Trouble Shooting

FlexiCAM Support Info Date:

10.03.2001

Version:

1.0

Trouble Shooting (Servo System) Symptom

Error

Solution

E-Stop (after system has been turned on)

E-Stop-Button on keypad is pressed Servos and spindle are not enabled Servos do not have power

Release E-Stop button

E-Stop (while system is active)

Turn of the system, turn it back on and press the green enable button 1. Open the control box and leave it open 2. Check if all fuses are turned on 3. Turn on the power 4. Press the green enable button 5. Check if the servos are turning on 6. If the servo are not turning on check if all three phases have power 7. Check if the servo error relais K2-K5 (K2-K4 on a three axis system) are active 8. Check if the enabled relais K6 is active Ribbon cables from the computer Flip the ribbon cables: The cable labled 'A' or marked to the outbreak boards are flipped with a label go to outbreak board A and C, the other (like after replacing the controller) one goes to outbreak board B and D. If this does not help maybe you flipped the connectors at the computer: Either flip these connectors or exchange A vs. C and B vs. D. Servo I/O card inside the controller Check function of the controller card: is bad 1. Open the control box 2. Enable the servo drives 3. Connect a screen and keyboard to the computer 4. Terminate controller process on task 1 by CTRLC 5. Switch to second task by CTRL-2, press SPACE and login with 'root' 6. Start program 'encoder' 7. Check the limit switches by holding some metal in front and check the feedback on the screen 8. Move the axes by hand and check the encoder readout on the screen (Readout order is XA, Y, Z, XB) Gantry has a bind 1. Leave the control box open and turn the system back on 2. After homing the system check if the torque values displayed on the servo drives are high: Normaly they should be below 100 when the system is not moving. If the values on XA and XA are higher then 100 you need to stress relieve the gantry. Follow the guideline on the appropriate support info! 3. If another axis (X or Z) show high values check if the axis is blocked or some other mechanical problems have occured. 4. The Z axis may have get stuck on the bottom or top of the lead screw. 5. The Z axis lead screw may be too tight or too loose. Please check for the right adjustment.

Page 1 / 3 FlexiCAM GmbH • Technical Support • Benkertsweg 9 • D-97246 Eibelstadt • Germany Phone +49-(0)9303-9081-0 • Fax 990352 • Website http://www.FlexiCAM.de • EMail [email protected]

Cannot start homing (after starting the homing function)

Limit switch is active

System stalls

Check which axis should be homed Check if on the specific axes the limit switch(es) are active. If yes, move the axis off the limit position 1. Check function of LS: 2. Open the control box and turn on the system. 3. Check the limit switches from this specific axis by holding a screwdriver in front of the limit switch: The LED on the limit switch should turn off. 4. Next check on the Opto-I/O--Board in the control box if the LED are turning on/off. 5. In the worst case you can check on the controller by running the 'encoder' diagnostics program if the switches are feed back to the control system. Check the racks for chips and other obstacles

System has expired

Call FlexiCAM's technical support for assistance!

System has expired

Call FlexiCAM's technical support for assistance!

Backlash on a rack and pinion driven axes Dumb tool

Check and readjust the position of the planetary gear boxes Replace the cutting or engraving tool with a new one

Wrong direction

Check if the opposite side is better. If yes, invert the direction of the contour. 1. Use a shorter tool 2. Use a tool with a larger diameter 3. Insert it further into the collet Ensure that the material is not vibrating.

Limitswitch broken

Following Error (while homing or during a job) Switch to Demomode (while starting the system) Job does not start when pressing the F1 key Bad edge quality, especially no round arcs and circles

Tool is vibrating

Material is loose Clamp connection between motor and planetary gear box is loose Difference in depth

Z axis is loose

Check if you can move the axis manually while the servos are powered on and active. If yes, call FlexiCAM's technical support for assistance! Check the nut from the z leadscrew for backlash

Material is loose

Arcs are not tangential to each other; Inlays do not fit; Rounded contours are not round

Spindle error

Check the way of mounting the material: If you are using sheet material try to tape it down or hold it down by vacuum to ensure it is laying flat on the table surface. If you clamp it you risk that it will bend in the middle. Kp, Ki, Kv, Windup are wrong (e.g. Check the tuning parameters in /flexicam/controller.ini after a software update) Tuning parameters on the servo Check the tuning parameters at the servo amplifier amplifier are wrong (e.g. after a replacement) Decimalpoint from arc radius is Check the country settings in the Windows system replaced by a comma settings. In some countries which use a decimalcomma instead of a dezimalpoint (like Germany) this may cause problems in Scanvec's EnRoute. Make sure that there is a decimapoint used in the country settings. Spindle overload turned off (Q2) Turn on Q2 Spindle inverter drive shows an error

Note the error message / number. Reset the spindle inverter and continue. If the error occurs more often consult FlexiCAM's technical support for assistance. Most problems can be eliminated by using longer ramp times. (Re)install init files

Controller does not boot

The init files have been damaged (e.g. after an update) Floppy disk in disk drive

No Tool mounted

Machine function (like surface set) If there is a tool in the spindle release tool and return it started without tool in spindle to tool holder manual. After that load a tool by using the keypad.

Eject the floppy disk

Page 2 / 3 FlexiCAM GmbH • Technical Support • Benkertsweg 9 • D-97246 Eibelstadt • Germany Phone +49-(0)9303-9081-0 • Fax 990352 • Website http://www.FlexiCAM.de • EMail [email protected]

System takes a long time to boot; No 'Remote' folder in the job manager

No network server connection

1.

Check if the system is connected to the workstation or hub. 2. Check if you are using the right network cable: If you connect the system to the workstation directly, you have to use a crosslink cable. If you connect the system to a hub, you have to use a straight patch cable. 3. Maybe the network configuration was changed? Reconfigure the network server or workstation according to the Network Setup Support Info. 4. If the network server configuration was modified you may have to change the controller system as well to enable the system to connect to the server. 5. If you are using Windows it is necessary to unshare the jobfolder, reboot and re-share it in case you make modifications to the network configuration on the workstation. Cannot start surfacing Surfaceblock has a short curcuit to Isolate the surface block from ground ground Note: This may happen with older systems that use a plain aluminium surface block. If used e.g. on an aluminium plate that is clampled to the table via t-slot clamps you may face this error. Use some plastic to isolate the bottom of the surface block. After that readjust the thickness in /flexicam/flexicam.ini. Vacuum table does not hold down Workpiece is too small The t slot vacuum table does not allow very small material (T slot profiles with workpieces to be hold down by vacuum. Use t-clamps regenerative blower) instead of vacuum to ensure a proper holddown. Too much airflow Cover all areas that allow unnecessary airflow with some vinyl or similar material Chips between workpiece and Clean the vacuum table before use table allow too much airflow Too many grooves in the PVC Mill flat the PVC table top table top PVC table top material is new The PVC panel table top needs to be milled after replacing panels before the first time use Filter does not allow enough air Clean or replace the vacuum filter flow Vacuum table does not hold down Workpiece is too small The t slot vacuum table does not allow very small material (high pressure vacuum table) workpieces to be hold down by vacuum. Use a template instead or seal with gasket directly under the workpiece. Filter does not allow enough air Clean or replace the vacuum filter flow Vacuum table does not hold down Workpiece is too small The t slot vacuum table does not allow very small material when using MDF as sacrificial workpieces to be hold down by vacuum. Use a material (high pressure vacuum table) template instead or seal with gasket directly under the workpiece. Too much airflow Cover all areas that allow unnecessary airflow with some vinyl or similar material Chips between workpiece and Clean the MDF sheet before use MDF allow too much airflow Too many grooves in the MDF Mill flat or replace the MDF sheet sheet allow too much airflow Filter does not allow enough air Clean or replace the vacuum filter flow Pump too small Add another vacuum pump to the system for more volume

Page 3 / 3 FlexiCAM GmbH • Technical Support • Benkertsweg 9 • D-97246 Eibelstadt • Germany Phone +49-(0)9303-9081-0 • Fax 990352 • Website http://www.FlexiCAM.de • EMail [email protected]