Alarms.pdf

A l A r m s

Any time an alarm is present, the lower right hand corner of the screen will have a blinking “Alarm”. Push the

Alarm display key to view the current alarm. All alarms are displayed with a reference number and a complete

description. If the Reset key is pressed, one alarm will be removed from the list of alarms. If there are more

than 18 alarms, only the last 18 are displayed and the Reset must be used to see the rest. The presence of

any alarm will prevent the operator from starting a program.

The Alarms Display can be selected at any time by pressing the Alarm Mesgs button. When there are no

alarms, the display will show No Alarm. If there are any alarms, they will be listed with the most recent alarm

at the bottom of the list. The Cursor and Page Up and Page Down buttons can be used to move through a

large number of alarms. Cursor right and left buttons can be used to turn on and off the Alarm history display.

Note that tool changer alarms can be easily corrected by performing Umbrella ATCS Recovery. First, correct

any mechanical problem, press Reset until the alarms are clear, select Zero Ret mode, and select Auto All

Axes. Some messages are displayed while editing to tell the operator what is wrong, but these are not alarms.

The following alarm list shows alarm numbers, text displayed along with the alarm, and a detailed description

of the alarm, what can cause it, when it can happen, and how to correct it. If alarm numbers have different

meanings between lathes and mills, it is indicated with a (L) or a (M) directly after the alarm number or

wording to which the text pertains. (L) and (M) do not appear in the alarm numbers on the machine display.

101 COMM. FAILURE WITH MOCON/MOCON MEMORY FAULT - During self-test of communications

between MOCON and main processor, the main processor does not respond, and one of them is possibly

bad. Check cable connections and boards. Re-seat or replace ADDRESS and DATA bus cables. This may

also be caused by a memory fault detected on the MOCON. Check MOCON/PROCESSOR Status Lights.

Verify correct power to MOCON.

102 SERVOS OFF - Indicates that the servo motors are off, the tool changer is disabled, the coolant pump

is off, and the spindle motor is stopped. Caused by Emergency Stop, motor fault, or power failure. Will also

appear upon start up of machine as an informative alarm. Press RESET to power servos on.

103 X SERVO ERROR TOO LARGE - Load on X-axis Servomotor has exceeded parameter 9 X-axis Max

Error. Servos are turned off and you must push RESET to clear the alarm and turn on the servos. Dull cutting

tools or an incorrect program is exceeding the Max Load for this axis. Lathe: Servo brake on X axis motor

may not be disengaging. 24VDC is needed to release brake. Servo brake power is supplied from Trans/Brake

PCB P5/P9, or on I/O PCB P78/P79 when servos are powered on. Verify power to hydraulic card.

104 Y SERVO ERROR TOO LARGE - Load on Live Tool Servomotor has exceeded parameter 23 Y-axis Max

Error. Servos are turned off and you must push RESET to clear the alarm and turn on the servos. Dull cutting

tools or an incorrect program is exceeding the Max Load for this axis. Horizontal mill: Servo brake may not

be disengaging. 24VDC is needed to release brake. Power for servo brake is supplied from Trans/Brake PCB

P5/P9, or on I/O PCB P78/P79 when servos are powered on. Verify power to AMP +/- 12 325VDC Buss.

105 Z SERVO ERROR TOO LARGE - Load on Z-axis Servomotor has exceeded parameter 37 Z-axis Max

Error. Servos are turned off and you must push RESET to clear the alarm and turn on the servos. Dull cutting

tools or an incorrect program is exceeding the Max Load for this axis. Vertical mill: Servo brake may not be

disengaging. 24VDC is needed to release brake. Power for servo brake is supplied from Trans/Brake PCB

P5/P9, or on I/O PCB P78/P79 when servos are powered on. Verify power to AMP +/- 12 325VDC Buss.

106 A SERVO ERROR TOO LARGE - Load on the A-axis Servomotor has exceeded parameter 51 Z-axis

Max Error. The servos will be turned off and you must push RESET to clear the alarm and turn on the servos.

This is the Turret Index Servo; this alarm indicates that there is a problem with the Turret. The Turret may

have hit something while trying to index, or a mechanical problem that prevents normal movement may have

occurred. Verify power to AMP +/- 12 325VDC Buss.

Lathe: Turret may need motor coupling adjustment (See mechanical service manual for details). Turret may

have rotated before being completely unclamped. Check adjustment of Turret Locked/Unlocked switches.

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107 EMERGENCY OFF - Emergency Stop button was pressed. Servos are also turned off. After the E-Stop is

released, the Reset button must be pressed at least twice to correct this; once to clear the E-Stop alarm and

once to clear the Servo Off alarm. This alarm will also be generated if there is a low pressure condition in the

hydraulic counterbalance system. In this case, the alarm will not reset until the condition has been corrected.

108 X SERVO OVERLOAD - The load on the X-axis Servo motor has been exceeded. Adjust your program

to reduce the tool load placed on the X-axis. Lathe: Servo brake on X axis motor may not be disengaging.

24VDC is needed to release brake. Power for servo brake is supplied from Trans/Brake PCB P5/P9, or on I/O

PCB P78/P79 when servos are powered on. Verify power to AMP +/- 12 325VDC Buss.

109 Y SERVO OVERLOAD - The load on the Live Tool Servo motor has been exceeded. Adjust your program

to reduce the tool load placed on the Live Tool Servo. Horizontal mill: Servo brake may not be disengaging.

24VDC is needed to release brake. Power for servo brake is supplied from Trans/Brake PCB P5/P9, or on I/O

PCB P78/P79 when servos are powered on. Verify power to AMP +/- 12 325VDC Buss.

110 Z SERVO OVERLOAD - The load on the Z-axis Servo motor has been exceeded. Adjust your program

to reduce the tool load placed on the Z-axis. Vertical mill: Servo brake may not be disengaging. 24VDC is

needed to release brake. Power for servo brake is supplied from Trans/Brake PCB P5/P9, or on I/O PCB P78/

P79 when servos are powered on. Verify power to AMP +/- 12 325VDC Buss.

111 A SERVO OVERLOAD - Excessive load on A-axis servo. Something is obstructing the turret; this is an

indication that there is a problem with the Turret Index Servo. Vertical mill with rotary: Rotary brake system

may not be releasing. Test brake system by temporarily disconnecting supplied air to brake. Verify correct

rotary model is selected in setting 30. Verify rotary parameters are correct.

112 NO INTERRUPT - Electronics fault. Call your dealer. No communication between processor and Mocon.

Power failure can be veriied if Status LED on Mocon blinks four times at power up. Test +12 / -12 VDC to

Mocon PCB from LVPS.

113 (L) TURRET UNLOCK FAULT - The turret took longer to unlock and come to rotation position than

allowed for in Parameter 62. The value in Parameter 62 is in milliseconds. This may occur if the air pressure

is too low, the tool turret clamp switch is faulty or needs adjustment, or there is a mechanical problem.

113 (M) SHUTTLE IN FAULT - Tool changer is not completely to the right. During tool changer operation, the

tool in/out shuttle failed to get to the in position. Parameters 62 and 63 can adjust the time-out times. Verify

parameters 62 and 63 are set to Haas speciications. This alarm can be caused by anything that jams the

motion of the slide, the presence of a tool in the pocket facing the spindle, incorrect spindle orientation or a

loss of power to the tool changer. Check relays K9-K12 and fuse F1 on I/O PCB. Check the shuttle arm clutch

for wear. Check shuttle motor for rotation during tool change. Check motor brushes and test for power at

motor.

114 (L) TURRET LOCK FAULT - The turret took longer to lock and seat than allowed for in Parameter 63.

The value in Parameter 63 is in milliseconds. This may occur if the air pressure is too low, the tool turret

clamp switch is faulty or needs adjustment, or there is a mechanical problem. If the Turret has not rotated to

the correct position, the motor coupling may need adjustment. Debris between the male and female turret

couplings can prevent the turret from locking completely.

114 (M) SHUTTLE OUT FAULT - Tool changer is not completely to the left. During a tool changer operation

the tool in/out shuttle failed to get to the out position. Parameters 62 and 63 can adjust the time-out times.

Verify parameters 62 and 63 are set to Haas speciications. This alarm can be caused by anything that jams

the motion of the slide, the presence of a tool in the pocket facing the spindle (not when moving away from

the spindle), a loss of power to the tool changer. Check the shuttle arm clutch for wear. Check shuttle motor

for rotation during tool change. Check motor brushes and test for power at motor. Check relays K9-K12 on

and fuse F1 on I/O PCB.

Recover: Make sure shuttle is clear to move away from the spindle. Place something soft under the spindle to

catch a tool, which may fall. Press ZERO RET, then ALL to manually move shuttle to the left.

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115 (L) TURRET ROTATE FAULT - Tool motor not in position. During a tool changer operation the tool turret

failed to start moving or failed to stop at the right position. Parameters 62 and 63 can adjust the time-out

times. This alarm can be caused by anything that jams the rotation of the turret. A loss of power to the tool

changer can also cause this, so check CB5, relays 1-8, 2-3, and 2-4.

115 (M) TURRET ROTATE FAULT - Tool carousel motor not in position. During a tool changer operation, the

tool turret failed to start moving or failed to stop at the right position. Turret motor may have rotated too fast

or too slow, causing the turret to stop in an incorrect position. Parameters 60 and 61 can adjust the time-out

times. This alarm can be caused by anything that jams the rotation of the turret, or a loss of power to the tool

changer. Check relays K9-K12 and fuse F1 on I/O PCB. Check turret motor brushes.

116 SPINDLE ORIENTATION FAULT - Spindle did not orient correctly. During a spindle orientation function,

the spindle rotated but never achieved proper orientation. This can be caused by failure of encoder, cables,

belts, MOCON or vector drive. Parameter 257 Spindle Orient Offset may not be set correctly, causing

misalignment with toolchangers.

117 SPINDLE HIGH GEAR FAULT - Gearbox did not shift into high gear. During a change to high gear,

the spindle is rotated slowly while air pressure is used to move the gears but the high gear sensor was not

detected in time. Parameters 67, 70 and 75 can adjust the time-out times for troubleshooting only. Check the

air pressure, the circuit breaker CB4 for the solenoids, and the spindle drive. In Diagnostics, check the status

of discrete inputs Spindle Hi Gear and Spindle Low Gear. One bit should read 0, the other a 1, then the bits

should change status when a gear change has completed.

118 SPINDLE LOW GEAR FAULT - Gearbox did not shift into low gear. During a change to low gear, the

spindle is rotated slowly while air pressure is used to move the gears but the low gear sensor was not

detected in time. Parameters 67, 70 and 75 can adjust the time-out times for troubleshooting only. Check

the air pressure, the solenoid’s circuit breaker CB4, and the spindle drive. In Diagnostics, check the status

of discrete inputs Spindle Hi Gear and Spindle Low Gear. One bit should read 0, the other a 1, then the bits

should change status when a gear change has completed.

119 OVERVOLTAGE - Incoming line voltage is above maximum. The servos are turned off and the spindle,

tool changer, and coolant pump stop. If this condition persists, an automatic shutdown begins after the interval

speciied by Parameter 296. Under certain conditions, SMTC Recovery must be performed to clear the alarm.

Incorrect power or loss of power to MOCON can also cause this alarm. For ofice machines and all other

machines that use the 320V power supply, Parameter 315 bit 8 (Mini power supply) needs to be set to 1.

120 LOW AIR PRESSURE - Air pressure dropped below 80 psi for period deined by Parameter 76. The Low

Air PR alarm appears on the screen as soon as the pressure gets low, and this alarm appears after some

time has elapsed. Check your incoming air pressure for at least 100 psi and ensure that the regulator is set

at 85 psi. Test the I/O by jumpering pins 1 to 3 on P12 and watch diagnostics bit Low Air Press. Under certain

conditions, SMTC Recovery must be performed to clear the alarm.

121 LOW LUBE OR LOW PRESSURE - Way lube is low or empty or there is no lube pressure or too high a

pressure. Check tank at rear of machine and below control cabinet. Also check connector on the side of the

control cabinet. Check that the lube lines are not blocked. Test the lube pressure by manually operating the

pump by hand and watching the oil pressure gauge. With a full stroke of the pump, the pressure should read

35-40psi and should drop gradually to zero between 8-10 minutes. The pressure switch should also change

state when pump is cycled and its status can be viewed in diagnostics. Test the I/O by jumpering pins 1 to 2

on P13 and watch diagnostics.

122 REGEN OVERHEAT - The regenerative load temperature is above a safe limit. This alarm will turn off the

servos, spindle drive, coolant pump, and tool changer. One common cause of this overheat condition is an

input line voltage too high. If this condition persists, an automatic shutdown will begin after the interval speci-

ied by Parameter 297. It can also be caused by a high start/stop duty cycle of spindle.

123 SPINDLE DRIVE FAULT - Failure of spindle drive, motor or regen load. This can be caused by a shorted

motor, overvoltage, overcurrent, undervoltage, failure of drive or shorted or open regen load. Undervoltage

and overvoltage of DC bus are also reported as alarms 160 and 119, respectively.

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124 LOW BATTERY - Memory batteries need replacing within 30 days. This alarm is only generated at power

on and indicates that the 3.3V Lithium battery is below 2.5 volts. If this is not corrected within about 30 days,

you may lose your stored programs, parameters, offsets, and settings. Back up memory before replacing the

battery as follows: Mill version 15 software and Lathe version 8 or earlier: Go to the position page, type a ile

name, then press F2 to save parameters, offsets, and settings onto a loppy or USB device. Mill 16 and Lathe

9 or later: Go to List Programs, select the USB Device or NET drive tab, press F4, highlight Save All- Back

Up, and press Write/Enter.

125 (L) TOOL TURRET FAULT - Turret has not seated itself properly. There may be something obstructing

the turret between the housing and the turret itself.

125 (M) SHUTTLE FAULT - Tool shuttle not initialized at power on, Cycle Start, or spindle motion command.

This means that the tool shuttle was not fully retracted to the Out position. The shuttle In/Out switches may

not be functioning normally. This alarm can be caused by anything that jams the motion of the slide, a loss

of power to the tool changer. Check the shuttle arm clutch for wear. Check shuttle motor for rotation. Check

motor brushes and test for power at motor. Check relays K9-K12 on and fuse F1 on I/O PCB.

126 GEAR FAULT - Gearshifter is out of position when a command is given to start a program or rotate

the spindle. This means that the two speed gear box is not in either high or low gear but is somewhere in

between. Check the air pressure, the solenoid’s circuit breaker CB4, and the spindle drive. Use the Power Up/

Restart button to correct the problem.

127 (L) DOOR FAULT - The machine has detected a problem with the Auto Door. The door either did not

Close or Open as commanded. An obstruction or a faulty proximity switch can cause this.

127 (M) NO TURRET MARK - Tool carousel motor not in position. The Auto All Axes button will correct this,

but be sure afterwards that the pocket facing the spindle does not contain a tool. M39 can be used to com-

mand the turret to rotate if the pocket facing the spindle contains a tool.

128 (M) SUPER TRAVEL ENABLED ON MULTIPLE AXES - Two or more axes are enabled for super travel.

Only one axis is allowed super travel capability. Super travel is enabled when a tool change offset parameter

is greater than or less than normal travel limits. Check the Zero Axis TC, Max Travel, and Tool Change Offset

parameter values for the X and Y axes.

129 M FIN FAULT - M-Fin was active at power on. Check the wiring to your M code interfaces. This test is

only performed at power-on. Parameter 734 bit M-CODE FINISH may be inverted.

130 (L) CHUCK UNCLAMPED - The Cycle Start Button was push while the chuck was unclamped. Clamp

the Chuck and Re-Start the cycle. Check setting #92 for proper chuck clamping.

130 (M) TOOL UNCLAMPED - The tool appeared to be unclamped during spindle orientation, a gear change,

a speed change, or TSC start-up. The alarm is also generated if the tool release piston is energized during

Power Up. This can be caused by incorrect TRP switch function or adjustment, an air solenoid fault, relays on

the I/O assembly, draw bar assembly, or the wiring.

131 (M) TOOL NOT CLAMPED - When clamping or powering up the machine, the Tool Release Piston is

not Home. Check TRP switches for correct operation and adjustment. There is a possible fault in the air

solenoids, relays on the I/O Assembly, drawbar assembly, or wiring.

132 POWER DOWN FAILURE - Machine did not turn off when an automatic power-down was commanded.

Check wiring to Power Interface (POWIF) card on power supply assembly, relays on the I/O assembly, and

the main contact K1.

133 (L) SPINDLE BRAKE ENGAGED - The Spindle was commanded to start while the spindle was clamped

(M14) correct your part program (M15) to unclamp the spindle.

133 (M) SPINDLE INOPERATIVE - Spindle does not respond when spindle motion is commanded. This can

be caused by failure of encoder, cables, belts, MOCON, or vector drive.

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134 (L) LOW HYDRAULIC PRESSURE - Hydraulic pressure is sensed to be low or has not come up to

pressure within the time allowed in parameter 222. Check pump pressure and hydraulic tank oil level. Verify

proper pump and machine phasing. Also check 3-phase power phasing. Phase detector on power card should

have green light under PASS when machine is powered up.

134 (M) TOOL CLAMP FAULT - While unclamping, the tool did not release from spindle when commanded.

Check air pressure, solenoid circuit breaker CB4, and for maladjustment of the draw bar assembly.

135 X-AXIS MOTOR OVERHEAT - Servo motor overheat. The temperature sensor in the motor indicates

over 150° F (65° C). This can be caused by an extended overload of the motor; such as leaving the slide at

the stops for several minutes.

136 Y-AXIS MOTOR OVERHEAT - Servo motor overheat. The temperature sensor in the motor indicates

over 150° F (65° C). This can be caused by an extended overload of the motor; such as leaving the slide at

the stops for several minutes.

137 Z-AXIS MOTOR OVERHEAT - Servo motor overheat. The temperature sensor in the motor indicates

over 150° F (65° C). This can be caused by an extended overload of the motor; such as leaving the slide at

the stops for several minutes.

138 A-AXIS MOTOR OVERHEAT - Servo motor overheat. The temperature sensor in the motor indicates

over 150° F (65° C). This can be caused by an extended overload of the motor; such as leaving the slide at

the stops for several minutes. (Mill) Check parameter 43 bit OVER TEMP NC. Make sure the correct model

rotary has been selected in setting 30.

139 X-AXIS MOTOR Z FAULT - Encoder marker pulse count failure. This alarm usually means that the

encoder has been damaged and encoder position data is unreliable. It can also be caused by damaged motor

cable or a loose encoder cable connection on motor or encoder input on the Mocon PCB.

140 Y-AXIS MOTOR Z FAULT - Encoder marker pulse count failure. This alarm usually means that the

encoder has been damaged and encoder position data is unreliable. It can also be caused by damaged motor

cable or a loose encoder cable connection on motor or encoder input on the Mocon PCB.

141 Z-AXIS MOTOR Z FAULT - Encoder marker pulse count failure. This alarm usually means that the

encoder has been damaged and encoder position data is unreliable. It can also be caused by damaged motor

cable or a loose encoder cable connection on motor or encoder input on the Mocon PCB.

142 A-AXIS MOTOR Z FAULT - Encoder marker pulse count failure. This alarm usually means that the

encoder has been damaged and encoder position data is unreliable. It can also be caused by damaged motor

cable or a loose encoder cable connection on motor or encoder input on the Mocon PCB. (Mill) Check A-axis

cable connection on side of electrical cabinet.

143 (L) SPINDLE ORIENTATION LOST - Spindle orientation lost during a ine spindle control motion. This

can be caused by failure of encoder, cables, belts, MOCON, or vector drive. It can also be caused by failure

to orient spindle prior to G05, Fine Spindle Control Motion. Be sure to run M19 before G05.

143 (M) SPINDLE ORIENTATION LOST - Spindle orientation lost during a tool change operation. This can be

caused by failure of encoder, cables, belts, MOCON, or vector drive.

144 TIMEOUT - CALL YOUR DEALER - Time allocated for use prior to payment exceeded. Call your dealer.

145 X LIMIT SWITCH - Axis hit limit switch or switch disconnected. Home switch input changed state while

machine was in use. Stored stroke limits should stop the slides before they hit the limit switches. Verify the

value of Parameter 125, Grid Offset, and check the wiring to the limit switch. Can also be caused by a loose

encoder shaft at the back of the motor or coupling of motor to the screw. X limit switch may need replacement.

146 Y LIMIT SWITCH - Live Tooling hit limit switch or switch disconnected. Home switch input changed state

while machine was in use. Stored stroke limits should stop slides before they hit the limit switches. Verify the

value of Parameter 126, Grid Offset, and check the wiring to the limit switch. Can also be caused by a loose

encoder shaft at the back of the motor or coupling of motor to the screw. Y limit switch may need replacement.

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