Error Messages - Flint Machine Tools, Inc.
Contents
1. FORMAT 1 G92 CANNOT BE USED IN CRC MODE N 238 User Manual 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 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 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 offsets can not be applied on lines with circular interpolation G2 or G3 Fixture offset must be applied prior to commencing arc command line at GO or G1 or unused fixture offset removed if not applicable to arc Before the control can execute the codes G28 or G29 the program must turn CRC off G40 Only G1 P and F are allowed with a G31 No other codes are supported CRC mir2. 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 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 for example the macro calculation is less than 0001 This message is displayed using the Utility UT command by pressing the MANUAL key when the CNC prompts you for a tool diameter It is also displayed by entering a diameter value that is too large The only non macro command allowed with a macro line is the block skip character Section 10 Error Messages April 2003 Fadal ONLY M3 M4 amp M5 ARE ALLOWED WITH M6 AT N ONLY Z L R amp F WORDS ALLOWED ORIENTATION FAILURE OUT OF FILE SPACE A FILE COMPRESSION IS BEING TRIED O WORD OUT OF RANGE PALLET DISABLED IN PARAMETERS PALLET IN STORAGE PALLET NOT FULLY STORED April 2003 User Manual 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 This message appears when the programmer uses the fixed subrouti
3. DID NOT MOVE UP April 2003 User Manual WARNING Power off the machine before checking fuses relays and or circuit breakers The Tool Count sensor indicates the Turret is located between Buckets or has been interrupted Move Turret to next Bucket position and apply SETTO where is the Bucket number in the Bucket ready position 1 Another system may have faulted while Turret was moving or the ATC was communicating Correct the fault and reset Turret locations with SETTO 2 Check the Door Interlock System 3 Check for power interruption to the Turret Motor fuses and circuit breakers 4 Check the Turret Motor for liquid contamination or inoperative brake 5 Check the Tool Count Sensor The Tool Up or Tool Down sensor indicates that Bucket is out of position and the Turret Locations may be lost Correct Bucket Up Down problem and apply SETTO where is the Bucket number in the Bucket Ready position 1 Check Tool Up Tool Down reed switches on Bucket Cylinder 2 Check for both air valves on at the same time 3 Check for inadequate air supply The Stopping Sensor or the Arm at Home Sensor indicates that the Arm is not in its Home Position and must be before the machine can continue 1 Check Door Interlock system 2 Check Head Position Sensor and Head Position 3 Check for power interruption to Arm Motor fuses and circuit breakers 4 Arm Motor may need to be moved manually The Arm at Home Sensor
4. PROBLEM NOT ENOUGH COUNT 8 SPINDLE MAGNET NOT DETECTED or SPINDLE NOT RUNNING 9 SPINDLE FAULT LINE DOWN 10 ENCODER AND MAGNET NOT RESPONDING or SPINDLE NOT RUNNING 11 MOTOR OVERLOAD EXCESSIVE FOLLOWING ERROR April 2003 User Manual This message appears during the rigid tap operation if the encoder feedback is interrupted during the spindle operation for any period longer than 3 seconds The spindle operation is halted and this error message is displayed This message appears on power up An illogical motor tach jumper configuration or failed component may cause the axis to run away in the opposite direction of the command signal To prevent runaway axis operation is halted and this error message is displayed This message appears on power up only for axes with a 1024 line encoder as motor feedback if the count of the encoder lines per revolution of the screw is not 1024 lines per turn This message appears during the cold start process if the index mark of the axis primary feedback device encoder or scale is not detected This message is not used This message indicates that the spindle feedback is not functioning properly Prior to the rigid tap cycle the spindle feedback is checked for operational accuracy Malfunction of the feedback results in termination of the cycle and display of this error message This message appears during spindle operation if the spindle magnet is not detected for any
5. The H code might not be in the program This is a programming error that could be due to a G90 or G91 code missing or being in the wrong place e g giving absolute positions while still in incremental Also check the end point description the beginning position and the arc center description l J and K or radius designation This message does not appear during the Auto mode It appears when using the SUM command SU Before using CRC G41 G42 mirror the desired axes G51 1 Also turn CRC off G40 before canceling mirror image G50 1 Section 10 Error Messages April 2003 Fadal CANCEL CRC BEFORE N CANCEL Z AXIS MIRROR BEFORE TOOL CHANGE AT N CANNOT RETURN FROM SUBPROGRAM OR SUBROUTINE CALLING LINE CANNOT BE FOUND CANNOT START DIRECTLY INA SUBPROG CHAR SIZE OR DEPTH EXCEEDS 2 5 IN CHECK EMERGENCY STOP SWITCH AND MOTOR OVERLOAD RELAYS A April 2003 User Manual The control requires the G40 code to cancel cutter radius compensation before the line number listed See the cutter radius compensation section for suggestions The G50 1 code must appear on a separate line before the M6 This is a background editing error message The line that called the subprogram or subroutine was deleted or cannot be found 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 pro
6. USED NO RESPONSE FROM AXIS NO TOUCH OR INCOMPLETED POINT AT N NOTE ERROR THEN HIT MANUAL NUMBER OUT OF RANGE OFFSET ENTRY ERROR ONLY BLOCK SKIP ALLOWED WITH MACRO 244 User Manual 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 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 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 M65 fora TS20 When the programmer is inputting a program through the RS 232 port using the command TA 1 0 or TA 1 1 the input will be terminated if the control detects a bad programming word EXAMPLE O for 0 or double letters XX1 5 etc The programmer will have to edit the program at the computer or Teletype before inputting the program again The control will ignore all errors in the program and continue input by using the error option
7. 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 Section 10 Error Messages 247 Fadal PROGRAM NOT FOUND PROGRAM BLOCK NOT FOUND P WORD TOO LARGE RESET THE EMERGENCY STOP SWITCH RESOLVER FAULT OR SCALE ERROR RAILS NOT ALIGNED RETURN PALLET TO THE LOAD POSITION ROTARY AXIS MOVE TOO LONG N RS 232 ERROR DURING DNC 248 User Manual be edited Delete the bad O word from O 1 or 0 1 which appears as 1000 when it is listed in PR to O1 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 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 The P word for referencing a line number using M99 is too large of a value Line numbers can not exceed 99 999 The EMERGENCY STOP button has been pushed Turn the button clockwise until it is released and then push JOG This message may
8. number on the array exceeds the expected amount This amount varies from variable to variable For example H 99 is acceptable H 102 is not Section 10 Error Messages 225 Fadal User Manual ATC FAILURE Check to see if the Z axis alignment was properly set at cold start The automatic tool changer has failed to respond to an M6 or the TC 1 command Try a power off and power on If this does not help check the fuses F5 F6 F7 and F8 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 WARNING Power off the machine before checking fuses relays and or AN 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 Check to see if the Z axis alignment was properly set at cold start Then check FAILURE 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 WARNING Power off the machine before checking fuses relays and or A N circuit breakers ATC WILL NOT MOVE Check to see if the Z axis alignment was properly set
9. 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 Call the service department when this message appears Note Do not run the machine when this message appears This message occurs when the rails for the palette hanger are not aligned or the feedback switches need adjustment Call the service department for adjustment 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 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 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 Section 10 Error Messages April 2003 Fadal SCALE ERROR SEE MENU FOR NEW CD FORMAT SEQUENCE NUMBER TOO LARGE SEQUENCE NUMBER TOO SMALL SERVO AMPLIFIER FAULT SINGLE STEP SLIDE HOLD April 2003 User Manual with the RS 232 cable or the communications port Check the cable and communications port and retry DNC Also failu
10. period longer than 3 seconds This problem could be related to either command signal spindle not turning or spindle magnet malfunction The fault line signal down to the inverter should stay high during spindle operation If this signal is held low when the spindle is running then this error message is displayed This is a spindle operation error message During spindle operation the encoder feedback and spindle magnet are monitored If no proper response from either of them is detected for any period longer than 3 seconds then this error message Is displayed This error could also be caused by the command signal i e if the spindle is not turning This message is not used Section 10 Error Messages 257 Fadal 12 MOTOR OVERLOAD PULSE COMMAND STEP COMMAND CHECKSUM ERROR 13 MOTOR OVERLOAD FOLLOWING ERROR GREATER THAN THE OVERLOAD FACTOR 14 MOTOR OVERLOAD MISSING 0 OR 1 COMMAND 15 TIME OUT ON RIGID TAP PRE CYCLE TEST 16 TIME OUT ON RESOLVER RESPONSE 17 BAD READING ON RESOLVER PORT 18 SERVO AMPLIFIER FAULT LINE DOWN 19 STACK OVERFLOW OVERLOADED WITH STEP COMMAND 20 MOVE TRANSFER FAULT INCOMPLETE DATA FOR MOVE COMMAND 258 User Manual This message appears at the completion of a move if the number of pulses required to complete the move does not match the number of pulses received from the CPU by the axis controller usually indicating a hardware related problem This messag
11. 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 This message is displayed when a G04 dwell is executed by the CNC You can TO INTERRUPT interrupt the dwell time and continue program execution by pressing the START key E WORD MAY ONLY Fixture offsets cannot be on the same line with a circular move G2 G3 BE USED WITH GO OR G1 N EMERGENCY STOP TAKE APPROPRIATE ACTION 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 EMERGENCY STOP An emergency stop has occurred If the emergency stop button is depressed TAKE APPROPRIATE turn it clockwise until it returns to its normal position Press the JOG button and ACTION the message WAIT 2 SECONDS THE AXES ARE BEING RESET appears If this message persists call the service department ENTER AGAIN OR HIT This message comes up when inserting program coding at the keyboard using MANUAL TO EXIT the IN
12. DATA TRANSFER IS STALLED AXIS DOES NOT RESPOND AXIS FAULT S AS FOLLOWS 230 User Manual 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 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 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 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 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 This could be 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 This appears when the EMERGENCY STOP button is pressed a motor overload relay is tripped or the machine places itself int
13. EM TRANSMIT BLOCK MISSED ERROR JOG AXES TO HOME POSITIONS THEN ENTER THE CS COMMAND 240 User Manual 5 The G41 or the G42 code has not been canceled with a G40 before using a fixed subroutine 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 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 currently on This messages is also displayed when any G code is on the line with a G53 N20 G1 F20 N21 G8 G41 X 5 The G41 and the G8 are incompatible Move the G8 to the line with the G1 N20 G1 G8 F20 This is correct N21 G41 X 5 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 of 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 This message occurs when the increment parameter of the program input IN command causes the sequence numbers to exceed 99999 or a
14. Fadal User Manual Section 10 Error Messages Error Messages ABSOLUTE MODE REQUIRED AT N AMPLIFIER FAULT ON AXIS ARM MUST BE LEFT ARRAY EXCEEDS ALLOWABLE NUMBER April 2003 The CNC must be in the G90 absolute mode during all probe functions Probe function L9101 is programmed in the G91 incremental mode 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 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 Depressing the EMERGENCY STOP button disconnects the axis amplifiers This is why this message appears 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 This message will appear when the
15. LIMIT AT N CHECK oran extra G90 or G91 code This message will appear only when the control is PROGRAM AND inthe Auto mode or Manual Data MD mode This message will not appear in TOOL OR FIXTURE the Sum mode SU OFFSETS When the control is executing the program processing of the program is ahead of the current line that is being executed If the control detects an over travel situation while processing the program then execution of the program will stop immediately 242 Section 10 Error Messages April 2003 Fadal MOVE TURRET TO TOOL 1 AND ENTER SETTO COMMAND NEXT ENTRY IS OUT OF RANGE NO ANGLE THE POINTS ARE THE SAME NO MEMORY AVAILABLE FOR NEW PROGRAM NO OTHER WORDS ALLOWED WITH O April 2003 WORD EXAMPLE User Manual The setup person may have to consider moving the fixture to another location on the table The program may be correct but the fixture may be set up incorrectly The programmer can provide information to the setup person indicating how close to the axis limits the fixture can be located When this occurs 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 then 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 c
16. S MUST BE AT Check to see if the Z axis alignment was properly set at cold start The operator COLD START FOR cannot use the TC 1 command unless the Z axis is at the Z axis CS position TC 1 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 ZO 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 Axis Spindle Controller Error Messages Descriptions Error numbers help discern the source of the problem the axis or spindle is reporting The error number and text will follow the message CALL THE SERVICE DEPARTMENT AND REPORT THE MESSAGE AND NUMBER ON THE SCREEN TO CORRECT THESE PROBLEMS Error numbers from the AXIS or SPINDLE CONTROLLER see MU pages 40 41 1 NO MOTOR This message appears on power up if no motor feedback resolver or encoder FEEDBACK orno motor motion is detected by the axis controller 256 Section 10 Error Messages April 2003 Fadal 2 ENCODER NOT RESPONDING PROPERLY 3 LOGIC JUMPER INCORRECT or COMMAND SIGNAL MISSING 4 ENCODER IS NOT 1024 LINE 5 NO INDEX MARK DETECTED 6 SWITCH 1 DISABLED 7 RIGID TAP PRECYCLE ENCODER COUNT
17. S TO BE ZEROED YOU MUST ENTER THE BACKLASH TABLE April 2003 User Manual 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 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 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 Check the way lube oil level if this message appears See Survey in the Maintenance Manual 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 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 opti
18. TS NOT SERVICEABLE 22 BAD SCALE READING 23 MOTOR OVERLOAD ERROR gt OVERLOAD FACTOR IN STANDBY MODE 24 MOTOR OVERLOAD ERROR gt OVERLOAD FACTOR IN POINT TO POINT MODE 25 MOTOR OVERLOAD ERROR gt OVERLOAD FACTOR IN CONTOURING MODE 26 MOTOR OVERLOAD ERROR gt OVERLOAD FACTOR IN JOB MODE 27 RETURN TO MAGNET TIME OUT 28 ORIENTATION TIME OUT OR TAPPING CALIBRATION FAILURE April 2003 User Manual This message appears if the interrupt currently being processed is an undefined interrupt and thus cannot be serviced indicating possible failure of the 1010 4 5 1030 or main CPU This could also indicate a software problem This message appears if the feedback from the scale port is outside allowable limits indicating possible failure of the EXE box scales cables or 1010 4 5 card This can also be caused by severe motor vibrations This message appears in stand by mode when the following error exceeds the user defined overload factor which sets in motor turns the maximum following error for the axis operation MESSAGES 23 24 25 AND 26 ARE NO LONGER RELATED TO ERROR 13 See ERROR 23 See ERROR 23 See ERROR 23 This message appears at the completion of the rigid tap cycle if the spindle controller could not detect the magnet within 6 seconds while returning to home position This message appears if the spindle controller could not detect the magnet within 10 seconds e
19. at cold start An attempt is TO POSITION made to make a tool change and something prevents the turret from going all the way out to the spindle Check the tracks that allow the turret to slide out to the spindle Sometimes chips stick to the track and prevent the rollers from rolling on the track When this message appears use the command SETCS then the command HO which will bring the tool to the Cold Start position It is important to visually check the axis indicator markers to see if they are aligned if not jog the table until the markers are aligned Use the command CS then answer Yes Y to the move to home question This will bring the tool to the part s home position and enable the operator to begin running the program in AUTO again It is also possible that the turret extended sensor is faulty Fuses F5 F6 F7 and F8 should be checked to see if they are burned out Circuit breakers 1 and 2 if present should be pressed to see if they have been tripped 226 Section 10 Error Messages April 2003 Fadal ATC AMBIGUOUS TURRET POSITION VERIFY POCKET WITH SETTO or TURRET LOCATION LOST RESET TURRET LOCATIONS WITH SETTO ATC AMBIGUOUS BUCKET POSITION VERIFY POCKET WITH SETTO or BUCKET NOT UP DOWN RESET TURRET LOCATIONS WITH SETTO ATC ARM IS NOT IN HOME POSITION ATC ARM SOLENOID SENSOR HOME SENSOR FAILURE or ARM DID NOT MOVE FROM HOME ATC BUCKET UP SOLENOID SENSOR FAILURE or BUCKET
20. 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 236 Section 10 Error Messages April 2003 Fadal ENTER COMMAND SETP AND SET THE MACHINE PARAMETERS ENTER COMMAND MU TO SEE THE MENU ERROR ERROR IN USER PROGRAM SUM TO SEE MESSAGE ERROR N WORD EXCEEDS 99999 ERROR WHILE PROCESSING BLOCK April 2003 User Manual 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 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 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 characte
21. d when the fourth parameter is typed in AU 50 1 This is acceptable Also if the DE command is used to delete a line that does not exist or the CO command is used to copy lines that do not exist this message appears This message appears during input through the RS 232 port and is caused by several factors 1 Unshielded cable is being 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 This occurs during DNC transmission of data see the error message PARITY ERROR 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 N 1 043 P N 34 765 Here a line was inserted before N1 using the command IN 1 N1 GO G90 S10000 M3 Section 10 Error Messages April 2003 Fadal POINTS ARE ON SAME LINE AT N POSSIBLE PROBE OVER TRAVEL POSITION LIMIT PRESS Y TO KEEP THIS POSITION PRESS N TO RETURN TO LAST POSITION PROBE TEST FAILURE PROBLEM POSITIONING SLIDES TO ZERO PROGRAM DOES NOT EXIST RETRY OR HIT MANUAL TO EXIT April 2003 User Manual A comment can be added to the line with the O word These comments help identify the program The 3 touc
22. e is not used This message appears if an axis move command is not initialized properly missing 0 or 1 command usually indicating a hardware related problem This message appears during rigid tap precycle test if the spindle rotation is interrupted or the spindle magnet is not detected for a certain length of time This message appears any time the resolver zero crossing pulse is not detected within the allowable time 4 10 msec The zero crossing pulse is hardware generated every 1 msec This can also be caused by motor over temperature or by severe motor vibrations This message 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 resolver cables 1010 4 5 card or the resolver itself This can also be caused by motor over temperature or by severe motor vibrations This message appears if the axis card cannot detect the fault line signal from the amplifier or the fault line signal strength drops below 10V indicating a possible amplifier fault This message appears if the stack on the axis card used to store CPU commands until they have been serviced overflows This message appears when an axis move command is improperly transferred to the axis card as indicated by a checksum comparison between what the CPU sent and what the axis card received Section 10 Error Messages April 2003 Fadal 21 SPURIOUS INTERRUP
23. e service department first Note the error number and see the list 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 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 The current software module 1610 detected spindle software that was not compatible Call the service department 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 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 ma
24. eck for proper Spindle orientation 5 Check for Tool alignment in ATC grippers The Tool Count Sensor indicates that the Turret Motor has not rotated the Turret as expected within the allotted time 1 Check Door Interlock system 2 Check for power interruption to Turret Motor fuses and circuit breakers 3 Check Tool Count Sensor and alignment The Drawbar Cylinder Sensor indicates that the Drawbar is still in release position and has not retracted from the Spindle 1 Check Drawbar mechanism for binding or no lubrication 2 Check Drawbar Cylinder Sensor alignment The Drawbar Cylinder Sensor indicates that the Drawbar could not fully release the tool from the Spindle and the Drawbar Cylinder Piston has not moved down full stroke 1 Check for inadequate air supply or inoperative air valve 2 Check Drawbar Cylinder Sensor alignment 3 Check for broken Drawbar Cylinder Piston In a macro statement a division by zero was attempted In a macro statement a square of a negative number was attempted 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 Section 10 Error Messages 229 Fadal ATTEMPT TO CHANGE TOOL WHILE IN CRC MODE N ATTEMPT TO SWITCH PLANE DURING CRC AXIS CONTROLLER DOES NOT RESPOND DURING POWER UP SEQUENCE AXIS CONTROLLER DOES NOT RESPOND TO NC AXIS
25. es in the program Use the NU renumber command and copy again now that the program is renumbered 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 This error message appears if a program contains over sixteen consecutive comment blocks with no program coding in the lines Put coding between the comment lines or put comments on lines with program coding so that 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 Commands have associated with them a certain number of parameters If more parameters are typed in than allowed this message appears AU 50 1 or AU 50 3 1 Refer to Menu MU on the control for the correct format of each command Nesting can only be seven deep If the program goes further than seven deep then this message appears When using the TS 20 touch probe is used for tool breakage detection this error message indicates the program line where the broken tool is detected Replace the tool and continue the program This error message is displayed in cutter radius compensation when the programmed move is smaller than the radius of the cutter To correct this problem 1 Check the tool diameter entered in the tool table
26. esignated amount of time 12 seconds If this message Is persistent call the service department This message should be reported to the service department It is caused by excessive stacking of keyboard commands Subroutines can be executed in AUTO mode ONLY 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 This is a message that occurs when a subroutine heading LO100 is entered after the M30 code This message will also occur if a Fixed Cycle is still active use a G80 to cancel or G68 rotation is still active when a tool change or end of program is coded use a G69 to cancel N20 M17 N21 M30 Section 10 Error Messages Fadal TAPE INPUT TERMINATED TAPE IS GOOD TEMPERATURE FAULT TEMPORARY CONFLICT WITH AUTO THE AXIS CONTROLLER IS NOT A 1010 4 THE SURVEY CONTAINS ERRORS PLEASE REVIEW THE SURVEY WAS NOT WRITTEN TO THE AXIS CONTROLLER THERE IS NO SURVEY THREAD LEAD NOT SPECIFIED AT N 252 User Manual N22 L200 This is not permitted after an M30 This message reports to the operator that the tape or program input process is complete When verifying a punched tape this message appears if the tape is accepted This message also appears if no errors are detected in
27. essage 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 This message occurs when a pallet changer command or code is used and the SETP parameters indicate no pallet changer exists on the machine This message occurs when there is an attempt to store a pallet where a pallet is already stored This message occurs when the time to store a pallet exceeds the allotted time The feedback on the arm may need to be adjusted Call the service department for assistance Section 10 Error Messages 245 Fadal PALLET MUST BE CLAMPED PARAMETER ERROR EXAMPLE EXAMPLE PARITY ERROR PARITY ERROR DURING DNC PLEASE PUT AN O WORD AT THE FIRST OF THE CURRENT PROGRAM THE FOLLOWING PROGRAMS ARE IN MEMORY EXAMPLE 246 User Manual This message occurs when both pallets are in storage and a command is given 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 After a command is entered and a comma is typed the control is expecting a parameter If a parameter is not typed before pressing the ENTER button this error message appears AU This is a parameter error Note If the operator is not using a parameter for instance the second and third out of a possible four then the parameters can be omitte
28. gram 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 Characters that are higher than 2 5 inches cannot be engraved using the Engraving mode L9201 If the EMERGENCY STOP button switch is not pressed it is necessary to check the motor overload relays WARNING Power off the machine before checking fuses relays and or 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 Section 10 Error Messages 233 Fadal CHECK SPINDLE LUBE WAY LUBE AND AIR PRESSURE CLEAR AN EMERGENCY STOP CONDITION COMMAND ERROR COMMAND PROHIBITED BY THE KEY LOCK CRC CALLED WITH NO TOOL ASSIGNED ATN D OR H TOO LARGE DATA TRANSFER FAULT 254 User Manual 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 mo
29. h points of L9101 function 1 are on the same line Check the program for positioning errors During the UT command this error occurs for two cases 1 when the Z axis home position is set below the Cold Start position and the tool change is made to the Probe 2 when there is a positive offset value used and the tool change is made to the Probe 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 that caused the over travel These messages appear after jogging while in Slide Hold or Single Step modes See Section Eight Commands for the proper application of the Jog Away feature 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 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 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
30. h the RS 232 port from an off line computer when the RO was typed incorrectly Example If RO is typed R with the letter O or R with no zero 0 is typed R 05 is accepted but not R 05 or R 05 Section 10 Error Messages 231 Fadal BAD R1 USING L91 AT N BAD T WORD AT N BAD Z OR RO IN CANNED CYCLE CALL N CALCULATED RADIUS ERROR OF CANCEL CRC BEFORE G50 1 OR 252 G51 1 AT N User Manual Correct the line in the CNC or correct the line in the text editor and send the program again 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 This message occurs during a SUM command It indicates that the T word value Is larger than the tool changer capacity This is a programming error due to the position of the R plane relative to the Z axis position when initializing a fixed canned cycle Problem 1 The R plane is described to be above the plane 2 The R plane is described to be below the final Z depth 4 3 The final Z depth is described to end above the or R planes Canned cycle not cancelled before returning to tool change position 5 Canned cycle not stated in absolute as required 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
31. he position at which the Jog function was initiated To exit single step press the AUTO button for continuous block execution 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 Section 10 Error Messages 249 Fadal SPINDLE CONTROLLER DOES NOT RESPOND SPINDLE CONTROLLER OR DRIVER FAULT SPINDLE CONTROLLER SOFTWARE UPDATE IS REQUIRED SPINDLE DRIVER FAULT SPINDLE FAILURE WHILE TAPPING 250 User Manual Note the error number and see the 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 th
32. indicates that the Arm has not moved away from ATC home position 1 Check Door Interlock system 2 Check Head Position Sensor and Head Position 3 Check for power interruption to Arm Motor fuses and circuit breakers The Tool Up Sensor has not reported a successful move up of the Bucket in preparation for rotating the Turret 1 Check the lower reed switch on the Bucket Cylinder Section 10 Error Messages Fadal ATC BUCKET DOWN SOLENOID SENSOR FAILURE or BUCKET DID NOT MOVE DOWN ATC COMMUNICATION ERROR WITH 1330 CARD ATC INTERLOCK IS ON ATC TOOL CLAMPING FAILURE or ARM DID NOT ARRIVE AT SPINDLE ATC TOOL UNCLAMPING FAILURE or ARM DID NOT LEAVE SPINDLE ATC TOOL ARM OBSTRUCTED or ARM DID NOT ARRIVE AT SPINDLE 228 User Manual 2 Check for inadequate air supply 3 Check air valve The Tool Down Sensor has not reported a successful move down of the Bucket in preparation for exchanging the tools 1 Check the upper reed switch on the Bucket Cylinder 2 Check for inadequate air supply 3 Check air valve A communication timeout has occurred between the CNC CPU and the DATC Controller 1330 1 Route ribbon cable connecting the 1470 to 1330 away from fans 2 If error occurs on power up there may not be an actual problem An inhibited ATC function has been attempted while interlocked The arm at Spindle Sensor or the Stopping Sensor has indicated that the Arm has not arrived at the Spi
33. ither during spindle orientation M19 M6 or on the last rotation during rigid tap precycle Section 10 Error Messages 259 Fadal 29 RIGID TAP PRECYCLE ENCODER FAILURE TOO MANY COUNTS 30 SURVEY CLEARED DUE TO BLANK OR CORRUPT SURVEY 31 TIME OUT ON ORIENTATION 32 SPINDLE WILL NOT STOP CHECK INVERTER ZERO SPEED 33 ENCODER CHANNELS ARE REVERSED RIGID TAP 260 User Manual See ERROR 7 This message appears during cold start if the checksum calculated from reading the survey table is not equal to the checksum stored in the survey table The survey will be zeroed If the spindle magnet does not align within 10 seconds of an orient spindle then this error message is displayed If the spindle does not stop in 3 seconds from entering a spindle stop command then this error message Is displayed This message will display if the encoder connection for spindle motor is reversed at spindle control card Section 10 Error Messages April 2003
34. load the program If this does not work save all the programs in the memory PU 3 and use the RI command answering Yes Y to all the questions After using the RI command load the programs back into the control MEMORY ERROR There is a possible hardware problem when this message appears If the RESPOND WITH Y TO operator answers Yes Y to this question the control may delete some of the DELETE BAD program in memory Answer Yes Y only if the program in memory can be BLOCKS 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 At power on the control is in the Inches mode The Metric mode must be REQUIRED turned on by using the SETME command OPERATOR MUST SET 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 The most common reason this message appears is because of either a missing
35. ndle 1 Check for Arm Plunger latching problem 2 Check Door Interlock system 3 Check Head Position Sensor and Head position 4 Check for power interruption to Arm Motor fuses and circuit breakers The Arm at Spindle Sensor or the Stopping Sensor has indicated that the Arm did not leave the Spindle 1 Check Door Interlock system 2 Check Head Position Sensor and Head position 3 Check for power interruption to Arm Motor fuses and circuit breakers 4 Check for tool release failure The Arm travel was interrupted before arriving at the Spindle 1 Check Door Interlock system 2 Check Head Position Sensor and Head position 3 Check for power interruption to Arm Motor fuses and circuit breakers Section 10 Error Messages April 2003 Fadal ATC TOOL SENSOR FAILURE or ARM NOT AT SPINDLE CAROUSEL SOLENOID FAILURE OR SENSOR or TURRET HAS NOT ROTATED DRAWBAR SENSOR FAILURE or DRAWBAR NOT CLAMPING TOOL DRAWBAR SOLENOID FAILURE OR NO AIR or DRAWBAR NOT RELEASING TOOL ATTEMPTED DIVISION BY ZERO ATTEMPTED SQR OF A NEGATIVE NUMBER ATTEMPT TO CHANGE CRC SIDE WITHOUT G40 AT N April 2003 User Manual The Stopping Sensor and the Arm at Spindle Sensor both indicate that the Arm has not fully positioned at the Spindle 1 Check Door Interlock system 2 Check Head position Sensor and Head position 3 Check for power interruption to Arm Motor fuses and circuit breakers 4 Ch
36. ne L9201 for engraving and has programmed other words in the line with the L9201 other than Z L R and F Visually check the air pressure it must be between 80 and 90 PSI If this problem persists call the service department This is a message that informs the programmer that the memory of the control is almost full It is usually 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 38K FADAL distributors have a memory expansion board available that increases the memory capacity to 16 Megabytes This m
37. o the Emergency Stop mode If any message or error number is presented on the screen record this message and number and report them if necessary 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 Section 10 Error Messages April 2003 Fadal AXIS OVERFLOW BAD CIRCLE OR MISSING G AT N BAD DATA OR NO TOOL DIA BAD FIXTURE NO BAD INTERPOLATION TYPE AT N BAD R FIELD April 2003 User Manual 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 The axis controller detected an overflow situation Power off the machine at the main power switch wai
38. odes and is also listed in the tool table display DT The starting tool number of the utility UT tool setting cycle must not exceed that of the tool changer capacity Rotate the tool turret so that tool 1 is adjacent to the spindle and then type SETTO See Survey command in Maintenance Manual The feedback from the external slide hold switches is erratic or inconsistent This is an indication that the external slide hold switch system is faulty Call the service department 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 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 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 Section 10 Error Messages April 2003 Fadal WAITING WAITING ON AIR VALVE WARNING POSSIBLE GOUGE AT N WAY LUBE PRESSURE SWITCH FAILURE WRITING ERROR WAIT 2 MIN AND RETRY X Y OR Z MOVE MUST BE SPECIFIED ATN YOU CANNOT DELETE THE PROGRAM THAT IS CURRENTLY ACTIVE YOU HAVE A VERSION UPGRADE OR MEMORY HAS BEEN CORRUPTED MEMORY NEED
39. ommand 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 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 The calculated angle of either function 3 or 4 of L9101 is the same as the expected angle When this occurs the operator will have to remove delete as many programs as necessary from the program library in order to input another program from the RS 232 port The standard memory capacity is 38K FADAL distributors have a memory expansion board available that increases the memory capacity to 16 MEG 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 N1 O1 GO G90 P N 1234 This line is incorrect N1 O1 P N 1234 This line is correct N2 GO G90 Section 10 Error Messages 243 Fadal NO PARAMETERS OR PARAMETERS CORRUPTED MACHINE DEFAULTS
40. on 3 to start a new program This will put the currently active program in the library and then the program can be deleted Or just simply use the DE command and delete starting from the first block in the program to the last 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 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 Section 10 Error Messages 255 Fadal User Manual 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 The control has detected an incompatibility with the CNC memory manager CNC MAIN NEEDS TO software on the 32MP pendant Call the service department for an update BE UPDATED Z Q OR F MISSING See Section Four Fixed Cycles for the proper format for each fixed cycle IN CANNED CYCLE CALL N Z amp M6 LOCKOUT IS This message indicates the Z axis and Tool Change Lockout option of the Run IN EFFECT 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 AXI
41. ool table 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 For this error it is important to note which axis the transfer fault is on Note the error message number and report it to the service department There is a data transfer problem between the 1030 card slot 8 and the 1010 card for the stated axis Section 10 Error Messages April 2003 Fadal DNC MODE DOOR BEGAN TO CLOSE WHILE ARM WAS MOVING DO YOU WANT TO MOVE TO THE LAST HOME POSITION DO YOU WANT TO ZERO TOOL TABLE A DO YOU WANT TO ZERO FIXTURE OFFSETS A DO YOU WANT REINITIALIZE MEMORY A DRY RUN OPTION __ IS IN EFFECT DUPLICATE NAME DUPLICATE OR BAD PROG NAME April 2003 User Manual 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 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 This is not an error message but this message comes up each time the operator uses the CS command and a home position is established SETH in memory 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 This p
42. ption can be selected or canceled using the Run Time Menu by typing MU in the Automatic mode This message indicates the M function Spindle and Tool change lockout option of the Run Time Menu has been selected In this mode M function Spindle or Tool Change commands will not be performed during Dry Run This option can be selected or canceled using the Run Time Menu by typing MU in the Automatic mode M functions cannot exceed a 2 digit value See Section Eight Commands or the menu MU for a list of the accepted M functions 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 Section Eight Commands 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 Section 10 Error Messages 241 Fadal User Manual 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 This is a memory error turn the machine s main power off Then power on and RELOAD PROGRAM re
43. re of the CPU may cause this error If the above corrections are unsuccessful contact the maintenance department 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 The CD command is different for some versions of software See the menu for these changes This error 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 This error 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 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 This message indicates that the control is in the Single Step mode If the green START button is pressed when in this mode the following program block is executed The feed rate potentiometer affects all axis motion At the end of each block the operator can press the JOG button and jog away from the current position without aborting the operation Program execution can be continued at the new location or the axes can be returned to t
44. rompt is accessed by reinitializing the memory via the RI command A Y response zeroes the fixture offset table WARNING A Y response deletes all fixture offsets from memory This prompt is accessed by reinitializing the memory via the RI command A Y response zeroes the memory of the CNC WARNING A Y response deletes all program data from memory After memory is reinitialized a cold start must be performed The selected dry run option 1 2 or 3 is displayed prior to automatic execution See the Run Time Menu for the appropriate option definition 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 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 Section 10 Error Messages 235 Fadal User Manual 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
45. ror image rotation and drill cycles are not allowed during the execution of a G31 code Codes G45 G48 and G52 are incremental offsets Rotation can only be used in the Absolute mode Therefore these codes are not allowed 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 The G92 code should be used in a line before CRC is turned on The code G92 can only be used after a G40 G40 is a default code Section 10 Error Messages April 2003 Fadal G92 MUST BE ONLY G CODE IN BLOCK GNN IS AN UNSUPPORTED G CODE AT N HELICAL MOVE TOO SHORT N HELICAL RADIUS TOO SMALL N HELICAL RISE TOO STEEP N I J OR K MUST BE SPECIFIED AT N ILLEGAL O WORD ILLEGAL G CODE DURING G91 1 MODE AT N IMPROPER USE OF CANNED SUBR April 2003 User Manual 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 The G code displayed is not a supported code of the FADAL CNC 88 See error message HELICAL RISE TOO STEEP See error message HELICAL RISE TOO STEEP The radius of the circle and the helical rise are radically different in length usually the rise is much longer in comparison to the radius Also depending on the programmed feed rate the control may or may not be able to handle the situation Reducing the feed ra
46. rs Also a 0 could have been typed as an O s See the Operators Manual for instructions on using the SUM SU command This message will occur when the control lists an error message in the Auto mode and the operator persists in running the program by pressing the START or AUTO button This message will appear when the line in which the error exists is at the top of the stack of lines to be executed This error occurs when the sequence number is larger than 99999 The sequence number must be between 001 and 99999 This is an indication that there may be a problem with the CPU board 1 Send the machine back to cold start alignment markers 2 Power off the machines main power wait 15 seconds and power on the machine 3 Cold start then run the program again If this error repeats 1 Save all the programs and offset information currently in memory write down the present home position 2 Send the machine back to cold start alignment markers 3 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 Section 10 Error Messages 237 Fadal ERROR S READING TAPE FILE OVERFLOW FIXTURE OFFSET OUT OF RANGE FIXTURE OFFSET MUST BE APPLIED WITH GO OR G1 G28 AND G29 USED WITH CUTTER RADIUS COMP AT SEQ G31 USED WITH AN INCOMPATIBLE WORD OR MODE G45 G48 amp G52 ARE NOT ALLOWED WITH ROTATION N G91 2 IS NOT ALLOWED IN
47. t ten seconds and turn the power on again If this problem is persistent call the service department 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 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 LO4NN LO5NN 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 RO variable is not specified it is assumed as RO O If the R1 variable is not specified it is assumed as R1 1 Fixtures are numbered E1 E48 This message is displayed when a fixture offset is programmed with a value greater than 48 Format 2 G54 G59 and E6 E48 are used 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 This occurs during input from the keyboard or throug
48. te in the program can sometimes correct this problem This message is displayed when an X Y or Z is used with an RO without a G2 or G3 Full circles must use either the J or K and the direction around the circle See the circular interpolation section for more details 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 This message appears when an illegal G code is programmed while in G91 1 See the Section Three for acceptable G codes This message may appear for the following reasons 1 No tool diameter in the tool table or No D word was specified 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 HO before using a fixed subroutine except for L93 bolt hole Ta lt 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 for 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 Section 10 Error Messages 239 Fadal INCHES MODE REQUIRED OPERATOR MUST SET INCOMPATIBLE G CODES AT SEQ EXAMPLE INCREMENT DIVIDED BY TWO INCREMENT TOO LARGE INCREMENT TOO SMALL INPUT XMOD
49. to see if it was entered correctly 2 Check the program to see if it contains any typographical errors 5 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 Section 10 Error Messages 253 Fadal TOOL OFFSET NOT ALLOWED DURING Z MIRROR TOOL NN IS IN THE SPINDLE TOOL NUMBER TOO HIGH TOOL TURRET LOCATION IS NOT SET TRANSFER ERROR PLEASE RETRY TROUBLE READING THE EXTERNAL SLIDE HOLD SWITCH TYPE A Y TO IGNORE OR TURN POWER OFF AND THEN ON AGAIN UNDEFINED MACRO ERROR WAIT 2 SEC THE AXIS DRIVERS ARE BEING RESET 254 User Manual 4 Check the math work to see that 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 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 ZO Identifies the current tool that is in the spindle This is displayed when entering the program execution AU and the Manual Data Input MD m
50. tor overload relays When this message is displayed it is necessary to check the way lube level spindle oiler level and the air pressure gauge It is advised to check these oil levels at least once a day An emergency stop condition was invoked To clear gently rotate the red EMERGENCY STOP button if depressed in the direction of the arrows on the button clockwise then press the JOG key Wait 2 seconds for the amplifiers to be reset then continue 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 With the key lock in the horizontal position editing commands CH CO DE IN cannot be used This occurs when the programmer has turned CRC on without an H word in the program or in format 2 no D word Table 1 CRC Called w No Tool Assigned at N Format 1 Format 2 N1 G41 N1H1 N2 H1 This is incorrect N2 G41 This is incorrect N1H1 N1H1D1 Diameter must be specified for For mat 2 N2 G41 This is correct for Format 1 style N2 G41 Format 2 style programming amp only acceptable for Format 1 style 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 t
51. transmission when the TA command is used 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 This message occurs when background editing is being used The edit just made is in the area where AUTO is currently executing The change will be made when AUTO is out of that area See Survey in the Maintenance Manual See Survey in the Maintenance Manual See Survey in the Maintenance Manual See Survey in the Maintenance Manual 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 then this message will appear If the programmer uses the fixed cycles G74 G75 or G84 and does not cancel the cycle with any of the following codes M6 G28 G29 G49 G80 HO then this message will appear at the next Z move Section 10 Error Messages April 2003 Fadal TOO MANY BLOCKS FOR GAP TOO MANY M FUNCTIONS AT N TOO MANY CONSECUTIVE NON MOTION BLOCKS TOO MANY PARAMETERS EXAMPLE TOO MANY SUBR CALLS TOOL BREAKAGE DETECTION FAILURE AT N TOOL DIAMETER TOO LARGE AT N April 2003 User Manual This happens when the CO copy command is used and there are too many lines being copied between existing lin
52. typing error in the program has been given a value that is too large Example X 125456789 This message occurs when the increment parameter of the program input IN command is less than 001 Example IN 0 00001 A packet has been missed or came out of order during Xmodem transmission 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 Section 10 Error Messages April 2003 Fadal LOOK AHEAD WAS CANCELED BY OPERATOR M S T LOCKOUT IS IN EFFECT M FUNCTION TOO LARGE AT N MAIN PROG NOT April 2003 FOUND User Manual position then enter HO to return the axes to home and when the axes are back at the Cold Start position visually check and then 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 This indicates that 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 o
53. y want to consider Section 10 Error Messages April 2003 Fadal SPINDLE FAILURE DURING REVERSAL SPINDLE HAS FAILED TO TURN ON SPINDLE FAULT LINE SPINDLE MOTOR TEMPERATURE FAULT SPINDLE WOULD NOT STOP STACK OVERFLOW SUBROUTINE CALL IS NOT ALLOWED IN MDI SUBR DOES NOT EXIST SUBR NESTING ERROR April 2003 User Manual thread milling as an alternative to tapping Call the service department if this is persistent 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 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 The spindle inverter has detected a fault See the fault number on the inverter and report this to the service department 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 The spindle would not stop in the d
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