MAINTENANCE MANUAL - Eurotech Sales Tools

MAINTENANCE
MANUAL
Preventive maintenance
Alarms and messages
CNC FANUC 18i-21i
Edition :
M.M. 03
Date :
01.09.01
Code: T140-00157
- M.M. 03 -
-2-
Officine E. BIGLIA & C. S.p.A.
Via Martiri della Libertà, N° 31
TEL.
FAX.
e.mail
Internet
:
:
:
:
-14045 INCISA SCAPACCINO (ASTI) ITALY-
01417831
0141783327
biglia@bigliaspa.it
www.bigliaspa.it
Registered office:
C.so Genova, 24 -20123 MILANO-
-3-
- M.M. 03 -
TABLE OF CONTENTS
1.
Technical and spare part service
-ITALY- ..........................................................
page 5
Technical and spare part service
-EUROPE and the rest of the world- ................
page 6
3.
Safety rules ......................................................
page 7
4.
Preventive maintenance ..................................
page 8
5.
Instructions for alarm identification ..................
page 18
6.
Alarm list ..........................................................
6.1 Detailed description of
alarms series "1000" .................................
page 19
Message list .....................................................
7.1 Detailed description of
messages series "2000" ...........................
page 37
page 39
8.
Biglia macro alarms .........................................
page 49
9.
Turrets and parts-catcher with electronic motor
unit alarms .......................................................
page 50
2.
7.
10. Batteries replacement ......................................
10.1 Procedure for CNC series "i" ...................
10.2 Procedures for driving units series “Beta”
(Turret) ......................................................
page 22
page 60
page 60
page 61
11. Power factor correction of the electric turret
to position one ..................................................
page 62
12. Power motion manager displaying ...................
12.1 Displaying for one turret ..........................
12.2 Displaying for several turrets ..................
page 65
page 65
page 66
13. Procedure for parameters setting ....................
page 68
Please carefully read this maintenance manual and follow the instructions and suggestions
therein, well aware that by doing this you improve reliability and productivity of your machine
substantially cutting down running costs.
Modifications
Date
Chapter
Paragraph
Description
01-07-00
01-09-00
1. 2. 3. 4.
4.
Chapters on preventive maintenance added
Routine maintenance timetable up-dated
01-09-01
01-09-01
6. 7. 8.
9.
Alarms and messages updated
Batteries replacement procedure added
- M.M. 03 -
-4-
To.
Officine E. BIGLIA &C S.p.A.
Spare parts service
SENDER
Fax : 0141 783227
e-mail : biglia@bigliaspa.it
ORDER NO.
DATED
For any queries please contact
or Purchase manager
Mr. :
We are hereby ordering spare parts for the machine identified herebelow:
MACHINE MODEL :
SERIAL NUMBER :
as detailed in the following list
Quantity
CODE
DESCRIPTION
Issue/Title
of Manual referred
to for part code
at the following conditions (subject to BIGLIA’s acceptance) :
- Shipping instructions
:………………………………………………………………………
- Delivery time
:………………………………………………………………………
- Payment conditions
:………………………………………………………………………
- Delivery to Messrs.
:………………………………………………………………………
(full address)
………………………………………………………………………
Your faithfully
date :…………………………Signature (in clear letters)…………………………………………
ORDER FORM
YEAR OF MANUFACTURE :
-5-
- M.M. 03 -
1.
TECHNICAL ASSISTANCE AND SPARE PART SERVICE
- ITALY-
1.1 Technical service
E.B.S. :
ELECTRONIC BIGLIA SERVICE s.r.l.
Via Martiri della Libertà N° 31 -14045 INCISA SCAPACCINO (ASTI) ITALY-
The company entrusted with the after-sale technical service to BIGLIA machine tools.
E.B.S. is the operative center where BIGLIA engineers are available every working day of
the week. It receives the first telephone call and supplies, whether directly or indirectly, any
intervention required to allow the user customer keep its lathe in good operating conditions.
The service is carried out by E.B.S. engineers only, every working day of the week.
Telephone call hours:
Morning : from 08.00 to 12.00
Afternoon : from 13.30 to 17.30
TEL
: 0141747025
FAX
: 0141783327
(3 lines with action finding)
1.2 Spare part service
Spare part service is ensured by BIGLIA engineers who are available on the phone every working
day of the week in the following hours:
Telephone call hours:
Morning : from 08.00 to 12.00
Afternoon : from 13.30 to 17.30
To order BIGLIA one or more spare parts :
-make a copy of and fill in the form of page 4 an send it by fax to
or send an e-mail to:
Officine E. BIGLIA & C. S.p.A.
-SPARE PARTS SERVICEFAX.
: 0141783327
e.mail :
biglia@bigliaspa.it
with the following data:
made by:
- MACHINE MODEL
Trademark of :
OFFICINE E. BIGLIA & C. S.p.A.
14045 INCISA SCAPACCINO - ITALY
- SERIAL NUMBER
Type
Serial No.
Year of manufacture
Weight Kg
- YEAR OF MANUFACTURE
taking them from the EC plate
- SPARE PART CODE AND NAME
- QUANTITY
- MANUAL ISSUE/TITLE
data taken from BIGLIA's Manuals
- SHIPPING INSTRUCTIONS
- DELIVERY TIME
- PAYMENT CONDITIONS
Our staff will contact you for any clarifications if required.
- M.M. 03 -
-6-
2.
TECHNICAL ASSISTANCE AND SPARE PART SERVICE
- EUROPE AND THE REST OF THE WORLD The service is ensured by the engineers of BIGLIA’s authorized dealers.
Every dealer keeps a store of the main spare parts and has a team of mechanical and electronic
engineers who regularly attend up-dating courses at BIGLIA’s.
Technicians and spare parts are proportional to the number of machines installed in the country.
In all cases BIGLIA ensures technical and spare part service to every user of CNC BIGLIA lathes.
- M.M. 03 -
3.
-7-
SAFETY RULES
BIGLIA’s lathes are designed and manufactured to guarantee maximum safety.
Nobody is allowed to touch to mechanical, electrical and electronic parts unless he has been duly trained
by specialized engineers, knows the current safety rules and has carefully read BIGLIA manuals.
The personnel entrusted with machine maintenance is identified as "MAINTENANCE
MAN".
The maintenance man, beside being professionally prepared for his task, must read the
manuals paying special attention to the safety rules and the chapters dealing with
maintenance.
Warning
Prior to carrying out any maintenance operation on a BIGLIA lathe, make sure electrical, hydraulic
and air supplies are cut off.
When carrying our visual checks on moving parts take care to stand clear of the moving part.
Since all components used on BIGLIA lathes are made to safety criteria and in compliance with
-EC- provisions they should not be removed without first consulting BIGLA "E.B.S." technical
service.
-8-
4.
- M.M. 03 -
PREVENTIVE MAINTENANCE
Accurate maintenance is important to maintain the lathe in ideal working conditions.
This is why BIGLIA recommends a number of general inspections, checks and routine maintenance
operations applicable to all BIGLIA lathe models.
Please do not consider recommended checks on parts or components your machine is not equipped with.
The Maintenance Tables below specify the item to check, how often to check it, and how to carry out the
check; specific accessories and equipment which are not part of the standard machine are not included
which does not mean they don’t need checks and inspections.
If during a preventive maintenance operation the need arises to repair or replace any components, these
should be repaired or replaced at once or within the shortest possible delay.
For your preventive maintenance to be easily done and effective carefully perform the operations
according to the Tables below.
-9-
- M.M. 02 -
DAILY
Grease chuck
Grease the jaws with special grease (about 5 grams to grease the three jaws).
Check oil level in the hydraulic station
Visual control.
Check pressure gauge on hydraulic station
Visual control.
Check for oil or coolant leaks
Visual control.
Check air circuit (by means of a pressure gauge)
Visual control.
Check oil level in the lubrication unit
Visual control.
Clean machine work area
Remove excess of accumulated swarfs particularly in the movable guards area.
- M.M. 02 -
- 10 -
EVERY 50 HOURS
Guide oil collecting pan
Empty the pan before exhausted oil fills it up.
N.B. : Recovered oil contains impurities do not use it in the guide lubrication unit to
avoid damaging the machine.
Clean sliding door rails
Remove any swarfs preventing door opening, grease upper guide as needed (do not use
compressed air to clean).
Electrical cabinet filter
Take down the filtering element and clean it using compressed air.
Replace if soaked with oil.
Oil leaks
check station, delivery pipes and solenoid valve bases.
Visual control.
Air pressure
check sliding valve, pressure gauge, pressure reducer and check for any leaks.
Visual control and manual operations.
Coolant or swarfs collecting container
Clean with the machine off (do not use compressed air to clean).
Check and replace guide covers
Clean and check the telescopic cover for unimpeded sliding.
If scraper ring lips are worn or damaged call for Technical service assistance.
Change oil in hydraulic station for axis lubrication
See “OPERATOR’S MANUAL”.
- 11 -
- M.M. 02 -
EVERY 500 HOURS
Motor spindle cooling
With machines equipped with motor spindle check coolant level in the radiator.
Clean off dust and impurities from radiator.
See “SPINDLE CHILLER MANUAL”.
Front door micro switch
Clean key and dowel, check for alignment, lightly grease the guide pin.
Travel end micro switch on hydraulic cylinder
Remove cover, clean, check for correct functioning; check micro switch cables for proper
fastening, functioning and good conditions.
Oil draining from chuck cylinder
Remove cover if necessary, make sure oil drains from the drain pipe and check this for
leaks.
With lathes fitted with a sub-spindle, carryout the same check on the sub-spindle.
Spindle motor belts
Check belts for tension and wear, remove any swarfs and clean off oil.
If there is oil on the belts there is a leak somewhere to look for; oil cuts down belt life.
Hydraulic chuck
Use the dynamometer provided to check that the clamping force of the chuck is actually
that recommended by the manufacturer.
Coolant tank
Take out and clean.
Tool coolant filter
Take down and clean the filter taking care not to spill any coolant on the floor.
N.B.: the 500 hour cleaning interval is given as a guide only and should be adjusted to
the type of material processed.
Clean air system filter
Drain through bleed tap (see “OPERATOR’S MANUAL”).
- M.M. 02 -
- 12 -
EVERY 500 HOURS
Operator’s panel functioning
Use individual controls to check all push-buttons, selector switches, hand-wheels, etc.
for correct operation. Check warning lights (bulbs and LEDs) (see “Operator’s Manual”).
Clean tank filter of guide lubrication oil
See “OPERATOR’S MANUAL”.
Clean or replace electrical cabinet filters
When the filter is soaked with oil replacement is recommended to allow a good transpiration of the panels which ensures a flow of fresh air to all electrical and electronic components.
Clean CNC’s and Operator’s keyboards
With the machine off, clean with a cloth soaked in alcohol.
Clean coolant radiator of the motor spindle
With the machine off, clean the cooling fins blowing compressed air (max. 8 atm.) through
them and outward.
- 13 -
- M.M. 02 -
EVERY 1000 HOURS
Swarf conveyor: cleaning and inspection
Remove any swarfs from the conveyor, inspect paddles, side chain links and guards/
sheets are not deformed or detached.
Make sure the safety micro is properly set and firmly fastened.
Cooling emulsion
Check water-oil ratio, check preservation of the emulsion and replace as needed.
Before pouring the new emulsion accurately clean the tank.
The life of the emulsion varies depending on the oil used and on the use.
Always consult your supplier.
Guide lubrication unit: general inspection
Check main delivery line and first distribution unit for leaks.
Clean oil infeed filter
Clean the see-through plastic container if there are deposits in it.
Guide guard
X and Z axes: remove any swarfs and grease.
B axis: take it off on the sub-spindle or tailstock side, clean and remove swarfs, then grease.
Machine leveling
This should be checked using the tools and following the procedure described in the
User’s Manual.
If the machine works with the feed bar, check the alignment also.
Turret geometry
Check alignment of tool holding-plate face, check concentricity of boring-bar bore with
spindle axis. (Carry out these checks on position No.1, with no tools mounted).
Turret with driven tools
Check for tension and wear; clean toothed belt.
Check noise when rotating.
Check positioning and fastening of belt presence micro switch.
Check drawing gear, spring cleanliness and elasticity.
Check for hydraulic oil leaks.
Noise when tools rotate
Grease bearings; if noise persists replace bearings.
Turret clearance
Check stiffness of turret clamping and relative clearance.
- M.M. 02 -
- 14 -
EVERY 1000 HOURS
Turret rotation
Check how fast and how uniform turret rotation is in both directions.
Spindle alignment with Z slide (for B1000 and B201/F models only)
This can be checked using a special BIGLIA device.
Spindle: general inspection
Check spindle nose for roundness and wobbling.
Check abnormal vibrations and noise when rotating at low, average and high speed.
Check sliding of piston controlling chuck clamping operation (use 6 bar pressure).
Carry out all the checks above on sub-spindle, too.
Check recirculating ball bearings and linear guides
Remove the covers through which bearings and linear guides can be visually inspected.
Thoroughly clean bearings, guides and sliding shoes sucking out swarfs as needed.
Check sliding shoe and bearing lubrication.
Check motor-bearing joint, too.
If possible check bearing noise and vibrations before mounting covers back in position.
Replace guide scraper ring
See “SPARE PARTS MANUAL”.
Axes limit switch
Clean off swarfs and coolant. Check wiring and electrical connector.
Check functioning.
Connectors of all axis, spindle and driven tool motors
First check cleanliness on the outside (if dirty disconnect and clean).
Then check fastening.
Chuck and gripper body
Take down and clean (follow the instructions of the clamping equipment manufacturer).
Hydraulic cylinder
Disassemble and clean, check functioning and oil leaks.
Hydraulic station
Disassemble and clean tank, replace filter.
- 15 -
- M.M. 02 -
EVERY 1000 HOURS
Overload relay
Check for efficiency.
Brake pad wear
Check C axis disc brake pads for wear, replace as needed.
A slightly worn brake disc does not impair good operation.
Hydraulic station heat exchanger
With the machine off, clean the cooling fins blowing compressed air (max. 8 atm.) through
them and outward.
Clean electrical cabinet inside
Clean with the machine completely off.
Clean cooling fans
With the machine off, take down the fans (if necessary) and clean them.
Check relays
Visual control in the electrical cabinet.
Hydraulic oil temperature
Check oil temperature placing a probe inside the hydraulic station
Max. recommended temperature around 50°C.
When oil temperature is constantly above 60° due to intensive work cycles or ambient
temperature, stop the machine and contact BIGLIA technical service (E.B.S.).
If after all necessary controls temperature remains above 60°, it will be your care to fit
the machine with an oil cooling system.
Speed change
Check oil level in the main spindle speed change.
Top up following the instructions of the manufacturer, as needed.
Cracks in or stiffness of flexible pipes
Carefully inspect all flexible and movable pipes for wear or cracks.
Electrical cables
Carefully check all movable electrical cables for wear or cracks.
- M.M. 02 -
- 16 -
EVERY 2000 HOURS
Gib adjustment
With machines equipped with flat guides, check reversing errors; if the clearance is too
large, adjust the tapered gib (contact E.B.S. Service).
Spindle encoder belt
Check for tension and wear, replace if worn out.
Driving belt for main spindle and sub-spindle
Check for tension and wear, replace if worn out.
Electrical cabinet air conditioning system
Check it works properly.
Check electrical cabinet’s air-conditioner or heat exchanger
Place a thermometer inside the cabinet, have a lathe work for about one hour, then check
the temperature inside the cabinet - this should not exceed 36°C.
This check is required when outside temperature is around 30°,
(at lower temperatures there is no need to carry out the check).
Cleaning of the labyrinth flange for spindle protection
Take off the clamping device from the spindle nose.
Take off the clamping device flanges, if required.
Take off the flange for spindle protection and clean it.
P.N. : do not use compressed air or coolant on the spindle nose.
EVERY 3000 HOURS
Motor fans
Take down motor fans and clean thoroughly.
Relays
Check a24V relays and replace them.
Feed bar
Check feed bar for leveling and alignment.
Hydraulic station
Change oil: for viscosity follow what prescribed in Biglia User’s Manual
- 17 -
- M.M. 02 -
EVERY YEAR
Batteries
When replacing batteries on the CN and on the ß motor drive turret use genuine FANUC
components.
See procedure described on next pages.
EVERY 5000 HOURS
Spindle bearings
Check bearings for noise, vibrations and temperature; replace as needed (contact E.B.S.
service).
EVERY 15000 HOURS
Sliding shoes and recirculating ball bearings
Check plays, reversing errors, noise and vibrations; replace the part as needed (contact
E.B.S. Service).
BIGLIA Turret
Carry out a general overhaul, replacing gaskets and any other worn part (contact E.B.S.
Service).
- M.M. 02 -
- 18 -
5.
INSTRUCTIONS FOR ALARM IDENTIFICATION
When "ALARM" is displayed on the CRT screen
•
if the alarm number is between 1000 and 1999
this means the alarm regards the machine
•
if the alarm number is between 2000 and 2999
this means a message covering the machine is displayed
•
For different alarms consult FANUC Operator’s Manual
appendix "G"
REMEDIES
•
check the type of alarm and clear it reading the instructions.
•
press RESET and start again.
•
if alarm is not cleared even pressing RESET, switch off the machine,
wait 10-15 sec., then switch on the machine and start again.
NOTE
The alarm message may be displayed on two different screen pages:
-- the first page is that of the alarm,
-- the second page that of the operator's message, that can be selected by means
of "SOFT" key.
In case of alarm, it is advisable to always check the page of operator's message.
- 19 -
+ +
ALARM LIST
TURRET ENCODER PARITY ERROR
1001
TURRET DRIVE ALARM
+ + + + + + + + +
1002
TOOL NOT FOUND
+ + + + + + + + +
1003
WRONG TOOL NUMBER
+ + + + + +
1004
DOOR MICROSWITCH INTEGRITY VERIFICATION
1004
PARTS-CATCHER DRIVE ALARM
+ + + + + + + + +
1005
TURRET UNLOCKED
+ + + + + + + + +
1007
MACHINE TOOL OFF
+ + + + + +
+ +
1008
BAR FEEDER ALARM
+ + + + + + + + +
1009
DEFECTIVE LUBRICATION
+ + + + + + + + +
1010
DOOR OPEN
+ + + + + + + + +
1011
HYDRAULIC UNIT THERMAL SWITCH
+ + + + + + + + +
1012
COOLANT PUMP THERMAL SWITCH
+ + + + + + + + +
1013
SWARF CONVEYOR THERMAL SWITCH
+ + + + + + + + +
1014
COLLET OPEN
+ + + + + + + + +
1015
SPINDLE ALARM
+ + + + + +
+ +
1016
TAILSTOCK OVERTRAVEL
+ + + + + +
+
1017
FUNCTION -M- NOT ENDED
1017
DEFECTIVE AIR PRESSURE
+ + + + + + + + +
1018
TOTAL MACHINED PARTS
+ + + + + + + + +
1021
LUBRICATION PRESSURE OPERATE CUT-OFF SWITCH DEFECTIVE
+ + + + +
+ +
1025
CYCLE TIME EXCEEDED
+ + + + + + + + +
1028
DRIVE THERMAL SWITCHES
+ + + + + + + + +
1030
HYDRAULIC PRESSURE LOW
1031
Y-AXIS UNLOCKED
1038
TAILSTOCK UNLOCKED
+ +
1040
COLLET QUILL OVERTRAVEL
+ + + + + +
1042
ALARM LIVE TOOLING
+
1043
SPEED CHANGE NOT OCCURRED
+
1047
SUB-SPINDLE ALARM
+
+
6.
1001
+ +
+ +
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
+
+
+ +
+
+
+
+
+ + + + + +
+
+ + + + + +
+
+ + +
- M.M. 03 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 20 -
+
+
1048
DOOR MICROSWITCH INTEGRITY VERIFICATION
1049
TOOL BELT BROKEN
1050
FUNCTION -M- NOT ENDED
1051
TURRET STROBE SIGNAL DEFECTIVE
1052
TOOL BELT BROKEN
+
1053
WANTED POSITION EXCEEDED
+ + + + + +
1056
LIVE TOOL NOT ORIENTED
1057
TAILSTOCK PRESSURE DEFECTIVE
1057
PARTS-CATCHER LIMIT SWITCH DEFECTIVE
1058
COLLET PRESSURE OUT-OF-RANGE
1059
COOLANT DEFECTIVE
1059
COLLET PRESSURE DEFECTIVE
1060
ELECTRICAL SPINDLE COOLING THERMAL SWITCHES
+ +
1060
LEFT COOLANT DEFECTIVE (HEAD 1)
+
1061
UNCLAMPED WORKPIECE
1061
ELECTRICAL SPINDLE COOLING ANOMALY
1062
B-AXIS NOT CORRECTLY POSITIONED
+
1063
PIECE NOT FOUND
+
1067
TURRET DRIVE ALARM
+
1068
AIR PRESSURE DEFECTIVE
1081
TURRET 2 DRIVE ALARM
+
1081
TURRET 2 ENCODER PARITY ERROR
+ +
1082
TURRET 2 TOOL NOT FOUND
+ +
1083
TURRET 2 WRONG TOOL NUMBER
+ +
1085
TURRET 2 UNLOCKED
+
1090
TURRET 2 DOOR OPEN
1094
SUB-SPINDLE COLLET OPEN
1094
HEAD 2 COLLET OPEN
1095
SUB-SPINDLE ALARM
1095
TURRET 2 SPINDLE ALARM
+ + +
+
+
+ +
+ +
+
+
+ +
+
+ +
+
+
+
+ + + + +
+
+ +
+
+
+ +
+
+ +
+
+
+
+
+
+
+
- 21 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
1098
HEAD 2 TOTAL MACHINED PARTS
+ +
1122
HEAD 2 LIVE TOOLING ALARM
+ +
1131
TURRET 2 STROBE SIGNAL DEFECTIVE
+
1132
HEAD 2 TOOL BELT BROKEN
+
1133
HEAD 2 WANTED POSITION EXCEEDED
+ +
1136
TURRET 2 LIVE TOOL NOT ORIENTED
+
1139
HEAD 2 COLLET PRESSURE DEFECTIVE
+
1139
SUB-SPINDLE COLLET PRESSURE DEFECTIVE
+ +
1140
HEAD 2 COOLANT DEFECTIVE
+
1141
HEAD 2 UNCLAMPED WORKPIECE
1141
SUB-SPINDLE UNCLAMPED WORKPIECE
+
- M.M. 03 -
+ +
+ +
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 22 -
+
6.1 Detailed description of alarms series "1000"
1001 TURRET ENCODER PARITY ERROR
Cause:
Effect:
Remedy:
Note:
+ +
+
+
Signals transmitted by turret sensors are not correct.
Cycle stops automatically in HOLD mode.
Turret has to be positioned again in MDI mode.
If trouble occurs again, contact BIGLIA Service (encoder may be faulty).
1001 TURRET DRIVE ALARM
Cause:
Effect:
Note:
+ + + + + + + + +
Alarm condition of the turret indexing drive, or a loss of parameters due to
battery defective.
Machine stopped with alarm on.
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
1002 TOOL NOT FOUND
Cause:
Tool change was not completed within 5 seconds (max. allowed time).
Effect:
AUTOMATIC cycle stops in HOLD.
Remedy: Check if turret can rotate without crashing against machine components.
Position turret again in MDI mode.
Note:
If trouble occurs again, contact BIGLIA Service (turret encoder and/or
turret limit-switch or indexing solenoid may be faulty).
+ + + + + + + + +
1003 WRONG TOOL NUMBER
Cause:
A wrong tool number has been entered (a T value higher than available
positions on tool-holding plate has been programmed).
Effect:
AUTOMATIC cycle stops
Remedy: Check if Technological Program contains any mistake.
+ + + + + +
+
1004 DOOR MICROSWITCH INTEGRITY VERIFICATION
Cause:
After switching off the electric equipment, when switching on again the
integrity of the "door closed" microswitch should be checked .
Effect:
Warning alarm.
Remedy: Close and re-open door.
Note:
If the alarm persists, this means that the ’door closed’ limit switch does not
work properly.
It does not close or is always closed.
- 23 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
1004 PARTS-CATCHER DRIVE ALARM
Cause:
Effect:
Note:
+ + + + + + + + +
Alarm condition of the partss-catcher drive, or a loss of parameters due to
battery defective.
Machine stopped with alarm on.
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
1005 TURRET UNLOCKED
Cause:
Turret is not locked properly.
Limit switch may be faulty or mechanical locking may be defective.
Effect:
AUTOMATIC cycle stops in HOLD.
Remedy: Position turret again in MDI mode (the first attempt is sometimes not
successful; try again and call T values which are distant from the present
position).
Nota:
If trouble occurs again, contact BIGLIA Service.
The alarm may appear together with "1002 tool not found".
+ + + + + + + + +
1007 MACHINE TOOL OFF
Cause:
Effect:
Remedy:
Note:
+ + + + + +
+ +
Machine auxiliary circuits are off.
Machine EMERGENCY.
Switch on auxiliary circuits by pressing push-button POWER ON.
If only alarm 1007 appears, it means that machine was switched off by an
operator (for instance) who has pressed the emergency push-button; if
this alarm appears together with another alarm, it means that a serious
fault caused machine switch off.
If the machine is equipped with bar-feeder, also the emergency pushbutton of it should be checked (insert the plug cap, if required).
1008 BAR-FEEDER ALARM
Cause:
Bar-feeder is faulty (ex.: insufficient oil pressure) or it is off.
Effect:
AUTOMATIC cycle stops.
Remedy: Check if bar-feeder is connected, if it works, and if it is preset to work in
automatic mode.
Note:
Since each type of bar-feeder has its own features, follow instructions
given by the manufacturer.
- M.M. 03 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 24 -
+ + + + + + + + +
1009 DEFECTIVE LUBRICATION
Cause:
Lubrication cycle has not occurred for one of the following reasons:
- in the tank of the lubrication unit oil level is too low,
- there is an oil leakage in the lubrication system,
- there is air in the lubrication system.
Effect:
AUTOMATIC cycle stops.
Remedy: Check oil level and, if necessary, fill up with suitable oil.
Find out and remove leakages; afterwards deaerate lubrication system
operating the pump manually.
If there is oil inside, check pump as well as pressure-operated cut-off
switch and float gauge.
+ + + + + + + + +
1010 DOOR OPEN
Cause:
Push-button CYCLE START has been pressed in AUTOMATIC mode
while sliding doors were open (operator side) (lathes without motor-driven
door).
Effect:
AUTOMATIC cycle stops.
Remedy: Close the doors.
Note:
This alarm appears also when the door is not correctly locked by magnet
when spindle rotates.
Check that safety tab enters the limit switch correctly, without forcing.
+ + + + + + + + +
1011 HYDRAULIC UNIT THERMAL SWITCH
Cause:
Thermal switch protecting oil pump motor has tripped.
Effect:
Machine EMERGENCY.
Remedy: Reset thermal switch (QF3) in the electrical cabinet.
Check if motor can rotate.
Check motor temperature.
+ + + + + + + + +
1012 COOLANT PUMP THERMAL SWITCH
Cause:
Effect:
Remedy:
Note:
Thermal switch protecting coolant pump has tripped.
AUTOMATIC cycle stops.
Reset thermal switch (QF4) in the electrical cabinet.
If the lathe is equipped with an additional pump, check thermal switch
of this pump too (QF9).
- 25 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+ + + + + + + + +
1013 SWARF CONVEYOR THERMAL SWITCH
Cause:
Thermal switch protecting swarf conveyor motor has tripped.
Effect:
AUTOMATIC cycle stops.
Remedy: Reset thermal switch (QF5 or QF10) in the electrical cabinet.
Mechanically unlock conveyor (remove swarfs or mechanical parts).
+ + + + + + + + +
1014 COLLET OPEN
Cause:
Effect:
Remedy:
Note:
+ + + + + + + + +
The operator has tried to make spindle rotate while collet or jaws were open.
AUTOMATIC cycle stops.
Close the collet or the jaws.
It can sometimes be necessary to allow spindle rotation while workpiece
is not clamped; this is possible entering the command M24 (collet opening)
in MDI mode before starting spindle rotation.
1015 SPINDLE DRIVE ALARM
Cause:
Spindle drive does not work properly.
Effect:
AUTOMATIC cycle stops.
Remedy: Without switching off the machine main breaker, open the electrical
cabinet (while pressing push-button DOOR UNLOCKED) and read alarm
code (i.e. AL12) on module display.
For further information, check FANUC manual relevant to drives.
To clear this alarm, switch off the machine by means of main circuit breaker
wait about 15 seconds before switching on again.
Note:
If trouble occurs again, contact BIGLIA Service.
+ + + + + +
+ +
1016 TAILSTOCK OVERTRAVEL
Cause:
Tailstock has overcome its normal “forward” position and it has reached
the limit-switch; this can depend on a wrong workpiece loading or on a too
short component.
Effect:
AUTOMATIC cycle stops.
Remedy: Check tailstock and workpiece length; if trouble occurs without reason, put
overtravel limit-switch on a different position.
Note:
Only some types of tailstock are fitted with this additional safety device.
- M.M. 03 -
+ + + + + +
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 26 -
+
1017 FUNCTION -M- NOT ENDED
Cause:
A function -M- is not ended within a stated period of time.
Effect:
AUTOMATIC cycle stops with alarm on.
Remedy: Check if the commanded function is waiting for a response from a limit
switch which is probably not operated.
The commanded function is not carried out because the actuator dos not
work.
+ +
1017 DEFECTIVE AIR PRESSURE
Cause:
Air pressure is low with respect to the pressure-operated cut-off switch
calibration value.
Effect:
Automatic cycle stops in HOLD.
Remedy: Check pressure in the pneumatic installation and adjust pressure-operated
cut-off switch, if required.
+ + + + + + + + +
1018 TOTAL MACHINED PARTS
Cause:
Effect:
Remedy:
Note:
+ + + + + + + + +
The number of required parts has been achieved.
Cycle stops on M90 block.
Reset and bring parts-counter to zero.
If this function is not required, enter 0 on parts required.
1021 LUBRICATION PRESSURE OPERATED CUT-OFF SWITCH DEFECTIVE
Cause:
Lubrication system is always under pressure, or pressure operated
cut-off switch is faulty.
Defective lubrication.
Effect:
Automatic cycle stops in HOLD.
Remedy: Replace pressure operated cut-off switch .
Check discharge valves fitted inside lubrication unit pump.
+ + + + +
+ +
1025 CYCLE TIME EXCEEDED
Cause:
The pre-set cycle time was exceeded.
Effect:
Automatic cycle stops in HOLD.
Remedy: Place selectors S and F to 100%. Increase pre-set time.
Machine stopped waiting for a signal from an external actuator.
+ + + + + + + + +
1028 DRIVE THERMAL SWITCHES
Cause:
One of the thermal switches protecting drive electronics or motor fans has
tripped.
Effect:
Machine stops in HOLD mode.
Remedy: Reset thermal switches (QF301-302-303-304).
- 27 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+ + + + + + + + +
1030 HYDRAULIC PRESSURE LOW
Cause:
Oil pressure is too low compared to pressure-operated switch adjustment.
Effect:
Machine stops in HOLD mode.
Remedy: Check on the gauge the hydraulic system general pressure.
Check there are not oil leakages.
Check the correct operation of the pump intake filter.
Check the calibration of pressure-operated switch SP14.
+
1031 Y-AXIS UNLOCKED
Cause:
Anomaly during Y-axis locking (controlled by a pressure-operated switch).
Effect:
Machine stops with alarm on.
Remedy: Check integrity of pipes, calibration of pressure-operated switch, correct
operation of the locking gearcase.
+
+
+
1038 TAILSTOCK UNLOCKED
Cause:
The operator has tried to make spindle rotate even if workpiece is not
clamped by tailstock.
This alarm appears only when workpiece clamping by tailstock is preset (third item of Operator’s Panel on "AVIAM"=ON -pedal activated on
tailstock).
Effect:
AUTOMATIC cycle stops.
Remedy: Move tailstock forward and adjust limit-switch.
Note:
In the B1000 fitted with tailstock for traverse movement, this alarm appears
while actuating tailstock forward movement with the support not locked on
slides.
Check clamping pressure in MDI mode, enter M50 and check the pressureoperated cut-off switch SP13.
+ + + + + +
+ +
1040 COLLET QUILL OVERTRAVEL
Cause:
Collet or chuck jaws have overcome the normal clamping position and
hydraulic cylinder has reached overtravel limit switch: it can depend on a
wrong loading or on a too small workpiece diameter.
Effect:
AUTOMATIC cycle stops.
Remedy: Check workpiece diameter; if trouble occurs without reason, position quill
limit switch on a different position.
Note:
Only some machine types are fitted with this additional safety device when
the fourth item of Operator’s Panel “COLLET LS” is on ON-AVIAM.
- M.M. 03 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 28 -
+ + + + + +
1042 ALARM LIVE TOOLING
Cause:
Motor drive does not work properly.
Effect:
AUTOMATIC cycle stops.
Remedy: Without switching off the machine main breaker, open the electrical
cabinet (while pressing push-button DOOR UNLOCKED) and read alarm
code (i.e. AL12) on module display.
For further information, check FANUC manual relevant to drives.
To clear this alarm, switch off the machine by means of main circuit breaker
wait about 15 seconds before switching on again.
Note:
If trouble occurs again, contact BIGLIA Service.
+ + + + + +
+
1043 SPEED CHANGE NOT OCCURRED
Cause:
Effect:
Remedy:
Note:
+
+ + +
+
Spindle speed change took more than 10 sec. (max. allowed time).
AUTOMATIC cycle stops.
Repeat speed change in MDI mode.
If the fault occurs again, contact BIGLIA Service (a limit switch of gearchange may be faulty or gears motor may be defective).
1047 SUB-SPINDLE ALARM
Cause:
Sub-spindle drive does not work properly.
Effect:
AUTOMATIC cycle stops.
Remedy: Without switching off the machine main breaker, open the electrical
cabinet (while pressing push-button DOOR UNLOCKED) and read alarm
code (i.e. AL12) on module display.
For further information, check FANUC manual relevant to drives.
To clear this alarm, switch off the machine by means of main circuit breaker
wait about 15 seconds before switching on again.
Note:
If trouble occurs again, contact BIGLIA Service.
+
1048 DOOR MICROSWITCH INTEGRITY VERIFICATION
Cause:
After switching off the electric equipment, when switching on again the
integrity of the "door closed" microswitch should be checked .
Effect:
Warning alarm.
Remedy: Close and re-open door.
Note:
If the alarm persists, this means that the ’door closed’ limit switch does not
work properly.
It does not close or is always closed.
- 29 -
+
+ + +
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
+
+ +
+ +
1050 FUNCTION -M- NOT ENDED
Cause:
A function -M- is not ended within a stated period of time.
Effect:
AUTOMATIC cycle stops with alarm on.
Remedy: Check if the commanded function is waiting for a response from a limit
switch which is probably not operated.
The commanded function is not carried out because the actuator dos not
work.
+
+
+ +
+ +
1049 TOOL BELT BROKEN
Cause:
During driven tool rotation sensor has detected the transmission belt
breakage.
Effect:
Machine stops with alarm on.
Remedy: Check belt condition.
Check sensor operation and adjust, if required.
Note:
Check that the pre-set rotation revolutions are not lower than 50.
1051 TURRET STROBE SIGNAL DEFECTIVE
Cause:
During turret rotation, the encoder signalling the positions failed.
Effect:
Machine stops with alarm on.
Remedy: Try calling other positions and, if the alarm repeats, check and replace
turret encoder.
Note:
Turret positions and strobe signal may be checked with the diagnostic
analysis at the corresponding address as shown in the wiring diagram.
1052 TOOL BELT BROKEN
Cause:
During driven tool rotation sensor has detected the transmission belt
breakage.
Effect:
Machine stops with alarm on.
Remedy: Check belt condition.
Check sensor operation and adjust, if required.
Note:
Check that the pre-set rotation revolutions are not lower than 50.
+
1053 WANTED POSITION EXCEEDED
Cause:
During turret positioning to a called station, the position was passed.
This may be caused by excessive rotation speed or by encoder failure.
Effect:
Machine stops with alarm on.
Remedy: Reduce rotation speed by reducing pressure.
Replace the encoder.
Note:
Turret positions and strobe signal may be checked with the diagnostic
analysis at the corresponding address as shown in the wiring diagram.
If trouble occurs again, replace turret encoder.
- M.M. 03 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 30 -
+ + + + + +
+
1056 LIVE TOOL NOT ORIENTED
Cause:
Turret rotation has been commanded with driven tools not properly
oriented.
The oriented tool limit switch is not properly oriented or does not work.
Effect:
Machine stops in HOLD mode.
Remedy: Select MDI, command M75 and try again.
Check the oriented tool limit switch.
1057 TAILSTOCK CLAMP PRESSURE DEFECTIVE
Cause:
Tailstock pressure is lower with respect to the value previously set on the
pressure-operated cut-off switch.
Effect:
Machine stops with alarm on.
Remedy: Check tailstock pressure adjust it, if required.
Set the pressure-operated cut-off switch.
+
1057 PARTS-CATCHER LIMIT SWITCH DEFECTIVE
Cause:
During command function of a parts-catcher move, both limit switches
were simultaneously engaged, e.g.: forward/backward or up/down pressed
together.
Effect:
Machine stops with alarm on.
Remedy: Check limit switches.
+
1058 COLLET PRESSURE OUT-OF-RANGE
Cause:
During programming the collet pressure has been set at a value out of the
permissible range, specified by a parameter.
Effect:
Machine stops with alarm on.
Remedy: Reset and set a value within the admissible range.
+ + + + +
+
+ +
1059 COOLANT DEFECTIVE
Cause:
During coolant pump working, coolant feeding to tool stopped.
Coolant lacking, filter clogged, pump does not work, a pipe broke or is
clogged.
Effect:
Machine stops with alarm on.
Remedy: Check coolant presence in the tank, coolant filter condition, integrity of
pipes.
1059 COLLET PRESSURE DEFECTIVE
Cause:
Pressure in the cylinder which commands collet closing is too low.
Effect:
Machine stops in HOLD mode.
Remedy: Check collet pressure gauge and calibration of the pressure-operated
cut-off switch fitted on the hydraulic installation.
- 31 -
+
+ +
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
1060 ELECTRICAL SPINDLE COOLING THERMAL SWITCHES
Cause:
Intervention of the thermal switch protecting the cooling unit of the
electrical spindle.
Effect:
Machine stops with alarm on.
Remedy: Check current absorption of the refrigerator and restore thermal switch.
+
+
1060 LEFT COOLANT DEFECTIVE (HEAD 1)
Cause:
During coolant pump working, coolant feeding to tool stopped.
Coolant lacking, filter clogged, pump does not work, a pipe broke or is
clogged.
Effect:
Machine stops with alarm on.
Remedy: Check coolant presence in the tank, coolant filter condition, integrity of
pipes.
+
1061 UNCLAMPED WORKPIECE
Cause:
Collet or chuck jaws have overcome the normal clamping position and
hydraulic cylinder has reached overtravel limit switch: it can depend on a
wrong loading or on a too small workpiece diameter.
Effect:
AUTOMATIC cycle stops.
Remedy: Check workpiece diameter; if trouble occurs without reason, position quill
limit witch on a different position.
Note:
Only some machine types are fitted with this additional safety device, when
the fourth item of Operator’s Panel “COLLET LS” is on ON-AVIAM.
+
+ +
+
1061 ELECTRICAL SPINDLE COOLING ANOMALY
Cause:
Cause:
Note:
+
Incorrect operation of the electrical spindle cooling unit.
Check the coolant level in the tank and top up, if required.
Check there is no clogging.
Consult the cooling unit manual given.
1062 B-AXIS NOT CORRECTLY POSITIONED
Cause:
The operator tried to move sub-spindle forward (in-line) or backward
(misaligned) or to lower the parts-catcher when B-axis is not in position
(B0 / B-200).
Effect:
AUTOMATIC cycle stops - Sub-spindle does not move.
Remedy: Position sub-spindle at a value between B0 and B-200.
- M.M. 03 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 32 -
+
1063 PIECE NOT FOUND
Cause:
During lifting a piece by B-axis with function M201 ON, the piece to be lifted
was not in the foreseen position.
Remedy: Check piece length or if it has moved away from its position.
+
1067 TURRET DRIVE ALARM
Cause:
Effect:
Note:
+
Alarm condition of the turret indexing drive, or a loss of parameters due to
battery defective.
Machine stopped with alarm on.
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
1068 AIR PRESSURE DEFECTIVE
Cause:
Air pressure is low with respect to the pressure-operated cut-off switch
calibration value.
Effect:
Automatic cycle stops in HOLD.
Remedy: Check pressure in the pneumatic installation and adjust pressure-operated
cut-off switch, if required.
+
1081 TURRET 2 DRIVE ALARM
Cause:
Effect:
Note:
+
1081 TURRET 2 ENCODER PARITY ERROR
Cause:
Effect:
Remedy:
Note:
+ +
Alarm condition of the turret (head 2) indexing drive, or a loss of parameters due to battery defective.
Machine stopped with alarm on.
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
Signals transmitted by turret internal sensors are not correct.
Cycle stops automatically in HOLD mode.
Turret has to be positioned again in MDI mode.
If trouble occurs again, contact BIGLIA Service (encoder may be faulty).
1082 TURRET 2 TOOL NOT FOUND
Cause:
Tool change was not completed within 5 seconds (max. allowed time)
Effect:
Automatic cycle stops in HOLD mode.
Remedy: Check if turret can rotate without crashing against machine components.
Position turret again in MDI mode.
Note:
If trouble occurs again, contact BIGLIA Service (turret encoder and/or
turret limit-switch or indexing solenoid may be faulty).
- 33 -
+ +
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
1083 TURRET 2 WRONG TOOL NUMBER
Cause:
A wrong tool number has been entered (a T value higher than available
positions on tool-holding plate has been programmed).
Effect:
AUTOMATIC cycle stops.
Remedy: Check if Technological Program contains any mistake.
+ +
1085 TURRET 2 UNLOCKED
Cause:
Turret is not locked properly.
Limit switch may be faulty or mechanical locking may be defective.
Effect:
Automatic cycle stops in HOLD mode.
Remedy: Position turret again in MDI mode (the first attempt is sometimes not
successful; try again and call T values which are distant from the present
position).
Note:
If trouble occurs again, contact BIGLIA Service.
The alarm may appear together with "1002 tool not found".
+
1090 TURRET 2 DOOR OPEN
Cause:
Push-button CYCLE START has been pressed in AUTOMATIC mode
while sliding doors were open (operator side) (lathes without motordriven door).
Effect:
AUTOMATIC cycle stops.
Remedy: Close the doors.
Note:
This alarm appears also when the door is not correctly locked by magnet
when spindle rotates.
Check that safety tab enters the limit switch correctly, without forcing.
+
1094 SUB-SPINDLE COLLET OPEN
Causa:
Effect:
Remedy:
Note:
+
The operator has tried to make spindle rotate while collet or jaws were open.
AUTOMATIC cycle stops.
Close the collet or the jaws.
It can sometimes be necessary to allow spindle rotation while workpiece
is not clamped; this is possible entering the command M53 (collet
opening) in MDI mode before starting spindle rotation.
1094 1094 HEAD 2 COLLET OPEN
Cause:
Effect:
Remedy:
Note:
The operator has tried to make spindle rotate while collet or jaws were open.
AUTOMATIC cycle stops.
Close the collet or the jaws.
It can sometimes be necessary to allow spindle rotation while workpiece
is not clamped; this is possible entering the command M24 (collet opening)
in MDI mode before starting spindle rotation.
- M.M. 03 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 34 -
1095 SUB-SPINDLE ALARM
Cause:
Sub-spindle drive does not work properly.
Effect:
AUTOMATIC cycle stops.
Remedy: Without switching off the machine main breaker, open the electrical
cabinet (while pressing push- button DOOR UNLOCKED) and read
alarm code (i.e. AL12) on module display.
For further information, check FANUC manual relevant to drives..
To clear this alarm, switch off the machine by means of main circuit
breaker; wait about 15 seconds before switching on again.
Note:
If trouble occurs again, contact BIGLIA Service.
+
1095 TURRET 2 SPINDLE ALARM
Cause:
Spindle drive does not work properly.
Effect:
AUTOMATIC cycle stops.
Remedy: Without switching off the machine main breaker, open the electrical
cabinet (while pressing push- button DOOR UNLOCKED) and read
alarm code (i.e. AL12) on module display.
For further information, check FANUC manual relevant to drives.
To clear this alarm, switch off the machine by means of main circuit
breaker; wait about 15 seconds before switching on again.
Note:
If trouble occurs again, contact BIGLIA Service.
+
1098 HEAD 2 TOTAL MACHINED PARTS
Cause:
The number of required parts has been achieved.
Effect:
Cycle stops on M90 block.
Remedy: Reset and bring parts-counter to zero; if this function is not required, enter
zero on parts required.
+ +
1122 HEAD 2 LIVE TOOLING ALARM
Cause:
Motor drive does not work properly.
Effect:
AUTOMATIC cycle stops.
Remedy: Without switching off the machine main breaker, open the electrical
cabinet (while pressing push- button DOOR UNLOCKED) and read
alarm code (i.e. AL12) on module display.
For further information, check FANUC manual relevant to drives.
To clear this alarm, switch off the machine by means of main circuit
breaker; wait about 15 seconds before switching on again.
Note:
If trouble occurs again, contact BIGLIA Service.
- 35 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
1131 TURRET 2 STROBE SIGNAL DEFECTIVE
Cause:
During turret rotation, the encoder signalling the positions failed.
Effect:
Machine stops with alarm on.
Remedy: Try calling other positions and, if the alarm repeats, check and replace
turret encoder.
Note:
Turret positions and strobe signal may be checked with the diagnostic
analysis at the corresponding address as shown in the wiring diagram.
+
1132 TOOL BELT BROKEN (HEAD 2)
Causa:
During driven tool rotation (head 2) sensor has detected the transmission
belt breakage.
Effect:
Machine stops with alarm on.
Remedy: Check belt condition.
Check sensor operation and adjust, if required.
Note:
Check that the pre-set rotation revolutions are not lower than 50.
+
1133 HEAD 2 WANTED POSITION EXCEEDED
Cause:
During turret positioning to a called station, the position was passed.
This may be caused by excessive rotation speed or by encoder failure.
Effect:
Machine stops with alarm on.
Remedy: Reduce rotation speed by reducing pressure.
Replace the encoder.
Note:
Turret positions and strobe signal may be checked with the diagnostic
analysis at the corresponding address as shown in the wiring diagram.
If trouble occurs again, replace turret encoder.
+ +
1136 TURRET 2 LIVE TOOL NOT ORIENTED
Cause:
Turret rotation has been commanded with driven tools not properly
oriented.
The oriented tool limit switch is not properly oriented or does not work.
Effect:
Machine stops in HOLD mode.
Remedy: Select MDI, command M75 and try again.
Check the oriented tool limit switch.
+
1139 HEAD 2 COLLET PRESSURE DEFECTIVE
Cause:
Pressure in the cylinder which commands collet closing is too low.
Effect:
Machine stops in HOLD mode.
Remedy: Check the pressure-operated cut-off switch fitted on the hydraulic installation of the section related to Sub-spindle.
- M.M. 03 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 36 -
1139 SUB-SPINDLE COLLET PRESSURE DEFECTIVE
Cause:
Pressure in the cylinder which commands collet closing is too low.
Effect:
Machine stops in HOLD mode.
Remedy: Check the pressure-operated cut-off switch fitted on the hydraulic installation of the section related to Sub-spindle.
+ +
1140 HEAD 2 COOLANT DEFECTIVE
Cause:
During coolant pump working, coolant feeding to tool stopped.
Coolant lacking, filter clogged, pump does not work, a pipe broke or is
clogged.
Effect:
Machine stops with alarm on.
Remedy: Check coolant presence in the tank, coolant filter condition, integrity of
pipes.
+
1141 HEAD 2 UNCLAMPED WORKPIECE
Cause:
Collet or chuck jaws have overcome the normal clamping position and
hydraulic cylinder has reached overtravel limit switch: it can depend on a
wrong loading or on a too small workpiece diameter.
Effect:
AUTOMATIC cycle stops.
Remedy: Check workpiece diameter; if trouble occurs without reason, position quill
limit witch on a different position.
Note:
Only some machine types are fitted with this additional safety device, when
the fourth item of Operator’s Panel “COLLET LS” is on ON-AVIAM.
+
1141 SUB-SPINDLE UNCLAMPED WORKPIECE
Cause:
Collet or chuck jaws have overcome the normal clamping position and
hydraulic cylinder has reached overtravel limit switch: it can depend on a
wrong loading or on a too small workpiece diameter.
Effect:
AUTOMATIC cycle stops.
Remedy: Check workpiece diameter; if trouble occurs without reason, position quill
limit witch on a different position.
Note:
Only some machine types are fitted with this additional safety device, when
the fourth item of Operator’s Panel “COLLET LS” is on ON-AVIAM.
- 37 -
+ +
MESSAGE LIST
TURRET NOT POSITIONED
2000
TURRET 1 DRIVE BATTERY LOW
+ + + + + + + + +
2006
TURRET UNLOCKED
+ + + + + + + + +
2019
TOOL-SETTING ARM DOWN
+ + + + + + + + +
2020
SPINDLE ROTATION
+ +
2022
LIMIT. 1 AXIS ... TOOL N. ...
+ +
2023
LIMIT. 2 AXIS ... TOOL N. ...
2024
TOOL LIFE END
2025
CYCLE TIME EXCEEDED
2026
AUTOCUTOFF
2027
B-AXIS TORQUE LIMIT EXCEEDED
2027
Z-AXIS TORQUE LIMIT EXCEEDED
2029
END OF TOOL GROUPS
+
2031
TURRET POSITION NUMBER NOT SET
+ +
2032
END OF BAR
+ + + + + + + + +
2033
AXES RESET
+ + + + + + + + +
2034
COLLET OPEN
+
+
+
2035
PEDAL ENABLE ON COLLET
+
+
+
2036
PEDAL ENABLE ON TAILSTOCK
+ + + + + + + + +
2037
BATTERY LOW
+ + + + + + + + +
2039
ZERO REFERENCE LIMIT SWITCH DEFECTIVE
+ + + + + + + + +
2041
SPINDLE LOCKED
+ + + + + + + + +
2044
DRY RUN
+ + + + + + + + +
2045
SWARF CONVEYOR BLOCKED
+ + + + + + + + +
2046
PARTS-CATCHER ALARM
+
2048
AXES X+ / Y OVERTRAVEL
+
2050
AXES X_ / Y OVERTRAVEL
+
2052
TURRET STROBE SIGNAL =0
+ + + + + + + + +
2054
PRESS RESET PUSH-BUTTON
+ + + + + + + + +
2055
LUBRICATING OIL LEVEL LOW
+
+
7.
2000
+ +
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
+ + + + + + + + +
+ +
+ + + + + + + + +
+
+ +
+ +
+
+ + + + + + + + +
+ +
+ +
+ + + + + +
+ +
+ +
- M.M. 03 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 38 -
+ + + + +
+
2057
X-AXIS STRESS LIMIT EXCEEDED
+ + + + +
+
2058
Z-AXIS STRESS LIMIT EXCEEDED
2058
AXES -B- / -Z2- OVERTRAVEL
2062
OIL FILTER CLOGGED
2063
X1-AXIS STRESS LIMIT EXCEEDED
2064
Y-AXIS NOT POSITIONED AT ZERO
+
2064
Z1-AXIS STRESS LIMIT EXCEEDED
+ +
2065
BAR-FEEDER STOP
+
2066
TURRET DRIVE BATTERY LOW
2070
PARTS-CATCHER DRIVE BATTERY LOW
2080
HEAD 2 - TURRET NOT POSITIONED
+
2080
TURRET 2 DRIVE BATTERY LOW
+ +
2086
HEAD 2 - TURRET UNLOCKED
+
2099
HEAD 2 - TOOL-SETTING ARM DOWN
+
2100
HEAD 2 - SPINDLE ROTATION
+
2102
HEAD 2 - LIMIT 1 AXIS …. TOOL No. … EXCEEDED
+
2103
HEAD 2 - LIMIT 2 AXIS …. TOOL No. … EXCEEDED
+ +
2104
HEAD 2 - TOOL LIFE END
+ +
2109
HEAD 2 - END OF TOOL GROUPS
+
2111
TURRET 2 POSITION NUMBER NOT SET
+
2113
HEAD 2 - AXES RESET
2114
SUB-SPINDLE COLLET OPEN
+
2114
HEAD 2 - COLLET OPEN
+
2119
RIGHT AXIS ZERO LIMIT SWITCH DEFECTIVE
+
2126
RIGHT PARTS-CATCHER ALARM
+
2132
TURRET 2 STROBE SIGNAL =0
+
2143
X2-AXIS STRESS LIMIT EXCEEDED
+
2144
Z2-AXIS STRESS LIMIT EXCEEDED
+
+
+
+
+
+ +
+
+
+
- 39 -
+ +
+ +
+
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
+
7.1 Detailed description of messages series "2000"
2000 TURRET NOT POSITIONED
Cause:
Turret position does not coincide with the last T value programmed on
CNC unit.
Remedy: Position turret again under MDI mode.
Note:
If trouble occurs again, contact BIGLIA Service (turret encoder and/or
turret limit-switch may be faulty).
2000 TURRET 1 DRIVE BATTERY LOW
Cause:
Battery supplying the encoder of turret indexing motor is to be replaced
since its voltage is too low.
The encoder cable, motor side or drive side, is disconnected.
Effect:
Machine stopped with message on.
Note:
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
+ + + + + + + + +
2006 TURRET UNLOCKED
Cause:
Turret is not locked properly.
Remedy: Position turret again under MDI mode (the first attempt is sometimes not
successful; try again and call T values which are distant from the present
position).
Note:
If trouble occurs again, contact BIGLIA Service (limit-switch controlling
turret lock may be faulty).
+ + + + + + + + +
2019 TOOL-SETTING ARM DOWN
Cause:
The operator tried to rotate spindle with tool-setter in forward position.
Effect:
Spindle cannot rotate.
Remedy: Actuate tool-setter backward movement.
Note:
Check that limit switch is properly working and positioned.
+ + + + + + + + +
2020 SPINDLE ROTATION
Cause:
The operator tried to let tool-setting arm down while spindle is rotating.
Effect:
Tool-setter does not move.
Remedy: Stop spindle.
+ +
2022 LIMIT 1 AXIS ... TOOL No. ...
Cause:
The 1st limit was exceeded by tool No. ... (1 to 12).
Effect:
Machine stops at cycle end.
Remedy: Reset alarm.
Move barrier position if tool is still in good cutting condition.
Replace insert if worn out. Cutting parameters were changed after the selflearning. Machining allowance or type of material different from the one
used for self-learning.
- M.M. 03 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 40 -
+ +
2023 LIMIT 2 AXIS ... TOOL No. ...
Cause:
The 2nd limit was exceeded by tool No. ... (1 to 12).
Effect:
Machine stops at cycle end.
Remedy: Reset alarm.
Move barrier position if tool is still in good cutting condition.
Replace insert if worn out. Cutting parameters were changed after the selflearning. Machining allowance or type of material different from the one
used for self-learning.
+ + + + + + + + +
2024 TOOL LIFE END
Cause:
The last available tool was used.
Remedy: Replace inserts.
Reset tool table.
If variable #1005 is used, it is possible to stop cycle.
+ +
2025 CYCLE TIME EXCEEDED
Cause:
The cycle time set value was exceeded.
Effect:
Automatic cycle stops in HOLD mode.
Rimedio: Replace the two selectors S and F to 100%.
Increase the time set value.
Machine stops waiting a signal from an external actuator.
+ + + + + + + + +
2026 AUTOCUTOFF
Cause:
+
+ +
+ +
If the machine remains stopped for a long time with an alarm on, or with
messages 2022 and 2023, it is possible to select to switch off the hydraulic
unit and all power after a set time has been elapsed.
This function is called from the operator’s panel.
2027 B-AXIS TORQUE LIMIT EXCEEDED
Cause:
While M78 function was activated, the absorbed torque in G1 (working)
from B-axis has exceeded the value set.
Remedy: Remove the cause of excessive torque.
Increase the value set.
Note:
M79 function remove the M78 control.
- 41 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
2027 Z-AXIS TORQUE LIMIT EXCEEDED
Cause:
While M78 function was activated, the absorbed torque in G1 (working)
from Z-axis has exceeded the value set.
Remedy: Remove the cause of excessive torque.
Increase the value set.
Note:
M79 function remove the M78 control.
+ + + + + + + + +
2029 END OF TOOL GROUPS
Cause:
This message appears when first workpiece, carried out with the new tool
of the new group, is finished.
Remedy: It is possible to stop cycle if the variable # 1006 is used in the program.
+ +
+ +
+
2031 TURRET POSITION NUMBER NOT SET
Cause: Turret position number was not set in the diagnostic machine data.
Remedy: Set relevant value.
+ + + + + +
+ +
2032 END OF BAR
ause:
In bar-feeders without magazine (e.g.: Idrobar) it signals that bar is
finished (N.B. - when M52 is entered with collet open, only).
Effect:
AUTOMATIC Cycle stops (with collet open, only).
Remedy: Manually load a new bar.
+ + + + + + + + +
2033 AXES RESET
Cause:
Cycle has been started by CYCLE START push-button without resetting
axes.
The operator has begun tool-setting with probe without having reset axes.
(N.B. - This message appears also after a graphic simulation with axes off).
Remedy: Set all axes to zero.
+ + + + + + + + +
2034 COLLET OPEN
Cause:
The operator has tried to make spindle rotate while collet or jaws were
open.
Effect:
Spindle cannot rotate.
Remedy: Stop spindle, close collet or jaws and then start spindle again manually.
- M.M. 03 -
+
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 42 -
+
2035 PEDAL ENABLE ON COLLET
Cause:
Note:
+
+
+
2036 PEDAL ENABLE ON TAILSTOCK
Cause:
Note:
+ + + + + + + + +
This message appears when switching on the machine, to remind which
workpiece clamping device the machine has been preset for.
This selection is carried out from the Operator’s panel, 2nd item "PZ/CT".
This message appears when switching on the machine, to remind which
workpiece clamping device the machine has been preset for.
This system is fit for machining shafts clamped between face-driver and
tailstock.
This selection is carried out from the Operator’s panel, 2nd item "PZ/CT".
2037 BATTERY LOW
Cause:
The battery of CNC unit is low and it has to be replaced.
Remedy: Replace battery.
Note:
When replacing battery, CNC unit must be on; otherwise, machine
parameters as well as all part programs will be cleared.
+ + + + + + + + +
2039 ZERO REFERENCE LIMIT SWITCH DEFECTIVE
Cause:
When searching machine zero point, at zero limit switch release, the
contact does not work or limit switch is mechanically blocked.
Remedy: Check the limit switch.
+ + + + + + + + +
2041 SPINDLE LOCKED
Cause:
The operator tried to rotate spindle with manual pushbuttons while it was
locked by the disc brake.
Effect:
Spindle cannot rotate.
Remedy: Unlock spindle in MDI mode before rotating it by means of manual
pushbuttons.
+ + + + + + + + +
2044 DRY RUN
Cause:
This message appears when "DRY-RUN" is effected in rapid traverse
under AUTO mode.
- 43 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+ + + + + + + + +
2045 SWARF CONVEYOR BLOCKED
Cause:
Swarf conveyor is blocked (usually owing to swarfs)
Remedy: Select JOG mode, switch selector for changing conveyor direction and
start swarf conveyor again by means of push-button.
Remove the cause of jam (e.g. too many swarfs, parts or service
spanners), and switch selector on previous position.
+ + + + + + + + +
2046 PARTS-CATCHER ALARM
Cause:
External parts-catcher does not work properly.
Remedy: Check the parts-catcher failure cause.
+
2048 AXES X+ / Y OVERTRAVEL
Cause:
X+ movement is prevented towards positive direction by Y axis position.
Y axis movement causes a movement of X+ axis more than the allowed
limit.
Remedy: Move to opposite direction.
+
2050 AXES X- / Y OVERTRAVEL
Cause:
X- movement is prevented towards positive direction by Y axis position.
Y axis movement causes a movement of X- axis more than the allowed
limit.
Remedy: Move to opposite direction.
+ +
+ +
+
2052 TURRET STROBE SIGNAL =0
Cause:
During turret rotation a failure occurred to the encoder controlling
positions.
Remedy: Try calling other positions and, if alarm repeats, check and replace the
turret encoder.
Note:
Turret positions and strobe signal may be checked with the diagnostic
analysis at the relevant address as shown in the wiring diagram.
+ + + + + + + + +
2054 PRESS RESET PUSH-BUTTON
Cause:
It signals that reset push-button has to be operated.
Remedy: Press the reset push-button.
- M.M. 03 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 44 -
+ + + + + + + + +
2055 LUBRICATING OIL LEVEL LOW
Cause:
Oil level in the lubricating unit is below the minimum limit.
Remedy: Add oil in the lubrication tank.
+ + + + +
+
2057 X-AXIS STRESS LIMIT EXCEEDED
Cause:
With M78 function enabled, the stress absorbed by X-axis in G (working)
has exceeded set value.
Remedy: Remove the cause of excessive stress.
Set a higher value.
Note:
Function M79 eliminates the M78 control.
+ + + + +
+
2058 Z-AXIS STRESS LIMIT EXCEEDED
Cause:
With M78 function enabled, the stress absorbed by Z-axis in G (working)
has exceeded set value.
Remedy: Remove the cause of excessive stress.
Set a higher value.
Note:
Function M79 eliminates the M78 control.
+
2058 AXIS -B- / -Z2- OVERTRAVEL
Cause:
Rimedy:
+
2062 OIL FILTER CLOGGED
Cause:
Rimedy:
+
Axis -B- / -Z2- moved out of the permissible limits.
Move the axis in the opposite direction by JOG.
ntervention of the sensor on the oil filter.
Replace the filter or clean the filter cartridge.
2063 X1-AXIS STRESS LIMIT EXCEEDED
Cause:
With M78 function enabled, the stress absorbed by X1-axis in G (working)
has exceeded set value.
Remedy: Remove the cause of excessive stress.
Set a higher value.
Note:
Function M79 eliminates the M78 control.
- 45 -
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
+
2064 Y-AXIS NOT POSITIONED AT ZERO
Cause:
Rimedy:
+
The Y-axis is not at zero point during Werkzeugsetzer operation in
manual mode.
Conduct Y-axis at zero point.
2064 Z1-AXIS STRESS LIMIT EXCEEDED
Cause:
With M78 function enabled, the stress absorbed by Z1-axis in G (working)
has exceeded set value.
Remedy: Remove the cause of excessive stress.
Set a higher value.
Note:
Function M79 eliminates the M78 control.
+
+ +
+ +
2065 BAR-FEEDER STOP
Cause:
Effect:
Rimedy:
+
2066 TURRET DRIVE BATTERY LOW
Cause:
Effect:
Note:
+
Battery supplying the encoder of turret indexing motor is to be replaced
since its voltage is too low.
The encoder cable, motor side or drive side, is disconnected.
Machine stopped with message on.
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
2070 PARTS-CATCHER DRIVE BATTERY LOW
Cause:
Effect:
Note:
+
The operator has tried to rotate the spindle without the bar-feeder
consent.
Spindle rotation locked.
Check the correct operation of the bar-feeder.
Battery supplying the encoder of parts-catcher motor is to be replaced
since its voltage is too low.
The encoder cable, motor side or drive side, is disconnected.
Machine stopped with message on.
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
2080 HEAD 2 - TURRET NOT POSITIONED
Cause:
Turret position does not coincide with the last T value programmed on
CNC unit.
Remedy: Position turret again under MDI mode.
Note:
If trouble occurs again, contact BIGLIA Service (turret encoder and/or
turret limit-switch may be faulty).
- M.M. 03 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 46 -
2080 TURRET 2 DRIVE BATTERY LOW
Cause:
Effect:
Note:
+ +
Battery supplying the encoder of turret indexing motor is to be replaced
since its voltage is too low.
The encoder cable, motor side or drive side, is disconnected.
Machine stopped with message on.
Check on the drive display the type of alarm and follow instructions of
Annexe (1) based on the number displayed.
2086 HEAD 2 - TURRET UNLOCKED
Cause:
Turret is not locked properly.
Remedy: Position turret again under MDI mode (the first attempt is sometimes not
successful; try again and call T values which are distant from the present
position).
Note:
If trouble occurs again, contact BIGLIA Service (limit-switch controlling
turret lock may be faulty).
+
2099 HEAD 2 - TOOL-SETTING ARM DOWN
Cause:
Effect:
Remedy:
Note:
+
The operator tried to rotate spindle with tool-setter in forward position.
Spindle cannot rotate.
Actuate tool-setter backward movement.
Check that limit switch is properly working and positioned.
2100 HEAD 2 - SPINDLE ROTATION
Cause:
The operator tried to let tool-setting arm down while spindle is rotating.
Effect:
Tool-setter does not move.
Remedy: Stop spindle.
+
2102 HEAD 2 - LIMIT 1 AXIS …. TOOL No. … EXCEEDED
Cause:
The 1st limit was exceeded by tool No. ... (1 to 12).
Effect:
Machine stops at cycle end.
Remedy: Reset alarm.
Move barrier position if tool is still in good cutting condition.
Replace insert if worn out.
Cutting parameters were changed after the self-learning.
Machining allowance or type of material different from the one used for
self-learning.
- 47 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- M.M. 03 -
2103 HEAD 2 - LIMIT 2 AXIS …. TOOL No. … EXCEEDED
Cause:
The 2nd limit was exceeded by tool No. ... (1 to 12).
Effect:
Machine stops at cycle end.
Remedy: Reset alarm.
Move barrier position if tool is still in good cutting condition.
Replace insert if worn out.
Cutting parameters were changed after the self-learning.
Machining allowance or type of material different from the one used for
self-learning.
+ +
2104 HEAD 2 - TOOL LIFE END
Cause:
The last available tool was used.
Remedy: Replace inserts.
Reset tool table.
If variable #1005 is used, it is possible to stop cycle.
+ +
2109 HEAD 2 - END OF TOOL GROUPS
Cause:
This message appears when first workpiece, carried out with the new
tool of the new group, is finished.
Remedy: It is possible to stop cycle if the variable # 1006 is used in the program.
+
2111 TURRET 2 POSITION NUMBER NOT SET
Cause:
Turret position number was not set in the diagnostic machine data.
Remedy: Set relevant value.
+
2113 HEAD 2 - AXES RESET
Cause:
Cycle has been started by CYCLE START push-button without resetting
axes.
The operator has begun tool-setting with probe without having reset axes.
(N.B. - This message appears also after a graphic simulation with axes off).
Remedy: Set all axes to zero.
+
2114 SUB-SPINDLE COLLET OPEN
Cause:
The operator has tried to make spindle rotate while collet or jaws were
open.
Effect:
Spindle cannot rotate.
Remedy: Stop spindle, close collet or jaws and then start spindle again manually.
- M.M. 03 -
+
B650
B445-B470
B200
B1000
B501Y
B501
B501 21i
B301
B301 21i
- 48 -
2114 HEAD 2 - COLLET OPEN
Cause:
The operator has tried to make spindle rotate while collet or jaws were
open.
Effect:
Spindle cannot rotate.
Remedy: Stop spindle, close collet or jaws and then start spindle again manually.
+
2119 RIGHT AXIS ZERO LIMIT SWITCH DEFECTIVE
Cause:
When searching machine zero point, at zero limit switch release, the
contact does not work or limit switch is mechanically blocked.
Remedy: Check the limit switch.
+
2126 RIGHT PARTS-CATCHER ALARM
Cause:
The machine external parts-catcher is in alarm condition.
Remedy: Find the cause which have generated the parts-catcher failure.
+
2132 TURRET 2 STROBE SIGNAL =0
Cause:
During turret rotation, the encoder signalling the positions failed.
Remedy: Try calling other positions and, if the alarm repeats, check and replace
turret encoder.
Note:
Turret positions and strobe signal may be checked with the diagnostic
analysis at the corresponding address as shown in the wiring diagram.
+
2143 X2-AXIS STRESS LIMIT EXCEEDED
Cause:
With M78 function enabled, the stress absorbed by X2-axis in G (working)
has exceeded set value.
Remedy: Remove the cause of excessive stress.
Set a higher value.
Note:
Function M79 eliminates the M78 control.
+
2144 Z2-AXIS STRESS LIMIT EXCEEDED
Cause:
With M78 function enabled, the stress absorbed by Z2-axis in G (working)
has exceeded set value.
Remedy: Remove the cause of excessive stress.
Set a higher value.
Note:
Function M79 eliminates the M78 control.
- 49 -
- M.M. 03 -
8.
BIGLIA MACRO ALARMS
8.1 From G131 (piece lifting with tailstock)
Alarm on display
Cause and remedy
3004 LIMIT D HIGHER THAN A-2
Modify either D value or parameter 1826/B.
3001 B -AXIS MIS POSITIONING
B-axis has gone over the limit D:
workpieces moved during machining.
8.2 From G183 (peck drilling)
Alarm on display
Cause and remedy
3005 EXCESSIVE REPETITION
Cycle has foreseen more than 18 times chip discharging:
modify value D (1° cut) or A (min. cut) or both.
3006 B VALUE IS HIGHER THAN -C-
Modify programme.
3007 C VALUE IS HIGHER THAN -I-
Modify programme.
3008 A VALUE IS HIGHER THAN -D-
Modify programme.
3009 K VALUE IS HIGHER THAN -0-
Modify programme.
8.3 From B- axis monitoring to drill
Alarm on display
Cause and remedy
3041 LIMIT 1 B-AXIS LOAD
Bit / inserts worn or limit 1 too near A.SET value.
Change bit / inserts if worn or increase limit 1.
3042 LIMIT 2 B-AXIS LOAD
Bit / inserts broken or limit 2 too near A.SET value.
Change bit / inserts if broken or increase limit 2.
8.4 From tool load monitoring (SBS)
Alarm on display
Cause and remedy
3001 LIMIT 1 AXIS LOAD
Inserts worn or limit 1 too near A.SET value.
Change inserts if worn or increase limit 1.
(See note)
3002 LIMIT 2 AXIS LOAD
Bit / inserts broken or limit 2 too near A.SET value.
Change bit / inserts if broken or increase limit 2.
(See note)
NOTE
Check also the four Timer 8, 9, 10, 11.
- M.M. 03 -
- 50 -
9.
TURRETS AND PARTS-CATCHER WITH ELECTRONIC MOTOR UNIT
ALLARMS
This part describes troubleshooting procedures to be applied in the event of a failure.
If a failure occurs, determine the cause and apply an appropriate countermeasure while referring to the
corresponding description in the manual. Firstly, check the LED display on the driving unit in the electric
box and the alarm number on the numeric control (PMM), see paragraph 11 [MSG].
Determine the cause and apply an appropriate countermeasure.
Number
from 000 to 299.....................
from 300 to 399.....................
from 400 to 499.....................
from 500 to 599.....................
– –
.......................
Alarm type
Program or setting alarm
Pulse coder alarm
Servo alarm
Overtravel alarm
System alarm or I/O link alarm
9.1 Program or setting alarms (PS alarms)
Alarmes No.
CNC
LED
display
Description
000
Cause:
A parameter that requires power-down has been specified.
Remedy: Turn the power off, back on.
011
Cause:
The specified feedrate is zero.
Remedy: Check the feed rate parameter specified with a function code.
013
Cause:
The specified feedrate (maximum feedrate) is zero.
Remedy: Check the value of parameter No.043, which indicates the maximum
feed-rate that can be specified.
070
Cause:
More than 32 blocks have been registered for a buffering operation.
Remedy: Reduce the number of registered blocks to 32.
085
Cause:
086
Cause:
087
Cause:
Input the reader/punch interface or the like caused an overrunm parity
or framing error.
Remedy: Correct the baud rate of the input/output unit (always 4800) or other
settings.
Input from the reader/punch interface or the like included an input/
output unit operation ready signal (DR) that is set to off.
Remedy: Turn the reader / punch on.
Check the cable connection.
After input from the reader/punch interface or the like stops, character
input does not stop even though ten characters have been input.
Remedy: Check the cable connection.
- 51 -
- M.M. 03 -
Alarmes No.
CNC
LED
display
Description
090
Cause:
Reference position setting cannot be executed normally.
Remedy: Move the tool in the direction of reference position return in jog mode
at a speed that causes the servo position error to exceed 128.
Then, specify another reference position setting.
093
Cause:
224
Cause:
250
Cause:
Input data 1 is invalid.
Remedy: Check input data 1, specified with a function code.
251
Cause:
Input data 2 is invalid.
Remedy: Check input data 2, specified with a function code.
254
Cause:
A function code or mode is invalid.
Remedy: Check the command code, specified with a function code.
Check the mode.
255
Cause:
290
Cause:
The interface switch signal (DRC) was switched during block execution.
Remedy: Switch the signal after block execution stops.
291
Cause:
292
Cause:
A checksum error for the battery-powered memory was detected.
Remedy: Parameters are cleared.
Set the parameters again. If this alarm subsequently recurs, replace
the unit.
A first to third reference position return cannot be executed because the
reference position has not yet been established.
Remedy: Set the reference position.
The reference position has not yet been established.
This occurs only when the ZRTN bit of parameter No. 001 is set to 0.
Remedy: Set the reference position.
Operation cannot be activated because an invalid mode is specified or
because block execution is in progress.
Remedy: Check the mode. Check whether a block is being executed.
The speed of an axial movement specified by an external pulse has
exceeded the upper limit.
This occurs only when the EPEXA bit of parameter No.001 is set to 1.
Remedy: Check the speed specified by the external pulse. Check the
magnification of the external pulse (parameters No.062 and 063).
- M.M. 03 -
- 52 -
9.2 Pulse coder alarms
Alarmes No.
CNC
LED
display
Description
300
Cause:
A communication error (DTER) for the serial pulse coder was detected.
Remedy: Check the continuity of the signal cable.
If the cable is normal, the pulse coder may be defective.
Turn the power off.
If the alarm recurs when the power is reapplied, replace the serial pulse
coder, together with the motor.
301
Cause:
A communication error (CRCER) for the serial pulse coder was detected.
Remedy: Check the continuity of the signal cable.
If the cable is normal, the pulse coder or servo unit may be defective.
This error may also be caused by external noise.
See the chapter on noise reduction in “Connection”.
302
Cause:
A communication error (STBER) for the serial pulse coder was detected.
Remedy: Check the continuity of the signal cable.
If the cable is normal, the pulse coder or servo unit may be defective.
This error may also be caused by external noise.
See the chapter on noise reduction in “Connection”.
303
Cause:
An LED disconnection (LDAL) was detected in the serial pulse coder.
Remedy: Turn the power off.
If this alarm recurs when the power is reapplied, replace the motor.
304
Cause:
A mispulse alarm (PMAL) for the serial pulse coder was detected.
Remedy: Turn the power off.
If this alarm recurs when the power is reapplied, replace the motor.
305
Cause:
A miscount alarm (CMAL) for the serial pulse coder was detected.
Remedy: Turn the power off.
If this alarm recurs when the power is reapplied, replace the motor.
If the alarm does not recur, restart the operation from reference position
return.
306
Cause:
The motor has overheated (CHAL).
Remedy: This alarm is issued when the amplified has overheated, causing the
thermostat to trip.
Possible causes include an excessively high ambient temperature and
excessively strict operating conditions.
Check the actual cause.
Disconnect the power for about ten minutes, then release the emergency
stop state .
If the alarm recurs, replace the amplifier.
- 53 -
- M.M. 03 -
Alarmes No.
CNC
LED
display
Description
308
Cause:
A soft phase alarm (SPHAL) was detected.
Remedy: Turn the power off. The alarm may be caused by noise.
319
Cause:
350
Cause:
The battery voltage of the absolute pulse coder is low.
Remedy: Replace the battery.
Restart the operation from reference position return.
351
Cause:
The battery voltage of the absolute pulse coder is low (warning).
Remedy: Replace the battery.
When the absolute pulse coder is used, the motor has not yet rotated
through more than one turn after the first power- up.
Remedy: Cause the motor to rotate through more than one turn in JOG feed
mode, then turn the power off then back on.
- M.M. 03 -
- 54 -
9.3 Servo alarms
Alarmes No.
CNC
LED
display
Description
400
Cause:
The servo motor has overheated (estimated value).
Remedy: Turn the power off. After a while, turn the power back on.
Possible causes include an excessively high acceleration / deceleration
frequency.
401
Cause:
Servo amplifier "ready" signal (DRDY) went off.
Remedy:
403
Cause:
The cooling fins have overheated (hardware detection).
Remedy: The load on the motor may be too high.
Re-examine the load conditions.
404
Cause:
The regenerative discharge unit has overheated.
Remedy: This alarm is issued when the average regenerative discharge
energy is too high (when the acceleration/deceleration frequency is
too high, for example).
When the regenerative discharge resistor is not being used, check
whether a dummy connector is fitted to the CX11-6 connector.
When the regenerative discharge resistor is being used:
(1) The average regenerative discharge energy may be too high.
Decrease the acceleration / deceleration frequency.
(2) The thermostat line of the separate regenerative discharge unit
may not be connected properly. Check the connection.
(3) The thermostat of the separate regenerative discharge unit may
be defective.
Disconnect the separate regenerative discharge unit, then check
the thermostat.
If the thermostat is open even though the separate regenerative discharge unit is cool, replace the separate regenerative
discharge unit.
If (1) to (3) are not the cause of the alarm, replace the servo amplifier.
405
Cause:
Reference position return could not be executed correctly.
Remedy: Re-execute reference position return.
410
Cause:
The servo position error in the stop state is larger than the value
specified in parameter No.110.
Remedy: Determine the mechanical cause of the large position error.
If no mechanical cause is found, specify a large value for the parameter.
- 55 -
- M.M. 03 -
Alarmes No.
CNC
LED
display
Description
411
Cause:
The servo position error during movement is larger than the value
specified in parameter No.182.
Remedy: Determine the mechanical cause of the large position error.
If no mechanical cause is found, apply any of the following countermeasure:
-- Specify a larger value for the parameter.
-- Specify a lower feedrate.
-- Increase the time constants.
412
Cause:
An overcurrent alarm is issued.
Remedy: This alarm is issued when an excessively large current flows in the main
circuit.
(1) Check whether a valid motor number is specified in parameter
No.30.
If yes, go to (2).
(2) Check whether the standard values are specified in the current control parameters to servo control.
Correct current control is possible only when the standard
values
are specified for the following
parameters:
No.70, 71, 72, 78, 79, 84, 85, 86, 87, 88, 89, 90.
(3) Disconnect the power line from the amplifier connector.
Then, release the emergency stop state.
-- If the overcurrent alarm continues to be issued, replace the
amplifier.
-- If no overcurrent alarm is issued, go to (4).
(4) Disconnect the power line from the amplifier connector.
Check the insulation between the ground and each of U, V and W
.
If the insulation is satisfactory, go to (5).
If a short-circuit is detected, disconnect the power line from the
motor
connector.
Then, check the insulation between the ground and each of U, V
and
W of the motor.
If a short-circuit is found between the ground and U, V or W of the
motor, replace the motor.
If the insulation is satisfactory, replace the power line.
(5) Connect the power line.
Observe the waveform of the motor current (IR, IS) while the motor
is accelerating or decelerating.
See the description of the checking of the motor current in
Appendix
E “Servo Check Board”.
If the motor current (IR, IS) does not exhibit a normal sine wave,
replace the amplifier.
(6) If (1) to (4) above are not the cause of the alarm, the pulse coder,
command cable, or internal hardware of the CNC may be defective.
- M.M. 03 -
- 56 -
Alarmes No.
CNC
LED
display
Description
413
Cause:
A DC link overvoltage alarm is issued.
Remedy: This alarm is issued when the DC voltage of the main circuit power
is too high.
(1) The supply voltage for dynamic power may exceed the rated value.
Check the voltage.
If the voltage is too high, reduce the voltage to an appropriate level.
(2) The regenerative discharge unit may not be properly connected .
Check the connection.
(3) The resistance of the separate regenerative discharge unit may
be abnormal.
Disconnect the separate regenerative discharge unit, then check
the resistance.
If the resistance is not within +20% of the predetermined resistance, replace the separate regenerative discharge unit .
If (1) to (3) are not the cause of the alarm, replace the servo amplifier.
414
Cause:
A DC link low voltage alarm is issued.
Remedy: This alarm is issued when the DC voltage of the main circuit power
is too low.
(1) The external circuit breaker may be turned off.
Check the circuit breaker.
(2) The supply voltage for dynamic power is lower than the rated value.
Check the voltage.
If the voltage is too low, increase it to an appropriate level.
(3) The external magnetic contactor may not be connected properly.
Check the connection.
If (1) to (3) are not the cause of the alarm, replace the servo amplifier.
417
Cause:
A parameter has been specified incorrectly
Remedy: Check the following parameters:
No.30: Is the specified motor type correct?
No.31: Is the specified direction of rotation of the motor correct?
No.106: Is the denominator of the number of pulses per single revolution
of the motor 0?
No.180:Is the specified reference counter capacity 0 or a negative
value?
418
Cause:
A DO alarm is issued.
Remedy: Replace the servo unit.
423
Cause:
The specified speed exceeds 32767000 detection units per second.
Remedy: Re-examine the CMR and speed settings.
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- M.M. 03 -
Alarmes No.
CNC
LED
display
Description
Cause:
The cooling fan has stopped.
Remedy: This alarm is issued when the fan motor built into the servo amplifier has
failed.
(1) Check that the fan is not clogged with foreign matter.
(2) Check that the power connector of the fan is connected properly.
(3) Replace the fan or servo unit.
425
9.4 Overtravel alarms
Alarmes No.
CNC
LED
display
Description
500
Cause:
The positive stroke limit has been exceeded.
Remedy: Check whether *+OT and * -OT are connected correctly.
Check whether a correct move command is specified.
Move the tool in the opposite direction in JOG mode, then perform
a reset.
501
Cause:
The negative stroke limit has been exceeded.
Remedy: Check whether *+OT and * -OT are connected correctly.
Check whether a correct move command is specified.
Move the tool in the opposite direction in JOG mode, then perform
a reset.
510
Cause:
The positive soft stroke limit has been exceeded.
Remedy: Check whether appropriate values have been specified for parameters
No.142 and 143.
Check whether a valid move command is specified.
Move the tool in the opposite direction in JOG mode, then perform
a reset.
511
Cause:
The negative soft stroke limit has been exceeded.
Remedy: Check whether appropriate values have been specified for parameters
No.142 and 143.
Check whether a valid move command is specified.
Move the tool in the opposite direction in JOG mode, then perform
a reset.
- M.M. 03 -
- 58 -
9.5 System alarms
Alarmes No.
CNC
LED
display
Description
--
Cause:
An error was detected in theRAM write / read test at power-up.
Remedy: Replace the unit.
--
Cause:
---
Cause:
An error was detected in the data collation check for the batterypowered memory.
Remedy: Turn the power off then back on.
Then, re-enter the parameters.
If thisalarm recurs, replace the unit.
A data transfer alarm for the battery-powered memory has been
issued.
Remedy: Replace the unit.
--
Cause:
A watchdog alarm was issued.
Remedy: Turn the power off then back on.
If thisalarm recurs, replace the unit.
--
Cause:
A checksum alarm for the control software ROM is issued.
Remedy: Replace the unit.
--
Cause:
A checksum alarm for the ROM that is built into the CPU is issued.
Remedy: Replace the unit.
--
Cause:
An error was detected in the control circuit.
Remedy: Replace the unit.
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- M.M. 03 -
9.6 I/O link alarms
Alarmes No.
CNC
LED
display
Description
Cause:
A FANUC I/O link error occurred.
A unit connected to the line was turned off.
Remedy: Turn off the power to all units connected to the line.
Then, turn on the "slave" devoces, followed by the "master" device.
--
9.7 No LED display
Alarmes No.
CNC
--
LED
display
Description
Cause:
The control circuit is not operating normally.
Remedy: (1) Check the 24-VDC control supply voltage.
If the voltage is low, increase the voltage to an appropriate level.
(2) Check whether a fuse in the servo unit has blown.
If a blown fuse is found, replace it, following the procedure described in Section 3 “Replacing Fuse”.
If (1) and (2) are not the cause, replace the servo amplifier.
- M.M. 03 -
- 60 -
10. BATTERIES REPLACEMENT
10.1 Procedure for CNC series "i"
Provide a new battery [code for reordering: A02B-0200-K102 (GE FANUC specification:
A98L-0031-0012)].
PROCEDURE
1. Open the numeric control compartment for access to rear
part.
(Batteries are placed behind the CNC video, see drawing).
2. Make sure that CNC has been turned on for a few minutes
before switching it off.
3. Remove the old battery form the CNC (see drawing).
Disconnect the battery cable and take out the battery from the
box.
4. Insert a new battery and reconnect the cable (do not leave
the control unit without the new battery for more than 30
minutes).
Battery box
Connector
Lithium battery
A02B-0200-K102
Warning
The use of a different battery may cause its explosion.
It is recommended to use original batteries type:
(A02B-0200-K102).
NOTE
The old batteries must disposed of in the special containers provided.
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- M.M. 03 -
10.2 Procedure for driving units series "Beta" (Turret)
Warning
This procedure must be performed only by qualified personnel.
When the message is displayed:
2000 TURRET DRIVE BATTERY LOW
It is necessary to replace the driving unit battery which controls the turret rotation.
Warning
If message 2000 is displayed, do not switch the numeric control off, otherwise the
turret position will be lost.
Replacement procedure
Provide a new battery (code for ordering: A06B-6093-K001).
PROCEDURE
1. Open the electric board without cutting off voltage.
2. Remove the cover of the battery which is placed at the bottom
of the driving unit for type SVU20 or on a side for type
SVU40/80.
Press slightly on the side to disjoin the cover clamps.
Battery
Cover
"Beta" driving unit
"Beta" driving unit
type SVU-20
type SVU-40, SVU-80
3. Remove the old battery from the driving unit.
4. nsert the new battery and connect it to connector CX5X or
CX5Y.
5. Reassemble the battery cover.
Warning
NOTE
The battery must be connected to the operation connectors CX5X or CX5Y.
The old batteries must disposed of in the special containers provided.
- M.M. 03 -
- 62 -
11. POWER FACTOR CORRECTION OF THE ELECTRIC TURRET TO
POSITION ONE
This procedure must be performed in the following cases:
•
•
The encoder cable of the turret has been disconnected and then reconnected.
An alarm of the turret battery has occurred, and it has been signalled simultaneously by alarm
message "1001 TURRET DRIVE ALARM" on CNC and by alarm message "2000 TURRET DRIVE
BATTERYLOW".
•
The electric cabin has been switched off and then on after the message "2000 TURRET DRIVE
BATTERYLOW", without replacing the battery.
PROCEDURE
1. When switching CNC ON for the first time it is necessary to enable the
parameters editing, see:
chapter 13 and set "PARAMETER WRITE =1".
2. Select the page concerning the turret parameters PMM -Power
motion manager displaying- chapter 12.
Should the machine have two turrets, it is necessary to select the
displaying of the wanted turret by following the instructions given at
paragraph 12.2 -Displaying for several turrets-.
3. Select parameter 11, write value 00000000 and press key 14
INPUT
.
4. Switch off and on the CNC.
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- M.M. 03 -
5. Select the page concerning the turret parameters PMM;
select parameter 11, write value 00000010 and press key 14
INPUT
.
6. Switch off and on the CNC and the machine.
?
7. Close the door and select the manual mode by pressing the key 45
JOG
"JOG".
AUTO
MPG
MDI
TEST
EDIT
JOG
RPD
ZRN
45
8. When the door is closed, press the turret rotation key 76
(press
it at least twice), if the turret is motorised.
The first command orients the motor-driven tool, whereas the second
one makes the turret rotate.
9. Increase the position number of one unit by key 75
the turret rotation key 76
+
and press
pulsing. (check that rotation and
closing are regular).
10.Step 9. must be repeated several times, always turning towards the
–
+
76
75
same direction, until reaching position 1 (one) of the turret.
NOTE
Position 1 (one) must be that indicated by the specification mark
on the turret head and not the one shown by the position display
73
, since the position given may be not actual.
Position
1
- M.M. 03 -
- 64 -
11.After reaching position 1 (one) select the page concerning the turret
parameters PMM;
select parameter 11, write value 10000011 and press key 14
INPUT
.
12.Switch off and on the CNC and the machine.
NOTE
73
If the operation has been executed in the correct way, number 1
will appear on the position display 73
.
13.End parameters editing "PARAMETER WRITE =0" by following the
instructions given at paragraph 5.1 -Parameters display and settingon page 106 of BIGLIA "Operating Manual".
–
+
- 65 -
- M.M. 03 -
12 . POWER MOTION MANAGER DISPLAYING
12.1 Displaying for one turret
PROCEDURE
1. Select key 25
SYSTEM
2. Press soft key
on CNC..
several times until the soft key PMM
appears.
3. By pressing soft key PMM the following options appears:
POS
: Current position displaying
SYSTEM : System information
MSG
: List of alarms/messages
4. By pressing soft key SYSTEM the following video page appears:
5. Press key soft PARAM to display the following parameters
list:
6. Use the keys 6
parameter.
to shift the cursor on the desired
- M.M. 03 -
- 66 -
12.2 Displaying for several turrets
PROCEDURE
1. Select head 1 by pressing key 54
2. Select key 25
3. Press soft key
SYSTEM
1
HEAD 1
.
on CNC.
several times until the soft key PMM
appears.
4. By pressing soft key PMM the following options appears:
POS
: Current position displaying
SYSTEM : System information
MSG
: List of alarms/messages
5. Press soft key
+ until the following video page appears
and then, by using the soft keys
NEXT -
BAK , display
the group.
6. The following figure shows the video page, with the sequence
displaying of the groups.
1st GROUP : Upper turret head 1
2nd GROUP : Lower turret head 2
3rd GROUP : Parts-catcher
- 67 -
- M.M. 03 -
7. After choosing the group by pressing the soft key
+,
the following video page appears:
8. By pressing soft key SYSTEM the following video page appears:
9. Press key soft PARAM to display the following parameters
list:
10.Use the keys 6
parameter.
to shift the cursor on the desired
- M.M. 03 -
- 68 -
13. PROCEDURE FOR PARAMETERS SETTING
PROCEDURE
1. Press key 41
"MDI".
MDI
PANEL
ENABLE
2. Set selector 36 on "ENABLE/EDIT".
ENABLE/
EDIT
LOCK
3. Press key 23
4. Press soft key
OFFSET
SETTING
.
PARAM .
36
5. Press soft key PREPRA , the following video page appears:
PARAMETER WRITE = 0 (0 : Disable - 1 : Enable)
6. Press page keys 7
PAGE
or
PAGE
until the desired video page is
displayed.
Video page example
SETTING (HANDY)