okuma OSP-P300S, OSP-P300L User Manual

CNC SYSTEM

OSP-P300S/P300L

ALARM & ERROR LIST

(1st Edition)

Pub No. 5921-E (LE37-006-R1) Nov. 2011

5921-E P-(i)

SAFETY PRECAUTIONS

The machine is equipped with safety devices which serve to protect personnel and the machine itself from hazards arising from unforeseen accidents. However, operators must not rely exclusively on these safety devices: they must also become fully familiar with the safety guidelines presented below to ensure accidentfree operation. This instruction manual and the warning signs attached to the machine cover only those hazards which Okuma can predict. Be aware that they do not cover all possible hazards.

1. Precautions Relating to Installation

(1) Please be noted about a primary power supply as follows.

 Do not draw the primary power supply from a distribution panel that also supplies a major

noise source (for example, an electric welder or electric discharge machine) since this could cause malfunction of the CNC unit.

 If possible, connect the machine to a ground not used by any other equipment. If there is

no choice but to use a common ground, the other equipment must not generate a large amount of noise (such as an electric welder or electric discharge machine).

(2) Installation Environment

Observe the following points when installing the control enclosure.

 Make sure that the CNC unit will not be subject to direct sunlight.

 Make sure that the control enclosure will not be splashed with chips, water, or oil.

 Make sure that the control enclosure and operation panel are not subject to excessive

vibrations or shock.

 The permissible ambient temperature range for the control enclosure is 5 to 40°C (41 to

104°F).

 The permissible ambient humidity range for the control enclosure is relative humidity 50%

or less at 40°C (104°F) (no condensation).

 The maximum altitude at which the control enclosure can be used is 1000 m (3281ft.).

2. Points to Check before Turning on the Power

(1) Close all the doors of the control enclosure and operation panel to prevent the entry of water,

chips, and dust.

(2) Make absolutely sure that there is nobody near the moving parts of the machine, and that there

are no obstacles around the machine, before starting machine operation.

(3) When turning on the power, turn on the main power disconnect switch first, then the CONTROL

ON switch on the operation panel.

5921-E P-(ii)

SAFETY PRECAUTIONS

3. Precautions Relating to Manual/Continuous Operation

(1) Follow the instruction manual during operation.

(2) Do not operate the machine with the front cover, chuck cover, or another protective cover

removed.

(3) Close the front cover before starting the machine.

(4) When machining the initial workpiece, check for machine operations, run the machine under no

load to check for interference among components, cut the workpiece in the single block mode, and then start continuous operation.

(5) Ensure your safety before rotating the spindle or moving a machine part.

(6) Do not touch chips or workpiece while the spindle is rotating.

(7) Do not stop a rotating part with hand or another means.

(8) Check that the condition of hydraulic chuck jaws as mounted, operating pressure, and

maximum permissible revolving speed.

(9) Check the condition and location of the cutting tool as mounted.

(10) Check the tool offset value.

(11) Check the zero offset value.

(12) Check that the SPINDLE OVERRIDE and FEEDRATE OVERRIDE dials on the NC operation

panel are set to 100%.

(13) When moving the turret, check the software limits for X- and Z-axes or the locations of limit

switch dogs to prevent interference with the chuck and tailstock.

(14) Check the location of the turret.

(15) Check the location of the tailstock.

(16) Cut workpieces with a transmitted power and torque within the permissible range.

(17) Chuck each workpiece firmly.

(18) Check that the coolant nozzle is properly located.

4. On Finishing Work

(1) On finishing work, clean the vicinity of the machine.

(2) Return the ATC, APC and other equipment to the predetermined retraction position.

(3) Always turn off the power to the machine before leaving it.

(4) To turn off the power, turn off the CONTROL ON switch on the operation panel first, then the

main power disconnect switch.

5921-E P-(iii)

SAFETY PRECAUTIONS

5. Precautions during Maintenance Inspection and When Trouble Occurs

In order to prevent unforeseen accidents, damage to the machine, etc., it is essential to observe the following points when performing maitenance inspections or during checking when trouble has occurred.

(1) When trouble occurs, press the emergency stop button on the operation panel to stop the

machine.

(2) Consult the person responsible for maintenance to determine what corrective measures need

to be taken.

(3) If two or more persons must work together, establish signals so that they can communicate to

confirm safety before proceeding to each new step.

(4) Use only the specified replacement parts and fuses.

(5) Always turn the power off before starting inspection or changing parts.

(6) When parts are removed during inspection or repair work, always replace them as they were

and secure them properly with their screws, etc.

(7) When carrying out inspections in which measuring instruments are used - for example voltage

checks - make sure the instrument is properly calibrated.

(8) Do not keep combustible materials or metals inside the control enclosure or terminal box.

(9) Check that cables and wires are free of damage: damaged cables and wires will cause current

leakage and electric shocks.

(10) Maintenance inside the Control Enclosure

a. Switch the main power disconnect switch OFF before opening the control enclosure door.

b. Even when the main power disconnect switch is OFF, there may some residual charge in

the MCS drive unit (servo/spindle), and for this reason only service personnel are permitted to perform any work on this unit. Even then, they must observe the following precautions.

 MCS drive unit (servo/spindle)

The residual voltage discharges two minutes after the main switch is turned OFF.

c. The control enclosure contains the NC unit, and the NC unit has a printed circuit board

whose memory stores the machining programs, parameters, etc. In order to ensure that the contents of this memory will be retained even when the power is switched off, the memory is supplied with power by a battery. Depending on how the printed circuit boards are handled, the contents of the memory may be destroyed and for this reason only service personnel should handle these boards.

(11) Periodic Inspection of the Control Enclosure

a. Cleaning the cooling unit

The cooling unit in the door of the control enclosure serves to prevent excessive temperature rise inside the control enclosure and increase the reliability of the NC unit. Inspect the following points every three months.

 Is the fan motor inside the cooling unit working?

The motor is normal if there is a strong draft from the unit.

 Is the external air inlet blocked?

If it is blocked, clean it with compressed air.

6. General Precautions

(1) Keep the vicinity of the machine clean and tidy.

(2) Wear appropriate clothing while working, and follow the instructions of someone with sufficient

training.

(3) Make sure that your clothes and hair cannot become entangled in the machine. Machine

operators must wear safety equipment such as safety shoes and goggles.

5921-E P-(iv)

SAFETY PRECAUTIONS

(4) Machine operators must read the instruction manual carefully and make sure of the correct

procedure before operating the machine.

(5) Memorize the position of the emergency stop button so that you can press it immediately at any

time and from any position.

(6) Do not access the inside of the control panel, transformer, motor, etc., since they contain high-

voltage terminals and other components which are extremely dangerous.

(7) If two or more persons must work together, establish signals so that they can communicate to

confirm safety before proceeding to each new step.

7. Symbols Used in This Manual

The following warning indications are used in this manual to draw attention to information of particular importance. Read the instructions marked with these symbols carefully and follow them.

5921-E P-(v)

SAFETY PRECAUTIONS

5921-E P-(i)

INTRODUCTION

Before using this NC unit, read this manual thoroughly in order to ensure correct use. This manual explains how to use and maintain the control so that it will deliver its full performance and maintain accuracy over the long term. You must pay particular attention to the cautions given in this manual; read them carefully and make sure you fully understand them before operating the NC.

5921-E P-(i)

TABLE OF CONTENTS

SECTION 1 CLASSIFICATION OF ALARMS ...........................................................1

1-1. Alarm Classifications ......................................................................................................... 1

1-2. Object Number and Object Message ................................................................................ 2

1-2-1. Alarm Codes........................................................................................................ 3

1-2-2. Bit conversion method......................................................................................... 3

1-2-3. How to check alarm contents .............................................................................. 4

SECTION 2 ALARM P...............................................................................................5

SECTION 3 ALARM A.............................................................................................74

SECTION 4 ALARM B...........................................................................................249

SECTION 5 ALARM C...........................................................................................464

SECTION 6 ALARM D...........................................................................................544

SECTION 7 ERROR..............................................................................................645

SECTION 8 APPENDIX ........................................................................................754

8-1. Factor Classification Code/Factor Parameter................................................................ 754

8-1-1. Factor Classification Code/Factor Parameter (for Machine) ........................... 754

SECTION 1 CLASSIFICATION OF ALARMS

Alarms related with the OSP are classified into five types such as Alarm P, A, B, C and D.

1-1. Alarm Classifications

5921-E P-1

Alarm

P Stops NC operation. All NC functions are inoperative.

B The commands in the active block are

C The part program being run is executed to

D This alarm does not have any influence on

Machine Conditions When ALARM Lamp

Comes ON

axis feed

Stops;

Shuts off power supply to X- and Z-axis servo drives.

Alarm display is displayed on the operation panel.

Stops;

Shuts off power supply to X- and Z-axis servo drives.

Alarm display is given on the operation panel.

completed. Spindle rotation and coolant supply do not

stop. Power supply to X- and Z-axis servo drives

is not shut off. Alarm display is given on the operation

panel.

the end (up to M02 command). Spindle rotation and coolant supply do not

stop. Power supply to X- and Z-axis servo drives

is not shut off. Alarm display is given on the operation

panel.

the machine operation. Alarm display is given on the operation panel.

spindle rotation coolant supply

axis feed Operations for display are possible. spindle rotation coolant supply

Operative NC Functions Thereafter

Concerning the control, cancel the alarm by turning power on again after turning it off once.

The machine remains inoperative until the control is reset and the alarm canceled.

Operations for display are possible. The machine remains inoperative until the control is reset and the alarm canceled.

Operations for display are possible. No new program can be run until the control is reset and the alarm is canceled.

Operations on the operation panel are all operative. Alarm cannot be canceled unless the cause of the alarm is removed.

SECTION 1 CLASSIFICATION OF ALARMS

LE37006R0100300020001

Display Format of Alarm P, A, B, C and D

ALARM-A

Alarm number

Object number

Alarm level

Alarm message

Object message

Alarm code

Alarm character-string

1-2. Object Number and Object Message

The object number and the object message show the programming system and the control axis where the alarm has occurred by the number and message as shown in the table blow:

5921-E P-2

Object No. Meaning Object message Notes

None No classification None

01 System 1 “A side” or “1-A sd” 1st spindle and turret A 02 System 2 “B side” or “1-B sd” 1st spindle and turret B 03 System 3 “2-A sd” 2d spindle and turret A 04 System 4 “2-B sd” 2d spindle and turret B 11 1st X-axis “XAaxis” or “X-axis” 12 1st Y-axis “YAaxis” or “Y-axis” 13 1st Z-axis “ZAaxis” or “Z-axis” 16 1st W-axis “W-axis” 19 1st C-axis “C-axis” or “Caxis1” 20 1st S-axis “SPDL” or “SPDL-1” 21 1st T-axis “TAaxis” or “T-axis” 22 1st M-axis “MAaxis” or “M-axis” 31 2d X-axis “XBaxis” 32 2d Y-axis “YBaxis” 33 2d Z-axis “ZBaxis” 39 2d C-axis “Caxis2” 40 2d S-axis “SPDL-2” Sub spindle, pick-off spindle 41 2d T-axis “TBaxis” 42 2d M-axis “MBaxis” 53 3d Z-axis “ZCaxis” LT series

As indicated above, the object numbers and messages to be used are determined by the machine specifications.

1-2-1. Alarm Codes

In this manual, alarm codes are explained using such as "X", "XX", and "XXYY". Explanation is given in the following methods:

(1) The alarm code indicated in this text can be used directly as the key to find the contents of error.

(2) The alarm code indicated in this text should first be converted into bit expression (pattern),

which is then used as the key to find the contents of error.

In the case of 2), the procedure to convert the alarm code into bit pattern is shown below.

1-2-2. Bit conversion method

5921-E P-3

SECTION 1 CLASSIFICATION OF ALARMS

Alarm Code

(Expressed in

hexadecimal)

0 0000 8 1000 1 0001 9 1001 2 0010 A 1010 3 0011 B 1011 4 0100 C 1100 5 0101 D 1101 6 0110 E 1110 7 0111 F 1111

Bit Pattern

Alarm Code

(Expressed in

hexadecimal)

Bit Pattern

1-2-3. How to check alarm contents

LE37006R0100300060001

The method to find the details of the alarm indicated by the bit pattern is explained below using an example.

Example:

[Code] XX

bit1->EC I/O power shut off error

bit2->ECC error

bit3->Not used

bit4->Not used

bit5->EDRQ INT signal

bit6->ECP INT signal

bit7->ECP RUN signal

bit0->Battery error

If an alarm occurs, a hexadecimal number is displayed.

If "$C1" is displayed, for example, first convert this "$C1" into bits.

5921-E P-4

SECTION 1 CLASSIFICATION OF ALARMS

After the conversion, it is known that Bit0, Bit6, and Bit7 are ON. See the information above and you will find that these error codes correspond to "battery error", "ECP INT signal", and "ECP RUN signal", respectively.

Error Display Format

ERROR

Error number

Error message

Indication of ERROR

Error code Error character-string

bit 0

bit 1

bit 2

bit 3

bit 4

bit 5

bit 6

bit 7

SECTION 2 ALARM P

0700 NC start-up error ........................................................................................... 10

0701 P100-Menu initialization failure ..................................................................... 10

0702 Power failure upon start-up ........................................................................... 11

0703 Load information file not found ..................................................................... 11

0704 File load error ................................................................................................ 11

0705 Default scheduling table error ....................................................................... 12

0706 Backup data file error .................................................................................... 12

0707 DTL link/unlink error ..................................................................................... 12

0708 RT thread stack overflow .............................................................................. 13

0709 Hardware exception ...................................................................................... 13

0710 System call error ........................................................................................... 13

0711 AlarmService library error .............................................................................14

0712 AlarmService internal error (exception) ........................................................ 14

0713 AlarmService error ........................................................................................ 14

5921-E P-5

SECTION 2 ALARM P

0714 Blue screen ................................................................................................... 14

0715 P100-Menu error ........................................................................................... 15

0716 Floating point exception ................................................................................ 15

0717 PLC control error .......................................................................................... 15

0718 Real time thread time over ............................................................................ 15

0719 HXCP thread error ........................................................................................ 15

0720 AlarmService internal error ........................................................................... 16

0721 DeviceNet error ............................................................................................. 16

0723 DeviceNet I/O data link file read ................................................................... 17

0725 M code data file ............................................................................................ 17

0726 Safety speed data error ................................................................................ 17

0727 MCS firmware doesn't support POS2 unit .................................................... 17

0728 FL-net error ................................................................................................... 18

0729 Non-responsive software detected. .............................................................. 18

0731 R Spec. error ................................................................................................18

0732 Unable to execute lost motion compensation ............................................... 18

0735 MCS DD encoder link error ........................................................................... 18

0736 MCS DD encoder error ................................................................................. 19

0737 MCS DD encoder (slave sensor) detected error ........................................... 19

0738 MCS DD encoder initialization failure ........................................................... 20

0739 MCS DD encoder (slave sensor) initialization failure .................................... 21

0741 MCS firmware version error .......................................................................... 22

0742 Relocation detection error ............................................................................. 22

0744 MCS power supply unit overload .................................................................. 22

SECTION 2 ALARM P

0750 The spec.-code or select-soft. was wrong .................................................... 22

0752 VDU communication error ............................................................................ 23

0753 VDU detected error ....................................................................................... 23

0754 VDU initialization failure ................................................................................ 24

0755 SIO link error ................................................................................................. 24

0756 PSC optical scale encoder error ................................................................... 25

0757 MF-SAFETY Error ........................................................................................ 25

0758 Safety I/O Error ............................................................................................. 26

0759 Safety Servo Link Error ................................................................................. 28

0782 Magnetic encoder speed detection error ...................................................... 29

0783 MCS Rotary encoder 5 initialization failure ................................................... 29

0784 MCS Rotary encoder 5 error ......................................................................... 30

0785 MCS Rotary encoder 4 initialization failure ................................................... 30

0786 MCS Rotary encoder 4 error ......................................................................... 30

0787 MCS Rotary encoder 3 initialization failure ................................................... 30

0788 MCS Rotary encoder 3 error ......................................................................... 30

0789 MCS Rotary encoder 2 error ......................................................................... 31

5921-E P-6

0790 MCS Rotary encoder 1 initialization failure ................................................... 31

0791 MCS Rotary encoder 1 error ......................................................................... 31

0792 MCS Linear scale 4 initialization failure ........................................................ 32

0793 MCS Linear scale 4 error .............................................................................. 32

0794 MCS Linear scale 3 initialization failure ........................................................ 32

0795 MCS Linear scale 3 error .............................................................................. 33

0796 MCS Linear scale 2 initialization failure ........................................................ 33

0797 MCS Linear scale 2 error .............................................................................. 33

0798 MCS Linear scale 1 initialization failure ........................................................ 33

0799 MCS Linear scale 1 error .............................................................................. 33

0800 Spindle D/A control data file read ................................................................. 34

0801 TCP/IP board detected error ......................................................................... 34

0802 Load information file not found ..................................................................... 35

0803 File load error ................................................................................................ 35

0804 MSB file mismatch ........................................................................................ 35

0805 MOP-Tool parameter PBU load .................................................................... 35

0806 MOP-Tool tool data PBU load ...................................................................... 35

0807 ACP panel status receipt error ...................................................................... 36

0808 Speed change ratio failure ............................................................................ 36

0810 NC I/O data file read ..................................................................................... 36

0812 MCS initialization error .................................................................................. 36

0813 MCS Communication error ........................................................................... 38

0814 MCS data file corrupt .................................................................................... 39

SECTION 2 ALARM P

0815 PLC real-time task loop error ........................................................................ 40

0816 PLC initialization error ................................................................................... 40

0817 MCS error ..................................................................................................... 41

0818 ADP initialization failure ................................................................................ 41

0820 Machine data file read .................................................................................. 41

0821 Spindle gear ratio .......................................................................................... 42

0822 Wheel data file read ...................................................................................... 42

0823 AXIS CONSTRUCTION DATA setting error ................................................. 42

0824 Unit connection mistake ................................................................................ 43

0825 AXIS CONSTRUCTION name not set .......................................................... 43

0826 AXIS CONSTRUCTION DATA file read ....................................................... 43

0827 Control axis not found ................................................................................... 43

0828 Wire feed axis No. error ................................................................................ 43

0833 MCS option program file not sent ................................................................. 44

0834 MCS servo data error ................................................................................... 44

0835 MCS communication error ............................................................................ 44

0836 Program request illegal ................................................................................. 45

5921-E P-7

0837 Loader spec. code data error ........................................................................ 45

0838 Loader backup data file read error ................................................................ 45

0839 Specification conditions failure ..................................................................... 45

0840 SuperHi-NC specification mismatch ............................................................. 46

0841 FCP4 board detected error ........................................................................... 46

0842 Safety monitor spec. error ............................................................................ 46

0845 Specification code setting failure .................................................................. 46

0846 Thermal deviation comp. backup data file read ............................................ 47

0847 DNC-DT preload task start error ...................................................................47

0848 PSCB error ...................................................................................................47

0849 Synchronous axis tandem control initialization failure .................................. 47

0850 MCS Undefined alarm number ..................................................................... 48

0851 MCS Inverter unit fault .................................................................................. 48

0852 Mistake in data from MCS to NC .................................................................. 49

0853 MCS CON APA deviation ............................................................................. 50

0854 MCS Power supply unit error ........................................................................ 50

0855 MCS Converter link error .............................................................................. 51

0856 MCS DC-bus voltage alarm .......................................................................... 51

0857 MCS Motor overcurrent ................................................................................ 51

0858 MCS Power unit overheat ............................................................................. 51

0859 MCS Power unit overload ............................................................................. 52

0860 MCS Supply voltage flutter ........................................................................... 52

0861 MCS Inverter capacity differs from spec. ...................................................... 52

SECTION 2 ALARM P

0862 MCS Winding change failure ........................................................................ 52

0863 MCS Encoder link error ................................................................................ 53

0864 MCS Encoder detected error ........................................................................ 53

0865 MCS Encoder initialization failure ................................................................. 54

0866 MCS Encoder with shaft detected error ........................................................ 54

0867 MCS Encoder with shaft initialization failure ................................................. 54

0868 MCS ABSO SCALE error .............................................................................55

0869 MCS ABSO SCALE initialization failure ........................................................ 55

0870 MCS Magnetic encoder alarm ...................................................................... 55

0871 MCS Resolver alarm ..................................................................................... 55

0872 MCS Pulse generator count over .................................................................. 56

0873 MCS Motor overheat ..................................................................................... 56

0874 MCS Servo link error .................................................................................... 56

0875 MCS Servo link disconnection ......................................................................57

0876 Mistake in data from NC to MCS .................................................................. 57

0877 MCS Servo data error ................................................................................... 57

0878 MCS Illegal command ................................................................................... 58

5921-E P-8

0879 MCS CON speed over .................................................................................. 58

0880 MCS Speed command over .......................................................................... 59

0881 MCS DIFF over ............................................................................................. 59

0882 MCS APA speed over ................................................................................... 59

0883 MCS Full-closed APA error ........................................................................... 59

0884 MCS Over speed .......................................................................................... 60

0885 MCS Speed deviation over ........................................................................... 60

0886 MCS Collision detected ................................................................................ 60

0887 MCS Urgent-stop time over .......................................................................... 61

0888 MCS Belt is broken ....................................................................................... 61

0889 MCS Axis change control error ..................................................................... 61

0890 MCS Independent encoder initialization failure ............................................ 61

0891 MCS Calculated current position lies outside range ..................................... 62

0892 MCS Motor overload ..................................................................................... 62

0893 MCS Safety speed monitor E-Link error ....................................................... 62

0894 MCS ABSO SCALE sub-slider detected error ..............................................62

0895 MCS Tandem control communication error .................................................. 63

0896 MCS Full abso scale link error ...................................................................... 63

0897 MCS Full abso scale error ............................................................................ 64

0898 MCS Full abso scale initialization failure ...................................................... 64

0899 MCS Axis stop signal error ........................................................................... 65

0940 Time sharing task control .............................................................................. 65

0941 Real-time task control ................................................................................... 65

SECTION 2 ALARM P

0942 Real-time task loop error .............................................................................. 65

0943 Main processor name incorrect .................................................................... 66

0944 Slave processor name incorrect ................................................................... 66

0945 Memory board/battery life ............................................................................. 66

0951 SMP error ..................................................................................................... 66

0952 Not equipped with processor board .............................................................. 67

0954 Peripheral processor start ............................................................................. 67

0955 Spec. code: data file ..................................................................................... 67

0956 Backup data file read .................................................................................... 68

0957 Graphic backup data file read ....................................................................... 68

0958 Pitch compensation data file read ................................................................. 68

0965 Configuration file format error ....................................................................... 69

0971 Cache data: Initialization error ...................................................................... 69

0988 Cache data: Operation error ......................................................................... 69

0989 CPU information table data incorrect ............................................................ 69

0990 TASK generate error ..................................................................................... 70

0991 TASK information table data incorrect ..........................................................70

5921-E P-9

0992 PLC backup data file read ............................................................................ 70

0993 TCP/IP board illegal ...................................................................................... 71

0994 TCP/IP configuration file ............................................................................... 71

0995 Machine axis data file ................................................................................... 71

0996 PLC axis data file .......................................................................................... 71

0997 PLC monitor backup data file read ............................................................... 72

0998 PLC sequence program load ........................................................................ 72

0999 Synchronous tap data file read ..................................................................... 73

0700 NC start-up error

An error occurred when NC started up.

[Object]

None

[Character-string]

None

[Code]

0x10000000: NC Configuration read error 0x10003000: Spec code read error 0x20000000: ServoLink board initializing error 0x3XXX00YY: NC data file read error XXX: 0x002: HD backup status file 0x004: Parameter data file 0x008: Machine data file 0x010: PLC backup data file 0x020: PLC-HMI data file 0x040: Alarm History data file 0x080: PLC AXIS data pbu file 0x100: POT TOOL data pbu file (M/C only) 0x200: MOP TOOL Tool data file (M/C only) 0x400: MOP TOOL Parameter file (M/C only) 0x800: Thermal deviation compensation data file YY: 0x01: File read open error 0x02: File read error 0x03: Version check error 0x04: Check sum error 0x05: Double check sum error 0x06: Backupped Memory error 0x07: File write open error 0x08: File write error 0x40000000: Axis information initializing error

-More than 8 axis 0x50000000: PLC data file read error

-Read failed M code data file 0x60000000: I/O Initializing error

-PLC variable backup file read error

-I/O forced data file read error 0x70000000: ServoLink Initializing error 0x80000000: Operation buffer get error 0x90000000: PBU data file read error 0xA0000000: Shared memory size definition error 0xA1XXXXXX: AlarmService start error XXXXXX: Error code of AlarmService library function 0xA2400002: Alarm History read error 0xA3000000: Thread monitor initializing error 0xA9000000: Initialization processing of the safety logic was not completed within 20 seconds 0xA9000001: Axis construction definition file open error 0xA9000002: Axis construction definition file read error 0xA9000003: Axis construction definition file mismatch 0xFFFFFFFF: Debug information file read error

5921-E P-10

SECTION 2 ALARM P

0701 P100-Menu initialization failure

An error occurred in P100-Menu while system startup.

[Object]

None

[Character-string]

None

[Code]

1: NC Control file was not found. 2: PLC Control file was not found. 3: NC-HMI was not found

4: 3D real sim file was not found. 5: MacMan file was not found. 6: Version mismatch between P100-Menu and PLC Control 7: Version mismatch between P100-Menu and MacMan 8: Version mismatch between P100-Menu and NC Control 11: Conf-P100-menu read error 12: An error occurred at RTOS 13: An error occurred at UPS Service 21: NC Control start failure 22: Error in obtaining shared objects 23: PLC Control start failure 24: NC-HMI start failure 25: 3D real sim start failure 26: MacMan start failure 101: Startup sequence 0x10 receive failure 200: Startup sequence 0x10 send failure 201: Startup sequence 0x20 receive failure 300: Startup sequence 0x20 send failure 301: Startup sequence 0x30 receive failure 400: Startup sequence 0x30 send failure 401: Startup sequence 0x60 receive failure 500: Startup sequence 0x60 send failure 501: Startup sequence 0x70 receive failure 600: Startup sequence 0x70 send failure 601: Startup sequence 0x7C receive failure 700: Startup sequence 0x7C send failure 701: AlarmService start failure 702: Activation sequence 0x80 receive failure

[Probable Faulty Locations]

1.Execution file name failure

2.Data file name failure

3.RTOS failure

4.UPS function failure

5.Software failure

6.Software Version failure

5921-E P-11

SECTION 2 ALARM P

0702 Power failure upon start-up

[Object]

None

[Character-string]

None

[Code]

None

[Probable Faulty Locations]

1.Power failure during while system startup

2.Power shutoff during while system startup

0703 Load information file not found

A load information file was not found.

[Object]

None

[Character-string]

None

[Code]

None

0704 File load error

An object file was not loaded correctly.

[Object]

None

[Character-string]

None

[Code]

1:A file was not found 2:The attribute of file was not correct. 3:The load address information of file was not correct 4:An error occurred when file was loaded FFFFFFFF:The details of alarm was displayed by message from OS

0705 Default scheduling table error

A default scheduling table error was detected.

[Object]

None

[Character-string]

None

[Code]

0x00010001: RTIN default scheduling table error (element number) 0x00010002: RTIN default scheduling table error (end element) 0x00020001: TSMN default scheduling table error (element number) 0x00020002: TSMN default scheduling table error (initial attribute)

[Probable Faulty Locations]

1.NC software failure

0706 Backup data file error

5921-E P-12

SECTION 2 ALARM P

Error occurred when load/save the backup file.

[Object]

None

[Character-string]

None

[Code]

XXXXYYYY XXXX 0x0002:HD backup status file 0x0004:Low speed NC backup data file 0x0008:High speed NC backup data file 0x0010:PLC backup data file 0x0020:PLC-HMI data file 0x0040:Alarm history data file 0x0080:PLC axis data file 0x0100:POT TOOL data file 0x0200:MOP TOOL Tool data file (M/C only) 0x0400:MOP TOOL Parameter data file (M/C only) 0x0800:Thermal deviation compensation data file YYYY 1:File read open error 2:File read error 3:Version check error 4:Check sum error 5:Double check sum error 6:Backup memory check error 7:File write open error 8:File write error

0707 DTL link/unlink error

An error occurred in DTL link or unlink.

[Object]

None

[Character-string]

None

[Code]

1:RTIN refresh error

2:TSMN refresh error

[Probable Faulty Locations]

1.Hardware failure

2.Software failure

0708 RT thread stack overflow

Stack overflow of RT thread was detected.

[Object]

None

[Character-string]

Occurred RT thread name

[Code]

None

[Probable Faulty Locations]

1.NC software failure

0709 Hardware exception

Hardware exception was occurred.

[Object]

None

[Character-string]

Occurred RT thread name

[Code]

Hardware exception code 0x5555: CPU Diagnose error 0x8100:Divide by 0 error 0x8101:Unexpected Single Step Interrupt 0x8102:Unexpected NMI 0x8103:Unexpected Debug Interrupt 0x8104:Overflow error 0x8105:Array Bounds error 0x8106:Invalid Opcode error 0x8107:NPX Device not present 0x8108:Double Fault error 0x8109:Unknown Device error 0x810A:Invalid TSS error 0x810B:Segment not Present error 0x810C:Stack Fault error 0x810D:General Protection error 0x810E:Page Fault error 0x8110:Unknown Device error 1 0x8111:Alignment error

[Probable Faulty Locations]

1.Hardware failure

2.Software failure

[Note]

Alarm information is also displayed also in the console window.

5921-E P-13

SECTION 2 ALARM P

0710 System call error

An error occurred in the INtime system call.

[Object]

None

[Character-string]

Occurred RT thread name

[Code]

XXXXYYYY XXXX:INtime system call code YYYY:Return value or status of INtime system call

[Probable Faulty Locations]

NC software failure

[Note]

Alarm information is also displayed also in the console window.

0711 AlarmService library error

An error occurred in the AlarmService library function.

[Object]

None

[Character-string]

Occurred thread name

[Code]

XXYYYYYY XX:AlarmService library function code YYYYYY:AlarmService library function error code

[Probable Faulty Locations]

NC software failure

[Note]

Alarm information is also displayed also in the console window.

0712 AlarmService internal error (exception)

An error occurred inside of AlarmService.

[Object]

None

[Character-string]

"ALMS"

[Code]

AlarmService internal error code

[Probable Faulty Locations]

NC software failure

[Note]

Alarm information is also displayed also in the console window.

5921-E P-14

SECTION 2 ALARM P

0713 AlarmService error

P100-Menu detected AlarmService error.

[Object]

None

[Character-string]

None

[Code]

None

[Probable Faulty Locations]

1.NC software failure

0714 Blue screen

Blue screen (kernel stop error) occurred.

[Object]

None

[Character-string]

None

[Code]

None

[Probable Faulty Locations]

1.Win32 application failure

2.Windows failure

3.Windows driver failure

0715 P100-Menu error

An abnormal condition of P100-Menu was detected.

[Object]

None

[Character-string]

None

[Code]

None

[Probable Faulty Locations]

1.P100-Menu failure

0716 Floating point exception

Floating point exception was occurred.

[Object]

None

[Character-string]

Occurred RT thread name

[Code]

XXXXYYZZ XXXX:Exception code YY:Not used (0 fixed) ZZ:FPU status word bit5:PE (Precision Exception Flag) bit4:UE (Underflow Exception Flag) bit3:OE (Overflow Exception Flag) bit2:ZE (Zero Divide Exception Flag) bit1:DE (Denormalized Operand Exception Flag) bit0:IE (Invalid Operation Exception Flag)

[Probable Faulty Locations]

NC software failure

5921-E P-15

SECTION 2 ALARM P

0717 PLC control error

Error occurred on PLC Control.

[Object]

None

[Character-string]

None

[Code]

XXXXYYYY XXXX:PLC Control status YYYY:PLC Control error code

[Probable Faulty Locations]

1.PLC software failure

0718 Real time thread time over

Real time-type thread did not finish within the stated time

[Object]

None

[Character-string]

RT thread name that was exceeded the stated time

[Code]

None

[Probable Faulty Locations]

1.NC software failure

0719 HXCP thread error

An abnormal condition of HXCP thread was detected.

[Object]

None

[Character-string]

None

[Code]

None

[Probable Faulty Locations]

1.NC software failure

0720 AlarmService internal error

An error occurred inside of AlarmService.

[Object]

None

[Character-string]

"ALMS"

[Code]

AlarmService internal error code

[Probable Faulty Locations]

1.NC software failure

2.P100-Menu failure

5921-E P-16

SECTION 2 ALARM P

0721 DeviceNet error

Error occurred on DeviceNet.

[Index]

None

[Character-string]

CH* SC$ * : Channel number where the error occurred. S : Sequence counter

[Code]

XXYYZZZZ XX Slave station MacID where the error occurred YY Slave station 0x00 Normal or nonexistent slave station 0x46 Duplicate MacID error 0x48 Communication stop 0x49 Discrimination information was not compatible with scan list 0x4D Data size was not compatible with scan list 0x4E No response in the connection check. 0x4F Other slave stations are nonexistence on network 0x50 Idle condition 0x53 Error received in the connection check 0x54 Timeout occurred in the connection check 0x56 Turn into the idle mode 0x5B Bus off 0x5C Network power supply off ( XXXX became 0xFFFF,if its not caused by slave station, such as communication delay.) ZZZZ Scanner error status bit 0 Memory check error bit 1 Scan list initialize error bit 2 Scan list mismatch error(MacID) bit 3 Scan list mismatch error(Input data) bit 4 Scan list mismatch error(Output data) bit 5 Duplicate MacID error bit 6 Network power supply status error bit 7 Memory parity error bit 8 Input data reception error(single) bit 9 Input data reception error(dowble) bit10 Output data transmission error(single) bit11 Output data transmission error(dowble)

bit12 Slave station communication delay error(single) bit13 Slave station communication delay error(dowble) bit14 Bus off bit15 Diagnostic information access error

[Probable Faulty Locations]

1)Hardware failure

2)Software failure

0723 DeviceNet I/O data link file read

The NC failed to read DeviceNet IO data link file.

[Code]

I/O data file load status (in hexadecimal) 2 ->File open error (no file) 3 ->File read error (no data) 4 ->File attribute error (not "PBU1") 5 ->File close error 6 ->File size error (too small) 7 ->File size error (too large) 100->Wrong PLC machine type 200->Wrong PLC class 300->Wrong file version 1002 ->DN SCAN LIST CHANGE FILE OPEN ERROR 1003 ->DN SCAN LIST CHANGE FILE READ ERROR (NO DATA) 1004 ->DN SCAN LIST CHANGE FILE ATTRIBUTE ERROR (NO 'PBU1') 1005 ->DN SCAN LIST CHANGE FILE CLOSE ERROR 1006 ->DN SCAN LIST CHANGE FILE SIZE ERROR (SIZE SMALL)

5921-E P-17

SECTION 2 ALARM P

0725 M code data file

Establishment data of reading M-code file is bad.

[Code]

1->The denial data is bad.

[Character string]

The number is M-code which is established bad data.

[Measures to Take]

Please correct the bad data of M-code.

0726 Safety speed data error

The safety speed data was in abnormal state in the machine without the CE marking safety speed monitor.

[Index]

Axis name or none (spindle)

[Character-string]

None

[Code]

X X=1:The guard number of the safety speed data was outside the range from -0 to 9.

[Measures to Take]

Change the safety speed monitor data file for axis control. Relevant specifications:Without CE mark safety speed monitor type

[Related Specifications]

Without CE mark safety speed monitor type

0727 MCS firmware doesn't support POS2 unit

This alarm occurs when the firmware ROM version of the NC axis/ machine(PLC) axis MIV unit is not 511 or later when the new POS unit is installed.

[Character-string]

None

[Code]

None

0728 FL-net error

An error occurred during startup of the FL-net card.

[Object]

None

[Character-string]

None

[Code]

Y000XXX Y:0 XXXX: 7F00:System error 7F01:Flash memory error 7F02:DRAM test error 7F03:NICE test error 7F04:EEPROM sum check error 7F05:CPU BUS error 7F06:illegal Instruction Y:1 XXXX: 0004:Timeout error for 4 sec or longer Y:F XXXX: FFFF: FL-net card is not mounted

[Probable Faulty Locations]

FL-net card is defective.

5921-E P-18

SECTION 2 ALARM P

0729 Non-responsive software detected.

Non-answered software was detected.

[Object]

None

[Character-string]

None

[Code]

NT Process name

[Probable Faulty Locations]

NC software failure

0731 R Spec. error

It is the illegal of "R SPEC".

[Index]

None

[Code]

1:"NON R SPEC" of NC is OFF, and "R-SPEC" of SVDN-ID is OFF. 2:"NON R SPEC" of NC is ON, and "R-SPEC" of SVDN-ID is ON. 3:When there are 2 SVDN-boards in the machine, "R-SPEC" of one board is ON, other is OFF. 4X:"NON R SPEC" of NC is OFF, and "R-SPEC" of SVDN-ID is ON, and Restriction-Spec is ON.

0732 Unable to execute lost motion compensation

0735 MCS DD encoder link error

An error occurred in the encoder communication link.

[Object]

Axis name or none (spindle)

[Character-string]

None

[Code]

XXYYZZZZ

XX = $FF (fixed) YY = $00: Error is detected at the DD encoder. $01: Error is detected at the DD encoder(slave sensor). ZZZZ = Encoder link error status at the time of error detection bit15: Undefined bit14: Undefined bit13: Error in communication with the DD encoder (slave sensor) bit12: Error in communication with the DD encoder bit11: MT buffer error bit10: Transmission loop error in AT mode bit9 : Data over error in data receiving part of interface bit8 : Undefined bit7 : Undefined bit6 : Modulation code error bit5 : CRC error bit4 : Format error bit3 : Double transmission error bit2 : Double reception error bit1 : Parity error bit0 : Time-out error This alarm occurs only at ICB-H.

[Probable Faulty Locations]

DD encoder of DD encoder (slave sensor) of the pertinent axis Encoder link cables or connectors Inverter unit control board

0736 MCS DD encoder error

5921-E P-19

SECTION 2 ALARM P

The DD encoder has become undetectable.

[Object]

Axis name or none (spindle)

[Character-string]

None

[Code]

XXYYZZZZ XX = Positional data status bit7 : Error bit (1:error) bit6 : Absolute position sensor margin error.(0:Normal, 1:Warning) bit5 : Gap-Warning (1:Gap-small,Toggle:Gap-big) bit4 : Inclination-Warning (1:CCW-big, Toggle:CW-big) bit3 : Auto set mode (0:Normal, 1:Auto mode) bit2 : Communication error (Toggle by detecting) bit1,0: Error bit number of absolute position code.(It is indicated by 2bits.) YY = Alarm code 01: Stop command has stopped. 02: Control parameter error 04: Absolutization error 05: Initialization speed too high 08: Auto-set-data error 0D: Speed too high 0E: Synchronization error 20: Absolutization mismatch (Only Format-5) 21: Communication-error of Master-sensor (Only Format-5) 3E: Code-error by Absolute-position-sensor 3F: Check-errotr by Absolute-position-code 40: Inclination-error (for plus) 41: Inclination-error (for minus) 42: Gap is narrow 43: Gap is wide ZZZZ = 0000 fixed This alarm occurs only at ICB-H.

[Probable Faulty Locations]

DD encoder

0737 MCS DD encoder (slave sensor) detected error

The DD encoder (slave sensor) has become undetectable.

[Object]

Axis name or none (spindle)

[Character-string]

None

[Code]

[Probable Faulty Locations]

DD encoder (slave sensor)

5921-E P-20

SECTION 2 ALARM P

0738 MCS DD encoder initialization failure

An error occurred in the initialization of the DD encoder.

[Object]

Axis name or none (spindle)

[Character-string]

None

[Code]

The transmitted frame information QC2MTINF appears. If YY = 4, The network address of the responding device appears. If YY = 5, Alarm code + positional data status Refer to MCS DD Encoder error (alarm 1136). If YY = 6, Parameter number at which the error is detected 1: Reception of insufficient number of parameters 2: Basic information for communication being incompatible 3: Multi-turn detection range over 4: Communication protocol version being incompatible 5: Positional data format being incompatible 6: Abbreviated data mode being incompatible However, when abnormal voltage is detected at the encoder fuse XXYY = $FFFF fixed ZZZZ = Detected voltage value of the encoder fuse (12[V] = $9980) Normal range: 10.6[V] to 13.8[V] Allowable range: $8800 to $B000 This alarm occurs only at ICB-H.

[Probable Faulty Locations]

DD encoder Encoder link cables and connectors Inverter unit control board

5921-E P-21

SECTION 2 ALARM P

0739 MCS DD encoder (slave sensor) initialization failure

An error occurred in the initialization of the DD encoder (slave sensor).

[Index]

Axis name or none (spindle)

[Character-string]

None

[Code]

XXYYZZZZ XX = Encoder link initialization sequence number (1B) at the time of the error detection 0: Reset 1: Network address setting 2: Request to send the basic information for communication 3: Change of communication software version 4: Acquisition of device information 5: Parameter change 6: Position detection start 7: AT mode start YY = Error content (1B) 0: Communication error 1: Transmission start time over 2: Transmission finish time over 3: Reception finish time over 4: Abnormal response address 5: Abnormal response code 6: Parameter error ZZZZ = Data (2B) If YY = 0, The encoder link error status C2ERR at the time of error detection appears. If YY = 1, 2 or 3, The transmitted frame information QC2MTINF appears. If YY = 4, The network address of the responding device appears. If YY = 5, Alarm code + positional data status Refer to MCS DD Encoder error (alarm 1136). If YY = 6, Parameter number at which the error is detected 1: Reception of insufficient number of parameters 2: Basic information for communication being incompatible 3: Multi-turn detection range over

4: Communication protocol version being incompatible 5: Positional data format being incompatible 6: Abbreviated data mode being incompatible However, when abnormal voltage is detected at the encoder fuse XXYY = $FFFF fixed ZZZZ = Detected voltage value of the encoder fuse (12[V] = $9980) Normal range: 10.6[V] to 13.8[V] Allowable range: $8800 to $B000 This alarm occurs only at ICB-H.

[Probable Faulty Locations]

DD encoder (slave sensor) Encoder link cables and connectors Inverter unit control board

0741 MCS firmware version error

The MCS software version was not correct.

[Object]

None

[Code]

1-> The MCS software version of the XA axis is not since ICBH590 in the premium thread cutting function spec.

[Probable Faulty Locations]

Specification code error MCS software version error

[Measures to Take]

Reinstall the software or reissue the install disk. MCS software Upgrade

5921-E P-22

SECTION 2 ALARM P

0742 Relocation detection error

Relocation detection error occurred

[Character-string]

ComErr :Communication error PBU :PBU data error PJ :PJ discord PwdTout :Password application timeout PwdChk :Password check error PwdTerm:Password application terminate

[Code]

ComErr: bit2 Atmega error bit1 RTC error bit0 Relocation detection module error PwdChk: Password check error code

0744 MCS power supply unit overload

Power Supply Unit over load

[Object]

Axis name or none (spindle)

[Character-string]

None

[Code]

1(fixed)

[Probable Faulty Locations]

Power unit Overload operation

0750 The spec.-code or select-soft. was wrong

The combination of NC-software and PLC-software was wrong. Or, the combination of specification-code was wrong.

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