Chapter 9: Troubleshooting User Console Version A3.
Chapter 9: Troubleshooting User Console Version A3.53 9.0 Alphabetical List of Abnormals MONITOR (CRT) DISPLAY "ABNORMAL" MESSAGE Axis Unit Display Codes SECTION # PAGE # 9.6 9-29 Axis Unit Lockout 9.4.16 9-27 Bad or Missing Command Interpreter 9.1.6 9-6 Cal Check Abnormal 9.4.2 9-19 CMOS Power On Self-Test (POST) Failure 9.1.3 9-4 Command Error 9.2.1 9-8 Communication Time Over 9.2.11 9-12 Communications I/F Abnormal 9.1.1 9-4 Console Dual Port Ram Abnormal 9.3.
Chapter 9: Troubleshooting User Console Version A3.53 MONITOR (CRT) DISPLAY "ABNORMAL" MESSAGE Presetting Error SECTION # PAGE # 9.2.3 9-9 Run Mode 9.2.10 9-11 Selected Sequence Does Not Exist 9.3.5 9-15 Servo I/F Power Supply Abnormal 9.4.14 9-26 Servo Type Abnormal 9.4.15 9-26 Servo Alarm 9.4.8 9-22 Spindle Download Error 9.2.7 9-10 Spindle Communication I/F Abnormal 9.3.6 9-15 Spindle Dual Port Ram Abnormal 9.3.1 9-13 Sub Command Error 9.2.
Chapter 9: Troubleshooting 9.1 User Console Version A3.53 Power on Abnormal WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED. 9.1.1 Communications I/F Abnormal The FC386 PCB did not communicate properly with the Multi PCB during the power on initialization of the System. 1. Turn off the power. Remove the FC386 PCB and the Multi PCB, and verify they have compatible software.
Chapter 9: Troubleshooting User Console Version A3.53 3. Ensure that there are no active PLC inputs during the POST. 4. Turn on the power. If the problem persists, perform CMOS Setup. (Refer to Section 8.3) 5. If the problem still exists, replace the affected component (hard drive, floppy drive, etc.) (Refer to Section 8.3) 6. If problem still exists, replace the FC386 PCB. (Refer to Section 8.3) 7. If problem still exists, replace the entire Main Unit. (Refer to Section 8.3) 9.1.
Chapter 9: Troubleshooting User Console Version A3.53 9.1.6 Bad or Missing Command Interpreter The System did not find the required files on Drive C: necessary to initialize the Disk Operating System (DOS). The screen displays : Bad or missing command interpreter The System operates from the RDISK daughter board located on the FC386 PCB. EPROMS located on the RDISK board contain the System operating files. From this board, the System looks to Drive C: for the file #OPTION1.SYS.
Chapter 9: Troubleshooting User Console Version A3.53 STOP input signal (normally closed) is not being received from the PLC, and the System will not operate. Determine the cause of the problem, and take appropriate action. 4. If the READY message is present and the problem still exists, attempt to operate the System from the manual control pushbuttons on the front of the Main Unit.
Chapter 9: Troubleshooting 9.2 User Console Version A3.53 Communication Abnormal WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED. 9.2.1 Command Error A command has been transferred to the MULTI board that is either not recognized or is impossible to respond to due to the machine configuration. Example: Data request for a spindle that is not connected. 1.
Chapter 9: Troubleshooting User Console Version A3.53 A command has been transferred to the MULTI board that is either not recognized or is impossible to respond to due to the machine configuration. Example: Invalid/out of range preset data for the configured equipment. 1. Verify that the MACHINE CONFIGURATION / SET SEQUENCE / SET PARAMETER screens match the physical machine configuration. 2.
Chapter 9: Troubleshooting User Console Version A3.53 3. If problem still exists, turn off power. Remove the FC386 and Multi PCBs, and verify compatibility of software between the two (2) circuit boards. This may be of concern if boards have been previously replaced. 4. Verify correct installation of all removable IC chips on both the FC386 and Multi PCBs. 5. Reinstall the FC386 and Multi PCBs. Ensure that the boards are properly seated. 6.
Chapter 9: Troubleshooting User Console Version A3.53 9.2.8 EEPROM Write Error Data write error occurred while attempting to write to the Multi PCB EEPROM. 1. Enter the preset data required for the specified screen. 2. If problem still exists, turn off power. Remove the FC386 and Multi PCBs, and verify compatibility of software between the two (2) circuit boards. This may be of concern if boards have been replaced. 3.
Chapter 9: Troubleshooting User Console Version A3.53 5. Reinstall the FC386 and Multi PCBs. Ensure that the boards are properly seated. 6. Ensure that the Main Unit is not located near any strong electrical or magnetic fields. 7. Turn on the power. If problem persists, replace the Multi PCB. (Refer to Section 8.3) 8. If problem still exists, replace the FC386 PCB. (Refer to Section 8.3) 9. If problem still exists, replace the entire Main Unit. (Refer to Section 8.3) 9.2.
Chapter 9: Troubleshooting 9.3 User Console Version A3.53 Controller Error WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED. 9.3.1 Spindle Dual Port RAM Abnormal An Axis Unit Dual Port RAM Error occurred while attempting communications between the Axis Unit and the Main Unit. 1. Check the connected Axis Units for indications of abnormality.
Chapter 9: Troubleshooting User Console Version A3.53 6. Reinstall the Multi and Axis Unit PCBs, as necessary. Ensure that the boards are properly seated. 7. Ensure that the Main Unit and Axis Unit are not located near any strong electrical or magnetic fields. 8. Verify correct input voltages and ensure the power cables are properly connected. 9. Turn on the power. If problem still exists, exchange the tool cables with a known good set. A spare set of cables is normally provided with each System. 10.
Chapter 9: Troubleshooting User Console Version A3.53 5. Reinstall the FC386 and Multi PCBs. Ensure that the boards are properly seated. 6. Ensure that the Main Unit is not located near any strong electrical or magnetic fields. 7. Check Main Unit input voltage and power cable connection. 8. Turn on the power. If problem still exists, replace the Multi PCB. (Refer to Section 8.3) 9. If problem still exists, replace the FC386 PCB. (Refer to Section 8.3) 10.
Chapter 9: Troubleshooting User Console Version A3.53 7. Verify input voltages and ensure the power cables are properly connected. 8. Turn on the power. If problem still exists, replace the Multi PCB. (Refer to Section 8.3) 9. If problem still exists, replace the affected AXIS UNit. (Refer to Section 8.3) 10. If problem still exists, replace the entire Main Unit. (Refer to Section 8.3) 9.3.7 Parameter Set Abnormal Presets for fastening are incorrectly set up. 1.
Chapter 9: Troubleshooting User Console Version A3.53 9.3.9 Console Dual Port Abnormal Multi PCB Dual Port error between the FC386 and Multi PCB. 1. Turn off the power. Remove the FC386 and Multi PCBs, and verify compatibility of software between the two (2) circuit boards. This may be of concern if a board has been replaced. 2. Verify correct installation of all removable IC chips on both the FC386 and Multi PCBs. 3. Reinstall the FC386 and Multi PCBs.
Chapter 9: Troubleshooting 9.4 User Console Version A3.53 Axis Unit Abnormal WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED. NOTE: Whenever an Abnormal condition occurs related to the Axis Unit, the Axis Unit Abnormal displays must be checked for any related Axis Unit display codes. Refer to Section 9.6.1 prior to performing any corrective maintenance. 9.4.
Chapter 9: Troubleshooting User Console Version A3.53 9.4.2 Cal Check Abnormal (Axis Unit display code "A1") The Calibration (Cal) level of the tool transducer is outside of the acceptable limits. The following table details the limits of the check for various equipment conditions. Cal level check at power on. The Cal level must be within ± 0.075 VDC (3% of 2.5 VDC) of the value read from the tool EEPROM.
Chapter 9: Troubleshooting User Console Version A3.53 1. Verify that the tool is properly secured to the mounting plate, and that there are no signs of stress or misalignment. Ensure that the socket is not engaged on a fastener and that there is no tool movement while the self-check is being performed. 2. CHECk the spindle assembly to verify there are no worn bearings, and ensure there is no binding or excessive prevailing torque. 3. Turn off the power.
Chapter 9: Troubleshooting User Console Version A3.53 16. Verify the Axis Unit input voltage and ensure the power cable is properly connected. 17. Turn on the power. If problem still exists, replace the affected Axis Unit(s). (Refer to Section 8.3) 9.4.5 Encoder Angle Pulse Abn. (Axis Unit display codes "A5, d0, d2, d7") An angle signal is not being received while the motor is supposed to be turning.
Chapter 9: Troubleshooting User Console Version A3.53 1. Check the connected Axis Units for any abnormal indications. If all spindles appear to be affected, the problem may be a result of some common item. 2. If the problem appears to be a common fault, verify correct input power to the Axis Units. 3. Turn off the power. Verify that the homerun cables are in good condition and are properly connected to the Axis Unit and the tool. 4.
Chapter 9: Troubleshooting User Console Version A3.53 3. if the problem only affects a single spindle, perform an encoder test procedure as provided in Section 8.2.2. 4. If the encoder test identifies a problem, then exchange the tool, cables, and/or the Axis Unit until the cause of the problem is identified. 5. If the encoder test does not identify a problem, verify the Axis Unit input voltage and ensure that the power cable is properly connected. 6.
Chapter 9: Troubleshooting User Console Version A3.53 6. If problem still exists, replace the affected tool. (Refer to Section 8.3) 7. If problem still exists, replace the affected Axis Unit. (Refer to Section 8.3) 9.4.10 Preamp EEPROM Read Abnormal (Axis Unit display code "A3") Data error has been detected in the tool EEPROM information. 1.
Chapter 9: Troubleshooting User Console Version A3.53 9. Turn on the power. If problem still exists, replace the Multi PCB. (Refer to Section 8.3) 10. If problem still exists, replace the FC386 PCB. (Refer to Section 8.3) 11. If problem still exists, replace the entire Main Unit. (Refer to Section 8.3) 12. If the problem only affects a single spindle, remove an affected Axis Unit PCB and the Main Unit Multi PCB. Verify compatibility of software between the two (2) Units.
Chapter 9: Troubleshooting User Console Version A3.53 D5/input voltage abnormal (high) errors D6/input voltage abnormal (low) errors 1. Ensure that the Axis Unit is not located near any strong electrical or magnetic fields. 2. Verify Axis Unit input voltage and ensure that the power cable is properly connected. 3. If problem still exists, replace the affected Axis Unit. (Refer to Section 8.3) 9.4.
Chapter 9: Troubleshooting User Console Version A3.53 15. Ensure that the Main Unit and Axis Unit(s) are not located near any strong electrical or magnetic fields. 16. Verify the Axis Unit input voltage and ensure the power cable is properly connected. 17. Power on. If problem still exists, replace the affected Axis Unit. (Refer to Section 8.3) 9.4.
Chapter 9: Troubleshooting 9.5 User Console Version A3.53 Input Abnormal 9.5.1 Input Error Input data has been entered in the incorrect format. 1. Data will display, but will not update. Enter the data in the correct format. 9.5.2 Data Error Input data has been entered that is beyond the limits of the existing configuration. 1. Data will display, but will not update. Enter the data within acceptable limits.
Chapter 9: Troubleshooting 9.6 User Console Version A3.53 Axis Unit Abnormal codes 9.6.1 AXis Unit Control abnormals DISPLAY CODE DESCRIPTION A1 ZERO CAL CHECK Review the abnormal display on the system CRT to determine whether the Abnormal condition is from a "Zero Check Abnormal", ABNORMAL "Cal Check Abnormal", or "Full Scale Torque Over Abnormal". Refer to Section 9.4.1 for a Zero Check Abnormal. Refer to Section 9.4.2 for a Cal Check Abnormal. Refer to Section 9.4.
Chapter 9: Troubleshooting User Console Version A3.53 9.6.2 Axis Unit Servo Drive Abnormals DISPLAY CODE DESCRIPTION D0 ENCODER CONNEC- This abnormal occurs if tool encoder circuit is not properly TION ABNORMAL connected or working properly. Refer to Sections 9.4.5. and 9.4.8. D1 TOOL / SERVO MISMATCH If this abnormal occurs during power on, the tool type and servo (Axis Unit) type do not match. Refer to Section 9.4.8.
Chapter 9: Troubleshooting 9.7 User Console Version A3.
Chapter 9: Troubleshooting 9.8 User Console Version A3.53 AFC1200 Axis Unit Fastening Faults and Causes 9.8.1 Accept Conditions The Accept LED will light for the three following reasons: 1. The Reset input is active on either the front panel or via a PLC input, and the reset condition (Zero Level) of the transducer is within acceptable limits. 2. The Cal input is active on either the front panel or via a PLC input, and the calibration condition (Cal Level) of the transducer is within acceptable limits.
Chapter 9: Troubleshooting User Console Version A3.53 The Time Reject LED will light for the following reasons: 1. A red TIme Reject LED on the Axis Unit indicates a Final step Time Reject. 2. An orange TIme Reject LED on the Axis Unit indicates a 1st step TIme Reject. May cause a Low Torque Reject. CAUSES: 1. The amount of time specified on the Parameter Set screen is insufficient. 2. The socket did not engage the fastener properly. 3. The fastener did not engage the workpiece properly. 4.
Chapter 9: Troubleshooting User Console Version A3.
