Troubleshooting

Fadal Maintenance Manual
Section 16: Troubleshooting
Error Messages Absolute Mode Required at N =

The CNC must be in the G90 (absolute) mode during all probe functions. Probe
function L9101 is programmed in the G91 (incremental) mode.
Amplifier Fault on Axis

This occurs at power on if the control does not detect an axis that should be
operational. This is often seen when the A axis is not in use and the dummy
termination plug has been installed. If the dummy termination plug is installed,
this message can be disregarded.
If this message appears for any of the other axes (X, Y, or Z), then power off to
check the motor overload relays. Power on and if the message appears again,
call the service department, noting the error message number.
Power off the machine before checking fuses, relays, and circuit breakers. The
motor overload relays can be recognized by their white reset buttons. They are
located in both control enclosures. The white button must be pressed to reset a
relay.
This message also appears when the EMERGENCY STOP button has been
pressed. The operator must release the EMERGENCY STOP button and press
the JOG button to reset the amplifiers. (Pressing in the EMERGENCY STOP
button disconnects the axis amplifiers. This is why this message appears when
the button is pressed.)
Arm Must Be Left

Before a pallet change can occur, the arm must be completely to the left with
the pallet on the table. The feed back on the arm is being read at this time.
Array Exceeds Allowable Number

This message will appear when the number on the array exceeds the expected
amount. This amount varies from variable to variable. For example, H(99) is
acceptable, H(102) is not.
March 2003 Section 16: Troubleshooting 509

ATC Failure
Check to see if the Z axis alignment was properly set at cold start. The
automatic tool changer has failed to respond to an M6 or the TC,1 command.
Try a power off and power on. If this does not help check the fuses.
The fuses F5, F6, F7, and F8 should be checked to see if they are burned out.
Circuit breakers 1 and 2 (if they are present) should be pressed to see if they
have been tripped.
Power off the machine before checking fuses, relays, and circuit breakers. If
this does not help, call the service department.
If this message appears with the turret in the extended position, it may be an
indication that the sensor for turret extension is faulty. Call the service
department.
ATC Turret Failure

Check to see if the Z axis alignment was properly set at cold start. Then check
to see if anything is caught between the sheet metal guard and the turret. If
not, this could be an indication that the sensor for turret rotation is faulty.
The fuses F5 and F6 should be checked to see if they are burned out. Circuit
breaker 2 (if it is present) should be pressed to see if it has been tripped.
Power off the machine before checking fuses, relays, and circuit breakers.
ATC Will Not Move to Position

Check to see if the Z axis alignment was properly set at cold start. An attempt is
made to make a tool change and something prevents the turret from going all
the way out to the spindle. Check the tracks that allow the turret to slide out to
the spindle. Sometimes chips stick to the track and prevent the rollers from
rolling on the track.
When this message appears use the command SETCS then the command HO
which will bring the tool to the Cold Start position. It is important to visually
check the axis indicator markers to see if they are aligned; if not, jog the table
until the markers are aligned. Use the command CS, then answer Yes (Y) to the
“move to home?” question. This will bring the tool to the part’s home position
and enable the operator to begin running the program in AUTO again.
It is also possible that the turret extended sensor is faulty.
Fuses F5, F6, F7, and F8 should be checked to see if they are burned out.
Circuit breakers 1 and 2 (if present) should be pressed to see if they have been
tripped.
510 Section 16: Troubleshooting March 2003

Power off the machine before checking fuses, relays, and circuit breakers.
Attempted Division by Zero

In a macro statement, a division by zero was attempted.
Attempted SQR of a Negative Number

In a macro statement, a square of a negative number was attempted.
Attempt to Change CRC Side Without G40 at N =

This message will occur when attempting to switch from G41 to G42, or vice
versa, on a linear move. However, switching from one to the other is permitted
during circular interpolation.
Attempt to Change Tool While in CRC Mode, N =

This message occurs if a G41 or G42 is used in the program and a G40 code
does not appear before an M6 code. The G40 cannot be on the same line with
M6. An M6 will not cancel CRC.
Attempt to Switch Plane During CRC

G40 must be in effect (CRC must not be on) when changing planes. The default
plane selection is G17. If CRC is in effect and a code to change to another
plane (G17, G18, G19) is used, this message will appear in the block where the
plane selection was called. G40 must be in effect (CRC must not be on) when
changing planes.
Axis Controller Does Not Respond During Power Up Sequence

This an indication that there is a communication problem between the CPU
(1400) board and the axis controller (1010). Note error number and call the
service department.
Axis Controller Does Not Respond to NC

This an indication that there is a communication problem between the CPU
(1400) board and the axis controller (1010). Note error number and call the
service department.
Axis Data Transfer is Stalled

This message is the result of a data transfer problem between the 1030 card
and a 1010 card. This message does not represent a serious problem and
should only be reported to the service department if it is persistent. Please note
error number.
Axis Does Not Respond

This is possibly a problem with the 1010 card for the stated axis. Try a power
off and a power on. If this does not help, call the service department.

Axis Fault(s) as Follows

This appears when the EMERGENCY STOP button is pressed, a motor overload
relay is tripped, or the machine places itself into the Emergency Stop mode. If
any message or error number is presented on the screen, record this message
and number and report them, if needed, to the service department.
Release the EMERGENCY STOP button if necessary, then press the JOG button
which will reset the machine. If the machine does not reset, call the service
department.
If the EMERGENCY STOP button is not depressed, then power off the machine
and press the reset buttons of the motor overload relays to see if they are
tripped.
The motor overload relays can be recognized by their white reset buttons. They
are located in both control enclosures. The white button must be pressed to
reset a relay.
If the machine stalls for one reason or another, the control places itself into the
Emergency Stop mode. Press the JOG button and jog the tool out of the stalled
position.
An axis fault also occurs during an emergency stop because the control
removes the power to each of the axis servo amplifiers as a safety feature. The
control then analyzes the situation and, as a part of the report, shows a servo
amplifier fault, a result of having removed power to the amplifiers.
Axis Overflow
The axis controller detected an overflow situation. Power off the machine at the
main power switch wait ten seconds, and turn the power on again. If this
problem is persistent, call the service department.
Bad Circle OR Missing G at N

This can indicate an incorrect starting position for the circle, an incorrect
ending position, or an incorrect description of the arc center location relative to
the starting position of the circle.
This can also indicate that the circle is programmed in absolute or incremental
and the G90 or G91 codes are incorrect.
Bad Data or No Tool Dia.

This occurs when an H word (in format 1) or the D word (in format 2) is missing
in the program. When a program uses cutter radius compensation (CRC) or a
fixed subroutine, an H word or D word must be specified.

This also occurs when no diameter value is placed in the tool table when using
Fixed subroutines L94NN, L95NN,L9601, L9701, L9801, L9901. A DIAMETER
VALUE MUST BE USED.
When the fixed subroutine for engraving (L9201) is used, the Z depth and the
R2 variable must be included in the line. See the Users Manual for the correct
format. If the R0 variable is not specified, it is assumed as R0+0. If the R1
variable is not specified, it is assumed as R1+1.
Bad Fixture No.

Fixtures are numbered E1-E48. This message is displayed when a fixture offset
is programmed with a value greater than 48. Format 2: G54-G59 and E6-E48
are used.
Bad Interpolation Type at N

Check to see what type of move is intended for this block. G1, G2, and G3 are
the interpolation codes; G1 is for linear moves and G2 and G3 are for circular
moves.
Bad R Field
This occurs during input from the keyboard or through the RS-232 port (from
an offline computer) when the R0 was typed incorrectly. Example: If RO is typed
(R with the letter O) or R with no zero (0) is typed (R-.05 is accepted but not
R.05 or R+.05).
Correct the line in the CNC; or correct the line in the text editor and send the
program again.
Bad R1 Using L91 at N =

The R1 parameter is not present in the block containing L9101, or it is present
with an improper value. L9101 has 9 possible functions that are defined by the
R1 parameter; R1+1. through R1+9.
Bad T Word at N =
This message occurs during a SUM command. It indicates that the T word
value is larger than the tool changer capacity.
Bad Z or R0 in Canned Cycle Call, N =

This is a programming error due to the position of the R plane relative to the Z
axis position when initializing a fixed (canned) cycle.
Problem:
1) The R plane is described to be above the I plane.

2) The R plane is described to be below the final Z depth.
3) The final Z depth is described to end above the I or R planes.
Solution:
Check to see if the program has the correct positioning mode (G90 or G91),
and check for correct signs and decimal point placement.
Note: The H code might not be in the program.
Calculated Radius Error Of

This is a programming error possibly due to a G90 or G91 code missing, or
being in the wrong place. (EXAMPLE: Giving absolute positions while still in
incremental). Also, check the end point description, the beginning position,
and the arc center description (I, J, and K), or radius designation.
This message does not appear during the Auto mode. It appears when using
the SUM command (SU).
Cancel CRC Before G50.1 OR G51.1 AT N =

Before using CRC (G41, G42), mirror the desired axes (G51.1). Also, turn CRC
off (G40) before canceling mirror image (G50.1).
Cancel CRC Before N =

The control requires the G40 code to cancel cutter radius compensation before
the line number listed. See the cutter radius compensation section for
suggestions.
Cancel Z Axis Mirror Before Tool Change at N

The G50.1 code must appear on a separate line before the M6.
Cannot Return from Subprogram or Subroutine

Calling Line Cannot Be Found
This is a background editing error message. The line that called the
subprogram or subroutine was deleted or cannot be found.
Cannot Start Directly in a Subprog.

A mid program start must begin from the main program. If it is necessary to
start the program in a subroutine, the COPY command can be used to copy the
subroutine to the main program as many times as the subroutine will be
repeated. The programmer or operator can now do a mid program start to
where the subroutine was copied into the main program. After the part is
complete, delete the copied portion and run the program as before.

Another method to start the program in a subroutine is to use the AUTO

command. Enter AU,# (see AUTO command in the Operators Manual), where #
is a sequence number in the subroutine. The control will process the program
from the beginning of the program up to the number specified then start
execution of the program.
Char. Size or Depth Exceeds 2.5 In.

Characters that are higher than 2.5 inches cannot be engraved using the
Engraving mode (L9201).
Check Emergency Stop Switch and Motor Overload Relays

If the EMERGENCY STOP button (switch) is not pressed, it is necessary to check
the motor overload relays.
Power off the machine before checking fuses, relays, and circuit breakers. The
motor overload relays can be recognized by their white reset buttons. They are
located in both control enclosures. The white button must be pressed to reset a
relay.
Also, check the brake relay fuse (F17) to see if it is burned out. It is advised to
power off the machine when checking the fuses or motor overload relays.
Check Spindle Lube, Way Lube and Air Pressure

When this message is displayed, it is necessary to check the way lube level,
spindle oiler level, and the air pressure gauge. It is advised to check these oil
levels at least once a day.
Clear an Emergency Stop Condition

An emergency stop condition was invoked. To clear, press the JOG key. Wait 2
seconds for the amplifiers to be reset, then continue.
Command Error
This occurs because a SET (parameter) command was typed in improperly.
Refer to the Users Manual or use the menu of the control to help with any
command format. The following is a list of available SET commands: SETH,
SETX, SETY, SETZ, SETA, SETB, SETCS, SETTO, SETP.
Command Prohibited by the Key Lock

With the key lock in the horizontal position, editing commands (CH, CO, DE, IN)
cannot be used.
CRC Called With No Tool Assigned at N =

This happens when the programmer has turned CRC on without an H word in
the program.

EXAMPLE: Format 1:
N1 G41
N2 H1 This is incorrect.
N1 H1
N2 G41 This is correct for Format 1 only.
Format 2:
N1 H1
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 table.
D or H Too Large
The control maintains a table of 99 tool diameters and 99 length offsets. The
control will only accept H words and D words up to 99.
Data Transfer Fault

For this error, it is important to note which axis the transfer fault is on and
report it to the service department. Please note the error message number.
There is a data transfer problem between the 1030 card (slot 8) and the 1010
card for the stated axis.
DNC Mode
This message appears after DNC is typed at the control. The VMC is then ready
for DNC operation and is waiting for CNC code from the RS-232 port.
Door Began to Close While Arm was Moving

This message will occur if the door begins to close during a pallet change. The
feedback of the door may need adjustment or there may have been a drop in
air pressure.
Do You Want to Move to the Last Home Position?

This is not an error message but it appears each time the operator uses the CS
command and a home position is established (SETH) in memory.
Do You Want to Reinitialize Memory?

This prompt is accessed by reinitializing the memory via the RI command. A ‘Y’
response zeroes the memory of the CNC.
WARNING

All program data is deleted from memory. After the memory is reinitialized,
! a cold start must be performed.

Do You Want to Zero Tool Table?

response zeroes the tool offset table.
WARNING
! All tool diameter and length offsets are deleted from memory.
Do You Want to Zero Fixture Offsets?

response zeroes the fixture offset table.
!
WARNING
All fixture offsets are deleted from memory.
Dry Run Option ___ is in Effect

The selected dry run option (1, 2, or 3) is displayed prior to automatic
execution. See the Users Manual or the Run Time Menu for the appropriate
option definition.
Duplicate Name
No two programs in the library can be identified by the same number. When
copying an existing program assign an unused number to the new, or copied
program. Use option 2 (display program numbers) of the PR menu to
determine which numbers have been used.
Duplicate or Bad Prog. Name

This will occur if a program is being input through the RS-232 port and the
program has an O word in the first line that is a duplicate of an existing number
in the program library. Use option 2 (display program numbers) of the PR menu
to determine which numbers have been used. Change the O word to one not
being used, or remove it. Then send the program out to the control again.
If the program currently active in memory has an O word in the first line, the
program will be moved into the program library when the new program is
transferred through the RS-232 port. If the program currently active does not
have an O word in the first line, the program will be deleted when the new
program is transferred.
Dwell, Hit Start to Interrupt

This message is displayed when a G04 (dwell) is executed by the CNC. You can
interrupt the dwell time and continue program execution by pressing the START
key.

E Word May Only Be Used With G0 or G1 N =

Fixture offsets cannot be on the same line with a circular move (G2, G3).
Emergency Stop - Take Appropriate Action

An emergency stop has occurred. If the emergency stop button is depressed,
turn it clockwise until it returns to its normal position. Press the JOG button and
the message WAIT 2 SECONDS, THE AXES ARE BEING RESET. If this message
persists, call the service department.
The appropriate action to take:
1) Release the EMERGENCY STOP button if it has been pressed.
4) Press the JOG button which resets the amplifiers if the problem has been
resolved.
5) Type HO and press ENTER, then after the waiting message appears press
START (see note).
6) The operator may now resume the running of the part.
Note: It is not necessary to move the axes to their Cold Start position or
establish the part home again unless the message, JOG AXES TO HOME
POSITIONS, THEN ENTER THE CS COMMAND appears.
Enter Again or Hit Manual to Exit

This message comes up when inserting program coding at the keyboard (using
the IN command) or when in Manual Data (MD) and Change (CH) mode. It is
referring to the line just typed. Something was not acceptable, for example the
letter O for the number zero (0) or anything else not correct. The control is still
on the line with the problem, so retype the entire line.
Enter Command SETP and Set the Machine Parameters

The SETP procedure will ask questions regarding the machine and certain
preferences. If any of the questions are not clear, call the service department
for help.
Enter Command MU to See the Menu

This happens when a command is typed incorrectly. Either it is an
unrecognizable command or a comma was omitted.
This message is only a suggestion. It is not necessary to go to the menu to use

a command. The menu is there to remind the operator of the command format.

Error
This message is a program input error. It is displayed when a program block
containing an error is transmitted to the CNC via the RS-232. It appears at the
time the error is received. Therefore, list the program at the control to display
the last block of code received. The following block of code in the program,
which was not received, is in error. This normally is caused by back to back
alpha characters, which must be separated by numeric characters. Also, a 0
could be typed as an O.
Error in User Program, ‘SUM’ to See Message

See the Operator Manual for instructions on using the SUM (SU) command.
This message will occur when the control lists an error message in the Auto
mode, and the operator persists in running the program by pressing the START
or AUTO button. This message will appear when the line in which the error
exists is at the top of the stack of lines to be executed.
Error N Word Exceeds 99999

This error occurs when the sequence number is larger than 99999. The
sequence number must be between .001 and 99999.
Error While Processing Block

This is an indication that there may be a problem with the CPU board.
1) Send the machine back to cold start alignment markers.
7) Power off the machine’s main power, wait 15 seconds and power on the
machine.
8) Cold start then run the program again.
If this error repeats:
1) Save all the programs and offset information currently in memory. Write
down the present home position.
9) Send the machine back to cold start alignment markers.
10) Use the command RI and answer Yes (Y) to all the questions.
If the above does not work please call the Service representative in your area.
Error(s) Reading Tape

While the control is inputting a tape or program with the TA command, error
option 2, this message appears after input is complete. If the TA command and
error option 1 is used (TA,0,1 or TA,1,1) the input of the program would have
been stopped if an error in the program is detected.

If errors are detected, list the program and look for missing line numbers to find
which lines the control did not accept. Use the IN command to insert the
missing lines where needed.
File Overflow
This message could mean that the program has too many G codes and M
codes on the same line.
It could also mean that during CRC, there were too many blocks that the control
had to look beyond for the next compensated move (comment lines, Z moves,
G code and M code lines, and dwells).
This message may also appear if a fixed cycle is in effect when attempting to
initiate cutter radius compensation.
Fixture Offset Out of Range

This message occurs when an E word value in the program exceeds 48 or in
Format 2 exceeds G54 - G59 or exceeds E1 - E48.
Fixture Offset Must Be Applied With G0 or G1

Fixture offsets cannot be applied on lines with circular interpolation (G2 or G3).
G28 and G29 Used With Cutter Radius COMP at SEQ

Before the control can execute the codes G28 or G29, the program must turn
CRC off (G40).
G31 Used With an Incompatible Word or Mode

Only G1, P and F are allowed with a G31. No other codes are supported. CRC,
mirror image, rotation and drill cycles are not allowed during the execution of a
G31 code.
G45-G48 & G52 are Not Allowed With Rotation. N =

Codes G45-G48 and G52 are incremental offsets. Rotation can only be used in
the Absolute mode. Therefore, these codes are not allowed.
G91.2 is Not Allowed in Format 1

The machine is in format 1 with the G91.2 code in the program. The G91.2
code can only be used in format 2. In format 1 you must remain in the
Incremental mode when G91.1 is coded.
G92 Cannot Be Used in CRC Mode. N =

The G92 code should be used in a line before CRC is turned on. The code G92
can only be used after a G40 (G40 is a default code).

G92 Must Be Only G Code in Block

There can be no other G codes in the line with a G92. The program does not
need to be in absolute (G90) to use the G92 code.
GNN is an Unsupported G Code At N

The G code displayed is not a supported code of the FADAL CNC 88.
Helical Move Too Short, N =

(See error message HELICAL RISE TOO STEEP)
Helical Radius Too Small, N =

(See error message HELICAL RISE TOO STEEP)
Helical Rise Too Steep, N =

The radius of the circle and the helical rise are radically different in length
(usually the rise is much longer in comparison to the radius).
Also, depending on the programmed feed rate, the control may or may not be
able to handle the situation. Reducing the feed rate in the program usually
helps.
I, J or K Must Be Specified at N =
This message is displayed when an X, Y, or Z is used with an R0 without a G2
or G3. Full circles must use the direction around the circle and either the I, J, or
K. See the circular interpolation section for more details.
Illegal O Word
This error occurs during program input via. the RS-232. The O word must have
a value of 1 through 9999. No other character or symbol is allowed.
Illegal G Code During G91.1 Mode at N =

This message appears when an illegal G code is programmed while in G91.1.
See the Users Manual for acceptable G codes.
Improper Use of Canned Subr.

This message may appear for the following reasons:
1) No tool diameter in the tool table.
11) The programmer omits a required R word from the subroutine.
12) The programmer does not cancel a fixed cycle with a G80, G28, G29, M6,
G49, or H0 before using a fixed subroutine, except for L93 (bolt hole).
13) Using L96 - L99, if R1 variable is equal to the radius of the tool. The R1
variable is used for the radius on the corner of the tool (fillet radius), not the

tool radius. For example, a 1.0 diameter end mill with a .125 corner radius,
the R1 variable will be R1+.125, and the tool diameter entered in the tool
table will be 1.0.
14) The G41 or the G42 code has not been canceled with a G40 before using a
fixed subroutine.
Inches Mode Required - Operator Must Set

The CNC is in the Metric mode (SETME), and the program has a G20 or G70
code to verify that the control is in the Inches mode. To run this program, the
operator must set the CNC to the Inches mode by entering the SETIN
command.
Incompatible G Codes at SEQ

Some codes, even though they are modal and from different groups (families),
are incompatible with one another. Break up the grouping of G codes on the
line by moving some of them to the line just before or after the line they are
presently on. This message is also displayed when any G code is on the line
with a G53.
EXAMPLE: N20 G1 F20.

N21 G8 G41 X.5 The G41 and the G8 are incompatible.
Move the G8 to the line with the G1.
N20 G1 G8 F20. This is correct.
N21 G41 X.5
Increment Divided By Two

If renumbering causes a line in the program to be greater than 99999, the
increment for renumbering is divided by two and renumbering is resumed.
All the lines or program blocks must have sequence numbers. The NU
command is used to renumber the lines in the program by the increment
specified in the first parameter. For example, entering NU,5 will renumber the
lines, incremented by five. If program is large, renumber by 1.
Increment Too Large

This occurs when the increment parameter of the program input (IN) command
causes the sequence numbers to exceed 99999 or a typing error in the
program has given a value too large. Example: X-123456789.
Increment Too Small

This alarm occurs when the increment parameter of the program input (IN)
command is less than .001 Example: IN, 0.00001

Input Xmodem Transmit Block Missed Error

This occurs when a packet has been missed or came out of order during
XModem transmission.
Jog Axes to Home Positions, Then Enter the CS Command

This message appears at power on. If the axes are at the Cold Start position
(machine home), enter the CS command. The operator needs only to jog the
axes if they are not at the Cold Start position.
This message also appears when the tool changer crashes and the AUTO
button is pushed or the MD command is used. However, the operator does not
have to jog to Cold Start. Use the SETCS command to reference the Cold Start
position, then enter HO to return the axes to home, and when the axes are back
at the Cold Start position, visually check, and enter the CS command.
SETP will also make this message appear. If the operator used the SETP
command at the part home, handle the situation in the same way as suggested
for a tool changer crash (see above).
Look Ahead Was Canceled By Operator

This indicates the NO LOOK AHEAD buffer option of the Run Time Menu has
been selected. The CNC processes only one block at a time, while displaying
only two blocks of the program on the screen. This option can be selected or
canceled using the Run Time Menu by typing MU in the Automatic mode.
M, S, T Lockout is in Effect
This message indicates the M function, Spindle, and Tool change lockout
option of the Run Time Menu has been selected. In this mode, M function,
Spindle or Tool Change commands will not be performed during Dry Run. This
option can be selected or canceled using the Run Time Menu by typing MU in
the Automatic mode.
M Function Too Large at N =

M functions cannot exceed a 2 digit value. See the Users Manual or the menu
(MU) for a list of the accepted M functions.
Main Prog. Not Found

This is a programming error. There are subroutines written in the beginning of
the program without an M30. M30 is used to separate the subroutines from the
main program. Insert the M30 in the proper place. See the Users Manual for
the accepted format for subroutines.
The M30 code on the first line of the program and a subroutine heading (L100)
on the next line will also cause this error message to appear.

N1 O1 (START OF PROGRAM
N2 (ACCEPTABLE PROGRAM EXAMPLE)
N3 L100 (SUB #1)
N4 X1.
N5 *
N6 L200(SUB #2)
N7 L105
N8 M46
N9 X-5.Y-1.
N10 M47
N11 *
N12 L300 (SUB #3)
N13 G91
N14 L204
N15 L104
N16 G90
N17 *
N18 M17 ——— This ends the last subroutine.
N19 M30 ——— This separates the subsection from the main program.
N20 *
N21 (MAIN PROGRAM)
Memory Error, Reload Program

This is a memory error. Turn the machine’s main power off. Then power on and
reload the program. If this does not work, save all the programs in the memory
(PU,3) and use the RI command, answering Yes (Y) to all the questions. After
using the RI command, load the programs back into the control.
Memory Error, Respond With Y to Delete Bad Blocks

There is a possible hardware problem when this message appears.
If the operator answers Yes (Y) to this question, the control may delete some of
the program in memory. Answer Yes (Y) only if the program in memory can be
replaced (if the program is stored on paper tape or on computer disk). Answer
No (N) if the program needs to be saved.
Turn the machine’s main power off. Then power on and reload the program. If
this does not work, save all the programs in the memory (PU,3) and use the RI
command, answering Yes (Y) to all the questions. After using the RI command,
load the programs back into the control.
If this does not help, call the service department.

Metric Mode Required - Operator Must Set

The control, at power on, is in the Inches mode. The Metric mode must be
turned on by using the SETME command.
This message will appear if the G21 or G71 code is present in the program to
verify that the Metric mode has been turned on by the operator.
Motor Overload
This is an indication that something has stalled or overheated a motor, and is
associated with an emergency stop (see EMERGENCY STOP).
Move Exceeds Axis Limit at N =

Check Program and Tool or Fixture Offsets
The most common reason this message appears is because of either a missing
or an extra G90 or G91 code. This message will appear only when the control is
in the Auto mode or Manual Data (MD) mode. This message will not appear in
the Sum mode (SU).
When the control is executing the program, processing of the program is ahead
of the current line that is being executed. If, while processing the program, the
control detects an over travel situation, execution of the program will stop
immediately.
The setup person may have to consider moving the fixture to another location
on the table. The program may be correct but the fixture is set up incorrectly.
The programmer can provide information to the setup person, indicating how
close to the axis limits the fixture can be located.
Move Turret to Tool 1 and Enter SETTO Command

When this happens, the head will be above the tools in the turret, with the turret
ready for loading. Move the turret using the turret CW or CCW buttons so that
the tool designated to be tool #1 is under the spindle, and remove tool #1 from
the turret. Press the JOG button. The head will stay where it is (4” above the Z
axis CS position), and the turret will move back to its home position. Now use
the command SETTO to establish this turret position as #1. Use the HO
command or jog the head down to the Z axis CS position. Next use the
command TC,1 to reopen the turret. Replace tool #1 in the turret and press the
MANUAL button to bring the head down over tool #1.
Next Entry is Out of Range

This message is displayed by entering pitch error compensation for the ball
screw when an entry exceeds the maximum allowable difference of 9 (See
Survey command in the Axis Drive Systems Section). For example, if an entry
is 15 and the next consecutive entry is 0, the difference is greater than 9.

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 O Word

If program coding is used on the first line of the program along with the O word,
this message appears. A comment is allowed with an O word and is used to
identify each program in the library. The first sixteen characters of this
comment are shown when the program library menu displays the programs in
memory.
EXAMPLE: N1 O1 G0 G90 (P/N 1234) — This line is incorrect.

N1 O1 (P/N 1234) — This line is correct.
N2 G0 G90
No Parameters or Parameters Corrupted

Machine Defaults Used
This message occurs most commonly after the memory has been zeroed from
the DI diagnostics mode. This will also occur if there is a memory error. Enter
the machine parameters with the SETP command. The parameters to use are
usually found recorded on a check off sheet on the inside door of the pendant.
No Response From Axis

This happens when powering on the machine and the CPU (1400) does not get
a response from the axis controller (1010).
If this message appears for the X, Y, Z, A, or B axes, power the machine’s main
power off and then on again. If this does not help, call the service department.
No Touch or Incompleted Point at N =

The move that causes the probe to touch the part was completed without a
touch. Increase the length of the move so that the probe touches. Also, you
must activate the selected probe by coding an M64 for an MP8 probe, or an
M65 for a TS20.
Note Error Then Hit Manual

When the programmer is inputting a program through the RS-232 port (using
the command TA,1,0 or TA,1,1), the input will be terminated if the control
detects a bad programming word (EXAMPLE: O for 0, or double letters (XX1.5),
etc.).
The programmer will have to edit the program at the computer or Teletype
before inputting the program again.
The control will ignore all errors in the program and continue input by using the
error option 2, with the TA command (EXAMPLE: TA,1,2). An error count is
given at the end of transmission. If there were errors detected, list the program
to find missing line numbers. If the lines are numbered in sequence before
transmission of the program, look for the numbers that are out of sequence.
After the numbers have been located use the IN command to insert the
missing lines.
Number Out of Range

This message appears when a number of twelve digits or greater is typed in.
This error may be detected by the machine after making a calculation. The
calculated number may be out of range. Macro calculation less than .0001.
Offset Entry Error

This message is displayed using the Utility (UT) command, by pressing the
MANUAL key when the CNC prompts you for a tool diameter. It is also
displayed by entering a diameter value that is too large.
Only Block Skip Allowed With Macro

The only non macro command allowed with a macro line is the block skip
character.
Only M3, M4 & M5 Are Allowed With M6 at N =

This message appears when the M6 is coded with an M function other than an
M3, M4 or M5. The unacceptable M function must be moved to another line.
Only Z, L, R & F Words Allowed

This message appears when the programmer uses the fixed subroutine L9201
for engraving, and has programmed other words in the line with the L9201
other than Z, L, R, and F.
Orientation Failure
Visually check the air pressure, it must be between 80 and 90 PSI. If this
problem persists call the service department.

Out of File Space, a File Compression is Being Tried

This message informs the programmer that the memory of the control is
almost full. It usually is displayed when editing the active program in memory,
or during program input via the RS-232. This does not destroy any portion of
the program. A file compression organizes the memory so that unused portions
are made available. The NE command will perform a file compression before
prompting you with a (Y or N) to delete the current program. Also, a file
compression is performed by deleting the current program using option 5 from
the PR menu.
It is always best to retry the command that caused this message to appear.
After the compression, the command will often work the second time.
If unwanted programs are stored in the program library, remove them to create
more room in memory. If there is only one program in memory, try to reduce
the size of the program by removing unnecessary comments and making full
use of all modal codes. Create subroutines for repetitive portions of the
program wherever possible. The program may have to be broken up into
separate operations.
The standard memory capacity is an equivalent of 277 feet of paper tape.

FADAL distributors have a memory expansion board available that increases
the memory capacity to 1205 feet of paper tape.
O Word Out of Range

This occurs using the program input (IN) command when typing an O word
greater than 4 digits. O words must be an integer of 1 through 9999.
Pallet Disabled in Parameters

This message occurs when a pallet changer command or code is used and the
SETP parameters indicate no pallet changer exists on the machine.
Pallet in Storage
This message occurs when there is an attempt to store a pallet where a pallet
already is stored.
Pallet Not Fully Stored

This message occurs when the time to store a pallet exceeds the allotted time.
The feedback on the arm may need to be adjusted. Call the service department
for assistance.

Pallet Must Be Clamped

This message occurs when both pallets are in storage and a command is give
to make a pallet change. One of the pallets must be loaded and clamped on
the table before a pallet change can occur. The feedbacks for pallet loaded and
pallet stored are being read at this time.
Parameter Error
After a command is entered and a comma is typed, the control is expecting a
parameter. If a parameter is not typed before pressing the ENTER button, this
error message appears.
EXAMPLE: AU, — This is a parameter error.
Note: If the operator is not using a parameter, for instance, the second and
third out of a possible four, the parameters can be omitted when the fourth
parameter is typed in.
EXAMPLE: AU,50,,,1 — This is acceptable.
Also if the DE command is used to delete a line that does not exist, or the CO
command is used to copy lines that do not exist, this message appears.
Parity Error
This message appears during input through the RS-232 port and is caused by
several factors.
1) Unshielded cable is used, and the cable is subject to electrical noise.

15) The baud rate is too fast for the length of cable used.
16) There is a failure in the RS-232 port (hardware problem).
17) There may be a problem with the computer that is sending the program.
Parity Error During DNC

This occurs during DNC transmission of data. (See the error message PARITY
ERROR)

Please Put an O Word at the First of the Current Program

The Following Programs Are in Memory
To use the PR command, the active program must have an O word and a
number in the first line. The number must be different than the other numbers
in the program library. This is why it lists the other programs in memory.
EXAMPLE: N.1 O43 (P/N 34-765) 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 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.

Program Does Not Exist

Retry or Hit Manual to Exit
This happens when the selected program number does not exist in the
program library. Enter a program number that does exist, or press the MANUAL
button, and then use the PR command again to display the programs that are
stored in memory (option 2).
The programmer may have put an O-1 or an O.1 as a program number. The
number will show up when the programs are displayed in the library but the
control will not be able to retrieve the program. If the operator uses the PU,3
command and presses the EMERGENCY STOP button when the lost program is
being displayed on the screen, that program is now active in memory and can
be edited. Delete the bad O word, from O-1 or O.1 (which appears as 1000
when it is listed in PR) to O1.
Program Not Found

This message is displayed when the PA command is used to display the active
program, and no program is active. Use the PR command to activate the
desired program stored in memory.
Program Block Not Found

This message is displayed when the LI command is used to list selected blocks
of the active program, and the selected blocks are not found or the program is
not active. View the program by using the PA command.
P Word Too Large

The P word for referencing a line number using M99 is too large of a value. Line
numbers can not exceed 99,999.
Reset the Emergency Stop Switch

The EMERGENCY STOP button has been pushed. Turn the button clockwise
until it is released and then push JOG.
Resolver Fault or Scale Error

This message may occur in three cases as follows:
1) A failure of the resolver.
18) An axis runaway during power on.
19) A large Scale or Motor error, indicating a possible scale failure.
! IMPORTANT
Report this to the service department when this message appears. Do not run
the machine when this message appears.

Rails Not Aligned

This message occurs when the rails for the pallet changer are not aligned or
the feedback switches need adjustment. Call service department for
adjustment.
Return Pallet to the Load Position

This message occurs when a pallet change is attempted and the other pallet is
away from the load position. The operator must slide the pallet into the load
position before the other pallet on the table can be changed. The feedback
from the pallet loaded and pallet stored are being read at this time.
Rotary Axis Move Too Long. N =

The maximum incremental rotary move for one block is 1080.00 degrees. If it
is necessary to go further, break up the move into several blocks.
RS-232 Error During DNC

This error only occurs during DNC operations. It may occur while using 9600
baud to DNC. Slow the baud rate.
It may also indicate line noise or the possibility of dropped characters. These
would indicate a possible problem with the RS-232 cable or the
communications port. Check the cable and communications port and retry
DNC.
A failure of the CPU may cause this error also. If the above corrections are
unsuccessful, contact the maintenance department.
Scale Error
A scale error has been detected. The LEDs in the scale interface box in the
back of the machine will indicate which axis gave the error. Call the service
department.
See Menu for New CD Format

The CD command is different for some versions of software. See the menu for
these changes.
Sequence Number Too Large

This occurs using the Program Input (IN) command when the ‘From’ parameter
is specified greater than the maximum allowable number. Sequence numbers
can not exceed 99,999.
Sequence Number Too Small

This occurs using the Program Input (IN) command when the ‘From’ parameter
is less than the minimum allowable number. Sequence numbers can not be
less than .001.

Servo Amplifier Fault

This message appears when the EMERGENCY STOP button is pressed. The
operator must pull the button out (for ‘85 and older models) or turn it clockwise
(for ‘86 to present models) and then press the JOG button to reset the
amplifiers. If the amplifiers do not reset, call the service department.
Single Step
This message identifies the control is in the Single Step mode. Should the
green START button be pressed when in this mode, the following program
block is executed.
The feed rate potentiometer affects all axis motion.
At the end of each block, the operator can press the JOG button and jog away
from the current position without aborting the operation. Program execution
can be continued at the new location, or the axes can be returned to the
position at which the Jog function was initiated.
To exit single step, press the AUTO button for continuous block execution.
Slide Hold
Pressing the SLIDE HOLD button stops all axis motion. The distance to finish
the move is presented under the blinking SLIDE HOLD message.
It is possible to press the JOG button and jog away from the current position
while in the Slide Hold mode without aborting the operation. Program execution
can be continued at the new location, or the axes can be returned to the
position at which the Jog function was initiated.
To exit from the Slide Hold mode, the operator must press the START button, if
in single step, or press the AUTO button for continuous block execution.
Spindle Controller Does Not Respond

Please note error number and see list at the end of this chapter. This simply
could be a problem that occurs when the operator is powering on the machine.
Turn the machine’s main power off. Press the motor overload relay button, and
then power on again. If this does not help call the service department with the
error message and number.
reset a relay. Call service department first.

Spindle Controller or Driver Fault

Please note error number and see list of Emergency Stop Error Messages at
the end of this chapter. This message is displayed if the spindle was
commanded to turn on after an emergency stop without pressing the JOG
button to reset the amplifiers.
If this message appears when not in the Emergency Stop mode, please take
these steps to help the service department analyze the problem:
1) Look at the air pressure gauge and write down the current air pressure (do
not change it at the machine!)
20) Check to see if the belts are on the pulleys.
21) Do not turn the power off.
22) Call the service department and report this problem (while the machine is
on).
Spindle Controller Software Update is Required

The current software module (1610) detected spindle software that was not
compatible. Call the service department.
Spindle Driver Fault

This is the result of the air pressure being too low while the spindle is on. Air
pressure should be set between 80 and 90 PSI. Visually check the air pressure
and start the program over again. If the air pressure is not the problem, power
off the machine and check the motor overload relays to see if they have been
tripped.
reset a relay.
Spindle Failure While Tapping

If the spindle stops while in G74, G75 or G84 modes, this message will appear.
Problems such as a dull tap, undersized hole, poor tapping lubricant or a
shallow hole must be eliminated. The programmer may want to consider
thread milling as an alternative to tapping. Call the service department if this is
persistent.

Spindle Failure During Reversal

This will occur when an M3 and an M4 are in the same line. If the spindle stops
while in G74, G75 or G84 modes, this message will appear. Problems such as
a dull tap, undersized hole, poor tapping lubricant or a shallow hole must be
eliminated. The programmer may want to consider thread milling as an
alternative to tapping. Call the service department if this is persistent.
Spindle Has Failed to Turn On

Either the Hall Effect Switch on top of the spindle pulley has not recognized that
the spindle is turning, or the spindle actually has not turned on and there is
another problem. Call the service department.
Spindle Fault Line

The spindle inverter has detected a fault. See the fault number on the inverter
and report this to the service department.
Spindle Motor Temperature Fault

Check to see if the spindle fan is on. If it is not, turn machine’s main power off
and check the fuse for the spindle fan (F24). Allow time for the spindle motor to
cool down and attempt to run the machine again. If this message persists, call
the service department.
Spindle Would Not Stop

The spindle would not stop in the designated amount of time (12 seconds). If
this message is persistent, call the service department.
Stack Overflow
This message should be reported to the service department. It is caused by
excessive stacking of keyboard commands.
Subr. Does Not Exist

This message indicates that a subroutine was called that is not in the
subroutine section of the program. Check to make sure that the subroutines
were numbered properly.
This message also appears if the G66 code is used on a line that does not have
a subroutine call on it.

Subr. Nesting Error

This is a message that occurs when a subroutine heading (L0100) is entered
after the M30 code. This message will also occur if a Fixed Cycle is still active
(use a G80 to cancel) or G68 (rotation) is still active when a tool change or end
of program is coded (use a G69 to cancel).
EXAMPLE: N20 M17

N21 M30
N22 L200 This is not permitted after an M30.
Tape Input Terminated

This message reports to the operator that the tape or program input process is
complete.
Tape is Good
When verifying a punched tape, this message appears if the tape is accepted.
This message also appears if no errors are detected in transmission when the
TA command is used.
Temperature Fault
For any temperature fault, the operator must check the cooling fans; if they are
not operational, turn the machine’s main power off and check the fan fuses
(F23, F24, F27, and F28).
If this message is persistent, call the service department.
Temporary Conflict With Auto

This message occurs when background editing is being used. The edit just
made is in the area where auto is currently executing from. The change will be
made when auto is out of that area.
The Axis Controller is Not a 1010-4

(See Survey in the Axis Drive Systems Section)
The Survey Contains Errors, Please Review

The Survey Was Not Written to the Axis Controller

There is No Survey

Thread Lead Not Specified at N =

Fixed cycles G74, G75 and G84 need a Q word in the line that represents the
decimal thread lead of the tap (see the Users Manual for the proper format). If
the Q word is omitted this message will appear.
If the programmer uses the fixed cycles G74, G75 or G84 and does not cancel
the cycle with any of the following codes: M6, G28, G29, G49, G80, H0, this
message will appear at the next Z move.
Too Many Blocks For Gap

This happens when the CO (copy) command is used and there are too many
lines being copied between existing lines in the program.
Use the NU (renumber) command and copy again, now that the program is
renumbered.
Too Many M Functions at N =

This error occurs when another M function is coded with the M17 or M30.
These two codes must be the only M function on the line.
Too Many Consecutive Non Motion Blocks

This error message appears if a program contains over sixteen consecutive
comment blocks (with no program coding in the lines).
A solution to this is to put coding between the comment lines or put comments
on lines with program coding. This way the program can have comments on
every line.
Comment blocks in the beginning of the program can be placed in an unused

subroutine. This way the control never reads the lines when executing the
program, but the operator can list the program and read the comment lines.
Too Many Parameters

Commands have associated with them a certain number of parameters. If
more parameters are typed in than allowed, this message appears.
EXAMPLE: AU,50,,,1, or AU,50,,,3,1
Refer to the Users Manual, or the Menu (MU) on the control for the correct
format of each command.
Too Many Subr. Calls

Nesting can only be seven deep. If the program goes further than seven deep,
this message appears.

Tool Breakage Detection = Failure at N =

When the TS-20 touch probe is used for tool breakage detection, this error
indicates the program line that the broken tool is detected at. Replace the tool
and continue the program.
Tool Diameter Too Large at N =

This is displayed in cutter radius compensation when the programmed move is
smaller than the radius of the cutter.
1) Check the tool diameter entered in the tool table to see if it was entered
correctly.
23) Check the program to see if it contains any typographical errors.
24) If the intention was to make a rough pass using a larger tool diameter than
the finish pass tool diameter, the smallest programmed inside radius, on
the part, should be as big as the tool radius (half the tool diameter) entered
for the roughing pass.
25) Check the math work to see if it is correct, and was transferred correctly to
the program.
When debugging a program that uses cutter radius compensation use a zero
diameter in the tool table when running the program or when using the SUM
command for the first time. Then put the tool diameter in the tool table and try
it again. This will make the debugging process easier.
Tool Offset Not Allowed During Z Mirror

If mirroring the Z axis is desired, first call up the tool length offset, then code
the G51.1 Z0. The H word must be on a line in the program before the G51.1
Z0.
Tool NN is in the Spindle

Identifies the current tool that is in the spindle. This is displayed when entering
the program execution (AU) and the Manual Data Input (MD) modes, and is
also listed in the tool table display (DT).
Tool Number Too High

The starting tool number of the utility (UT) tool setting cycle must not exceed
that of the tool changer capacity.
Tool Turret Location is Not Set

Rotate the tool turret so that tool #1 is adjacent to the spindle and then type
SETTO.
Transfer Error, Please Retry

(See Survey command in Maintenance Manual)
Trouble Reading the External Slide Hold Switch

The feedback from the external slide hold switches is erratic or inconsistent.
This is an indication that the external slide hold switch system is faulty. Call the
service department.
Type A Y To Ignore, Or Turn Power Off And Then On Again

This error message appears only after the message AXIS CONTROLLER DOES
NOT RESPOND DURING POWER UP SEQUENCE.
This is an indication that there is a communication problem between the CPU

and the axis controller. Call the service department.
Undefined Macro Error

This message will appear when situations during a macro execution cause the
system to fail, but there is no specific error or message associated to the
situation.
Wait 2 Sec., The Axis Drivers Are Being Reset

This message occurs when the JOG key is pressed after an axis fault. The
control returns to the Command mode after 2 seconds. The axis drivers are
reset and the machine can continue normal operation.
Waiting
In the Waiting mode, the operator has the choice of pressing either the START
or AUTO button to execute automatic motion. Or, the operator can press the
MANUAL button to exit to the Command mode.
Waiting On Air Valve

When this occurs, the control is waiting on a signal from one of the air valves
indicating that the valve has completed its job - usually air pressure to the
machine has dropped below 80 PSI.
If this message persists, call the service department.
Warning Possible Gouge at N =

Generally caused by math errors in the program. The CNC has processed a
move that possibly could cause the cutting tool to damage the part. The error
usually is not large enough to make any noticeable difference on the machined
part. Therefore, only a warning is displayed. If there is a noticeable difference,
review your program math.
Way Lube Pressure Switch Failure

Check the way lube oil level if this message appears.

Writing Error, Wait 2 Min. and Retry

(See Survey in the Axis Drive Systems Section.)
X, Y, or Z Move Must Be Specified at N =

Probe function #1 (L9101) has been programmed without an axis specified for
the given plane. For example, if probing is to be used in the XY plane (G17), X
and/or Y must be programmed in the same block as L9101 R1+1. Z can be
used if in the ZX (G18) or YZ (G19) plane.
You Cannot Delete the Program That is Currently Active

To delete a program in memory, it must be in the library. Use the PR command
and switch the program currently in memory with a program in the library. The
program can then be deleted. If there are not any programs in the library, use
option 3 to start a new program. This will put the currently active program in
the library and the program can then be deleted.
Or just simply use the DE command and delete starting from the first block in
the program to the last.
You Have a Version Upgrade or Memory Has Been Corrupted

Memory Needs to Be Zeroed
This occurs when the control detects that a new module has been inserted. See
the Maintenance Manual for proper zeroing procedures. This may also occur
because of a memory error and the memory needs zeroing.
You Must Enter the Backlash Table

The CNC does not have a valid backlash table. Enter the backlash for each axis
by using the BL command. The backlash set at the factory is documented on
the inside surface of the pendant door.
The backlash information is retained by the battery backed memory card. If this
message appears again, after the BL command has been used, call the service
department.
Your Version of CNCMAIN Needs to Be Updated

The control has detected an incompatibility with the CNC memory manager
software on the 32MP pendant. Call the service department for an update.
Z, Q, or F Missing in Canned Cycle Call, N =

See the Users Manual in the fixed cycle section for the proper format for each
fixed cycle.

Z & M6 Lockout is in Effect

This message indicates the Z axis and Tool Change Lockout option of the Run
Time Menu has been selected. In this mode, Z axis movement and tool change
commands will not be performed during Dry Run. This option can be selected
or canceled by using the Run Time Menu.
Z Axis Must Be at Cold Start for TC,1

Check to see if the Z axis alignment was properly set at cold start. The operator
cannot use the TC,1 command unless the Z axis is at the Z axis CS position.
Use the HO command or jog the axis to the Cold Start (Z0).
If the SETZ command has been used, first use the HO command to bring all
axes home, then enter the SETCS command. Jog the Z axis to Z0 and then use
the command SETH so the X and Y home position is not lost. The TC,1
command can now be used to open the tool changer. If necessary return the Z
axis to the previous setting and use the SETZ command.
(See the error message JOG AXES TO HOME POSITIONS if the tool changer
crashes).
Emergency Error Error numbers help discern the location of the problem the axis or spindle is
Codes 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.
Error Numbers From [ 1 ] NO MOTOR FEEDBACK

the Axis or Spindle This error appears during power up, when no motor feedback (either resolver
Controller or encoder) is detected by the axis controller.
[ 2 ] ENCODER NOT RESPONDING

This error appears during the rigid tap operation. If the encoder feedback is
interrupted during the spindle operation then the spindle operation is halted.
[ 3 ] LOGIC JUMPER INCORRECT OR COMMAND SIGNAL MISSING OR

MOTOR-TACH CONNECTION INCORRECT
This error appears during power up. An incorrect motor—tach—jumper
configuration or failed component may cause the axis to run away in the
opposite direction of the command signal. Axis operation is halted.
[ 4 ] ENCODER IS NOT 1024 LINE

This error appears during power up, and only applies to axes with
encoder(1024 line) as motor feedback. The axis controller will count the
encoder lines in one revolution of the screw and compare it to the expected
count of 1024

[ 5 ] NO INDEX MARK DETECTED

This error appears during the cold start process, if the index mark of the axis
primary feedback device, encoder or scale, is not detected.
[ 6 ] SWITCH 1 DISABLED
Currently not used.
[ 7 ] RIGID TAP PRECYCLE ENCODER COUNT PROBLEM

This error appears during the rigid tap precycle process, when the spindle
feedback is not within tolerance.
[ 8 ] SPINDLE MAGNET NOT DETECTED OR SPINDLE NOT TURNING

This error appears during spindle operation if the spindle magnet is not
detected for any period longer than 3 seconds.
[ 9 ] SPINDLE FAULT LINE DOWN

This error appears any time the axis card no longer detects the fault line signal
from the inverter, or the signal strength has dropped below 10V, indicating a
possible inverter fault.
[ 10 ] ENCODER AND MAGNET NOT RESPONDING OR SPINDLE NOT

TURNING
This error appears during spindle operation if both the encoder feedback and
the spindle magnet are not detected for any period longer than 3 seconds.
[ 11 ] FOLLOWING ERROR CANNOT BE SCALED FOR COMMAND SIGNAL

This error appears when the signal strength of the following error, after scaling,
exceeds the maximum allowable command signal.
[ 12 ] MOTOR OVERLOAD — STEP COMMAND CHECKSUM ERROR

This error appears at the completion of a move, when the actual move by the
axis controller is not equal to the move commanded by the CPU.
[ 13 ] MOTOR OVERLOAD — FOLLOWING ERROR > OVERLOAD FACTOR

This error appears when the following error exceeds the overload factor, which
is a user-defined parameter that sets, in motor turns, the maximum allowable
following error for the axis operation.
[ 14 ] MOVE TRANSFER FAULT — BUFFER INDICATOR NOT SET

This error appears prior to executing the first step command of a move
command, if the flag indicating completion of the move transfer process is not
set.

[ 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 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


[ 25 ] MOTOR OVERLOAD DURING CONTOURING MODE

[ 26 ] MOTOR OVERLOAD DURING JOG MODE

Troubleshooting
Checklist RS-232
Commmunications Use this procedure to determine which device or cable is not functioning
properly. At the end of each step check to see if communications are possible.
If no
communications
occur:
1. If a switch box is used, determine that the switch is in the proper position.
• Turn the switch handle back and forth a few times. Sometimes the con-
nections are corroded and turning the handle will TEMPORARILY correct
the problem.
2. Check to see if all cable connections are firmly connected.
• Loose cable connections are the MOST COMMON cause of communi-

cations failures.
3. 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.
• The phone modem WILL interfere with communications through the

RS-232 port.
4. 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.
5. Check to see if the communication parameter settings in the software of the

computer are set properly.
a. Baud rate - This is variable, depending on the default setting at the

machine established in SETP or with a CD,# command
• Sometimes a computer can communicate at the lower baud rates (600

or 1200) and not at the higher baud rates (2400 - 9600). The customer
should try a lower baud rate as a temporary solution.
b. Parity - Even

c. Data Bits - Seven
d. Stop Bits - One
e. EOB (End Of Byte) - CR,LF (ASCII 13,10)
f. Starting and ending character - % (ASCII 37)
g. Xon/Xoff (Software handshaking) - disabled for TA or PU, enabled

for DNC
h. Hardware handshaking - disabled
i. The IO port number (RS-232 or serial port) on the computer must

be identified (i.e.,COM 1, COM2. COM3 or COM4).
6. Determine that the IO port on the machine is functioning properly. Exercise

the port by putting a mirror plug in the port and sending a character out.
which should then be received back again.
• The mirror plug, found in the control cabinet of the machine, is a DB-25
plug with pins 2 and 3 crossed, and is usually shipped with the
machine. or can be ordered from our parts department.
a. Put the mirror plug in the RS-232 port of the machine.
b. Move to the cold start position and go into the diagnostics mode.
c. From the command mode type DI then press the enter button.
Then type GO 3000 (G zero, space, three thousand) then press the
enter button. A menu will appear, then select number four by
pressing the 4 button. A second selection will appear. Select the
baud rate that is desired for the test by pressing one of the 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
S100 board and cable if needed. Note: It is our experience that the
S100 board and inside cable rarely need to be changed.
f. This test can be repeated with each section of cable plugged into
the machine leading up to the computer. This will test the integrity

of each section. A gender changer may be needed to plug in the

mirror plug in some sections.
• If a switch box is used in the chain of cables, it must be checked also.

Check it in the same manner that the cables were checked.
7) After thoroughly checking the machine and the cables it can be safely
concluded that something in the computer is at fault.
• Introducing another computer into the line of communication is a quick

way to determine if the computer in question is faulty.
a. A mouse or network board. screen savers, and other software run-

ning concurrently 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.
b. The output voltage of the IO board across pins 7 and 12; when
transmitting a program, should be between 10 and 12 VAC.
c. The file being sent may have something wrong with it. Incorrect
syntax in a line of code may interrupt transmission.

Troubleshooting Charts Chart 1 Quick Checkout

Chart 2 Automatic Tool Changer
Chart 3 Spindle Driver
Chart 4 Axis Control
Chart 5 Repeatability
Chart 6 Computer
Chart 7 Axis Motor Runaways
Chart 8 Baldor SWEO Spindle Drive
Chart 9 Z200/Z300 Spindle Drive
Chart 10 Keyboard
Chart 11 Finish Problems
Chart 12 Bad Power / Bad Voltage
Chart 13 Rotary Heads A Axis
Chart 14 FADAL TR65 Rotary Heads A & B Axis
Chart 15 Tsudakoma 301 Rotary Heads A & B Axis
Chart 16 Servo Coolant Control
Chart 17 Circle Roundness
Chart 18 Error Codes Reported by Axis Card
Chart 19 Serial Port Communications
Chart 20 FADAL Servo Indexer
Chart 21 Positioning Problems
Chart 22 Scale Problems
Chart 23 Rigid Tap
Chart 24 M-Function

CHART 1 DA S H ED S YM B O L S
AP PL Y TO C E N OR M
Q U IC K C H E C K O U T P R O C E D U R E EU R O P EA N M AC H IN E S
9- 2 0 -9 5 ONLY
Q U IC K C H EC K OU T
DIF FIC UL T T O D IA GN O S E P RO B LE M S C A N O C CU R IF M AC H INE IS N O T P R OP E RL Y G R O UN D ED .

TH ER E MU S T B E A CO N TIN U O US G RO U N DIN G CO N D UC TO R (AS S PE CIF IED O N T H E G R OU N D IN G LA B EL
IN TH E M AC H INE 'S D IS CO N N EC T B O X) F RO M TH E VM C 'S GR O U ND BU S TO TH E GR O U ND B US IN T HE
BU ILD ING 'S P OW E R DIS TR IB UT IO N P AN E L.
PR OP ER AIR PR E SS U R E AN D A D EQ U ATE A IR V O L U M E IS C RI TIC A L FO R TO O L C HA N G E S.

AIR PR E SS U R E RE G U L A TOR O N MA C H IN E M US T BE S ET AS L A BE L ED (8 0 - 9 0 PS I A N D
IS TH ER E NO CO R R EC T AIR 12 0 PS I F OR TOO L O U T R EG U L A TO R ) . AIR SU P PL Y TO MA C H IN E S HO U L D BE 1 2 0 P SI .
AIR PR E SS U R E?
PR E SS U R E AIR HO SE TO M AC H IN E M US T BE 3 /8 " AN D A S S HO R T A S PO S S IBL E .
(8 0 P SI ))
AIR DI ST RI BU T IO N P IP E IN B UI L D IN G S H O U L D B E A M IN IM U M OF 3/ 4 ".
TH E PR E SS U R E DR O P A T TH E MA C H IN E D UR I N G A TOO L C H AN G E S H O U L D B E A
1. 1 YE S 1. 1 .1 MA XI MU M O F 3 -5 P S I.
CH E C K + 5 V, +1 2 V , -1 2 V , SE T M ET ER F O R
AN D 1 1 0 V AC VA C AN D CH E C K FO R NO SE E
AC R IP P L E O N IS
AT PO W ER S U P PL Y ( 12 2 0 ) CH A R T
+5 V , + 1 2 V A N D - 1 2 V D C PO W ER O K?
(U S E O SC IL L O SC O P E NO . 1 2
(0 .01 5V AC R IP P LE M AX O N + /-12 V,
IF A VA IL A BL E ) 0.00 5V AC R IP P LE M AX O N + 5V )
1. 2 .2
1. 2 1. 2 .1 YE S 1. 2 .3
VE R IFY MA KE S U R E CH E C K D OO R S . CH E C K
YE S CH E C K CH E C K
PU L S E L E D 's FEE D R A TE (C E MA C H IN E S CI R C UI T SE E
IS IT A N A XI S EM ER G E N C Y MO T O R
O N A LL IS N O T L IM IT M O V EM E NT BR E AK ER S CH A R T
PR O B L EM ? STO P O VE R L OA D
AX IS BO AR D S AT 0 % W H EN D O O R S (C E NO . 4
BU TT O N RE L A YS
AR E BL I N KIN G AR E O P EN .) MA C H IN ES )
1. 3 NO 1. 3 .1 1. 3 .2 . 1. 3 .3 1. 3 .4 1. 3 .5 1. 3 .6 1. 3 .7
IS IT CH E C K TH AT R E LA Y S CH E C K FU S ES
YE S CH E C K
A T OOL K5 , K6 , K3 3 , K1 1 , F5 , F6 , F7 , F8 , F 19 , F2 0 SE E
CO L D ST AR T
CH A N G E R K1 2 , K 1 3 , & K 1 4 AN D C IR C U IT B RE A KE R S CH A R T
PO S ITI O N
PR O B L EM ? AR E FIR M L Y SE AT ED CB 1 & C B 2 NO . 2
OF Z AX IS
O N 1 1 0 0 -2 B O A R D O N 1 1 0 0 -2
1. 4 NO 1. 4 .1 1. 4 .2 1. 4 .3 1. 4 .4
VE R IFY
IS IT YE S PU L S E L E D 's TO O L D U L L ? SE E
A S P IN D L E O N A LL OR TO O L AR G E CH A R T
PR O B L EM ? AX IS BO AR D S A C U T? NO . 3
AR E BL I N KIN G
1. 5 NO 1. 5 .1 1. 5 .2 1. 5 .3
YE S CH E C K AD J U ST
CH E C K FO R CH E C K CH E C K FO R SE E
LE V EL N E SS PO S ITI ON L O O P
RE P EA TA BI LI TY CH I PS IN TO OL I S FIX TU R E CH A R T
OF G AI N AN D
PR O B L EM ? SP IN D L E TIG H T MO V E ME N T NO . 5
MA C H IN E FEE D R AT E C L O C K
1. 6 NO 1. 6 .1 1. 6 .2 1. 6 .3 1. 6 .4 1. 6 .5 1. 6 .7
YE S CH E C K
SE E
CO N TR O L PU L S E L E D 's
CH A R T
PR O B L EM ? ON A LL BO AR D S .
NO . 6
AR E TH E Y B L IN K IN G .
1. 7 1. 7 .1 1. 7 .2
NO
YE S SE E
KE YB O A R D
CH A R T
PR O B L EM ?
NO . 1 0
1. 8 1. 8 .1
GO T O
PA G E 2 O F
CH A R T 1
Figure 16-1 Quick Checkout Procedure

CO N T IN U E D
FROM
CH A R T 1
C H A R T 1 c o ntin u e d (p a ge 2 )
PA G E 1
Q U IC K C H E C K O U T P R O C E D U R E
9- 2 0 -9 5
CHE C K SIN/C OS
IS IT YES CHE CK S IG N A L S U S I N G SEE
A F IN IS H BA LAN CE O F S E R VIC E T O O L S T 4 8 . CHA RT
PROBLEM ? A X IS A M P L IF IE R S A D J U S T IF V A R IA N C E NO . 11
> 0.001 V
1A .1 1A .1 .1 1A .1 .2 1A .1 .3
NO
YES SEE
IS IT
CHA RT
A RO TAR Y HE AD
13, 14 . 0 R 1 5
PROBLEM ?
1A .2 1A .2 .1
NO
YE S MAKE SURE V E R IF Y
IS IT A SEE
P O S IT I O N O V E R R I D E SE R VO C OO LA N T
SE R VO C OO LA N T CHA RT
P O T IS A X IS IS S E T T O
PROBLEM ? NO . 16
CE N TE R ED C O O L A N T IN S E T P
1A .3 1A .3 .1 1A .3 .2 1A .3 .3
NO
CH E C K SIN/C O S
IS IT A YES CHE C K S IG N A L S U S I N G SEE
RO U N DN E S S BA LAN CE O F S E R V IC E T O O L S T 4 8 . CHA RT
PROBLEM ? A X IS A M P L IF IE R S A D J U S T IF V A R IA N C E NO . 17
> 0 . 00 1 V
1A .4 1A .4 .1 1A .4 .2 1A .4 .3
NO
YES SEE
ERROR
CHA RT
CO D E?
NO . 18
1A .5 1A .5 .1
NO
YES V E R IF Y
IS IT A V E R IF Y SEE
BAUD RATE AND
C O M M U N IC A T IO N CO N N EC TIO N CHA RT
C O M M U N IC A T IO N
PROBLEM ? OF R S 232 C AB LES NO . 19
PA RAM ET ER S
1A .6 1A. 6.1 1A .6 .2 1A .6 .3
NO
YES
IS IT A N YES IS IT A SEE
IN D E X E R FAD A L CHA RT
PROBLEM ? IN D EX E R ? NO . 20
1A .7 1A .7 .1
1A .7 .2
NO NO
IS IT YE S SEE
A N M -F U N C T IO N CHA RT
PROBLEM ? NO . 24
1A .8
NO 1A .8 .1
GO TO
PAGE 3 OF
CH A R T 1
Figure 16-2 Quick Checkout Procedure (Continued)

CONTINUED
FROM
CHART 1 continued (page 3)
CHART 1
PAGE 2
QUICK CHECKOUT PROCEDURE
9-20-95
IS IT A YES DOES NO SEE

POSITIONING MACHINE HAVE CHART
PROBLEM? SCALES? NO. 21
1B.1 1B.1.1
NO 1B.1.2
YES,
START WITH SCALE CHART
REMOVE COVER
FROM SCALE
IS IT A YES SEE
BOX ON OUTSIDE
SCALE CHART
OF CONTROL BOX
PROBLEM? NO. 22
AND CHECK FOR
ERROR LED
1B.2
1B.2.1 1B.2.2
NO
SPINDLE SOFTWARE
IS IT A YES SPINDLE INVERTER SEE
(IN 1010-S)
RIGID TAPPING MUST BE LABELED CHART
MUST BE
PROBLEM? "RIGID TAPPING" NO. 23
RIGID TAP
1B.3 NO 1B.3.1 1B.3.2 1B.3.3
FOUNDATION IS IMPORTANT MOVE ONE AXIS

YES MACHINE MUST BE POSITIONED ON CHECK ALIGNMENT OF CONSULT
IS IT A AT A TIME TO
A SINGLE SLAB OF CONCRETE MOTOR MOUNTS CHART 3,
VIBRATION WITHOUT CRACKS
DETERMINE WHICH
AND CHART 22,
PROBLEM? SEE MAINTENANCE MANUAL AXIS HAS VIBRATION
BALLSCREW MOUNTS CHART 23
FOR DETAILS PROBLEM
1B.4
1B.4.1 1B.4.2 1B.4.3
1B.4.4
Figure 16-3 Quick Checkout Procedure (Continued)

CH AR T 2
TOOL CH A N GE R
A UT OM A T IC T OO L CH AN G E R
10-18-95
PROP ER AIR PR E SS U RE AN D A D EQ UATE A IR V OLU M E IS C RI TIC A L FOR TOOL CHA N GE S.

AIR PR E SS U RE RE GU LA TOR O N MA C H IN E M US T BE S ET AS LA BE LED (80-90 PS I A N D
120 PS I F OR TOO L OU T R EGU LA TOR ). AIR SUP PLY TO MA CH IN E S HO ULD BE 120 P SI .
US E T OOL IN/ OU T
AIR HO SE TO M AC H IN E M US T BE 3/8" AN D A S S HO R T A S POS S IBLE .
TO IN S ER T /R E MO VE
AIR DI ST RI BU T ION P IP E IN B UI LD IN G S HOULD B E A M IN IM U M OF 3/ 4".
TOOL F RO M S PI N D LE
TH E PR E SS U RE DR O P A T THE MA C HIN E DURI N G A TOO L C H ANG E S H OU LD B E A
MA XI MU M OF 3-5 P S I.
2. 1
CH E C K AI R PR E SS U R E
MA N U ALLY AC T IVA TE DO ES CH E C K AI R
DO ES NO (80P SI AN D 120P SI ) CH E C K NO
DR A W B AR SOLE N OID DR A WB AR W OR K DE LIV ERY TO
TOOL I N/OUT (M AX 3-5 PS I DR O P F20 AN D K24
AT MA C A IR W H EN M A NUA LLY DRA WB AR
W OR K ? DU R I NG TOO L ON 1100-2.
VA LVE A SS Y. OPE R AT ED ? CY LIN D E R .
CH A N GE )
2. 2 YE S 2. 2.1 2. 2.2 2. 2.3 (IF A T OOL IS IN YE S 2. 2.6

TH E S PIN D LE ,
2. 2.4
HA VE H EL PE R
HO LD O N TO IT.) CHE CK 1040 AN D W IR ING
CH E C K D RAW B A R
(S EE D R A WIN G 1002
PRE SS EUROP EAN CE N ORM CY LIND E R FOR
AN D K EY B OAR D
TUR R ET CW MACH INES M UST HAVE BA D SE A LS O R
TR OU BLE S HO OTI NG
AN D DOOR S CLOSED FOR BR OK EN PI STO N
TUR R ET C C W ATC TO WORK PROPER LY DI AG RA M )
2. 2.5 2. 2.7
2. 3
CH E C K FU SE S F5 & F6 & CB 2
TU R RET FAC T OR AN D R E LAY S K5, K33,
EM ER GE NC Y ST OP SE R VO IN S ETP M U ST BE 1
DI D NO GE NE V A K11, & K 12 ON 1100-2.
MUS T B E RE LE AS ED FOR S E R VO TU RR ET .
TU R RET MOV E OR S E RVO K12 M UST BE LOW
AN D
C ORR E C TLY? TU RR ET ? C2 ON 1100-2 MU S T LE A KA GE (GREE N ).
AM PLIF IE RS R E SE T
BE B YP AS S ED . CH E C K F4 A N D
2. 4.2 SE R VO TUR R ET FUS ES .
2. 4 YE S 2. 4.1 GEN E VA 2. 4.3
2. 4.4
C H ECK S ER V O T U RRE T ME C HAN IS M

GO TO C S PO SI TI ON. CH E C K TUR R ET
CH E C K FU SE S F5 & F6 & CB 2 FOR B IN D ING OR E XC E SS IV E PLA Y.
(I F N O T C O LD S TA R T ED , FA CTOR I N SE TP .
AN D RE LAY S K5, K33,
DO A C OLD ST A RT.) CH E C K GE NE V A
K11, & K 12 ON 1100-2. CH E C K TU R R ET MO TOR W IR IN G.
M EC H A N ISM .
K12 M U ST BE R A TE D FOR
IN M DI E N TE R M19 CH E C K TUR R E T
3 AM P OU TP U T (BLA C K) . CH E C K TU R RET MO TOR E N C OD E R
M OTOR WIR IN G.
2. 5 AND W I R IN G.
2. 4.2a 2. 4.2b
2. 4.5
GO T O IF T UR R E T A M PLIF IER FUSE I S

DI D NO DI D NO CHA RT BLOW N OR O VE R-C UR R E N T
SP IN DLE SP IN D LE NO . 3
OR IE NT ? LE D IS O N, C H ECK M OTO R
TU RN ? SP IN D LE WIR E S F OR S H OR T T O C H AS S IS.
DRI VE R (WI R ES TO MO TOR
2. 6.1 YE S AR E SH I ELD E D ;
2. 6 YE S 2. 6.1a
SH IE LD M US T BE S TR IP PE D
GO T O BA C K F ROM C ON D UC TOR).
DI D ADJ UST CH A R T 2. 4.6
YE S
OR IE NT AT ION OR IE NT AT ION NO . 3
AR M SW IN G FAC T OR SP IN D LE IF T UR RE T M OV ES
IN ? IN S ETP DR I VE R CO R REC TLY E XC E PT
FOR D IR E C TIO N,
2. 6.2 CHA NGE D IR E C TION
NO 2. 6.2a 2. 6.2b
CO N TR OL FR O M
TB1- 7 TO TB 1-5
CH E C K
ON 1100-2
F19 & K23 (OR VICE V ER S A)
ON 1100-2
2. 4.7
2. 6.3
IF TU R RE T R U NS A WAY :
1 .RE V ER SE MO TOR LE AD S ,
RE M OV E TO OL 2 .CH E CK EN C O DE R WIRIN G,
3 .RE P LA CE EN C ODE R ,
FR OM S PI N D LE
4 .RE P LA CE TU R RE T
AND MAN U A L LY A CTI VA T E C ONT RO L MOD U LE .
OR IE N TA TI ON A IR S OL EN O ID
AT M A C AI R V A LV E ASS Y . 2. 4.8
2. 6.4
IF V ERY HE AV Y TOO LS
AR E U N EV E NLY
DI D CHE CK WIR I NG. DI ST RI BU TE D,
YE S RE D IS TR IB UTE TOO LS
OR IE NT AT ION
ARM SW IN G TR Y KN OW N ON TUR R E T
IN? GOOD 1040.
2. 4.9
2. 6.5 D IP S W ITC H SE TT ING S
NO 2. 6.6 SP EE D SW 1 S W2
GO T O F AS T OP E N OP E N CO N SU LT FACT OR Y
PA GE 2 OF M E DF A ST C LO S E D O PE N SE RVIC E D E PT .
CH E C K AI R PR E SS U R E.
CH A R T 2 M E DS LO W O P EN C L OS E D AB OU T D I P S WI TC H
S LO W C LO S E D C LO S ED SE TTIN G S F OR
CH E C K AN D RE P AIR MO T OR T YP E: S W3 & SW 4 O PE N SP EE D A N D PI D
2. 7 OR IE NT M EC H A N ISM C O N SU LT FA CT ORY A BO U T O TH E R
AN D A IR LIN E S . MO T OR S ET TIN GS.
2. 4.10
2. 6.5a
Figure 16-4 Automatic Tool Changer

C H A R T 2 c o nti nu e d (p a ge 2 )
A U T OM A T IC T OO L C H A N G E R
CO N TIN U E D 1 0 -1 8 - 9 5
FR OM
PA GE 1 OF
CH A R T 2
MA N U A LL Y MO VE A T C
TO EX TE N D E D P OS ITI ON
(G R AS P A N D SW IN G
UP P ER GE N E VA A R M)
2A .1
DI D NO CL E A N, A DJ U S T, RE P L AC E
ME C H AN IS M MO VE AN D L U B R IC AT E ME C H AN IS M
SM OOTH L Y ? ME C H AN IS M IF D A MA GE D
2A .2 2A .2 .1 2A .2 .2
YE S
IS CH E C K AN D A D J US T CH E C K IF T OOL
TU R R ET FAC T OR AD J U ST
TOOL C A R R IE R NO CA R R IE R IS OU T
TU R R ET AL IG N ME N T
PR OP ER L Y A L IGN E D OF P OS ITIO N
(T U RR E T FA C TO R AN D /O R
W ITH S P IN D L E? MU S T B E 1 FO R OR S KE W E D
CO L D ST AR T PO SIT ION
SE RV O TU R RE T.) DU E TO A C R AS H
2A .3 2A .3 .1 2A .3 .2 2A .3 .3 (S E RV O TU R RE T M U S T
MA K E A M OV E BE FO R E
YE S TU RR E T A LIG N ME N T IS
AD JU ST E D.)
RE TU R N A TC T O
RE TR A C T ED PO SI TI ON .
TH EN IN MD I E N TE R (IF TO O L 2 IS IN T H E
M6 T2 SP IND LE , U SE M 6T 1.)
2A .4
AR E CH E C K AT C H OME S W IT C H .
DI D FU SE S CH E C K A TC FA U L T S W IT CH . CH E C K SL I DE M OTO R
NO YE S
ATC SL ID E F7 , F8 , & C B1 CH E C K C ON TR OL CH E C K AT C BE L T TE N SI ON
CO ME AN D R E L AY S K6 , V OL TA GE A T K 1 4 . AL IG NM E N T AN D A D JU S TM EN T
IN ? K1 3 & K 1 4 CH E C K SL I DE M OTO R O F G EN E VA S L OT
OKA Y ? & W I R IN G.
2A .5
2A .5 .1 2A .5 .2 2A .5 .3 2A .5 .4
YE S NO
RE S ET C B1 O R
RE P L AC E
F7 , F8 , K 6, K 13 , K 14
AS N EE D E D
2A .5 .1 a
CH E C K TU R R ET FA C TOR
DI D YE S TU R R ET MU S T B E
AD J U ST FOR GE N E VA .
TOOL C A R R IE R AT AN E M PTY
CO L D ST AR T PO SIT ION , CH E C K EN C OD E R A N D
CR A S H IN TO POC K ET
AN D TU R R E T A L IGN M EN T EN C OD E R W IR I NG
SP IN D L E? (A D JU S T S ET TO)
FOR S E R VO TU R R ET .
2A .6
2A .6 .1 2A .6 .2 (S E RV O TU R RE T M U S T 2A .6 .3 (T U RR E T FA C TO R M US T
NO MA K E A M OV E BE FO R E BE 1 FO R SE R VO T UR R ET .)
TU RR E T A LIG N ME N T IS
AD JU ST E D.)
GO T O
PA GE 3 OF
CH A R T 2
2A .7
Figure 16-5 Automatic Tool Changer (Continued)

C H A R T 2 continu ed (page 3)
AUTOM A TIC TOO L CHA NG E R
C O N T IN U E D 10 - 1 8 -9 5
FROM P R O P E R A IR P R E S S U R E A N D A D E Q U A T E A IR V O L U M E IS C R I T IC A L F O R T O O L C H A N G E S .
PA GE 2 OF A IR P R E S S U R E R E G U L A T O R O N M A C H IN E M U S T B E S E T A S L A B E L E D (8 0 - 9 0 P S I A N D
CH A R T 2 12 0 P S I F O R T O O L O U T R E G U L A T O R ) . A IR S U P P L Y T O M A C H IN E S H O U L D B E 1 2 0 P S I .
A IR H O S E T O M A C H IN E M U S T B E 3 /8 " A N D A S S H O R T A S P O S S IB L E .
A IR D I S T R I B U T IO N P IP E IN B U I L D IN G S H O U L D B E A M IN IM U M O F 3/ 4 " .
T H E P R E S S U R E D R O P A T T H E M A C H IN E D U R I N G A T O O L C H A N G E S H O U L D B E A
M A X I M U M O F 3 -5 P S I.
IS IS IS A IR P R E S S U R E M U S T B E
DI D NO YE S YE S YE S
TOOL STUCK DR A W B A R M A C H IN E IN 80 P S I A N D 1 2 0 P S I
Z A X IS
IN S P IN D L E ? FU SE OK A Y? A T A P -T A P (M A X 3 - 5 P S I D R O P
GO UP?
(F 2 0 ) CY C L E? DU R I NG TO O L C H AN G E)
2B .1 2B .1 .1 2B .1 .2 2B .1 .3
YE S NO NO NO 2B .1 .4
CH E C K K24
CH E C K S L I D E E X T E N D E D S W IT C H . CH E C K
RE P LAC E AN D C O N T RO L
CH E C K A T C F A U LT S W IT C H . DR A W B AR SW I TC H
FU SE VOLT AGE TO K 24
CH E C K D R A W B A R S W IT C H . (A N D A D J U S T M E N T ) ,
F20
CH E C K Z A XIS SE R VO. AN D D R A W BA R 2B .1 .5
2B .1 .1 a 2B .1 .2 a C Y L IN D E R A S S Y
2B .1 .3 a
TO O L H O L DE R S
MU S T B E CLE A N .
DI D NO GO B AC K
TURRET TO S TA RT OF
IN D E X ? 2B .1 .6
CH A R T 2
2B .2
YES 2B .2 .1
IF O V E R S H O O T /
DI D NO GO BACK
CH E C K TU R R ET UN D E R SH O OT
TURRET TO S TA RT OF
F E E D B A C K S W IT C H CH E C K/ AD J U ST
STO P? CH A R T 2
TU R R ET FAC T OR
2B .3
2B .3 .1 2B .3 .2 (T U R R E T F A C T O R 2B .3 .3
YE S MU S T B E 1 FO R
SE RV O TU R RE T.)
DI D NO CH E C K
CH E C K AT C
Z A X IS C O M E Z A X IS
SA FE TY SW ITCH
DO W N ? SE R VO
2B .4
2B .4 .1 2B .4 .2
YE S
CH E C K D R AW BA R CH E C K AIR PR E SS U R E
NO YE S CH E C K Z A XI S
DI D VA LVE FU S E F20 . (8 0 P S I ) A N D 1 2 0 P S I
DI D SL I D E FOLLOW ING
Z A X IS G O (N O T T O E X C E E D
PU LL B AC K ? ER R OR ,
UP ? C H E C K K 2 4 A N D IT S 3- 5 P S I D R O P D U R IN G
IS IT E X C E S S I V E ?
CO N TR O L V OL TA G E . TOOL CHA NGE )
2B .5 .1
2B .5
YES NO 2B .5 .2 2B .5 .3 2B .5 .4
CH E C K: SE E
CH E C K FU SE S
CH E C K AT C S L I D E E X T E N D E D S W IT C H , TOOL CHA NGE R
F7 & F8 & CB1.
A L IG N M E N T & A T C F A U LT S W IT C H , AD J U STM E NT S
CH E C K R EL A YS
BE LT TE N SION D R A W B A R S W IT C H , IN M A IN T E N A N C E
K6, K13, & K 14
SL I DE M O TO R MA N U AL
2B .5 .1 a 2B .5 .1 b 2B .5 .1 c 2B .5 .5
DI D NO CH E C K AT C CH E C K
S L ID E M O T O R S L ID E H O M E AD J U STM E NT O F
STO P? SW ITC H GEN E VA S LOT
2B .6 2B .6 .1 2B .6 .2
YE S
YE S CH E C K
MAKE SURE T OOL
D I D S P IN D L E CO L D ST AR T
HA S PR O PE R
DR O P T OO L ? P O S IT I O N .
PULL STUD.
2B .7
2B .7 .1 2B .7 .2
NO
ATC SY ST EM S OK
END
2B .8
Figure 16-6 Automatic Tool Changer (Continued)

DA SHED SYM BOLS

SPINDLE DRI VER CHART 3 APPLY TO CE NORM
EUROPEAN M ACHINES
SPIND LE DRIVE R ONLY
10-20-95
NOT E: DIF FICUL T T O D IA GN OS E P ROB LE MS CA N OCCU R IF MAC HINE IS NOT P R OP E RL Y GROUN DED .
SPINDLE WILL NOT TH ERE MU ST B E A CONTINUOUS GROUNDIN G CON DUCTOR (AS S PE CIF IED ON T H E GROUND ING LA B EL
RUN ON A CE M ACHINE IN THE MACHINE 'S D IS CON NECT B OX) F ROM THE VMC'S GR OU ND BUS TO THE GROUND B US IN T HE
WITH THE DO ORS OPEN BUILDING'S P OWE R DIS TR IB UT ION P AN E L.
CHE CK ERROR MESS AGES

ON INV ERTE R DISPLAY
(M ITSUBI SHI INVE RTERS
REQUIRE INSTA LLAT ION
OF PARAM ETER UNIT )
CO RRECT FAULT
AND RESET I NVERTER
3. 1
DO ES NO WILL NO SP INDLE
CHECK
SP INDLE SP INDLE TURN MA Y BE
BELTS
RUN? BY HAND? FROZE N
3. 2
3. 2.1
YES 3. 2.2 3. 2.3
YES
CHA NGE
IS YES
SPINDLE
SP INDLE POT
POT
AT 0?
SETTING
3. 2.1a NO 3. 2.1a.1
CHECK ERROR MESSAGES
ON INVERTER DISP LAY
CHECK
VERIFY LE D ON CHECK CHECK CHECK (M ITS UBI SHI INVERTE RS
AND RE SE T
SPINDLE 1010 AND RESET AIR 3-PHASE AC RE QUIRE INS TALLAT ION
CE CIRCUIT
(S LOT 14) OVERLOA D PRE SS URE POW ER T O OF P ARAM ETER UNIT )
BREAKERS
IS BLINKING RELA Y (80-90 PS I) INVERTER
A12, B12, C12
AFT ER F AULT IS CORRECTE D
3. 2.1b 3. 2.1b.1 3. 2.1b.2 3. 2.1b.3 3. 2.1b.4 PRESS RESET O N INVERTER
3. 2.1b.5
RUNS CHECK SPINDLE
3 SECONDS YE S HALL EFFECT SWIT CH ON 1100-2:
AND STOPS? AND WI RING CHECK F1 & F3.
(ERROR #8) (USE DI DS TO S EE I F
SWI TCH IS B EI NG READ) CHE CK K7, K9,
K3, & K4.
3. 3 NO 3. 3.1
3. 2.1b.6
MOT OR CHECK INSPECT BELTS VE RIFY THA T

TURNS B UT YES AND BELT TENSIO N INSPECT
AIR PRE SS URE 1010S /J 1, J2, & J 3 *
SP INDLE DO ES HI /LOW RANGE
(SHOULD BE AND 1100-1/ J2 & J3
NO T OR DO NOT OVE R TIGHTE N MECHANIS M
80-90 P SI ) BE LT S
ARE PLUG GED IN
SLIP S?
3. 4 3. 4.1 3. 4.2 3. 4.3 3. 2.1b.7
NO
IF SPI NDLE STILL
DO ES NOT RUN,
SP INDLE YES CHECK FOR *GOL D COAX C ONNE CT OR CHECK FUSES IN I NVERTE R,
CHECK
RUNS IN ONE LO OS E W IRES M US T FIR MLY GRIP CE N TE R P IN (US E THEN T ES T I NVE RTER
F3, K 9, & K4
DI RECTI ON OR TERMI NALS S ERV ICE TOOL S T4 4 T O T ES T A N D A DJUST ), USING BATTERY BO X
ON 1100-2 M US T B E S OLIDLY CRIM PE D T O CEN TE R WIRE ,
ONLY? * (SERV ICE TOO L ST 03)
M US T MAK E FIRM C ONTA CT WITH JA CK.
3. 2.1b.8
3. 5 NO 3. 5.1 3. 5.2
SPINDLE YES SP INDLE CARD

US E OHM METER
YE S RUNS WI TH MAY BE BAD.
SPINDLE CHECK REGEN TO CHECK
CHECK FUSES BATTERY SWAP IN KNOWN
TAKES A LONG RESIST OR OR REGEN RESISTO R
IN INVERTE R BOX ? GOOD 1010-S
TIM E T O EXTE RNAL BRAK E (CHE CK DRA WING
STO P? 1002 FOR VALUE) 3. 2.1b.9
NO 3. 2.1b.10
3. 6 NO 3. 6.1 3. 6.2 3. 6.3
CHECK MO TOR WI TH CHECK FOR VOLTAGE

CHECK
OHMM ET ER AT OVERLOAD RELAY
SP INDLE YES CHECK/ ADJ UST SP INDLE
TO DE CIDE IF M OT OR
SP EE D J1 CONNECTOR * ENCODER
LE G TO LEG OR INV ERTER I S BAD
VARIES ? ON SPINDLE CARD WITH ENCODE R
ABOUT 0. 6 OHM .
TESTER
LEG TO G ND O.L. 3. 2.1b.11
3. 7
3. 7.1 3. 7.3
NO 3. 7.2
TY PICAL SYM PTOMS O F A CO NSULT FACT ORY
BAD ENC ODER :
CO NTINUED BALDOR SWEO :
SERVICE DEPT .
ON PAGE 2 SPINS SLOWLY, SIN KS LOTS OF CU RREN T, BE FORE REP LACING
SPINDLE DRI VER THEN FAULTS O UT (OC ). MOT OR OR
(CHA RT 3) MITSUBIS HI: INVERTER
NO VISIB LE S YMPTOM S
3. 8 MITSUBIS HI DOE S NOT RE QUIRE ENCO DER 3. 2.1b.12
FEEDBACK TO RUN .
PERFOR MANC E SUFFERS ( BUT NO T OBVIOU SLY).
Figure 16-7 Spindle Driver

CONTINUED
FROM PAGE 1
SPINDLE DRIVER SPINDLE DRIVER
(CHART 3) 10-20-95
CHECK SPINDLE USE DI DS TO CHECK CHECK 0-5V SWITCHING

SPINDLE YES TYPE IN SETP HALL SWITCHES AT K27 AND K10 ON 1100-1
IDLERS WILL NOT (CPU WILL NOT SWITCH (IDLER WILL NOT SWITCH (5V PULL-UP IS SUPPLIED
SWITCH? IDLERS IF IT IS NOT A 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
BUZZ WIRING IF ORIENTATION

YES USE DI DS ADJUST
FROM SOLENOID IS NOT
ORIENTATION TO CHECK ORIENTATION
1060 J10-8 ACTIVATING
FAILURE? ORIENTATION FACTOR
TO CHECK F19 AND
MAGNET IN SETP
SLOT 14 J2 K23 ON 1100-2
3A.2
3A.2.1 3A.2.2 3A.2.3 3A.2.4
NO 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.
CHECK THAT
"BAD TERMINALS ON USE ENCODER TESTER
ENCODER" ON YES GREEN CONNECTOR TO TEST AT EACH
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,
YES RUN SPINDLE AT DOES YES CONSULT FACTORY CONSULT FACTORY
SPINDLE
MAXIMUM SPEED SPINDLE MOTOR SERVICE DEPT. SERVICE DEPT.
MOTOR
AND CUT POWER SHAKE WHILE ABOUT BALANCING BEFORE REPLACING
SHAKES?
(MOTOR COASTS COASTING? SPINDLE MOTOR SPINDLE MOTOR
TO STOP)
3A.4 3A.4.2
3A.4.1 3A.4.3 3A.4.4
NO NO
YES DOES RUN AN EXTERNAL

BRING SPINDLE TO NO
SPINDLE VIBRATION CABLE BETWEEN
MAXIMUM RPM AND
VIBRATION? OCCUR WHILE ENCODER ON MOTOR
SHUT OFF POWER
COASTING? AND INVERTER
3A.5 3A.5.1
3A.5.2 3A.5.3
YES
POSSIBILITIES: POSSIBILITIES:
BELTS, DOES NO INVERTER SOFTWARE,
PULLEY OUT OF ROUND, SHAKING/VIBRATION BENT ENCODER PIN,
MOTOR SHAFT BENT, STOP? ENCODER DISK RUNOUT,
BAD SPINDLE. BAD ENCODER,
CONSULT FACTORY. 3A.5.4 3A.5.5

YES
3A.5.2a CONSULT FACTORY
SERVICE DEPT.
ENCODER CABLE IS BAD,
ABOUT INSTALLING
INCORRECTLY ROUTED, SOLID MOTOR MOUNTS
OR INCORRECTLY SHIELDED.
3A.5.6
CONSULT FACTORY.
CONSULT FACTORY
3A.5.4b SERVICE DEPT.
BEFORE REPLACING
INVERTER
3A.5.7
Figure 16-8 Spindle Driver (Continued)

CHART 4 DA S H ED S YM B OL S
AP PL Y TO C E N OR M
AX IS C ON TR OL
A XIS C O N T R O L EU R OP EA N M AC H IN E S
10 - 2 0 -9 5 ON L Y
DIF FIC UL T T O D IA GN O S E P RO B LE M S C A N O C CU R IF M AC H INE IS N O T P R OP E RL Y G R O UN D ED .

IS YE S MOV E OFF TH ER E MU S T B E A CO N TIN U O US G RO U N DIN G CO N D UC TO R (AS S PE CIF IED O N T H E G R OU N D IN G LA B EL
AX IS AT LI MI T IN TH E M AC H INE 'S D IS CO N N EC T B O X) F RO M TH E VMC 'S GR O U ND BU S TO TH E GR O U ND B US IN T HE
LI MI T? POS ITI ON BU ILD ING 'S P OW E R DIS TR IB UT IO N P AN E L.
4. 2
4. 2 .1
NO
CH E C K VO L TAG ES :
W AS AR E +5 V , + 12 V, - 12V & IF V OL TA GE S AR E
IS IT YE S NO YE S
MOT OR AL L 3 A X ES 1 1 0V AC A T 122 0 OU T OF TOL E R AN C E ,
A RUNAWAY (A L SO C HE C K F OR A C
RE P L AC E D ? RU N N IN G CH A N GE L OGI C
PR OB LEM ? RIP PL E O N DC V OL TA G ES :
AW A Y ? 0.01 5V AC MAX O N +/-1 2V
POW ER S U PP L Y
4. 1 4. 1 .1 4. 1 .2 0.00 5V AC MAX O N +5 V)
YE S NO 4. 1 .4
NO 4. 1 .3
GO T O
DO ES YE S
CH A R T 7
TH E AX IS R U N
TO A LIM IT?
4. 1 .1 a
4. 1 .2 a
NO
SW A P TH E AX IS
CH E C K C E DI D
IS AX IS YE S CH E C K SW A P CO N TR OL L ER
CI R C UI T PR OB L EM NO
CO MP L ET EL Y MOT OR SE R VO CA RD S (1010)
BR E AK ER S FOL LOW TH E
IN OP ER A TIV E? OVE R L OA D AM PL IF IE R (R E ME MB E R TO
(A 1 0 ,B1 0, C1 0 AM PL IF IE R
RE L A Y CA R D CH A N GE J UM P ER
OR 1 4 ) CA R D ?
4. 3 BL OC K ON J 4)
4. 3.1 4. 3.2 4. 3 .3 4. 3 .4
NO YE S
4. 3 .5
DI D
RE P LAC E YE S RE P LAC E
CH E C K PR OB LEM
YE S SE R VO AX IS
IS TH ER E EM ER GE N C Y ST OP FOL L OW TH E
AM PL IF IE R CO N TR OL L ER
AN A MP L IFI ER AN D AX IS
CA R D CA R D
FAU LT? MOT OR OV ER L O AD CA R D ?
RE L A YS 4. 3 .6 4. 3 .7
4. 3 .4 a NO
4. 4
4. 4.1
NO
CH E C K C E
W AS TH E YE S
CI R C UI T RE P LAC E
PR OB L EM
BR E AK ER S RE S OL VE R
RU N A W A Y?
(A 1 0, B 1 0 , C 10
OR 1 4 )
4. 3 .6 a 4. 3 .6 a .1
NO
4. 4 .2
CO N SU L T FAC T OR Y
WAS SE R VIC E D E PT .
MOT OR W I RE S
MOT OR YE S AR E BE FOR E R EP L A C IN G
YE S AR E SH I EL D E D .
RE C E NT L Y MOT OR W I RE S SE R VO MO TOR
VE R IFY TH A T S H IE L D
RE P L AC E D OR SH OR TE D TO
IS STR I PP ED BA C K 4. 3 .6 b
RE W I RE D ? CH A S SIS ?
FR OM C ON D U C TOR .
4. 4.3 NO 4. 4 .4 4. 4 .5
NO
IF A OR B A X IS AR E
W ITH P OW ER O N W ITH P OW ER O N
YE S NO T U S ED T H EY VE R IFY TH A T
A OR B AN D D U M MY P L U G AN D D U M MY P L U G
MU S T B E IN AC T IVE DU M M Y P L U G
AX IS W H IC H A R E IN ST AL LE D , V ER IF Y IN ST AL LE D , V ER IF Y
IN P AR A ME TE R S O R SH OR TS
NO T IN U SE ? TH AT 11 0 0 -1 T B1 TH AT 1 0 6 0 J5 - 6 A N D
DU M M Y P L U G M U ST PIN S H & G
PIN 1 TO P IN 6 IS 0 V J4 - 6 AR E 0V
BE IN P L A CE .
4. 4 .3a NO 4. 4 .3 a .1 4. 4 .3 a .2 4. 4 .3 a .3 4. 4.3 a .4
YE S DO N O T M OV E Z-A X IS !
DO ES NO CO N SU L T FAC T OR Y
IS IT PR E SS EM E R GE N CY ST OP .
IT M OV E BE FOR E R E PLA C IN G
Z-A X IS?
FR EE L Y? BA L LSC R E W
TR Y TO M OV E Z-A X IS BY H A N D .
4. 4 .3 b 4. 4 .3 b .3
NO 4. 4 .3 b .1 4. 4 .3 b .2
YE S
CH E C K K1 , K2 ,K 18 ,K 2 0, JU M PE R
PR E SS J OG. NO F1 2 , & F1 4 EM ER GE N C Y CH A N GE A MP
GO T O DO A MP L IFIE R S ON 1 1 0 0-1 . STO P C I R CU I T IN D IC AT ED B Y
PA FE 2 OF STA Y ON ? CH E C K OV ER L OA D (J U MP F1 6 T O F12 FAU LT LIGH T
CH A R T 4 RE L A YS ON 1 1 00 -1 )
4. 4 .3c
4. 4 .3 c. 1 4. 4.3 c. 2 4. 4.3 c. 3
Figure 16-9 Axis Control


CONTINUED AXIS CONTROL
FROM 10-20-95
PAGE 1 OF
CHART 4
CHECK AND ADJUST CHECK BUS VOLTAGE

YES COMMAND CONNECTOR AT BLUE CAPACITOR GO TO
MOTOR * GOLD COAX CONNECTOR :
AT AXIS CARD J1 WITH ON AMPLIFIER CHASSIS. PAGE 3 OF
OVERLOADS? MUST FIRMLY GRASP CENTER PIN (USE SERVICE
SERVICE TOOL ST44 (SHOULD BE APPROX. 130-165VDC CHART 4 TOOL ST44 TO TEST AND ADJUST),
DEPENDING ON MODEL)
* CONSULT FACTORY IF DIFFERENT
MUST BE SOLIDLY CRIMPED TO CENTER WIRE,
4A.1 MUST MAKE FIRM CONTACT WITH JACK.
NO 4A.1.1 4A.1.2 4A.1.3
TEMPERATURE SNAP SWITCH

ISOLATE CHECK AND ADJUST WILL SHORT COS SIGNAL TO GND
YES WHICH AXIS RESOLVER CONNECTOR ON RESOLVER BOARD IN MOTOR
RESOLVER IF MOTOR OVERHEATS.
USING 201060-0-1 AT AXIS CARD J2 WITH
FAULTS? CHECK COS OUTPUT TO RESOLVER
RESOLVER SERVICE TOOL ST44 (PIN 8 OF J1-J6 ON 1060)
TESTBOARD * FOR SHORT TO GND.
4A.2 LET COOL.
NO 4A.2.1 4A.2.2
4A.2.3
CHECK
RESOLVER NO RESOLVER
FAULTS ON CABLE.
MULTIPLE REPLACE
AXES? RESOLVER.
4A.2.4 4A.2.5
YES
CHECK SINE &

CHECK COSINE OUTPUT
CHECK
+12V & -12V OF CLOCK CARD
J14 ON 1060
ON 1220 (1020) USING
SERVICE TOOL ST48
4A.2.4a 4A.2.4b 4A.2.4b
CHECK SINE &

CHECK
YES ALL 3 YES COSINE OUTPUT CHANGE
RUNS 1060-0-1 OR
AXES RUN OF CLOCK CARD CLOCK CARD
ROUGH? JUMPER PCB
ROUGH? (1020) USING (1020)
IN J14 OF 1060
SERVICE TOOL ST48
4A.3 4A.3.1
4A.3.2 4A.3.3 4A.3.4
NO NO
CHECK AND ADJUST

RESOLVER CONNECTOR CHECK CHECK
SWAP
AT AXIS CARD J2 WITH CHECK MOTOR COUPLER MOTOR
AMPLIFIERS
SERVICE TOOL ST44 WAYLUBE AND BALLSCREW THRU-BOLTS
AS ABOVE
* FOR LOOSENESS. ARE TIGHT.
CHECK RESOLVER
4A.3.1a.1 4A.3.1a.2 4A.3.1a.3 4A.3.1a.4
4A.3.1a
CHECK
GROUNDING
4A.4
CONSULT
FACTORY
4A.5
Figure 16-10 Axis Control (Continued)

C H A R T 4 c o n tin u e d (p a g e 3)
A X IS C O N T R O L
6-1 5 -9 5
MOTOR OVERLOADS
C O N T IN U E D
FROM
PAGE 2 OF
CHART 4
IS T H E F A U L T NO
DU R ING P R O G R A M
GO TO
EX EC U TIO N ?
PAGE 4 OF
CHART 4
4 B .1
YES
4 B .1 .1
IS T H E
PROG RAM
U S IN G M 9 0 - M 9 3 NO
P R O G R A M M A B L E G A IN
S E T T IN G S ?
M90 = U S E S E T P G A IN
M91 = N O R M A L G A IN
4 B .2 M 9 2= IN T E R M E D IA T E G A IN
M93 = H IG H G A IN
YES
IN S E R T A N M 9 1
A T B E G IN N IN G
OF PROGRAM.
R E M O V E A L L G 8 's .
4 B .3
DO ES ERROR YES SLOW DOW N THE

STILL OCCUR
FEE D R A TES IN
DU R ING PRO GRAM
THE PROG RAM
EXEC U TIO N ?
4 B .4 .1
4 B .4
NO
PROBLEM NO IS YES
SHOULD BE T H E R E S T IL L A
RESOLVED PROBLEM ?
4 B .5
4 B .4 .1 a
IF N O T G O T O
PAGE 4 OF CHART 4
END
4 B .6

MOTOR OV ERLOA DS
CO N T IN U E D
C H A R T 4 c o nt in u e d ( p a ge 4)
FROM
PA G E 3 O F AXIS CO NTRO L
CH A R T 4 6- 1 5 -9 5
CHE C K W A YLU B E
OVE RLOA D YE S CH E C K
O C C U RS A T B A L L SC R E W
CH E C K AN D A D J US T
SLOW AL IG NM E N T
G IB S A N D S T R A P S
SP E E D ?
4C . 1
NO 4C . 1 .1 4C . 1 .2
O VE R L O A D YE S CH E C K AN D A D J US T
O C C U RS N E AR M E C H A N IC A L A XIS
P O S IT I O N LI M I T S T O P
LI M I T ?
4C . 2
NO 4C . 2 .1
LO O P G A IN P O T O N A M P L IF IE R
CU R R E N T L IM IT P O T
OCCUR YE S SH O U L D B E M O S T L Y C W .
O N A M P L IF IE R
W H IL E S T O P P E D (T U R N F U LL Y C W F O R T E S T A N D
MUS T BE FULLY CW
O R IN G 0 ? RE - AD J U ST L O O P G A IN
(E X C E P T F O R VH 6 5 )
IF T HI S CO R R E C T S P R O B LE M )
4C . 3 NO 4C . 3 .1 4C . 3 .2
M A K E A D JU S T M EN T S IN T H E
F O L L O W IN G O RD E R :
M AS T E R F E ED R A T E C L O C K ,
P O S I T IO N L O O P G A IN ,
B AL A N C E A D J US T M EN T .
4C . 4
SW I T C H T O
NO S E R V IC E P R O G R A M
PR O B L E M "P R ,5 8 1 1 "
RE S O L V E D ?
CH A N G E G 1 's T O G 0 's .
RU N PR O G R A M .
4C . 5
YE S 4C . 5 .1
W AS CH E C K BU S V O L T A G E
CH E C K SE T P
FOLLOWING YE S IS M A C H IN E YE S AT BL U E C AP A C IT O R
PA R AM ET ER :
EN D E R R O R C O RR E C T * W IR E D F O R O N A M P L IF IE R
"3 PH A S E > 5 % L O W "
THROUGHOUT 20 8 V A C ? CH A S SIS .
SH O U L D B E Y E S
4C . 6 MOVE? SH O U L D B E 1 1 5 V A C
4C . 5 .2
4C . 5 .3
NO 4C . 5 .4 4C . 5 .5
* G0 FOLLOWING ERRO R:
NO
INCH - 1840 +/-20
METRIC - X/Y 1630 + /-20
Z 1380 + /-20 DO E S
20 " M O VE NO AD J U ST M A S T ER AD J U ST PO S IT IO N
AT 1 00 IP M T AK E
F EE D R A T E C L O C K LO O P G A IN
12 . 2 -1 2 .5
SE C?
CH A N G E T H E G 0 's 4C . 5 .3 a 4C . 5 .3 a .1 4C . 5 .3 a .2
BA C K T O G 1 ' s YE S
AN D R U N P R O G R A M
AG A IN
SW A P Q U E ST I O N AB L E
AM PL IF IE R W IT H O N E O F DID YE S
4C . 5 .2 a T H E O T H E R A X E S. P R O B L EM S T A Y
W IT H A X IS?
RU N P R O G RA M AG A I N
4C . 5 .3 b 4C . 5 .3 b .1 NO , ST A YE D
W ITH A M P LI F IE R
W AS
FOLLOWING NO
E R R O R C O RR E C T *
RE P L A C E CH A N G E
THROUGHOUT
AM P L IF IE R MOT OR
MOVE?
4C . 5 .2 b
4C . 5 .3 b .3 4C . 5 .3 b .2
* G1 FO LL O W ING E R R O R : YE S
I N CH - 59 5 + / -1
M E TR IC - 30 2 + / -1
A D J U ST
P O S IT I O N
CO N SU L T
LO O P G A IN
F AC T O R Y
4C . 5 .2 b .1
4C . 5 .2 c

DI F F IC U L T T O D I A G NO S E P R O B L E M S C AN O C C UR
CHART 5 IF M A C H I NE I S N O T P R O P E R L Y G R O U N D E D.
T H E R E M U ST B E A C O N T I NU O U S G R O U N D IN G
RE P E A T A B I LI T Y
R EP EAT A B IL ITY CO N D UC T O R ( A S S P E C IF I ED O N T H E G R O U N D IN G L A B E L
9- 2 0 -9 5 IN T H E M A C H IN E 'S D IS CO N N E C T BO X ) F R O M T H E V M C 'S
G R O U N D B US T O T H E G R O UN D BU S IN T H E B U IL D IN G ' S
F O R A D D IT IO N A L P R E C I SIO N IN L E V E L IN G , POW ER DISTR IBU TION P AN E L.
V E R IF Y P E R F O R M SQ U A R E N E S S T E ST O N X & Y ,
M A C H IN E IS L EV EL T H E N S Q U A R N ES S T E S T O N C O L U M N ,
(S E E M A I NT E N A N C E T H E N S P IN D L E T R A M T E S T .
M A N U AL ) (C O N S U L T F A D A L S E R V I C E D E P T F O R P R O C E D U R E)
5. 1
RE M O VE S U B P L A T E O R F I X T U R I NG .
IS T H E R E MA C HI N E MU S T B E T ES TE D W I TH O UT FI X TU R I NG .
A S U BP LA TE YE S SU BP LA T ES O R F IXT UR IN G C A N IN D UC E P O S IT I O NIN G
PR O BL EM S TH A T A RE NO T INH E RE N T IN T H E M A CH IN E.
O R L A R G E H EA VY PO S IT IO NIN G PR O B LE MS I N DU C ED BY FI X TU R I NG
F IX T U R IN G ? MU S T B E D E AL T W IT H S EP A RA TE LY FR O M PR O BL EM S
IN TH E M AC H I NE ITS EL F.
5. 2 NO 5. 2 .1
CH E C K A N D A D J US T :
B AC K LAS H ,
B A L A N C E O N A X IS A M P S , N1 L 01 0 0
L O O P G AIN O N A M P S N2 G1 F20.
N3 X 4 .0
5. 3 N4 X - 4 .0
IN S E R T P R O G R A M N5 G 4 P 1 0 00
A T R IG H T . N6 M17
N7 M30
S E T U P IN D IC A T O R N8 L 01 9 9
N9 M2
F O R P R O B LE M A X IS
5. 4
* GO L D C O AX CO N N EC TO R (J1 , J 2 & J3 O N 101 0):
M U ST FI R M LY GR A SP C EN TE R PIN (US E SE RV IC E
RU N T O O L S T4 4 TO T ES T A N D A D JU ST ),
PR O G RA M M U ST BE SO L I DL Y C R IMP E D T O C E NT E R W IR E ,
M U ST M AK E F IRM C O NT A CT W ITH JA CK .
5. 5 RE PE A T A BIL I TY CA N BE AF FE C TE D IF CO N NE C TO R IS LO O S E.
IN S P E C T M O T O R C O U P L ER
CH E C K G O L D C O AX CH E C K A N D A D J US T
AN D B A L L S C R E W
DO ES NO CO N N EC T O RS A D J U S T G A I N A ND G IB S AN D S T R A PS
FOR LOO SE N ES S .
T H E AX IS (J 1 , J 2 O N 1 0 1 0 ) CO M P E N S A T IO N
RE P EA T ? W IT H S E R V IC E O N A XIS A M P L IF I E R CH E C K BA L L SC R E W
CH E C K F O R L O O SE
TOOL S T44 * A L IG NM E N T
5. 6 RE S O L V E R O R C O U P L IN G .
YE S 5. 6 .1 5. 6 .2 5. 6 .3 5. 6 .4
CH E C K S I NE &
CO S I NE O UT P U T
IF B A C K L A S H I S E X C E S S I VE ,
O F C L O C K C AR D
DO E S A XI S YE S CH E C K F O R
AD JU ST (1 0 2 0 ) U S IN G
HA V E A B A CK L A S H LO O S E N E S S IN M O T O R C O U P L E R ,
BA C KLA SH S E R V IC E T O O L S T 4 8
PR OB LEM ? W O R N B A L L S C R E W , A ND
BA L L S C R E W A L IG N M E N T 5. 6 .5
5. 7 5. 7.1 5. 7 .2
NO CH A N G E
RE S O L V E R
RE - IN S T A L L 5. 6 .6
S U B P L A T E AN D
F IX T U R IN G RE P EA T A B I LI T Y P R O BL E M S M A Y A L S O
BE C AU S E D BY T E M P E R AT U RE G RO W T H CH E C K
A N D R E PE AT T E S T
O F B AL L S C R E W S O R S P IN D L E . S U R V E Y T A BL E
5. 8
5. 6 .7
A X IS R E P E AT S W I T H O U T S U B P L A T E A ND F IX T U R IN G
DO ES NO CO R R EC T M E C H A N IC A L
B U T DO ES N O T R EP E A T W IT H S U B P L A T E A ND F IX T U R IN G .
T H E AX IS B IN D
T H E R E F O R E F I XT U R I NG O R S U B P L A T E IS D IS T O R T I NG T A BL E
RE P EA T O N OR C H AN G E
O R C R E A T IN G A M E C H AN I CA L B IN D .
X & Y? M A C H IN IN G P R O C E D U RE
O R A M A C H IN IN G PR O C E D U R E IS C A U S IN G N O N -R E P E A T AB IL IT Y.
5. 9 5. 9 .1 5. 9 .2
YE S
YE S IS YE S
IS IS C O O L A NT
S P IN D L E
Z A XIS O F F S E T F L O W IN G IN
CO O L ER
CH A N G IN G ? RE S E R V O IR ?
RU N N IN G ?
5. 1 0 5. 1 0 .2 5. 1 0 .3
NO NO NO
CH E C K F O R A C R IP P LE S E R V IC E T H E
EN D ON THE DC V OLTAGE S SP IN D L E CO O L E R
A L L A XE S R E P E A T (0 .01 5V AC M AX O N + / -1 2V , A S SE M B L Y
0. 00 5V AC M AX O N + 5 V) A N D P U M P A SS E M B L Y
5. 1 1
5. 1 0 .4 5. 1 0 .5
Figure 16-13 Repeatability

CO M P U T E R
CHART 6
COMPUTE R
PO W ER O N 9- 2 0 -9 5
(W A IT A F EW SE C O N D S
AN D P R E S S
CN C PO W ER S W IT C H )
6. 1
PRE SS A ND HOLD
A R E L ED S NO CN C PO W E R S W IT C H IS T H E R E NO
GO T O
ON B OARDS 5V O N T H E
CH A R T 1 2
F L AS H IN G ? RE S ET BO AR D S TH A T 10 6 0 ?
A R E N O T F L A S H IN G
6. 2
6. 2 .1 6. 2 .2 6. 2 .3
YE S
G O I NT O D IA G N O S T I CS
(IF C O N T R O L IS " D EA D "

T R Y PO W ER IN G U P W ITH
JU M P E R A T J 2 O N 1 4 0 0
6. 3
IF M EM O R Y W A S
CA N YE S RU N DI AG NO S T IC S RE P L A C E D O R A D D ED
YO U G ET IN TO O N M EM O R Y , V ID EO , O R E PR O M M O D U L E
DI AG NO ST IC S? CL O C KS , M IL L IN T E R F A C E , W A S C H A N G ED ,
ETC . ZE R O M E M O R Y AN D
RE S E T P A R A M E T E R S
6. 4 6. 4 .1
NO 6. 4 .2
EP R O M M O DU L E ( 1 6 1 0) , CH E C K CH A N G E
EX PA N D ED M E M O RY ( 1 4 6 0 ), 5 V O LT S (5 .0 5 V ),
IS T H ER E YE S VID E O B O A R D ( 14 2 0 ) ,
AN D B U S B R ID G E ( 1 7 3 0 ) +/- 1 2 V O L T S
G AR B AG E O N T H E CO M P U T E R IN T E R F A C E ( 1 0 3 0 ),
M U S T B E F IR M L Y S E A TE D (A L SO S ET M E TE R FO R VA C
SCRE EN? CP U ( 1 4 0 0 ),
IN T H E IR C O N N E C TO R S . AN D C H EC K FO R AC RIP P LE
ON + 5V , + 12 V A ND -12 V D C ) E X P A N D ED M E M O RY ( 1 4 5 0 )
CH E C K FO R B E N T P IN S.
6. 5 .2 6. 5 .3
NO 6. 5 .1
6. 5
CH E C K VI DE O
SWITCH ON
YE S IS V ID E O CH E C K V I DE O C AB L E. IF 3 2 M P,
DI D F R O N T P A NE L YE S CH A N G E
M O N I T O R A L IV E ? CH E C K F U S E F 2 5 CH E C K
SCRE EN VID E O
(C H E CK F O R O N 1 1 0 0 -1 . CN C / DO S
G O D E AD ? CH E C K B R IG H TN E S S MONITOR
GLOW) CH E C K V I DE O C AR D . SW I T C H
A N D C O N T RA S T
P O T S O N M O N IT O R
6. 6 6. 6 .2 6. 6 .3 6. 6 .4 6. 6 .5
NO
6. 6 .1
NO PO W E R O F F
AND CHE CK
FUSE S ON
MONITOR
6. 6 .2 a
T E S T B A T T E R Y BA C KU P
IS NO O N C PU B O A R D .
CO N SU L T
M E M O RY L O S IN G RE P L A C E C PU B O A R D
F AC T O R Y
PR O G R AM S? IF B A T TE RY T ES T
FAILS.
6. 7 6. 7 .1 6. 7 .2
YE S
"E R R O R SUM PRO GRAM

YE S NO CH A N G E
W H IL E TO F IN D A N D P R O B L EM
CP U /M EM O R Y
P R O C E SS IN G CO R R E C T CO R R EC T E D ?
BOA RD
BL O C K "? A N Y ER R O RS
6. 8 6. 8 .1 6. 8 .2 6. 8 .3
NO
M E M O RY L O C A T I O N S :
RU N RA M T E S T S Z ER O M E M O R Y. O N C P U ( 1 4 0 0) 4 0 0 0 0 -5 F F F F, 80 0 0 0 - 8 F F F F
YE S IN D IA G N O S T IC S . O N R A M EX P AN S IO N ( 1 4 6 0 -2 ) 9 0 0 0 0 - EF F F F
"ME MO RY
IF T E S T F A IL S IF P R O B L EM R E CU R S
E R R O R "?
RE P L A C E C PU O R RE P L A C E C P U O R
M E M O RY E XP A N SIO N RA M E X P AN S IO N .
6. 9 6. 9 .1 6. 9 .2
Figure 16-14 Computer

CHART 7
A X IS M O T O R R U N A W A Y S
A X IS M O T O R 6- 1 5 -9 5
RU N A W A YS
W H E N R E P LA C IN G M O T O R S , C O N N E C T A L L W IR I N G A N D V E R IF Y
C O R R E C T O P E R A T IO N B E F O R E IN S T A LL I N G M O T O R IN V M C .
T H IS W IL L P R E V E N T D A M A G E T O M A C H IN E D U E T O R U N A W A Y S .
A X IS M O T O R
RUNS AW AY AFTER
R E P L A C IN G T H E
MOTOR
7.1
P O W E R D O W N M A C H IN E .
PRE SS EMERGE NCY S TOP .
C H E C K W IR IN G A T A M P
AND
J4 J U M P E R O N C O N T RO LLER C A R D .
7.2
POW ER O N.
RELEAS E EM E RGENCY
STO P.
RES ET AM PS BY
P R E S S IN G J O G .
7.3
W AS M OTO R NO
DO ES YE S
W IR E D E X A C T L Y C O R R E C T W IR IN G
T H E A X IS
THE SAME AS OLD AND RE TE ST
RUN AW AY?
MOTOR?
7.4
7. 4 .1 7.4 .2
YES
NO
CH E C K RES OLV ER C O UP LE R .
CHECK AND A DJUST
RE SO LVE R CONNECTO R
W I T H S E R V IC E T O O L S T 4 4 .
CH E C K TA CH C ON N EC TION S.
RETEST.
7. 4 .1 a
RE V ER S E
MOT OR W IRE S
AND RE TE ST
7. 4 .1 b
T H E R E A R E 4 P O S S IB LE
M O T O R W I R E /T A C H W I R E
C O M B IN A T IO N S .
DO ES YE S RE V ER S E MOT OR W IR ES A ND R ETE S T.
GO TO
IT S T IL L IF S T IL L R U N N IN G A W A Y ,
CH A R T 4
RU N AW A Y ? R E V E R S E T A C H W IR E S A N D R E T E S T .
IF S T IL L R U N N IN G A W A Y ,
P U T W IR E S B A C K I N O R IG I N A L
7. 4 .1 c C O N F IG U R A T IO N . 7. 4 .1 c.2
NO
7. 4 .1 c.1
IS T H E PU T MOT OR W IRE S
M O T O R T U R N IN G NO B A C K A S W IR E D
RETEST
IN T H E C O R R E C T BE FORE A ND
DIR EC TION ? S W I T C H T A C H W IR E S
7. 4 .1 d 7. 4 .1 d .1 7. 4 .1 d .2
YES
END
7.5
Figure 16-15 Axis Motor Runways

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. OH E
Baldor SWEO drive is over temperature. OH C
Overspeed on the motor has been detected. OSP
The Baldor SWEO power supply has momentarily experienced a 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

Inverter output current exceeded the overcurrent limit during accelera- EOC1
tion.
Inverter output current exceeded the overcurrent limit during constant EOC2
speed operation.
Inverter output current exceeded the overcurrent limit during decelera- E0C3
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

Table 2: Z200/Z300 Spindle Drive Error Messages

Stall preventative function was activated during constant speed opera- EOLT
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 EOPT

CHART 10 DA S HED S YM B OLS
KE YB OA RD
KEYBO ARD AP PLY TO CE NORM
EUROPEA N M ACHINES
10-18-95 ONLY
YE S IS MILL YE S MA KE S URE ALL CHE CK THAT DOOR

IS ENTI RE TES T F OR 5V
WAI TING FOR DO ORS ARE CLOS ED, SWI TCHES A RE
KE YB OA RD AT KE YB OA RD
DO OR TO BE THEN O PE N AND CLOSE CO NNECTE D (1060 J13)
LO CKE D UP? (1090)
ACTUATED? FRONT DO OR AND WO RKING
10.1 NO 10. 1.2 10.1.3 10. 1.4

10.1.1 NO
WILL NOT NO
POSS IBLE CAUSES:
CO NTINUE YE S 32M P ?
KE Y BOA RD ( 1090)
TO JOG WHEN JOG
1030
BUTT ON IS HE LD
1040 10. 1.2a YE S
DO WN?
MA KE SURE LE D ON
10. 2 10. 2.1 1030 IS BLINK ING.
DO ES YE S
NO CHANGE POSITION IF NOT , P RES S
DISP LAY
OF CNC/DOS SWIT CH EM ERGE NCY ST OP
CHA NGE ?
AND RE SE T CP U
GO TO 10.1.2a.1 (1400 B OA RD).
KE YBOARD T ES T 10. 1.2a.2 NO
IN DI AGNOS TI CS 10. 1.2a.3
10. 3 DI SCONNE CT
CHE CK CAB LE TO 1060.
SE RIAL PO RT
CHE CK 1040 BO ARD.
ARE FROM 1090
CHE CK 1030 BO ARD.
STA RT, SLIDE CHECK WIRING TO TO P C (J15)
YE S
HO LD, OR E S TOP SWITCHES. 10. 1.2a.4
BUTT ONS (NOT KE Y S) 10. 1.2a.2a
ERRA TIC? RE P LACE CONTACTS .
CHE CK ALL P OW ER
10.4 10. 4.1 NO CO NNECTI ONS TO
PROB LEM
KE YB OA RD (1090) .
NO SOLV ED?
POW ER O FF M ILL
AND RE ST ART.
POS S IBLE P ROB LE M S:
TOO LIGHT A TOUCH 10. 1.2a.2b YE S
SOM E YE S 10. 1.2a.5
KE Y PA D
KE YS DO NO T
KE Y BOA RD (1090)
WORK ? UP DA TE
CAB LE TO 1060
TO LA TE ST
1040 BO ARD
1090 SOF TWA RE
10.5 NO 10.5.1
10. 1.2a.6
POSS IBLE PROB LE M S:

WRONG YE S KE Y PA D IF PROB LEM RECURS,
KE YS KE Y BOA RD ( 1090) RE P LACE K EY BO ARD
DI SP LAYED? CAB LE TO 1060 LO GIC
1040 BO ARD (1090)
10.6 NO 10.6.1
10. 1.2a.7
MA KE SURE J OG
MP G YE S CHECK CABLE RE P L ACE
WAS P RES SE D A ND RE P LACE
DO ES NOT CO NNECTI ONS TO KE YB OA RD LOGI C
JOG SW ITCHE S MP G
WORK ? MP G. (1090)
PROP ERLY S ET
10.7
10. 7.1 10. 7.2 10. 7.3 10. 7.4
NO
THE FIRST TIME JOG I S P RESSED, THE KEYBOA RD IN THE K EYBO ARD DIA GNO STI CS NO N-PRINTA BLE CHARACTE RS
LO GIC S E NDS "-J ", THE A XI S ("X ", " Y", "Z", "A" , "B " ARE DIS PLA YE D WI TH A "- ". T HE TAB LE SHO WS THE KE Y AND
OR "C"), A ND THE RES OLUTION ("H", "M ", OR "L"). THE CHA RACT ER T HAT WILL B E DIS PLA YE D.
WHEN JOG IS P RE S SE D A GAIN, THE K EY B OARD STA RT "- B"
SE NDS "-J " ONLY . AUTO "-D"
WHEN T HE M P G IS T URNE D, T HE K E YB OA RD MA NUAL NO DIS PLA Y, EX IT S T ES T
LO GIC S E NDS "-P " FOR A P OS ITIVE TURN O R SING LE S TE P "-H"
"-Q" FOR A NE GA TIV E TURN. JOG "-J "
"-J ", " -P ", A ND "-Q" ARE SI NG LE CHARACT ERS, NOT "-" SP INDLE ON/OF F "-L"
AND "J ". SHIF T-S P INDLE O N/OFF "-O "
THEY A RE DI SP LAY E D IN THE DIA GNOS TI CS W ITH SLIDE HOLD "-A "
THE "-" TO DIFFE RENTI ATE T HE M FROM THE CO OLANT 1 "-C"
LE TT ERS "J ", "P " A ND "Q". CO OLANT 2 "-E "
TOOL I N/OUT "-G "
TURRET CCW "-I"
MIS S ES YE S POSSIBLE CAUSES: TURRET CW " -M "
JOG PULS ES 1030 BA CKS PA CE "_"
FROM MP G? MP G DE LE TE "& "
10.8 ENTE R "-N"
10. 8.1 RA P ID TRAVEL SWIT CH NOT DI SP LAYABLE, SCREEN WILL SHOW " "
NO KE YLO CK S ENT WHEN ES TOP P RES S ED. ~ = LOCKE D
OPT IONA L ST OP ON = '"' O FF = " "
EM ERGE NCY ST OP GENE RALLY NOT DIS PLA YA B LE . ES TO P S E NDS
S TA TUS OF K E YLOCK A ND ES TOP , STA TUS
GO T O O F OP TIO NAL S TO P S WITCH, S TA TUS OF
PA GE 2 OF B LOCK S KIP S WIT CH, A ND STA TUS OF RAP ID
CHA RT 10 T RAV EL SWI TCH. A NY COM BINA TIO N OF
' ' OR '~" ' M AY A PP E AR.
MP G + "-P "
MP G - "-Q"
Figure 16-16 Keyboard

CONTINUED
FROM PAGE 1
OF CHART 10 CHART 10 continued (page 2)
KEYBOARD
10-18-95
RETURN TO
CNC MODE
10.9
MISSES DISCONNECT RS232

KEYSTROKES YES CABLE AND TRY AGAIN
OR JOG PULSES IN (MILL LISTENS FOR KEYBOARD
CNC MODE BUT NOT IN AND RS232 INPUT IN MILL MODE.
DIAGNOSTICS? NOISE ON THE RS232 CAN
MASK KEYSTROKES.)
10.10
NO 10.10.1
CHECK +5V AND GND

OTHER POSSIBLE CAUSES:
YES (THIS MAY HAPPEN WIRING FROM
KEYBOARD KEYPAD
ONLY IN CNC MODE POWER SUPPLY TO
(BUT NOT SCREEN) KEYBOARD (1090)
AND NOT IN 1090
DROPS OUT ESTOP (OR REMOTE ESTOPS)
DIAGNOSTICS) (RUN EXTERIOR +5V
OF JOG? REMOTE TOOL IN/OUT
AND GND FOR TEST)
10.11 10.11.1 10.11.2 10.11.3
NO
IF THIS ONLY HAPPENS

COULD BE:
IN CNC MODE AND
CNC YES RUN AXIS CARD 1030
NOT IN DIAGNOSTICS
(AND KEYBOARD) DIAGNOSTICS 1400
IT IS PROBABLY A PROBLEM
DROPS OUT AXIS CARD
WITH ONE OF THE CARDS
OF JOG? OR ???
IN THE CARD CAGE
10.12 10.12.1 10.12.2 10.12.3
NO
ATC
VERIFY THAT
CHANGES
YES 1090 AND 1040
DIRECTIONS WHEN
ARE LATEST
TURRETCCW IS
VERSIONS
HELD DOWN?
WITH UPDATES
10.13 10.13.1
NO
CONSULT
FACTORY
10.14
Figure 16-17 Keyboard (Continued)

DIFFICULT TO DIAGNOSE PROBLEMS CAN OCCUR
CHART 11 IF MACHINE IS NOT PROPERL Y GROUNDED.

THERE MUST BE A CONTINUOUS GROUNDING
FINISH CONDUCTOR (AS SPECIFIED ON THE GROUNDING
PROBLEMS FINISH PROBLEMS LABEL IN THE MACHINE'S DISCONNECT BOX)
FROM THE VMC'S GROUND BUS TO THE GROUND
10-20-95 BUS IN THE BUILDING'S POW ER DISTRIBUTION PANEL.
IF PROBLEM IS NOT RESOLVED QUICKLY, AND BEFORE DOING ANY MAJO R

WORK LIKE CHANGING SPINDLE, BALL SCREW S, MO TORS ETC..
DO FADAL STANDARD TEST CUT.
SEND SAMPLE PART CUT WITH TEST CUT TOOL SUPPLIED BY FACTORY.
CO NTACT FACTORY FOR TEST CUT KIT.
CHECK +5V,+12V,-12V.
ALSO SET METER FO R VAC
AND CHECK FOR AC RIPPLE
ON +5V, +12V AND -12V DC
(0 .015VAC RIPPLE MAX ON +/-12V,
0.00 5VAC RIPPLE MAX ON +5V)
11.0
VERIFY FOR ADDITIO NAL PRECISIO N IN LEVELING,

MACHINE IS LEVEL PERFORM SQUARENESS TEST ON X & Y,
(SEE MAINTENANCE THEN SQUARNESS TEST ON COLUMN,
MANUAL) THEN SPINDLE TRAM TEST.
(CONSULT FADAL SERVICE DEPT FOR PROCEDURE)
11.1
CHECK SIN/COS
CHECK
YES CHECK SIG NALS USING CHECK FOR
WAVY FINISH CHECK SPINDLE MOTOR
BALANCE SERVICE TOOL ST48. SPINDLE
ON STRAIGHT BELTS TENSION CABLE
ON AXES ADJUST IF VARIANCE VIBRATIONS
CUTS? AND MOTO R MO UNTS
> 0.001V
11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.2.5

NO DO NOT OVERTIGHTEN BELTS.
DO CHECK CHECK SIN/COS

CIRCLES HAVE YES MATCH X & Y AXIS AMPLIFIER SIG NALS USING
CHECK
STEPS AT 90 & 45 FOLLOWING CO MPENSATION SERVICE TO OL ST48.
BACKLASH
DEGREES? ERROR SETTING ADJUST IF VARIANCE
ON X & Y > 0.001V
11.3 11.3.1 11.3.2 11.3.3 11.3.4

NO
CHECK
DO
YES AXIS AMPLIFIER
ANGLES HAVE
COMPENSATION
STAIR-STEP
SETTING
FINISH?
ON X & Y
11.4
11.4.1
NO
DO CO NSULT FACTORY
CUT S HAVE A YES CHECK BELTS SERVICE DEPT
CRISS-CROSS AND BEFORE
APPEARANCE? BELT TENSION REPLACING
(ESP X) SPINDLE
11.5
11.5.1 11.5.2
NO
DO ES
CO NSULT FACTORY
A BAD CUT YES CHECK SERVICE DEPT
CO RRESPOND TO
SURVEY TABLE BEFORE
A PARTICULAR PLACE
AND BACKLASH CHANGING
ON THE BALL
BALLSCREW
SCREW?
11.6.1 11.6.2
11.6
NO
CO NSULT
FACTORY
11.7
Figure 16-18 Finish Problems

DASHED SYMBOLS
BAD POWER/ CHART 12 APPLY TO CE NORM
BAD VOLTAGE EUROPEAN MACHINES
BAD POWER/BAD VOLTAGE ONLY
6-16-95
CHECK
INCOMING VOLTAGE
AT MAIN DISCONNECT
AND AT INPUTS TO
TRANSFORMER
12.1
CONSULT
CHECK 1170
INCOMING NO CHECK FUSES ELECTRICIAN
SURGE
VOLTAGE IN MAIN POW ER FOR WIRING
SUPPRESSOR
GOOD? DISCONNECT FAULTS IN
BOARD
BUILDING
12.2 12.2.1 12.2.2 12.2.3

YES
A12, B12, C12 SHOULD BE 230-245 VAC LEG TO LEG.

CHECK OUTPUT 15 & 16 SHOULD BE 120 VAC.
VOLTAGES OF *A10, B10, C10 SHOULD BE 95 VAC LEG TO LEG.
TRANSFORMER *13 & 14 SHOULD BE 120 VAC WITH T817E OR T818E TRANSFORMER.
*TRANSFORMER WILL HAVE A10,B10,C10 OR 13 & 14, BUT NOT BOTH.
12.3
USE CLAMP-ON VERIFY THAT

OUTPUT NO AMMETER TO TRANSFORMER IS
VOLTAGES CHECK FOR PROPERLY
GOOD? EXCESSIVE CONFIGURED FOR
12.4.1 CURRENT DRAW 12.4.2 INPUT VOLTAGE
12.4 TYPICAL CURRENT WITH MACHINE AT REST:

YES A12,B12,C12 - 0.3A
15 & 16 - 1.5A
A10,B10,C10 OR 13 & 14 - 0.4A
CHECK INPUT VOLTAGE THESE ARE TYPICAL VALUES. ACTUAL VALUES MAY VARY.
EXCESSIVE VALUES WOULD BE OVER 5A HIGHER WITH MACHINE AT REST.
TO AMPLIFIER CHASSIS
AND BUS VOLTAGE
ON LARGE BLUE INPUT VOLTAGE SHOULD BE 95 VAC AND CAPACITOR VOLTAGE 133 VDC WITH T816 TRANSFORMER.
CAPACITOR INPUT VOLTAGE SHOULD BE 120 VAC AND CAPACITOR VOLTAGE 165VDC WITH T817E OR T818E TRANSFORMER.
12.5
ON CE MACHINE
INPUT NO CHECK
CHECK FOR
VOLTAGE CIRCUIT BREAKERS
LOOSE TERMINALS
GOOD? ON SUPPLY TO
AXIS AMP CHASSIS
12.6 12.6.1 12.6.2

YES
EMERGENCY STOP CHECK K2 AND F17 VERIFY OVERLOAD

BUS NO MUST BE OUT ON 1100-1 RELAYS ARE RESET.
VOLTAGE AND (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 12.7.1 12.7.2 12.7.3

YES
GO TO
PAGE 2 OF
CHART 12
12.8
Figure 16-19 Bad Power/Bad Voltage

CO N TIN U E D
FR OM
PA G E 1 O F
C H A R T 1 2 c o nti nu e d (p a ge 2)
CH A R T 1 2 B A D D C VO L T A G E
6- 1 6 -9 5
CH E C K IN PU T
VOL T AGE TO
DC POW ER S U P PL Y
(1 2 2 0 )
SH O U L D B E 1 2 0 VA C
12 A .1
US E C L AM P -ON AM ME TE R
NO CH E C K FOR
IN PU T TO C H E C K F OR E XC E SS IV E
LO OS E
VOL T AGE CU R R E N T D R A W ON
TER M IN A L S
GOO D ? 12 0 VA C L IN E S FR O M
O N 1 2 0 VA C L I NE S
12 A .2 .2 TR AN S FOR M ER
12 A .2 YE S 12 A .2 .1
TYP IC A L C U R R EN T TO 1 2 2 0 I S 1 . 5 A.
O TH E R BO AR D S (1 1 0 0 - 1 , 1 1 0 0 - 2, C H IL L E R, E TC .)
MA Y BE P UL L I N G D OW N L IN E VOL T AG E.
CH E C K D C PO W ER
SU P PL Y OU TP U TS :
+5 V & C OM , AL S O C H E CK F OR A C R IP PL E ON T H E D C VOL T AGE .
+1 2 V & C O M, SE T M ET ER F OR V AC A N D C H E C K + 5 V , + 1 2V , AN D - 1 2 V;
-1 2 V & C OM ME TE R SH O U L D SE TTL E TO L ES S TH AN 0 .0 1 V AC .
IF A C R IP PL E IS P R ES E N T R E PL A C E 1 2 2 0 P OW ER S U PP L Y .
12 A .3
CH E C K CH E C K BR OW N OU T
AL L YE S RE L A Y ( K 1 )
FU SE ON
VOL T AGE S ON 1 220
POW ER S U PP L Y
BA D ? BR O W NO U T R E LA Y M U ST
(1 2 2 0 )
BE W HIT E 1 40 2-1 (7 0Y Y2 108 4)
12 A .4 .2
12 A .4 NO 12 A .4 .1 BR O W NO U T R E LA Y (K 1) O N 1 22 0 W ILL NO T LA TC H A T L ES S TH AN 4.5 V
AN D W IL L R EL E AS E IF +5V D R O PS BE LO W 4 .5V .
DI SC ON N E C T + /- 1 2 V O U TP UT S
NO FR OM 1 2 2 0 AN D T ES T A GA IN .
+/- 1 2 V RE P L AC E 1 2 2 0
GOO D ? DC POW ER S U P PL Y
IF N O W GOO D , L OO K F OR B AD
BOA R D P U LL I N G TO O M U C H 1 2 V. 12 A .5 .2
12 A .5 .1
12 A .5
IF + / -12V I S B A D IT C A N E FF E CT CH ILL ER C O NT RO L , R S 232 , CL O CK S, S I NE /C O SIN E, A N D A XIS CO N T RO L.
YE S +/ -1 2V M AY RE A D O K ON A DC M ET ER A ND S TI LL BE BA D ; AN O SC ILL OS C O PE IS N E ED E D T O F UL LY TE S T + /-12 V,
BU T A C R IP PL E M A Y S H OW U P W HE N M ET ER IS S E T FO R VA C .
TU R N OFF MA C H IN E .
+5 V PR E SS E ME R GE N CY S TOP .
NO
GOO D ? RE M OVE A L L C A RD S
(5 .0 1 - 5 .1 0 V) FR OM C AR D C A GE.
UN P L U G J 9 -J 1 3 FR O M 1 0 6 0 .
PO W ER O N MA C H IN E .
12 A .6
YE S 12 A .6 .1
DI SC ON N E C T + 5 V
EN D IS +5 V NO O U TP UT S FR O M 1 2 2 0 . NO
+5 V
PO W ER G OO D U N D E R NO W GO OD ? ATT AC H 1 0 O H M 5 W
GOO D ?
STA TIC C O N D ITIO N S RE S IST OR B E TW E EN
12 A .7 +5 V AN D C OM.
12 A .6 .2 12 A .6 .3 12 A .6 .4
YE S SW I T CH IN G P O W E R S UP P LIE S R EQ U IR E YE S
A LO A D T O W O RK PR O P ER LY .
LO OK FO R I N D IVI D U AL C A R D
TH AT MA Y BE P U L L IN G T OO RE C ON N E C T
MU C H + 5 V +5 V O U TP U TS
(R E PL AC E CA R DS O NE A T A T IM E.) TO 1 2 2 0 .
(R E PL AC E J9-J 13 O N E AT A T IM E . )
12 A .6 .2 a (C A RD S SH O U LD NE VE R BE 12 A .6 .4 a
RE M O VE D O R R EP LA CE D
W ITH TH E P O W ER O N .)
US E C L AM P -ON
AM ME TE R
PU T AL L C A R D S RE P L AC E 1 2 2 0
TO L OO K FOR
BA C K I N C AR D C A GE DC PO W ER S U P PL Y
EX C ES SI VE
CU R R E N T D R A W
12 A .6 .4 b
12 A .6 .2 b TYP IC A L C U R R EN TS 12 A .6 .5
W ITH M A C HI N E A T R ES T:
1 0 6 0 - 5 .5 A
1 1 0 0 -1 - 0 A
1 1 0 0 -2 - 0 A
P EN D A N T - 0 .5 A
TH ES E A R E T YP I C AL VA LU ES .
AC TU A L V AL UE S M A Y V A RY .
EX CE S SIV E V A LU ES W O UL D B E 2-5A H IG H E R.
Figure 16-20 Bad DC Voltage (Continued)

CHART 13 SO M E H E AD S HA VE T E M P ER A T U RE
RO TAR Y HE ADS
SW I T C H E S I N ST EA D O F ( O R I N
AD D IT I O N T O ) F U SE S T O PR O T E CT
RO T A RY H E A D S T H E M O T O R F R O M O V E RH E AT I NG .
A A X IS A A XIS T H ES E A U T O M A T I C AL LY RE S ET
W HE N TH E M O TO R C O O L S.
7- 4 - 95
T E M P E RA T UR E S N AP S W I TC H
W I L L S H OR T C O S SI G N AL T O G ND
GO TO
YE S CH E C K CH E C K O N R ES O LV ER B O A R D I N M O TO R
IF M O T O R O V ER H E AT S. CH A R T 4
A X IS D E A D ? OVE R LO A D RO T A RY H E A D CH E CK CO S O UT PU T T O RE S O L VE R A X IS
RE L A Y S FU SE (P I N 8 O F J 5 O N 1 06 0 ) CO N T R O L
FO R S H O RT T O G ND .
LE T C OO L .
13 . 1 NO 13 . 1 .1 13 . 1 .2 13 . 1 .4
13 . 1 .3
YE S
HE A D
O VE RH EA TS ?
13 . 3 NO
CH E C K F O R
HE A D CH E C K
YE S W AT ER IN
KE EP S FOR
FU SE HO LD E R
B L O W IN G M E C H A N IC A L
OR M OTOR
FU SE S? B IN D
HO U S IN G
13 . 4 NO 13 . 4 .1 13 . 4 .2
US E C L A M P -O N G E A R IS D A M A G E D
AM ME TE R TO CU R R E N T YE S BY A C R AS H.
YE S CH E C K F O R E X C E S S I V E IN RE T U R N H E A D
LE A K IN G RE P L A C E S E A L
EX C ES SI VE ON E SP OT? T O F A C T O RY
O IL ? T H A T IS L E A K IN G
CU R R E N T D R A W F O R R E P A IR S
13 . 4 .3 13 . 4 .4 13 . 4 .5
13 . 5 NO
NO 13 . 5 .1
BA CKLA SH YE S
AR E YE S CH E C K RE A D JU S T
AD J U ST OR GE AR ME SH
TH E GEA R S O IL L E V E L GEA R M ES H BA C KLA SH
A D J U S T M E NT
NO IS Y ? IN H E A D AN D GE A R ME S H
T O O T IG H T ?
13 . 6 NO 13 . 6 .1 13 . 6 .2 13 . 4 .4 a 13 . 4 .4 a .1
NO
DO E S
C H ECK W AS
A X IS H A V E YE S
YE S A X IS J U M P E R CA P A C IT Y
LI M I T E D M O T IO N ? DO N O T E X C E E D
ON 1010 CA RD. O F T HE H E A D
(W I L L N O T D O F U L L LO A D C A P A C IT Y
IT M U S T B E A N EX CEE D ED ?
RO T A T IO N )
A - A X IS J U M P E R.
13 . 7 .1 13 . 4 .4 b 13 . 4 .4 b .1
13 . 7 NO
NO
CH E C K R A T I O
GO TO IN S E T P IS CH A N G E
C H ART 4 YE S
DUTY CYCLE P R O G RA M
A X IS C O N T R O L
E X C E S S IV E ? T O G IV E M O T O R
13 . 7 .2 T IM E T O C O O L
13 . 9 13 . 4 .4 c
13 . 4 .4 c. 1
NO
M O T O R W I RE S
ARE
YE S AR E SH IELD E D .
M O T O R W IR E S
V E R IF Y T H A T S H IE L D
SH OR TE D TO
IS S T R I P P E D B A C K
CH A S S IS ?
FR OM COND UC TOR.
13 . 4 .4 d 13 . 4 .4 d .1
IS
S H O R T IN MOT OR RE P L A C E
MOT OR OR MOT OR
CA B L E ?
13 . 4 .4 d .2 13 . 4 .4 d .3
CA B L E
RE P A IR /
RE P L A C E
CA B L E
13 . 4 .4 d .4
Figure 16-21 Rotary Heads A Axis

C H A R T 14
FA D A L T R 65 SO M E H E AD S HA VE TE M P ER A TU RE
SW IT CH E S I N ST EA D O F (O R IN
TR 6 5 R OTA R Y H EA D S
R O TA R Y H E A D S AD D IT I O N T O ) F U SE S T O PR O TE CT
TH E M O TO R FR O M OV E RH E AT ING .
A & B A XI S A & B A XIS TH ES E A U TO M A TIC AL LY RE S ET
W HE N TH E M O TO R C OO L S.
6- 15-95
TE MP E RA T UR E S N AP S W ITC H
W ILL S H OR T C O S SIG N AL TO G ND
YE S CH E C K CH E C K ON R ES O LV ER B OA R D IN M O TO R
IF M O TO R O V ER H E AT S.
AX IS D EA D ? OVE R LOA D RO TA RY H E AD CH E CK CO S O UT PU T T O RE S OL VE R
RE LA YS FU SE (P IN 8 O F J4 0R J5 O N 10 60 )
FO R S H O RT TO G ND .
LE T C OO L .
14. 1 NO 14. 1.1 14. 1 .2
14. 1.3
FOLLOW I N G E R RO R
DO ES GO T O
YE S IMP R OP ER LY
B- AX IS CH A R T 4
AD J U STE D
FAU L T D U RI N G AX IS
RA P ID ? B A XI S SE TS FO L LO W IN G E R RO R *W HE N AD JU S TIN G B -A XIS AM P : CO N TR OL
DIF FE RE N TL Y F RO M O TH E R A XE S .* S ET PA R AM E TE R S F OR 90 : 1
D I SC O N NE C T S CA LE
14. 2 NO 14. 2.1 14. 1.4
B- AX IS
YE S YE S IN H IBI T R E LAY NO RE P L AC E R ELA Y * *A U GA T R D I R ELA Y
HE A D TR 65
TU R N S O FF A M P O R C O R R E CT IN C ON TR OL C AB IN E T
OVE R H EA TS ? B- AX IS ?
WH EN B R A KE W IR IN G
IS ON ?
14. 3 14. 3.1 14. 3.2
NO 14. 3.3
NO
YE S
CH E C K FOR US E C L AM P -ON GEA R IS D A MA GE D

HE A D CH E C K YE S
YE S WAT ER I N AM ME TE R TO CU R R E N T BY A C R AS H .
KE EP S FOR
FU S E H OL D ER CH E C K FOR EX C ES SI VE IN RE TU R N H E AD
BL OW IN G ME C H AN I CA L
O R M OTOR EX C ES SI VE ON E SP O T? TO F AC TO RY
FU SE S? BIN D
HO U SIN G CU R R E N T D R A W FOR R E PA IR S
14. 4
14. 4.1 14. 4 .4
NO 14. 4.2 14. 4.3 NO 14. 4.5
BA C KLA SH YE S RE A D JU S T
YE S OR GE AR ME SH
LE A KIN G RE P LAC E S EA L BA C KLA SH
AD J U STM E NT
OIL? TH AT IS LEA K IN G AN D GE A R ME S H
TO O TIGH T?
14. 5
NO 14. 5.1 14. 4.4a 14. 4.4a.1
NO
W AS
AR E YE S CH E C K CA P AC IT Y YE S
AD J U ST DO N OT EX C EE D
TH E GEA R S OIL LE VE L OF T HE H E AD
GEA R M ES H LO AD C A P AC IT Y
NO IS Y? IN H EA D E XC E ED E D ?
14. 6 14. 4.4b
NO 14. 6.1 14. 6.2
NO 14. 4.4b.1
TR 65 IS CH A N GE
YE S BR A KE M AY B E YE S
B- AX IS D U TY C YC LE PR O G RA M
B A X IS C LUT C H DE FE C TIV E
LO SI NG EX C ES S IV E? TO G IVE M OTO R
MA Y BE LOOS E
POS ITI ON ? TIM E T O C O O L
CH E C K AI R SO LEN OI D
14. 4.4 c
14. 7 NO 14. 4.4c. 1
NO 14. 7.1 14. 7.2
MOT OR W I RE S
AR E
GO TO YE S AR E SH I ELD E D .
MO TOR W IR ES
C H AR T 4 VE R IFY TH A T S H IE L D
SH OR TE D TO
AX IS C ON TR O L IS STR I PP ED BA C K
CH A S SIS ?
FR OM C ON D U C TOR .
14. 4.4 d
14. 8 14. 4.4d.1
IS MOT OR
SH OR T IN RE P LAC E
MOT OR OR MOT OR
CA B L E?
14. 4.4d .2 14. 4.4d.3

CA B L E
RE P AIR /
RE P L AC E
CA B LE
14. 4.4d.4
Figure 16-22 TR65 Rotary Heads A & B Axes

CHART 15
TS UDAKO M A 301 SO M E H E AD S HA VE TE M P ER A TU RE
ROTAR Y HEADS
SW I T CH E S IN ST EA D O F (O R I N
AD D IT IO N T O ) F U SE S T O PR O TE CT
TSU D A KO MA 301 TH E M O TO R FR O M OV E RH E AT I NG .
A & B A XIS A & B AXIS TH ES E A U TO M A T IC AL LY RE S ET
W HE N T H E M O TO R C OO L S.
6- 1 5 -9 5
TE MP E RA T UR E S N AP S W I TC H
W ILL S H OR T C O S SI G N AL TO G ND
YE S CH E C K CH E C K ON R ES O LV ER B OA R D I N M O TO R
IF M O TO R O V ER H E AT S.
A X IS D E A D ? OVE R LOA D RO T A RY H E A D CH E CK CO S O UT PU T T O RE S OL VE R
RE L A Y S FU SE (P I N 8 O F J4 O R J 5 O N 1 06 0)
FO R S H O RT TO G ND .
15 . 1 15 . 1 .1 15 . 1 .2 L E T C OO L .
NO
15 . 1 .3
F O L L O W I N G E R RO R
DO E S GO T O
YE S IM P R O P E R L Y
B- A X IS CH A R T 4
A D J U ST E D
F A U L T D U RI N G AX IS
RA P ID ? B A XI S SE TS FO L LO W IN G E R RO R * W HE N AD JU S TIN G B -A XIS AM P : CO N T R O L
DI F FE RE N TL Y F RO M O T H E R A XE S .* S ET PA R AM E TE R S F OR 90 :1
D I SC O N NE C T S CA LE
15 . 2
NO 15 . 2 .1 15 . 1 .4
YE S
HE A D
OVE R H EA TS ?
15 . 3 NO
CH E C K F O R US E C L A M P -O N G EA R IS D A M A G E D
HE A D CH E C K YE S
YE S W AT ER I N AM ME TE R TO CU R R E N T BY A C R AS H .
KE E P S FOR
FU SE H OLD E R CH E C K F O R E X C E S S I V E IN RE T U R N H E A D
B L O W IN G M E C H A N I CA L
OR M OTOR EX C ES SIVE ON E SP OT? T O F A C T O RY
FU SE S? B IN D
HO U S IN G CU R R E N T D R A W F O R R E P A IR S
15 . 4
NO 15 . 4 .1 15 . 4 .2 15 . 4 .3 15 . 4 .4 NO 15 . 4 .5
YE S BA C KLA SH YE S
LE A K IN G RE P L A C E S E A L RE A D JU S T
OR GE AR ME SH
O IL ? T H A T IS L E A K IN G BA C KLA SH
A D J U ST M E NT
AN D GE A R ME S H
T O O T IG H T ?
15 . 5 15 . 5 .1
NO
15 . 4 .4 a 15 . 4 .4 a .1
NO
AR E YE S CH E C K W AS
AD J U ST YE S
TH E GEA R S O IL L E V E L CA P A C IT Y
G EA R M E S H DO N O T E X C E E D
NO IS Y ? IN H E A D O F T HE H E A D LO A D C A P A C IT Y
E X C EE D E D ?
15 . 6 15 . 6 .1 15 . 6 .2
NO
15 . 4 .4 b 15 . 4 .4 b .1
NO
GO TO
C H AR T 4
A X IS C O N T R O L IS CH A N G E
YE S
DU T Y C Y C L E P R O G RA M
EX C ES SIVE ? T O G IV E M O T O R
15 . 8 T IM E T O C O O L
15 . 4 .4 c NO 15 . 4 .4 c. 1
M O T O R W I RE S
AR E
YE S A R E S H I EL D E D .
M O T O R W IR E S
V E R IF Y T H A T S H IE L D
SH OR TE D TO
IS S T R I P P E D B A C K
CH A S S IS ?
FROM CONDUCTOR.
15 . 4 .4 d
15 . 4 .4 d .1
IS MOT OR
S H O R T IN RE P L AC E
MOT OR OR MOT OR
CA B L E ?
15 . 4 .4 d .2 15 . 4 .4 d .3
CA B L E
RE P AIR /
RE P L A C E
CA B L E
15 . 4 .4 d .4
Figure 16-23 Tsudakoma 301RotaryHeads A & B Axes

CHART 16
SERVO COOLANT CONTROL
12-5-95
SERVO THE COOLANT AXIS MUST BE SET TO COOLANT IN SETP.
COOLANT
IF AXIS IS SET TO 90:1, THE MILL WILL NOT COLD START.
AXIS CARD MUST HAVE SERVO COOLANT SOFTWARE.
POSITION OVERRIDE
POT MUST BE:
COMMAND SIGNAL ENCODER MUST BE AMPLIFIER MAY BE
CENTERED,
COOLANT YES MUST BE CONNECTED UNPLUGGED OR DEAD.
PLUGGED INTO J3
NOZZLE WILL CONNECTED AT (J5 OF 1010, CHECK AMPLIFIER FUSE.
OF APPROPRIATE
NOT MOVE AMPLIFIER AND J2 & J3 OF 1890-0, AND (AMPLIFIER IS ALIVE
1010 CARD,
J1 OF 1010 9-PIN MOLEX AT MOTOR) IF GREEN LED IS LIT.)
CONNECTED TO GND
16.1 AND +12V. 16.1.4 AMPLIFIER FUSE
NO 16.1.2 16.1.3 HOLDER IS PART OF
16.1.1
POWER RECEPTACLE
ON AMPLIFIER.
ADJUST OVERTEMP SWITCH

NOZZLE YES POSITION OVERRIDE CHECK ON MOTOR MAY
AMPLIFIER MAY BE
POSITIONING IS POT TO PARAMETERS HAVE TRIPPED
MISADJUSTED.
WRONG NEUTRAL (VERTICAL) IN SETP
POSITION
16.1.5
16.2 16.2.1 16.2.2 16.2.3
NO
AXIS MUST BE
ACTIVE IN SETP
AND SET TO
"COOLANT"
YES MOTOR LEADS SIGNAL UNPLUGGED ENCODER CABLE
NOZZLE 16.1.6
REVERSED AT FROM AMPLIFIER DISCONNECTED
RUNS AWAY
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 16.3.1 16.3.2 16.3.3 3- IN (ON) 100% CURRENT SCALING
NO
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
YES AMPLIFIER ENCODER IS 10- OUT (OFF) 120/60 PHASING
RESPONSE AMPLIFIER IS
DIP SWITCHES UNPLUGGED
IS MUSHY MISADJUSTED POT PRESETS:
ARE SET WRONG FROM AMPLIFIER
LOOP GAIN FULLY CCW, THEN 5 TURNS CW.
CURRENT LIMIT FULLY CW.
REF IN GAIN FULLY CW.
16.4 NO 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.
YES COOLANT VALVE IN SETP SET COOLANT AXIS RATIO TO COOLANT.
NO COOLANT FLOOD COOLANT
FOR SERVO COLD START.
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,
"UP" DIRECTS NOZZLE POT IS MISWIRED
RESPONSE YES OVERSHOOT IS OK.)
UP THE TOOL. OR WHEN AMP IS ADJUSTED, SET COOLANT AXIS RATIO
OF OVERRIDE POT
"DOWN" DIRECTS J4 ON 1890-0 IS TO COOLANT IN SETP.
IS REVERSED
NOZZLE DOWN THE TOOL. MISWIRED *
16.6 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.
YES WIRES TO MOTOR ARE SHIELDED. AMPLIFIER

AMP MAY BE INHIBITED
RED LED SHIELD MUST BE STRIPPED BACK DIP SWITCH FOR
BY EMERGENCY STOP
ON AMPLIFIER FROM CONDUCTOR OR A PHASING
OR OVERTEMP OF MOTOR SHORT TO GROUND WILL OCCUR. MAY BE MIS-SET
16.7
16.7.1 16.7.2 16.7.3
Figure 16-24 Servo Coolant Control

C I R C LE
CHART 17 DI F F IC U L T T O D I A G NO SE P R O B L E M S C A N O C C UR
IF M A C H I N E I S N O T P R O PE R L Y G R O U N D E D.
RO U N D N E S S C IR C L E R O U N D N ESS T H E R E M U ST BE A C O N T I NU O U S G R O U N D IN G
1 0 -3 - 9 5 CO N D UC T O R ( AS S PE C IF I ED O N T H E G R O U N D IN G L AB E L
IN T H E M A C H IN E 'S D IS C O N N E C T BO X ) F R O M T H E V M C 'S
G R O U N D B US T O T H E G R O U N D B U S IN T H E B U IL D IN G ' S
V E R IF Y F O R A D D IT IO N AL P R E C I S IO N IN L E V E L IN G , PO W E R D I S T R I BU T I O N P AN E L .
M A C H IN E IS L EV EL P E R F O R M S Q U A R E N ES S T E ST O N X & Y ,
(S E E M A I NT EN A N C E T H EN S Q U A R N E S S T E S T O N C O L U M N ,
MA NUAL) T H EN S P IN D L E T R A M T E S T .
(C O N S U L T F A D A L S E R V I C E D E P T F O R PR O C E D U R E)
17 . 1
TES T B A LAN C E OF
S IN / C O S S IG N A L S IF SI N A ND C OS A RE NO T
B A LA NC E D W I T H IN 0 . 0 0 1 V,
US IN G
B A LA NC E S I N AN D CO S
F A D A L S IN /C O S T E S T ER A N D R U N T ES T C U T A G A I N .
(S ER V IC E T O O L ST 4 8 )
17 . 2
CH E C K A N D A D J U S T PR O CE D UR E F O R A D J U ST I N G L O OP G AI N A N D B A LA N CE I S I N T H E MA I N T E NA N C E M A NU A L .
US I NG T HE F O L L O W I N G E R RO R DI S P L A Y I S MO R E AC C UR A T E T H A N A M E T E R .
P O S IT I O N L O O P G A I N ON C E T HE L O O P GA I N AN D B A L A NC E AR E A D JU ST E D, R ED U CE TH E F E ED R AT E T O F2 0 . AN D
AN D B A L A N C E F O R FI N E T UN E T H E L OO P G A I N AN D BA L A N CE A DJ US TM E N T S .
X A N D Y AX E S.
17 . 3
CH E C K
B A C KL A SH (T H E S CR E W P I T CH C O M P E NS A TI O N TA B L E S CA N AL SO A FF E C T
CI R CL E R O U ND N E S S W HE N CU T T I NG L AR G ER D I A M E TE RS . )
O F X & Y AX E S
17 . 4
CH E C K F O R
LO O S EN E S S IN
M O T O R C O U P L ER S
AND WO RN OR LOO SE
BA L L S C R E W S
17 . 5
CH E C K W A Y L U B E
AN D V ER I F Y W A Y L U B E
IS B E IN G DE L IV ER E D
T O A L L A X E S.
(L U B RI C AT E L I NE A R W A Y S .)
17 . 6
PA R T M U S T B E IN S P E C T E D O N M A C H IN E
B E F O R E A NY C L A M P IN G IS R E M O V ED .
IN SP E C T E D CL A M P I NG A ND FI X T U R I NG C A N D I S T O RT TH E P A RT .
IS PA R T
O F F M A C H IN E IF TH I S H A PP E NS , TH E P A RT W I L L B E RO U N D W H E N C U T
IN S P EC T ED O N O R
B U T W H E N P AR T IS R EL E A S ED F R O M T H E C L A M P IN G
O F F M A C H IN E ? TH E C U T W I L L BE D IS T OR T ED .
T O F I N D T H E S O UR C E O F D I S T O R TI O N, P A RT MU S T
B E I NS P EC T E D O N M AC H I NE B EF O RE I T I S R E L E AS E D.
17 . 7 IN S P EC T ED O N M A C H IN E
17 . 7 .1
N 1 (C IR C L E R O U N D N E S S T E S T
E N T E R T H E T E S T P R O G R AM
AT R I G H T T O C U T A 1 IN C H N 2 (0 .5 0 0 D I A E N D M IL L , T O O L D IA M E T E R M U S T B E IN T O O L T AB L E , T O ,1 ,.5
IN S ID E D IA H O L E 0 .2 5 D E E P N 3 (H O M E IS C EN T ER O F P A R T
IN A L U M I N U M . N 4 (S E T T O O L AT T O P O F P AR T
T E S T C IR C L E W IL L B E N 5 G 0 G 1 7 G 4 0 G 8 0 G 9 0 E0
RO U GH C U T A N D T H EN N 6 X 0 Y 0 M 3 S 1 00 0 0
F IN I SH C U T . N 7 H 1 D 1 Z 0 .1 M 8
N 8 G 1 Z - 0 .2 5 F 4 .
17 . 8 N9 G8
N 1 0 L9 4 0 2 R 0 + 1 5 . R 1 + 0 .9 8 0
N 1 1 L9 4 0 2 R 0 + 1 5 . R 1 + 1 .
PL A C E D I A L I N DI C A T O R N12 M5 M 9
IN S P IN D L E N13 G0 H 0 Z0
(A D J U S T X A N D Y
S O S P I N DL E I S AT
N14 X0 Y 0 E 0
EX AC T C E NT E R O F H O LE N15 M2
A C C OR D I NG T O I N D IC A T O R )
17 . 9
RO T A T E SP IN D L E SP EC IF IC A T IO N S F O R C IR C L E RO U N D N E S S :
MA N U ALLY TO M A XI M U M D E VIA T I O N
CH E C K R O U N D N E S S V M C 8 0 30 , VM C 6 0 3 0 < .0 0 0 6 - .0 0 1 2
O F C IR C L E V M C 5 0 20 A , 4 0 2 0 A , 4 0 2 0 , 3 01 6 , 2 2 1 6 , 1 5 < .0 0 0 4 -.0 0 0 8
17 . 1 0
CO N T IN U E D
O N P AG E 2
OF CHART 17
Figure 16-25 Circle Roundness

CONTINUED
FROM PAGE 1
OF CHART 17
CIRCLE ROUNDNESS
10-3-95 NOTE 1: IF A MEASUREMENT 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 REMOVE PART FROM IS

CIRCLE YES FIXTURING AND CIRCLE YES
ROUND? INSPECT OFF ROUND?
(SEE NOTE 1) (SEE NOTE 1)
MACHINE
17A.1
NO 17A.1.1 17A.1.2 NO
CHECK AND ADJUST

CLAMPING IS
GIBS AND STRAPS
DISTORTING PART.
ON BOX WAY MACHINES
CHANGE CLAMPING
METHODS
CHECK FOR TIGHT SLIDES
AND RETEST
ON LINEAR WAY MACHINES
17A.2 17A.1.3
DO ANOTHER
CIRCLE TEST
CUT
17A.3
IS
CIRCLE YES
ROUND?
(SEE NOTE 1)
17A.4
NO FINISHED
REMOVE SUBPLATE OR FIXTURING. 17.7.4a.1

IS THERE MACHINE MUST BE TESTED WITHOUT FIXTURING.
YES SUBPLATES OR FIXTURING CAN INDUCE POSITIONING DO ANOTHER
A SUBPLATE IF MACHINE PASSES
PROBLEMS THAT ARE NOT INHERENT IN THE MACHINE. CIRCLE TEST
OR LARGE HEAVY CIRCLE ROUNDNESS TEST,
POSITIONING PROBLEMS INDUCED BY FIXTURING CUT
FIXTURING? MUST BE DEALT WITH SEPARATELY FROM PROBLEMS BUT HAS ROUNDNESS
IN THE MACHINE ITSELF. PROBLEMS FOR FEEDRATES
ABOVE F30., USE M92 IN
PROGRAM AND TRY AGAIN.
17A.5 17A.5.1 17A.5.2
REPEATABLITY MAY ALSO BE AFFECTED
NO
BY TEMPERATURE GROWTH.
IS DO IS
REINSTALL
CIRCLE YES ANOTHER CIRCLE YES
FIXTURING
ROUND? CIRCLE ROUND?
AND
(SEE NOTE 1) TEST (SEE NOTE 1)
SUBPLATE
CUT
17A.5.3
17A.5.4 17A.5.5 17A.5.6 NO
NO
FIXTURING OR SUBPLATE
IS DISTORTING MACHINE
WHICH WILL CREATE
A MECHANICAL BIND.
17A.5.7
CONSULT
FACTORY
17A.6
Figure 16-26 Circle Roundness (Continued)

CHART 18 ER R OR D IA GN O S IS
ME A NI N G
ER R O R C O DE S
ERROR CODES NU M B ER
#
PR O CE D U R ES
R EP O RT E D B Y AX IS
8- 18 -95
NO M OTO R F EE D BA C K
#1 CH E C K TH AT US E FA D AL RE S OL VE R IN P U T
(E ITH E R R ES OL V ER OR CH E C K C AR D
NO M OTOR FEE D BA C K D EV IC E (S ) EN C OD E R TE ST ER AT J2 O F 1 0 10
EN C OD E R ) IN J 14
FEE D BA C K AR E PL U G GED IN TO OR S CA L E TE ST ER SH OU L D B E AB OU T
DE TE C TE D AT O F 10 6 0
10 1 0 CA R D J 2 (J 5 , J6 ) TO T ES T E N C OD ER S 1. 7 VA C
POW ER - U P
18. 1 18 . 1 .2 18. 1 .3 18. 1 .4 18 . 1 .5 18 . 1 .6
EN C O D E R US E F A D AL
#2 VE R IFY SW A P SP IN D L E
F EE D BA C K EN C O D E R TE ST ER
EN C OD E R N O T CO N N EC TI ON CO N TR OL LER C AR D
ON S PIN D L E O R S CA L E TE ST ER
RE S PON D I NG OF E N C OD ER W ITH K N OW N GOOD
FAI L ED D U R IN G T O T ES T S PI N D LE
CA B LES CA R D
RI GID T AP EN C OD E R
18. 2
18 . 2 .1 18 . 2 .2 18 . 2 .3
#3 MA C H IN E CH E C K S F O R
IN ST AL L J U MP E R AT DI SC ON N E C T
LO GIC J U MP E R RU N A W A Y AT POW ER - U P. YE S M OT OR W IR E S
A1 O N AX IS C A RD J1 O N DO ES
IN C OR R EC T O R ME SS AG E IN D IC AT ES A N OR TA C H
TO B YP A SS AX IS C AR D . AX IS R U N
SIG N AL M IS SI N G OR IN C O R R EC T MO TOR - TAC H - W IR E S A R E
FEE D BA C K TE ST AW A Y ?
MOT O R -T AC H JU M PE R C O N F I GU R AT ION RE V ER S ED
O N P O W E R -U P . POW ER O N .
IN C OR R EC T OR FA ILE D C OM PO N EN T.
18 . 3 .4
18 . 3 .1 18 . 3 .2 18 . 3 .3 NO 18 . 3 .5
18 . 3
J4 J U MP E RS O N AX IS
CA R D A R E W R ON G
OR
AX IS C AR D I S BA D
18 . 3 .4a
US E FA D AL
IN D EX ER MA R K OF
#5 VE R IFY C ON N E C T ION EN C OD E R TE ST ER
EN C OD E R OR S C AL E
NO IN D E X M A R K OF E N C OD ER OR OR S CA L E T E ST ER
NO T D E TE CT ED
DE T E C T E D SC A LE C A B LE S T O T ES T E N C OD ER
DU R I NG C OL D S T A R T
OR S CA L E
18 . 5 18 . 5 .1 18 . 5.2 18 . 5 .3
#7
EN C OD E R C OU N TS STO P S P IN D L E US E FA D AL
RI GID T AP
N OT W ITH IN AN D U S E DI D S EN C OD E R TE ST ER
PR E C YC LE
TOLE RA N C E T O C H E C K M A GN ET OR S CA L E T E ST ER
EN C OD E R C OU N T
DU R I NG R IG I D TA P (TU R N S P IN D L E T O T ES T E N C OD ER
PR O BL E M
PR E C YC L E TE ST BY H AN D ) AT AX IS C AR D (J 5 )
18 . 7 18 . 7 .1 18. 7 .2 18. 7.3
SP IN D L E MA GN E T W A S STO P S P IN D LE US E KN O W N GO OD
#8 IS YE S VE R IFY M AG N E T
NO T D E TE CT ED F OR AN D U S E DI D S H ALL E FF E C T SW I TC H
SP IN D L E MA GN E T SP IN D L E IS C ON N EC TE D
O VE R 3 S E CO N D S TO C H E C K M A G N ET AN D TE S T W I T H
NO T D E TE CT ED O R TU R N IN G? AN D C H E C K
W H EN S P IN D L E SH O U L D (T U R N S P IN D LE A M A GN ET
SP IN D LE N O T AD J U STM E NT
HA V E B E EN T U R NI N G BY H AN D ) US IN G D I D S
TU R N IN G 18 . 8 .2
18. 8.1 NO 18 . 8 .3 18 . 8 .4 18. 8 .5
18 . 8
OR IE NT AT IO N M A G NE T IS RE A D B Y C P U T HR O U GH 10 60 J10 PIN 8
BU T T HE SP IN DL E C A RD R EA D S IT T H RO U G H J 2.
G O TO IF W IRIN G IS B A D, C PU M AY B E A BL E T O RE AD M A GN E T,
CH A R T 3 BU T T HE SP IN DL E C A RD M AY N O T B E A BL E T O R E AD IT.
SP IN D L E
18. 8 .2a DR I VE R
SP IN D LE FAU L T L IN E CH E C K F A UL T L IN E CH E C K
#9 CH E C K
IS N OT D E T E C T ED CH E C K IN VE R T E R CA B LIN G F R O M OPE R AT ION
SP IN D L E FAU L T O VE R L OA D
OR H AS F ALL E N F OR FA U LT IN VE R TE R OF K 2
LI N E D O W N RE L A Y
BE LO W 1 0V (J 6 -6 ) ON 1 100 - 1
18 . 9 18 . 9 .3 18. 9.4 18 . 9.5

18 . 9 .1 18 . 9 .2
CO N TIN U E D
ON N EX T
PA GE
Figure 16-27 Error Codes

CO NTINUE D
FROM CH ART 1 8 continued (page 2)
DIA GNOS IS
ERROR
PRE VIO US
PA GE ERROR CODE S NUM B ER
#
ME A NI NG
PRO CE DURES
REPORTED BY AXIS
8-18-95
#10 OCCURS DURING

ENCODE R SP INDLE OPE RA TION CHE CK SP INDLE
IS YE S
AND M AG NET NOT IF BOTH E NCODER F EE DBA CK ENCODE R AND
SP INDLE
RE S PONDI NG OR AND SPI NDLE M AG NET MA GNET A ND
TURNING?
SP INDLE NOT ARE NOT DE TE CTE D FOR THEI R CAB LING
TURNING LO NGER THAN 3 SE CONDS
18. 10
18. 10.1 18. 10.2 NO 18. 10.3
GO TO
CHA RT 3
SP INDLE
DRI VE R
18. 10.2a
#12 ERROR O CCURS A T E ND RUN DI AG NO ST ICS

CHE CK
MOT OR OF M OV E WHEN NUM B ER ON CPU AND A X IS:
+5V , + 12V, & -12V
OVERLOA D - OF P ULSE S COUNTE D IF O NE A XI S FAI LS, REP LACE
VOLT AGE S FROM
STEP COM MA ND BY A XIS CONT ROLLER THAT AXIS CA RD AND RE TE ST .
POW ER S UPPLY
CHE CKS UM DO ES NOT EQ UAL IF M ULTIP LE CARDS FA IL, RE PLA CE
SE E CHA RT 12A
ERROR NUM B ER S ENT B Y CP U 1030 OR 1400 A ND RETE S T
18. 12 18. 12.2 18. 12.3
18. 12.1
#13
MOT OR CHE CK PO WER GOTO
FOLLOWI NG E RRO R CHE CK
OVE RLOA D - CHA RT 4
EX CEE DS THE OVE RLOAD FA CTOR
FOLLOWI NG E RRO R > GOTO CHART 12 AX IS
OVE RLOA D FA CTOR PA RAMET ER.
OVE RLOA D BA D PO WE R/ CO NTROL
PA RAM ET ER IS IT T OO LO W?
FACT OR BA D VO LTA GE
18. 13 18. 13.1 18. 13.2 18. 13.3 18. 13.4
RUN DI AG NO ST ICS
AX IS MO VE COMMA ND CHE CK
#14 ON CPU AND A X IS:
WAS NOT PRO PE RLY +5V , + 12V, & -12V
MOV E TRA NS FE R IF O NE A XI S FAI LS, REP LACE
TRANS FE RRE D TO VOLT AGE S FROM
FAULT - MOVE SE TUP THAT AX IS CA RD AND RE TE ST .
AX IS CARD POW ER S UPP LY
INCOMP LE TE IF M ULTIP LE CARDS FA IL, RE PLA CE
(CHE CK S UM F AI LE D) SE E CHART 12A
1030 OR 1400 AND RETE ST
18. 14 18. 14.1 18. 14.2 18. 14.3
STO P S P INDLE US E KNO WN GO OD

#15 SP INDLE MA GNE T IS VE RIFY M AGNE T
YE S AND US E DI DS HALL E FFE CT SWI TCH
TIM E O UT E RROR - WAS NOT DET ECTE D SP INDLE IS CONNECTE D
TO CHE CK M A GNET AND TE S T WI TH
RI GID T AP WITHIN THE TURNING? AND CHE CK
(TURN S P INDLE A M A GNET
PRE CYCLE ALLOWA B LE T IM E ADJUSTM E NT
BY HAND) US ING DI DS
TES T
18. 15.2 NO
18. 15 18. 15.1 18. 15.3 18. 15.4 18. 15.5
ORIENT AT ION MAG NE T IS RE AD B Y CP U T HRO UGH 10 60 J10 PIN 8
BUT T HE SP INDL E CARD REA DS IT T HROUG H J 2.
GO TO IF WIRING IS B AD, CPU MAY B E A BL E T O RE AD MA GNET,
CHA RT 3 BUT T HE SP INDL E CARD MAY NOT B E A BL E T O RE AD IT.
SP INDLE
DRI VE R
TE MP ERAT URE SNAP S WITCH

WILL S HORT COS SIG NAL TO G ND
#16 ON R ESO LV ER B OARD IN MO TO R GO T O
RES OLVE R ZE RO-
TIM E O UT E RROR - VERIFY RES OLV ER IF MO TO R OV ERHE AT S. CHART 4A
CROSS ING WA S NO T DE TECT ED
RE S OLVE R RE SP ONS E IS PLUGG ED I NTO CHE CK IF MO TO R IS HO T OR AX IS CONTROL
BY A XIS CA RD WIT HIN THE CHE CK COS OUT PUT T O RES OL VER
OR M OTOR O VE R J2 O F 1010 CA RD (RESOLV E R
ALLOWA B LE T IM E (PIN 8 OF J1 -J6 ON 10 60 )
TEM P FAULTS )
FO R S HO RT TO GND .
18. 16 LET MO TO R CO OL.
18. 16.1 18. 16.2 18. 16.4
18. 16.3
RE A DING FRO M T HE MA KE S URE CA B LE S A RE

#17
RE S OLVE R P ORT PROP ERLY ATTACHED CHA NGE
BA D REA DING ON
INDICAT ES A S PINDLE (S PI NDLE "RE SO LVER" I S SP INDLE
RE S OLVER P ORT
SP EE D G RE A TE R THE SPINDLE ORIE NTAT ION CA RD
THAN P OS SIBLE HA LL E FFECT S ENS OR)
18. 17 18. 17.1 18. 17.2 18. 17.3
CO NTINUE D
ON NEX T
PA GE
Figure 16-28 Error Codes (Continued)

CO NTIN UE D
FROM
CHA RT 1 8 con tin ued (pag e 3)
PRE VIO US
PA GE
ER RO R CO DE S ERROR
ME A NI NG
DIA GNOS IS
REP ORT E D BY AX IS NUM B ER PRO CE DURES
#
8-2 3-95
AX IS C ARD DO ES N OT
#18 GO T O
DE TE CT F AULT LI NE IF THE LS E CB I S LI T,
AM PLIF IE R CHE CK CAB LING CHA RT 4
OR CHE CK FOR
FAULT LINE AND A MP LIFI ER (A MP LIFI ER
SIG NAL HA S FA LLE N ME CH ANICA L B IND
DO WN FAULT)
BE L OW 1 0V
18. 18 18. 1 8.1 18. 1 8.2 18. 18 .3 18. 18.4
#19
STA CK
THE STA CK ON THE A XI S CA RD PROB LEM COULD B E
OVE RFL OW -
(US ED T O S TORE C P U COMM A NDS AX IS CARD (1010),
OVE RLOA DED W ITH
UNT IL TH E Y ARE S ERV ICE D) CP U CA RD (1400 ),
STE P COM MA ND
HA S OV ERFLO WE D OR 1 030
18. 1 9
18. 1 9.1 18. 19.2
#20 THE MOV E TRA NSFE R RU N DI AG NO ST ICS

CHE CK
MOV E PR OCE SS WA S NOT ON CPU AND A X IS:
+5V , + 12V, & -1 2V
TRAN S FE R CO MP LET ED IF O NE A XI S FAI LS, REP LACE
VOLT AGE S FROM
FAULT - BUF FER (A COM MUNICA TIO N THAT AX IS CA RD AND RE TE ST .
POW ER S UPP LY
IN DIC AT OR FAI LURE B ET WE EN IF M ULTIP L E CARDS FA IL, RE PLA CE
SE E CH A RT 12A
NO T S ET AX IS C ARD A ND CP U) 1030 OR 1 400 A ND RETE S T
18. 20 18. 20.2
18. 20.1 18. 20.3
#21
AN UNK NOWN CHE CK CONNECTI ONS
SP URIOUS
OR ILLE GA L RE P LACE
INTE RRUP T - NOT
INTE RRUP T FAUL TY CON NE CTIO N AX IS CARD
SE RVICE A BLE
HA S OCCURR ED CA N CA USE NOI SE
18. 2 1 18. 2 1.3

18. 21.1 18. 21.2
FEE DBA CK FROM CHE C K

#22 CH E CK
SC A LE P OR T IS CA B LING CHE CK BO ARDS
BA D SCA LE ALIG NM E NT
OUTS ID E ALLOW AB LE IN S CA LE BO X
RE A DING OF S CALE
LI MI TS TES T S CA LE
18. 2 2
18. 22.1 18. 2 2. 2 18. 2 2. 3 18. 2 2. 4
#23, #24 , CHE CK PO WER GOTO

#25 #26 FOLLOWI NG E RRO R CHE CK CHA RT 4A
MOT OR OV ERLO AD - EX CEE DS THE USE R- OVE RLOA D FA CTOR AX IS CONTR OL
GOTO CHART 12
FOLLOWI NG E RRO R > DE FI NE D OV E RLOAD PA RAM ET ER. (M OTOR
BA D PO WE R/
OVE RLOA D FAC T OR IS IT T OO L O W? OVE RL OA D)
BA D VO L TA GE
FAC T OR
18. 23 18 . 23.1 18. 23.2 18. 23.3
18. 23.4
CO ULD NOT F IND

#27 MA GNET A FTE R
ORIE NT AT ION
RE TURN TAP P ING HO LE.
SP EE D M AY B E
TO M AG NET 5 SE COND TI ME OUT.
TOO LO W
TIM EOUT (DURING
RI GID T AP PI NG)
18 . 27 18 . 27.1 18 . 27.2
10 SE COND TI ME OUT.-
#28 STO P S P INDLE
DI D NOT ORIE NT IS VE RIFY M AGNE T
ORIE NT AT ION ORIE NT AT ION YE S AN D U S E DI DS
OR SP INDL E IS CONNECTE D
TIM EOUT OR T AP PI NG SP EE D M AY TO C HE CK M A GNET
DI D NOT ARR IV E AT 5TH TURNING? AND CHE CK
CA LIB RAT ION BE TOO LOW (TURN S P INDLE
MA GNET DURING ADJ USTM E NT
ERROR BY HAND )
CA L IB RAT ION
18 . 28 18 . 28.1 18 . 28.2 18 . 28.3 NO 18. 28.4 18. 28 .5
GO TO OR IE NT AT IO N M A G NE T IS RE A D B Y C P U T HR O U GH 10 60 J10 PIN 8
BU T T HE SP IN DL E C A RD R EA D S IT T H RO U G H J 2.
CHA RT 3 IF WIRIN G IS B A D, C PU M AY B E A BL E T O RE AD MA GN E T,
SP INDLE BU T T HE SP IN DL E C A RD M AY N O T B E A BL E T O RE AD IT.
DRI VE R
SP INDLE THIS E RR O R IS R EP O RT E D B Y PROB LEM COULD B E

CO NTROLLER THE C P U N O T THE AX IS C A RD . VE RIFY THA T AN A XI S CARD (N O T
DO ES NOT R ES P ON D IT IS N O T A N E R RO R #. ALL A XI S CA RDS NE CES SA R ILY THE
#48 AX IS DAT A T R ANS FE R ARE BLI NKING SP INDLE C ARD ) ,
(CO U LD BE HA S ST AL LE D. THE 1030, OR THE 14 00
1-25 5)
18 . 48 18 . 48.1 18. 48.2 18 . 48.3
Figure 16-29 Error Codes

S E R IA L
CHART 19
CO M M U N IC AT IO N S S E R IA L P O R T C O M M U N I C A T IO N S
6 -1 4 - 9 5
IS
IS S IN G LE YE S
LO O K F O R IT A S Y N T A X S E N D F IL E
PROB LEM W ITH A LL F IL E F IL E M U S T B E
HID DEN ER R OR ? U S IN G T A ,1 ,1
C O M M U N IC A T IO N S O R SA VE D IN A T E X T
CH A R AC T ER S (D O E S P A R T O F F I L E SO C ON TR OL S TOP S
O N L Y A S IN G L E ONLY F ORMAT
IN T H E F I L E TRAN S MIT?) AT SYN TA X E R ROR
FILE ?
1 9 . 1 .1 1 9 . 1 .2 1 9 . 1 .3 1 9 . 1 .4
19 . 1 NO
ALL C OM M UNIC ATIO N
CHE C K BA UD R A TE LO O K F O R I L L EG A L
AN D O T H ER C O M M U N IC AT IO N CHA R AC T ERS B EFO RE
P A R A M E T E R S A T M A C H IN E A N D T H E IN IT IA L P E R C E N T
AT C OMP U TE R SIG N
19 . 2
1 9 . 1 .3 a
V E R IF Y T H A T A L L R S 2 3 2
C A B L E S A R E P L U G G E D IN
(A T 1 0 3 0 , B A C K O F C A B I N E T ,
CO MP U TE R)
19 . 3
YE S CHE C K
IS A
S W I T C H P O S I T IO N O F
NU LL M OD E M
NU LL M OD E M,
B E IN G U S E D ?
T R Y A G A IN I N O T H E R P O S I T IO N
19 . 4 NO 19 . 4 . 1
CH E C K G R O U N D IN G O F M A CH IN E.
G R O U N D M U S T B E A C O N T IN U O U S W IR E DIFF IC U LT T O D IA GN O SE P RO B LEM S C AN OC C U R
T O T H E P O W E R D IS T R IB U T IO N P A N E L
O F T H E B U IL D IN G . IF M A C H I N E I S N O T P R O P E R L Y G R O U N D E D .
G RO UN D RO DS AR E N OT A CC E P TAB LE TH E R E M U ST BE A C ON T IN U O U S G R O U N DIN G
A S T H E P R I M A R Y G R O U N D IN G M E T H O D . C O N D U C T O R ( A S S P E C I F IE D O N T H E G R O U N D IN G L A B E L
19 . 5 IN T H E M A C H I N E ' S D IS C O N N E C T B O X ) F R O M T H E V M C 'S
G R O U N D B U S T O T H E G R O U N D B U S I N T H E B U I L D I N G 'S
T H E G R O U N D W IR E O F P O W E R D IS T R IB U T IO N P A N E L .
TH E RS 232 D B 25 PLUG TH E C O M P U TE R BEIN G U S ED M U ST AL SO BE P R OP ER LY
IN T H E M A IN C A B IN E T G R O U N D ED (U N LE SS IT IS A B AT T E R Y O P E R A TE D LA P T O P ).
MUS T B E ATT AC HE D
TO T HE CA BIN ET.
P A IN T M U ST B E R E M O VE D
FOR GO OD CONTA CT.
19 . 6
IF M A C H I N E H A S A P H O N E M O D E M ,
M A K E S U R E I T IS D IS C O N N E C T E D
FROM TH E RS232 P OR T
19 . 7
PLU G R S 232 TE ST P LUG

IN T O R S 2 3 2 P O R T O N C A B IN E T .
FROM COM MA ND MO D E,
T Y P E " D I" , P R E S S E N T E R ,
T YP E "G 0 3 0 0 0 ", P R E SS E N T ER ,
SE LEC T TH E RS232 TES T.
19 . 8
M A C H IN E P A S S E S D I A G N O S T I C S
PL U G R S 2 3 2 C A BL E IN TO PO R T YE S
DO ES YE S DO ES AN D IS N O T A T FA U L T I N
AN D M OV E T ES T P LU G
RS 232 TE S T P AS S RS 2 32 TE S T P AS S C O M M U N IC A T IO N P R O B L E M .
TO C OM P UTER EN D O F C A BLE .
W IT H O U T W IT H O U T
RE R U N TE ST .
ER R OR S? ER RORS ? A N U L L M O D E M M IG H T B E N E E D E D .
19 . 9 19 . 9 . 1 1 9 . 9 .2 19 . 9 . 3
NO NO
EIT H ER T HE 1 0 3 0 C A R D CA B LE M A Y B E
OR TH E RS232 CA B LE D E F E C T IV E ,
FROM THE 1030 T O O LO N G ,
T O T HE D B 2 5 P LU G O R R O U T E D IN A
IS B A D N O IS Y E N V IR O N M E N T
19 . 1 0 1 9 . 9 .2 a
IF P R O B L E M S P E R S I S T , G O T O
C O M M U N IC A T IO N S T R O U B L E S H O O T IN G
S E C T IO N O F M A IN T E N A N C E M A N U A L
F O R A D D IT IO N A L I N F O R M A T I O N
19 . 1 1
Figure 16-30 Serial Port Communications

CHART 20
SE R VO
IN D EX ER
FA D A L S E R V O IN D E X ER
10- 20 -95
W ITH 5V
IS
W ILL NO CH E C K FU SE MOT OR C A BLE NO NO BE TW E EN NO
PU LS E L E D
IN D EX ER ON B AC K OF DI SC ON N E C TE D , PIN 1 AN D P IN 6
ON 181 0-0
POW ER -U P? CO N TR O L B OX W ILL IN D E XE R OF J 11 ON
BLIN K IN G?
POW ER 18 10- 0?
UP ?
20 . 1 20 . 1.1 20 . 1.2 20 . 1.3 20 . 1.4
YE S YE S YE S YE S
CH E C K CH E C K FOR
CH E C K FOR S H OR T
CH E C K CO N N EC TI ON S OF 12 0V A C AT
OF 5V TO GR OU N D
CO N N EC TO R 5V R E GU L A TOR PIN S 1 & 2 OF J 1
IN C AB L E
TO D IS P LAY O N P O W E R SU P P LY ON P OW E R SU P P LY
OR E NC O D ER
(1 818-0 -2 ) (181 0-0- 2)
20 . 1.2 a 20 . 1.3 a 20. 1 .4a 20 . 1.5

CH E CK FO R BA D S O LD E R J OIN TS A T
AL L FO U R V O LT AG E RE G U LA TO R S.
LI ST EN C A R EF U LL Y TO U N IT.
CH E C K
DO ES VE R IFY IF M OTO R IS TU R N IN G
W ILL NO YE S PA R AM ET ER S
DI SP LAY I ND I C ATE FEE D R A TE PO T AN D H E AD I S N OT,
HE A D MO VE ? (R A TIO AN D
MOT ION ? IS N OT S ET A T 0 A C O UP LE R IS LOOS E
EN C OD E R C OU N TS )
IN SI DE H E AD .
20 . 2.1
20 . 2 20 . 2.2 20. 2 .3 20 . 2.4
YE S NO
CH E C K VO LTAG ES
TU R N OFF AN D
CH E C K FU SE S IF A MP LIFI ER IS BLOW N , 181 0-0- 1 J3 :
UN P LU G U N IT .
ON M OTOR , LO OK FOR C A U S E. P IN 1 +5 V & P IN 2 GN D
CH E C K FOR S H OR TE D
ON 181 0-0- 1 A ND ON AR E MO TOR L E A DS P IN 5 +1 2V & PI N 6 C O M
(B LOW N )
181 0- 0-2 SH OR TE D TO C H AS S IS? 181 0-0 J11:
IGB T'S ON A M PLIF IER
P IN 1& 2 + 5V
20. 2 .1a 20. 2.1b 20 . 2.1c W IRE S T O MO T O R A R E P IN 3 +12V
SH IEL DE D . S H IEL D M U S T P IN 4 -1 2V
BE ST RIP P ED BA C K F RO M P IN 5& 6 GN D
CO N DU C TO R .
20 . 2.1 d
DO ES IF M OTO R W A S RE S ET PA R AM E TER S
DO ES YE S DI SP LAY YE S RE P LAC E D , TO F AC TO RY D E FA U L TS
HE A D R U N
IN D IC AT E MOT OR L E AD S (M IS C/ PA R AM /FA C S ET)
AW A Y ?
MOT ION ? MA Y BE R EV E R SE D AN D R E TR Y
20. 2 .1e
20 . 3 20. 3.1 20 . 3.2
NO
NO CH E C K C AB LE AN D
EN C OD E R C AB LE SOC K ET FOR D AM AG ED
CH E C K C ON N EC TO R S ON O R E N C OD E R MA Y BE B A D: PIN S OR SOC K E TS
MOT OR C A BL E A ND BOX
FOR P U SH E D IN O R CH E C K ALL E N C OD E R C ON N EC T ION S . 20. 2.1f
DA M AGE D CH E C K FOR C O NT IN U ITY OF A L L EN C OD E R
PIN S O R SO C K E TS LIN ES F RO M EN C OD E R TO U 4 ON 181 0-0 .
CH E C K FOR 5V A T E N C OD ER .
20. 3 .1a
20. 3.1b
MOT OR OV ER L O AD IF H E AD MO V E S
DO ES OR OV ER C U R R E NT BU T POS ITI ON D IS P LA Y
HE A D JO G IN BOT H NO FAU LTS I ND I C ATE DO ES N 'T C H A N GE
DI R EC TI ON S? A BL OW N IGB T TH ER E IS A N E NC O D ER
ON A MP LIFIE R FEE D BA C K PR O BLE M
20 . 4 20 . 4.1 20 . 4.2
YE S IF AM P LIF IER IS B LO W N ,
FIN D C AU S E B E FO R E R EP LA C ING .
RE SIS TA N CE A CR O SS M O TO R LE AD S S H O UL D B E 4 -6 O H M S.
RE SIS TA N CE FR O M M O TO R L EA D TO C HA S SIS S H O UL D B E IN F IN IT E.
W IRE S T O MO T O R A R E S HIE LD E D. S HIE LD M US T B E ST RIP P ED BA C K
FR O M C O N DU C TO R .
CH E C K BR A KE TR Y RU N N IN G
CH E C K C AB LE
YE S AIR LI N ES NO IN D EX ER W ITH
MOT OR DI SC ON N E C T AN D S OC K ET IS L OAD
(1 I S O U TPU T TO H EA D , NO FIX TU R IN G ,
OVE R LOA D S? AIR FOR D A MA GE D TOO HE A VY ?
2 IS IN P U T FR O M AU X ILIA R Y C H U C K ,
PIN S OR SOC K E TS
AIR SU P PL Y ) OR P AR T
20. 5 NO 20. 5.1 20 . 5.2 20. 5.3 20. 5.4 YE S 20. 5 .5
RE D U C E
FEE D R AT E
GO T O
PA GE 2 OF 20A .5.6
CH A R T 20
CO N SU LT FAC T OR Y
AB OU T M OTO R TY PE
JU M PE R S ETT IN GS
20. 5 .6
Figure 16-31 Servo Indexer

CO N TIN UE D
FR OM CHART 20 conti nued (page 2)
PA GE 1 OF
CHA RT 20 FAD AL S ERV O IN DEX ER
10- 20-95
ENC ODE R C AB LE
IN DEX ER YE S TES T E N COD E R
MAY BE B AD , ENC ODE R MA Y B E
MIS POSITION S, LO SE S WITH F ADA L
VER IFY C ONTI NUI TY OF SLIP PI N G ON MOT OR
POS ITI ON ( MAY ALS O ENC ODE R TE ST ER
ENCOD E R SI GN ALS SHA FT,
MOT OR OV ER LO AD ) (E NC ODER M A Y B E B AD)
IN C AB LE
20.6 20.6.1 20. 6.2 20. 6.3
NO
AR E HEA D MUS T F INIS H

HE AD
YE S YOU US IN G YE S MOV E BE FOR E
MIS SES
SIM ULTA N EOUS NEX T STA RT IS S ENT.
STA RT
MOV E ME N T? ADD DWE LL TO VM C
PU LS ES ?
PROG RA M .
20. 7.1 20. 7.2

20. 7 NO
NO
DI SCON NE CT I NDE XER MILL M A Y NE ED

CHE CK C OMM UN ICA TION
IN TE RF ACE C A BLE DO ES YES 0. 001uF CAP A CITOR
PROT OC OL
AND RU N P R OGRA M PROG RA M R UN AC ROS S FINIS H
BETWE EN IND EX ER
USING TH E PROP ER LY ? TERM INA LS O F
AN D M ILL
STAR T B U TTO N . MILL.
20.7.1b
20. 7.1a 20. 7.1c 20. 7.1d
FIR ST M AKE SU RE CHE CK C ONN ECTO R S ON ENC ODE R C AB LE

YE S UN I T J OGS IN BOT H MOT OR CA BLE A ND BOX OR E NCO DER
WILL NOT
DI REC TI ONS AND FOR PU SHE D IN O R MAY BE B AD .
C OLD S TART ?
CO R REC TLY DISPLA Y S DA M AGE D CH E C K ALL E N COD E R C ONNECT ION S .
POSITI ON PINS OR SOCK E TS CH EC K CON TIN UIT Y OF E NC ODER LINE S.
20. 8 20. 8.1 20. 8.2 20. 8.3

NO
CH E CK AI R SUP PLY
CHE CK CH EC K
BRA KE AND AIR LIN E TEST I N MD I
YES PA RAM ET ER S SOLI D ST ATE
DO ES N'T CO NN ECTO RS (M 60 BRA K E O N,
TO S EE I F BR AK E RE LA Y (K 1) ON
WOR K ? (A IR PR ES SUR E M61 BRA KE OF F)
IS ACTI VE 1810- 0-2)
SHOU LD B E 80 PSI)
20. 9 20. 9.1 20. 9.2 20. 9.3 20. 9.4

NO
AIR SOLE NOID PORT S

AR E 1 & 2.
FEE D 2 IS AI R IN.
YES REC A LI BRA TE
RATE POT D O ES 1 IS AI R OU T TO HE AD .
FEEDRAT E POT
NO T R ESP ON D
IN DIA GN OSTICS
PROP ER LY ? 20.9.5
20. 10 20.10.1
NO
IN SE RT DU M MY PLU G
IN TO R S232 DB 25 CONNEC TO R CHE C K CAB LING,
RS 232 YES DO ES YE S BA UD RAT E,
(P IN S 2 & 3 J UMP E RED )
DO ES N OT RS 232 TE ST AND P ROTOCO L
WORK ? WOR K ? (IN DEX E R IS 7 D AT A B ITS ,
RU N RS232 TE S T EV EN P ARITY, 1 S TOP B IT)
IN DIA GNOS TICS
20. 11
20. 11.1 20. 11.2 20. 11.3
INDEXE R HA S CTS, DT R , & DSR NO
JUMP E RE D INT ER NAL LY.
CHE C K VO LTAG ES
1810-0 J11:
P IN 1& 2 + 5V
P IN 3 +12V
P IN 4 -12V
P IN 5& 6 GN D
20. 11.2a
Figure 16-32 Servo Indexer (Continued)

CO N T IN U E D
C H A R T 2 1 c o nti nu e d (p a ge 2 )
FR O M PA G E 1
OF C H A R T 2 1
P O S IT IO N IN G P R O B L E M S
10 - 2 0 -9 5
SU R VE Y F O R S CA L ES IS N O T
IF B AL L S C R EW SU R VE YS A RE BA LL SC R EW D E PE N DE N T. TH E S AM E AS S UR V EY FO R
HA S BE E N R EP L AC E D CH A NG IN G T H E B AL LS CR E W INV A LID AT ES TH E SU R VE Y. RE SO L VE R . F O R P O SIT ION IN G
A N E W S U R VE Y TO BE C OR R EC T , S U RV E Y F OR
M U S T B E DO N E RE SO L VE R MU S T B E E N TE RE D
W HE N SC AL E S A RE U NP LU G G ED
AN D S U RV E Y F O R S CA LE S MU S T
21 A .1 BE EN TE R ED W H EN S CA LE S AR E
RE C ON N EC T ED .
IF O VE R SH O O TIN G
IF O VE R SH O O T IN G O C C U R S
DO ES N O T O C C U R
O VE R - YE S W IT H A H E AV Y PA R T O R F IX TU R E , DO ES YE S PO W ER OF F M A C H IN E . W ITH OU T SC A L ES
SH O O T IN G BU T DO ES N O T O C C U R W I TH OU T I T : MA C H IN E HA V E DI S C O N N EC T S C A L E S.
CO N TAC T F A C TO R Y
PO S IT I ON ? US E G 5 1 R 0 - # W IT H A VA L U E >1 SC A L ES ? PO W ER ON M A C H I N E.
AB O U T S O FT W A RE
F O R X A N D Y TO L E N G T H E N F EE D R AM P S
21 A .2 .3 CH A N G E
21 A .2 21 A .2 .2
NO 21 A .2 .1 NO 21 A .2 .4
DO ES
J1 3 ON 1 0 60 MU S T
DO ES YE S DI S C O N N EC T S C A LE S, MA C H IN E YE S GO TO
BE P LU G G E D IN
M A C H IN E HA V E PO W ER D O W N MA C H I N E POS IT I O N C O R R E C T L Y CH A R T 2 2
FO R S C AL E S T O
SC A L ES ? AN D R ES T A R T W IT H O U T SC A L ES
W OR K R EL IA B L Y
SC A L ES ?
21 A .3 21 A .3 .1 21 A .3 .2 21 A .3 .3
NO TH E S C AL E E RR O R IN P UT IS O N J13 SU R VE Y F O R S CA L ES IS N O T TH E SA M E A S 21 A .3 .4
SO IT IS CR ITIC A L TO S CA LE S TH AT SU R VE Y F O R R ES O LV E R. FO R P OS ITIO N ING NO
J13 BE PL UG G E D IN . HO W V E R, TO BE C OR R EC T , S U RV E Y F OR R ES O LV ER
PO S IT IO NIN G ER R O RS CA N AL SO MU S T B E E N TE RE D W HE N SC A LE S A RE
OC C UR W ITH R ES O LV E RS IF J1 3 UN P LU GG E D AN D S U RV E Y F O R S CA LE S
IS N OT PL U GG E D IN . FO R SC A LE S MU S T B E E N TE RE D W HE N SC A LE S A RE
AN D R E SO L VE R S IT IS IM PO R TA N T RE C ON N EC T ED .
TH AT J13 BE PL U GG E D IN A ND D OO R SU R VE Y F O R S CA L ES AN D SU R VE Y F O R
IN T ER LO C KS FU N C TIO N P R OP E RL Y. RE SO L VE R CA N B E FO U ND IN M A C HIN E
RE C OR D S.
IS PA R T
EN S U RE T HA T PA R T
SL IP PI N G IN YE S AN D F I XT UR E
F IX T U R E O R
AR E AD E Q U A TE L Y
IS F IX TU R E
SE C U RE D
MO V IN G ?
21 A .4 21 A .4 .1
NO
DO ES
CO N SU L T TR Y DN C X ,
YE S TH E MA C H IN E NO
IS D NC CH A R T 1 9 SH O R T E N TH E C A BL E ,
M IS P O SI T IO N W H EN
BE IN G U S E D? SE R IAL US E A SL O W ER BA U D R AT E,
NO T U S IN G
CO MM U N IC AT IO N S TR Y AN O T HE R C O M P U T ER AN D C A BL E
DN C ?
21 A .5 21 A .5 .2 21 A .5 .3
NO 21 A .5 .1
YE S
PO W ER O F F
MA C H IN E AN D
IN SP EC T W IR I N G
21 A .6
CH E C K F OR L O O SE
OR B RO KE N W I RE S
OR B AD C R IM P S
21 A .7
T ES T A L L
GOLD COAX
CO N N EC TO RS
US IN G ST 44
SE R VIC E T O O L
21 A .8
CO N T IN U E D
O N P AG E 3
OF CHART 21
Figure 16-33 Positioning Problems

CHART 21 conti nued (page 3)

CO NTINUE D
FROM PA GE 2
OF CHA RT 21
POSIT IO NING P RO BL EM S
10-20-95
CHE CK RES OLV ER

CO NNECTO RS A T
MOT ORS
21B .1
CHE CK LEV EL
AND TRA M
21B .2
CHE CK FOR
BROK EN OR LOO SE
RE S OLVE R
CO UPLING S
21B .3
CHE CK
BA LLSCRE W
ALIG NM E NT
21B .4
US E CLAM P -ON
AM ME TE R TO CHE CK
EA CH AX IS .
AM P DRA WS M UST BE
IN S PE C A ND CONSI STE NT
21B .5
CHE CK ST RA P
ADJUSTM E NT S
(C HECK AM P DR AWS
AG AIN A FT ER
ADJUST ING S TR APS )
21B .6
IS INS PE CT PART
POS ITI ONING YE S ON M ACHINE DO ES P ART YE S OFF-MA CHINE
CLA M PING MA Y BE
ERROR RE VE A LED B Y BE FO RE REM OV I NG INSP ECT GOO D ME AS URING M A Y B E
DI ST ORTING PA RT
OFF-MA CHINE PA RT CL AMP S OR ON M ACHINE ? OUT OF CALI BRA TIO N
INS PE CTION? RE LE AS ING V IS E
21B .7 21B .7.1 21B .7.2 NO 21B .7.3 21B .7.4

NO
WHEN MAT ERIAL IS CUT THE
ST RES SE S IN TH E MATER IAL
CHANG E SO THE DIM ENS IO NS
MAY MO VE W HE N IT IS UNCL AMPED . THERM AL CHA NGE S
BE TWE EN MA CHINING
SING LE S TE P THRU
AND INS P ECTI ON M AY
THE PROG RA M TO
BE A FFE CTING PA RT
FIND P OS SIB LE
PROG RA M MING E RRO RS
21B .7.5
21B .8
HAV E AN APP LI CATIO N

ENGI NE ER REV IE W
THE P RO GRAM AND
FIX TURI NG
21B .9
ARE ALL YE S TRY RE S ETT ING

THERM AL EX PA NSI ON THERMAL GRO WT H IS A NATURA L E F FECT OF H IGH S PEED MA CHIN ING .
POS ITI ONS HO ME A T RE GULAR
MA Y BE THE P ROBLE M IT CA N BE LIMITE D, BUT NOT T OT A LLY EL IM INA TE D. IT O CCURS IN T HE
CHA NGING ? INTE RV A LS
BA LL SCREWS , THE HEAD, TH E SP INDL E, A ND EV EN T HE COLU MN, SADD LE
AND T ABL E WHEN T HER E A RE TE MP ERAT U RE SW ING S .
21B .10 21B .10.1 21B .10.2
NO
INSP ECT AND FLUSH

THE LUB E SY S TEM .
VE RIFY E NT IRE SY S TEM
IS WORK ING P ROP ERLY
21B .11
Figure 16-34 Positioning Problems

SCALE PROBLEMS CHART 22 SCAL E PROBLEMS CAN SHOW UP AS SCALE ERRORS (AN ERROR CODE),
MISPOSITIONING, REPEATABILITY PROBLEMS, ROUNDNESS PROBL EMS
SCALE PROBLEMS OR UNEXPECTED POSITION SHIFTS.
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
IS IT YES CO NSULT IN THE MACHINE'S DISCONNECT BOX) FROM THE VMC'S GROUND BUS TO THE GROUND BUS IN THE
AN ERROR CHART 18 BUILDING'S POWER DISTRIBUTION PANEL.
MESSAGE? ERROR CO DES
22. 1
NO 22.1.1
YES, AND
ERROR IS
NO T EASILY CO NNECT
SCALE
YES WILL RECREATED SCALE ENCODER
ERROR MESSAGE?
SCALE BOARD TESTER (ST40)
(AND LED IN SCALE
RESET? BETWEEN SCALE
BOX LIT)
BOX AND AXIS CARD
22. 2 22. 2.1 NO, OR 22.2.2

ERROR REOCCURS EASILY
NO
SWITCH
EXE BOARDS
IN SCALE BOX
22.2.1a
ERROR EXE
STAYS W ITH BOARD REPLACE
EXE BOARD OR EXE BOARD
SCALE?
22.2.1b.1
22. 2.1b SCALE
CONTINUED
ON PAGE 2
COLUMN 2
OF CHART 22
22.2.1c
DO ES RECONNECT SCALES AXIS ZERO OFF SET

POWER OF F MACHINE. YES NO
IS IT YES ALSO J13 ON 1 060
DI SCONNECT SCALE PROBLEM G O CO LD STARTS IN SV F OR AXI S
A POSITI ONING (SCALE ERROR LINE)
FROM 1010 CARD. AWAY WITH TO CORRECT MAY BE
PROBLEM? MUST BE
PO WER ON MACHINE. NO SCALES? POSITION? SET WRO NG
PLUGGED IN)
22.3.4
22.3.2 22. 3.5
22. 3 22.3.1 22. 3.3
NO NO YES
SURVEY FOR SCAL ES IS NOT THE SAME AS REMEMBER TO RE-ENTER THE
SURVEY FOR RESOLVER. FOR POSITIONING SURVEY FOR SCAL ES. RUN AN
TO BE CORRECT, SURVEY FOR RESOLVER NOT A EXTERNAL
MUST BE ENTERED WHEN SCALES ARE IF Y-AXIS, THE CABLE TO
UNPLUGGED AND SURVEY FOR SCALES SCALE PROBLEM.
GO T O CHART 21 SCALE MOUNTING THE SCALES
MUST BE ENTERED WHEN SCALES ARE
RECONNECTED. POSITIONING MAY BE DEF LECTED
SURVEY FOR SCAL ES AND SURVEY FOR PROBLEMS BY SCALE CABLE 22.3.6
RESOL VER CAN BE FOUND IN MACHINE
RECORDS. USE
22. 3.2a 22.3.4a SCALE T ESTER
(1710-0) OR
VERIFY SCALE CABLING ENCODER
IS CORRECT AND TESTER (ST40)
PLUGGED INTO AND CHECK
CO RRECT INPUT OF FOR INDEX
CO NTINUED 1010 CARD (J6) FROM SCALES
ON PAGE 2 22.3.7
CO LUMN 1 22.3.4b
OF CHART 22
VERIFY THAT SURVEY FOR SCALES
IS NOT THE SAME AS
22.4 SURVEY IS CORRECT SURVEY FOR RESOLVER
FOR SCALE FEEDBACK.
22.3.4c
CO NTINUED
ON PAGE 2
CO LUMN 5
OF CHART 22
22.3.4d
Figure 16-35 Scale Problems

CO NTINUED
FROM PAGE 1
CONTINUED
FROM PAGE 1 CHART 22 conti nued (page 2) CO NTINUED
FROM PAGE 1
CO LUMN 1
OF CHART 22
CO LUMN 2
OF CHART 22 SCALE PROBLEMS CO LUMN 5
OF CHART 22
10-20-95
22A.1 22A.2 22A.3
CO NNECT
SCALE ENCODER
PO WER DOWN TESTER (ST40)
MACHINE BETW EEN SCALE
AND DISCO NNECT BO X AND AXIS CARD
SCALES F RO M
AXIS CARDS 22A.3.1
22A.2.1 SWAP A
YES KNOW N GOOD
SCALE
CABLE BETWEEN
PUT X SCALE CABLE TESTER SHO WS
SCALE BOX
INTO Y JACK O F ERROR?
AND AXI S CARD
SCALE BO X, ETC. AND RETEST
22A.3.2 NO
PO WER ON MACHINE 22A.3.2a
22A.2.2
SWAP
AXI S CARDS
EXE 22A.3.3
ERROR BOARD REPLACE
STAYS W ITH 1580-1A BOARD
EXE BOARD OR (SCALE BOX PROBLEM YES
SCALE? MOT HERBOARD) REPLACE
STAYS W ITH
AXIS CARD
AXIS CARD?
22A.2.3
22A.2.3a 22A.3.4
SCALE 22A.3.4a
NO
SCALE CABL E MAY CHECK

BE DAMAGED. GIBS AND
RUN A NEW CABL E STRAPS
OUTSIDE O F MACHINE 22A.3.5
TO TEST .
GO TO
22A.2.4 CHART 21
PO SIT IONING ,
CHART 5
REPEATABI LITY
CHECK DISCONNECT READER HEAD
ERROR YES FROM BRACKET AND
ALIGNMENT
STI LL OCCURS? INSTALL SHIPPING M OUNT S
OF SCALE 22A.3.6
(LED LITES) ON READER HEAD.
MOUNTI NG
MOVE HEAD BY HAND.
22A.2.5 22A.2.5a 22A.2.5b

NO
CABLE DAMAGED, SCALE IS GOOD.

ERROR
REPLACE
STI LL OCCURS NO PROBLEM IS ALIG NMENT
WHEN SCALE M OVED
RETURN BAD CABLE OF SCALE OR
BY HAND?
TO F ADAL FOR OF READER HEAD
(LED LITES)
FAILURE ANALYSIS AND BRACKET
22A.2.5c 22A.2.5c.1
22A..2.6 YES
WHEN SCAL E IS REPLACED

REPLACE SCALE A NEW SURVEY MUST BE DONE.
YES CO NSULT FACT ORY
ABOUT AXIS
OVERSHO OTING?
SOF TWARE 22A.2.5d
UPDATE
22A.1.1 22A.1.1a
NO
DO ES IT
CHECK MECHANICAL
YES GO AWAY WHEN YES CHECK BACKLASH YES
CAVITATION ADJUSTMENT BACKLASH BACKLASH
SCALES ARE WIT H SCALES
OR VIBRATIO N? OF GIBS >20? MUST BE
DISCONNECTED? DISCONNECT ED.
AND STRAPS CO RRECTED.
22A.1.2
22A.1.2a 22A.1.2d
22A.1.2b 22A.1.2c 22A.1.2e
NO
NO
NO T A
SCALE
PROBLEM
CROSSOVER
YES CO NSULT GO T O
PROBLEM ?
(BUMP AT FACT ORY CHART 1
QUADRANT S)
22A.1.2a. 1
22A.1.3a
22A.1.3
Figure 16-36 Scale Problems (Continued)

R I G ID T A P
CHART 23 D I F F I C UL T T O D I A GN O S E P R O B L E M S C A N O C C U R
IF M AC H I N E I S N O T P R O P E RL Y G R O U N D ED .
R IGID TA P T H ER E MU S T B E A C O N T I N U O U S G RO U N D I N G
C O N D U C T O R ( AS SP E C I F I E D O N T H E G R OU N D I N G
10 - 2 0 -9 5 LA BE L I N T H E M A C H I N E' S D I S C O N N E C T B OX )
F R O M T H E V MC 'S G RO U N D B U S T O T H E G R O U N D
IS T H E C O R R E C T G O /N O G O BU S I N TH E BU I L D I N G 'S P OW ER D I S T R I B U T I O N P AN E L .
YE S G A G E B E IN G U S E D ?
TAP P ED H OLE
IS B A D ( NO G O )?
IS T H E P R O P E R G R A D E
O F T A P B E IN G U S E D ?
23 . 1 A C L A SS 3 H O L E I S U SU A L L Y
23 . 1 .1 TA P P E D W I T H A G H - 1 T A P.
NO
PI T C H D I A M E T E R O F T A P I N C R E A S E S
0 . 0 0 0 5 " F O R E V E R Y G H N U M B E R.
TAP M U ST BE IS C O O L A N T A N D / O R
YE S IS T H E D R I L L E D RU N R IG ID T A P T E S T
TAP 2 F L U T E S P IR A L P O IN T T A P P IN G C O M P O U N D
HO LE T H E C O R RE C T A S D E S C R IB E D I N
BR E AK S? (O R R O L L P O IN T ) TH E CO R R EC T TYP E
S IZ E F O R T H E T A P ? M A I NT E N A N C E M A N U A L
IF L E S S T H A N 5 /1 6 " A N D M IX T U R E ?
23 . 2 NO 23 . 2 .1 23 . 2 .2 23 . 2 .3 23 . 2 .4
B E F O R E D O I N G R I G ID T A P T E ST ,
Z - A XI S GA I N AN D BA C K L A S H M U S T B E
V E R I F I ED A N D / O R A D JU ST E D A S D ES C R I B E D
IN D IC A T O R YE S T H IS IS IR R E L E V A N T .
FAILS IN M A IN T EN A NC E M A N U A L .
YE S OVE R SH O OTS A T T A P IS N O T IN T H E
R I G ID T A P
T O P O F T A P P IN G HO LE A T TH E TO P O F
TES T?
CY C LE? T H E T A P P IN G C Y C L E .
23 . 3 23 . 3 .1
23 . 3 .2
NO NO
B E L T S M A Y B E S L IP P IN G
D U R I NG A CT U A L T A P P I N G .
PA SS ES
YE S CH E C K B E L T T E N S IO N IN D IC A T O R YE S
RI G ID T A P T E S T
A N D ID L E R A S S E M B L Y . OVE R SH O OTS A T AD JU ST R AM P
BU T TAP P ED
C H E C K F O R O IL O R B O T T O M O F T A P P IN G IN S E T P
HO LES A R E N O T
C O O L A N T O N B E LT S CY C LE?
GOOD?
O R E X C E S S IV E A IR IN
H Y D R A U L I C H I/L O A C T U A T O R . 23 . 3 a. 1 23 . 3 a. 2
23 . 4 NO
NO 23 . 4 .1
IS T H E C O R R E C T
G O /N O G O G A G E S P IN D L E IS T U R N IN G
B E IN G U S E D? P O S IT I V E YE S TOO FAS T,
IN D IC A T O R
23 . 4 .2 DE C R EA S E T H E
R E A D IN G W H I L E
GAIN PA RAM E TE R
IS T H E C O R R E C T G R A D E M O V IN G
IN S E T P
O F T A P B E IN G U S E D ? DO W N ?
A C L A SS 3 H O L E I S U S U A L L Y 23 . 3 b .1 NO 23 . 3 b .2
TA PP ED W I T H A G H - 1 T A P. .
P I TC H D I A M E T E R O F T A P I N CR E AS E S
0 . 0 0 0 5 " F O R EV E RY G H N U MB E R .
S P IN D L E IS T U R N IN G
23 . 4 .3 N E G A T IV E
YE S TOO SLOW ,
IN D IC A T O R
TAP M U ST BE IN C R E A S E T H E
R E A D IN G W H I L E
2 F L U T E S P IR A L P O IN T GAIN PA RAM E TE R
M O V IN G
(O R R O L L P O IN T ) IN S E T P
DO W N ?
IF L E S S T H A N 5 /1 6 "
23 . 3 c.1 NO 23 . 3 c.2
23 . 4 .4
IS T H E D RI L L T H E
C O R R E C T S IZ E ?
IN D IC A T O R R E M O V E IN D I C A T O R .
23 . 4 .5 RE A D IN G M O V IN G YE S DO A 1 0 IN C H R I G ID T A P .
UP D O E S N O T M A T C H CH E C K F OLL O W IN G E R R OR
IS C O O L A NT A N D / O R RE A D IN G M O V IN G O N Z -A X IS U P A N D D O W N .
T A P P IN G C O M P O U N D DO W N ? IS Z - A X IS B A L A N C E D ?
T H E CO R R E C T T Y P E 23 . 3 d .1
A N D M IX T U R E ? 23 . 3 d .2
23 . 4 .6
CH E C K F O L L O W IN G
HA S Z E R O O F F S E T CO N S U L T F A C T O R Y E R R O R O N C -A X I S
B E E N S E T IN A P P L IC A T I O N UP A N D D O W N .
IN V E R T E R ? E N G I NE E R IS IT T H E S A M E ?
23 . 4 .7 23 . 4 .8
23 . 3 d .3
CO N S U L T F A C T O R Y B E L T S M A Y B E S L IP P IN G .
YE S S E R V IC E D E P T . GO TO CH E C K B E L T T E N S IO N
S P IN D L E
A B O U T P O S S I B I LI T Y O F CH A R T 3 A N D ID L E R A S S E M B L Y .
MOT OR
EN C O D E R R U N O U T S P IN D L E CH E C K F O R O IL O R
SH A KE S?
A N D IN S T A L L IN G DR IVE R C O O L A N T O N B E LT S
SOLID MO TOR M OU N TS O R E X C E S S IV E A IR IN
23 . 5 NO H Y D R A U L I C H I/L O A C T U A T O R .
23 . 5 .1 23 . 5 .2
23 . 3 d .4
IS A
BU M P F ELT CH E C K + 5 V ,+ 1 2 V ,- 1 2 V .
YE S CH E C K R IG ID T A P ALS O S ET ME TE R FO R VA C
W H E N S P IN D L E
P A R A M E T E R S IN S E T P A N D C H E C K F O R A C R IP P L E
STA R TS OR
(E S P E C I A L L Y R A M P ) O N + 5V , + 1 2 V A ND -1 2 V D C
RE V ER S ES ?
(0 . 0 1 5 V AC R IP P L E M AX O N + / - 1 2 V ,
23 . 6 .1 0 . 0 0 5 V AC R IP P L E M AX O N + 5 V )
23 . 6 23 . 3 d .5
NO CO N SU LT FAC T O R Y
S E R V IC E D E P T .
23 . 7
Figure 16-37 Rigid Tap

TH I S C HA R T C O VE R S M -FU N C TI O NS C O NT RO L LE D T HR O U GH T HE 10 50 B O AR D .
M0 - 19 , M 3 0-M 4 9 , M 60 -6 9, A ND M 90 -9 9 A R E S PE C I FI C FU NC T IO N S TH AT AR E
CHART 24
CO N TR O LL ED TH R OU G H TH E 1 04 0 BO A R D O R AX IS C A RD S .
TH EY AR E NO T CO V ER E D H E RE ..
M ,- F U N C T IO N M-F U NC TI O N SE TT I N GS A ND TE R MI N A LS AR E L I ST E D I N CH A P T ER 7 O F T H E
M - F U N C T IO N MA IN TE NA N CE M AN U AL . BE SU R E Y O U A R E U S IN G TH E TA BL E F O R T HE 1 0 5 0
BO A RD YO U H AV E .
9- 1 9 -9 5
YE S CH E C K D E C A D E
M - F U N C T IO N 1 0 5 0 -3 A D E C A D E S 1050-0 D E C A D E SE LE C TION
SE L EC T I O N
DO E S N O T DE C AD E A - M 20- 2 9 DO N OT SE T 1 05 0- 0 F O R D EC A DE S 0, 1, 3 ,4 ,6 O R 9 B EC A US E T H E S E
JU M P E R S / SW I T C H E S
A C T IV A T E ? DE C AD E B - M 80- 8 9 D E CA D ES AL R E A DY H AV E S P EC I FI C FU N CT I O NS AS S IG N E D T O TH E M .
ON 1050 B OAR D 10 5 0 - 3 A HA S 2 M - F UN CT I O N S (A DO N OT SE T D E CA D E A A N D DE C AD E B T O T HE S AM E VA LU E .
O R B ) W H IC H A N Y N U M B ER I N
TH A T D EC A DE W IL L AC T IV A TE . TH E A C TI VE D EC A DE S O N TH E 1 05 0-0 AR E A S SI G N ED U SI N G D I P
24 . 1 S W I TC H ES LA B EL ED A1 , A 2 , A 3, A 4 , B 1, B 2, B3 , AN D B4 .
24 . 1 .1 2 A
3 B TO SE T D E CA D E A FO R :
4 M 20 -29 : A 1-C L OS E D, A 2-O P EN , A 4-C LO S E D, A 8 -C LO S ED .
W IT H U S E R D EV IC E A T T A CH E D 5 M 50 -59 : A 1-O P E N, A2 -CL O SE D , A 4-O P EN , A8 -CL O S E D.
NO 6
M E AS U R E V O L T A G E 7 M 70 -79 : A 1-O P E N, A2 -O P E N, A 4-O P E N , A 8-C LO S ED .
A C R O S S A P P R O P R IA T E 8 M 80 -89 : A 1-C L OS E D, A 2-C LO S ED , A4 -C LO S E D , A8 -O P E N.
9
T ER M IN A L S O F T B 1 O R T B 2 FO R D E CA D E B , US E SW I T CH E S B 1, B 2 , B4 , B 8 .
O N 1 0 6 0 W H IL E
M - F U N C T IO N IS A C T IVA T E D .
M -FU N C TIO N T E R M I N A LS
24 . 1 .2 UN ITS D E C A DE
DI G IT A B
T B1 TB 2
0 * 7+ 1 3 - 1 1+ 10 -
M - F U N C T IO N YE S 10 5 0 B O A R D 1 9 15 13 12
DO E S N O T YE S IS A C T I V A T IN G 2 2 4 19 20
DID RELA Y
R E L E A S E? M - F U N C T IO N . 3 5 6 14 1
CO N TAC T S 4 8 10 2 3
(V O LT A G E AC R O SS CH E C K C A B L IN G
CL O S E ? 5 11 16 16 15
24 . 2 TE RM I N AL S W IL L B E 0 A N D U S E R D E V IC E.
6 19 20 18 17
W HE N CO N TA C TS CL O S E )
24 . 1 .3 7 17 18 9 8
NO NO 24 . 1 .4 8 1 3 7 6
9 12 14 5 4
AR E YO U SU R E ? * FO R 1 05 0- 3 A ( P O L A R I T Y
RE LA YS P R OVID E A IM P OR T AN T F O R B O AR D S
CO N TAC T C LOS UR E , CH E C K S E T T I N G S U S IN G O PT O -I SO L A TO R S )
M - F U N C T IO N YE S
NO T A V O L T A G E . OF 1A 2A OR 1B 2B
RE L E A S E S
VO L T AG E O R C U R R E N T DIP SW ITC H ES
PR E MA TU R ELY ?
TH R OU G H R E LAY C O N TA C TS ON 1050 B OAR D
M U S T B E S U P PL IE D B Y
US E R D E V IC E . 24 . 1 .5
24 . 2 a US ER D E V I C E A ND
M-F U NC TIO N BO A R D
NO 24 . 1 .3 a MU S T B E S ET FO R
TH E S AM E PR O TO C O L .
CH E C K V O L T A G E A T
YE S CHE C K SE TTIN GS TB3-2 (M-FU N CTION R E SE T) ON 1060.
DISC ON N E C T U S ER
C N C IS OF 1A 2A OR 1B 2B S H O U L D B E 5 V W H EN R E L E A S E D ,
DE V IC E F R O M 1 0 6 0
H U N G U P? DI P S W I T C H E S 0V W HE N C L O S E D.
T B 1 / T B 2 A N D T B3
ON 1050 B OAR D RE S ET MU S T B E R ELE AS E D BE FO R E
NE X T M -F UN C T IO N O C C U R S .
24 . 2 b 24 . 2 .1 US ER D E V I C E A ND AL L M - FU N CT I ON S O N T HE 10 50 24 . 2 .3
M-F U NC TIO N BO A R D 24 . 2 .2 SH AR E TH E S A M E R E S E T LI N E .
NO
MU S T B E S ET FO R
TH E S AM E PR O TO C O L . CO N N E C T O H M M E T E R O R
SP IN D L E/ M - F U N C T IO N T E ST E R ( ST 0 3)
T O S E L E C T E D M -F U N C T I O N
T E R M IN A L S O F T B 1 O R T B 2 .
24 . 2 .4
R E L A Y A C T I O N / R E S E T C O N D IT IO N D IP S W I T C H E S
TH E R E LA Y A CT IO N A N D R ES E T C O ND I TIO N S A R E S E L E C T E D BY D IP S W ITC H ES EX E C U T E M -F U N C T IO N
L A B E LE D 1A ,2 A , 1 B ,2 B , W HE R E A AN D B A R E T HE DE C AD E S . FROM MDI.
O N TH E 1 05 0-0 A T HI R D D I G IT I N DIC A TE S T HE M -FU N CT IO N W I T HI N TH E DE C AD E .
FO R D E CA D E A , TH E S E TT IN G S A R E: RE L A Y T ER M IN A LS
1 A-O P EN 2A -O P E N = RE L A Y GI V E S A 0. 1 S E C P UL S E , SH OU LD C LOS E . *
C N C P R OC E ED S A F TE R P U LS E.
(O H M M E T E R W I LL S H O W 0 O H M
1 A-C LO S ED 2A -O P EN = R E LA Y G IV E S A 0 .1 S E C P U LS E ,
C N C P R OC E ED S A F TE R R E SE T R E LE AS E. O R S T 0 3 L ED W IL L L IG H T )
1 A-O P EN 2A -CL O SE D = R E LA Y H E L D U N TI L RE SE T C L OS E S, 24 . 2 .5 * RE LA Y T ER M I N AL S W IL L C L O S E
C N C P R OC E ED S A F TE R R E SE T R E LE AS E. OR C LO SE FO R 0. 1 S E C. A N D T HE N O P E N
1 A-C LO S ED 2A -C LO S E D = RE LA Y HE LD U NT IL R ES E T C L O S E S AN D IS R EL EA S ED , DE P E N DIN G O N T HE O PT IO N S E L EC T E D
C N C P R OC E ED S A F TE R R E SE T R E LE AS E. BY TH E D I P S W I T CH E S.
FO R D E CA D E B , TH E D I P S W I T CH E S A RE 1B A ND 2 B .
FO R M -F UN C TIO N 9 O F D EC A DE A (e. g. M 29 ) O N T HE 10 50-0 , TH E D I P S W IT CH E S S H O R T T B 3- 2 ( R E S E T ) T O T B 3 - 1 .
W OU L D B E 1 A 9 AN D 2A 9.
US U A L L Y T H E S ET TI N G S A R E F OR A 0 .1 S E C P UL S E A ND TH E CN C P R O CE E DS (O R P R E S S B U T T O N O N S T 0 3 )
A F TE R R E SE T R E LE AS E: S O TH E S E TTI N G S W OU L D B E 1 A-C L O S E D , 2A -O P E N , RE L A Y W IL L O P E N A N D
1 B -C L O S E D, 2 B- O P E N . CN C W IL L P R O C EE D
A C C O R D IN G T O T H E O P T IO N
SE L E C T E D B Y T H E D IP SW IT C H E S .
24 . 2 .6 CN C W I LL N O T P RO C E ED U NT I L
CO N DIT IO N F OR R ES E T I S S A TI S FI E D.
IF 1 0 5 0 B O A R D O P E R A T E S C O R RE C T L Y
DI SC O N N E C T E D F R O M U S E R D E V IC E ,
RE FE R TO C H AP TE R 7 O F
M A IN T E N A N C E M AN U A L A N D
MA N UAL F OR U S ER D E VIC E F OR
P R O P E R C O N F IG U R A T IO N S .
24 . 2 .7
CO N S U L T F A C T O R Y
S E R V IC E D E PT .
24 . 3
Figure 16-38 M-Function

INDEXER WIRING DIAGRAM

10- 20-95
U1
(1 2 VOLT
U2 REGULATORS)
SOLID S TATE R ELAY

FOR AIR S OLENOID
U3
IGBT's AIR
SOLENOID
Q1 Q2 Q3 Q4
J4 K1
J2
120VAC POWER SUPPLY
1 BLACK 1
FU SE 165VDC
(A GC 10 ) WHITE 2
COM FOR 165VDC
BLACK 3
WHITE 4
1810-0-1
U4
1810-0-2
AMPLIFIER J2
(5 VOLT REGULATOR)
6 - GND (isolated)
5 - +12V (isol ated) FU SE
4 - NC (A GC 10 )
3 - NC
2 - GND
1 - +5V
1
1
1 J3 J3 J1
J1 1 1 2 3 4
WHITE
BLACK
1 3
ELECTROCUB E SNUB BER

POWER
6 7 FUSE SWI TCH
4
(A GC10)
9
8 10 11 12
13 15 16
MOV130LA20A
17 19
1 4
2 3
L N
W POWER
O
L L EN CORD
GREEN
YE RE CONNECTOR
BLACK
WHITE
RED
E
G U
BL
N
W
O
SHIE LD
E
BR G
1 ED AN
R R
O J11
2 J15
VI OLET
FINIS H START J3
BLACK 1 1 1
J1 J10 GRAY 1&2 - + 5V IN DEXER
1 RS -232
WHITE 3 - +12V IN TE RFACE
J1-1 P WM* ENCODER 4 - -12V
J1-2 DIR J3-3 TXD DB25-2
J10-1 T O U4 PIN 7 A- 5&6 - GND J3-5 RXD DB25- 3
J1-4 OVERCURRENT 8 - BRAK E
J1-6 OVERTEMP J10-2 T O U4 PIN 6 A+ J3-7 RTS DB25-4
J1-8 S TOP/ GO* J10-3 T O U4 PIN 1 B- J3-9 CTS DB25-5
J1-10 RES ET* J10-4 T O U4 PIN 2 B+ J3-11 DSR DB25- 6
J10-5 T O U4 PIN 14 Z - J3-13 GND DB25-7
J10-6 T O U4 PIN 15 Z + J3-14 DTR DB25- 20
J10-7&8 +5V
J10-9&10 GND CONTROL BOARD CTS IS JUMPERED TO D TR AND
DSR IS JUMPERED TO DTR.
J2
DISPLA Y 1 J6
1
J4
J5 1 1810-0
KEYPAD
RED
EMERGENCY
STOP BLACK
RED
BLACK
FEED RATE
WHITE
WHITE
START
GREEN
Figure 16-39 Indexer Wiring Diagram

9-PIN CONNECTOR TO
ENCODER ON MOTO R
MOTOR 19- PIN CONNECTOR ON MOT OR CABLE
WHITE
3 GRAY
1
14 GA. SHIELDED B LACK BROWN
9 Z-
4 6 7 YELLOW
8 A+
9 RED 7
14 GA. GREEN 8 11 A-
10 12
GREEN
BLUE 6 Z+
13 15 16
ORANGE
5 B+
14 GA. SHIELDED R ED
19 VI OLET 4 B-
17
MOTOR WI RES ARE SH IELDED. BLACK
3 COM
SHIELD MUST NOT TOUCH CONDUCTOR!!!
SHIE LD 2 +5V
1 SHIE LD
MOTOR CABLE WIRING FOR VH-5C INDEXER

4-6-95
8-PIN CONNECTOR TO
MOTOR 19- PIN CONNECTOR ON MOT OR CABLE ENCODER ON MOTOR
WHITE
1 +5V
3 GRAY
1 2 COM
14 GA. SHIELDED B LACK YELLOW 3 B-
4 6 7 4 B+
BROWN
5 Z-
9 RED
14 GA. GREEN 8 10 11 12
GREEN 6 Z+
BLUE 7 A-
13 15 16 8 A+
ORANGE
14 GA. SHIELDED R ED
19 VI OLET
17
MO TOR WI RES ARE SH IELDED. BLACK
SHIELD MUST NOT TOUCH CO NDUCTO R!!!

SHIE LD
MOTOR CABLE WIRING FOR VH-65 INDEXER

4-6-95
BULKHEAD CONNECTOR WIRING

FOR CLOCKWISE POSITIVE MOTION
6-20-95
WHITE 1 3
6 7
4
9
8 10 11 12
BLACK 13 15 16
17 19
N
EE
R W
G O
LL
YE U
E
BL
N
W
SHIE LD
O E
BR ED
G
R AN
R
O
2
VI OLET
BLACK
J1 0 GRAY
1
WHITE
ENCODER
Figure 16-40 Motor Cable Wiring & Bulkhead Connector Wiring

Figure 16-41 Servo Coolant Wiring

Figure 16-42 Servo Turret Wiring

Troubleshooting

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Troubleshooting

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Fadal Maintenance Manual

Section 16: Troubleshooting

Error Messages Absolute Mode Required at N =

Amplifier Fault on Axis

Arm Must Be Left

Array Exceeds Allowable Number

March 2003 Section 16: Troubleshooting 509

ATC Turret Failure

ATC Will Not Move to Position

It is also possible that the turret extended sensor is faulty.

510 Section 16: Troubleshooting March 2003

Attempted Division by Zero

Attempted SQR of a Negative Number

Attempt to Change CRC Side Without G40 at N =

Attempt to Change Tool While in CRC Mode, N =

Attempt to Switch Plane During CRC

Axis Controller Does Not Respond During Power Up Sequence

Axis Controller Does Not Respond to NC

Axis Data Transfer is Stalled

Axis Does Not Respond

March 2003 Section 16: Troubleshooting 511

Axis Fault(s) as Follows

Bad Circle OR Missing G at N

Bad Data or No Tool Dia.

512 Section 16: Troubleshooting March 2003

Bad Fixture No.

Bad Interpolation Type at N

Bad R1 Using L91 at N =

Bad Z or R0 in Canned Cycle Call, N =

1) The R plane is described to be above the I plane.

March 2003 Section 16: Troubleshooting 513

2) The R plane is described to be below the final Z depth.

3) The final Z depth is described to end above the I or R planes.

Note: The H code might not be in the program.

Calculated Radius Error Of

Cancel CRC Before G50.1 OR G51.1 AT N =

Cancel CRC Before N =

Cancel Z Axis Mirror Before Tool Change at N

Cannot Return from Subprogram or Subroutine

Cannot Start Directly in a Subprog.

514 Section 16: Troubleshooting March 2003

Another method to start the program in a subroutine is to use the AUTO

Char. Size or Depth Exceeds 2.5 In.

Check Emergency Stop Switch and Motor Overload Relays

Check Spindle Lube, Way Lube and Air Pressure

Clear an Emergency Stop Condition

Command Prohibited by the Key Lock

CRC Called With No Tool Assigned at N =

March 2003 Section 16: Troubleshooting 515

Data Transfer Fault

Door Began to Close While Arm was Moving

Do You Want to Move to the Last Home Position?

Do You Want to Reinitialize Memory?

516 Section 16: Troubleshooting March 2003

! a cold start must be performed.

March 2003 Section 16: Troubleshooting 517

Do You Want to Zero Tool Table?

Do You Want to Zero Fixture Offsets?

Dry Run Option ___ is in Effect

Duplicate or Bad Prog. Name

Dwell, Hit Start to Interrupt

518 Section 16: Troubleshooting March 2003

E Word May Only Be Used With G0 or G1 N =

Emergency Stop - Take Appropriate Action