Fadal Maintenance Manual

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

March 2003 Section 16: Troubleshooting 577

Fadal Maintenance Manual

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

AX IS MO VE COMMA ND
#14
WAS NOT PRO PE RLY
MOV E TRA NS FE R
TRANS FE RRE D TO
FAULT - MOVE SE TUP
AX IS CARD
INCOMP LE TE
(CHE CK S UM F AI LE D)
18. 14 18. 14.1
RUN DI AG NO ST ICS
CHE CK
ON CPU AND A X IS:
+5V , + 12V, & -12V
IF O NE A XI S FAI LS, REP LACE
VOLT AGE S FROM
THAT AX IS CA RD AND RE TE ST .
POW ER S UPP LY
IF M ULTIP LE CARDS FA IL, RE PLA CE
SE E CHART 12A
1030 OR 1400 AND RETE ST
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)

578 Section 16: Troubleshooting March 2003

Fadal Maintenance Manual

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

March 2003 Section 16: Troubleshooting 579