22001

Access Machine Data Parameters

Navigate to Commissioning → Machine Data → Channel/Axis Specific → Select affected axis → MD36100 (minus software limit switch).

Always backup machine data before making changes using Archive function

Verify Current Limit Values

Check MD36100 value against machine drawings and compare with MD36000 (reference point coordinate) to ensure proper working envelope.

Incorrect limits can cause collision damage

Adjust Software Limits

Modify MD36100 to appropriate negative value based on machine geometry, then perform RESET and reference point approach.

Set limits 2-3mm inside physical travel to allow safety margin

Check Active Work Offset

In Machine panel, navigate to Parameters → Work Offsets to view active G54-G59 values and verify which coordinate system is active.

Use ACTUAL VALUES display to see machine coordinate position

Verify Coordinate System Calculation

Calculate machine coordinate position by adding workpiece coordinate to active work offset, compare against MD36100 limit.

Large work offsets can push machine coordinates beyond software limits

Correct Work Offset Values

Adjust work offset parameters or switch to appropriate coordinate system (G53 for machine coordinates) to bring position within limits.

Use G53 command temporarily to move in machine coordinates for recovery

Check Reference Point Status

In Diagnostics → Service → Axis Status, verify REF point validity for affected axis and check for encoder alarms.

Never assume position is correct without valid reference point

Perform Reference Point Approach

Execute reference point approach using Machine → Reference Point or JOG mode REF function to re-establish axis position.

Approach reference point slowly if unsure of actual position

Verify Position Accuracy

After referencing, check machine position display matches expected location and verify MD36000 reference point coordinate is correct.

Use dial indicator to verify mechanical position matches display

Review Active NC Program

In Program Manager, examine the NC block that triggered the alarm and check absolute coordinate values against work offset settings.

Use Program Test function to simulate without axis movement

Verify Program Coordinate System

Check if program uses correct G54-G59 work offset and verify coordinate values are within expected workpiece envelope.

Mixing up coordinate systems is a common cause of overtravel

Correct Program or Setup

Either modify NC program coordinates or adjust work offset values to ensure all programmed positions remain within software limits.

Use graphical simulation to visualize complete tool path before execution

Check Following Error Values

In Diagnostics → Service → Servo Trace, monitor following error during movement and compare against MD36350 (maximum following error).

High following errors indicate mechanical or servo problems

Inspect Backlash Compensation

Review MD32450 (backlash compensation) settings and verify mechanical condition of axis drive components.

Backlash compensation should match actual measured backlash

Optimize Servo Parameters

Adjust servo gain parameters or perform servo optimization using SINUMERIK Optimize function to reduce following errors.

Use automatic servo optimization for consistent results