1A0-008E

Check Current Spindle Positions

Press the position display key and verify current angular positions of both master and slave spindles. Note the position difference in degrees or revolutions.

Switch to spindle position display mode by pressing the SPINDLE POS key multiple times to see both S1 and S2 (or configured spindle axes) simultaneously.

Review Safety Clearance Parameter

Access MOD > Machine Parameters > enter password > navigate to MP7680.x where x = slave spindle number. Note the configured safety clearance value (typically in degrees or mm depending on configuration).

Do not modify this parameter without consulting machine manufacturer documentation, as it is safety-critical.

Reposition Spindles

In MDI mode, use M3/M4 with S-value or M19 (spindle orientation) commands to move spindles to positions that satisfy the clearance requirement. Ensure physical clearance matches or exceeds MP7680.x value.

Use M19 S1 with angular position specification (e.g., M19 S1 P90) to precisely position the master spindle before attempting synchronization.

Retry Synchronization Command

After establishing adequate clearance, execute M138 (synchronous spindle operation) or M139 (exact angular synchronization) as required by your application. Monitor the synchronization process in the position display.

First verify clearance with M138 for speed synchronization before attempting M139 for angular synchronization.

Verify Spindle Configuration Parameters

Access MOD > Machine Parameters and review MP7670.x (spindle axis assignment), MP7671.x (master spindle number), and MP7672.x (synchronization enable). Verify x index matches your slave spindle number and values are correctly set.

Document all current parameter values before making any changes. Incorrect spindle configuration can cause severe machine damage.

Check Safety Clearance Value

Examine MP7680.x value and verify it is realistic for your machine configuration. Typical values range from 30-180 degrees for angular clearance. Compare with machine builder specifications.

If MP7680.x = 0, synchronization may be attempted immediately without clearance checking, which can be dangerous on some machines.

Validate Encoder Assignment

Check MP7673.x to ensure correct position encoder is assigned to slave spindle. Mismatched encoder assignment can cause the control to calculate incorrect clearance values.

Use TNC diagnostic screen (Test Run > Spindle) to verify encoder signals are being read correctly for both master and slave spindles.

Test After Parameter Correction

If parameters were modified, perform a control restart (reboot TNC). Then test synchronization with spindles at known safe positions using M138 in MDI mode.

Always test synchronization at reduced feed rates and with operator presence at emergency stop during initial validation.

Verify Encoder Functionality

Navigate to Test Run > Spindle test mode. Manually rotate each spindle and verify position feedback updates correctly and smoothly on the TNC display. Look for jumps, stuck values, or erratic readings.

Compare displayed position change with actual physical rotation using a mark on the spindle. One revolution should equal exactly 360.000 degrees on display.

Check Encoder Reference Marks

Review whether spindle encoders have valid reference marks. Check Status > Positions display for REF indicator next to spindle axes. If missing, perform spindle reference run using M19 or machine-specific homing procedure.

Loss of encoder reference can cause unpredictable synchronization behavior and position errors.

Inspect Encoder Hardware

Physically inspect encoder discs, sensors, and cable connections for both master and slave spindles. Clean encoder heads and check cable shield continuity if erratic behavior is observed.

Check PLC diagnostic inputs for encoder error signals (typically marked as encoder monitoring bits in machine-specific PLC).