FlexiCAM Support Info

Date: 10.03.2001

Version: 1.0

Trouble Shooting (Servo System)

Symptom Error Solution

E-Stop E-Stop-Button on keypad is Release E-Stop button

(after system has been turned on)
E-Stop
(while system is active)
pressed
Servos and spindle are not Turn of the system, turn it back on and press the green
enabled enable button
Servos do not have power 1. Open the control box and leave it open
2. Check if all fuses are turned on
3. Turn on the power
4. Press the green enable button
5. Check if the servos are turning on
6. If the servo are not turning on check if all three
phases have power
7. Check if the servo error relais K2-K5 (K2-K4 on a
three axis system) are active
8. Check if the enabled relais K6 is active
Ribbon cables from the computer Flip the ribbon cables: The cable labled 'A' or marked
to the outbreak boards are flipped with a label go to outbreak board A and C, the other
(like after replacing the controller) one goes to outbreak board B and D.
If this does not help maybe you flipped the connectors
at the computer: Either flip these connectors or
exchange A vs. C and B vs. D.
Servo I/O card inside the controller Check function of the controller card:
is bad 1. Open the control box
2. Enable the servo drives
3. Connect a screen and keyboard to the computer
4. Terminate controller process on task 1 by CTRL-
C
5. Switch to second task by CTRL-2, press SPACE
and login with 'root'
6. Start program 'encoder'
7. Check the limit switches by holding some metal in
front and check the feedback on the screen
8. Move the axes by hand and check the encoder
readout on the screen (Readout order is XA, Y, Z,
XB)
Gantry has a bind 1. Leave the control box open and turn the system
back on
2. After homing the system check if the torque
values displayed on the servo drives are high:
Normaly they should be below 100 when the
system is not moving. If the values on XA and XA
are higher then 100 you need to stress relieve the
gantry. Follow the guideline on the appropriate
support info!
3. If another axis (X or Z) show high values check if
the axis is blocked or some other mechanical
problems have occured.
4. The Z axis may have get stuck on the bottom or
top of the lead screw.
5. The Z axis lead screw may be too tight or too
loose. Please check for the right adjustment.

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FlexiCAM GmbH • Technical Support • Benkertsweg 9 • D-97246 Eibelstadt • Germany

Phone +49-(0)9303-9081-0 • Fax 990352 • Website http://www.FlexiCAM.de • EMail Support@FlexiCAM.com
Cannot start homing Limit switch is active
(after starting the homing function)
Limitswitch broken
Following Error System stalls
(while homing or during a job)
Switch to Demomode System has expired
(while starting the system)
Job does not start when pressing the System has expired
F1 key
Bad edge quality, especially no round Backlash on a rack and pinion
arcs and circles driven axes
Dumb tool
Wrong direction
Tool is vibrating
Material is loose
Clamp connection between motor
and planetary gear box is loose
Difference in depth Z axis is loose
Material is loose
Kp, Ki, Kv, Windup are wrong (e.g. Check the tuning parameters in /flexicam/controller.ini
after a software update)
Tuning parameters on the servo
amplifier are wrong (e.g. after a
replacement)
Arcs are not tangential to each other; Decimalpoint from arc radius is
Inlays do not fit; replaced by a comma
Rounded contours are not round
Spindle error Spindle overload turned off (Q2)
Spindle inverter drive shows an
error
Controller does not boot The init files have been damaged
(e.g. after an update)
Floppy disk in disk drive
No Tool mounted Machine function (like surface set) If there is a tool in the spindle release tool and return it
started without tool in spindle
Page 2 / 3
FlexiCAM GmbH • Technical Support • Benkertsweg 9 • D-97246 Eibelstadt • Germany
Phone +49-(0)9303-9081-0 • Fax 990352 • Website http://www.FlexiCAM.de • EMail Support@FlexiCAM.com
Check which axis should be homed
Check if on the specific axes the limit switch(es) are
active. If yes, move the axis off the limit position
1. Check function of LS:
2. Open the control box and turn on the system.
3. Check the limit switches from this specific axis by
holding a screwdriver in front of the limit switch:
The LED on the limit switch should turn off.
4. Next check on the Opto-I/O--Board in the control
box if the LED are turning on/off.
5. In the worst case you can check on the controller
by running the 'encoder' diagnostics program if
the switches are feed back to the control system.
Check the racks for chips and other obstacles
Call FlexiCAM's technical support for assistance!
Call FlexiCAM's technical support for assistance!
Check and readjust the position of the planetary gear
boxes
Replace the cutting or engraving tool with a new one
Check if the opposite side is better. If yes, invert the
direction of the contour.
1. Use a shorter tool
2. Use a tool with a larger diameter
3. Insert it further into the collet
Ensure that the material is not vibrating.
Check if you can move the axis manually while the
servos are powered on and active. If yes, call
FlexiCAM's technical support for assistance!
Check the nut from the z leadscrew for backlash
Check the way of mounting the material:
If you are using sheet material try to tape it down or
hold it down by vacuum to ensure it is laying flat on the
table surface. If you clamp it you risk that it will bend in
the middle.
Check the tuning parameters at the servo amplifier
Check the country settings in the Windows system
settings. In some countries which use a
decimalcomma instead of a dezimalpoint (like
Germany) this may cause problems in Scanvec's
EnRoute. Make sure that there is a decimapoint used
in the country settings.
Turn on Q2
Note the error message / number.
Reset the spindle inverter and continue.
If the error occurs more often consult FlexiCAM's
technical support for assistance.
Most problems can be eliminated by using longer ramp
times.
(Re)install init files
Eject the floppy disk
to tool holder manual. After that load a tool by using
the keypad.
System takes a long time to boot;
No 'Remote' folder in the job manager
Cannot start surfacing
Vacuum table does not hold down
material (T slot profiles with
regenerative blower)
Vacuum table does not hold down
material (high pressure vacuum table)
Vacuum table does not hold down
material when using MDF as sacrificial
material (high pressure vacuum table)
FlexiCAM GmbH • Technical Support • Benkertsweg 9 • D-97246 Eibelstadt • Germany
Phone +49-(0)9303-9081-0 • Fax 990352 • Website http://www.FlexiCAM.de • EMail Support@FlexiCAM.com
No network server connection
Surfaceblock has a short curcuit to Isolate the surface block from ground
ground
Workpiece is too small
Too much airflow
Chips between workpiece and
table allow too much airflow
Too many grooves in the PVC
table top
PVC table top material is new
Filter does not allow enough air
flow
Workpiece is too small
Filter does not allow enough air
flow
Workpiece is too small
Too much airflow
Chips between workpiece and
MDF allow too much airflow
Too many grooves in the MDF
sheet allow too much airflow
Filter does not allow enough air
flow
Pump too small
Page 3 / 3
1. Check if the system is connected to the
workstation or hub.
2. Check if you are using the right network cable:
If you connect the system to the workstation
directly, you have to use a crosslink cable.
If you connect the system to a hub, you have to
use a straight patch cable.
3. Maybe the network configuration was changed?
Reconfigure the network server or workstation
according to the Network Setup Support Info.
4. If the network server configuration was modified
you may have to change the controller system as
well to enable the system to connect to the
server.
5. If you are using Windows it is necessary to
unshare the jobfolder, reboot and re-share it in
case you make modifications to the network
configuration on the workstation.
Note: This may happen with older systems that use a
plain aluminium surface block. If used e.g. on an
aluminium plate that is clampled to the table via t-slot
clamps you may face this error. Use some plastic to
isolate the bottom of the surface block. After that
readjust the thickness in /flexicam/flexicam.ini.
The t slot vacuum table does not allow very small
workpieces to be hold down by vacuum. Use t-clamps
instead of vacuum to ensure a proper holddown.
Cover all areas that allow unnecessary airflow with
some vinyl or similar material
Clean the vacuum table before use
Mill flat the PVC table top
The PVC panel table top needs to be milled after
replacing panels before the first time use
Clean or replace the vacuum filter
The t slot vacuum table does not allow very small
workpieces to be hold down by vacuum. Use a
template instead or seal with gasket directly under the
workpiece.
Clean or replace the vacuum filter
The t slot vacuum table does not allow very small
workpieces to be hold down by vacuum. Use a
template instead or seal with gasket directly under the
workpiece.
Cover all areas that allow unnecessary airflow with
some vinyl or similar material
Clean the MDF sheet before use
Mill flat or replace the MDF sheet
Clean or replace the vacuum filter
Add another vacuum pump to the system for more
volume