18002

Check Physical Coolant Level

Visually inspect the coolant reservoir tank to verify actual coolant level against the sensor position.

Ensure machine is in safe state before opening coolant tank covers

Verify Sensor Operation

Navigate to Diagnostics > PLC > Inputs/Outputs to check the coolant level sensor input status (typically DB31.DBX or similar PLC interface).

Compare sensor reading with visual inspection to confirm sensor accuracy

Refill Coolant System

Add appropriate coolant mixture to reservoir tank, ensuring proper concentration ratio as specified in machine documentation.

Use only manufacturer-approved coolant types to prevent system damage

Reset Alarm

Press RESET key or navigate to Alarms > Reset to clear the alarm after coolant level is restored.

Monitor for alarm recurrence which may indicate leakage or consumption issues

Access PLC Diagnostics

Navigate to Diagnostics > PLC > Service > Inputs to monitor the coolant level sensor input signal in real-time.

Document the input address and current state for troubleshooting reference

Test Sensor Manually

Manually actuate the float switch or test the sensor while monitoring the PLC input status to verify sensor operation.

Ensure electrical safety when testing sensors near coolant systems

Check Sensor Wiring

Inspect sensor cable connections at both sensor and PLC input terminal, checking for corrosion, loose connections, or damaged wiring.

Coolant environments are corrosive - check for green corrosion on terminals

Replace Sensor if Defective

If sensor fails testing, replace with identical part number and reconfigure PLC input parameters if necessary.

Power down PLC input module before disconnecting sensor wiring

Check PLC Interface Configuration

Navigate to Commissioning > Machine Data > PLC Interface and verify MD11210 settings for coolant monitoring inputs.

Document current settings before making changes for rollback capability

Verify Input Logic

Check if the sensor input logic is inverted - some sensors are normally open, others normally closed when coolant level is adequate.

Incorrect logic inversion can cause false alarms or missed low-level conditions

Test Input Signal

Use PLC diagnostics to force the input state and verify alarm behavior matches expected logic configuration.

Test both high and low input states to confirm proper alarm generation and clearing

Correct Configuration

Modify MD11210 parameters or input logic as needed, then perform a PLC reset to activate changes.

Always backup machine data before making parameter changes

Inspect for External Leaks

Check all visible coolant lines, fittings, pump connections, and tank seams for signs of coolant leakage or staining.

Use a flashlight to check hidden areas behind panels and under the machine base

Check Internal Coolant Passages

Inspect spindle coolant passages and tool changer coolant connections for internal leaks that may not be immediately visible.

Internal spindle leaks may require spindle removal for proper repair

Monitor Consumption Rate

Fill reservoir to known level and monitor coolant consumption over a specific operating period to quantify leak rate.

Normal coolant loss is minimal - significant consumption indicates leakage

Repair Identified Leaks

Replace damaged fittings, tighten connections, or seal tank cracks as identified during inspection.

Use only compatible sealants and fittings approved for coolant system use

Check Coolant Return Flow

Observe coolant return lines to the reservoir tank to verify adequate return flow during pump operation.

Return flow should be steady and consistent - intermittent flow indicates blockage

Inspect Return Filters

Remove and inspect coolant return filters for clogging with chips, debris, or biological growth that restricts flow.

Wear gloves when handling used coolant filters due to potential bacterial contamination

Clear Return Line Blockages

Use compressed air or appropriate cleaning methods to clear blocked return lines and restore proper coolant circulation.

Work from reservoir back toward machine to push debris toward collection point

Replace Filters and Test

Install new return filters and run coolant system to verify proper return flow and stable reservoir level.

Dispose of used coolant filters according to local environmental regulations