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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. If problem still exists, replace the affected Axis Unit. (Refer to Section 8.3)

7. If problem still exists, replace the affected tool. (Refer to Section 8.3)

Note: Abnormal will not clear until the problem is corrected

D1 - Tool/Servo Mismatch

1. Verify the correct tool is being used for the application (Refer to Section 2.5).

2. Determine which Axis Unit type is required to operate the tool (Refer to Section 2.4).

3. Replace components as required.

Note: Abnormal will clear when when the tool and axis unit are properly matched.

D7 - overload

1. Check the SET PARAMETER screens and verify that the settings do not result in a Duty

Cycle higher than 50%, and that the resultant Cycle Time is not less than 12 seconds.

2. Check the connected Axis Units for any abnormal indications. If all spindles appear to be

affected, the problem is likely to be found in another System component.

3. If the problem appears to be a common fault, verify correct input power to the Axis Units.

4. If the problem only affects a single spindle, check the affected spindle for binding and

excessive prevailing torque. If either condition is found, isolate and correct the cause.

5. If no binding or excessive prevailing torque is found, verify correct Axis Unit input voltage

and ensure that the power cable is properly connected.

6. If problem still exists, replace the affected Axis Unit. (Refer to Section 8.3)

7. If problem still exists, replace the affected tool. (Refer to Section 8.3)

Note: Abnormal will clear after depressing the reset button.

9.4.9 Full Scale Torque Over Abnormal (Axis Unit display code "A1")

Measured torque exceeded Full Scale (Calibration) torque.

1. Verify that the tool is properly secured to the mounting plate, and that there are no signs of

stress or misalignment. Ensure that there is no tool movement while the self-check is

being performed.

2. Turn off the power.Verify that the homerun cables are in good condition and are properly

connected to the Axis Unit and the tool.

3. Ensure that the Axis Unit is not located near any strong electrical or magnetic fields.

4. Verify Axis Unit input voltage and ensure the power cables are properly connected.

5. 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.

Chapter 9: Troubleshooting User Console Version A3.53

Page 9-23