88

Emergency Stop and Visual Inspection

Press E-STOP and visually inspect the affected axis for obvious obstructions, crashed tooling, or workpiece interference.

Ensure all motion has stopped before approaching the machine

Manual Axis Movement Test

Use HANDLE JOG mode to manually move the axis at slow feed rates (10-50 IPM) to identify binding points or resistance.

Listen for unusual grinding or scraping sounds during manual movement

Check Way Lubrication

Verify way oil level and operation through DIAGNOSTICS > WAY LUBE menu, ensure proper lubrication flow to axis ways.

Low way oil can cause increased friction and servo overload conditions

Inspect Ball Screw and Coupling

Check ball screw for damage, debris, or coupling misalignment that could cause mechanical binding during axis movement.

Check Servo Current Limit

Navigate to SETTING > PARAMETERS and verify Parameter 70 (Servo Current Limit) matches factory specifications for your axis motor model.

Factory default is typically 75-85% of motor rated current

Review Acceleration Parameters

Check Parameters 71-74 (Axis Acceleration) and Parameters 75-78 (Max Velocity) for excessive values that could cause current spikes.

Never exceed manufacturer recommended acceleration values

Verify Servo Gain Settings

Access DIAGNOSTICS > SERVO menu and compare current gain values against factory backup parameters or service manual specifications.

Perform Servo Optimization

Run automatic servo tuning through SETTING > SERVO SETUP if parameters appear incorrect or after mechanical repairs.

Check Motor Temperature

Feel motor housing temperature after alarm - excessive heat indicates winding problems or inadequate cooling.

Allow motor to cool before touching - servo motors can reach 150°F+

Verify Encoder Feedback

Access CURRENT COMMANDS > POSITION and compare commanded vs actual position for the affected axis during slow movements.

Test Motor Resistance

With power OFF and motor disconnected, use multimeter to check motor winding resistance between phases - should be balanced within 5%.

Disconnect all power and verify lockout before electrical testing

Monitor Amplifier Status

Check DIAGNOSTICS > AMPLIFIER STATUS for fault codes or abnormal voltage/current readings on the affected axis amplifier.

Review Cutting Parameters

Examine current program for excessive feed rates, spindle speeds, or depth of cut that could overload axis servos during cutting.

Check for missing or incorrect G-code feed rate commands

Inspect Cutting Tools

Check for dull, chipped, or improperly sized cutting tools that increase cutting forces and axis loading.

Verify Workholding

Ensure workpiece is properly secured and not shifting during cutting operations, causing sudden load changes.

Monitor Servo Load Display

Use CURRENT COMMANDS > SERVO LOAD to monitor real-time axis loading during test cuts at reduced parameters.

Check Input Voltage

Verify incoming AC voltage at main disconnect is within ±10% of nameplate rating using DIAGNOSTICS > AC VOLTAGE display.

Inspect DC Bus Voltage

Monitor DC bus voltage in DIAGNOSTICS > DC VOLTAGE - should be stable within manufacturer specifications during axis movement.

Verify Motor Connections

Inspect motor power cable connections at both motor and amplifier for looseness, corrosion, or damage.

Perform electrical inspections only with qualified personnel and proper lockout procedures

Test Regenerative Resistor

Check regenerative braking resistor operation during rapid deceleration - faulty regen can cause current spikes.