1003

Check Following Error Parameters

Navigate to SETTING > PARAMETERS > press PAGE DOWN to Parameter 29 (Following Error Limit). Verify current setting is appropriate for trunnion mass and typical loads (usually 0.0050-0.0100 inches).

Inspect Trunnion Mechanical Condition

Manually rotate trunnion table through full range checking for binding, debris, or damaged worm gear teeth. Remove workpiece and check if alarm persists during light moves.

Ensure spindle is retracted and all clamps are released before manual rotation

Verify Drive Current Settings

Check Parameter 78 (Trunnion Drive Current) in SETTING > PARAMETERS. Compare to machine specifications and increase by 10-15% if within motor ratings to overcome mechanical resistance.

Test with Reduced Feed Rate

Execute slow positioning moves (F10-20) using MDI mode with G0 A90 commands to isolate if alarm occurs only during rapid movements or all motion.

If alarm only occurs at high feed rates, gradually increase Parameter 29 until stable operation is achieved

Check Encoder Cable Connections

Power down machine and inspect encoder cable connections at both the trunnion motor and control cabinet. Look for loose connections, corrosion, or damaged pins on the feedback connector.

Verify Encoder Signals in Diagnostics

Navigate to CURRENT COMMANDS > DIAGNOSTICS > ENCODER and observe trunnion encoder counts during manual rotation. Signals should increment smoothly without dropouts or erratic jumping.

Each degree of rotation should show approximately 4000 counts on standard Haas trunnion encoders

Test Cable Continuity

Using multimeter, check continuity of encoder cable conductors from motor junction box to control cabinet connector. Test for shorts between signal wires and ground.

Ensure machine power is OFF and locked out before performing electrical measurements

Inspect for Electrical Interference

Check routing of encoder cable for proximity to power cables or VFD lines. Verify proper shielding and grounding of encoder cable shield at control cabinet end only.

Verify Air Pressure Supply

Check main air pressure gauge reads 80-100 PSI. Navigate to CURRENT COMMANDS > DIAGNOSTICS > INPUTS and verify air pressure switch input is active when pressure is adequate.

Test Brake Solenoid Operation

In CURRENT COMMANDS > DIAGNOSTICS > OUTPUTS, manually activate trunnion brake solenoid output and listen for audible click at trunnion motor brake assembly.

Brake should release when solenoid energizes and engage when de-energized - opposite of spindle orientation

Check Brake Mechanical Function

With machine in EMERGENCY STOP (brake engaged), attempt to manually rotate trunnion. Should require significant force. When brake releases during normal operation, rotation should be smooth.

Never force rotation when brake is engaged as this can damage brake disc or motor

Inspect Brake Air Lines

Check pneumatic lines to trunnion brake cylinder for leaks, kinks, or disconnections. Verify quick-disconnect fittings are properly seated and O-rings are intact.

Check Drive Status LEDs

Locate trunnion servo drive module in control cabinet and observe status LEDs. Green indicates normal operation, red indicates fault condition. Record LED pattern for diagnosis.

Verify Drive Power Connections

Inspect power connections to servo drive including DC bus voltage, motor power leads, and control power. Check for loose connections, burnt terminals, or damaged wiring.

High voltage present - use proper PPE and lockout procedures when inspecting drive connections

Monitor Drive Parameters

Access servo drive diagnostics through NGC control if available, or use drive manufacturer's software to check internal fault codes, current output levels, and feedback signal quality.

Test Drive Communication

Verify communication between NGC control and servo drive by checking for proper command/feedback exchange in real-time diagnostics during attempted axis movement.