515

Navigate to SYSTEM > PARAM and check parameters 5500-5549 series. Specifically verify parameters related to rotary axis interference zones (exact parameter depends on axis: A-axis typically uses 5530-5539, B-axis 5540-5544). Note the current minus-side limit settings.

Check parameter 5490 bit settings to verify which interference check function is enabled (bit 0=rotary axis interference check). If bit is ON, the function is active.

Compare the current rotary axis position (visible in POSITION screen - RELATIVE or MACHINE coordinates) against the interference zone parameters. Verify if the commanded move truly violates the mechanical interference zone or if parameters are overly restrictive.

If interference zone parameters are incorrect, adjust parameters 5530-5544 (specific to your rotary axis) to reflect actual mechanical interference boundaries. Record original values before modification. Power cycle the control after parameter changes.

Incorrectly setting interference zones may allow actual collisions. Verify new settings with manual jog mode at reduced feedrate override before automatic operation.

Note the active program name and block number (N-number) displayed with the alarm on the alarm screen. Press RESET to clear alarm, then review the program at the flagged block.

Check the commanded rotary axis position in the flagged block and several preceding blocks. Verify incremental (G91) vs absolute (G90) programming modes. Check for accumulated incremental moves that exceed limits.

Navigate to OFFSET/SETTING > WORK and verify all active work coordinate system offsets (G54-G59) for the rotary axis. Incorrect offsets can shift the effective commanded position into interference zones.

Correct the program command or work coordinate offset as needed. Use GRAPHICS or DRY RUN with machine lock (parameter 3007#0=1) to simulate corrected program before actual execution.

Always verify rotary axis positioning in simulation mode before running corrected programs to prevent crashes.

Check DIAGNOSIS > PARAMETER screen #300-#399 (axis-specific diagnostics). For the affected rotary axis, verify diagnostic #301 bit 5 (zero return complete flag). If OFF, reference point has not been established.

Perform manual reference point return (G28) for the affected rotary axis. Navigate to MDI mode, enter 'G28 Hn0;' (where n is the rotary axis letter: A, B, or C). Observe that axis moves to reference point and #301 bit 5 turns ON.

Ensure no tooling or workpiece interference exists before executing reference point return. Use override controls for first movement.

If reference point return fails or alarm persists, check absolute encoder battery voltage. Navigate to DIAGNOSIS screen and check diagnostic #007 (battery voltage, should be >3.0V). Check amplifier for BAT LED if voltage is low.

If battery voltage is low (<3.0V), replace encoder battery per manufacturer procedure and re-establish absolute position using reference point return or manual pulse generator at known mechanical reference position.

Battery replacement on absolute encoders requires re-establishment of machine zero. Document current position before battery disconnection if possible.