUNICATION PROBLEM PLUG RS232 CABLE INTO PORT AND MOVE TEST PLUG TO COMPUTER END OF CABLE RERUN TEST RS232 TEST PASS A NULL MODEM MIGHT BE NEEDED 19 9 1 19 9 3 EITHER THE 1030 CARD CABLE MAY BE OR THE RS232 CABLE DEFECTIVE FROM THE 1030 TOO LONG TO THE DB25 PLUG OR ROUTEDINA IS BAD NOISY ENVIR
27. OAR WORK DURING TOOL ON 1100 2 CHANGE VALVE ASSY CYLINDER 2 2 2 2 1 2 2 2 2 2 3 IF ATOOL IS IN YES THE SPINDLE HAVE HELPER HOLD ONTO IT PRESS TURRET CW AND TURRET CCW EUROPEAN CE NORM MACHINES MUST HAVE DOORS CLOSED FOR ATC TO WORK PROPERLY DID TURRET MOVE CORRECTLY AND EMERGENCY STOP MUST BE RELEASED AMPLIFIERS RESET GENEVA OR SERVO TURRET 2 4 2 2 4 1 GO TO CS POSITION IF NOT COLD STARTED DO A COLD START INMDI ENTER M19 GENEVA 2 2 6 CHECK 1040 AND WIRING SEE DRAWING 1002 AND KEYBOARD TROUBLESHOOTING DIAGRAM CHECK DRAWBAR CYLINDER FOR BAD SEALS OR BROKEN PISTON 2 2 5 2 2 7 CHECK FUSES F5 amp F6 amp CB2 TURRET FACTOR IN SETP MUST BE 1 FOR SERVO TURRET C2 ON 1100 2 MUST BE BYPASSED AND RELAYS K5 K33 K11 amp K12 ON 1100 2 K12 MUST BE LOW LEAKAGE GREEN CHECK F4 AND gt SERVO TURRET FUSES 2 4 3 CHECK FUSES F5 amp F6 amp CB2 AND RELAYS K5 K33 K11 amp K12 ON 1100 2 K12 MUST BE RATED FOR 3 AMP OUTPUT BLACK CHECK TURRET FACTOR IN SETP CHECK GENEVA MECHANISM CHECK TURRET MOTOR WIRING 2 4 2a 2 4 2b 2 4 4 CHECK SERVO TURRET MECHANISM FOR BINDING OR EXCESSIVE PLAY CHECK TURRET MOTOR WIRING
28. RELEASED CNC PROCEEDS AFTER RESET RELEASE AND 2 9 FOR DECADE B THE DIP SWITCHES ARE 1B AND 2B FOR M FUNCTION 9 OF DECADE A e g M29 ON THE 1050 0 THE DIP SWITCHES USUALLY THE SETTINGS ARE FOR A 0 1SEC PULSE AND THE CNC PROCEEDS AFTER RESET RELEASE SO THE SETTINGS WOULD BE 1A CLOSED 2A OPEN 1B CLOSED 2B OPEN EXECUTE M FUNCTION FROM MDI RELAY TERMINALS SHOULD CLOSE OHMMETER WILL SHOW 0 OHM OR ST03 LED WILL LIGHT 24 2 5 RELAY TERMINALS WILL CLOSE OR CLOSE FOR 0 1 SEC AND THEN OPEN DEPENDING ON THE OPTION SELECTED BY THE DIP SWITCHES SHORT TB3 2 RESET TO TB3 1 OR PRESS BUTTON ON ST03 RELAY WILL OPEN AND CNC WILL PROCEED ACCORDING TO THE OPTION ISELECTED BY THE DIP SWITCHES 24 2 6 CONDITION FOR RESET IS SATISFIED WILL NOT PROCEED UNTIL IF 1050 BOARD OPERATES CORRECTLY DISCONNECTED FROM USER DEVICE REFER TO CHAPTER 7 OF MAINTENANCE MANUAL AND MANUAL FOR USER DEVICE FOR PROPER CONFIGURATIONS 24 2 7 Figure 16 38 M Function CONSULT FACTORY SERVICE DEPT 24 3 Section 16 Troubleshooting March 2003 Fadal INDEXER WIRING DIAGRAM Maintenance Manual 10 20 95 ul 12 VOLT U2 REGULATORS 5 ao co e El 9 IGBT s AIR be SOLENOID Sc a a2 a4
29. SPINDLE IS TURNING TOO SLOW INCREASE THE GAIN PARAMETER IN SETP YES 23 3c 2 REMOVE INDICATOR DO A 10 INCH RIGID TAP HECK FOLLOWING ERROR ON Z AXIS UP AND DOWN IS Z AXIS BALANCED 23 34 2 CHECK FOLLOWING ERROR ON C AXIS UP AND DOWN IS IT THE SAME 23 3d 3 L BELTS MAY BE SLIPPING CHECK BELT TENSION AND IDLER ASSEMBLY CHECK FOR OIL OR COOLANT ON BELTS OR EXCESSIVE AIR IN HYDRAULIC HI LO ACTUATOR 23 3d 4 CHECK 5V 12V 12V ALSO SET METER FOR VAC AND CHECK FOR AC RIPPLE ON 5V 12V AND 12V DC 0 015VAC RIPPLE MAX ON 12V 0 005VAC RIPPLE MAX ON 5V 23 34 5 587 Fadal 24 1 24 2 588 M FUNCTION DOES NOT ACTIVATE M FUNCTION DOES NOT RELEASE M FUNCTION RELEASES HUNG UP CHART 24 M FUNCTION YES CHECK DECADE JUMPERS SWITCHES ON 1050 BOARD SELECTION 24 1 1 L WITH USER DEVICE ATTACHED MEASURE VOLTAGE ACROSS APPROPRIATE TERMINALS OF TB1 OR TB2 M FUNCTION IS ACTIVATED ON 1060 WHILE 24 1 2 9 19 95 Maintenance Manual MAINTENANCE MANUAL BOARD YOU HAVE THIS CHART COVERS M FUNCTIONS CONTROLLED THROUGH THE 1050 BOARD M0 19 M30 M49 M60 69 AND M90 99 ARE SPECIFIC FUNCTIONS THAT ARE CONTROLLED THROUGH THE 1040 BOARD OR AXIS CARDS THEY ARE NOT COVERED HERE M FUNCTION SETTINGS AND TERMINALS ARE LISTED IN CHAPTER 7 OF
30. accelera EOC1 tion Inverter output current exceeded the overcurrent limit during constant EOC2 speed operation Inverter output current exceeded the overcurrent limit during decelera EOC3 tion Braking regenerative power from motor exceeded the regenerative EOVT overvoltage limit Electronic thermal relay in the inverter was activated current is below ETHM 150 of preset current Electronic thermal relay in the inverter was activated current is over ETHT 150 of preset current 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 Maintenance Manual Fadal Table 2 Z200 Z300 Spindle Drive Error Messages DESCRIPTION ALARM DISPLAY EOLT Stall preventative function was activated during constant speed opera tion and stopped the motor 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 March 2003 Section 16 Troubleshooting 565 Maintenance Manual Fadal C HART 1 0 DASHED SYMBOLS APPLY TO CE NORM KEYBOARD EUROPEAN MACHINES 10 18 95 ONLY
31. be below the final Z depth 3 The final Z depth is described to end above the 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 0f 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 l 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
32. 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 2 654 659 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 RO 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 word value Is larger than the tool changer capacity Bad Z or RO 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 plane Section 16 Troubleshooting 513 Fadal 514 Maintenance Manual 2 The R plane is described to
33. 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 Section 16 Troubleshooting March 2003 Fadal EXAMPLE March 2003 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 RS 232 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 0 Word If program coding is used on the first line of the program along with the O word this message appears 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 1 01 GO G90 P N 1234 This line is incorrect N1 O1 P N 1234 This line is correct N2 GO 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
34. 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 Section 16 Troubleshooting 551 Fadal 532 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
35. 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 Section 16 Troubleshooting March 2003 Fadal March 2003 Maintenance Manual This also occurs when no diameter value is placed in the tool table when using Fixed subroutines L94NN L95NN L9601 19701 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 RO variable is not specified it is assumed as 0 0 If the R1 variable is not specified
36. 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 Section 16 Troubleshooting 541 Fadal Emergency Error Codes Error Numbers From the Axis or Spindle 542 Controller Maintenance Manual Z amp 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 n
37. 1 18 9 1 18 9 2 18 9 3 18 9 4 18 9 5 Figure 16 27 Error Codes March 2003 Section 16 Troubleshooting 577 Fadal 578 CONTINUED FROM PREVIOUS PAGE 10 ENCODER AND MAGNET NOT RESPONDING OR 12 MOTOR OVERLOAD STEP COMMAND CHECKSUM 18 12 OVERLOAD FOLLOWING ERROR gt OVERLOAD FACTOR 14 MOVE TRANSFER AULT MOVE SETUP INCOMPLETE 18 14 15 IME OUT ERROR RIGID TAP PRECYCLE TEST 18 15 IME OUT ERROR RESOLVER RESPONSE OR MOTOR OVER TEMP BAD READING ON RESOLVER PORT CHART 18 continued page 2 ERROR CODES REPORTED BY AXIS 8 18 95 OCCURS DURING SPINDLE OPERATION IF BOTH ENCODER FEEDBACK AND SPINDLE MAGNET ARE NOT DETECTED FOR LONGER THAN 3 SECONDS 18 10 1 ERROR OCCURS AT END OF MOVE WHEN NUMBER OF PULSES COUNTED BY AXIS CONTROLLER DOES NOT EQUAL NUMBER SENT BY CPU 18 12 1 18 10 2a SP IS INDLE Maintenance Manual ERROR NUMBER CHECK SPINDLE ENCODER AND MAGNET AND THEIR CABLING 18 10 3 MEANING DIAGNOSIS PROCEDURES CHECK 5V 12V amp 12V VOLTAGES FROM POWER SUPPLY SEE CHART 12A RUN DIAGNOSTICS ON CPU AND AXIS IF ONE AXIS FAILS REPLACE THAT AXIS CARD AND RETEST IF MULTIPLE CARDS FAIL REPLACE 1030 OR 1400 AND RETEST 18 12 2 18 12 3 FOLLOWING ERROR E
38. 14 L lovERtoap H Pressure gt POWER TO OF PARAMETER UNIT IS BLINKING RELAY 80 90 PSI hao 812 GN INVERTER dade AFTER FAULT IS CORRECTED 3 2 1b 3 2 1b 1 3 2 1b 2 3 2 1b 3 3 2 1b 4 PRESS RESET ON INVERTER 3 2 1b 5 sli CHECK SPINDLE HALL EFFECT SWITCH ON 1100 2 AND WIRING CHECK F1 amp USE DI DS TO SEE IF SWITCH IS BEING READ CHECK K7 K9 K3 amp K4 3 3 3 3 1 3 2 1b 6 MOTOR CHECK INSPECT BELTS VERIEV THAT TURNS BUT NYES AND BELT TENSION INSPECT AIR PRESSURE 1010S J1 J2 amp J3 SPINDLE DOES SHOULD BE gt AND 1100 1 J2 amp J3 NOT OR 80 90 PSI DO NOT OVERTIGHTEN MECHANISM ARE PLUGGED IN SLIPS BELTS 3 4 3 4 1 3 4 2 3 4 3 3 2 1b 7 IF SPINDLE STILL DOES NOT RUN PINDLEN YES CHECK FOR sS0LDGSNSSONNEGFOE CHECK FUSES IN INVERTER RUNS IN ONE K9 amp K4 gt LOOSE WIRES MUST FIRMLY GRIP CENTER PIN USE THEN TEST INVERTER DIRECTION ON 1100 2 OR TERMINALS SERVICE TOOL ST44 TO TEST AND ADJUST USING BATTERY BOX MUST BE SOLIDLY CRIMPED TO CENTER WIRE SERVICE TOOL ST03 MUST MAKE FIRM CONTACT WITH JACK 3 2 1b 8 3 5 3 5 1 3 5 2 USE OHM METER SURE Rabe SPINDLE _ YES CHECK REGEN TO CHECK CHECK EUSES RUNS WITH SWAP INKNOWN TAKES A LONG RESISTOROR Y REGEN RESISTOR N INVERTER BATTERY GOOD 10 10 S TIME TO EXTERNAL BRAKE CHECK DRAWING BOX STOP 1002 FOR VALUE 3 2 1b 9 3 2 1b 10 3 6 3 6 1 3 6 2 3 6 3 CHECK MOTOR WITH CHECK FOR VOLTAGE SPINDLE CHECK ADJUST
39. 18 9 8 8 1 3 7 6 9 12 14 5 4 FOR 1050 3A POLARITY IMPORTANT FOR BOARDS USING OPTO ISOLATORS 24 1 5 N CNC IS CHECK SETTINGS OF 1A 2A OR 1B 2B ON 1050 BOARD DIP SWITCHES NO 24 2 1 CHECK VOLTAGE AT TB3 2 M FUNCTION RESET ON 1060 SHOULD BE 5V WHEN RELEASED OV WHEN CLOSED RESET MUST BE RELEASED BEFORE NEXT M FUNCTION OCCURS USER DEVICE AND M FUNCTION BOARD MUST BE SET FOR ALL M FUNCTIONS ON THE 1050 24 2 2 Shar E THE SAME RESET LINE TB1 TB2 AND TB3 24 2 3 NZ USER DEVICE AND M FUNCTION BOARD MUST BE SET FOR daly THE SAME PROTOCOL DISCONNECT USER Y DEVICE FROM 1060 THE SAME PROTOCOL CONNECT OHM METER OR SPINDLE M FUNCTION TESTER ST03 TO SELECTED M FUNCTION TERMINALS OF TB1 OR TB2 24 2 4 1A OPEN 1A OPEN WOULD BE 1A9 2A CLOSED 1A CLOSED 2A CLOSED RELAY ACTION RESET CONDITION DIP SWITCHES THE RELAY ACTION AND RESET CONDITIONS ARE SELECTED BY DIP SWITCHES LABELED 1A 2A 1B 2B WHERE A AND B ARE THE DECADES ON THE 1050 0 A THIRD DIGIT INDICATES THE M FUNCTION WITHIN THE DECADE FOR DECADE A THE SETTINGS ARE 2A OPEN RELAY GIVES A 0 1 SEC PULSE CNC PROCEEDS AFTER PULSE 1A CLOSED 2A OPEN RELAY GIVES A 0 1 SEC PULSE CNC PROCEEDS AFTER RESET RELEASE RELAY HELD UNTIL RESET CLOSES CNC PROCEEDS AFTER RESET RELEASE RELAY HELD UNTIL RESET CLOSES AND IS
40. 216 15 lt 0004 0008 17 10 CONTINUED ON PAGE 2 OF CHART 17 March 2003 Figure 16 25 Circle Roundness Section 16 Troubleshooting 575 Fadal Maintenance Manual CHART 17 continued page 2 CIRCLE ROUNDNESS 10 3 95 CONTINUED FROM PAGE 1 NOTE 1 IF AMEASUREMENT TEST FAILS ALWAYS MEASURE AGAIN USING A DIFFERENT TOOL OR DIFFERENT MEASURING PROCEDURE THE FAULT MIGHT BE IN THE MEASURING TOOL OR PROCEDURE INSTEAD OF THE MACHINE Is 15 CIRCLE ene AD M CIRCLE ROUND INSPECT OFF YES MACHINE 17 1 CHECK AND ADJUST CLAMPING IS GIBS AND STRAPS ON BOX WAY MACHINES PDC TART CHANGE CLAMPING CHECK FOR TIGHT SLIDES 4 ON LINEAR WAY MACHINES 17 2 17A 1 3 17A 3 IS CIRCLE ROUND 17 4 FINISHED REMOVE SUBPLATE OR FIXTURING 17 7 4 1 15 MACHINE MUST TESTED WITHOUT FIXTURING DO ANSE SUBPLATES OR FIXTURING CAN INDUCE POSITIONING PROBLEMS NOT INHERENT IN THE MACHINE CIRCLE TEST IF MACHINE PASSES POSITIONING PROBLEMS INDUCED BY FIXTURING CUT CIRCLE ROUNDNESS TEST EIXTURING MUST BE DEALT WITH SEPARATELY FROM PROBLEMS ROUNDNESS IN THE MACHINE ITSELF PROBLEMS FOR FEEDRATES ABOVE F30 USE M92 IN 17 5 PROGRAM AND TRY AGAIN REPEATABLITY MAY ALSO BE AFFECTED BY TEMPERATURE GROWTH YES Is DO 15 CIRCLE CIRCLE FIX
41. 3 4 3 5 REPLACE DID REPLACE CHECK Soa PROBLEM hae EMERGENCY STOP FOLLOW THE CONTROLLER AND CARD S CARD MOTOR OVERLOAD ARD RELAYS 4 3 4 sh 4 4 1 CHECK CE CIRCUIT REPLACE BREAKERS F RESOLVER A10 B10 C10 UNAWAY OR 14 4 3 6a 4 3 6a 1 4 4 2 CONSULT FACTORY SERVICE DEPT ARE are Mee BEFORE REPLACING RECENTLY MOTOR WIRES SERVO MOTOR ERIFY THAT SHIELD REPLACED OR SHORTED TO IS STRIPPED BACK 4 3 6b FROM CONDUCTOR 4 4 3 4 4 5 IF A OR B AXIS ARE YES NOTUSED THEY VERIFY THAT EE ONER ON WITE EOWER ON Moe s s P AND DUMMY PLUG AND DUMMY PLUG LS L gt INSTALLED VERIFY Y INSTALLED VERIFY IN PARAMETERS OR SHORTS OHI LUG Mee bei THAT 1100 1 1 THAT 1060 J5 6 AND SHIN PEAGE PIN 1 TO PIN 6 IS OV J4 6 ARE 0V 4 4 3a 4 4 3a 1 4 4 3a 2 4 4 3a 3 4 4 4 DO MOVE Z AXIS PRESS EMERGENCY STOP TRY TO MOVE Z AXIS BY HAND CONSULT FACTORY BEFORE REPLACING BALLSCREW 4 4 3b 3 CHANGE AMP Y INDICATED BY FAULT LIGHT CHECK K1 K2 K18 K20 JUMPER PRESS JOG F12 amp F14 EMERGENCY DO AMPLIFIERS ON 1100 1 gt STOP CIRCUIT STAY ON CHECK OVERLOAD JUMP F16 TO F12 RELAYS ON 1100 1 4 4 3c 1 4 4 3c 2 Figure 16 9 Axis Control Section 16 Troubleshooting 4 4 3c 3 557 Fadal CONTINUED FROM PAGE 1 OF CHART 4 MOTOR OVERLOADS 4A 1 RESOLVER FAULTS 4A 2 NO
42. 56 Section 16 Troubleshooting March 2003 Fadal AXIS CONTROL 4 2 ISIT A RUNAWAY PROBLEM 4 1 4 3 IS THERE AN AMPLIFIER FAULT 4 4 NO GO TO PAFE 2 OF CHART 4 March 2003 CHART 4 AXIS CONTROL 10 20 95 Maintenance Manual DASHED SYMBOLS APPLY TO CE NORM EUROPEAN MACHINES ONLY MOVE OFF LIMIT POSITION BUILDING S POWER DISTRIBUTION PANEL 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 CHECK VOLTAGES WAS 5V 12V 12V amp IF VOLTAGES ARE MOTOR 110VAC AT 1220 OUT OF TOLERANCE REPLACED ALSO CHECK ROR AC gt CHANGE LOGIC RIPPLE ON DC VOLTAGES 0 015VAC MAX ON 12V POWER SUPPLY 0 005VAC MAX ON 5V 4 1 4 4 1 3 GOTO CHART 7 DOES THE AXIS RUN YES TO A LIMIT NO SWAP THE AXIS RBI SWAP ROBLEM CONTROLLER MOTOR BREAKERS SERVO CARDS 1010 OVERLOAD PREKERS AMPLIFIER REMEMBER TO RELAY me CARD CHANGE JUMPER BLOCK ON J4 4 3 1 4 3 2 4 3
43. ADJUSTED AXIS B AXIS SETS FOLLOWING ERROR WHEN ADJUSTING B AXIS CONTROL DIFFERENTLY FROM OTHER AXES SET PARAMETERS FOR 90 1 DISCONNECT SCALE 15 2 1 15 1 4 HEAD CHECK CHECK FOR USE CLAMP ON GEAR IS DAMAGED KEEPS FOR WATER IN AMMETER TO CURRENT BY A CRASH gt FUSE HOLDER gt CHECK FOR EXCESSIVE IN RETURN HEAD PETENS OR MOTOR EXCESSIVE TO FACTORY 7 HOUSING CURRENT DRAW FOR REPAIRS 45 15 4 1 15 4 2 15 4 3 15 4 5 REPLACE SEAL THAT IS LEAKING READJUST BACKLASH ASTM ENT AND GEAR MESH TOO TIGHT 15 5 1 15 4 4a 15 4 4 1 ARE YES CHECK WAS ADJUST YES THE GEARS QIL LEVEL gt GEAR MESH CAPACITY DO NOT EXCEED NOISY INHEAD OF THE HEAD LOAD CAPACITY 15 6 1 15 6 2 ZCEEDEDI 15 4 4b 1 GO TO CHART 4 AXIS CONTROL CHANGE PROGRAM TO GIVE MOTOR TIME TO COOL 15 4 4c 1 MOTOR WIRES YES ARE SHIELDED ERIFY THAT SHIELD IS STRIPPED BACK FROM CONDUCTOR ARE MOTOR WIRES SHORTED TO CHASSIS 19449 15 4 4d 1 IS MOTOR SHORT IN REPLACE MOTOR OR MOTOR 15 4 4d 2 15 4 4d 3 REPAIR REPLACE CABLE 15 4 4d 4 Figure 16 23 Tsudakoma 301RotaryHeads A amp B Axes March 20035 Section 16 Troubleshooting 575 Fadal Maintenance Manual
44. CK FOR EXCESSIVE L gt CURRENT DRAW ON 120 VAC LINES FROM ON 120VAC LINES TRANSFORMER 12A 2 2 12 2 1 TYPICAL CURRENT 1220 IS 1 5 OTHER BOARDS 1100 1 1100 2 CHILLER MAY BE PULLING DOWN LINE VOLTAGE CHECK DC POWER SUPPLY OUTPUTS 5V amp COM ALSO CHECK FOR AC RIPPLE ON THE DC VOLTAGE 12V amp COM SET METER FOR VAC AND CHECK 5V 12V AND 12V 12V amp COM METER SHOULD SETTLE TO LESS THAN 0 01 VAC IF AC RIPPLE IS PRESENT REPLACE 1220 POWER SUPPLY 12 3 CHECK BROWNOUT ALL YES RELAY K1 VOLTAGES FUSE ON BAD POWER SUPPLY ON 1220 1220 BROWNOUT RELAY MUST BE WHITE 1402 1 70YY21084 12A 4 2 12 4 12 4 1 BROWNOUT RELAY 1 1220 WILL LATCH LESS 4 5V AND WILL RELEASE IF 5V DROPS BELOW 4 5 DISCONNECT 12V OUTPUTS FROM 1220 AND TEST AGAIN gt REPLACE 1220 DC POWER SUPPLY 12A 5 2 IF 12V IS BAD IT CAN EFFECT CHILLER CONTROL RS232 CLOCKS SINE COSINE AND AXIS CONTROL 12V MAY READ OK ON A DC METER AND STILL BE BAD AN OSCILLOSCOPE IS NEEDED TO FULLY TEST 12V BUT AC RIPPLE MAY SHOW UP WHEN METER IS SET FOR VAC WV TURN OFF MACHINE IF NOW GOOD LOOK FOR BAD BOARD PULLING TOO MUCH 12V 12A 5 1 12A 5 YES 5V GOOD 5 01 5 10V PRESS EMERGENCY STOP REMOVE ALL CARDS FROM CARDCAGE
45. COMBINATION OF MAY APPEAR pe GO TO PAGE 2 OF CHART 10 MPG MPG Figure 16 16 Keyboard 566 Section 16 Troubleshooting March 2003 Fadal CONTINUED J a CHART 10 continued page 2 KEYBOARD 10 18 95 RETURN TO CNC MODE 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 CHECK 5V AND GND ves THIS MAY HAPPEN WIRING FROM ONLY IN CNC MODE POWER SUPPLY TO AND NOT IN 1090 DROPS OUT DIAGNOSTICS RUN EXTERIOR 5V AND GND FOR TEST 10 11 1 10 11 2 Maintenance Manual OTHER POSSIBLE CAUSES KEYPAD KEYBOARD 1090 ESTOP OR REMOTE ESTOPS REMOTE TOOL IN OUT 10 11 3 IF THIS ONLY HAPPENS CNC AND KEYBOARD DROPS OUT IT IS PROBABLY A PROBLEM WITH ONE OF THE CARDS IN THE CARD CAGE 10 12 1 10 12 2 NCES VERIFY THAT DIRECTIONS WHEN NYES TURRETCCW IS VERSIONS KELD DOWN WITH UPDATES 10 13 10 13 1 NO CONSULT FACTORY 10 14 Figure 16 17 Keyboard Continued March 2003 Section 16 Troubleshooting ves ACM run aas caso DIAGNOSTICS COULD BE 1030 1400 AXIS CARD OR 10 12 3 567 Fadal FINISH PROBLEMS CHECK 5V 12V 12V ALSO SET METER FOR AND CHECK FOR AC RIPPLE ON 5V 12V AND 12V DC 0 015VAC RIPPLE MAX ON 12V 0 005VAC RIPPLE MAX ON 5V
46. CT IN CONTROL CABINET WHEN BRAKE WIRING 14 3 3 EK CHECK FOR USE CLAMP ON GEAR IS DAMAGED WATER IN AMMETER TO CURRENT BY CRASH MECHANICAL FUSE HOLDER S CHECK FOR EXCESSIVE IN RETURN HEAD OR MOTOR EXCESSIVE ONE SPOT TO FACTORY HOUSING CURRENT DRAW FOR REPAIRS 14 4 2 14 4 3 14 4 5 READJUST REPLACE SEAL BACKLASH THAT IS LEAKING AND GEAR MESH 14 5 1 14 4 4a 14 4 4a 1 WAS CHECK CAPACITY ADJUST DO NOT EXCEED OIL LEVEL gt G AR MESH OF THE HEAD LOAD CAPACITY IN HEAD 14 6 1 14 6 2 TORTS CHANGE BRAKE MAY BE PROGRAM TO GIVE MOTOR TIME TO COOL 14 4 4c 1 MOTOR WIRES ARE SHIELDED ERIFY THAT SHIELD IS STRIPPED BACK FROM CONDUCTOR 14 4 4d 1 15 SHORT IN REPAIR REPLACE CABLE 14 4 4d 4 MOTOR REPLACE MOTOR 14 4 4d 3 March 2003 Fadal Maintenance Manual CHART 15 TSUDAKOMA 301 SOME HEADS HAVE TEMPERATURE ROTARY HEADS ADDITION TO FUSES TO PROTECT TSUDAKOMA 30 A amp B AXIS e ee 6 15 95 TEMPERATURE SNAP SWITCH WILL SHORT COS SIGNAL TO GND CHECK CHECK ON RESOLVER BOARD IN MOTOR IF MOTOR OVERHEATS AXIS DEAD OVERLOAD gt ROTARY HEAD RELAYS FUSE CHECK COS OUTPUT TO RESOLVER PIN 8 OF J4 OR J5 ON 1060 FOR SHORT TO GND 15 1 1 15 1 2 TET GUEL 15 1 3 FOLLOWING ERROR gt IMPROPERLY
47. DIRECTION PUT MOTOR WIRES 7 5 Figure 16 15 Axis Motor Runways BACK AS WIRED gt BEFORE AND RETEST SWITCH TACH WIRES 7 4 1d 1 7 4 1d 2 Section 16 Troubleshooting 565 Fadal 564 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 DCLO even momentarily This fault occurs when the main bus supply voltage has gone too high DCHI even momentarily These faults are usually the result of an excessive load on the drive out PH 1 put The fault condition can be permanent occurring when the drive is PH 2 enabled or intermittent occurring randomly during normal operation PH 3 Motor is over temperature OHE Baldor SWEO drive is over temperature OHC Overspeed on the motor has been detected OSP The Baldor SWEO power supply has momentarily experienced a reduc 15DC tion of the 15 volts below allowable levels 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 DESCRIPTION ALARM DISPLAY Inverter output current exceeded the overcurrent limit during
48. ED BLACK x 4 Q7 14 GA GREEN 8 11 13 15 916 14 GA SHIELDED RED z MOTOR WIRES ARE SHIELDED SHIELD MUST NOT TOUCH CONDUCTOR WHITE GRAY BROWN YELLOW RED GREEN BLUE ORANGE VIOLET BLACK SHIELD Maintenance Manual 9 PIN CONNECTOR TO ENCODER ON MOTOR 9 QZ S OAN TOA Wy Sx 6 SN Z 5 4 DB XER 1 SHIELD MOTOR CABLE WIRING FOR VH 5C INDEXER 4 6 95 8 PIN CONNECTOR TO MOTOR 19 PIN CONNECTOR ON MOTOR CABLE ENCODER ON MOTOR WHITE TD i 3 GRAY 2 14 GA SHIELDED BLACK A YELLOW 3 4 e BROWN 40 z RED 50 z 910011 GREEN 6 O 2 z N 7 Va BLUE X DA a 13 15 216 ORANGE 8 0 A 14 GA SHIELDED RED Z 5 17D 19 VIOLET MOTOR WIRES SHIELDED BLACK SHIELD MUST NOT TOUCH CONDUCTOR aes MOTOR CABLE WIRING FOR VH 65 INDEXER 4 6 95 BULKHEAD CONNECTOR WIRING FOR CLOCKWISE POSITIVE MOTION 6 20 95 WHITE 3 BLACK 2 15 16 Violet JT BLACK GRAY ENCODER E Figure 16 40 Motor Cable Wiring amp Bulkhead Connector Wiring 590 Section 16 Troubleshooting March 2003 Maintenance Manual Fadal SIXV OLOL AIGWASSV 31ZZON LNV1O09 Houws xovg OWV ZZ YalslNd NV any SYOLOANNOS Wows 1333 vl nia
49. ED BY FIXTURING FIXTURING MUST BE DEALT WITH SEPARATELY FROM PROBLEMS IN THE MACHINE ITSELF 5 2 NO 5 2 1 N CHECK AND ADJUST BACKLASH BALANCE ON AXIS AMPS N1 10100 LOOP GAIN ON AMPS N2 G1 F20 N3 X4 0 5 3 V N4 X 4 0 INSERT PROGRAM Na AT RIGHT N7 M30 SET UP INDICATOR 8 20199 FOR PROBLEM AXIS 2 5 4 N GOLD COAX CONNECTOR J1 J2 amp J3 ON 1010 MUST FIRMLY GRASP CENTER PIN USE SERVICE RUN TOOL ST44 TO TEST AND ADJUST PROGRAM MUST BE SOLIDLY CRIMPED TO CENTER WIRE MUST MAKE FIRM CONTACT WITH JACK 5 5 REPEATABILITY CAN BE AFFECTED IF CONNECTOR IS LOOSE INSPECT MOTOR EO ISSN CHECK GOLD COAX CHECK AND ADJUST DOES POR CONNECTORS ADJUST GAIN AND GIBS AND STRAPS THE AXIS 2 1010 4 COMPENSATION REPEAT WITH SERVICE ON AXIS AMPLIFIER CHECK BALLSCREW GHECK FORT OOSE TOOL ST44 ALIGNMENT 55 RESOLVER OR COUPLING 5 6 1 5 6 2 5 6 3 5 6 4 V CHECK SINE amp IF BACKLASH IS EXCESSIVE COSINE OUTPUT OF CLOCKCARD KAVE A BACKLASH N LOOSENESS N MOTOR CO REER 10201 USING PROBLEM a al WORN BALLSCREW AND SERVICE TOORS Tae BALLSCREW ALIGNMENT TT J 5 7 1 5 7 2 CHANGE RESOLVER RE INSTALL sss J SUEDA TED REPEATABILITY PROBLEMS MAY ALSO AND HEBERT TEST BE CAUSED BY TEMPERATURE GROWTH CHECK OF BALLSCREWS OR SPINDLE SUR
50. F AXIS CONTROL CHART 4 6 15 95 VES CHECK WAYLUBE CHECK CHECK AND ADJUST ONERE GIBS AND STRAPS OVERLOAD OCCURS AT SLOW PEED 40 1 1 40 1 2 OVERLOAD OCCURS NEAR POSITION LIMIT YES CHECK AND ADJUST MECHANICAL AXIS LIMIT STOP 262 4C 2 1 Maintenance Manual LOOP GAIN POT ON AMPLIFIER ves CU SHOULD BE MOSTLY CW OMPEIFIER w TURN FULLY CW FOR TEST AND EA ERT FOR vies RE ADJUST LOOP GAIN IF THIS CORRECTS PROBLEM OCCUR HILE STOPPED OR IN G0 4C 3 4C 3 1 4C 3 2 MAKE ADJUSTMENTS IN THE FOLLOWING ORDER MASTER FEED RATE CLOCK POSITION LOOP GAIN BALANCE ADJUSTMENT 4C 4 SWITCH TO SERVICE PROGRAM 5811 PROBLEM RESOLVED CHANGE G1 s TO G0 s RUN PROGRAM 4C 5 4C 5 1 FOLLOWING ERROR CORRECT THROUGHOUT MOVE S MACHINE WIRED FOR 208 VAC 3 4 6 4 5 2 SHOULD YES CHECK BUS VOLTAGE AT BLUE CAPACITOR ON AMPLIFIER CHASSIS SHOULD BE 115VAC CHECK SETP PARAMETER gt PHASE gt 5 LOW G0 FOLLOWING ERROR 4 5 4 4 5 5 INCH 1840 20 METRIC X Y 1630 20 DOES 20 MOVE Z 1380 20 12 2 12 5 SEC ADJUST MASTER ADJUST POSITION FEEDRATE CLOCK LOOP GAIN CHANGE THE G0 s 4C 5 3a BACK TO G1 s AND RUN PROGRAM AGAIN SWAP QUESTIO
51. FEEDRATE TO F20 AND FINE TUNE THE LOOP GAIN AND BALANCE ADJUSTMENTS CHECK WAY LUBE AND VERIFY WAYLUBE IS BEING DELIVERED TO ALL AXES LUBRICATE LINEAR WAYS 17 6 IS PART INSPECTED ON OR MACHINE 17 7 INSPECTED OFF MACHINE INSPECTED ON MACHINE PART MUST BE INSPECTED ON MACHINE BEFORE ANY CLAMPING IS REMOVED CLAMPING AND FIXTURING CAN DISTORT THE PART IF THIS HAPPENS THE PART WILL BE ROUND WHEN CUT BUT WHEN PART IS RELEASED FROM THE CLAMPING THE CUT WILL BE DISTORTED TO FIND THE SOURCE OF DISTORTION PART MUST BE INSPECTED ON MACHINE BEFORE IT IS RELEASED ENTER THE TEST PROGRAM AT RIGHT TO CUTA 1 INCH INSIDE DIA HOLE 0 25 DEEP IN ALUMINUM TEST CIRCLE WILL BE ROUGH CUT AND THEN FINISH CUT PLACE DIAL INDICATOR IN SPINDLE ADJUST X AND Y SO SPINDLE IS AT EXACT CENTER OF HOLE ACCORDING TO INDICATOR 17 9 AP N1 CIRCLE ROUNDNESS TEST N3 HOME IS CENTER OF PART N4 SET TOOL AT TOP OF PART N5 GO G17 G40 G80 G90 EO N6 X0 YO M3 510000 N7 H1 D1 20 1 M8 N8 G1 Z 0 25 F4 N9 G8 N10 L9402 R0 15 R1 0 980 N11 L9402 R0 15 R1 1 N12 M5 M9 N13 G0 H0 Z0 N14 X0 YO EO N15 M2 ROTATE SPINDLE MANUALLY TO CHECK ROUNDNESS OF CIRCLE SPECIFICATIONS FOR CIRCLE ROUNDNESS N2 0 500 DIA ENDMILL TOOL DIAMETER MUST BE IN TOOL TABLE TO 1 5 MAXIMUM DEVIATION VMC 8030 VMC 6030 lt 0006 0012 VMC 5020A 4020A 4020 3016 2
52. Fadal Error Messages March 2003 Maintenance Manual Section 16 Troubleshooting 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 o
53. Figure 16 14 Computer 6 8 3 MEMORY LOCATIONS ON CPU 1400 40000 5FFFF 80000 8FFFF ON RAM EXPANSION 1460 2 90000 EFFFF Section 16 Troubleshooting March 2003 Fadal Maintenance Manual CHART 7 AXIS MOTOR RUNAWAYS AXIS MOTOR RUNS AWAY AFTER REPLACING THE MOTOR CORRECT OPERATION BEFORE INSTA THIS WILL PREVENT DAMAGE AXIS MOTOR RUNAWAYS 6 15 95 WHEN REPLACING MOTORS CONNECT ALL WIRING AND VERIFY LLING MOTOR IN VMC HINE DUE TO RUNAWAYS POWER DOWN MACHINE PRESS EMERGENCY STOP CHECK WIRING AT AMP AND J4 JUMPER ON CONTROLLER CARD March 2003 7 2 POWER RELEASE EMERGENCY STOP RESET AMPS BY PRESSING JOG 7 3 WAS MOTOR WIRED EXACTLY NNO NAW Re THE SAME AS OLD MOTOR 7 4 CORRECT WIRING AND RETEST CHECK RESOLVER COUPLER CHECK AND ADJUST RESOLVER CONNECTOR WITH SERVICE TOOL ST44 CHECK TACH CONNECTIONS RETEST 7 4 1a REVERSE MOTOR WIRES AND RETEST 7 4 2 DOES IT STILL RUN AWAY REVERSE MOTOR WIRES AND RETEST REVERSE TACH WIRES AND RETEST THERE ARE 4 POSSIBLE MOTOR WIRE TACH WIRE COMBINATIONS IF STILL RUNNING AWAY IF STILL RUNNING AWAY PUT WIRES BACK IN ORIGINAL CONFIGURATION 7 4 1 1 GO TO CHART 4 7 4 1 2 15 MOTOR TURNING IN THE CORRECT
54. HECK FAULT SWITCH FUSE DRAWBAR SWITCH VOLTAGE TO K2 CHECK DRAWBAR SWITCH AND ADJUSTMENT CHECK Z AXIS SERVO AND DRAWBAR 2B 15 281718 2B 12a CYLINDER ASSY 2B 1 3a TOOL HOLDERS MUST BE CLEAN DID NO GO BACK TURRET INDEX 2B 2 YES 2B 3 2B 3 1 2B 3 2 TURRET FACTOR 2833 MUST 1 FOR SERVO TURRET DID NO CHECK CHECK ATC Z AXIS COME Z AXIS Lie Sena SAFETY SWITCH 28 4 28 4 1 28 4 2 YES CHECK DRAW BAR CHECK AIR PRESSURE ip Su p F DID YES VALVE FUSE 20 80 PSI AND 120PSI BULLBACK Z AXIS GO ERROR TO EXCEED TO START OF CHART 2 2B 2 1 CHECK TURRET FEEDBACK SWITCH IF OVERSHOOT UNDERSHOOT CHECK ADJUST TURRET FACTOR gt UP To START OF GO BACK CHART 2 2B 1 6 IS IT EXCESSIVE CHECK K24 AND ITS CONTROL VOLTAGE 3 5 PSI DROP DURING TOOL CHANGE 2B 5 1 28 5 YES NO 28 5 2 28 5 3 28 5 4 CHECK SEE CHECK ent SLIDE EXTENDED SWITCH TOOL CHANGER ALIGNMENT amp 5 ATC FAULT SWITCH ADJUSTMENTS BELT TENSION ee He RIG DRAWBAR SWITCH IN MAINTENANCE K13 SLIDE MOTOR MANUAL 2B 5 1a 2B 5 1b 2B 5 1 28 5 5 CHECK SLIDE HOME I ADJUSTMENT OF SWITCH GENEVA SLOT 2B 6 2B 6 1 28 6 2 CHECK MAKE SURE TOOL COLD START POSIT
55. ING IN FIXTURE OR IS FIXTURE YES 21 5 NZ POWER OFF MACHINE AND INSPECT WIRING 21A 6 CHECK FOR LOOSE OR BROKEN WIRES OR BAD CRIMPS 21A 7 N TEST ALL GOLD COAX CONNECTORS USING ST44 SERVICE TOOL CONTINUED ON PAGE 3 OF CHART 21 March 2003 ENSURE THAT PART AND FIXTURE ARE ADEQUATELY SECURED 21 4 1 DOES THE MACHINE CERRY 4S ISPOSITION WHEN SERIAL NOT USING DNC COMMUNICATIONS TRY DNCX SHORTEN THE CABLE USE A SLOWER BAUD RATE TRY ANOTHER COMPUTER AND CABLE 21 5 2 21A 5 3 Figure 16 33 Positioning Problems Section 16 Troubleshooting IF OVERSHOOTING DOES NOT OCCUR WITHOUT SCALES CONTACT FACTORY ABOUT SOFTWARE CHANGE 21 2 4 GO TO CHART 22 SCALES 21 3 4 585 Fadal Maintenance Manual CHART 21 continued page 3 FROM PAGE 2 POSITIONING PROBLEMS CONTINUED OF CHART 21 10 20 95 NZ CHECK RESOLVER CONNECTORS AT MOTORS 21B 1 N CHECK LEVEL AND TRAM 21 2 BROKEN OR LOOSE RESOLVER COUPLINGS 21B 3 N CHECK BALLSCREW ALIGNMENT 21 4 USE CLAMP ON AMMETER TO CHECK EACH AXIS AMP DRAWS MUST BE IN SPEC AND CONSISTENT 21 5 V CHECK STRAP ADJUSTMENTS CHECK AMP DRAWS AGAIN AFTER ADJUSTING STRAPS 15 INSPECT PART POSITIONING ON MACHINE DOES PAR
56. ING USED A CLASS 3 HOLE IS USUALLY TAPPED WITH GH 1 TAP PITCH DIAMETER OF TAP INCREASES 0 0005 FOR EVERY GH NUMBER 23 4 3 NZ TAP MUST BE 2 FLUTE SPIRAL POINT OR ROLL POINT IF LESS THAN 5 16 23 4 4 IS THE DRILL THE CORRECT SIZE 23 4 5 IS COOLANT AND OR TAPPING COMPOUND THE CORRECT TYPE AND MIXTURE 23 4 6 TOP OF TAPPING CYCLE 23 3 1 NO POSITIVE INDICATOR READING WHILE MOVING DOWN 23 3b 1 NO YES NEGATIVE INDICATOR READING WHILE MOVING DOWN 23 3c 1 NO YES INDICATOR READING MOVING UP DOES NOT MATCH READING MOVING 23 34 1 HAS ZERO OFFSET BEEN SET IN INVERTER y CONSULT FACTORY APPLICATION ENGINEER 23 4 7 SPINDLE MOTOR SHAKES CONSULT FACTORY ABOUT POSSIBILITY OF SOLID MOTOR MOUNTS SERVICE DEPT ENCODER RUNOUT AND INSTALLING 23 5 1 2 WHEN SPINDLE STARTS OR PARAMETERS IN SETP CHECK RIGID TAP ESPECIALLY RAMP 23 6 1 23 4 8 3 5 2 Sy COS ir FACTORY Figure 16 37 Rigid Tap March 2003 SERVICE DEPT 23 7 Section 16 Troubleshooting THIS IS IRRELEVANT TAP IS NOT IN THE HOLE AT THE TOP OF THE TAPPING CYCLE 23 3 2 ADJUST RAMP IN SETP 23 3a 2 SPINDLE IS TURNING TOO FAST DECREASE THE GAIN PARAMETER IN SETP 23 3b 2
57. INGS 2 4 10 Figure 16 4 Automatic Tool Changer Section 16 Troubleshooting March 2003 Fadal CONTINUED FROM PAGE 1 OF CHART 2 MANUALLY MOVE TO EXTENDED POSITION GRASP AND SWING UPPER GENEVA ARM DID SMOOTHLY 2A 2 TOOL CARRIER PROPERLY ALIGNED WITH SPINDLE RETURN ATC TO RETRACTED POSITION THEN IN MDI ENTER M6T2 DID ATC SLIDE COME IN 2A 5 DID TOOL CARRIER CRASH INTO SPINDLE YES 2 6 GO TO PAGE 3 OF CHART 2 2 7 March 2003 CHART 2 continued page 2 AUTOMATIC TOOL CHANGER 10 18 95 CLEAN ADJUST REPLACE AND LUBRICATE I MECHANISM MECHANISM IF DAMAGED 2A 2 1 2A 2 2 Maintenance Manual CHECK AND ADJUST TURRET FACTOR TURRET FACTOR MUST BE 1 FOR SERVO TURRET CHECK IF TOOL CARRIER IS OUT OF POSITION OR SKEWED DUE TO A CRASH gt TURRET ALIGNMENT COLD START POSITION ADJUST AND OR 2A 3 1 2A 3 2 2A 3 3 SERVO TURRET MUST MAKE A MOVE BEFORE TURRET ALIGNMENT IS ADJUSTED IF TOOL 2 IS IN THE SPINDLE USE M6T1 ARE CHECK ATC HOME SWITCH FUSES YES CHECK ATC FAULT SWITCH CHECK SLIDE MOTOR F7 F8 amp 1 CHECK CONTROL CHECK gt BELT TENSION AND RELAYS K6 VOLTAGE AT K14 ALIGNMENT AND ADJUSTMENT K13 amp K14 CHECK SLIDE MOTO
58. ION gt E STUDS 287 28 71 28 722 SYSTEMS END 2B 8 554 Figure 16 6 Automatic Tool Changer Continued Section 16 Troubleshooting March 2003 Fadal Maintenance Manual DASHED SYMBOLS CHART 3 APPLY TO CE NORM SPINDLE DRIVER SPINDLE DRIVER EUROPEAN MACHINES N 10 20 95 NOTE DIFFICULT TO DIAGNOSE PROBLEMS CAN OCCUR IF MACHINE IS NOT PROPERLY GROUNDED SPINDLE WILL NOT THERE MUST BE A CONTINUOUS GROUNDING CONDUCTOR AS SPECIFIED ON THE GROUNDING LABEL RUN ON A CE MACHINE IN THE MACHINE S DISCONNECT BOX FROM THE VMC S GROUND BUS TO THE GROUND BUS IN THE WITH THE DOORS OPEN BUILDING S POWER DISTRIBUTION PANEL NZ CHECK ERROR MESSAGES ON INVERTER DISPLAY MITSUBISHI INVERTERS REQUIRE INSTALLATION OF PARAMETER UNIT CORRECT FAULT AND RESET INVERTER 3 1 SPINDLE CHECK Mayas 3 2 3 2 2 3 2 3 CHANGE 15 YES SPINDLE SPINDLE POT POT AT 0 SETTING 9 2 18 3 2 1 1 CHECK ERROR MESSAGES HECK ON INVERTER DISPLAY VERIFY LED ON CHECK CHECK SNE RESET CHECK MITSUBISHI INVERTERS SPINDLE 1010 AND RESET AIR GE CIRGUIT 3 PHASE AC REQUIRE INSTALLATION SLOT
59. LE RND CHECK ERROR MAGNET DURING EV HAND ADJUSTMENT CALIBRATION 18 28 18 28 1 18 28 2 18 28 4 18 28 5 GO TO ORIENTATION MAGNET IS READ BY CPU THROUGH 1060 J10 PIN 8 CHART 3 BUT THE SPINDLE CARD READS IT THROUGH J2 IF WIRING IS BAD CPU MAY BE ABLE TO READ MAGNET SPINDLE BUT THE SPINDLE CARD MAY NOT BE ABLE TO READ IT DRIVER THIS ERROR IS REPORTED BY PROBLEM COULD BE THE CPU NOT THE AXIS CARD VERIFY THAT AN AXIS CARD NOT 48 COULD BE 1 255 18 48 IT IS NOT AN ERROR AXIS DATA TRANSFER HAS STALLED ALL AXIS CARDS ARE BLINKING NECESSARILY THE SPINDLE CARD THE 1030 OR THE 1400 18 48 1 18 48 2 Figure 16 29 Error Codes March 2003 18 48 3 Section 16 Troubleshooting 579 Fadal Maintenance Manual aan CHART 19 SERIAL PORT COMMUNICATIONS 6 14 95 IS SINGLE PROBLEM WITH ALL FILE MUST USGS TA CO as NOI E ss CHARACTERS O S DOES PART OF FILE SO CONTROL STOPS PE IN THE FILE TRANSMIT AT SYNTAX ERROR 19 1 1 19 1 2 19 1 3 19 1 4 ALL COMMUNICATION CHECK BAUD RATE LOOK FOR ILLEGAL AND OTHER COMMUNICATION CHARACTERS BEFORE PARAMETERS AT MACHINE AND THE INITIAL PER CENT AT COMPUTER SIGN 19 2 19 1 3 VERIFY ALL RS232 CABLES ARE PLUGGED IN AT 1030 BACK OF CABINET COMPUTER 19 3 CHECK
60. NABLE AMPLIFIER WITH ONE OF 4C 5 3a 1 4 5 3 2 4C 5 2a THE OTHER AXES RUN PROGRAM AGAIN 4C 5 3b 4C 5 3b 1 Y No STAYED WAS WITH AMPLIFIER WV FOLLOWING ERROR COROT REPLACE CHANGE MOVES AMPLIFIER MOTOR 4C 5 2b 4C 5 3b 3 4C 5 3b 2 G1 FOLLOWING ERROR INCH 595 1 METRIC 302 1 WV ADJUST POSITION CONSULT LOOP GAIN FACTORY NANET 4C 5 2b 1 Figure 16 12 Axis Control Continued Section 16 Troubleshooting March 2003 Fadal Maintenance Manual DIFFICULT TO DIAGNOSE PROBLEMS CAN OCCUR CHART 5 IF MACHINE IS NOT PROPERLY GROUNDED THERE MUST BE A CONTINUOUS GROUNDING REPEATABILITY REPEATABILITY CONDUCTOR AS SPECIFIED ON THE GROUNDING LABEL 9 20 95 IN THE MACHINE S DISCONNECT BOX FROM THE VMC S GROUND BUS TO THE GROUND BUS IN THE BUILDING S a FOR ADDITIONAL PRECISION IN LEVELING POWER DISTRIBUTION PANEL VERIFY PERFORM SQUARENESS TEST ON X amp Y MACHINE IS LEVEL THEN SQUARNESS TEST ON COLUMN SEE MAINTENANCE THEN SPINDLE TRAM TEST MANUAL CONSULT FADAL SERVICE DEPT FOR PROCEDURE 5 1 REMOVE SUBPLATE OR FIXTURING IS THERE MACHINE MUST BE TESTED WITHOUT FIXTURING A SUBPLATE YES SUBPLATES OR FIXTURING CAN INDUCE POSITIONING OR LARGE HEAVY PROBLEMS THAT ARE NOT INHERENT IN THE MACHINE POSITIONING PROBLEMS INDUC
61. OHMMETER SPINDLE AT OVEREOAD RELAY TO DECIDE IF MOTOR SPEED J1 CONNECTOR LEG TO LEG I ENCODER OR INVERTER IS BAD VARIES ON SPINDLE CARD WITH ENCODER ABOUT 0 6 OHM TESTER LEG TO GND OLL a7 3 2 1b 11 i 3 74 3 7 3 TYPICAL SYMPTOMS OF A CONSULT FACTORY CONTINUED SERVICE DEPT ON PAGE 2 SPINS SLOWLY SINKS LOTS OF CURRENT BEFORE REPLACING SPINDLE DRIVER THEN FAULTS OUT OC MOTOR OR CHART 3 MITSUBISHI INVERTER NO VISIBLE SYMPTOMS 3 8 MITSUBISHI DOES NOT REQUIRE ENCODER 3 2 1b 12 FEEDBACK TO RUN PERFORMANCE SUFFERS BUT NOT OBVIOUSLY 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 PINDLE DRIVER CHART 3 10 20 95 GBINBIEE CHECK SPINDLE USE DI DS TO CHECK CHECK 0 5V SWITCHING YES TYPE IN SETP HALL SWITCHES AT K27 AND K10 ON 1100 1 IDLERS WILL NOT CPU WILL NOT SWITCH IDLER WILL NOT SWITCH gt 5V PULL UP IS SUPPLIED SWITCH IDLERS IF IT IS UNLESS OTHER IDLER IS IN THRU THE RELAY HI LOW SPINDLE TYPE 01 OUT 00 IN SO RELAY MUST BE IN PLACE 3A 1 NO 3A 1 1 3A 1 2 3A 1 3 Tann JARTA nN ORIENTATION TO CHECK 1060 J10 8 ORIENTATION gt ACTIVATING FAILURE ORIENTATION 7 FACTOR MAGNET TO IN SETP CHECK F19 AND SLOT 14 J2 K23 ON 1100 2 2 1 2 2 2 3 2 4 NO ORIENTATION MAGNET
62. OM AIR bine ane a JRO HEAVY AUXILIARY CHUCK AIR SUPPLY OR PART 20 5 1 20 5 2 20 5 3 20 55 REDUCE FEEDRATE Go TO PAGE 2 OF 20A 5 6 CHART 20 CONSULT FACTORY ABOUT MOTOR TYPE JUMPER SETTINGS 20 5 6 Figure 16 31 Servo Indexer March 2003 Section 16 Troubleshooting 581 Fadal CONTINUED FROM PAGE 1 OF CHART 20 INDEXER MISPOSITIONS LOSES POSITION MAY ALSO MOTOR OVERLOAD 20 6 WILL NOT COLD START FEED RATE POT DOES NOT RESPOND PROPERLY 582 Main CHART 20 continued page 2 FADAL SERVO INDEXER 10 20 95 tenance Manual TEST ENCODER WITH FADAL ENCODER TESTER ENCODER MAY BE BAD YES ENCODER CABLE MAY BE BAD gt VERIFY CONTINUITY OF ENCODER SIGNALS IN CABLE ENCODER MAY BE SLIPPING ON MOTOR SHAFT 20 6 1 ARE YOU USING SIMULTANEOUS MOVEMENT DISCONNECT INDEXER INTERFACE CABLE AND RUN PROGRAM USING THE START BUTTON 20 7 1a 20 6 2 HEAD MUST FINISH MOVE BEFORE NEXT START IS SENT ADD DWELL TO VMC PROGRAM 20 7 2 20 6 3 DOES PROGRAM RUN PROPERLY YES CHECK COMMUNICATION PROTOCOL BETWEEN INDEXER AND MILL gt ACROSS FINISH MILL MAY NEED 0 001uF CAPACITOR TERMINALS OF MILL 20 7 1 20 7 1d FIRST MAKE SURE UNIT JOGS IN BOTH DIRECTIONS AND CORRECTLY DISPLAYS CHECK CONNECTO
63. ONMENT 19 10 l 19 9 2a IF PROBLEMS PERSIST GO TO COMMUNICATIONS TROUBLESHOOTING SECTION OF MAINTENANCE MANUAL FOR ADDITIONAL INFORMATION 19 11 Figure 16 30 Serial Port Communications 580 Section 16 Troubleshooting March 2003 Fadal Maintenance Manual CHART 20 FADAL SERVO INDEXER 10 20 95 WITH 5V 15 WILL CHECK FUSE MOTOR CABLE BETWEEN io INDEXER ON BACK OF DISCONNECTED Pao PIN 1 AND PIN 6 POWER UP CONTROL BOX WILL INDEXER OF J11 ON BLINKING POWER 1810 0 UP 20 1 20 1 1 20 1 2 YES CHECK CHECK FOR IN CABLE CONNECTOR 5V REGULATOR PINS 1 amp 2 OF J1 OR ENCODER TO DISPLAY ON POWER SUPPLY ON POWER SUPPLY 1818 0 2 1810 0 2 20 1 2a 20 1 3a 20 1 4a 20 1 5 CHECK FOR BAD SOLDER JOINTS AT ALL FOUR VOLTAGE REGULATORS LISTEN CAREFULLY TO UNIT CHECK VERIFY IF MOTOR IS TURNING WILL PARAMETERS HEAD MOVE FEED RATE RATIO AND gt HEAD IS NOT A COUPLER IS LOOSE INSIDE HEAD IS NOT SET ATO ENCODER COUNTS 20 2 2 20 2 3 20 2 4 CHECK VOLTAGES CHECK FUSES INE IF AMPLIFIER IS BLOWN 1810 0 1 J3 ON MOTOR LOOK FOR CAUSE PIN 1 5V amp PIN 2 GND ON 1810 0 1 AND ON gt
64. PER GRADE OF TAP BEING USED 23 1 1 A CLASS 3 HOLE IS USUAL TAPPED WITH A GH 1 TAP PITCH DIAMETER OF TAP INCREASES 0 0005 FOR EVERY GH NUMBER LY CHART 2 RIGID TA 10 20 95 Maintenance Manual 3 DIFFICULT TO DIAGNOSE PROBLEMS CAN OCCUR IF MACHINE IS NOT PROPERLY GROUNDED P 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 2 TAP MUST BE FLUTE SPIRAL POINT OR ROLL POINT IF LESS THAN 5 16 HOLE THE CORRECT IS THE DRILLED SIZE FOR THE TAP TAPPING COMPOUND IS COOLANT AND OR THE CORRECT TYPE AND MIXTURE 23 2 1 23 2 2 23 2 3 RUN RIGID TAP TEST AS DESCRIBED IN MAINTENANCE MANUAL 23 2 4 FAILS RIGID TAP XES BEFORE DOING RIGID TAP TEST Z AXIS GAIN AND BACKLASH MUST BE VERIFIED AND OR ADJUSTED AS DESCRIBED IN MAINTENANCE MANUAL INDICATOR OVERSHOOTS AT YES TEST PASSES RIGID TAP TEST BUT TAPPED HOLES ARE NOT GOOD BELTS MAY BE SLIPPING DURING ACTUAL TAPPING CHECK BELT TENSION AND IDLER ASSEMBLY CHECK FOR OIL OR COOLANT ON BELTS OR EXCESSIVE AIR IN HYDRAULIC HI LO ACTUATOR NO 23 4 1 IS THE CORRECT GO NOGO GAGE BEING USED 23 4 2 N IS THE CORRECT GRADE OF TAP BE
65. R OF GENEVA SLOT amp WIRING 2 5 2 2 5 3 2 5 4 RESET CB1 OR REPLACE F7 F8 K6 K13 K14 AS NEEDED 2A 5 1a TURRET MUST BE CHECK TURRET FACTOR AT AN EMPTY ADJUST FOR GENEVA POCKET COLD START POSITION CHECK ENCODER AND ADJUST SETTO AND TURRET ALIGNMENT ENCODER WIRING FOR SERVO TURRET 2A 6 1 2A 6 2 SERVO TURRET MUST MAKE A MOVE BEFORE TURRET ALIGNMENT IS ADJUSTED 2A 6 3 TURRET FACTOR MUST BE 1 FOR SERVO TURRET Figure 16 5 Automatic Tool Changer Continued Section 16 Troubleshooting 593 Fadal CONTINUED Maintenance Manual CHART 2 continued page 3 AUTOMATIC TOOL CHANGER 10 18 95 PROPER AIR PRESSURE AND ADEQUATE AIR VOLUME IS CRITICAL FOR TOOL CHANGES AIR PRESSURE REGULATOR ON MACHINE MUST BE SET AS LABELED 80 90 PSI AND 120 PSIFOR TOOL OUT REGULATOR AIR SUPPLY TO MACHINE SHOULD BE 120 PSI AIR HOSE TO MACHINE MUST BE 3 8 AND AS SHORTAS POSSIBLE MAXIMU M OF 3 5 PSI AIR DISTRIBUTION PIPE IN BUILDING SHOULD BE A MINIMUM OF 3 4 THE PRESSURE DROP AT THE MACHINE DURING A TOOL CHANGE SHOULD BE A IS IS AIR PRESSURE MUST BE TOOL STUCK NYES DRAW BAR YES MACHINE IN NYES 80 PSI AND 120 PSI IN SPINDLE FUSE OKAY A TAP TAP MAX 3 5 PSI DROP F20 CYCLE DURING TOOL CHANGE 2B 1 1 2B 1 2 2B 1 3 YES NO NO NO 2B 1 4 CHECK SLIDE EXTENDED SWITCH REPLACE CHECK C
66. RS Ls 6 4 1 6 4 2 IS THERE SCREEN 6 6 IS MEMORY LOSING PROGRAMS 6 7 ERROR WHILE PROCESSING BLOCK 6 8 MEMORY ERROR YES EPROM MODULE 1610 EXPANDED MEMORY 1460 AND BUS BRIDGE 1730 MUST BE FIRMLY SEATED IN THEIR CONNECTORS CHECK FOR BENT PINS CHECK 5 VOLTS 5 05V gt 12 VOLTS ALSO SET METER FOR VAC JAND CHECK FOR AC RIPPLE ON 5V 12V AND 12V DC CHANGE VIDEO BOARD 1420 COMPUTER INTERFACE 1030 CPU 1400 EXPANDED MEMORY 1450 6 5 1 6 5 2 6 5 3 CHECK VIDEO SWITCH ON IS VIDEO CHECK VIDEO CABLE IF 32MP FRONT PANEL ONITOR ALIVETNYES CHECK FUSE F25 CHECK AGE CHECK FOR ON 1100 1 gt CNC DOS CHECK BRIGHTNESS MONITOR ERNE GLOW CHECK VIDEO CARD SWITCH POTS ON MONITOR 6 6 2 6 6 3 6 6 4 6 6 5 6 6 1 POWER OFF AND CHECK FUSES ON MONITOR 6 6 2a TEST BATTERY BACKUP ON CPU BOARD REPLACE CPU BOARD IFBATTERY TEST FAILS CONSULT FACTORY 6 7 1 SUM PROGRAM TO FIND AND CORRECT ANY ERRORS 6 8 1 6 7 2 PROBLEM CORRECTED CHANGE CPU MEMORY BOARD RUN RAM TESTS IN DIAGNOSTICS IF TEST FAILS REPLACE CPU OR MEMORY EXPANSION gt IF PROBLEM RECURS ZERO MEMORY REPLACE CPU OR RAM EXPANSION 6 9 1 6 9 2
67. RS ON MOTOR CABLE AND BOX FOR PUSHED IN OR DAMAGED MAY ENCODER CABLE OR ENCODER CHECK ALL ENCODER CONNECTIONS BE BAD POSITION PINS OR SOCKETS CHECK CONTINUITY OF ENCODER LINES 20 8 1 20 8 2 20 8 3 GEK CHECK AIR SUPPLY ase PARAMETERS CONNECTORS MEO DRAKE OH SJ SOLID STATE O SEL IF BRAKE AIR PRESSURE BRAKE OFF RELAY KIPON IS ACTIVE 1810 0 2 SHOULD BE 80 PSI 20 9 1 RECALIBRATE FEEDRATE POT IN DIAGNOSTICS 20 10 1 20 9 2 20 9 3 INSERT DUMMY PLUG INTO RS232 DB25 CONNECTOR PINS 2 amp 3 JUMPERED RUN RS232 TEST IN DIAGNOSTICS DOES RS232 TEST WORK 20 11 1 INDEXER HAS CTS DTR amp JUMPERED INTERNALLY DSR CHECK VOLTAGES 1810 0 J11 PIN 1 amp 2 5V PIN 12V PIN 4 12V PIN 5 amp 6 GND 20 11 2a Figure 16 32 Servo Indexer Continued 20 9 t4 AIR SOLENOID PORTS ARE 18 2 2 IS AIR IN 1 IS AIR OUT TO HEAD 20 9 5 CHECK CABLING BAUD RATE AND PROTOCOL INDEXER IS 7 DATA BITS EVEN PARITY 1 STOP BIT 20 11 3 Section 16 Troubleshooting March 2003 Fadal CONTINUED FROM PAGE 1 OF CHART 21 IF BALLSCREW HAS BEEN REPLACED A NEW SURVEY MUST BE DONE 21 1 OVER SHOOTING POSITION 21A 2 Maintenance Manual CHART 21 continued page 2 POSITIONING PROBLEMS 10 20 95 SURVEY
68. S ARE BALLSCREW DEPENDENT CHANGING THE BALLSCREW INVALIDATES THE SURVEY IF OVERSHOOTING OCCURS WITH A HEAVY PART OR FIXTURE BUT DOES NOT OCCUR WITHOUT IT USE G51 RO WITH A VALUE gt 1 FOR X AND Y TOLENGTHEN FEED RAMPS 21A 2 1 SCALES 21 2 2 SURVEY FOR SCALES 15 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 POWER OFF MACHINE DISCONNECT SCALES POWER ON MACHINE 21A 2 3 NO YES MACHINE HAVE 21A 3 NO J13 ON 1060 MUST BE PLUGGED IN FOR SCALES TO WORK RELIABLY 21A 3 1 THE SCALE ERROR INPUT IS ON J13 SO IT IS CRITICAL TO SCALES THAT J13 BE PLUGGED IN HOWVER POSITIONING ERRORS CAN ALSO OCCUR WITH RESOLVERS IF J13 IS NOT PLUGGED IN FOR SCALES AND RESOLVERS IT IS IMPORTANT THAT J13 BE PLUGGED IN AND DOOR INTERLOCKS FUNCTION PROPERLY 21A 3 2 RECONNECTED RECORDS DISCONNECT SCALES POWER DOWN MACHINE AND RESTART DOES MACHINE POSITION CORRECTLY WITHOUT SCALES 21A 3 3 YES SURVEY FOR SCALES IS NOT THE SAME AS SURVEY FOR RESOLVER FOR POSITIONING NO TO BE CORRECT SURVEY FOR RESOLVER MUST BE ENTERED WHEN SCALES ARE UNPLUGGED AND SURVEY FOR SCALES MUST BE ENTERED WHEN SCALES ARE SURVEY FOR SCALES AND SURVEY FOR RESOLVER CAN BE FOUND IN MACHINE IS PART SLIPP
69. SCREW 11 6 1 11 6 2 Figure 16 18 Finish Problems Section 16 Troubleshooting CHECK SIN COS er CHECK SIGNALS USING CHECK FOR BALANCE service TooL stag SHECK 5 MOTOR ON AXES ADJUST IF VARIANCE VIBRATIONS INDO OD SUR S gt 0 001V 11 2 1 11 2 2 11 2 3 11 2 4 11 2 5 DO NOT OVERTIGHTEN BELTS CHECK CHECK SIN COS MATCH X amp Y AXIS AMPLIFIER SIGNALS USING FOLLOWING COMPENSATION Y SERVICE TOOL ST48 ERROR SETTING ADJUST IF VARIANCE ON X amp Y gt 0 001V 11 3 1 11 3 2 11 3 3 11 3 4 CHECK March 2003 Maintenance Manual Fadal DASHED SYMBOLS BAD POWER CHART 12 APPLY TO CE NORM BAD VOLTAGE EUROPEAN MACHINES BAD POWERIBAD VOLTAGE ONLY 6 16 95 CHECK INCOMING VOLTAGE AT MAIN DISCONNECT AND AT INPUTS TO TRANSFORMER 12 1 CONSULT INCOMING CHECK FUSES CREERLO ELECTRICIAN VOLTAGE IN MAIN POWER gt I FOR WIRING GOOD DISCONNECT SURPREND FAULTS IN BUILDING 12 2 12 2 1 12 2 2 12 2 3 A12 B12 C12 SHOULD 230 245 VAC LEG TO LEG 15 amp 16 SHOULD BE 120 VAC A10 B10 C10 SHOULD BE 95 VAC LEG TO LEG 13 amp 14 SHOULD BE 120 VAC WITH T817E OR T818E TRANSFORMER TRANSFORMER WILL HAVE A10 B10 C10 OR 13 amp 14 BUT NOT BOTH CHECK OUTPUT VOLTAGES OF TRANSFORMER 12 3 USE CLAMP ON VERIFY THAT OUTPUT AMMETER TO TRANSFORMER IS VOLTAGES CHECK FOR gt PROPERLY GOOD EXCES
70. SIN COS IS IT CHECK SIGNALS USING SEE FINISH BALANCE SERVICE TOOL S748 CHART PROBLEM AXIS AMPLIFIERS ADJUST IF VARIANCE NO 11 gt 0 001V 1A 1 1 1A 1 2 1A 1 3 SEE IS IT A ROTARY HEAD ORME PROBLEM 1 2 1A 2 1 YES MAKE SURE VERIFY SEE POSITION OVERRIDE SERVO COOLANT EO T POT IS D axis IS SET TO gt CENTERED COOLANT IN SETP 1A 3 1A 3 1 1A 3 2 1A 3 3 CHECK SIN COS IS ITA CHECK SIGNALS USING SEE ROUNDNESS BALANCE OF SERVICE TOOL ST48 CHART PROBLEM AXIS AMPLIFIERS ADJUST IF VARIANCE NO 17 gt 0 001V 1A 4 1 1A 4 2 1A 4 3 SEE CHART 18 1A 5 1 VERIFY ISITA VERIFY SEE BAUD RATE AND COMMUNICATION l connection I CHART COMMUNICATION PROBL M OF RS232 CABLES NO 19 6 1A 6 1 1A 6 2 18 6 3 IS IT AN IS ITA SEE INDEXER FADAL CHART PROBLEM INDEXER NO 20 1A 7 2 IS IT SEE AN M FUNCTION gt CHART PROBLEM NO 24 1A 8 1 Figure 16 2 Quick Checkout Procedure Continued 550 Section 16 Troubleshooting March 2003 ISITA YES POSITIONING PROBLEM NO ISITA SCALE PROBLEM YES NO ISITA YES RIGID TAPPING PROBLEM 1B 3 NO ISITA YES VIBRATION PROBLEM March 2003 Maintenance Manual CHART 1 continued page 3 QUICK CHECKOUT PROCEDURE 9 20 95 REMOVE COVER FROM SCALE BOX ON OUTSIDE OF CONTROL BOX AND CHECK FOR ERROR LED 1B 2 1 DOES MACHINE HA
71. SIVE CONFIGURED FOR 12 4 1 CURRENT DRAW 12 4 2 INPUT VOLTAGE TYPICAL CURRENT WITH MACHINE AT REST A12 B12 C12 0 3A 15 amp 16 1 5 A10 B10 C10 OR 13 amp 14 0 4 THESE TYPICAL VALUES ACTUAL VALUES MAY VARY EXCESSIVE VALUES WOULD BE OVER 5 HIGHER WITH MACHINE AT REST 12 4 CHECK INPUT VOLTAGE TO AMPLIFIER CHASSIS AND BUS VOLTAGE ON LARGE BLUE CAPACITOR 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 ON CE MACHINE CHECK CIRCUIT BREAKERS ON SUPPLY TO AXIS AMP CHASSIS CHECK FOR LOOSE TERMINALS 12 6 12 6 1 12 6 2 12 7 GO TO PAGE 2 OF CHART 12 12 8 Figure 16 19 Bad Power Bad Voltage March 2003 EMERGENCY STOP CHECK K2 AND F17 VERIFY OVERLOAD BUS MUST BE OUT ON 1100 1 RELAYS ARE RESET VOLTAGE AND gt 110VAC CONTROL CHECK K1 K18 K20 GOOD AMPLIFIERS RESET VOLTAGE FOR F12 F14 AND F16 BY PRESSING JOG SSR ON AMP CHASSIS ON 1100 1 12 7 1 12 7 2 12 7 3 Section 16 Troubleshooting Maintenance Manual Fadal CONTINUED FROM PAGE 1 OF HART 12 CHART 12 continued page 2 BAD DC VOLTAGE 6 16 95 CHECK INPUT VOLTAGE TO DC POWER SUPPLY 1220 SHOULD BE 120 VAC USE CLAMP ON AMMETER are ss TO CHE
72. Section 16 Troubleshooting 539 Fadal 540 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 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 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 t
73. 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 Section 16 Tro
74. T ERROR REVEALED BY BEFORE REMOVING INSPECT GOOD CLAMPS OR ON MACHINE RELEASING VISE SINGLE STEP THRU THE PROGRAM TO FIND POSSIBLE PROGRAMMING ERRORS HAVE AN APPLICATION ENGINEER REVIEW THE PROGRAM AND FIXTURING ARE ALL POSITIONS CHANGING TRY RESETTING gt HOME AT REGULAR INTERVALS THERMAL EXPANSION MAY BE THE PROBLEM 21B 10 21B 10 1 21B 10 2 INSPECT AND FLUSH THE LUBE SYSTEM VERIFY ENTIRE SYSTEM IS WORKING PROPERLY 21B 11 Figure 16 34 Positioning Problems OFF MACHINE CLAMPING MAY BE gt MEASURING MAY BE DISTORTING PART OUT OF CALIBRATION 21B 7 3 21B 7 4 WHEN MATERIAL IS CUT THE STRESSES IN THE MATERIAL MAY MOVE WHEN IT IS UNCLAMPED THERMAL CHANGES BETWEEN MACHINING AND INSPECTION MAY BE AFFECTING PART 21B 7 5 THERMAL GROWTH IS A NATURAL EFFECT OF HIGH SPEED MACHINING IT CAN BE LIMITED BUT NOT TOTALLY ELIMINATED IT OCCURS IN THE BALLSCREWS THE HEAD THE SPINDLE AND EVEN THE COLUMN SADDLE AND TABLE WHEN THERE ARE TEMPERATURE SWINGS 584 Section 16 Troubleshooting March 2003 Fadal SCALE PROBLEMS 1 CHART 22 SCALE PROBLEMS Maintenance Manual SCALE PROBLEMS CAN SHOW UP AS SCALE ERRORS AN ERROR CODE MISPOSITIONING REPEATABILITY PROBLEMS ROUNDNESS PROBLEMS OR UNEXPECTED POSITION SHIFTS 0 20 95 CONSULT CHART 18 ERROR CODES IS IT
75. THE BE SURE YOU ARE USING THE TABLE FOR THE 1050 1050 oonona on DECADE A M20 29 DECADE B M80 89 1050 3A HAS 2 M FUNCTIONS A OR B WHICH ANY NUMBER IN THAT DECADE WILL ACTIVATE 3A DECADES H 0 1050 0 DECADE SELECTION A2 CLOSED A2 OPEN DO NOT SET 1050 0 FOR DECADES 0 1 3 4 6 OR 9 BECAUSE THESE DECADES ALREADY HAVE SPECIFIC FUNCTIONS ASSIGNED TO THEM DO NOT SET DECADE A AND DECADE B TO THE SAME VALUE THE ACTIVE DECADES ON THE 1050 0 ARE ASSIGNED USING DIP SWITCHES LABELED A1 A2 A3 A4 B1 B2 B3 AND B4 TO SET DECADE A FOR M20 29 A1 CLOSED A2 OPEN 50 59 A1 OPEN M70 79 A1 OPEN M80 89 A1 CLOSED A2 CLOSED FOR DECADE B USE SWITCHES B1 A4 CLOSED A8 CLOSED A4 OPEN A8 CLOSED A4 OPEN A8 CLOSED A4 CLOSED A8 OPEN B2 B4 B8 DID RELAY CONTACTS CLOSE NO YES 1050 BOARD IS ACTIVATING M FUNCTION VOLTAGE ACROSS TERMINALS WILL BE 0 WHEN CONTACTS CLOSE ARE YOU SURE RELAYS PROVIDE A CONTACT CLOSURE NOT A VOLTAGE VOLTAGE OR CURRENT THROUGH RELAY CONTACTS MUST BE SUPPLIED BY USER DEVICE 24 1 3a CHECK CABLING AND USER DEVICE 24 1 4 CHECK SETTINGS OF 1A 2A OR 1B 2B DIP SWITCHES ON 1050 BOARD M FUNCTION TERMINALS UNITS DECADE DIGIT A B TB1 TB2 7 13 11 10 9 15 13 12 2 2 4 19 20 8 5 6 14 1 4 8 10 2 3 5 11 16 16 15 6 19 20 18 17 7 17
76. TURING ROUND AND CIRCLE ROUND SEE NOTE 1 SUBPLATE TEST SEE NOTE 1 CUT 17 5 3 17 5 5 17 5 6 FIXTURING OR SUBPLATE IS DISTORTING MACHINE WHICH WILL CREATE A MECHANICAL BIND 17 5 7 CONSULT FACTORY 17 6 Figure 16 26 Circle Roundness Continued 576 Section 16 Troubleshooting March 2003 Fadal Maintenance Manual CHART 18 ERROR MEANING DIAGNOSIS ERROR CODES UMBER gt PROCEDURES ERROR CODES REPORTED BY AXIS 8 18 95 1 EITHER RESOLVER OR CHECK THAT USE FADAL RESOLVER INPUT SARC ERED NO MOTOR ENCODER FEEDBACK DEVICE S ENCODER TESTER AT J2 OF 1010 FEEDBACK DETECTED At ARE PLUGGED INTO OR SCALE TESTER SHOULD BE ABOUT an tee 1010 CARD J2 J5 J6 TO TEST ENCODERS 1 7VAC POWER UP 18 1 2 18 1 3 18 1 4 18 1 5 18 1 6 2 FEEDBACK VERIFY ENCODER TESTER SWAP SPINDLE ENCODER NOT EN SPIND LE CONNECTION Gn Genie TESTER CONTROLLER CARD RESPONDING eaten DURING OF ENCODER gt TO REST GHINDE WITH KNOWN GOOD CABLES CARD RIGID TAP ENCODER 182 18 2 1 18 2 2 18 2 3 MACHINE CHECKS FOR COGIC JUMPER RUNAWAY AT POWER UP NS ON SASS DISCONNECT Base MOTOR WIRES INCORRECT OR MESSAGE INDICATES AN TO BYDASS ASIS RUN OR TACH SIGNAL
77. VE SCALES NO SEE CHART NO 21 1B 1 2 YES START WITH SCALE CHART SEE CHART NO 22 1B 2 2 SPINDLE INVERTER MUST LABELED MUST BE CHART RIGID TAPPING RIGID TAP NO 23 1B 3 1 1B 3 2 1B 3 3 FOUNDATION IS IMPORTANT MACHINE MUST BE POSITIONED ON por CHECK ALIGNMENT OF CONSULT A SINGLE SLAB OF CONCRETE MOTOR MOUNTS CHART 3 WITHOUT CRACKS DETERMINE WHICH CHART 22 AXIS HAS VIBRATION AND SEE MAINTENANCE MANUAL gan BALLSCREW MOUNTS CHART 23 FOR DETAILS 1 4 1 1 4 2 1 4 3 1B 4 4 Figure 16 3 Quick Checkout Procedure Continued Section 16 Troubleshooting Maintenance Manual Fadal TOOL CHANGER USE TOOL IN OUT TO INSERT REMOVE TOOL FROM SPINDLE CHART 2 AUTOMATIC TOOL CHANGER 10 18 95 MAXIMUM OF 3 5 PSI PROPER AIR PRESSURE AND ADEQUATE AIR VOLUME IS CRITICAL FOR TOOL CHANGES AIR PRESSURE REGULATOR ON MACHINE MUST BE SET AS LABELED 80 90 PSI AND 120 PSI FOR TOOL OUT REGULATOR AIR SUPPLY TO MACHINE SHOULD BE 120 PSI AIR HOSE TO MACHINE MUST BE 3 8 AIR DISTRIBUTION PIPE IN BUILDING SHOULD BE A MINIMUM OF 3 4 THE PRESSURE DROP AT THE MACHINE DURING A TOOL CHANGE SHOULD BEA AND AS SHORT AS POSSIBLE CHECK AIR PRESSURE MANUALLY ACTIVATE CHECK AIR DOFS NO 80PSI AND 120F S1 CHECK DRAWBAR SOLENOID DELIVERY TO TOOL IN OUT MAX 3 5 PSI DROP F20 AND K24 SpORAWBAR SOLE RAW
78. VEY TABLE 5 6 7 AXIS REPEATS WITHOUT SUBPLATE AND FIXTURING THU RRIS BUT DOES NOT REPEAT WITH SUBPLATE AND FIXTURING a ae THEREFORE FIXTURING OR SUBPLATE IS DISTORTING TABLE REPEAT ON OR CHANGE OR CREATING A MECHANICAL BIND On Na PROCEDURE A MACHINING PROCEDURE IS CAUSING NON REPEATABILITY 5 9 2 5 9 5 9 1 Is 15 18 COOLANT 2 AXIS OFFSET SNES FLOWING IN CHANGING RUNNING RESERVOIR 5 10 CHECK FOR AC RIPPLE SERVICE THE END ON THE DC VOLTAGES N SPINDLE COOLER ALL AXES REPEAT 0 015VAC MAX ON 12V ASSEMBLY 0 005VAC MAX ON 5V AND PUMP ASSEMBLY 5 11 5 10 4 5 10 5 Figure 16 13 Repeatability March 2003 Section 16 Troubleshooting 561 Fadal 562 COMPUTER POWER ON WAIT A FEW SECONDS AND PRESS CNC POWER SWITCH 6 1 ARE LEDS ON BOARDS FLASHING 6 2 PRESS AND HOLD CNC POWER SWITCH RESET BOARDS THAT ARE NOT FLASHING 6 2 1 CHART 6 COMPUTER 9 20 95 N GO INTO DIAGNOSTICS IF CONTROL IS DEAD TRY POWERING UP WITH JUMPER AT J2 ON 1400 6 3 YOU GET INTO DIAGNOSTICS 6 4 YES Maintenance Manual IS THERE NO bone 5V ON THE 10667 CHART 12 6 2 3 RUN DIAGNOSTICS ON MEMORY VIDEO CLOCKS MILL INTERFACE IF MEMORY WAS REPLACED OR ADDED OR EPROM MODULE WAS CHANGED ZERO MEMORY AND RESET PARAMETE
79. 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 Section 16 Troubleshooting 557 Fadal 538 EXAMPLE 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 HO 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 Con
80. XCEEDS THE OVERLOAD FACTOR CHECK OVERLOAD FACTOR PARAMETER CHECK POWER L GOTO CHART 12 BAD POWER CH ax GOTO ART 4 IS CONTROL PARAMETER IS IT TOO LOW s 18 131 18 13 2 18 13 3 18 13 4 AXIS MOVE COMMAND CHECK WAS PROPERLY 5V 12V amp 12V ASIS EAN TRANSFERRED TO AXIS CARD CHECKSUM FAILED VOLTAGES FROM POWER SUPPLY SEE CHART 12 THAT AXIS CARD AND RETES 1030 OR 1400 AND RETEST IF MULTIPLE CARDS FAIL REPLACE 18 14 1 SPINDLE MAGNET WAS NOT DETECTED WITHIN THE ALLOWABLE TIME 18 15 1 18 18 14 2 15 18 14 3 STOP SPINDLE AND USE DI DS VERIFY MAGNET IS CONNECTED USE KNOWN GOOD HALL EFFECT SWITCH AND TEST WITH gt SPINDLE TO CHECK MAGNET TURNING TURN SPINDLE US MEN A MAGNET BY HAND USING DI DS 15 2 NO 18 15 3 18 15 4 18 15 5 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 RESOLVER ZERO BY AXIS CARD WITHIN TH ALLOWABLE TIME CROSSING WAS NOT DETECTED E VERIFY RESOLVER IS PLUGGED INTO J2 OF 1010 CARD IF MOTOR OVER CHECK IF MOTOR TEMPERATURE SNAP SWITCH WILL SHORT COS SIGNAL TO GND ON RESOLVER BOARD IN MOTOR HEATS IS
81. YMBOLS APPLY TO CE NORM ONLY 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 CORRECT AIR PRESSURE 1 1 PROPER AIR PRESSURE AND ADEQUATE AIR VOLUME IS CRITICAL FOR TOOL CHANGES AIR PRESSURE REGULATOR ON MACHINE MUST BE SET AS LABELED 80 90 PSI AND 120 PSI FOR TOOL OUT REGULATOR AIR SUPPLY TO MACHINE SHOULD BE 120 PSI AIR HOSE TO MACHINE MUST BE 3 8 AIR DISTRIBUTION PIPE IN BUILDING SHOULD BE A MINIMUM OF 3 4 THE PRESSURE DROP AT THE MACHINE DURING TOOL CHANGE SHOULD BE A MAXIMUM OF 3 5 PSI AND AS SHORT AS POSSIBLE CHECK 5V AND 110 AT POWER SUPPLY 1220 USE OSCILLOSCOPE IF AVAILABLE 12V 12V SET METER FOR VAC AND CHECK FOR AC RIPPLE ON 5V 12V AND 12V DC 0 015VAC RIPPLE MAX ON 12V 0 005VAC RIPPLE MAX ON 5V 1 3 1 6 March 2003 1 2 1 IS POWER OK IS IT AN AXIS PROBLEM IS IT A TOOL CHANGER PROBLEM IS IT A SPINDLE PROBLEM REPEATABILITY PROBLEM CONTROL PROBLEM KEYBOARD PROBLEM SEE CHART NO 12 1 2 3
82. apay ON CPU AND AXIS TRANSFER COMPLETED OTAGES ERON IF ONE AXIS FAILS REPLACE FAULT BUFFER A COMMUNICATION POWER SUGCLY THAT AXIS CARD AND RETEST INDICATOR FAILURE BETWEEN BEE CHARTA IF MULTIPLE CARDS FAIL REPLACE AXIS CARD AND CPU 1030 OR 1400 AND RETEST 18 20 1620A 16205 18 20 3 AN UNKNOWN CHECK CONNECTIONS OR ILLEGAL REPLACE TERRIER T ENE INTERRUPT FAULTY CONNECTION gt AXIS CARD HAS OCCURRED CAN CAUSE NOISE 18 21 18 211 18 21 2 18 21 3 Pr FEEDBACK FROM CHECK Buea SCALE PORT IS CABLING CHECK BOARDS SBE RING OUTSIDE ALLOWABLE gt IN SCALE BOX LIMITS TEST SCALE 18 22 18 22 1 18 22 2 18 22 3 18 22 4 23 24 25 26 FOLLOWING ERROR CHECK CHECK P OW ER CHART 4A MOTOR OVERLOAD EXCEEDS THE USER OVERLOAD FACTOR AXIS CONTROL FOLLOWING ERROR gt DEFINED OVERLOAD PARAMETER gt MOTOR OVERLOAD FACTOR IS IT TOO LOW OVERLOAD BAD VOLTAGE FACTOR 18 23 18 23 1 18 23 2 18 23 3 mas 27 RETURN TO MAGNET TIMEOUT 18 27 28 ORIENTATION ORIENTATION SPEED MAY BE TOO LOW COULD NOT FIND MAGNET AFTER TAPPING HOLE 5 SECOND TIMEOUT DURING RIGID TAPPING 18 27 1 18 27 2 10 SECOND TIMEOUT DID NOT ORIENT ORIENTATION 15 STOP SPINDLE AND USE DI DS VERIFY MAGNET OR SPINDLE 15 CONNECTED CALIBRATION DID NOT ARRIVE AT STH 7 BE Too LOW TURNING SPIND
83. 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
84. e 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 Section 16 Troubleshooting 521 Fadal 522 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 STEEP Helical Radius Too Small N See error message HELICAL RISE 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 1 J or K Must Be Specified at N This message is displayed when an X Y or Z is used with an RO without a G2 or G3 Full circles must use the direction around the circle and either the J or K See the circular interpolation sectio
85. e 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 70 The H word must be on a line in the program before the G51 1 20 Tool NN is 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
86. e 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
87. e 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 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
88. e 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 Section 16 Troubleshooting March 2003 Fadal March 2003 Maintenance Manual N1 01 START 0F PROGRAM N2 ACCEPTABLE PROGRAM EXAMPLE N3 L100 SUB 1 N4 X1 5 6 L200 SUB 2 N7 L105 N8 M46 N9 X 5 Y 1 N10 M47 11 12 L300 SUB 3 N13 G91 N14 L204 N15 1104 N16 G90 17 18 17 N19 M30 N20 N21 MAIN PROGRAM This ends the last subroutine This separates the subsection from the main program Memory Error Reload Program This is 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
89. eing 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 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 Para
90. elays 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 Section 16 Troubleshooting 515 Fadal 516 EXAMPLE Maintenance Manual Format 1 N1 G41 N2 H1 This is incorrect N1H1 N2 G41 This is correct for Format 1 only Format 2 N1H1 N2 G41 This is incorrect N1 H1 D1 Diameter must be for Format 2 programming and N2 G41 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 tab
91. en 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 Section 16 Troubleshooting 519 Fadal 520 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 Error in User Program SUM to
92. essage 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 have a subroutine call on it Section 16 Troubleshooting March 2003 Fadal EXAMPLE March 2003 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 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
93. fore 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 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 Section 16 Troubleshooting March 2003 Fadal March 2003 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
94. 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 b
95. he 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 Section 16 Troubleshooting March 2003 Fadal March 2003 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
96. he 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 Section 16 Troubleshooting 555 Fadal 554 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 exi
97. his 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 Section 16 Troubleshooting March 2003 Fadal EXAMPLE March 2003 Maintenance Manual Please Put an 0 Word at the First of the Current Program The Following Programs Are in Memory To use the PR command the active program must have 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 N 1 043 P N 34 765 Here a line was inserted N1 G0 G90 S10000 M3 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
98. is message appears Do not run the machine when this message appears Section 16 Troubleshooting March 2003 Fadal March 2003 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 t
99. is variable depending on the default setting at the machine established in SETP or with a CD 4 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 Section 16 Troubleshooting 545 Fadal 546 Maintenance Manual Data Bits Seven d Stop Bits 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 2 COM3 or COM4 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 f
100. 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 Section 16 Troubleshooting March 2003 Fadal March 2003 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 r
101. le 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 Section 16 Troubleshooting March 2003 Fadal Maintenance Manual All program data is deleted from memory After the memory is reinitialized A a cold start must be performed March 2003 Section 16 Troubleshooting 517 Fadal 518 Maintenance Manual Do You Want to Zero Tool Table This pro
102. mand 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 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 Section 16 Troubleshooting 525 Fadal 524 Maintenance Manual Input Xmodem Transmit Block Missed Error This occurs when a packet
103. may want to consider thread milling as an alternative to tapping Call the service department if this is persistent Section 16 Troubleshooting 5535 Fadal 556 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 m
104. 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 Section 16 Troubleshooting 527 Fadal 528 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
105. meters 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 Section 16 Troubleshooting 529 Fadal EXAMPLE EXAMPLE 550 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 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 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 T
106. mpt is accessed by reinitializing the memory via the RI command A Y response zeroes the tool offset table WARNING Alltool diameter and length offsets are deleted from memory Do You Want to Zero Fixture 0ffsets 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 por
107. n for more details Illegal 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 HO 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 Section 16 Troubleshooting March 2003 Fadal EXAMPLE March 2003 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 com
108. n 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 Section 16 Troubleshooting 509 Fadal 510 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 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 be
109. olant Control 574 Section 16 Troubleshooting March 2003 Fadal CIRCLE ROUNDNESS NZ VERIFY MACHINE IS LEVEL SEE MAINTENANCE MANUAL 17 1 N TEST BALANCE OF SIN COS SIGNALS USING FADAL SIN COS TESTER SERVICE TOOL ST48 17 2 N CHECK AND ADJUST POSITION LOOP GAIN AND BALANCE FOR X AND Y AXES 47 3 N CHECK BACKLASH THE SCREW PITCH COMPENSATION TABLES CAN ALSO AFFECT OF X amp Y AXES CIRCLE ROUNDNESS WHEN CUTTING LARGER DIAMETERS 17 4 CHECK FOR LOOSENESS IN MOTOR COUPLERS AND WORN OR LOOSE BALLSCREWS 17 5 CHART 17 CIRCLE ROUNDNESS 10 3 95 FOR ADDITIONAL PRECISION IN LEVELING PERFORM SQUARENESS TEST ON X amp Y THEN SQUARNESS TEST ON COLUMN THEN SPINDLE TRAM TEST CONSULT FADAL SERVICE DEPT FOR PROCEDURE IF SINAND COS ARE NOT BALANCED WITHIN 0 001V BALANCE SIN AND COS AND RUN TEST CUT AGAIN Maintenance Manual 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 PROCEDURE FOR ADJUSTING LOOP GAIN AND BALANCE IS IN THE MAINTENANCE MANUAL USING THE FOLLOWING ERROR DISPLAY IS MORE ACCURATE THAN A METER ONCE THE LOOP GAIN AND BALANCE ARE ADJUSTED REDUCE THE
110. ot 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 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 when 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
111. our 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 num bers 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 5100 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 Section 16 Troubleshooting March 2003 Fadal March 2003 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 mouse or network board screen savers and other software run ning conc
112. 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 Section 16 Troubleshooting March 2003 Fadal March 2003 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 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 no
113. roubleshooting 571 Fadal 14 1 14 2 14 3 14 4 14 5 14 6 14 7 14 8 572 AXIS DEAD TR65 ROTARY HEADS A amp B AXIS NO ARE THE GEARS NOISY POSITION GO TO CHART 4 AXIS CONTROL YES CHART 14 FADAL TR65 ROTARY HEADS A amp B AXIS Maintenance Manual SOME HEADS HAVE TEMPERATURE SWITCHES INSTEAD OF OR IN ADDITION TO FUSES TO PROTECT THE MOTOR FROM OVERHEATING THESE AUTOMATICALLY RESET WHEN THE MOTOR COOLS TEMPERATURE SNAP SWITCH gt ICHECK COS OUTPUT TO RESOLVER WILL SHORT COS SIGNAL TO GND ON RESOLVER BOARD IN MOTOR IF MOTOR OVERHEATS PIN 8 OF J4 OR J5 ON 1060 6 15 95 CHECK CHECK OVERLOAD gt ROTARY HEAD RELAYS FUSE 14 1 1 14 1 2 FOLLOWING ERROR IMPROPERLY ADJUSTED Sie FOR SHORT TO GND LET COOL 14 1 3 B AXIS SETS FOLLOWING ERROR DIFFERENTLY FROM OTHER AXES 14 2 1 WHEN ADJUSTING B AXIS AMP SET PARAMETERS FOR 90 1 DISCONNECT SCALE CONTROL 14 1 4 B AXIS CLUTCH MAY BE LOOSE gt CHECK AIR SOLENOID DEFECTIVE 14 7 1 14 7 2 Figure 16 22 TR65 Rotary Heads A amp B Axes Section 16 Troubleshooting REPLACE RELAY AUGAT RDI RELAY TURNS OFF AMP OR CORRE
114. secutive 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 AU 50 1 or AU 50 5 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 Section 16 Troubleshooting March 2003 Fadal March 2003 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 15 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 se
115. t 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 Section 16 Troubleshooting March 2003 Fadal March 2003 Maintenance Manual E Word May Only Be Used With GO 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 operator resume 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 wh
116. t 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 gt 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 Section 16 Troubleshooting 543 Fadal 544 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 hardware generated every 1 millisecond 17 BAD READING ON RESOLVER PORT This error
117. t 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 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 Section 16 Troubleshooting March 2003 Fadal March 2003 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 messag
118. 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 amp 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 amp 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 Section 16 Troubleshooting March 2003 Fadal March 2003 Maintenance Manual Out of File Space a File Compression is B
119. 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 Section 16 Troubleshooting 511 Fadal 512 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
120. ubleshooting March 2003 Fadal March 2003 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 GO 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 amp 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 thes
121. urrently in the host computer may interfere with commu nications Check the IRQ and DMA settings in the computer for conflicts with the values assigned to the IO port The output voltage of the IO board across pins 7 and 12 when transmitting a program should be between 10 and 12 VAC The file being sent may have something wrong with it Incorrect syntax in a line of code may interrupt transmission Section 16 Troubleshooting 547 Fadal Troubleshooting Charts 548 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 Maintenance Manual Quick Checkout Automatic Tool Changer Spindle Driver Axis Control Repeatability Computer Axis Motor Runaways Baldor SWEO Spindle Drive 2200 2300 Spindle Drive Keyboard Finish Problems Bad Power Bad Voltage Rotary Heads A Axis FADAL TR65 Rotary Heads A amp B Axis Tsudakoma 301 Rotary Heads A amp 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 QUICK CHECKOUT IS THERE 80 1 CH ART 1 QUICK CHECKOUT PROCEDURE 9 20 95 Maintenance Manual EUROPEAN MACHINES DASHED S

Section 16: Troubleshooting

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