Atlas Series Problem and Solution
Problem
SOLUTION
1 – Spindle inverter display showing OC error on the screen.
A spindle “jam” may cause an overcurrent or “OC” error.
First, reset the error: Shut down the machine for 30 seconds or until the VFD display powers down, then restart. When powered on, the VFD should read “0.0” or “RDY”.
If the error appears again upon reboot, reference the OC Error Troubleshooting Guide in order to troubleshoot further.
2 – Spindle randomly starts rotating counter clockwise. Not consistent.
There is a problem with the connection between the output of the spindle inverter and the harness plug connected directly to the spindle…
Start by first running a ‘continuity test’ between the inverter and the spindle power cable/harness.
If there is a short or break in any of the conductor wires, the spindle harness cable should be replaced.
If there are no shorts or breaks noticed during the continuity test, replace the spindle
3 – When trying to run a file, the machine prompts a soft limit or over travel error in the z-axis.
The z-zero is not set properly.
Reset the z-zero and try again.
Another reason for this error could be that the gcode file is using a z-axis clearance height that is too high for the z-travel of the machine. Reset the z-origin and check that the clearance height is set to an appropriate value for the model machine being used. This can also be identified in the g-code file itself. During the first z-axis move, look at the coordinate value in reference to the position the z-axis zero position is set. If the coordinate is a large positive value, this could prompt a positive soft limit.
On the other hand, a z-zero that is set very close to the vacuum table, using a very small tool may also prompt a negative soft limit. Compare the depth cut value in the g-code with the absolute coordinate that can be seen on the handheld. To view absolute coordinates on the handheld, press and hold the Shift button then select the blue #8 button.
The coordinates will change labels from 1X, 1Y, and 1Z to X*, Y*, and Z*. Compare the z-axis value to the negative stroke limit (Menu –> Mfr Params –> Password = 33587550 –> Machine Stroke –> NegStrkLmt) set on the controller. This will determine if the position for the cut is going lower than the machine is capable of. If machine coordinates at cut depth exceed machines z-axis soft limit (Stroke limit), then fixturing or tooling need to be changed to accomodate machine’s z-axis limits.
4 – What is the minimum RPM for VFD?
3000RPM limited by VFD, depending on VFD we can change minium speed. Some VFD’s may also be programmed with 6K RPM as lowest value.
To adjust values for Atlas machine view ‘MS300 Programming Guide‘,
to adjust values for HD-series machines view ‘VFD-E Programming Guide’.
Reference ‘navigating the delta display’ guide for assistance with navigating the machine’s VFD display.
5 – Machine does not move displays “Override 0”
Feedrate override is set to 0, cannot be 0 must have a feedrate.
The blue #7 button, or “zig zag +” button will increase the FR override in 10% increments. It is advised to run at 100% so that the machine will run programmed files at 100% of their programmed feedrate. Changing this value above or below 100% will run the same file at a feedrate that is the product of the percentage multiplied by the programmed feed rate value.
6 – Loosing steps / Drifting—–
1-High acceleration (In handheld go to menu –> MFG Params –> Password = 33587550 –> Velocity, check value for single axis acceleration? Jerk? Ref circle accel?)
2) Very small line segments (could be a CADCAM compatability issue, may need to send a sample file to support@technocnc.com)
3) Insufficient grounding (plastic or foam can give off static electricity which can discharge onto electronics, also make sure machine frame is grounded)
7 – HSD Spindle keeps throwing error on inverter when powered on
Move the spindle by hand, if it sounds rough or there is resistance when rotating in some spots, the bearings may be bad and therefore the HSD spindle needs to be replaced.
8 – 3MS controller states an “Overide 0” error.
For this style of controller, first put the controller in feedrate mode. Once in feedrate mode increase the feedrate override. Unlike the currently used G2 version of the controller, the percentages are represented as decimals and whole numbers rather than percentages. It is recommended the override be set to 1.0.
9 – Changing the retract distance when measuring z zero off the touchpad.
On the handheld pendant, press menu → Oper Params → Cali Height. Change this variable to the desired retract distance. Reboot the controller after changing the value for the new value to take effect.
10 – Machine will not perform tool touch off procedure and instead keeps going down into the tool touch off puck.
Check the ‘spindle to tool ground loop’. Attach an alligator clip to the cutting tool/router bit from a ground that the spindle is connected to. Try performing tool touch off again, if it works then the spindle is not completing its ground loop from the bit to the rest of the machine.
If there is still no reaction from the machine while using the alligator clip for grounding. You need to test ‘touch pad continuity’. Remove the touch pad connector and test continuity between the touch pad wire and the brass button on the touch pad. If there is no continuity, the touch pad is damaged and needs to be replaced.
11 – New Inverter installed onto machine. When testing inverter by manually turning on the spindle, nothing happens. Inverter displays “H 0.0” and wiring is done properly. Controller also shows outputs are being triggered.
If the initial gear setting is 7S. Try shifting down to 6S. If the spindle turns on to the highest RPM value (300Hz = 18000RPM), the initial gear setting has to be changed in the ‘Mfr Params’ to match the programming of the new inverter. Set the correct parameters for spindle speed by following parameters guide for MS300 VFD (Atlas) or VFD-E (HD Series)
12 – Performed factory reset and all parameters are incorrect.
The back up needs to be restored to the system. This is a billable procedure as the controls manufacturer charges for these firmware back-ups. To request a quote for a backup, contact support@technocncsystems.com or call 631-648-7481 |
13 – Axis travel accuracy is not consistent. Pulse equivalence (scale factor) must be changed
Formula: (measured distance/expected distance) * existing pulse equivalence = new pulse equivalence
Change pulse equivalence: Menu à MFR Param à Password = 33587550 à Pulse Equiv
14 – Machine does not execute the correct programmed spindle speed.
I.e) Program shows M3 S18000. The inverter should read 300, or 1800, depending on set up, but the inverter reads 266, or 1600, defining that the spindle is running at 16,000 rpm, not 18,000.
– On the handheld pendant, go to menu –> Mfr Params –> Password = 33587550 –> Spindle Set
– For the variable labeled “Total Gears”, ensure the number is set to “8”
– On the machine’s VFD, ensure that parameters 04-00 to 04-07 is set to the required output frequencies. Refer to parameters guide for MS300 VFD or VFD-E (depending on your machine)
– Once changes have been made. Cycle power to the unit. Ensure the VFD display shuts off prior to turning the machine back on.
– Test using a gcode file.
15 – When the axis moves after being enabled, the servo motor makes a loud noise. Noise does not subside until the machine is powered down, or pressure is applied to the axis.
FOR MACHINES EQUIPPED WITH STEPPER MOTORS, PLEASE DISREGARD ANY INSTRUCTIONS PERTAINING TO THE ENCODER CABLE OR CONNECTOR.
1-Power off the machine completely. Re-seat the power and encoder cables from the drive and servo motor. Try again, if noise persists proceed to step 2.
2-Power off the machine completely. Disable the Y2 axis by removing the encoder, power, and controller signal cables. View the servo drive wiring diagram. Once the Y2 axis is disabled, swap the same cable types from the x-axis to the Y1-axis. Power machine on and test the x-axis.
DO NOT JOG THE Y-AXIS. If the axis continues to make the noise, move on to step 3. If it does not, replace the servo drive.
3-Power off machine completely. Re-seat all the cables to their original drives. Remove the X-axis motor and plug into the Y1-axis power and encoder cables. Remove the power and encoder cables from the Y2-axis to disable. Test the motor. The motor should not be mounted to the Y-axis. Test should be bench tested. If the noise persists, replace the motor, if the noise does not occur, replace the power and encoder cables for the x-axis.
16 – Machine not homing. All homing sensors are fine but not being triggered.
Make sure the incoming power connections for the controller are properly seated (24V is connected to 24V and 0V is connected to GND).
If problem persists, a backup for the controller must be purchased. Contact support@technocncsystems.com or call to receive a quote.
17 – Spindle Overheats to the point where the inverter shuts it down and displays Ot1, or Ot2 error message. (Delta MS300 Inverter)
-First check incoming voltage to the machine and to the inverter. Voltage range should be between 210 – 240V AC. No more, no less.
-Spin the spindle shaft by hand and listen for any crunching, or strange sounds. Rotation should be smooth. The fan above, should also rotate with the spindle shaft.
-Run the spindle through the controller at high RPM. Check the fan again to ensure air is being moved into the motor.
-Lastly check the cutting tools. If the tools are very dull, this would cause the spindle to stall over time and also is a very big safety hazard!
– Lastly, check spindle rotation. When the spindle is turned on, it should be rotating clockwise. If it is rotating counter clockwise, the tools are being run in reverse and not actually cutting the material, but burning it, increasing the load on the spindle.
18 – Machine not moving. When machine is powered on, it does not prompt “Back To REF Pt.” message
Check if X, Y or Z axis are sitting on a limit switch. If yes, manually move it off the limit switch with the power off.
-When pushing off the limit switch for z-axis, pull down on the spindle mounting plate. Do not pull down on the spindle itself.
-When pushing off the x or y axis, carefully push the gantry in the direction away from the limit switch.
19 – NC File Running Error
Use the up and down arrow buttons to read the rest of the message. The message will either indicate the feedrate is set to 0, or that it does not recognize a line of code in the program file.
– If the error indicates feedrate is set to 0, the feedrate override is currently set to 0%. Increase the value by pressing the blue #7 button on the handheld controller. Each time the button is pressed, the feedrate override will increase by 10%.
– If the error indicates an unrecognized gcode command, the incorrect post processor is being used and outputting foreign gcode to the machine. Techno CNC can provide a post for Vectric vcarve pro or Aspire. All other posts must be provided by the CAD/CAM manufacturer.
20 – Process File Not Found
This error indicates that the controller sees that there is a USB plugged in, but it does not see that there are any supported file types on the USB.
– A common mistake when organizing a USB is when the USB contains multiple sub folders without having an .nc files provided on the main directory. Sub folders can be used and navigated through using the controller, but there must be at least one .nc file on the main directory for the controller to read them.
– There are no .nc files anywhere on the USB and the machine is refusing to read the USB.
21 – Machine is prompting E-stop error. The error occurred in the middle of running a file, or upon initial boot up of the machine. Restarting the machine does not rectify the issue and the machine is not sitting on any of its limit switches.
– Open the back of the control cabinet and check the inputs being triggered.
– Ensure that none of the limit switch inputs are illuminated (GX01, GX03, GX04, GX06, GX07, GX08). If they are, check again that none of the axes are sitting on their limits. If they are not, check each limit switch individually and see if the red LED on the switch is illuminated, or if the switch is damaged. If the light is illuminated, clean off the switch to ensure there is no metal making contact. If they are damaged, replace the switch.
– Check any other inputs that are illuminated, particularly, the GX15 input. This is the e-stop input and connects to the machines spindle inverter. If the input is illuminated, check the digital display on the inverter for error messages. If there is an error on the inverter, look up the code in the Delta and/or Schneider manuals and perform the recommended actions to rectify.
– If there is no message on the inverter, or there is no GX15 connection going to the inverter, then on the controller, go to menu → diagnostics → port list: scroll down to the GX15 input and press the shift button to change the polarity. Press the OK button twice. The input polarity should be changed and the error message should no longer appear on the main screen.
22 – File not fully running. Only Spindle Comes on and then shuts off.
May hit machine limit. Check File. Go into Settings, and Select Line Number. Check how many lines the file has.
23 – Z Axis Cutting too deep
Check Z Touch off puck height.
Bring bit down where ever It is being touched off from and check if Z reads 0. If it reads 0 but then changes when running the file, load file first and then turn on vacuum and perform the touch off. Double check the 0 at the location before running.
24 – Handheld Controller is backlit but not showing anything. Machine does not move.
First power down the machine, open the back of the control cabinet and re-seat the connection for the handheld. After re-seating, close the cabinet and try powering on again. If the issue persists, replace the handheld.
25 – All functions work with the exception of the spindle and spindle inverter.
– Fuses are blown in the electrical cabinet. Check which fuses are blown.
-Identify the wire labels associated with the fuses and look up the circuit in the machine’s wiring diagram. If needed, request a wiring diagram for the machine from support@technocnc.com.
– Once the circuit is identified, check for continuity across the entire circuit. This will allow you to identify any high voltage shorts. If there are any, replace the cable causing the short.
– If the circuit has continuity throughout, check the grounds for the high voltage cables. All grounds should be tightly secured to ONLY ground terminals. If grounds are not secured, or not in the correct position, make the necessary changes.
– Once these steps are completed, replace the fuse(s) and restart the machine.
26 – Atlas not turning On. Red Off Light is on, vacuum works, gate valves work.
First, rapidly press the off button, The off button may be stuck closed and sticking. Next check incoming power at the back. Next check the green button wiring. Next check if any breakers or fuses are tripped. Next check the starter for the machine, may want to press the reset buttons.
27 – Gate valves not working
-First, check that the gate valve button is turning on and off when compressed and decompressed. Have a helper check the solenoid on the back of the machine on the gate valve to ensure the solenoid is clicking on and off.
– Check incoming air. Check PSI on regulator and may want to increase.
-If air pressure is fine, and your helper hears the air being released from the gate valve when being turned on and off, the gate valve may be working fine, but the filter for the gate valve may be clogged, inhibiting any vacuum air from getting to the table. Clean out this filter and check again.
28 – Random Pausing during cut
Check cut file. This machine does not have a toolchanger so you cannot have different tool numbers in the same file.
An M0 command in the file is also a pause command and should not be used.
29 – M37 Error
M37 is for tool heights, but this machine does not come with a toolchanger so no too heights can be applied. May be using wrong post. This is true for Atlas machines equipped with a WinCNC PC based controller, not for a handheld controller.
30 — USB not being detected
First, plug in the USB directly at the Weihong controller. If not check files in the USB, there must be at least one .nc file on the root directory in order for the machine to pick it up.
31 — Machine does not respond to any commands, no errors appear, coordinates do not change when jogging. Top right corner of the screen reads Estp.
– Check that the spindle inverter is not throwing an alarm. If it is, look up the error in the correct inverter manual(MS300 for Atlas or VFD-E for HD Series) and trouble shoot.
– Look at the inputs for limit switches, GX01, GX03, GX04, GX06, GX07, and GX08. If any are active, the corresponding axis is currently sitting on its limit and needs to be pushed off manually. This can be done with the power to the machine off. For the z-axis, you may need to remove the the top cover and rotate the belt by hand.
32 — When switching from 3MS controller to G2 controller, scale is off.
Calculated new scale for both x/y, and z. Results are as follows:
X/Y Axis Pulse Eq – 0.00787
Z Axis Pulse Eq – 0.00253
33 — One side of the gantry seems to be moving in the y-axis and the other seems to be dragging behind
One of the stepper motors is not getting power. First check the connections at the motor and the Yako stepper drive: With the machine off, check and make sure the connections aren’t loose. If they are, tighten up the connections and try to run the machine again. If this doesn’t work, proceed to step 2.
Step 2 – You may have to check the power connections going to the axis drivers. Measure the incoming AC power to the drive. There should be 110V AC. If not, the transformer at the front of the cabinet is bad. If there is power, replace the Yako drive.
