Maintenance

Manual
Section Eleven:
Troubleshooting

Fadal
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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.

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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.

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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.

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.

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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.

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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-E48are 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.

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BAD R FIELD :
This occurs during input from the keyboard or through the RS-232 port
(from an off line 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).

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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).

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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 oilier 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.
It is suggested to look in 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.

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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.

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DO YOU WANT TO MOVE TO THE LAST HOME

POSITION?
This is not an error message but it should be mentioned that this message
comes up 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? :

This prompt is accessed by reinitializing the memory via the RI command.
A ‘Y’ response zeroes the tool offset table.

WARNING! All tool diameter and length offsets are deleted from
memory.

DO YOU WANT TO ZERO FIXTURE OFFSETS? :

This prompt is accessed by reinitializing the memory via the RI command.
A ‘Y’ response zeroes the fixture offset table. Warning !! All fixture offsets
are deleted from memory.

DRY RUN OPTION ___ IS IN EFFECT :

The selected dry run option (1, 2, or 3) is displayed prior to automatic
execution. See the Users Manual or the Run Time Menu for the
appropriate option definition.

DUPLICATE NAME :
No two programs in the library can be identified by the same number.
When copying an existing program assign an unused number to the new,
or copied program. Use option 2 (display program numbers) of the PR
menu to determine which numbers have been used.

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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.

2) Press the JOG button which resets the amplifiers if the problem has
been resolved.
3) Type HO and press ENTER, then after the waiting message appears
press START (see note).
4) 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.

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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(s).

ERROR IN USER PROGRAM, ‘SUM’ TO SEE

MESSAGE :
See the Operators Manual for instruction 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.

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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.
a. Send the machine back to cold start alignment markers.
b. Power off the machines main power , wait 15 seconds and power
on the machine
c. Cold start then run the program again.

If this error repeats :

a. Save all the programs and offset information currently in memory,
write down the present home position
b. Send the machine back to cold start alignment markers.
c. 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.

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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 can not 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.

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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, dependent 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.

2) If the programmer omits a required R word from the subroutine.

3) If 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).

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4) 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.

5) 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 messages 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 alarm 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 to large. Example : X-123456789.

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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

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, 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.

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M FUNCTION TOO LARGE AT N = :

M functions can not 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 sub section from
N20 * the main program.
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.

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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.

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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 Maintenance Manual). 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.

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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.

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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 to 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.

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OUT OF FILE SPACE, A FILE COMPRESSION IS BEING

TRIED :
This is a message which 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 alarm 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 a service
department for assistance.

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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.

2) The baud rate is too fast for the length of cable used.
3) There is a failure in the RS-232 port (hardware problem).
4) 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)

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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 M3before 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.

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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.

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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.

2) An axis runaway during power on.
3) A large Scale or Motor error, indicating a possible scale failure.

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 palette hanger 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.

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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 alarm 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 alarm 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 effects 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.

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To exit single step, press the AUTO button for continuous block execution.

SLIDE HOLD- :
Pressing the SLIDE HOLD button stops all axis motion. The distance to
finish the move is presented under the blinking SLIDE HOLD message.

It is possible to press the JOG button and jog away from the current
position while in the Slide Hold mode without aborting the operation.
Program execution can be continued at the new location, or the axes can
be returned to the position at which the Jog function was initiated.

To exit from the Slide Hold mode, the operator must press the START
button, if in single step, or press the AUTO button for continuous block
execution.

SPINDLE CONTROLLER DOES NOT RESPOND :

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

The motor overload relays can be recognized by their white reset buttons.
They are located in both control enclosures. The white button must be
pressed to reset a relay. Call service department first.

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!)
2) Check to see if the belts are on the pulleys.
3) Do not turn the power off.
4) Call the service department and report this problem (while the
machine is on).

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SPINDLE CONTROLLER SOFTWARE UPDATE IS

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

SPINDLE DRIVER FAULT :

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

The motor overload relays can be recognized by their white reset buttons.
They are located in both control enclosures. The white button must be
pressed to reset a relay.

SPINDLE FAILURE WHILE TAPPING :

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

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.

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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.

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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 Maintenance Manual)

THE SURVEY CONTAINS ERRORS, PLEASE REVIEW :

(See Survey in the Maintenance Manual)

THE SURVEY WAS NOT WRITTEN TO THE AXIS

CONTROLLER :
(See Survey in the Maintenance Manual)

THERE IS NO SURVEY :
(See Survey in the Maintenance Manual)

THREAD LEAD NOT SPECIFIED AT N = :

Fixed cycles G74, G75 and G84 need a Q word in the line that represents
the decimal thread lead of the tap (see the Users Manual for the proper
format). If the Q word is omitted this message will appear.

If the programmer uses the fixed cycles G74, G75 or G84 and does not
cancel the cycle with any of the following codes: M6, G28, G29, G49,
G80, H0, this message will appear at the next Z move.

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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.

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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.
2) Check the program to see if it contains any typographical errors.
3) 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.
4) 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.

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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 slid 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.

Mar 2000 Troubleshooting

Fadal Maintenance Manual

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 Maintenance Manual)

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.

Troubleshooting Mar 2000

Fadal Maintenance Manual

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.)

Mar 2000 Troubleshooting

Fadal Maintenance Manual

EMERGENCY ERROR CODES

Error numbers help discern the location of the problem the axis or spindle
is reporting . The error number will follow a message to call the service
department and report the error number on the screen to correct the
problem.

Error numbers from the AXIS or SPINDLE

CONTROLLER:
[ 1 ] NO MOTOR FEEDBACK.
This error appears during power up, when no motor feedback (either
resolver or encoder) is detected by the axis controller.

[ 2 ] ENCODER NOT RESPONDING

This error appears during the rigid tap operation. If the encoder feedback
is interrupted during the spindle operation then the spindle operation is
halted.

[ 3 ] LOGIC JUMPER INCORRECT OR COMMAND SIGNAL MISSING OR

MOTOR-TACH CONNECTION INCORRECT
This error appears during power up. An incorrect motor—tach—jumper
configuration or failed component may cause the axis to run away in the
opposite direction of the command sigal. 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.

Troubleshooting Mar 2000

Fadal Maintenance Manual

[ 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.

Mar 2000 Troubleshooting

Fadal Maintenance Manual

[ 17 ] BAD READING ON RESOLVER PORT

This error appears if the value of resolver “counts”, read from the resolver
port when the “zero-crossing” pulse is detected, is too large, indicating
possible failure of the resolver cables, 1010-4 card, or the resolver itself.
Also caused by severe motor vibrations.

[ 18 ] AMPLIFIER FAULT LINE DOWN

This error appears any time the axis card no longer detects the fault line
signal from the amplifier, or the signal strength has dropped below 10V,
at least 5V indicating a possible amplifier fault.

[ 19 ] STACK OVERFLOW — OVERLOADED WITH STEP COMMAND

This error appears if the stack on the axis card, used to store CPU
commands until they have been serviced, overflows.

[ 20 ] MOVE TRANSFER FAULT — MOVE SETUP INCOMPLETE

This error appears when an axis move command is not properly
transferred to the axis card, as indicated by a checksum comparison
between what the CPU sent and what the axis card received.

[ 21 ] UNEXPECTED INTERRUPT
This error appears if the interrupt currently being processed is not an
expected interrupt, and therefore cannot be serviced, indicating possible
failure of the 1010-4, 1030, or main CPU.

[ 22 ] BAD SCALE READING

This error appears if the feedback from the scale port is outside allowable
limits, indicating possible failure of the EXE box, scales, cables, or 1010-4
card. Also caused by severe motor vibrations.

[ 23 ] MOTOR OVERLOAD DURING STAND-BY MODE

SEE ERROR CODE 13 ABOVE

[ 24 ] MOTOR OVERLOAD DURING RAPID MODE

SEE ERROR CODE 13 ABOVE

[ 25 ] MOTOR OVERLOAD DURING CONTOURING MODE

SEE ERROR CODE 13 ABOVE

[ 26 ] MOTOR OVERLOAD DURING JOG MODE

SEE ERROR CODE 13 ABOVE

Troubleshooting Mar 2000

Fadal Maintenance Manual

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

Mar 2000 Troubleshooting

Fadal Maintenance Manual

CHART 1 DA S H ED S YM B O LS
AP PLY T O C E N OR M
QU IC K C H E C K OU T P R O C E D U R E EU R O P EA N M AC H IN E S
9- 20 -95 ON L Y
Q U IC K C H E C K O U T

DIF FI CUL T T O D IA GN O S E P RO B LE MS CA N O C CU R IF M ACH INE I S NO T P R OP E RL Y G R O UN D ED .

TH ER E MUS T B E A CO N TI NU O US G RO U NDIN G CO N D UC TO R (AS S PE CI F I ED O N T HE G ROU ND ING 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 BUS TO THE GRO U ND B US IN T HE
BUI LD ING 'S P OW E R DI S TR IB UT I O N P AN E L.

PR O P ER AIR PR E SS U R E A N D A D EQ U ATE A IR V OL U M E IS C RI T IC A L F OR TO O L C HA N G E S.
AIR PR E SS U R E RE GU LA T OR O N MA C H IN E M US T BE S E T AS LA BE LED (80- 90 PS I A N D
IS T H ER E NO CO R R EC T AIR 12 0 PS I F OR T OO L OU T R EG U LA T OR ) . AIR SU P PLY T O M A C H IN E S HO U LD BE 120 P SI .
A IR PR E SS U R E?
PR E SS U R E AIR HO SE T O M A C H IN E M US T BE 3/8" AN D A S S HO R T A S PO S S IBLE .
(80 P SI ))
AIR DI ST RI BU T IO N P IP E IN B UI LD IN G S H O U LD B E A M IN IM U M O F 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 T OO L C H AN G E S H OU LD B E A
1. 1 YE S 1. 1.1 MA X I MU M O F 3-5 P S I.

CH E C K + 5V, +12V , -12V , SE T M ET ER F O R

AN D 110 V AC VA C AN D CH E C K FO R NO SE E
AC R IP P LE O N IS
AT P OW ER S U P PLY ( 1220) CH A R T
+5V , +1 2V A N D - 12 V D C P OW ER O K?
(U S E O SC ILL O SC OP E NO . 12
(0 .01 5V AC RIP P LE MAX O N + /-12 V,
IF A VA ILA B LE ) 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 IF Y 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 LS E LE 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 GE N C Y MO T OR
O N A LL IS N O T LIM IT M O V EM E NT BR E AK ER S CH A R T
PR OB LEM ? ST O P O VE R L OA D
A X IS BO AR D S AT 0% WH EN D O O R S (C E NO . 4
BU T T O N RE L A YS
AR E BLI N KIN G AR E OP 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 T H AT R E LA Y S CH E C K FU S ES
YES CH E C K
A TOOL K5, K6, K33 , K11, F5, F 6, F7, F 8, F 19, F20 SE E
CO LD ST AR T
CH A N GE R K 12, K 13 , & K 1 4 AN D C IR C U IT B RE A KE R S CH A R T
PO S IT I O N
PR OB LEM ? AR E F IR M LY SE A T ED CB 1 & C B 2 NO . 2
O F Z AX IS
ON 1 100-2 B O A R D ON 11 00-2

1. 4 NO 1. 4.1 1. 4 .2 1. 4.3 1. 4.4

VE R IF Y
IS IT YE S PU LS E LE D 's TOO L D U LL ? SE E
A S P IN D L E O N A LL OR T OO L AR G E CH A R T
PR OB LEM ? AX IS BO AR D S A C U T? NO . 3
AR E BLI N KIN G

1. 5 NO 1. 5.1 1. 5.2 1. 5 .3

YES CH E C K AD J U ST
CH E C K FO R CH E C K CH E C K FO R SEE
LE V ELN E SS POS ITI ON LO O P
RE P EA TA BI LI T Y CH I PS IN T OO L I S F IX T U R E CH A R T
OF GAI N AN D
PR OB LEM ? SP IN D LE T IGH T MOV E ME N T NO . 5
M A C H IN E F EE 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

CH E C K
YE S SE E
CO N T R OL PU LS E LE D 's
CH A R T
PR O B LE M ? O N A LL B O AR D S .
NO . 6
AR E T H E Y B L IN K IN G .

1. 7 1. 7.1 1. 7 .2
NO

YE S SE E
KE YB OA R D
CH A R T
PR OB LEM ?
NO . 10

1. 8 1. 8 .1

GO TO
PA G E 2 OF
CH A R T 1

Troubleshooting Mar 2000

Fadal Maintenance Manual

C O N T IN U E D
FROM
CH A R T 1
C H A R T 1 c o n t in u e d (p a g e 2 )
PAGE 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/CO S
IS I T YE S CH E CK S IG N A L S U S I N G SE E
A F IN IS H BA LAN C E OF SE R VIC E TO O L S T 4 8 . CHA R T
PR OB LEM ? A X IS A M P L IF IE R S A D J U S T IF V A R IAN C E NO . 11
> 0.001V

1 A .1 1 A .1 . 1 1 A .1 .2 1 A .1 .3
NO

YE S SE E
IS I T
CH A RT
A RO TAR Y H E AD
13 , 1 4 . 0 R 1 5
PR OB LEM ?

1 A .2 1 A .2 .1
NO

YE S MAKE SURE V E R IF Y
IS IT A SE E
P O S IT I O N O V E R R I D E SERVO COOLANT
SE R VO C OO LA NT CH A RT
P O T IS A X IS IS S E T T O
PR OB LEM ? NO . 16
CE NTE R ED C O O L A N T IN S E T P

1 A .3 1 A .3 .1 1 A .3 . 2 1 A .3 .3
NO

CH E CK SIN/C OS
IS IT A YE S CH E C K S IG N A L S U S I N G SE E
RO UN DN E S S BA LANC E O F S E R V IC E T O O L S T 4 8 . CHA R T
PR OB LEM ? A X I S 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

1 A .4 1 A .4 .1 1 A .4 . 2 1 A . 4 .3
NO

YE S SE E
ER RO R
CH A RT
CO D E?
NO . 18

1 A .5 1 A .5 .1
NO

YE S V E R IF Y
IS I T A V E R IF Y SE E
BA UD R AT E A N D
C O M M U N IC A T IO N CO N N EC TIO N CHA R T
C O M M U N IC A T I O N
PR OB LEM ? OF R S 232 C AB LES NO . 19
PA R AM ET ERS

1 A .6 1 A . 6 .1 1 A .6 . 2 1 A . 6 .3
NO

YE S
IS IT A N YE S IS I T A SE E
IN D E X E R FADA L CH A RT
PR OB LEM ? IN D E X E R ? NO . 20

1 A .7 1 A .7 .1
1 A .7 .2
NO NO

IS I T YE S SE E
A N M -F U N C T IO N CH A RT
PR OB LEM ? NO . 24

1 A .8
NO 1 A .8 .1

GO TO
PA GE 3 O F
CH A R T 1

Mar 2000 Troubleshooting

Fadal Maintenance Manual

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 A SINGLE SLAB OF CONCRETE
AT A TIME TO
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

Troubleshooting Mar 2000

Fadal Maintenance Manual

CH AR T 2
TOOL CHA NGE R
AU T OM A T IC T OO L CH AN G E R
10-18 -9 5

PROP ER AIR PRE SS URE AN D AD EQ U ATE A IR V OLUM E IS C RI TIC A L FOR TOOL CHA NGE S.
AIR PRE SS URE REGU LA TOR O N MA CHINE M UST BE SET AS LA BE LED (80- 9 0 PS I AN D
12 0 PSI F OR TOO L OUT REGUL ATOR) . AIR SU PPLY TO MA CHINE S HO UL D BE 120 PSI .
USE T OOL IN/ OU T AIR HO SE TO M AC HINE MUS T BE 3/8 " AND AS S HO RT A S POS S IBLE .
TO INS ERT /RE MO VE
AIR DI ST RI BU T ION P IPE IN B UI LD ING S H OU LD B E A MIN IMU M OF 3/ 4 ".
TOOL F RO M S PIN DLE
THE PR E SS URE DRO P A T THE MA CH INE D URI NG A TOO L CHANG E S HOUL D B E A
MAXI MU M OF 3 -5 P S I.
2. 1

CHE CK AI R PRE SS UR E
MA NU ALL Y ACT IVA TE DO ES CHE CK AI R
DO ES NO (8 0P SI AND 1 20P SI ) CHE CK NO
DR AW B AR SOLE NOID DR AW B AR W OR K DE LIV ERY TO
TOOL I N/OUT (M AX 3 -5 PS I DRO P F20 AN D K24
AT MA C A IR WH EN M A NUAL LY DRA W B AR
W OR K? DURI NG TOO L ON 1100 -2 .
VAL VE A SS Y. OPE RAT ED? CY LIN DE R.
CHA NGE)

2. 2 YE S 2. 2 .1 2. 2.2 2. 2 .3 (I F A T OOL IS IN YE S 2. 2 .6
TH E S PI N DLE , 2. 2.4
HA VE H EL PE R
HO LD ON TO IT.) CHE CK 1040 AND W IRING
CHE CK DRAWB A R
(S EE DR AW ING 100 2
PRE SS EURO P EAN CE N O RM CY LIND ER FOR
AN D K EY BOAR D
TURRET CW M A C H IN E S M U S T H A V E BA D SE A LS O R
TROUBL ES HO OTING
AN D DO OR S CLOSED FOR BROK EN PI STO N
TURRET CCW A TC T O W O R K PR O P ER LY DI AG RAM )
2. 2 .5 2. 2.7
2. 3

CHE CK FU SE S F5 & F6 & CB 2

TURR ET FAC T OR AND R EL AY S K5, K33,
EM ER GE NC Y ST OP SE RVO IN S ETP M UST BE 1
DI D NO GE NE VA K11 , & K 12 ON 1100 -2 .
MUS T B E RE LE AS ED FOR S E RVO TUR RET .
TU RRET MOVE OR S E RVO K12 M UST BE LOW
AND
CORRE CTL Y? TU RRET ? C2 ON 11 00-2 MUS T LE A KA GE ( GREEN ).
AM PLIF IE RS RE SE T
BE B YP AS S ED. CH EC K F4 A ND
2. 4 .2 SER VO TURR ET FUS ES .
2. 4 YE S 2. 4 .1 GENE VA 2. 4.3
2. 4.4

CHECK SERV O T URRE T ME CHANIS M

GO TO CS PO SI TI ON. CH EC K TU RRET
CHE CK FUSE S F5 & F6 & CB 2 FOR BIND ING OR E XCE SS IV E PLA Y.
(I F NO T C O LD S TA RT ED, FA CTOR I N SE TP.
AN D RE LAY S K5, K33 ,
DO A C OLD ST ART.) CH EC K GE NE VA
K1 1, & K 12 ON 110 0- 2. CH EC K TUR RET MO TOR W IRING.
M EC HA NISM .
K12 MU ST BE RA TE D FOR
IN M DI E NTE R M19 CH EC K TUR RE T
3 AM P OU TP UT ( BL AC K) . CH EC K TU RRET MO TOR E NCODE R
M OTOR W IRING.
2. 5 AND W I R IN G.
2. 4.2 a 2. 4 .2 b
2. 4.5

GO T O IF T URR ET A M PLIF IER FUSE I S

DI D NO DI D NO CHA RT
SP IN DLE BLOW N OR O VE R-CUR RE NT
SP INDLE NO . 3
ORIE NT ? LE D IS O N, CH ECK M OTO R
TURN ? SP INDL E WIRE S F OR SH OR T T O C HAS S IS.
DRI VER (W I R ES TO MO TOR
2. 6.1 YE S ARE SHI ELD E D;
2. 6 YE S 2. 6 .1 a
SHIE LD M US T BE S TR IPPED
GO T O BA CK F ROM CONDUC TOR) .
DI D ADJ UST CH AR T 2. 4.6
YES
ORIE NT AT ION ORIE NT AT ION NO . 3
ARM SW ING FACT OR SP INDLE IF T URRE T MOV ES
IN? IN S ETP DR I VE R CO RREC TLY EXCE PT
FOR DIRE CTIO N,
2. 6.2 CHA NGE DIRE CTION
NO 2. 6 .2 a 2. 6.2b
CO N TR OL FR O M
TB1- 7 TO TB 1-5
CHE CK ON 11 00-2
F19 & K23 (OR VICE V ERS A)
ON 110 0-2
2. 4.7
2. 6.3
IF TU RRE T R UNS A W AY :
1 .RE V ER SE MO TOR LE ADS ,
RE M OVE TO OL 2 .CH E CK EN CO DE R WI RIN G ,
3 .RE P LA CE EN C ODE R ,
FR OM S PI NDLE
4 .RE P LA CE TU R RE T
AND MAN UAL LY ACTI VAT E C ONT RO L MOD U LE .
ORIEN TATI ON A IR S OL ENO ID
AT M AC AI R V ALV E A SS Y. 2. 4.8
2. 6.4
IF V ERY HE AV Y TOO LS
AR E U NEV E NLY
DI D CHE CK W IRI NG. DI ST RI BU TE D,
YE S
OR IE NT AT ION RED IS TRIB UTE TOO LS
ARM SW ING TRY KNOW N ON TUR RE T
IN? GOOD 1 040 .
2. 4.9
2. 6.5 D IP S WI TC H SE TTI NGS
NO 2. 6.6 SP EE D SW 1 SW2
GO T O F AS T OPEN OP E N CO NSUL T FACT OR Y
PA GE 2 OF M E DF A ST C LOS E D OPE N SE RVICE DE PT .
CHE CK AI R PRE SS URE.
CH AR T 2 M E DS LOW OP EN C L OS E D AB OU T D I P S W I TCH
S LOW C LO S E D CLO S ED SE TTING S F OR
CH EC K AND RE P AIR MOT OR T YP E: S W 3 & SW 4 OPE N SP EE D A ND PI D
2. 7 ORIE NT M ECHA NISM C ON SULT FA CTO RY A BOU T OTH E R
AN D A IR LINE S . M OT OR S ET TI NG S.
2. 4.10
2. 6.5a

Mar 2000 Troubleshooting

Fadal Maintenance Manual

C H A R T 2 co nti nue d ( p a ge 2)
A U T OM A T IC T O O L C H A N G E R
CO N T IN U E D 10 -1 8 - 9 5
F R OM
PA G E 1 O F
CH A R T 2

MA N U A LL Y MO VE A T C
TO EX T E N D E D P O S IT I O N
(G R AS P A N D SW IN G
UP P ER G E 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
M E C H AN IS M M O VE AN D L U B R IC AT E M E C H AN IS M
SM O OT H L Y ? ME C H AN IS M IF D A MA G E 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 OO L
T U R R ET FAC T O R AD J U ST
T OO L C A R R IE R NO CA R R IE R IS O U T
T U R R ET AL IG N M E N T
PR OP ER L Y A LIG N E D OF P O S ITIO N
(T U RR E T FA C TO R AN D /OR
W IT H S P IN D LE? MU ST B E 1 FO R O R S KE W E D
CO L D ST AR T PO SIT IO N
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 (SE 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 ET A LIG N ME N T IS
AD JU ST E D.)

RE T U R N A T C T O
RE TR A C T ED PO SI TI O N .

TH EN IN MD I E N TE R (IF TO O L 2 IS IN T H E
M 6 T2 SP IND LE , U SE M6T 1.)

2A .4

AR E CH E C K AT C H O ME S W IT C H .
DI D F U SE S CH E C K A T C FA U LT S W IT CH . CH E C K SL I DE M OT O R
NO F7 , F8 , & C B1 YE S
ATC SLID E CH E C K C O N T R OL CH E C K AT C BE LT TE N SI O N
CO M E AN D R E L AY S K6 , V O L TA GE A T K 1 4. AL IG NM E N T AN D A D JU S TM EN T
IN ? K13 & K 14 CH E C K SL I DE M O TO R O F G EN E VA S L O T
O KA 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 F A C TO R
DI D YE S T U R R ET MU S T B E
AD J U ST F OR G E N E VA .
T OO L C A R R IE R AT AN E M PT Y
CO L D ST AR T PO SIT IO N , CH E C K EN C OD E R A N D
CR A S H IN TO PO C K ET
AN D T U R R E T A L IG N M EN T EN C O D E R W IR I NG
SP IN D L E? (A D JU S T S ET TO )
F OR S E R VO T U R R ET .
2A .6
2A .6 .1 2A .6 .2 (SE RV O TU R RE T MU S T 2A .6 .3 (T U RR E T FA C TO R MUS T
NO MAK E A M OV E BE FOR E BE 1 FO R SE R VO T UR R ET .)
TU RR E T A LIG N ME N T I S
AD JU ST E D.)

GO T O
PA G E 3 O F
CH A R T 2
2A .7

Troubleshooting Mar 2000

Fadal Maintenance Manual

C H A R T 2 c o nti nu e d (p a ge 3 )
AU T O M A TIC T OO L C HA N G E R
C O N T IN U E D 10 - 1 8 -9 5
FR O M 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 HA 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
CHA RT 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 HO U L D B E 1 2 0 P S I .
A IR HO 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 DI 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 DR 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
DID NO YE S YES YE S
TOOL STUCK DRA W B AR 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 ? FUSE OK A Y? A T A P -T A P (M AX 3 -5 PS I DR O P
GO UP?
(F2 0 ) CY CLE? DU RING TOO L CH ANG E)
2B .1 2B .1 .1 2B .1 .2 2 B .1 .3
NO NO 2B .1 .4
YE S NO

CH E C K K 2 4
CHE CK S L I D E E X T E N D E D S W IT C H . CHE CK
RE PLAC E AND C ONT RO L
CHE CK A T C F A U L T S W IT C H . DR AW BAR SW ITCH
FU SE VOLT AGE TO K 24
CHE CK 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
CHE CK Z A XIS SE RVO. AN D DR AW BAR 2B .1 .5
2B .1 .1 a 2B .1 .2 a CY L IN D E R A S S Y
2B .1 .3 a
T O O L H O L DE R S
MU ST B E CLEA N .
DID NO GO B ACK
TURR ET TO START OF
IN D E X ? 2B .1 .6
CHA RT 2
2B .2
YE S 2B .2 .1

IF O V E R S H O O T /
DID NO GO B ACK
CH E C K TU R R ET UNDE RSHO OT
TURR ET TO S TA R T O F
F E E D B A C K S W IT C H CHE CK/ADJU ST
STO P? CH A R T 2
TURR ET FACT OR
2B .3
2 B .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 R V O T U R R E T . )

DID NO CH E C K
CH E C K A T C
Z A X IS C O M E Z A X IS
SA FETY SW ITCH
DO W N? SE RVO
2B .4
2 B .4 .1 2 B .4 .2
YES

CHE CK DRAW BA R CHE CK AIR PRE SS URE

NO YES CHE CK Z A XIS
DID VA LVE FUS E F20 . (8 0 P S I ) A N D 1 2 0 P S I
DID SLI DE FOLLOWIN G
Z A X IS G O (N O T T O E X C E E D
PU LL B ACK ? ERR 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 O LTAG E . TOOL CHANGE)
2B .5 .1
2B .5 NO
YES 2B .5 .2 2B .5 .3 2B .5 .4

CHE CK: SE E
CH E C K F U S E S
CHE CK AT C S L I DE E X T E N D E D S W IT C H , TOOL CH AN GER
F7 & F8 & C B 1.
A L IG N M E N T & A T C F A U LT S W IT C H , ADJU STM ENT S
CHE CK R ELA YS
BE LT TE NSION 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
S L I DE M O T O R MA NUAL

2B .5 .1 a 2B .5 .1 b 2 B .5 .1 c 2B .5 .5

DID NO CHE CK AT C CH EC K
S L ID E M O T O R S L ID E H O M E ADJU STM ENT OF
STO P? SW ITCH GEN E VA S LOT

2B .6 2B .6 .1 2 B .6 .2
YES

YE S CHE CK
M A KE S UR E T O O L
DI D S P IN D L E CO LD ST AR T
HAS PRO PE R
DR O P T O O L ? P O S IT I O N .
PU LL S TUD.

2B .7
2B .7 .1 2B .7 .2
NO

ATC SYST EM S OK
EN D

2B .8

Mar 2000 Troubleshooting

Fadal Maintenance Manual

DA S HED S YM B OLS
SP IND LE DRI VE R CHART 3 AP PLY TO CE N OR M
EUR OP EA N M ACH IN E S
SPIND LE DRIVE R ON LY
10-20-95

NO T E: DIFFICUL T TO DIA GNO SE P RO BLE MS CA N O CCUR IF MAC HINE IS NOT P ROP E RL Y G RO UND ED.
S P I N D L E W IL L N O T THERE MUS T B E A CO NTI NUOUS GRO UNDING CO NDUCTOR (AS S PE CIF IED O N THE G ROUNDING LA B EL
RU N O N A C E M A C H IN E IN THE MACHINE 'S DI SCON NECT B OX) FRO M THE VMC'S GRO UND BUS TO THE GRO UND B US IN THE
W IT H T H E D O O R S O P E N BU ILDING'S P OWE R DIS TRI BUTIO N PANEL.

CH E CK ER ROR ME SS A GES
ON IN V ER TE R DIS P LAY
(M ITS UBI SH I IN VE R TE RS
RE QU IR E INS TA LLAT ION
OF P AR A METE R U NIT)

CO R RECT FAULT
AN D RE SE T I N VE R TE R

3. 1

DO ES NO WILL NO SP IND LE
CH E CK
SP IND LE SP INDLE TUR N MA Y BE
BE LTS
RU N? BY H AN D? FROZE N

3. 2
3. 2.1
YE S 3. 2.2 3. 2.3
YE S

CHA N GE
IS YE S
SP IN DLE
SP INDLE POT
POT
AT 0?
SE TTING

3. 2.1a NO 3. 2.1a.1
CHE C K ERR OR ME SS A GES
ON INV ERTE R D IS P LAY
CH E CK
VE R IFY LE D ON CH E CK CH E CK CHE C K (M ITS U BI SHI INVE RTE R S
AND R E SE T
SP IN DLE 1010 AND R E SE T AIR 3- P HAS E AC RE QUIRE IN S TA LLATION
CE C IR CU IT
(S LOT 14) OVE RLOA D PR E SS U RE POW ER TO OF P ARA M ETE R UN IT )
BRE AK ER S
IS BLIN K IN G RE LA Y (80-90 PS I) INVE RTE R
A12, B 12, C12
AFT ER F AULT IS COR RECTE D
3. 2.1b 3. 2.1b.1 3. 2.1b.2 3. 2.1b.3 3. 2.1b.4 PRE SS R E SE T O N IN VE R TE R
3. 2.1b.5
R UN S CH E CK SP IN DLE
3 S ECON DS YE S HA LL E FFE CT S WIT CH ON 1100-2:
AN D S TOP S? AND WI RING CH E CK F1 & F3.
(E R ROR #8) (U S E DI DS TO S E E I F
SWI TCH IS B EI NG R EA D ) CH E CK K7, K9,
K3, & K 4.
3. 3 NO 3. 3.1
3. 2.1b.6

MOT OR CH E CK INSP ECT BE LTS VE RIFY THA T

TUR NS B U T YE S AND B ELT TE NSIO N INSP EC T
AIR PRE SS UR E 1010S /J1, J2, & J3 *
SP IND LE DO ES HI /LOW RANGE
(S HOULD BE AN D 1100- 1/ J2 & J3
NO T OR DO N OT O VE RTI GHTE N ME C HANIS M
80-90 P SI ) BE LT S
ARE PLU G GED IN
SLIP S?
3. 4 3. 4.1 3. 4.2 3. 4.3 3. 2.1b.7
NO
IF S PI N DLE S TILL
DO ES N OT RU N,
SP IND LE YE S CHE CK FOR *GOL D CO AX CONNE CT OR CH E CK FUSE S IN I N VE R TE R,
CHE C K
RU NS IN ONE LO OS E W IR ES MU ST FIRMLY G RIP CE NTER P IN (U SE TH EN T ES T I NVE RTE R
F3, K 9, & K 4
DI RECTI ON OR TE RMI NA LS SERVICE TOO L S T4 4 TO TES T AND A DJUST), US ING BA TTE RY BO X
ON 1100-2 MU ST B E S OLIDLY CRIMPE D TO CE NTE R WIR E,
ONLY? * (S ER V IC E TOO L ST03)
MU ST MAK E FIRM CONTA CT WITH JAC K.
3. 2.1b.8
3. 5 NO 3. 5.1 3. 5.2

SP IND LE YE S SP IND LE CA RD
US E OHM ME TE R
YE S RUN S WI TH MA Y BE B AD .
SP IND LE CHE C K R EGE N TO CH E CK
CH E CK FU SE S BA TTE RY SWA P IN K NOWN
TAK E S A LONG RE S IST OR OR RE GE N R E SIS TO R
IN IN V ER TE R BOX ? GOOD 1010-S
TIM E TO EX TE RNA L B RAK E (C HE CK DR A WING
STO P? 1002 FOR V ALU E ) 3. 2.1b.9
NO 3. 2.1b.10
3. 6 NO 3. 6.1 3. 6.2 3. 6.3

CH E CK MO TOR WI TH CHE C K FOR V OLTA GE

CHE C K
OHMM ETER AT OVE R LOA D RELA Y
SP IND LE YE S CHE C K/ ADJU ST SP IND LE
TO DE C ID E IF MOT OR
SP EE D J1 CON NE C TOR * ENC ODE R
LE G TO LE G OR INV ERTE R I S B A D
VA RIES ? ON S PIN DLE CA RD WITH E NC ODE R
AB OUT 0. 6 OH M .
TES TE R
LE G TO G ND O.L. 3. 2.1b.11
3. 7
3. 7.1 3. 7.3
NO 3. 7.2
TY P IC A L S Y M P T O M S O F A CO NSULT FAC T OR Y
BAD ENCODER:
CO N TIN UE D BALDOR SW EO :
SE RVIC E D E PT .
ON P AGE 2 S P IN S S L O W L Y , S IN K S L O T S O F C U R R E N T , BE FORE REP LA CING
SP IN DLE DR I VE R T H E N F A U L T S O U T (O C ). MOT OR OR
(C HA RT 3) M I T S U B IS H I: INVE RTE R
N O V IS IB L E S Y M P T O M S
3. 8 M IT S U B IS H I D O E S N O T R E Q U IR E E N C O D E R 3. 2.1b.12
FE ED B A C K TO R U N .
P E R F O R M A N C E S U F F E R S ( B U T N O T O B V IO U S L Y ).

Troubleshooting Mar 2000

Fadal Maintenance Manual

CONTINUED
CHART 3 continued (page 2)
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,
RUN SPINDLE AT DOES YES CONSULT FACTORY CONSULT FACTORY
SPINDLE YES
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

Mar 2000 Troubleshooting

Fadal Maintenance Manual

C HA R T 4 DA S H ED S YM B O L S
AP PL Y T O C E N OR M
AX IS C O N TR OL
A XIS C O N T R O L EU RO P EA N M ACH IN E S
10 -2 0 -95 ON L Y

DI F FIC UL T T O D I AGN O S E P RO BLEM S C A N O C CU R I F M AC H I NE I S N O T P R OPE RL Y G R O UN D ED .

IS YE S MOV E OFF TH ER E MU S T BE A CO N TI N U OUS GRO U N DI N G CON D UC TO R (AS S PE CI F I ED O N T H E G R OU N D IN G LA BEL
AX IS AT LI MIT IN TH E MAC H I NE 'S D I SCO N N EC T BO X) F RO M TH E VM C 'S GR OU ND BU S TO TH E GR O U ND BUS IN T HE
LI MI T? POS IT IO N BU ILD I NG 'S P OW ER DI S TR IB UT I O N P AN E L.

4. 2
4. 2.1
NO

CH E C K VO L TAG ES :
WAS AR E +5V , + 1 2 V, -1 2V & IF V OL TA G E S ARE
IS IT YE S NO YE S
MOT OR ALL 3 A X ES 1 1 0V AC A T 12 2 0 O U T OF T OL E R AN C E ,
A R U N A WA Y (A L SO C HEC 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 ? RI P PL E O N DC V OL TA GES :
AW A Y ? 0. 015VAC MAX O N + /-1 2V
PO W ER S U PP L Y
4. 1 4.1 .1 4. 1.2 0. 005VAC MAX O N + 5V)
YE S NO 4. 1 .4
NO 4.1 .3

GO T O
DO ES YE S
CHA R T 7
TH E AX IS R U N
T O A LIM IT?
4. 1 .1 a
4. 1 .2 a
NO

SWA 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 O B L EM NO
CO MP L ET EL Y MO T OR SE RVO CA RD S (10 1 0 )
BR E AK ER S FO LL O W TH E
IN OP ER A T IV 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 NG E J UM P ER
OR 1 4) CA RD ?
4. 3 BL OC K O N J 4 )
4. 3 .1 4. 3 .2 4. 3 .3 4.3 .4
NO YE S
4. 3.5

DID
RE P L AC E YE S RE P L ACE
CH E C K PR OB L EM
SE R VO AX IS
IS TH ER E YE S EM ER GE N C Y ST O P F OL L OW T H E
AM PL IF IE R CO N TR O LL ER
AN A MP L IFI ER AN D AX IS
CA R D CA R D
FAU LT ? MOT O R 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
WAS TH E YE S
CI R C UI T RE P L ACE
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 1 0
OR 1 4 )
4. 3.6 a 4.3 .6 a .1
NO
4. 4 .2
CO N SUL T F AC T OR Y
WAS SE R VIC E D E PT .
MO T OR W IRE S BE FOR E R EP L A C IN G
MOT O R YE S AR E
YE S AR E SH IEL D E D .
RE C E NT L Y MOT OR W IRE S SE RVO MO TO R
VE R IF Y T HA T S HIE L D
RE P L AC E D OR SH OR TE D TO
IS STR I PP ED BA CK 4. 3.6 b
RE WI RE D ? CH A S SIS ?
FR OM CO N D UC T OR .

4. 4 .3 NO 4. 4 .4 4. 4.5
NO

IF A OR B A X IS AR E
WITH P O W ER O N WITH P O W ER O N
YE S NO T U S ED T HEY VE RIFY T H A T
A OR B AND 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 WH IC H A R E IN ST ALL E D , V ER IF Y IN ST ALL E 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 1 10 0 -1 T B1 TH AT 1 0 6 0 J5-6 A N D
DU M M Y P LU G M U ST PINS H & G
PIN 1 T O P IN 6 IS 0 V J4 -6 ARE 0 V
BE IN P L A CE .
4.4 .3 a NO 4. 4 .3 a.1 4. 4 .3 a.2 4. 4 .3a .3 4. 4 .3a .4

YE S DO N O T M O V E Z-A X IS !
DO ES NO CO N SU LT F AC T OR Y
IS IT PR E SS EM E R G E N CY ST OP .
IT M OV E BE FOR E R E PL A C IN G
Z-A X IS?
FR EE L Y? BA L L SC RE W
T R Y TO M O V E Z -A X IS BY H A N D .
4. 4.3b 4.4 .3 b .3
NO 4. 4 .3 b .1 4. 4.3b .2
YE S

CH E C K K1, K2 ,K 1 8 ,K 2 0, JU M PE R
PR E SS J O G. NO F1 2 , & F1 4 EM ER GE N C Y CH A N GE A MP
GO TO DO A MP LIF IE R S O N 1 10 0 -1. STO P C IR CU IT IN D IC AT ED B Y
PA FE 2 OF STA Y O N ? CH E C K OV ER L OA D (J U MP F 16 T O F1 2 FAU L T L IGH T
CH A R T 4 RE L A YS O N 1 10 0 -1)
4.4 .3 c
4. 4.3c. 1 4.4 .3 c.2 4.4 .3 c.3

Troubleshooting Mar 2000

Fadal Maintenance Manual

CHART 4 continued (page 2)

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
(SHOULD BE APPROX. 130-165VDC CHART 4
SERVICE TOOL ST44 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.
4A.2.1 4A.2.2
NO
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

Mar 2000 Troubleshooting

Fadal Maintenance Manual

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
D U R IN G P R O G R A M
GO TO
EX E C 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 SLO W DO W N T HE

STILL OCCUR
FE E D R A TE S IN
DU R ING PRO G RAM
THE PROG RAM
EXEC U TIO N ?

4B .4 .1
4 B .4
NO

PROBLEM NO IS YES
SHO ULD 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

Troubleshooting Mar 2000

Fadal Maintenance Manual

MO TO R O V ERL O A DS

CO N T IN U E D
C H A R T 4 c o n t in u e d ( p a g e 4)
FRO M
PAGE 3 OF AXIS CONTROL
CH A R T 4 6- 1 5 -9 5

CH E C K W A YL U B E
O VE R L O A D YE S CH E C K
O C C U RS A T BA LLSCR 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 PS
S P EE 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 AN IC A L A X IS
P O S IT I O N LI M I T S T O P
LI MI T ?
4C . 2
NO 4C . 2 .1

LO O P G A IN P O T O N AM P L IF IE R
CU R R E N T L IM IT P O T
OCCUR YE S S H O U L D B E MO ST L Y C W .
O N A M P L IF IE R
W H IL E ST O PP E D (T U R N F U LL Y C W F O R T ES T A N D
MUS T B E FULLY CW
O R IN G 0 ? RE - A D J U S T L O O P G A IN
(E XC E P T F O R V H 6 5 )
IF T HI S CO R R EC T S P R O B LE M )

4C . 3 NO 4C . 3 .1 4C . 3 .2

M A KE 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 A S TE R F E E D R A T E C L O C K ,
P O S I TIO N L O O P G A IN ,
B AL A N C E A D J US T M EN T .

4C . 4

SWITCH TO
NO S E R V IC E P R O G R A M
PR O B L EM "P R ,5 8 1 1 "
RE S O L VE D ?
CH A N G E G 1 's T O G 0 's .
RU N PR O G RA M .
4C . 5
YE S 4C . 5 .1

WAS CH E C K B U S V O L T A G E
CH E C K S E TP
FO L L O W I N G YE S IS M A C H IN E YES AT B L U E C A P A C ITO R
PA R AM E T ER :
END 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 S IS .
SHOU LD B E YE S
4C . 6 MO V E ? SHOU LD B E 115VA C
4C . 5 .2
4C . 5 .3
NO 4C . 5 .4 4C . 5 .5
* G 0 F O L L O W IN G E R R O R : NO
IN C H - 1 8 4 0 + /-2 0
M E T R IC - X /Y 1 6 3 0 + /-2 0
Z 1 3 8 0 + /-2 0 DO E S
20 " MO VE NO AD J U S T M A ST ER AD J U ST PO S IT IO N
A T 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
SEC?
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
AND RUN PROGRAM
AG A IN
SW A P Q U E S TI O N AB L E
AM P L IF IE R W IT H O N E O F DI D YES
4C . 5 .2 a T H E O T H E R AX E S. PR O B L EM S T A Y
W IT H A X IS?
RU N PR O G RA M AG AI N

4C . 5 .3 b 4C . 5 .3 b .1 NO , ST A YE D
W I TH AM P LI F IE R
WAS
FO L L O W I N G NO
E R R O R C O RR E C T *
RE P L A C E CH A N G E
THROUGHOUT
A M PL IF IE R MO T O R
MO V E ?
4C . 5 .2 b
4C . 5 .3 b .3 4C . 5 .3 b .2
* G1 FO LL O W I NG E RR O R : YE S
I N CH - 5 9 5 + / -1
M E T R I C - 30 2 + / - 1

ADJUST
PO S IT I O N
CO N S U L T
LO O P G A IN
FACT ORY

4C . 5 .2 b .1
4C . 5 .2 c

Mar 2000 Troubleshooting

Fadal Maintenance Manual

DI F FI C U L T T O D I AG NO SE P R O B L EM S C AN O C C UR
CHART 5 IF M AC H I NE I S N O T P R O PE R L Y G R O U N D E D.
TH ER E M U ST BE A C O N T I NU O U S G R OU N D IN G
RE P E A T A B I LI TY
R EP EA TA BIL ITY CO N D UC T O R ( AS S PE C IF I ED O N T H E GR OU N D IN G L AB EL
9- 2 0 -9 5 IN T H E M AC H I N E ' S D IS CO N N EC T BO X ) FR OM T H E V M C 'S
GR O U N D B US T O T H E G R O UN D BU S I N T H E B U IL D IN G' S
F OR A D D IT IO N A L P R EC I SIO N IN L E V EL IN G, POW ER D I S TR I BU T I O N P AN E L .
VE R IF Y PE R F OR M SQ U AR E N ES S T E ST ON X & Y,
M A C H IN E I S L EV E L T H EN S Q U A R N ES S TE ST O N C OL U M N ,
(S EE M AI NT E N A N C E T H EN S P IN D L E T R AM T E S T .
M A N U AL ) (C O N S U L T FA D AL SE R VI C E D E P T FO R PR O C E D U R E)

5. 1

RE M O VE S U BP L A T E OR FI XT U R I NG .
IS T H E R E MA C HI N E MU S T B E T E S TE D W I TH O UT FIX TU R ING .
A S U BP L A T E YE S SU BP L A T E S O R F I XT UR IN G C A N IN D UC E P O S IT I O NI N G
P R O BL E M S TH A T A RE NO T INH E RE N T I N T H E M A CH IN E.
O R L A R G E H EA VY P O S IT IO N IN G PR O B LE M S 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 A L T W I TH S E P A RA TE LY FR O M P R O B L EM S
IN TH E M A C H I NE I TS E L F.
5. 2 NO 5. 2 . 1

CH E C K AN D A D J US T:
B AC K L AS H ,
B AL A N C E O N AX 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 X4 . 0
5. 3 N4 X- 4 .0
IN SE R T P R O GR A M N5 G 4 P 1 0 00
AT R I GH T. N6 M17
N7 M30
N8 L 01 9 9
SE T U P I N D IC A T O R
FO R P R O B LE M A XIS N9 M2

5. 4
* GO L D C O AX CO N N E C TO R (J1 , J 2 & J3 O N 101 0 ):
M U ST FIR M LY GR A S P C EN TE R P I N (US E S E RV IC E
RU N TO O L S T4 4 TO T ES T A N D A D JU S T ) ,
PR O G RA M M U ST BE SO L IDL Y C R IM P E D T O C E NT E R W I R E ,
M U ST M A K E F IRM C O NT A CT W I TH JA CK .

5. 5 RE P E A TA BI L I TY CA N B E A F FE C TE D IF CO N N E C TO R IS LO O S E .

IN S PE C T M OT O R C O U P L ER
CH E C K G O L D C O AX CH E C K AN D A D J US T
A N D B AL L S C R EW
DO ES NO CO N N EC T O RS AD J U ST G AI N A ND G IB S AN D S T R A PS
F O R L O O SE N ES S .
T H E AX I S (J 1 , J 2 O N 1 0 1 0 ) CO M P EN S A T IO N
RE P E A T ? W IT H S E R V IC E ON A X IS A M P L I FI ER CH E C K BA L L SC R E W
CH E C K FO R L O O SE
TO O L S T4 4 * A L IG NM E N T
5. 6 RE S O L VE R O R C O U PL IN G .
YE S 5. 6 .1 5. 6 .2 5. 6 .3 5. 6 .4

CH E C K SI NE &
CO SI NE O UT PU T
I F B AC K L A SH I S E X C ES SI VE ,
O F C L OC K C A R D
DO E S A XI S YE S CH E C K F OR
AD J U ST (1 0 2 0 ) U SIN G
HA V E A B A CK L A SH LO O S EN E SS I N M OT OR C O U P L ER ,
BA C KL A SH SE R VIC E T O O L S T4 8
PR O B L EM ? W OR N B AL L S C R EW , A ND
BA L L SC R E W A L IG N M EN T 5. 6 . 5
5. 7 5 .7 .1 5. 7 .2
NO CH A N G E
RE S OL VE R

RE - IN ST AL L 5. 6 .6
SU B P L A T E AN D
FIX T U R IN G RE P EA T A BI LI T Y PR O BL E M S M AY A L SO
BE C AU S E D BY TE M PE R AT U RE G RO W TH CH E C K
AN D R E PE AT T E ST
O F B AL L S C R EW S O R SP IN D L E . SU R V EY T A B L E

5. 8
5. 6 .7

AX IS R EP E AT S W I T H O U T SU B PL A T E A ND FI X T U R I N G
DO ES NO CO R R EC T M E C H AN IC A L
BU T DO ES N O T R EP E AT W IT H SU B PL A TE A ND FIX T U R IN G.
T H E AX I S BIN D
T H ER E F OR E FI XT U R I NG O R S U B PL A TE IS D I S T O R TI NG T A BL E
RE P EA T O N O R C H AN G E
O R C R E A T IN G A M E C H AN I CA L B I N D .
X & Y? M A C H I N IN G P R O C E D U RE
OR A M A C H IN I N G P R O C E D U R E IS C AU S IN G N O N -R E PE AT 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
SP I N D L E
Z A XI S O FF S ET FLOWING IN
CO OL ER
CH A N GI N G ? RE S ER V O IR ?
RU N N I N 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 I P P LE S E R V IC E T H E
EN D ON THE DC VOLTAGE S S P I N D L E CO OL E R
AL L A XE S R EP E AT (0 . 01 5V A C M AX O N + / -1 2V , AS SE M B L Y
0 .0 0 5V A C 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

Troubleshooting Mar 2000

Fadal Maintenance Manual

CO M P U T E R
CHART 6
COMPUTER
PO W E R O N 9- 2 0 -9 5

(W A IT A FE W SE C O N D S
A N D P R ES S
CN C PO W ER S W IT C H )

6. 1

P R E SS A N D H O L D
AR E L E D S NO CN C P O W ER S W IT C H IS TH ER E NO
GO TO
O N B O AR D S 5V O N T H E
CH A R T 1 2
F L AS H IN G ? RE S E T B O A R D S T H A T 10 6 0 ?
AR 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 E R IN G U P W IT H
JUM PE R A T J2 ON 1400

6. 3

IF M E M O R Y W A S
CA N YE S RU N DI AG NO ST IC S RE P L A C E D O R A D D ED
Y O U G E T IN T O O N M E M 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 ER F A C E , W A S C H A N G ED ,
ET C . Z E R O M E M O R Y AN D
RE S E T PA R A M E T ER 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 E D M E MO RY ( 1 4 6 0 ), 5 V O LT S (5 .0 5 V ),
IS T H E R E YE S VID E O B O A R D ( 14 2 0 ) ,
A N D B U S BR ID G E ( 1 7 3 0 ) + /- 1 2 V O L T S
G A R B AG E O N T H E CO M P U TE R IN T E R F A C E ( 1 0 3 0 ),
M U S T B E FIR M L Y S E A T E D (A L SO S ET M E T E R FO R VA C
SC R E EN ? CP U ( 1 4 0 0 ),
IN T H E IR C O N N E C T O R S . AN D C H EC K F O R AC RI P P LE
ON + 5 V , + 12 V A ND -1 2 V D C ) E X PA N D ED M E M O RY ( 1 4 5 0 )
CH E C K F O 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
SW I T C H O N
YE S IS VID E O CH E C K V I DE O C A B L E. IF 3 2 M P ,
DI D F R O N T P A NE L YES CH A N G E
M O N I T O R A L IV E ? CH E C K FU SE F 2 5 CH E C K
SC R E E N VID E O
(C H E CK F O R O N 1 1 0 0 -1 . CN C / DO S
GO DEAD? CH E C K BR IG H T N ES 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 ER O F F
AN D C H E C K
F U SE S O N
MONITOR

6. 6 .2 a

T ES T B A T T E R Y BA C KU P
IS NO O N C PU BO A R D .
CO N S U L T
M E M O RY L O S IN G RE P L A C E C PU BO A R D
FACT ORY
PR O G R AM S? IF B AT TE RY T ES T
F A I L S.

6. 7 6. 7 .1 6. 7 .2
YES

" ER R O R SU M P R O G R A M
YE S NO CH A N G E
W H IL E T O F IN D AN D PR O B L EM
CP U /M EM O R Y
P R O C E S S IN G CO R R EC T CO R R EC T E D ?
BO A R D
BL O C K "? A N Y E R R O RS

6. 8 6. 8 .1 6. 8 .2 6. 8 .3
NO

M E MO RY L O C A T I O N S :
RU N RA M T E S T S Z ER O ME M O R Y. O N C P U ( 1 4 0 0) 4 0 0 0 0 -5 FF F F, 80 0 0 0 - 8 F F F F
YES IN D IA G N O S T IC S . O N R A M EX P A N S IO N ( 1 4 6 0 -2 ) 9 0 0 0 0 - EF F F F
"M E M O R Y
IF T ES T F A IL S IF P R O B L E M R E CU R S
ERR OR"?
RE P L A C E C PU O R RE P L AC E C P U O R
ME M O RY E X P A N S IO N RA M EX P AN S IO N .

6. 9 6. 9 .1 6. 9 .2

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Fadal Maintenance Manual

CHART 7
A X IS M O TO R R U N A W A Y S
AX IS M O TO 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 .
AX IS M O TO R
RUN S A W A Y A FTE R
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 .

PR E SS E M E R GE N CY S TO P .

C H E C K W IR IN G A T A M P
AN D
J4 J U M P E R O N C O N T RO LL ER C A R D .

7.2

PO W ER O N .
RELE AS E EM E R GEN C Y
STO P.
RE S ET AM PS B Y
P R E S S IN G J O G .

7.3

YE S W AS M O TO R NO
DO ES
W IR E D EX AC T L Y CO R R EC T W IR IN G
T H E A X IS
TH E SA M E A S O LD AND R E TE ST
RU N AW A Y ?
MOTOR?

7.4 7. 4 .1 7. 4 .2
YE S
NO

CH E C K R ES O LV ER C O UP LE R .
CH E C K AN D A D JUS T
RE SOLV E R C O N NEC TO 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 CO N N EC TIO N S.
RE TE ST .
7. 4 .1 a

RE V ER S E
MO T O R 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 M OT 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 ,
CHA RT 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
7.4.1c C O N F IG U R A T IO N . 7. 4 .1 c. 2
NO
7.4.1c.1

IS TH E PU T MO T O R W IRE S
M O T O R T U R N IN G NO BA C K A S W IR E D
RE TE ST
IN T H E C O R R E C T BE FO R E A ND
DIREC TIO N ? S W I T C H T A C H W IR E S

7.4.1d 7. 4 .1 d .1 7. 4 .1 d .2
YE S

EN D

7.5

Troubleshooting Mar 2000

Fadal Maintenance Manual

Mar 2000 Troubleshooting

Fadal Maintenance Manual

Troubleshooting Mar 2000

Fadal Maintenance Manual

CHART 10 DA S H ED S YM B OLS

KE YB OA RD KEY BOARD AP PLY TO CE NORM

EUR OP EA N M AC HINE S
10-18-95 ONLY

YE S IS MILL YE S MA KE S UR E A LL CHE C K TH AT DOOR

IS EN TI RE TES T F OR 5V
WAI TIN G F OR DO OR S ARE CLOS ED, SWI TC HES A R E
KE YB OA RD AT KE YB OA RD
DO OR TO BE THEN O PE N A N D CLOSE CO NN EC TE D ( 1060 J13)
LO CKE D UP? (1090)
AC TUA TE D ? FRON T D O OR AND WO R KING

10. 1 NO 10. 1.2 10. 1.3 10. 1.4

10. 1.1 NO

WILL NOT NO
POS S IBLE CA U SE S:
CO NT IN UE YE S 32MP ?
KE Y BOA RD (1090)
TO JOG WH EN JOG
1030
BUT T ON IS H E LD
1040 10. 1.2a YE S
DO WN ?
MA KE S U RE LE D ON
10. 2 10. 2.1 1030 IS BLINK ING.
DO ES YE S
NO CH A NGE P OSI TION IF NOT , P RES S
DI SP LAY
OF CN C/DOS S WIT CH EM ERGE NC Y ST OP
CH A NGE ?
AND R E SE T CP U
GO TO 10. 1.2a.1 (1400 B OA RD ).
KE Y B OA RD T ES T 10. 1.2a.2 NO
IN DI A GNOS TI C S 10. 1.2a.3

10. 3 DI SC ONN E CT
CH E CK CAB LE TO 1060.
SE RIAL PO RT
CHE C K 1040 BO ARD .
ARE FROM 1090
CHE C K 1030 BO ARD .
STA RT , SLIDE CHE CK WIR IN G TO TO P C ( J15)
YE S
HO LD , OR E S TOP SWI TCH ES . 10. 1.2a.4
BU TT ON S (N OT KE Y S) 10. 1.2a.2a
ERR A TIC? RE P LACE CON TA CTS .
CH E CK ALL P OW ER
10. 4 10. 4.1 NO CO N NECTI ON S TO
PROB LEM
KE YB OA RD (1090).
NO SOLV ED?
POW ER O FF M ILL
AN D RE ST ART.
POS S IBLE P R OB LE M S:
TOO LIGH T A TOU CH 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 R D (1090)
WORK ? UP D A 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

POS S IBLE P ROB LE M S:

WR ONG YE S KE Y PA D IF P ROB LEM RE CU RS ,
KE YS KE Y BOA RD (1090) RE P LACE K EY BO ARD
DI SP LAY E D? C AB LE TO 1060 LO GIC
1040 BO AR D (1090)

10. 6 NO 10. 6.1

10. 1.2a.7

MA KE S UR E JOG
MP G YE S CHE C K C AB LE RE P LACE
WAS P RES SE D A ND RE P LACE
DO ES N OT CO N NECT I ON S T O KE YB OA R D LOGI C
JOG SW ITC HE 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
TH E FIR S T TI ME J OG I S P R E SS ED, THE KE Y BOA R D IN THE K EY BO ARD D IA GN O STI CS N O N- P RINTA BLE C HARA C TE RS
LO GIC S E ND S "-J ", TH E A XI S ( "X ", " Y", "Z", "A" , "B " ARE DIS PLA YE D WI TH A "- ". T HE TAB LE SH O WS TH E KE Y AN D
OR "C"), A N D THE RES OLUTI ON ("H", "M ", OR "L"). TH E CH A RACT ER T HAT WILL B E DIS PLA YE D.
WHEN JOG IS P RE S SE D A GAI N , TH E K EY B OAR D STA RT "-B"
SE ND S "- J" ON LY . AU TO "-D "
WHEN T HE M P G IS T UR NE D , T HE K E YB OA RD MA N UAL NO D IS PLA Y, EX IT S T ES T
LO GIC S E ND S "-P " F OR A P OS ITI VE TUR N O R SING LE S TE P "-H"
"-Q" FOR A NE GA TIV E T UR N. JOG "-J"
"-J", " -P ", A N D "- Q" A R E SI NG LE C HA R AC T ERS , N OT "- " SP IND LE ON/OF F "-L"
AND "J". SH IF T-S P IND LE O N/OFF "-O "
TH EY A R E DI SP LAY E D IN THE DIA GNOS TI CS W ITH SLIDE HOLD "-A "
TH E "-" T O DI F FE RENTI ATE T HE M FROM T HE CO OLAN T 1 "-C"
LE TT ERS "J ", "P " A ND "Q". CO OLAN T 2 "-E "
TOOL I N/OUT "-G "
TUR RET CCW "-I"
MIS S ES YE S POS S IBLE C A USE S: TUR RET CW " -M"
JOG PULS ES 1030 BA C KS PA CE "_"
FR OM MP G? MP G DE LE TE "& "
10. 8 EN TE R "-N"
10. 8.1 RA P ID T RA VE L S WIT CH NOT DI SP LAY AB LE , S CR EE N WILL SH OW " "
NO KE YLO CK S ENT WH EN ES TOP P R ES S ED . ~ = LOCKE D
OPT ION A L ST OP ON = '"' O FF = " "
EM ERGE N CY ST OP GEN E RALLY NOT D IS PLA YA B LE . ES TO P S E NDS
S TA TU S OF K E YLOC K A N D ES TOP , ST A TUS
GO T O O F OP TIO NAL S TO P S WI TC H, S TA TU S OF
PA GE 2 OF B LOC K S KIP S WIT CH, A ND STA TU S OF R AP ID
CHA R T 10 T R AV EL SWI TCH . A N Y C OM BINA TIO N OF
' ' OR ' ~" ' MAY A PP E AR.
MP G + "-P "
MP G - "- Q"

Mar 2000 Troubleshooting

Fadal Maintenance Manual

CONTINUED
FROM PAGE 1
OF CHART 10 CHART 10 continued (page 2)
KEYBOARD
10-18-95

RETURN TO
CNC MODE

10.9

MISSES 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

Troubleshooting Mar 2000

Fadal Maintenance Manual

DIF FICULT TO DIAGNOSE PROBLEMS CAN OCCUR

IF MACHINE IS NOT PROPERLY GROUNDED.
CHART 11 THERE MUST BE A CONTINUOUS GROUNDING
FINISH CONDUCTOR (AS SPECIFIED ON THE GROUNDING
PROBLEMS FINISH PROBLEMS LABEL IN THE MACHINE' S DISCONNE CT BOX)
FROM THE VMC'S G ROUND BUS TO T HE GROUND
10-20-95 BUS IN THE BUILDING'S POW ER DISTRIB UTION PANEL.

IF PROBLEM IS NOT RESOLVED Q UICKLY, AND BEFORE DOI NG ANY MAJOR

WORK LIKE CHANGING SPINDLE, BALL SCREW S, MOTORS ETC..
DO FADAL STANDARD TEST CUT.
SEND SAMPLE PART CUT WITH TEST CUT TOOL SUPPLIED BY FACTORY.
CONTACT FACTORY FOR TEST CUT KI T.

CHECK +5V,+12V,-12V.
ALSO SET METER FO R VAC
AND CHECK FOR AC RIPPLE
ON +5V, +12V AND -12V DC
(0.015V AC RIPPLE MAX ON +/-12V,
0.005VAC RIPPLE MAX ON +5V)

11. 0

VERIFY FOR ADDITIONAL PRECI SION IN LEVELING,

MACHINE IS LEVEL PERFORM SQUARENESS TEST ON X & Y,
(SEE MAI NTENANCE THEN SQUARNESS TEST ON COLUMN,
MANUAL) THEN SPINDLE TRAM TEST.
(CONSULT FADAL SERVI CE DEPT FO R PROCEDURE)
11.1

CHECK SI N/ COS
CHECK
YES CHECK SIG NALS USI NG CHECK FOR
WAVY FINISH CHECK SPINDLE MOTOR
BALANCE SERVICE TOOL ST48. SPINDLE
ON STRAI GHT BELTS TENSION CABLE
ON AXES ADJUST IF VARIANCE VIBRATIONS
CUT S? 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 O VERTIG HTEN BELTS.

DO CHECK CHECK SI N/ COS

CI RCLES HAVE YES MATCH X & Y AXIS AMPLIFIER SIG NALS USI NG
CHECK
STEPS AT 90 & 45 FOLLOWI NG COMPENSATION 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 CONSULT FACTORY
CUTS HAVE A YES CHECK BELTS SERVICE DEPT
CRI SS-CROSS AND BEFORE
APPEARANCE? BELT TENSION REPLACING
(ESP X) SPINDLE
11.5
11. 5.1 11. 5.2
NO

DO ES
CONSULT FACTORY
A BAD CUT YES CHECK SERVICE DEPT
CORRESPO ND 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

Mar 2000 Troubleshooting

Fadal Maintenance Manual

DASHED SYMBOLS
BAD POWER/ CHART 12 APPLY TO CE NORM
BAD VO LTAGE EUROPEAN MACHINES
BAD POWER/BAD VOLTAGE ONLY
6-16-95

CHECK
INCOMING VOLTAGE
AT MAIN DISCONNECT
AND AT I NPUTS TO
TRANSFORMER

12.1

CO NSULT
CHECK 1170
INCOMING NO CHECK FUSES ELECTRICIAN
SURGE
VOLTAGE IN MAIN POWER 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 BOT H.

12.3

USE CLAMP-ON VERIFY THAT

OUTPUT NO AMMETER TO TRANSFORM ER IS
VOLTAGES CHECK FOR PROPERLY
GOOD? EXCESSIVE CONFIGURED FOR
12.4.1 CURRENT DRAW 12. 4.2 INPUT VO LTAG E

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 T YPICAL VALUES. ACTUAL VALUES MAY VARY.
EXCESSIVE VALUES WOULD BE OVER 5A HIGHER WITH MACHINE AT REST.
TO AMPLIFIER CHASSIS
AND BUS VOLTAGE
ON LARG E BLUE INPUT VO LTAG E SHOULD BE 95 VAC AND CAPACITOR VOLTAGE 133 VDC WITH T816 TRANSFORMER.
CAPACITOR INPUT VO LTAG E SHOULD BE 120 VAC AND CAPACITOR VOLTAGE 165VDC WITH T817E O R T818E TRANSFORMER.
12.5

ON CE MACHINE
INPUT NO CHECK
CHECK FOR
VOLTAGE CI RCUIT BREAKERS
LO OSE TERM INALS
GOOD? ON SUPPLY TO
AXIS AMP CHASSIS

12.6 12. 6.1 12.6.2

YES

EMERGENCY STOP CHECK K2 AND F17 VERIFY OVERLO AD

BUS NO MUST BE OUT ON 1100-1 RELAYS ARE RESET.
VOLTAGE AND (110VAC CONTROL CHECK K1, K18, K20,
GOOD? AMPLIFIERS RESET VOLTAGE FO R 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

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Fadal Maintenance Manual

CO N TIN U E D
F RO M
PA GE 1 OF
C H A R T 12 co nt i nu e d ( p age 2)
CH A R T 12 BAD DC VOLTAGE
6- 1 6-9 5

CHE C K IN PU T
VO LT AGE TO
DC PO W ER S U P PLY
(1 2 2 0)
SH O UL D B E 1 2 0 VA C

12 A .1

US E C L AM P -O N AM ME TE R
NO CH E C K FO R
IN PU T TO C H E C K F OR E XCE SS IV E
LO OS E
VOL T AG E CU R R E N T D R A W ON
T ER M IN A L S
GOO D ? 120 VA C L IN E S F R OM
ON 1 2 0 VA C L INE S
12A .2 .2 TR AN S FO R M ER

12 A .2 YE S 12 A .2 .1
TYP ICA L C UR R EN T TO 12 2 0 IS 1 . 5 A.
OT H E R BO AR D S (1 1 00 - 1 , 11 0 0 - 2, C H ILL E R, E TC .)
MA Y BE P ULL I N G D OW N L IN E VO L T AG E.
CH E C K DC PO WER
SU P PL Y O UT P 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 DC VOL T AGE .
+12 V & C OM, SE T M ET ER F OR V AC A ND C H E C K + 5V , + 1 2V , AN D - 1 2 V;
-1 2 V & CO M ME TE R SH OU L D SE TTL E TO L ES S T HAN 0.01 V AC .
IF A C R IP PLE 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 .
12A .3

CH E C K CH E C K BR OW N O UT
AL L YE S RE L A Y ( K 1 )
FU SE ON
VOL T AGE S ON 1 2 2 0
POW ER S U PP L Y
BA D ? BR O WNO U T R EL AY M U ST
(12 2 0 )
BE WHI T E 1 40 2-1 (7 0Y Y2 108 4)
12A .4 .2
12A .4 NO 12 A .4 .1 BR O WNO U T R E LA Y (K 1) O N 1 22 0 WI LL NO T LA TC H A T L ESS TH AN 4. 5 V
AN D W IL L R EL EASE I F + 5V D R O PS BE LO W 4 . 5V .

DI SC O N NE C T + /- 12 V O U TP UT S
NO F RO M 1 2 2 0 AN D T ES T A GA IN .
+/- 1 2 V RE P L ACE 1 22 0
GOO D ? DC POW ER S U P PL Y
IF N OW GOO D , L OO K F OR B AD
BO A R D P U LL I NG TO O M U C H 12 V. 12A .5 .2
12A .5 .1
12A .5
IF +/ -12 V I S BA D I T C A N E FF ECT CH I LL ER C O NT RO L , R S 232 , CL O CK S, S I NE / C O SI N E, AN D A XI S CO N T RO L.
YE S +/ -1 2 V M AY RE AD O K ON A DC M ET ER A ND STI LL BE BA D ; AN O SC I LL OS C O PE IS N E ED ED T O F UL LY TE S T + /- 12 V,
BU T AC R I PPL E M AY S H OW U P W HE N M ET ER I S SE T FO R VA C .

T UR N O FF MA C H IN E .
+5 V PR E SS E ME R GE N CY S T OP .
NO
GOO D ? RE M O VE A L L C A RDS
(5 .0 1 - 5 .1 0V) FR O M C AR DC A GE.
UN P L U G J 9 -J 1 3 FR O M 1 06 0 .
POW ER O N MA C H IN E .
12A .6
YE S 12A .6 .1

DI SC ON N E C T + 5V
EN D IS +5 V NO OU TP UT S FR OM 1 2 20 . NO
+5 V
PO W ER G O OD U N DE R NO W GO OD ? ATT AC H 10 O H M 5 W
GOO D ?
ST A TIC C ON D ITIO N S RE S IST OR B E TW E EN
12 A .7 +5V AN D C OM.
12 A .6.2 12 A .6.3 12A .6 .4
YE S SWI T CH I N G P O WE R S UPP LI E S R EQ U I R E YE S
A L OA D T O W ORK PR O P ER L Y.

LO OK FOR I N D IVID U AL C A R D
T H AT MA Y BE P U LL IN G T O O RE CO N NE C T
MU C H + 5 V +5V OU TP UT S
(R E PL AC E CA R DS ONE AT A T IM E. ) TO 1 22 0 .
(R E PL AC E J9-J 1 3 O N E AT A T IM E. )

12 A .6 .2 a (C A RD S SH OU LD NEVER BE 12 A .6 .4 a
RE M O VED O R R EP LA CED
W ITH TH E P OW ER O N . )
US E C L AM P -ON
AM ME TE R
PU T AL L CA R DS RE P LAC E 1 2 2 0
TO LO O K FO R
BA C K IN C AR D C A GE DC POW ER S U P PL Y
EX C ES SI VE
CU RR E N T D R A W
12 A .6.4 b
12 A .6 .2 b TYP IC A L C UR R EN TS 12 A .6 .5
W ITH M A C HI NE 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 END A NT - 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 VA RY .
EX CE S SIV E V A LU ES W O UL D B E 2-5A H IG H E R.

Mar 2000 Troubleshooting

Fadal Maintenance Manual

CHART 13 S O M E H E AD S HA V E TE M P E R A TU RE
S W IT CH E S I N S T EA D O F (O R I N
R O TA R Y HE AD S A D D IT I O N T O ) F U S E S T O PR O TE CT
RO TA RY HE ADS TH E M O TO R FR O M O V E RH E AT I NG .
A A XIS A A XIS TH ES E A U TO M A TIC A L LY RE S E T
W HE N TH E M O TO R C OO L S.
7- 4 - 95

TE MP E R A T UR E S N A P S W I TC H
W IL L S H O R T C O S SI G N AL TO G ND
GO T O
YE S CHE CK CHE CK O N R E S O LV E R B O A R D IN M O TO R
IF M O TO R O V E R H E AT S . CH A R T 4
A X IS D EA D ? O VER LO AD R O TA R Y H E A D CH E CK CO S O UT P U T T O R E S OL V E R AXIS
REL AYS FU SE (P IN 8 O F J 5 O N 1 06 0 ) CO N TR O L
FO R S H O RT TO 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 AD
O VE R H EA TS ?

13 . 3 NO

CH E C K FO R
HE AD CHE CK
YE S W AT ER I N
KE EP S FO R
FUSE HOLDER
B L O W IN G M E C H A N IC A L
OR M OTOR
FU SE S? B IN D
H O 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 M E TE R TO CUR REN T YE S B Y A C R AS H .
YES CH E C K FO 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 ONE SPOT? TO F AC TO RY
O IL ? T H A T IS L E A K IN G
CURR EN T DRA 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 C KLA SH YES
AR E YE S CHE CK R E A D JU S T
AD JU ST O R GE AR M ESH
TH E G EA R S O IL L E V E L BACKLASH
G EA R M ES H A D J U S TM E N T
NO IS Y ? IN H E A D AN D G E AR ME S H
TO O TI G 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 EC K WAS
A X IS H A V E YE S
YE S AXIS JU MP ER CA P A C I T Y
LI M I T E D M O T I O N ? DO N O T EX C EE D
ON 1010 CARD . O F T HE H E AD
(W I L L N O T D O FU L L LO A D C A P A C IT Y
IT MU ST B E AN EX C EE D ED ?
R O T A TIO 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 ATI O
GO TO IN S E T P IS CHA NG E
CHART 4 YE S
D U TY C Y C L E PRO G RAM
A X IS C O N TR O L
E X C E S S IV E ? TO G IVE 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

MO T O R W IRE S
AR E
YE S AR E SH I ELD E D .
M OTOR WIRE S
VE R IF Y TH A T S H I E L D
S H O R T E D TO
I S STR I PP E D BA C K
CH A S S I S ?
FROM CONDU CTOR .
13 . 4 .4 d 13 . 4 .4 d . 1

IS
S H O R T IN MOT OR RE P LAC E
M OT OR OR MOTOR
CA BL E?
13 . 4 . 4 d .2 13 . 4 .4 d .3
CA B L E

RE P A IR /
RE PLACE
CAB LE

13 . 4 . 4 d .4

Troubleshooting Mar 2000

Fadal Maintenance Manual

C HA R T 1 4
FA D A L T R 6 5 SOM E H E AD S HA VE TE M P ER A TU RE
SW IT CH E S IN ST EA D OF (O R IN
R O TA R Y H E A D S AD D IT IO N T O) F U SE S T O PR OTE CT
TR 65 ROTA RY H EA D S TH E M OTOR 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 TI C AL LY RE S ET
W HE N TH E M O TOR C OOL S.
6- 1 5-95

TE MP E RA T UR E S N AP S W ITC H
W ILL S H OR T C O S SI GN AL TO GND
YES CH EC K CH E CK ON R ES OLV ER B OA R D IN M OTOR
IF M O TO R OV ER H E AT S.
AX IS D EA D ? OVE R LOA D RO TA RY HE AD CH E CK CO S OUT PUT T O RE S OL VE R
RE L AYS FUSE (P I N 8 OF J4 0R J5 ON 10 60 )
FO R S H O RT TO GND .
LE T COO L .
14 . 1 NO 14. 1.1 14 . 1 .2
14. 1 .3

FOL LOW I N G E RRO R

DO ES GO T O
YE S IMP R OP ER LY
B- AX IS CH AR T 4
ADJ U STE D
FAULT DU RI N G AX IS
RA P ID? B A XIS SE TS FO L LO W IN G E R RO R * W HE N AD JU S TI N G B -A XIS AM P : CO NTROL
DI F 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 ISC ON NE C T S CA LE
14 . 2 NO 14. 2.1 14 . 1 .4

B- AX IS
YE S YE S INH IBI T R E LAY NO RE P LACE RELA Y * *A U GA T RD I RELA Y
HE A D TR6 5
TU RN S O FF A M P OR COR RE CT IN CON TROL CAB INE T
OVER HEA TS ? B- AX IS ?
W H EN BR A KE W IRIN G
IS ON?
14 . 3 14. 3.1 14. 3.2
NO 14. 3.3
NO
YE S

CHE CK FOR US E CL AM P -ON GEA R IS DA MA GE D

HE A D CHE C K YE S
YES WAT ER I N AM ME TE R TO CU RR E NT BY A C RAS H.
KE EP S FOR
FU SE H OLD ER CHE C K FOR EXC ES SI VE IN RE TU RN HE AD
BLOW IN G ME C HANI CA L
OR M OTOR EX C ES SI VE ONE SP OT? TO F AC TO RY
FU SE S? BIND
HO USING CU RR E NT DR 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 CKLA SH YE S RE A D JU S T
YES OR GE AR ME SH
LE AKING RE P L ACE S EA L BA C KL A SH
ADJ U STM E NT
OIL ? TH AT IS L EA K IN G AN D GE A R M E S H
TOO TIGHT?
14 . 5
NO 14 . 5 .1 14. 4.4 a 14 . 4 .4a.1
NO

W AS
ARE YE S CH EC K CA P ACIT Y YE S
AD J UST DO NOT EX C EE D
THE GEA RS 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 HEA D EXCE EDE D ?
14. 6 14. 4.4 b
NO 14 . 6 .1 14 . 6 .2
NO 14 . 4 .4 b.1

TR6 5 IS CHA N GE
YE S BRA KE M AY B E YE S
B- AX IS D UTY CYCL E PROG RA M
B A X IS CL UT C H DE FEC TIV E
LO SI NG EX C ES S IV E? TO G IVE M OTO R
MA Y BE L OOS E
POS ITI ON ? TIM E T O C OO L
CH E CK AI R SO L EN OI D
14 . 4 .4c
14. 7 NO 14 . 4 .4 c. 1
NO 14. 7.1 14 . 7 .2

MOT OR W I RE S
ARE
GO TO YE S ARE SHI EL DE D.
M O TOR W IRES
CHART 4 VE R IFY TH A T S HIE LD
SH ORTE D TO
AX IS CON TRO L IS STRI PP ED BA CK
CH A S SIS ?
FROM CON DU CTOR.
14 . 4 .4d
14. 8 14. 4.4 d.1

IS MOT OR
SH ORT 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 LACE
CA B LE

14. 4.4 d.4

Mar 2000 Troubleshooting

Fadal Maintenance Manual

CHART 15
TSUDAKOM A 301 S O M E H E AD S H A V E TE M P ER A TU R E
S W IT C H E S I N ST EA D O F (O R I N
ROTAR Y HEADS A D D IT I O N T O ) F U S E S T O PR O T E C T
T S U D A K O MA 3 0 1 T H E M O TO R FR O M OV E R H E AT IN G .
A & B A XI S A & B A X IS T H ES E A U T O M A T I C AL LY RE S E T
W HE N TH E M O TO R C OO L S.
6- 1 5 -9 5

T E M P E R A T U R E S N AP S W IT C H
W I LL S H OR T C O S S IG N AL T O G ND
YES CH E C K CH E C K ON R ES O LV ER B OA R D I N M O T O R
IF M O TO R O V E R H E A T S.
A X IS D EA D ? OVE R LOA D R O T A R Y H E AD C H E CK C O S O UT PU T T O R E S OL VE R
RE L A YS F U SE (P IN 8 O F J 4 O R J 5 O N 1 06 0)
FO R SH ORT TO G ND .
15 . 1 15 . 1 .1 15 . 1 .2 LET COOL .
NO
1 5 . 1 .3

F O L L O W I N G E R RO R
DO ES GO T O
YES IMP R O P ER L Y
B - A X IS CH A R T 4
AD JUSTED
F A U L T D U RI N G A X IS
RA P ID ? B A XIS SE T S F O L LO W IN G E R R O R *W HE N A D JU S T IN G B -A XI S AM P : CO N T R O L
D I F FE R E N T L Y F R O M O T H E R A XE S .* S ET PA R AM E TE R S F OR 90 : 1
D ISC O N N E C T S C A LE
15. 2
NO 15 . 2 . 1 15 . 1 .4

YES
HE A D
OVE RH EA TS ?

15. 3 NO

CH E C K F O R US E C L AM P -O N G EA R IS D A M A G E D
HE A D CH E C K YES
YES WATER IN AM ME TE R TO CU R R E N T BY A C R A S H .
KEEPS FOR
FU SE HO LD E R CH E C K F O R E X C ES S I VE 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
O R M O TOR EXCESSIVE ON E SP OT? T O F A C T O RY
FUSES? 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

YES BA C K L A SH
LE A K IN G RE P L A C E S EA L YES RE A D JU S T
OR GEAR MESH
O IL ? T H AT IS L EA K IN G BA C K L A S H
AD J U ST M E NT
AN D G E A R M E 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

ARE YES CH E C K W AS
AD JUST YE S
TH E GEAR S O IL L E VE L CA P A C IT Y
GEAR M ESH DO N O T E X C EE 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
EX C E E D ED ?
15 . 6 15 . 6 .1 15 . 6 . 2
NO
15 . 4 .4 b 15 . 4 .4 b .1
NO

GO TO
CHART 4
A X IS C O N T R O L IS CH A N G E
YES
DU T Y C Y C L E PR O G RA M
EX C E S S I V E ? 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
YES A R E S H I EL D E D .
MO T O R W IR E S
V E R IF Y T H A T S H IE L D
SH O R T E D T O
IS ST R I PP E D B A C K
C H A S S IS ?
FR OM C ON D UC TOR .
15 . 4 .4 d
15 . 4 .4 d .1

IS MOT OR
S H O R T IN RE P L A C E
MOTOR OR MOTOR
CA B L E ?

15 . 4 .4 d .2 15 . 4 . 4 d .3
CA B L E

RE P A IR /
RE P L A C E
CA B L E

1 5 . 4 .4 d .4

Troubleshooting Mar 2000

Fadal Maintenance Manual

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, IF GREEN LED IS LIT.)
J1 OF 1010 9-PIN MOLEX AT MOTOR)
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
AMPLIFIER ENCODER IS 10- OUT (OFF) 120/60 PHASING
RESPONSE YES 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 CONNECT COMMAND SIGNAL.
VERIFY
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 OVERSHOOT IS OK.)
RESPONSE YES 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 FROM CONDUCTOR OR A
ON AMPLIFIER 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

Mar 2000 Troubleshooting

Fadal Maintenance Manual

CI R C LE
CHART 17 DI F FI C U L T T O D I AG NO SE P R O B L EM S C AN O C C UR
IF M AC H I NE I S N O T P R O PE R L Y G R O U N D E D.
RO U N DN E S S C IR C L E R O U N D N ESS T H ER 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 P E C IF I ED O N T H E G R O U N D I N G L AB EL
IN T H E M AC H IN E ' S D I S CO N N EC T BO X ) F R O M TH E V M C 'S
G R O U N D B US T O T H E G R O UN D B U S I N T H E B U IL D IN G ' S
VE R I FY FO R A D D IT IO N AL P R E C I SI O N IN L E V EL I N G , PO W ER D I S TR I BU T I O N P AN E L .
M A C H IN E IS L EV EL PE R F O R M SQ U AR E N ES S T E ST O N X & Y,
(S EE M AI NT EN A N C E TH EN S Q U A R N ES S T E ST O N C O L U M N ,
M A N U AL ) TH 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 AL S E R VI C E D E P T F O R P R O C E D U R E)
17 . 1

T ES T B A L AN C E O F
SIN / CO S SI G N AL S IF S I N A ND C O S A RE N O T
B A L A NC E D W I T H IN 0 . 0 01 V ,
US IN G
B A L A NC E S I N A N D CO S
FA D A L S I N / C O S T E S TE R A N D R U N T E S T C U T A G A IN .
(S ER V I C E T O O L ST 4 8 )

17 . 2

CH E C K AN D A D J US T P R O CE D UR E FO R A D JU S T IN G L O O P G A I N A N D B A L A N CE I S I N TH E MA I N TE NA N C E M A NU A L.
US IN G T H E FO L L O W I N G E R RO R D IS P LA Y I S MO R E A C C UR A TE TH AN A M E TE R .
PO S IT I O N L O O P G A I N O N C E T HE LO O P G A I N A N D B A L A NC E A R E A D JU ST E D , R E D U CE T H E FE ED R A T E T O F 20 . A N D
AN D B AL A N C E F O R FI N E T UN E T H E L OO P G A IN A N D B A LA N C E A DJ US TM E N TS .
X A N D Y AX E S.

17 . 3

CH E C K
BA C K L A SH (T H E S CR E W P IT CH C O M PE NS A TI O N TA B L E S CA N A L SO A FF E C T
CI R CL E R O U N D N E S S W HE N CU TT I NG L A R G ER D I AM E T E RS . )
OF X & Y AXE S

17 . 4

CH E C K FO R
LO O S EN E SS IN
M O T O R C O U P L ER S
AN D W O R N O R L O O 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 E R I F Y W A YL U B E
IS BE IN G DE L I V ER E D
T O A L L A XE S.
(L U B RI C A T E L I NE A R W A Y S . )

17 . 6

PA R T M U ST BE IN S P E C T E D O N M A C H IN E
BE F O R E A NY C L A M P I N G IS R EM O V E D .
I N SP EC T ED CL A M P I NG A ND FI X TU R I NG C A N D IS T O RT TH E P A RT .
IS P A 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
BU T W H E N P A R T IS R E L E A S E D FR O M TH E C L A M P IN G
O FF M A C H IN E ? TH E C U T W I LL B E D IS T O R T E D .
T O FI N D T H E S O UR C E O F D I S TO R TI O N, P A RT MU S T
B E I NS P EC TE D O N M A C H I NE B EF O RE I T I S R E LE A S E D .
17 . 7 I N SP EC T ED O N M A C H IN E
17 . 7 . 1

N1 (C IR C L E R O U N D N ES S T E ST
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 I N C H N2 (0 .5 0 0 D I A E N D M IL L , TO O L D IA M E T E R M U ST BE IN T O O L T AB L E , T O , 1 ,. 5
I N S ID E D I A H O L E 0 . 2 5 D E E P N3 (H O M E I S C E N T E R O F P AR T
IN A L U M I N U M . N4 (S E T T O O L A T T O P O F P AR T
TE S T C IR C L E W I L L B E N5 G 0 G 1 7 G 4 0 G 8 0 G 9 0 E 0
RO U G H C U T A N D T H EN N6 X0 Y 0 M 3 S 1 00 0 0
F IN I S H C U T . N7 H 1 D 1 Z0 .1 M 8
N8 G 1 Z - 0 .2 5 F 4 .
17 . 8 N9 G 8
N1 0 L9 4 0 2 R 0 + 1 5 . R 1 + 0 .9 8 0
N1 1 L9 4 0 2 R 0 + 1 5 . R 1 + 1 .
PL A C E D I AL I N DI C AT O R N1 2 M 5 M 9
IN S PIN D L E N1 3 G 0 H 0 Z 0
(A D JU S T X A N D Y
S O SP IN DL E I S A T N1 4 X0 Y 0 E 0
EX AC T C E NT E R O F H O L E N1 5 M 2
A C C O R D I NG T O I N D IC A TO R )

17 . 9

RO T A TE SP IN D L E SP E C IF IC A T IO N S F O R C IR C L E RO U N DN E S S :
M A N U AL L Y T O M A XI M U M D E VI A TI 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 TI N U E D
ON P AGE 2
OF CHAR T 17

Troubleshooting Mar 2000

Fadal Maintenance Manual

CONTINUED
CHART 17 continued (page 2)
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 POSITIONING PROBLEMS INDUCED BY FIXTURING CIRCLE ROUNDNESS TEST,
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

Mar 2000 Troubleshooting

Fadal Maintenance Manual

CHART 18 ERR O R DIA G N O S IS

M E A NI N G
ERR O R C O DE S NUM B ER PR O CE D UR ES
ERROR CODES #
RE P O R T E D BY AX IS
8- 18 -9 5

NO M O TO R F EE DBA CK
#1 CH E CK TH AT US E FA D AL RE S O L VE R INP U T
(E ITH E R R ES O L V ER O R CH E CK C AR D
NO M O TO R FEE D BA C K DEV ICE (S ) ENC O DE R TE ST ER AT J2 O F 10 10
ENC O DE R ) IN J 14
FEE D BA C K AR E PL UG G ED IN TO O R S CA LE TE ST ER SH OUL D B E AB OUT
DE TE C TE D AT O F 10 60
10 10 CA R D J 2 (J 5 , J6) TO T ES T E NC O DERS 1. 7 VA C
PO W ER- U P

18. 1 18. 1.2 18. 1.3 18 . 1 .4 18. 1.5 18. 1.6

EN CO D E R US E FA DAL
#2 VE RIFY SW A P SP IN DL E
FEE D BA C K EN CO D E R TE ST ER
EN CO D E R N O T CO NN EC TI O N CO NTR O LL ER C AR D
ON S PIN DL E O R S CA L E TE ST ER
RE S PO ND I NG OF E N COD ER W ITH K N O W N G O O D
FAI LED D UR ING TO T ES T S PI ND LE
CA B L ES CA R D
RI G ID T AP EN CO D E R
18. 2
18. 2.1 18. 2.2 18 . 2 .3

#3 M A CH INE CH E CK S F OR
INST ALL J UM P E R AT DI SCO N NE C T
LO G IC J UM P E R RUN A W A Y AT PO W ER - UP. YE S M O TO R W IR E S
A1 O N AX IS CA RD J1 O N DO ES
IN CO R RECT O R ME SS AG E IND ICAT ES A N O R TA C H
TO B YP A SS AX IS CARD . AX IS RU N
SIG N AL M IS SI NG O R INC O RR EC T M O TO R - TAC H- W IR E S A R E
FEE D BA C K TE ST AW A Y ?
MO T O R-T ACH JUM PE R C O NFI G UR AT IO N RE V ERS ED
ON P O W E R-UP . PO W ER O N .
IN CO R RECT O R FA IL E D C O M PO NENT.
18 . 3 .4 NO
18. 3.1 18 . 3 .2 18. 3.3 18 . 3 .5
18 . 3

J4 J U MP E RS O N AX IS
CA R D A R E W RO N G
OR
AX IS C AR D I S BA D

18 . 3 .4a

US E FA DAL
IN DEX ER M A RK O F
#5 VE R IFY CO N NE C TIO N EN CO D E R TE ST ER
EN COD E R O R S CALE
NO IND E X M A R K OF E N COD ER O R O R S CA L E TE ST ER
NO T D E TE CT ED
DE TE CTE D SCA L E C A B LE S TO T ES T E N CO D ER
DUR I NG CO L D S TA R T
O R S CA L E

18 . 5 18. 5.1 18. 5.2 18. 5.3

#7
ENC O DE R COU NTS STO P S P IND LE US E FA DAL
RI G ID T AP
N O T W ITH IN AND US E DI DS EN CO D E R TE ST ER
PR E CYCL E
TO LE RA N CE TO CH E CK M A G NET O R S CA L E TE ST ER
ENC O DE R COU NT
DU RI NG R IG I D TA P (TU RN S P IND LE TO T ES T E N CO D ER
PRO BL E M
PRE C YC LE TE ST BY HAND ) AT AX IS CARD (J 5)

18. 7 18. 7.1 18. 7.2 18 . 7 .3

SP IN DL E MA G N E T W A S STO P S P IND LE US E KNO W N GO OD

#8 IS YE S VE RIFY M AG NE T
NO T DE TE CT ED F O R AND US E DI DS H AL L E FFE C T SW I TC H
SP IN DL E MA G N E T SP IND LE IS C O NN EC TE D
O VE R 3 S E CO ND S TO CH E CK M A G NET AND TE S T W I TH
NO T DE TE CT ED O R TU RN ING ? AN D C HE C K
W HEN S P IN DL E SH O UL D (TU RN S P IND LE A M A G NET
SP IND LE N O T ADJ U STM E NT
HA V E B E EN T U RNI NG BY HAND ) US ING DI D S
TU RN ING 18 . 8 .2
18 . 8 .1 NO 18 . 8 .3 18. 8.4 18 . 8 .5
18 . 8
OR I E 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 I N 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 I S B A D, C PU M AY B E A BL E T O RE AD M A GN E T,
CH A RT 3 BU T T HE SP I N DL E C A RD M AY N O T B E A BL E T O R E AD I T.
SP IND LE
18 . 8 .2a DRI VE R

SP IND LE FAUL T L INE CHE C K FA ULT LIN E CH E CK

#9 CHE C K
IS NO T D E TE CTED CH E CK IN VE R TE R CA B L ING FR O M O PE R AT IO N
SP IN DL E FAU LT O VE RL O A D
OR HAS F ALL E N FO R FA UL T IN VE R TE R OF K2
LI N E D O W N RE L A Y
BE LO W 1 0V (J 6 -6 ) ON1 100 - 1

18 . 9 18. 9.3 18. 9.4 18 . 9 .5

18. 9.1 18 . 9 .2

CO NTIN UE D
O N N EX T
PA G E

Troubleshooting Mar 2000

Fadal Maintenance Manual

CO NTINUED
FROM CH ART 18 con tinued (p age 2)
DIAGNOSIS
ERROR
PREVIO US MEA NI NG
PAGE ERROR CODE S NUMB ER
#
PRO CEDURES

REP ORTE D BY AXIS

8- 18-95

#10 OCCURS DURING

ENCODER SP INDLE OPERA TION CHE CK SPINDLE
IS YE S
AND MAG NET NOT IF BOTH E NCODER F EE DBACK ENCODER AND
SP INDLE
RES PONDI NG OR AND SPI NDLE MAG NET MAGNET A ND
TURNING?
SP INDLE NOT ARE NOT DETECTED FOR THEI R CAB LING
TURNING LO NGER THAN 3 SECONDS
18. 10
18. 10.1 18. 10.2 NO 18. 10.3

GO TO
CHART 3
SP INDLE
DRI VE R
18. 10.2a

#12 ERROR O CCURS A T END RUN DI AG NO ST ICS

CHE CK
MOT OR OF MOV E WHEN NUMB ER ON CPU AND AX IS:
+5V , + 12V, & -12 V
OVE RL OAD - OF PULSE S COUNTED IF O NE A XI S FAI LS, REP LACE
VOLT AGE S FROM
STE P COMMA ND BY AXIS CONT ROLLER THAT AX IS CARD AND RE TE ST .
POW ER SUPP LY
CHECKS UM DO ES NOT EQ UAL IF MULTIPLE CARDS FA IL, REPLA CE
SEE CHART 12A
ERROR NUMB ER S ENT B Y CPU 1030 OR 1400 AND RETE ST
18. 12 18. 12.2 18. 12.3
18. 12.1

#13
MOT OR CHECK PO WER GOTO
FOLLOWI NG ERROR CHE CK
OVERLOAD - CHART 4
EXCEE DS THE OVE RLOA D FACTOR
FOLLOWI NG E RRO R > GOTO CHART 12 AX IS
OVERLOA D FA CTOR PA RAM ET ER.
OVERLOAD BA D POW ER/ CO NTROL
PARAMET ER IS IT T OO LO W?
FACT OR BA D VO LTAGE

18. 13 18. 13.1 18. 13.2 18. 13.3 18. 13 .4

RUN DI AG NOST ICS

AX IS MO VE COMMA ND CHECK
#14 ON CPU AND AX IS:
W AS NOT PRO PERLY +5V , + 12V, & -12V
MOVE TRA NS FE R IF O NE AXI S FAI LS, REP LACE
TRANS FE RRE D TO VOLT AGES FROM
FAULT - MOVE SE TUP THAT AXIS CARD AND RETEST .
AX IS CARD POW ER SUPPL Y
INCOMP LETE IF M ULTIPLE CARDS FA IL , REPL ACE
(CHE CK SUM F AI LED) SEE CHART 1 2A
1030 OR 1400 A ND RETES T
18. 14 18. 14.1 18. 14.2 18. 14.3

STO P SP INDLE US E KNO WN GO OD

#15 SPINDLE MA GNET IS VERIFY MAGNET
YE S AND US E DI DS HALL E FFECT SWI TCH
TIME O UT E RROR - WAS NOT DET ECTED SP INDLE IS CONNECTE D
TO CHE CK MAGNET AND TEST WI TH
RI GID T AP WITHIN THE TURNING? AND CHECK
(TURN S PINDLE A MA GNET
PRE CYCLE ALLOW ABL E T IME ADJ USTM ENT
BY HAND) USING DI DS
TEST
18. 15.2 NO
18. 15 18. 15.1 18. 15.3 18. 15.4 18 . 15.5
ORI E NTAT ION M A GNE T I S RE A D B Y C P U T HROU GH 10 60 J10 PIN 8
BUT THE SP I NDL E C A RD REA D S I T T HROU GH J 2.
GO TO IF WI RIN G IS B A D, CPU MAY B E A BL E TO RE AD M A GN E T,
CHA RT 3 BUT THE SP I NDL E C A RD MAY N OT B E A BL E TO R E AD IT.
SPINDLE
DRI VE R

TE MP E RA TUR E S NAP S W ITC H

WI LL S H OR T C OS SIGN AL TO GND
#16 ON R ES OLV ER B OA RD IN MOTOR GO T O
RE SOLVER ZE RO-
TIME O UT ERROR - VERIFY RESOLVER IF MOTOR OV ERH E AT S. CHA RT 4A
CROSSING WA S NO T DE TECT ED
RE SOLVER RESP ONSE IS PLUGG ED I NTO CH E CK IF MOTOR IS H OT OR AXIS CONTROL
BY AXIS CA RD W IT HIN THE CHE CK COS OUT PU T T O RE S OL VE R
OR MOTOR O VER J2 OF 1010 CARD (RESOLVE R
ALLOW AB LE T IM E (P IN 8 OF J1 -J6 ON 10 60 )
TEM P FAULTS)
FOR S H ORT TO GND .
18. 16 LE T M OTOR COOL.
18. 16.1 18. 16.2 18. 16.4
18. 16.3

REA DING FRO M T HE MAKE S URE CA BLES ARE

#17
RESOLVER P ORT PROP ERL Y ATTA CHED CHANGE
BAD READING ON
INDICAT ES A S PINDL E (SPI NDLE "RESO LVER" I S SPINDLE
RES OLVER P ORT
SP EED GREA TE R THE SP INDLE ORIENTAT ION CARD
THAN POS SI BLE HALL E FFECT S ENSOR)

18. 17 18. 17.1 18. 17.2 18. 17.3

CO NTINUED
ON NEX T
PAGE

Mar 2000 Troubleshooting

Fadal Maintenance Manual

CO N TIN U E D
FR OM
C H A RT 1 8 contin ued (pag e 3)
PR E VIO U S
PA GE
ER R O R C O DE S ER RO R
MEANI N G
D IA GN OS IS
NU M BER PRO CE D UR ES
REP O RTE D BY AX IS #
8- 23-95

AX IS CAR D DO ES N OT
#18 GO T O
DETE CT FAU LT LI N E IF TH E LSE C B I S LI T,
AM PLIF IER CH EC K C ABLIN G CH AR T 4
OR CH E CK FOR
FAU LT LIN E AN D AMPLIFI ER (AMP LIFI ER
SIG NAL H AS FALLE N MEC H AN IC A L BIN D
DO WN FAU LT)
BELOW 10V

18. 18 18. 18.1 18. 18.2 18. 18.3 18. 18.4

#19
STAC K
TH E STA CK O N TH E AXI S CA R D PR OBLEM C OU LD B E
OVE RFLOW -
(U S ED T O STOR E C P U CO MM AN DS AXIS C AR D (1010),
OVE R LO AD ED W ITH
UN T IL TH E Y AR E S ERV IC E D) CPU CA R D (1400) ,
STE P C OM MA N D
HAS OVER FLO WED O R 1030

18. 19
18. 19.1 18. 19.2

#20 TH E MOVE TR AN SFER RU N DI AG NO ST IC S

CH EC K
MO VE PR OC ESS WA S N OT O N C PU AN D A X IS:
+5V, +12V, & -12V
TRAN SFER CO MPLET ED IF O NE AXI S FAI LS, REP LAC E
VOLT AGES FR OM
FAU LT - BUF FER (A C O M MU N IC A TIO N TH AT AXIS C AR D AN D R ETE ST.
PO W ER SU PPLY
IN D IC AT OR FAI LUR E BET WE EN IF M ULTIP LE C AR D S FAIL, R E PLAC E
SE E CH A R T 12A
NO T SET AX IS CAR D A N D C P U ) 1030 O R 1400 AND R ETEST
18. 20 18. 20.2
18. 20.1 18. 20.3

#21
AN U N K N OWN CH E C K C ON N ECTI ON S
SPU R IOU S
OR ILLE GAL RE PLAC E
IN TE RR U P T - N OT
IN TERR UP T FAU LTY C ON N E C TIO N AX IS C AR D
SE RVIC EA BLE
HA S OC CU R R ED CAN C A USE N OI SE

18. 21
18. 21.1 18. 21.2 18. 21.3

FEED BAC K FRO M CH E CK

#22 CH EC K
SC ALE POR T IS CAB LIN G CH E C K BO AR D S
BAD SC ALE ALIG NM E N T
OU TSID E ALLO W ABLE IN S CALE BO X
RE A D IN G OF SC ALE
LI MI TS TES T S C A LE

18. 22
18 . 2 2 .1 18. 22. 2 18. 22. 3 18. 22. 4

#23, #24, G OTO

CH EC K PO WER
#25 #26 FOLLOWI N G ER RO R CH EC K CH AR T 4A
MOT OR OVER LO AD - EX CEE DS TH E U SE R - OVE RLO AD FAC TO R AX IS C O NTR OL
GO TO C H AR T 12
FOLLOWI N G E RRO R > DE FI NE D O VER LOAD PAR AM ET ER. (M OTOR
BAD PO WE R/
OVE R LO AD FACT O R IS IT T OO LO W ? O VE R LOA D )
BA D VO LTA GE
FAC T OR
18. 23 18. 23.1 18. 23.2 18. 23.3
18. 23.4

CO U LD N OT FIN D
#27 MA GN ET A FTE R
OR IENTAT ION
RE TU R N TAP PIN G H O LE.
SPEED M AY BE
TO M AG N ET 5 SE CO ND TI ME OU T.
TO O LO W
TIM EOU T (D U R IN G
RI GID T APPI N G)
18. 27 18. 27.1 18. 27.2

10 SE CO ND TI ME OU T.-
#28 STO P S PIN DLE
DI D N OT OR IENT IS VER IFY M AGN ET
O RIENT ATION OR IENTAT ION YES AN D U SE DI DS
OR SP IN D LE IS CO N NEC TE D
TIM EOU T OR TAP PI NG SPEE D M AY TO C HE C K M A GN ET
DI D NO T AR R IV E AT 5TH TU R N IN G? AN D C HE C K
CALIBR ATION BE TOO LOW (TU R N S PIND LE
MAGN ET DU R ING AD J USTM ENT
ER R OR BY HAN D )
CA LIB R AT ION
18. 28 18. 28.1 18. 28.2 18. 28.3 NO 18. 28.4 18. 28.5

G O TO ORI E NT AT IO N M A GNE T IS RE A D B Y CP U T HRO U GH 10 60 J10 PI N 8

BUT THE SP INDL E C ARD R EA DS IT TH RO U G H J 2.
CH AR T 3
IF WI RI NG IS B A D, CPU MAY B E A BL E T O RE AD MA GN E T,
SP IN D LE BUT THE SP INDL E C ARD MAY N OT B E A BL E TO RE AD I T.
DR I VER

SP IND LE TH IS E RRO R IS REP O RT E D B Y PR OBLEM C OU LD B E

CO N TRO LLER THE CP U NO T TH E AX IS C A RD . VE RIFY TH AT AN A XI S C AR D (N OT
DO ES N OT R ESPO ND IT I S N O T A N E RRO R #. ALL AXI S CA R DS NE C ES SA R ILY THE
#48 AXIS DAT A T RAN S FER AR E BLI N KIN G SP IND LE CARD) ,
(C OU LD BE HAS ST ALLE D . TH E 1030, OR TH E 1400
1-25 5)

18. 48 18. 48.1 18. 48.2 18. 48.3

Troubleshooting Mar 2000

Fadal Maintenance Manual

CHART 19
SE R IAL
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 I N G LE YE S
LO O K F O R IT A S YN TA X SE N D FILE
PR O BLEM W ITH A LL F IL E F IL E M U S T B E
HI D D EN ERR OR? U S I N 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 EX T
CHA RACT ERS (D O E S P A R T O F F I L E SO CONTROL STO P S
O N LY A S IN G L E ONLY F ORMA T
IN T H E F I L E TR AN S M I T? ) AT SYN TA X E RRO R
FIL E ?

19 . 1 . 1 19 . 1 .2 1 9 . 1 .3 19. 1.4
19 . 1 NO
ALL C O M M UN IC ATIO N

CHEC K BAUD RA TE LO O K F O R I L L E G A L
A N D O T H E R C O M M U N IC A T I O N CHAR ACT ERS BEFO 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 I N IT I A L P E R C E N T
AT C OM PUTER SIG N

19 . 2
19 . 1 .3 a

VE R IF Y TH A T A L L R S2 32
CA B LES A R E P LU 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 M P U TE R )

19 . 3

YE S CHEC K
IS A
SW IT C H P O SITIO N O F
NULL M ODE M
NULL M ODEM,
BE 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 I O N

19 . 4 NO 1 9 . 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 US T BE A C O N T IN U O US W IR E
DIFFIC U LT TO D IA GN O SE P RO B LEM S CAN OC C U R
T O T H E P O W E R D I S T R IB U T IO N P A N E L
O F T H E B U IL D I N 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 .
GROUND RODS ARE N OT ACCE PTABLE TH E R E M U S T B E A C O N T IN U O U S G R O U N D IN G
AS T H E P RIM A R Y G R O U N D IN G M E TH 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
TH E G R O U N D W IR E O F P O W E R D IS T R IB U T I O N P A N E L .
THE RS232 DB 25 PLUG TH E C O M P U TE R B EIN G U S ED M U ST A L SO B E P R O P ER LY
IN TH E M AIN C AB IN ET G R O U N D ED (U N LE SS IT IS A B A T T E R Y O P E R A TE D LA P T O P ).
MUS T BE ATT ACHED
TO T HE C A BIN ET .
P A IN T M U S T B E R E M O V E D
FOR G O O D CO NTA CT.

19 . 6

IF M AC H INE H A S A PH O N E M O D EM ,
M A KE S U R E IT IS D IS C O N N E C T ED
FR OM TH E R S232 PO R T

19 . 7

PLU G R S 232 TEST P LUG

IN T O R S 23 2 P O R T O N C AB IN E T .
FROM COM M AND MO DE,
TYP E "D I", PR E SS E N TE R ,
TYP E "G 0 30 0 0 ", P R E SS E N TER ,
SELECT THE RS232 TES T.

19 . 8

M A C H IN E PA SS E S D I AG N O STI C S
P L U G R S 2 3 2 C A B L E IN T O P O R T YE S
DO ES YE S DO ES AN D IS N O T A T F A U L T IN
AN D M OV E T ES T P LU G
RS 2 3 2 TE S T P AS S RS232 TES T PAS S C O M M U N I C A T IO N P R O B L E M .
TO C O M P U TER EN D O F C A BL E .
W ITH O U T W IT H O U T
RER UN TEST .
ERRORS ? ERR ORS ? A N U LL M O D E M M IG H T B E NE E D ED .

19 . 9 1 9 . 9 .1 19 . 9 .2 19 . 9 . 3
NO NO

E IT H E R T H E 1 0 3 0 C A R D CA B L E M A Y B E
O R T H E R S2 3 2 CA B L E DE FE C TIV E,
FRO M THE 1030 T O O LO N G ,
T O T H E D B 2 5 P LU G O R R O U T E D IN A
IS BA D NO IS Y E N V IR O N M E N T

19 . 1 0 19 . 9 .2 a

IF P R O B L EM S PE R SI ST, G O TO
C O M M U N IC A T I O N S T R O U B L E S H O O T IN G
SE C TIO N O F M A IN T E NA N C E M A N U AL
F O R A D D ITIO N AL I N FO R M ATI O N

19 . 1 1

Mar 2000 Troubleshooting

Fadal Maintenance Manual

C H A R T 20
SE R VO
IN D EX ER
FA D A L S ER V O IN D EX ER
10 - 2 0-9 5

W I TH 5V
IS
W IL L NO CH E C K F USE MO T O R C A BL E NO NO BE T W E EN NO
PUL S E LE D
IN D EX ER ON B AC K OF DI SC O N NE C TE D , PIN 1 AN D P IN 6
ON 1 8 1 0-0
PO W ER - U P? CO N TR OL B OX W IL L IN D E XE R OF J 1 1 ON
BLI NK IN G?
PO W ER 181 0 - 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 F OR
CH E C K FOR S H OR T
CH E C K CO N N EC TI ON S O F 12 0 V A C AT
O F 5 V T O GR OU N D
CO N N EC TO R 5V RE GU L A T OR PIN S 1 & 2 OF J 1
I N C AB LE
TO D IS P LAY ON P OW E R SU P P LY O N P O W E R SU P P LY
OR E NC O D ER
(1 8 1 8-0 - 2 ) (1 81 0 -0 - 2 )

20 . 1 .2 a 20 . 1 .3 a 20 . 1 .4 a 20 . 1 .5
CH E CK FO R BA D S O LD ER J OI N TS A T
AL L FO U R VO LT AG E RE G U LA TO R S.

LI ST EN C A R EF U LLY TO U N IT.
CH E C K
DO ES VE R IFY IF M OT O R IS T U RN IN G
W IL L NO YE S PA R AM ET ER S
DI SP L AY I NDI C ATE F EE D R A TE PO T AN D H E AD I S N OT ,
HE A D MO VE ? (R A T IO AN D
MO T ION ? IS N OT S ET A T 0 A CO UP L E R IS L OOS E
EN C O DE 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

TU R N OFF AN D CH E C K VO L TAG ES
CH E C K FU SE S IF A MP L IFI ER IS BLO W N , 1 8 1 0-0 - 1 J3 :
UN P L U G UN IT .
O N M OT OR , LO OK FO R 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 1 8 10 -0 - 1 A ND ON AR E MO TOR L E A DS P IN 5 +1 2 V & PI N 6 C O M
(B L OW N )
18 10 - 0 -2 SHO R TE D T O C HAS S IS? 18 1 0 - 0 J1 1 :
IG B T 'S O N A M PL IF IER
P IN 1 & 2 + 5 V
20 . 2.1 a 20. 2 .1 b 20. 2 .1 c W IRE S T O MO T OR A R E P IN 3 +1 2 V
SH I EL DE D . S H I EL D M U S T P IN 4 -1 2 V
BE ST RI P P ED BA C K F RO M P IN 5 & 6 G ND
CO N DU C TO R .
20 . 2 .1 d

DO ES IF M OT O R W A S RE S ET PA R AM E TER S
DO ES YE S DI SP L AY YE S RE P L ACE D , TO F AC T O RY D E FA U L TS
HE A D RU N
I ND IC AT E MOT O R LE ADS (M IS C/ PA RAM /FA C S ET)
AW A Y ?
MO T ION ? MA Y BE REV E R SE D AN D R E T R Y

20. 2 .1 e
20 . 3 20 . 3 .1 20. 3 .2
NO
NO CH E C K CAB LE AN D
EN C OD E R C AB LE SO C K ET FOR D AM AG ED
CH E C K C ON N ECT O R S ON O R E N C OD E R MA Y BE B A D: PIN S OR SO C K E T S
MOT O R CA BLE A ND BOX
FO R P U SH E D IN O R CH E CK AL L E N C OD E R C O NN EC T ION S . 20. 2 .1 f
DA M AG E D CH E CK FO R C O NT IN U ITY OF A L L EN C OD E R
PIN S OR SO C K E T S L IN ES F RO M EN C OD E R T O U4 O N 1 81 0 - 0 .
CH E CK FO R 5V A T E N C OD ER .
20 . 3 .1 a
20 . 3. 1b

MOT OR O V ER LO AD IF HE AD MOV E S
DO ES OR O V ER CU R R E NT BU T POS IT I O N D IS P LA Y
HE A D JO G IN BOT H NO FAU L TS I NDI C ATE DO ES N 'T CH A N GE
DI R EC TI ON S? A BL OW N I GB T TH ERE IS A N E NC O D ER
ON A MP L IFIE R FEE D BA C K PRO BL E M

20 . 4 20 . 4 .1 20 . 4 .2
YE S IF AM P LI F I ER I S BL OW N ,
FI N D C AU SE B E FOR E R EP LA C I NG .
RE SI S TAN CE A CR O SS M O TO R LE AD S SH O UL D B E 4 -6 O H M S.
RE SI S TAN CE FR O M M O TO R L EA D TO C HA S SI S S H O UL D B E IN F IN I T E.
WI RE S T O MO T O R A R E S HIE LD ED. S HIE LD M US T BE ST RI P PED BA C K
FR OM C O N DU C TOR .

CH E C K BRA 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
MO T OR DI SC ON N E C T AN D S O CK ET IS LO AD
(1 I S O U TPU T TO H EA D , NO FIX T U RI N G ,
O VE R LO A D S? AIR FO R D A MA G E D TO O HE A VY ?
2 IS IN P U T F RO M AU X IL IA R Y C HU C K ,
PIN S OR SOC K E TS
AI R SU P PL Y ) OR P ART

20. 5 NO 20 . 5. 1 20. 5 .2 20 . 5. 3 20. 5 .4 YE S 20. 5 .5

RE D U CE
F EE D R AT E
GO T O
PA G E 2 OF 20 A .5 .6
CH A RT 20
CO N SU L T FAC T OR Y
AB O U T M O TO R TY PE
JU M PE R S ETT IN GS

20. 5 .6

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Fadal Maintenance Manual

CO NTINU E D
FR OM
PA GE 1 OF
CHART 20 c ont inued ( page 2)
CH A RT 2 0 FAD AL S ERV O IN DEX ER
10- 20-9 5

EN COD E R CAB LE
IN DEX ER YES TES T E N COD E R
MA Y BE B AD , EN COD E R MA Y B E
MIS P OSI TION S , LO SE S W ITH F ADA L
VE R IFY C ON TI N UI TY OF SLIP PI NG ON MOT OR
PO SITI ON (MA Y ALS O EN COD E R TE ST ER
EN COD E R SI GN A LS SH A FT,
MOT OR OV ER LO AD ) (E N COD ER M A Y B E B AD)
IN CAB LE

20. 6 20 . 6.1 20 . 6.2 20. 6 .3

NO

AR E HE A D MU S T F IN IS H
HE AD
YE S YOU US IN G YE S MOV E BE FORE
MIS S ES
SIM U LTA NEOUS NE X T S TART IS S EN T.
STA RT
MOV E ME N T? AD D DW EL L TO VM C
PU LS ES?
PROG RA M .

20. 7.1 20. 7 .2

20. 7 NO NO

DI SCO NN E CT I N DE X ER MIL L M A Y NE E D
CH E CK COMM U NICA TION
INTE RF ACE CA BL E DO ES YE S 0. 001uF C AP A CITOR
PR OT OC OL
AND R UN P R OGR AM PROG RA M R UN ACR OS S FINIS H
BE TWE EN IN DEX ER
US IN G THE PR OP ER LY ? TER M IN A LS O F
AND M ILL
STA RT B UTTO N. MIL L.
20. 7.1b
20. 7 .1a 20. 7.1c 20 . 7.1 d

FIRS T M AK E SUR E CH E CK CON NECTO RS 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 NC O D ER
WILL NOT
DI R ECTI ON S AND FOR P USHE D IN O R MA Y BE B AD.
COLD S TART ?
CO R RECTLY DIS PLA Y S DA M AGE D CH EC K ALL E NC ODE R C ONN EC T IONS .
POS ITI ON PIN S OR SOC K ETS CHE C K C ONTINU IT Y OF E N COD ER L IN ES.

20. 8 20 . 8.1 20. 8.2 20. 8.3

NO

CHE C K AI R SUP PLY

CH E CK CH E CK
BRA KE AND A IR L IN E TES T I N MDI
YE S PA R AM ET ER S SOLI D ST ATE
DO ES N'T CO NN EC TO RS (M 60 BRA K E O N ,
TO S EE I F B RAK E RE LA Y (K 1) ON
WOR K ? (A IR P RES SU RE M61 B R A KE OF F)
IS ACTI VE 1810 -0 -2)
SHOU LD B E 8 0 PS I)

20. 9 20 . 9.1 20. 9 .2 20. 9.3 20. 9.4

NO

AIR SOLE N OID POR T S

AR E 1 & 2 .
FEE D 2 IS AI R IN .
YE S RE CA LI BR A TE 1 IS AI R OUT TO H E AD .
RA TE P OT DO ES
FEE DR AT E P OT
NO T R E SP ON D
IN DIA GNOS TIC S
PR OP ER LY ? 20 . 9.5

20. 10 20. 10.1

NO

INSE R T D UM MY P L UG
IN TO R S 232 DB 25 C ON NECTO R CHE C K C AB LING,
RS 2 32 YE S DO ES YE S BA UD R AT E,
(PIN S 2 & 3 JUMPERE D )
DO ES NOT RS 232 TE S T AN D P ROTOC O L
WOR K ? W ORK ? (IN D EXER IS 7 D ATA BITS ,
RU N RS 23 2 TE S T EV EN P AR ITY , 1 STO P B IT)
IN DIA GNOS TICS
20. 11
20. 11 .1 20. 11.2 20. 11 .3
IN D EXER H AS C TS, DT R , & D SR NO
JU MPE RED IN T ER NAL LY.
CHE C K VO L TAG ES
1810 -0 J1 1:
P IN 1& 2 +5 V
P IN 3 +1 2V
P IN 4 -12 V
P IN 5& 6 GND

20 . 11.2a

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Fadal Maintenance Manual

CHART 21
POS ITI ON I N G DIF FIC UL T T O D I A GN O S E P RO B LE M S C A N O C CU R
PR O B L EM S PO SITIO NING P ROBL EM S IF M AC H INE I S N O T P RO P E RL Y G R O UN D ED .
TH E R E MU S T B E A CO N TI N U O US G RO U N DI N G
10 - 2 0 -9 5 CO N DU C TO R (AS SP E CI F I ED O N T H E G R OU N DI N G
LA BE L I N TH E M A CH I N E ' S D I SC O N NE C T B OX )
FR O M T HE V MC 'S G RO U N D B US TO T HE G RO U N D
RE FE R T O C H AR T 4 BU S IN TH E B U I LD ING 'S P OW ER DI S TR I B UT IO N P AN E L.
AX IS C ON T R OL
F OR
M A JO R PO SIT IO N IN G
PR O B L EM S

21 . 1

RE FE R TO :
CH A R T 5 FO R R E PE A T AB IL I T Y,
CH A R T 1 1 F O R FI N ISH ,
CH A R T 1 7 F O R R OU N D N E SS ,
CH A R T 18 FOR ERROR CODES

21 . 2

CH E C K +5 V ,+ 1 2 V,- 1 2 V.
AL S O S ET M E TE R FO R VA C
AN D C H E C K F OR A C R I P PL E
O N + 5V , +1 2 V A ND -1 2 V D C
(0 . 01 5V A C R IP P LE M AX O N + / -12 V,
0. 00 5V AC R IP P LE M A X O N +5 V )
21 . 3

CH E C K PA R AM E TER S
IN S ET P e s p .
A- AX IS & B- A XIS R A TIO ,
DE FA U L T:I N C H / M E TR IC ,
CR C M OD E , A N D S C R EW : M E T R IC

21 . 4

IS C RC YE S VE R IF Y T OO L
BE IN G U S E D? DI AM ET ER S I N
TO OL T AB L E

21 . 5 21 . 5 .1
NO

CH E C K SI N/ C OS
SIG N AL S U SI N G
SE R VIC E T O OL S T4 8 .
AD J U ST IF V A R I AN C E
>0 .0 0 1 V
21 . 6 IF A S U BP L AT E O R L AR G E H E A VY FI XT U R IN G IS P R ES EN T
AN D TH E FI R ST R O U N D O F AD J U ST M E N T S D OE S N O T
IF P OS ITIO N I N G CO R R EC T T H E PR O B L EM , RE M O V E S U BP L A TE AN D F IX TU R IN G
PR OB L EM I S AN D R U N T H R O UG H A DJ U S T M E N T S A N D TE STS A G A I N .
IN T E RM I T TEN T , SU B PL A TE AN D F IX T U R IN G M A Y B E C R EA TIN G A M E C H AN I CA L B IN D .
CH E C K GR O U N D IN G
OF M AC H I NE
21 . 7

CH E C K/ AD J U ST
G AI N AN D B A LAN C E
OF A XI S AM PL I FI E R S

21 . 8

BA CK LA S H C A N B E A D JU ST E D B Y V AR IO U S M E TH O DS .
CH E C K BA C KL A S H FA DA L R E CO M M E N D S T H E P RO G R A M M A TIC ( OR D Y N A M IC) M E TH O D
O F A XE S DE S C R IB E D IN T HE M A IN TE N AN C E M A NU A L IN ST EA D OF TH E S T AT IC M E TH O D
US I NG JO G . VM C 6 0 3 0 A N D V M C 80 3 0 M U ST US E TH E D Y NA M I C M E TH O D.

21 . 9

CH E C K F OR L O O SE N E SS
IN M O TO R C O U PL E R S,
M O T O R M OU N T S ,
OR W O R N O R L O OS E IF A B A D B AL LS C RE W IS S U SP EC T E D ,
BA LL SC R E W S CO N SU L T W I TH FA C TO R Y S E R V I CE D EP T.
B E FO R E C H AN GI NG B AL LS C RE W !! !
21 . 1 0

CH E C K SU R V E Y F O R S CA L ES I S N O T TH E S A M E A S SU R VE Y F O R R E S O LV E R.
FO R P O S IT IO NI N G TO B E C O RR E CT , SU R VE Y F OR S CA L ES M US T B E E N TE R ED W H E N SC A L E S A R E U S E D ,
SU R V EY TA BL E AN D S U RV E Y F O R R ES O LV E R M U ST BE EN T E R E D W H E N R E S OL V E R I S US E D ( N O SC A L ES O R S C A L ES A RE UN P LU G G ED ).
O F E VE R Y AX I S SU R V E Y F O R S CA L ES AN D SU R VE Y F O R R E SO LV E R C A N B E F O UN D I N M A CH I N E R E COR DS .
TH E S U RV EY M U S T HA VE E I TH E R ZE R O S O R VA L U ES ; "N O SU R V E Y " I S N O T A C CE P TA BL E.
21 . 1 1

CO N TI N U E D
O N P AG E 2
OF C H A R T 2 1

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Fadal Maintenance Manual

CO N T IN U E D
C H A R T 2 1 c o n ti 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- 20-95

SU RVE Y F OR S CA L ES IS N OT
IF B AL LS C R E W SU R VE YS A RE BA LL SC R EW DE PE N DE N T. TH E S AME AS S UR V EY FO R
HA S BE E N R E P L AC E D CH A NGI NG T HE B AL LS CRE W INV A LI DAT ES TH E SUR VE Y. RE SO L VE R . F OR P OSI TI ON IN G
A N E W S U R VE Y TO BE COR R EC T, S U RV E Y F OR
MU S T B E DO N E RE SO L VE R MU S T B E E NTE RE D
W HE N SC AL E S A RE U NP LU GGED
AN D S URV E Y F OR S CA LE S MU S T
21 A .1 BE EN TE R ED W HEN S CA LE S AR E
RE CON N ECT ED .
IF O V E R SH O O T IN G
IF O VE R S H O O T IN G O C C U R S
DO ES N O T O C C U R
OV E R - YE S W ITH A H E A V Y PA R T O R F IX T U R E , DO E S YE S PO W ER O F F M A C H IN E . WIT H O U T SC A LE S
SH O O TIN G BU T DO ES N O T O C C U R W I T H O U 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 T AC T F A C T O R Y
P OS IT I O N ? US E G 51 R 0- # W IT H A VA LU E >1 SC A LE S ? PO WE R O N MA C H I N E.
AB O U T S O F T W A RE
F O R X A N D Y T O L E N G TH E N F EE D R A M P S
21A .2.3 CH A N GE
21 A .2 21A .2.2
NO 21 A .2 .1 NO 21A .2.4

DO ES
J13 O N 1060 MU S T
DO ES YE S DI S C O N N EC T S C A L E S, MA C H IN E YE S GO TO
BE P LU G GE D IN
MA C H IN E HA V E P O W ER D O WN MA C H I N E P OS IT I O N C O R R E C T LY CH A R T 22
F O R S C AL E S T O
S C A LES ? AN D R ES TA R T W IT H O U T S C A LES
W O R K R ELIA B LY
SC A LES ?
21A .3 21 A .3 .1 21 A .3 .2 21 A .3 .3
NO THE S C AL E E RR OR IN P UT IS ON J13 SUR VE Y F OR S CA L ES IS N OT TH E SA M E A S 21A .3.4
SO IT IS CRI TI CA L TO S CA LE S TH AT SUR VE Y F OR RES OLV E R. FO R P OS I TI ON ING NO
J13 BE PL UG GE D I N. HOW V E R, TO BE C OR R ECT , S U RV E Y F OR R ES OLV ER
POS IT IONIN G ER R ORS 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 OLV E RS IF J1 3 UN P LU GGE D AN D S U RV E Y F O R S CA LE S
IS N OT PL U GGE 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 SOL VE RS IT IS IM POR TA N T RE C ON N ECT ED .
THAT J13 BE PL U GGE D I N A ND D OOR SUR VE Y F OR S CA L ES AN D SU R VE Y F OR
IN T ER LO C KS FU N C TI ON P R OP E RL Y. RE SO L VE R CA N B E FOU ND IN M A C HI N E
RE C OR D S.

IS P A R T
E N S U RE T HA T PA R T
SLIP PI N G IN YE S AN D FI XT UR E
F IX TU R E OR
AR E AD E Q U A T E LY
IS FIX T U R E
SE C U RE D
M OV IN G ?

21 A .4 21A .4.1
NO

DO ES
CO N SU LT T R Y DN C X ,
YE S T H E MA C H IN E NO
IS D NC CH A R T 1 9 S H O R T E N T H E C A BLE ,
MIS P OS I T IO N W H E N
BE IN G U S E D? SE R IAL US E A S LO W ER BA U D R AT E ,
NO T U S IN G
CO MM U N IC A T IO N S T R Y AN O T HE R C O M P U T E R A N D C A BL E
DN C ?
21A .5 21 A .5 .2 21 A .5 .3
NO 21 A .5 .1
YE S

PO W ER O FF
MA C H IN E AN D
IN SP E C T W IR I N G

21 A .6

CH E C K F O R LO O SE
OR B RO K E N WI RE S
O R B AD C R IM P S

21A .7

T ES T A L L
GO LD C O A X
CO N N EC T O RS
US IN G S T 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
O F C H A R T 21

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CHART 21 conti nued (page 3)

CO NTIN UE D
FR OM PA GE 2
OF CH A RT 2 1
PO SITIONING P RO BLEM S
10 -20 -9 5

CH E CK R ES OL V ER
CO N NECTO RS A T
MOT OR S

21B .1

CH E CK L EV EL
AND TRA M

21B .2

CH E CK FOR
BR OK EN OR LOO SE
RE S OL VE R
CO UPLIN G S

21B .3

CHE C K
BA LL SC RE W
ALIG NM E NT

21B .4

US E CL AM P -ON
AM ME TE R TO C HE CK
EA C H AX IS .
AM P DRA WS M U ST BE
IN S PE C A ND CON SI STE N T

21 B .5

CHE C K ST RA P
ADJ U STM E NT S
(C H EC K AMP DR AWS
AG AIN AFT ER
AD JU ST IN G STR APS )

21B .6

IS IN S PE C T PAR T
POS ITION ING YE S ON M A CH INE DO ES P AR T YE S OFF-MA CH INE
CLA M PING MA Y BE
ERR OR R E VE A L ED B Y BE FO R E REM OV ING IN SP ECT GOO D ME AS U RIN G M A Y B E
DIST OR TING PA R T
OFF-MA CH INE PA RT CL A MP S OR ON M ACH INE ? OU T OF C AL IBRA TIO N
IN S PE C TION? RE LE A S ING V IS E

21B .7 21 B .7.1 21 B .7.2 NO 21 B .7.3 21 B .7.4

NO
WHEN MA T ER IAL I S C U T TH E
ST RES SES IN TH E MATER IAL
CH ANGE SO TH E DIMENSION S
MAY MOV E W HE N IT IS U N CL AMPED . TH ER M AL CH A NGE S
BE TWE EN MA CH ININ G
SIN G LE S TE P TH RU
AN D IN S P EC TION M AY
THE PROG RA M TO
BE A FFE CTIN G PA RT
FIN D P OS SIB LE
PR OG RA M MING E RRO RS
21 B .7.5
21 B .8

HAV E A N APP LIC ATIO N

EN GIN E ER R EV IE W
TH E P RO GR AM A ND
FIX TUR IN G

21 B .9

ARE ALL YE S TR Y RE S ETT ING

TH ER M AL EX PA N SI ON TH ER MAL G RO WT H IS A N ATU RA L E F FE CT OF H IGH S PEED MACH IN IN G .
POS ITI ONS HO ME A T R E GUL AR
MA Y BE THE P R OBL E M IT CAN BE LIMI TE D , BU T N OT T OT A LLY ELI MINATED . IT O CC U RS IN T H E
CHA N GING ? INTE RV A L S
BALL SC R EWS, TH E H E AD , TH E SP IND LE, A ND EVE N T H E C O LU MN, S AD D LE
AN D T ABL E WH EN T HE R E A RE TEMP ER AT U RE SW INGS .
21 B .10 21B .1 0.1 21 B .10 .2
NO

INSP EC T AND FL USH

TH E LUB E SY S TEM .
VE RIFY E NT IRE SY S TEM
IS WOR K ING P R OP ER LY

21B .1 1

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SCALE PROBLEMS CHART 22 SCALE PROBL EMS CAN SHOW UP A S S CA LE E RRORS (AN ERROR CODE),
MISP OSITIONING, REPE ATAB ILITY PROB LEMS, ROUNDNESS PROBL EMS
SCALE PROBLEMS OR UNEX PE CTE D P OSITION S HIFTS.

10-20-95

DIFFICULT TO DIAGNOSE PROBLE MS CAN OCCUR IF MACHINE IS NOT PROP ERLY GROUNDED.
THERE MUS T BE A CONTINUOUS GROUNDING CONDUCTOR (AS SPE CIFIED ON THE GROUNDING LA BEL
IS IT YES CO NSULT IN THE MACHINE'S DISCONNECT B OX) FROM THE VMC'S GROUND BUS TO THE GROUND B US IN THE
AN ERROR CHART 18 BUILDING'S POWER DISTRIBUTION P ANEL.
MESSAG E? ERROR CODES

22.1
22.1.1
NO

YES, AND
ERROR I S
NOT 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 EASI LY

NO
SWITCH
EXE BOARDS
IN SCALE BO X

22.2.1a

ERROR EXE
STAYS WITH 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

RECONNECT SCAL ES AXIS

PO WER OF F MACHINE. DO ES YES NO ZERO OFF SET
IS IT YES AL SO J13 ON 1060
DISCONNECT SCALE PROBLEM GO CO LD STARTS IN SV FOR AXIS
A POSITIONING (SCALE ERROR LINE)
FROM 1010 CARD. AWAY WIT H TO CORRECT MAY BE
PROBLEM? MUST BE
POWER ON MACHI NE. NO SCALES? POSITION? SET WRONG
PLUGGED I N)
22. 3.4
22. 3.2 22.3.5
22.3 22.3.1 22. 3.3
NO NO YES
SURVE Y FOR S CAL ES IS NOT THE SAME A S RE MEMBER TO RE -ENTER THE
SURVE Y FOR RESOLVE R. FOR POSITIONING SURVEY FOR SCA LES . RUN AN
TO BE CORRECT, S URV EY FOR RES OLVER EXTERNAL
NOT A
MUST BE ENTERE D WHEN SCA LE S A RE IF Y-AXIS, THE CABL E TO
UNPLUGGE D AND SURVEY FOR SCALE S
SCALE PROBLEM.
GO TO CHART 21 SCALE MOUNTING THE SCALES
MUST BE ENTERE D WHEN SCA LE S A RE
RECONNECTED. POSITIONING MAY BE DEF LECTED
SURVE Y FOR S CAL ES AND SURVE Y FOR PROBLEMS BY SCALE CABLE 22. 3.6
RESOLVER CA N B E FOUND IN MA CHINE
RECORDS. USE
22. 3.2a 22. 3.4a SCALE TESTER
(1710-0) OR
VERIFY SCALE CABLING ENCODER
IS CORRECT AND TESTER (ST40)
PLUGGED INTO AND CHECK
CORRECT INPUT OF FOR INDEX
CO NTINUED 1010 CARD (J6) FROM SCALES
ON PAGE 2 22. 3.7
COLUMN 1 22. 3.4b
OF CHART 22
VERIFY THAT SURVEY FOR SCA LES
IS NOT THE SA ME AS
22. 4 SURVEY IS CORRECT
SURVEY FOR RES OLV ER
FOR SCALE FE EDBACK.

22. 3.4c

CO NTINUED
ON PAGE 2
CO LUMN 5
OF CHART 22

22. 3.4d

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Fadal Maintenance Manual

CO NTINUE D
FROM PAGE 1
CO NTINUE D
FROM PAGE 1 CHART 22 conti nued (page 2)
CO NTINUE D
FROM PAGE 1
CO LUMN 2 CO LUMN 5
CO LUMN 1
OF CHA RT 22 OF CHA RT 22 SCALE PROBLEM S OF C HA RT 22
10-20-95
22A .1 22A .2 22A .3

CO NNECT
SC ALE ENCODE R
PO WER DOWN TES TE R (S T40 )
MACHINE BE TW EEN S CALE
AND DI SCO N NECT BO X A ND AX IS CA RD
SCALE S F RO M
AX IS CARDS 22A .3.1

22A .2.1 SWAP A

YES KNOW N GOOD
SCA LE
CA BLE BE TWE EN
PU T X S CALE CABLE TES TE R SHO WS
SC ALE BOX
INTO Y JACK O F ER ROR ?
AND A XIS CA RD
SCALE BO X , E TC. AND RE TEST
22A .3.2 NO
PO WER ON MACHI NE 22A .3.2a

22A.2.2
SWAP
AX IS CARD S
EXE 22A .3.3
ER ROR BOA RD REP LACE
STAY S W ITH 1580-1A BOAR D
EX E BOA RD OR (S CALE B OX PROB LEM YES
SCA LE? MOT H ERB OAR D) RE P LACE
STA YS W ITH
AX IS CAR D
AX IS C ARD?
22A .2.3
22A .2.3a 22A .3.4
SCA LE 22A .3.4a
NO

SCA LE CABL E MA Y CHE CK

BE DAM AGED. GIB S A ND
RUN A N EW CA BL E STRA PS
OUTS IDE O F M ACH INE 22A.3.5
TO TE ST .
GO TO
22A .2.4 CHA RT 21
PO SIT ION IN G ,
CH AR T 5
RE P EA TA BILI TY
CH EC K DIS CONNEC T RE ADER HEAD
ER ROR YE S FROM B RA CKE T AND
ALIG NM ENT
STILL OCCUR S? INS TALL S HIP PING M OUN T S
OF S CALE 22A .3.6
(LE D LITE S) ON RE ADER HEAD .
MOUNTING
MOV E HE AD BY HAND.

22A.2.5 22A .2.5a 22A .2.5b

NO

CA BLE DA MA GE D, SCA LE I S GOOD .

ERROR
RE P LACE
STILL OC CURS NO PROB LEM IS ALIG NME NT
WHEN S CA LE M OVED
RE TURN B AD CAB LE OF SCALE OR
BY H AND?
TO F ADA L FOR OF READE R HEAD
(LE D LITE S)
FAI LURE A NALY SIS AND B RAC KET
22A .2.5c 22A.2.5c.1
22A..2. 6 YES

WHEN SCALE IS REPLACED

REP LACE S CALE A NEW SURVEY MUST BE DONE.
YES CO N SULT FACT OR Y
AB OU T A XIS
OVER SHO OTING ?
SOF TWA RE 22A.2.5d
UPDA TE

22A .1.1 22A.1.1a

NO

DO ES IT
CHE CK ME CHANICA L
YE S GO A WAY WHEN YE S CHE CK BAC KLA SH YES
CA VITA TION ADJUSTM ENT BACKLA SH BAC KLA SH
SCALES A RE WIT H S CALES
OR VIBRATIO N? OF G IBS >20? MUS T B E
DISCONNE CTE D? DIS CONNECT ED.
AND S TRAPS CO RR ECTED .
22A.1.2
22A.1.2a 22A .1.2d
22A .1.2b 22A .1.2c 22A.1.2e
NO
NO

NO T A
SCA LE
PROBLEM
CROSS OVER
YE S CO NSULT GO T O
PROBLEM?
(BUMP AT FAC T OR Y CH ART 1
QUADRANTS)
22A.1.2a.1
22A.1.3a
22A .1.3

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RI G ID T A P
CHART 23 D IF F IC U L T T O D I A GN O S E P R O B LE M S C A N O C C U R
IF M AC H I N E IS N O T P R O P E R L Y G R O U N D ED .

R IG ID T A P TH ER E MU S T B E A C O N T IN U O U S G R O U N D I N G
C O N D U C T O R (AS SP E C IF IE D O N T H E G R OU N D I N G
10 - 2 0 -9 5 LA BE L IN T H E M A C H I N E' S D I SC O N N E C T B OX )
FR O M T H E V MC 'S G R O 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 IN T H E BU I LD IN G 'S P OW ER D I S T R IB U T I O N P A N E L .
YES G A G E B E IN G U S E D ?
TAPP ED H O LE
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 LA S S 3 H O L E I S U SU A LL Y
23 . 1 . 1 T A PP 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 MB E R .

TAP M U ST BE IS C O O L A N T A N D / O R
YES IS TH E D RI LLED RU N R I G ID T A P T E S T
TAP 2 F L U T E S P IR A L P O I N T T A P P IN G C O M P O U N D
H O L E T H E C O R RE C T AS D E S C R IB E D I N
BR EAK S? (O R R O L L P O IN T ) T H E CO R R E C T T Y P E
S IZ E F O R T H E T A P ? MA I NT EN 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

BE F O R E D O I N G R I G ID T A P T E S T ,
Z- A XI S GA I N A N D BA C K LA S H M U S T B E
VE R I F I ED A N D / O R A D J U ST ED A S D E S C R I B E D
I N D IC A T O R T H IS IS IR R E L E V A N T .
FAILS IN M A IN T EN A N C E M A N U A L. YE S
YES OVERSH O OTS AT T A P IS N O T IN T H E
RIGID T AP
T O P O F T A P P IN G HO LE A T TH E TO P OF
TEST?
CY C L E ? TH E TAP P IN G C Y C LE.
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
DU R I NG A C T U A L T A P P I N G .
PA SS ES
YES CH E C K B E L T T E N S IO N I N D IC A T O R YE S
R I G ID T A P T E S T
AN D IDLER ASS EM BLY. OVERSH O OTS AT AD J U ST R AM P
BU T TAP PED
C H E C K F O R O IL O R BO T TOM O F TA PPIN G IN S E T P
HO LES AR E N O T
CO O L A N T O N B E LT S CY C L E ?
GOOD?
O R E X C E S S IV E A I R 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 I N G
P O S IT I V E
B E IN G U S E D? YE S TO O FAST,
IN D IC A T O R
23 . 4 . 2 DE C R E A S E T H E
RE A D I N G W H I L E
GAI N PA R AM E TE R
MO VIN G
IS T H E C O R R E C T G R A D E IN S E T P
DO W N?
O F T A P B E IN G U S E D ?
A C L A SS 3 H O LE IS U S U A L L Y 23 . 3 b . 1 NO 23 . 3 b .2
T A P P 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 C R E AS E S
0. 00 0 5" FO R EV E R Y G H N U MB E R .
S P IN D L E IS T U R N I N G
23 . 4 . 3 NE GA TIV E
YE S TO O SLOW ,
IN D IC A T O R
TAP M U ST BE IN C R EA SE TH E
RE A D I N G W H I L E
2 F L U T E S P IR A L P O I N T GAI N PA R AM E TE R
MO VIN G
(O R R O L L P O IN T ) IN S E T P
DO W N?
I F 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 YES D O A 1 0 IN C H R I G ID T A P .
UP DOES NOT MA TCH CH E C K F O LL O W I N G E R R OR
IS C O O L A N T 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 I S 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
AN D M IXTU R E? 23 . 3 d .2
23 . 4 .6
C H 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 SU LT FAC 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 AN D DOW N.
IN VE R TE R ? ENGINEE R IS IT T H E S A M E ?
23 . 4 . 7 23 . 4 . 8
23 . 3 d .3

CO N SU LT FAC T O R Y B E L T S M A Y B E S L IP P IN G .
YE S SERVIC E D EPT . GO TO C H E C K B E L T T E N S IO N
SPIN D LE
A B O U T P O S S I B I LI T Y O F CHA RT 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 C H 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 O U N TS O R E X C E S S IV E A IR IN
23 . 5 NO HY 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 C H E C K + 5 V , + 1 2 V ,- 1 2 V .
YES C H E C K R IG ID T A P ALS O SET 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
STAR TS O R
(E S P E C I A L L Y R A M P ) O N + 5V , + 1 2 V A N D -1 2 V D C
REV ER S ES?
(0 . 01 5V A C R IP P LE M AX O N + /- 12 V,
23 . 6 .1 0. 0 0 5V AC R IP P LE M A X O N + 5 V )
23 . 6
NO CO N S U L T F A C T O R Y 23 . 3 d .5
S E R V IC E D E P T .

23 . 7

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Fadal Maintenance Manual

T H IS C H A R T C O VE R S M -FU N C T I O N S C O N T R O L LE D T HR O U GH T HE 10 50 B O AR D .
M 0 - 1 9 , M 3 0- M 49 , M 60-6 9, A ND M 90 -99 A R E S PE C IF I C F U NC T IO N S T H AT AR E
C O N TR O LL ED T H R OU G H T H E 1 040 BO A R D O R AX I S C A R D S .

M ,- F U N C T IO N
CHART 24 T H EY AR E N O T C O V ER E D H E R E ..
M -F U N C TI O N SE TT I N GS A ND TE R M IN A LS AR E L I ST E D IN CH A PT ER 7 O F T H E
M - F U N C T IO N M A I N T E N A N C E M AN U A L . BE SU R E Y O U A R E U S IN G T H E TA BL E F O R T H E 10 50
BO A RD YO U H AV E.
9- 1 9 -9 5

YES CH E C K D EC 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 DE C A DE SE LE C TION
SE L E C T I O N
DO E S N O T D E 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 ES E
J U M P E R S/ SW I T C H E S
A C T IV A T E ? D E C AD E B - M 80-8 9 D E CA D ES AL R EA DY H AV E S P EC IF I C F U N CT IO NS AS S IGN E D T O T H EM .
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 C A D E A AN D D E C AD E B T O T H E S AM E VA LU E .
O R B ) W H IC H A NY 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 105 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 , A2 , A 3, A 4, B 1, B 2, B3 , AN D B4 .
2 4 . 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 E V IC E AT T A CH E D 5 M 50 - 59 : A 1- O P E N, A2 - C L O SE D , A 4- O P EN , A8 - C L O SE D .
NO 6
ME A S U R E V O L T A G E 7 M 70 - 79 : A 1- O P E N, A2 - O PE N , A 4- O PE N , A 8- C LO S ED .
A C R O S S AP 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 SE D , A8 - O P E N.
9
FO R D E CA D E B , U S E SW I T C H E S B 1 , B 2, B4 , B8 .
T E R M IN A L S O F T B 1 O R T B 2
O N 1 0 6 0 W H IL E
M - F U N C T IO N IS A C T IV A T E D .
M -F U N C TI O N T ER M IN A L S
24 . 1 .2 U N IT S D EC A D E
D IG IT A B
T B1 TB2
0 * 7+ 1 3- 1 1+ 10 -
M - F U N C T IO N YES 10 5 0 B O A R D 1 9 15 13 12
DO E S N O T YES IS AC T I V A T IN G 2 2 4 19 20
DI D R E L A Y
RE L E A S E? M - F U N C T IO N . 3 5 6 14 1
CO N T AC T S 4 8 10 2 3
(V O LT AG E A C R O SS CH E C K C A B L IN G
CL O SE ? 5 11 16 16 15
24. 2 TE R M IN AL S W IL L B E 0 AN D U S E R D E V IC E .
6 19 20 18 17
W H E N CO N T A C T S CL OS 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 Y O U S U R E ? * F O R 1 05 0- 3 A ( P OL AR IT Y
RE L A Y S P R O VI D E A I M P OR T AN T F O R B O AR D S
CO N T A C T C L O S UR E , CH E C K S E T T I N G S U S IN G O PT O -I SO LA T O 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 AS E S
V O L T A G E O R C U RR E N T DI P SW I T C H E S
PRE MA TU RELY ?
T H R O U G H R E L AY C O N T A C T S ON 1050 B OARD
M U S T B E SU P P L IE D B Y
US E R D EV IC E . 24 . 1 .5
24 . 2 a US ER D EV I C E A N D
M-F U N C T IO N BO A R D
NO 24 . 1 .3 a MU S T B E S ET F O R
TH E S AM E PR O T O C O L.

CH E C K VO L T AG E A T
YE S CH E C K SE T T I N G S TB3-2 (M-FU NC TIO N R E SE T) ON 1060.
DI S C O N N E C T U S ER
CN 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
HU N G U P? DI P S W I T C H ES 0V W HE N C L O S E D.
TB1/TB2 AND TB3
ON 1050 B OAR D RE S E T M U S T B E R EL E AS E D B E F O R E
NE X T M -F UN C T IO N O CC U R S .
24 . 2 b 24 . 2 .1 U S ER D EV IC E A N D AL L M -FU N CT I ON S O N T HE 10 50 24 . 2 .3
M - F U NC T I O N BO A R D 24 . 2 .2 SH AR E T H E S A M E R ES E T L IN E .
NO
M U S T B E S ET FO R
T H 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 S T 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 ER M IN A L S O F T B 1 O R T B2 .
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 ES
TH E R E LA Y A CT I O N A N D R ES E T C O N D I TI O N S A R E S EL EC T ED BY D IP S W I TC H ES E X EC U T E M -F U NC T IO N
LA BE LE D 1A , 2A ,1 B , 2B , W H E R E A AN D B A R E T H E DE C AD E S. FR OM MDI.
ON TH E 105 0- 0 A T H IR D D I G I T I N DI C A T E S T H E M - F U N CT I O N W IT H I N T H E DE C AD E .
FO R D E CA D E A , T H E S E TT IN G S AR E: RE L A Y T ER M IN A LS
1 A- O P EN 2A - OP E N = R E LA Y GI V E S A 0.1 S E C P UL SE , SH O U L D C L O S E . *
C N C P R OC E ED S AF T E R P U LS E.
(O H M ME T E R W I LL S H O W 0 O H M
1 A- C LO S E D 2A -O P EN = R E LA Y G IVE S A 0 .1 S E C PU LS E ,
C N C P R OC E ED S AF T E R R E SE T R E LE AS E. O R S T 0 3 L E D W IL L L IG H T )
1 A-O P EN 2A - CL O SE D = R E LA Y H EL D U N T IL R E SE T C L OS E S, 24 . 2 .5 * R E LA Y T ER M IN AL S W IL L C LO S E
C N C P R OC E ED S AF T E R R E SE T R E LE AS E. OR C LO SE FO R 0.1 SE C. A N D T H E N OP E N
1 A- C LO S E D 2A - C LO S ED = RE LA Y HE LD U NT I L R ES E T C LO SE S AN D IS R EL EA S ED , D E PE N D IN G O N T H E O PT IO N S EL EC T ED
C N C P R OC E ED S AF T E R R E SE T R E LE AS E. BY T H E D IP S W I T C H E S.
FO R D E CA D E B , T H E D IP S W I T C H E S A R E 1B A ND 2B .
FO R M -F U N C T IO N 9 O F D EC A DE A ( e. g. M 29 ) O N T H E 10 50 - 0 , T H E D IP S W I T C H E S
SH O R T T B 3- 2 ( R E S E T ) T O T B3 - 1 .
W OU L D B E 1 A9 AN D 2A 9.
US U AL LY T H E S ET TI N G S A R E F OR A 0. 1S E C P UL S E A ND T H E CN C PR O CE E DS
(O R P R E S S B U T T O N O N S T 0 3 )
AF T E R R E SE T R E LE AS E: S O T H E S E TT I N G S W O U L D B E 1 A- C LO S ED , 2A - O PE N , RE L A Y W IL L O P EN A N D
1B -C L OS E D , 2 B- O P E N . CN C W IL L P R O C E E D
A C C O R D IN G T O T H E O P T IO N
S E L EC T E D B Y T H E D IP S W IT C H ES .
24 . 2 .6 C N C W ILL N O T P R O C E ED U NT I L
C O N D I T IO N F OR R ES E T I S S A T IS F IE D.

IF 1 0 5 0 B O A R D O P ER A T E S C O R RE C T L Y
DI S C O N N E C T E D F R O M U S ER D E V IC E,
RE F E R T O C H A P T E R 7 O F
M A IN T E N A N C E M A N U A L AN D
MA N U AL F O R U S E R D E VI C E F O R
P R O P ER C O N F IG U R A T IO N S.
24 . 2 .7

CO N S U L T F AC T O R Y
S E R VIC E D E PT .

24 . 3

Troubleshooting Mar 2000

Fadal Maintenance Manual

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
1810-0-1 WHITE 4

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
LL 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

Mar 2000 Troubleshooting

Fadal Maintenance Manual

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

Troubleshooting Mar 2000

Fadal Maintenance Manual

Mar 2000 Troubleshooting

Fadal Maintenance Manual

Troubleshooting Mar 2000