DUPLOMATIC DDC4SW 2.

4 Lite Release 11/05

DDC4SW 2.4 Lite

Diagnostic Software for SM and SMA Turrets
Equipped with DDC4 Electronic Units
INSTRUCTIONS FOR INSTALLATION AND USE

Edition 11/05

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COPYRIGHT 2005 DUPLOMATIC AUTOMAZIONE SPA. ALL RIGHTS RESERVED.

This Instruction manual must not be copied, duplicated, transferred or reduced in any form
(either electronic means or mechanical ones) or transmitted or published in any way (either
electronic or in other manner), without prior written authorization from Duplomatic.

The information in this Manual is given only as a guideline and may be changed without
prior notice. It is not subject to any obligation from Duplomatic Automazione SpA.

Duplomatic Automazione SpA. does not assume any responsibility for errors or imprecise
information contained herein.

The software contains commercial secrets and confidential information which are subject
to copyrights in other countries.

Any unauthorized use of the software and of the respective documentation may violate civil
laws and have penal consequences.

TRADE NAMES
Microsoft Windows is a registered trade-name of Microsoft Co.
All other names of products and companies are trade-names of Duplomatic Automazione
SpA.

EDITION CHRONOLOGY
05-2005 Provisional publication
10-2005 Official release
11-2005 Updated release

DUPLOMATIC AUTOMAZIONE SPA

I-20025 LEGNANO (MI) – ITALY
P.LE Bozzi, 1
E-mail: duploaut@duplomatic.com

Printed in ITALY

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Index

Presentation of DDC4SW 2.4 Lite...........................................................4

Hardware and software requirements ................................................5
Hardware requirements................................................................................................................5
Software requirements .................................................................................................................6
Windows Tips & Tricks .................................................................................................................6
Installation of DDC4SW 2.4 Lite ................................................................7
Use of DDC4SW 2.4 Lite ..................................................................................10
Connection to the electronic circuit board ...............................................................................11
Supervisor and Controller ..........................................................................................................12
Interpretation of input signals ....................................................................................................13
Interpretation of output signals..................................................................................................14
Interpretation of internal signals................................................................................................15
Power voltage checking .............................................................................................................16
Meaning of operation modes .....................................................................................................17
Force Mode ..................................................................................................................................18
Force Mode – Auto, AutoCW, AutoCCW (Mode 1,2,3) ..........................................................20
Force Mode – Jog Next Tool (Mode 4) .....................................................................................21
Force Mode – Service (Mode 5).................................................................................................22
Force Mode – Maintenance (Mode 6) .......................................................................................24
Force Mode – Safety (Mode 7)...................................................................................................25
Emergency ...................................................................................................................................26
Autotest Mode..............................................................................................................................27
Alarm memory – “Event History”................................................................................................28
Event History – RAM memory and Eeprom memory..............................................................30
Meaning of “Info” window ...........................................................................................................31
Setting window.............................................................................................................................32
Modification of the active table .................................................................................................32
Modification of the position number .........................................................................................33
Meaning of alarms .....................................................................................................34
Description of alarms ..................................................................................................................35
Possible causes of alarms .........................................................................................................37
Troubleshooting .............................................................................................................................41

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Chapter
1

Presentation of DDC4SW 2.4 Lite

The software DDC4SW 2.4 Lite has been developed by DUPLOMATIC in order
to supply a simple and flexible basis for installation, configuration and
diagnostics of the electronic DDC4 circuit board, which is part of the turrets
using servomotor technology (SM, SMA, TRMS, etc.).

This program enables access to the complete functions of the turret, to which
extended operation modes have been added, thus offering a gradual operation
sequence. This program allows access to the archive of extended alarms. The
real condition of all input and output signals pertaining to the turret is displayed
during use.

Index

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Chapter
2

Hardware and software requirements

Hardware requirements

The software DDC4SW 2.4 Lite requires an IBM COMPATIBLE PC with at least
one free RS232 serial port, at least 20 MBYTE free memory on the hard disk for
the operating system, 1900 kbyte on the hard disk for applications and 20
MBYTE additional space for storing the temporary data for the installation. The
system requires the use of a mouse. The serial connection consists of a DCE-
DCE cable. Not all signals are necessary. For preparing the connection cables,
the following diagrams must be taken into account.

Attention: Pins 1 and 9 of the serial port of the DDC4 unit are reserved and
cannot be connected to the PC. When however these pins are connected to the
PC, there is no risk of damage, but slowing down of the logical management of
the digital inputs and outputs may occur.

PC-SIDE CONNECTIONS DDC4-SIDE

SUB-D 25 FEMALE SUB-D 9 FEMALE
2 2
3 3
7 5

SUB-D 9 FEMALE SUB-D 9 FEMALE

3 2
2 3
5 5

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Software requirements

The software DDC4SW 2.4 Lite has been developed in the 32-bit technology
and therefore runs under the operating systems Microsoft Windows 95,
Microsoft Windows 98, Microsoft Windows 2000 and Microsoft Windows XP.
The memory requirements depend on the operating system. These values are
listed below as a guideline.
When installing the system under Windows 2000 SP3 some incompatibilities
occurred, which are now being subject to a solution.

Requirements on the RAM memory for the operating systems

Windows 95 4 Mbytes
Windows 98 32 Mbytes
Windows 2000 32 Mbytes
Windows XP 64 Mbytes

Windows Tips & Tricks

Microsoft Windows offers a simple user’s surface, where however some users
may have certain difficulties. Here in the following you can find the basic
information about Windows.

1) Window : A part of the screen which is surrounded by a frame. The entire

program takes place on the respective window.

2) Nearly every window has a menu, i.e. a list of options, which by selection via
mouse will show another menu or enable another step. If the mouse is not
being used, the Alt+Tab keys can be pressed.

3) Keys, Text boxes, Check boxes : The user can interact with the program by
using either keys or icons. For example, the user can press a key and select
it with the L.H. mouse key or move along by means of the keys or other
objects using the Tab key and then press the SPACE BAR for confirming the
step. At the same manner, a check box can either be highlighted or the text
can be selected for being modified inside of the text box.

4) Therefore, when speaking about “Click”, “Double-Click”, “Select”, “Press” in

this Manual, we refer to one of the operation modes described before.

Index

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Chapter
3

Installation of DDC4SW 2.4 Lite

The software DDC4SW 2.4 Lite is supplied on a CD-ROM or as an installation

file of the CABINET type (*.CAB).

(Before carrying out the installation, make sure that all applications previously
opened have been closed in order to avoid any conflict).

To begin the installation, put the CD into the respective drive. From the window
“My computer”, select the respective drive (normally D) and click the file which
is called “Setup”.
The file can be also be executed in the following manner. From the Start-menu
bar, click “Start” and immediately after this click “Run”. Then enter the following
command line:
D:\Setup
Note: The letter “D” refers to the CD-ROM drive.

After a few seconds, the screen will show the first window, which enables the
installation of the program.

The use can decide whether to interrupt the installation by clicking the “Exit
Setup” button or to continue the installation by clicking the “OK” button.
Note: If the message shown in this figure is displayed, please go on. This message means that the installation program
has found some files which must be installed. In this case, by selecting “OK” , the existing files will be replaced by the
latest version.

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At the next step the user must decide in which directory the software shall be
installed (the directory selected by default is the one recommended).

Click here to continue the

installation without changing the
directory

Click here to change the

installation directory

In order to accept the default directory, click the button which shows the PC icon
by using the L.H. mouse button.

After a few seconds the installation program asks in which folder the
DDC4SW_2.4_Lite software shall be installed. The default folder is called
“DDC4SW”. It is recommended not to change this name. Click the “Continue”
button to continue the installation.

Click here to continue the

installation without changing
the folder

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After a few seconds, the following message will be shown, which means that the
installation has been completed:

Click the “OK” button to terminate this step and to quit the installation.

Inside of the folder “Programmi” there is the “DDC4_Lite” folder, which contains
the software.

NOTE: The program requires the MDAC-TYP.EXE library, which is distributed

by Microsoft and will be automatically installed.
Generally, the library existing in the operating system is the most updated
version or is available in other languages. The instructions on the screen shall
be followed.

Index

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Chapter
4

Use of DDC4SW 2.4 Lite

The main window of the program shows the following:

RESET
Menu bar Tools bar
button

Window for serial

connection status

Current
position

Turret status
Window for
INPUT status

Window for turret

OPERATION MODES Window for status
Window for of INTERNAL
OUTPUT status signals

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Connection to the electronic circuit board

Before making the connection to the circuit board, make sure that the serial
cable has been connected both to the PC and to the electronic unit.

Click here to enable the Communication

communication status

Node number
Current set-up of serial
port

After having completed the set-up, the “Link” button must be clicked. If both
indicators “Tx” and “Rx” flash, this means that the PC is connected to the turret
and will interact with it.

If any communication error occurs, the screen will show the respective message
window.

Note: Please refer to the Chapter “Troubleshooting “ for further information.

Index

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Supervisor and Controller

The software operates in two different modes:

• Controller mode
• Supervisor mode

The Supervisor mode allows displaying of information about the turret and the
electronic DDC4 control system.

In the Supervisor mode, all signals to and from CNC will be displayed. The
software will not interfere with the turret functions.

This operation mode will be selected by default when the software is opened.

In the Controller mode, the PC assumes the control of the turret. Therefore, the
signals coming from the CNC do not have any influence on the turret (with the
exception of the 0 mode, which allows the CNC to set the turret in the
Emergency mode).

In Controller mode the signals displayed by the software do not represent the
current state of the CNC.

Index

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Interpretation of input signals

This part of the screen shows in real time all input signals which enter the
controller. This is very useful for immediate data display when troubleshooting
any components or connections.

Number of positions
required (depending on the
electric connections carried
Code of required out)
position Selection of
Std./ High inertia
Start signal (depending on the electric
Number of positions connections carried out)
required (depending
Turret operation mode
on the electric
connections carried
out)
Indicator for high/low
speed

unassigned

When the hard wired signal of the input “PTAB” has been changed, the unit
must be switched off and switched on again, so that the change can be
recognized by the circuit board.

Index

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Interpretation of output signals

The output signals are very useful for identifying the real state of the turret. They
may be used as an aid for error analysis. It must be noted that the INDEXD and
LOCKED outputs are logical outputs and do not come directly from the
proximity switches.

The data on the screen refers to the logical commands from the outputs. If the
output transistors are faulty, if the thermal fuses have tripped, if any false
contact exists on the wiring, then the physical state may be different. In such a
case, this window allows the checking of coherence between the logical output
and the physical output.

Signal: Turret locked

Signal: Turret in position unassigned

Coding bit for alarm group Command for locking

solenoid-valve

Coding of current turret Command for unlocking

position. solenoid-valve
In case of alarm, it
decodes the alarm
subgroup unassigned

Index

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Interpretation of internal signals

The window for the internal signals is used to check the state of the proximity
switches on the turret and the state of the thermal contact on the motor.

Zero sensor status Status of thermal contact

on motor
Locking sensor status

Unlocking sensor status

For normal operation, the signal of the thermal contact on the motor named
“MOT0VL” must be active. In the opposite case, please refer to the Chapter
“Troubleshooting“ for further information.
Note: The ZEROSW signal may be OFF, even if the turret is locked in position 1. This occurs when it is only used for
zero-search and does not have any other function. When however during the zero-search cycle there is no variation, the
proximity switches or the respective connections could be faulty.

Index

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Power voltage checking

By clicking the indicated button during operation of the device, the external
power voltages and the internal voltages generated by the circuit board can be
checked.

Press this key after having powered the

circuit board for monitoring the power
voltages

The following window will be displayed:

If a voltage does not satisfy the requirements, the respective red Led will be on.
If however the voltages are inside of the range, this will be indicated by the
respective green Led.
NOTE: In the aforesaid case, the voltage of Vbus is approx. 2V, i.e. a value which would not allow regular functioning of
the turret. Therefore, the respective Led becomes red.

Index

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Meaning of operation modes

When the software is used in the Controller mode, it supports two operation
modes: “Force” mode and “Autotest” mode.

State of Tools bar in “Force” mode

State of Tools bar in “Autotest” mode

Index

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Force Mode

When the operation mode “Force” has been selected, the following window will
be shown at the bottom on the left side of the main screen page:

General notes

For assuming the control of the turret, the software requires previous setting of
an external mode (MODE01, MODE02, MODE03) from the CNC. This is a
safety measure, which offers security both for the system and the operator. The
“Force” button must be clicked for enabling this mode. In this way, the CNC no
longer has any influence on the control of the turret (the software recognizes the
presence of at least one of the operation modes). Click “SI” (YES) in order to
accept the control of the turret by the PC.

Click “SI” (YES) to enable

the Force mode

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The operation modes available for the DDC4 2.4 Lite software are the same as
the ones which can be selected by the CNC (for example AUTOMATIC,
MANUAL, EMERGENCY).

When the ‘Force’ mode has been enabled, the label “Not Forced” switches to
“Forced” and the background becomes green.

For disabling the “Force” mode, click again the “Force” button or click the
“Autotest” button on the Tools bar.

When the serial connection has been interrupted (cable disconnected, PC

power missing, program terminated), the CNC will be able to assume the control
of the turret, by setting first the “Emergency” mode and then any other mode.

As soon as the label

becomes green, it means
that the system is in
Force mode

Once the system has been

forced, from the pull-down
menu the different
movement options and
turret functions can be
selected

Index

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Force Mode – Auto, AutoCW, AutoCCW (Mode 1,2,3)

These three options allow the turret to move to the required position by
selecting the position number and by entering the START command.

The “Auto” mode selects the shortest direction to reach the desired position.
Select the required position using
the arrow keys

Click this key for

positioning

The “AutoCW” mode and the “AutoCCW” mode force the rotation of the turret
either clockwise or counterclockwise only.

NOTE: The first step, after on-switching, must be the zero-point search.

Index

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Force Mode – Jog Next Tool (Mode 4)

Select via the

appropriate menu the
Jog Next Tool mode
From this menu
select the required
sense of rotation

Click here for

positioning

This mode allows the turret to rotate clockwise or counterclockwise (according

to the direction selected) by one single position.

Index

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Force Mode – Service (Mode 5)

Select via the

appropriate menu
the Service mode

From this menu select

the required command

Click here for

executing the
command

This mode allows step-by-step operation of the turret during positioning.

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Locking : This command enables the locking solenoid valve (this step takes
place without any need to press the “PStart” key). It must be taken into account
that this step is carried out immediately after a locking command is selected.

Unlocking : This command enables the unlocking solenoid valve (this step takes
place without any need to press the “PStart” key). The motor will be enabled
and can be switched off by setting the Emergency mode.

NextToolCW : This command allows the turret to carry out a CW positioning of

30° (in case of a 12-station turret).

NextToolCCW : This command allows the turret to carry out a CCW positioning
of 30° (in case of a 12-station turret).

Continuous rotation CW : This command enables continuous clockwise turret

rotation.

Continuous rotation CCW : This command enables continuous

counterclockwise turret rotation.

Index

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Force Mode – Maintenance (Mode 6)

For the selection of the “Maintenance” mode, the turret must not be unlocked as
was necessary for the previous version of circuit boards. When selecting this
command, the electronic board automatically unlocks the turret.

Operation mode not yet enabled.

Index

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Force Mode – Safety (Mode 7)

This operation mode has not been enabled when this instruction manual was
edited.

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Emergency

This mode allows the resetting of any alarms and restarting of the normal
operation of the electric system.

The “Emergency” mode can be disabled (same as for the CNC) by setting any
other operation mode.

When no operation mode has been

entered, the turret goes to “Emergency”
and remains there until one of the operation
modes has been entered

When the operation mode has been set, the device must not be switched off
and then on again.

Index

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Autotest Mode

When the Autotest mode has been enabled, a sequence of automatic

commands are started, which carry out the test of the turret functions.

For enabling this function, press the “Auto Test” button on the Tools bar.

Click here to enable the function

of automatic turret test

The main page shows the window for AutoTest. Test number
under progress

Press here to start the

AutoTest
Number of tests
carried out

By pressing the START button, an enabling message for the start-up of

AutoTest will be shown. Press “SI” (YES) to continue.

Press to continue

By pressing this button, the AutoTest will start automatically.

To stop the AutoTest, press the START button again.

Index

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Alarm memory – “Event History”

In order to display the last 15 alarms which have occurred in the controller, open
the archive window “Event History” using the indicated button.

Press to display the alarm

archive

After pressing the button, the following window will be displayed:

Alarm display window:

• ID: Cycle N°, where the alarm occurred
• Alarm N°: Alarm family
• Alarm code: Alarm N°
• Mode: Operation mode of turret when the alarm
occurred
• Start Pos: Start position before the event of
alarm
• End Pos: Arrival position required/reached

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Cycle display window:

• ID: Cycle N° carried out
• Mode: Mode where the turret was when
carrying out the cycle
• Start Pos: Position from where the turret
started at cycle start
• End Pos: Position of cycle end

Press here to read the list Press here to read the list Press here to save the
of alarms in the RAM of alarms in the EEprom list of the last 15 alarms
memory memory occurred

Index

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Event History – RAM memory and Eeprom memory

The difference between the RAM alarm memory and the EEPROM alarm
memory is that the RAM memory is the most recent one, i.e. the most updated
memory.

The RAM memory contains the last 15 alarms generated for approx. 15 days,
even when the controller is switched off. This feature is enabled by a buffer
condensator on the electronic circuit board.

Each time an alarm occurs, it will be stored immediately in the RAM memory.

The EEPROM memory on the other hand will be updated every 48 hours by
means of the backup from the RAM memory.

Updating of the EEPROM memory also takes place whenever the device is
switched on.

In order to display list of last alarms, click the “Read from RAM” button in the
window of archives.

NOTE: An explanation of alarm types is given in Chapter “Meaning of Alarms” .

Index

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Meaning of “Info” window

In order to display the “Info” window, click the indicated button on the Tools bar.

Press here to display the

Info window

After pressing the button, the following window will be shown:

Firmware at present Running time of motor Absolute position of

loaded to DSP during the last cycle motor shaft in
hexadecimal
(FF->360°)

• Zero cycle exec.: The turret already did the zero search
Checking of indexing
• Space loop closed : The turret disk is running under
quality
position control
• E2prom ok : The non-volatile E2prom memory works
regularly
• E2prom deleted: The non-volatile E2prom memory has
been deleted or does not work
• Anti clock-wise dir.: The disk is running CCW

Index

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Setting window

The “Setting” window is used for modifying some of the operation parameters
on the turret, such as the position number or the table containing the
parameters suitable for this turret type.

Before opening this window, make sure that there is a connection between the
PC and the electronic unit.

System in Force Press and wait a few

mode seconds for internal
updating

After a few seconds the following window will be displayed:

Window for setting the desired

number of positions

Window for displaying the selected

number of positions and type of
Box for setting the desired inertia. These parameters depend
table on the hardware set-up carried out
(wiring)

Displaying of the active table

number

Modification of the active table

In order to modify the active table, make sure that the system is in the Force
mode and NOT in the Emergency mode. Inside of the respective box “Active
table selection” enter the number of the table to be set. Now press the “Set
table” key. Then press the “Close” key, finally open the window again and make
sure that the value entered has been displayed correctly in the “Active Table”
box.

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Modification of the position number

In order to modify the number of positions, make sure that the system is in the
Force mode and NOT in the Emergency mode. Click inside of the box
containing the value to be modified (8 or 12) and enter the new value.

Then press the “Update” button, switch the electronic unit off and on again. Now
open the window again and make sure that the new values have been
accepted.

Index

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Chapter
5

Meaning of alarms
In the event of an alarm, the following window will be displayed:

Alarm family and type Possible causes for the Description of alarm
generated generation of error generated

Index

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Description of alarms

The description of the alarms must be interpreted as follows:

for ex.: 3.5 Alarm family 3
Alarm N° 5

Alarm family 1
1.0 Driver not powered. Resolver powering incorrect
1.1 Driver not powered. Low-voltage powering incorrect
1.2 Vanref () powering incorrect
1.3 Powering +15 V incorrect
1.4 Powering +5 V incorrect
1.5 Internal powering +24 V incorrect
1.6 Powering -+15 V incorrect

Alarm family 2
2.0 Overvoltage
2.1 Overvoltage during the dynamic braking

Alarm family 3
3.0 Overload
3.1 Overcurrent
3.2 Drive error
3.3 Timeout on positioning window
3.5 Thermal sensor
3.6 Turret faulty
3.7 Overtemperature in the ambient
3.8 Overtemperature on the dissipator
3.9 Motor current derivative too high (short circuit)
3.10 Alarm due to enabling at Input2 missing
3.11 Timeout during the execution of the selected mode (only for 1,2,3,4 and
zero_search)

Alarm family 4
4.0 Locking signal ON during unlocking
4.1 Unlocking signal OFF during unlocking
4.2 Unlocking signal goes to OFF when turret is unlocked
4.3 Locking signal goes to ON when turret is unlocked
4.4 Turret unlocked during on-switching

Alarm family 5
5.0 Unlocking signal is at ON during locking
5.1 Locking signal is at OFF during locking
5.2 Locking signal goes to OFF when turret is locked
5.3 Unlocking signal goes to ON when turret is locked

Alarm family 6
6.0 Timeout during the execution of ‘0’ cycle
6.1 Timeout during the execution of search of ‘0’ end (zero signal does not
return to zero)
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Alarm family 7
7.0 Motion start before the execution of ‘0’ cycle
7.1 Parity error
7.2 Tool does not exist
7.3 PSTART does not arrive within 5 sec. after position code
7.4 Timeout for rotation
7.7 Wrong combination of PTAB01, PTAB02, PTAB03
7.11 Read error on Eeprom
7.12 Write error on Eeprom
7.13 Checksum error on Eeprom
7.14 Interrupt vector invalid

Index

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Possible causes of alarms

Alarm family 1
1.0 Problems with resolver voltage
- Check the wiring and the motor resolver
- If the fault persists, there is a fault on the device
1.1 Three-phase current missing, when motor start-up is called
- Check connections and respective fuses
- If the fault is systematic, probably the device is faulty
1.2 Problems with internal control voltages
1.3 - Probable fault on the device
1.4
1.6
1.5 Problems on 24 V powering voltage to the sensors
- Check the wiring to the turret. Remove the cable to check it
- If the fault persists, there is a fault on the device

Alarm family 2
2.0 Overcurrent:
- If it occurs casually, check all external 400 V power and, if necessary,
install voltage stabilizers
- If the fault is systematic, probably the device is faulty
2.1 Overvoltage reached during the dynamic braking cycle:
- Inertia loaded to the disk too high. Make sure that the configuration
signal (PTAB03 -LK3 on junction box) is set to the correct inertia value.
- If the fault is systematic, probably the braking resistor coil is faulty

Alarm family 3
3.0 Overcurrent
- Short-circuit on motor cables
- Short-circuit to ground
- Heavy overload
- Wiring problems with the resolver
Due to overcurrent and consequently to a possible overheating of the
power module, the unit must be switched off and then switched on again
to create a forced pause for cooling down
3.1 Overload (medium current value too high):
- The inertia loaded to the disk exceeds the limits entered (make sure that
the correct inertia value has been set on the signal PTAB03 – LK3 in the
junction box)
- The unbalanced load exceeds the limits
- Crash during tool rotation
- The sensor or zero cam is not correctly positioned (if this alarm occurs,
when the turret gets locked at the end of reference cycle)
- Wiring to motor or to resolver faulty
3.2 Contouring error (the motor does not follow the trajectory entered):
- The inertia loaded to the disk exceeds the limits (make sure that the
correct inertia value has been set on the signal PTAB03 – LK3 in the
junction box)
- The unbalanced weight exceeds the limits
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- The tool touches slowly the workpiece during tool-disk rotation
- Wiring to resolver faulty
3.3 Timeout reached during the execution of the cycle:
- The tool touches slowly the workpiece at cycle end and therefore cannot
reach its final position
3.5 Tripping of thermal sensor on the motor:
- Indexing frequency too high
- Motor faulty
- Thermal sensor not connected
The alarm will disappear, when the motor has cooled down
3.6 Problems with resolver
- Wrong connection
- Resolver powering interrupted
3.7 Overtemperature in the ambient
- Resolver powering interrupted
3.8 Overtemperature on the dissipator
3.11 Timeout on cycle execution
There has been an abnormal condition not covered by other alarms.

Alarm family 4
4.0 Signal of locking sensor is active during the unlocking stage:
- Unlocking pressure too low
- Position of locking sensor wrong
- Connection/wiring of sensor wrong (remote control application)
- Locking sensor faulty
4.1 Signal of unlocking sensor is not active during the unlocking stage:
- Unlocking pressure too low
- Position of unlocking sensor wrong
- Connection/wiring of sensor wrong (remote control application)
- Unlocking sensor faulty
4.2 Signal of unlocking sensor is not active when the turret is unlocked:
- Problems with pressure
- Connection/wiring of sensor wrong (remote control application)
- Unlocking sensor faulty
4.3 Signal of locking sensor is active when the turret is unlocked:
- Problems with pressure
- Connection/wiring of sensor wrong (remote control application)
- Locking sensor faulty

Alarm family 5
5.0 Signal of unlocking sensor is active during the locking stage:
- Locking pressure too low (only hydraulics)
- Position of unlocking sensor wrong
- Connection/wiring of sensor wrong (remote control application)
- Unlocking sensor faulty
5.1 Signal of locking sensor is not active during the locking stage:
- Locking pressure too low (only hydraulics)
- Position of locking sensor wrong
- Connection/wiring of sensor wrong (remote control application)
- Wrong code on the electronic unit (Circuit board refers to another size)
- Wrong setting of the reference cam (Turret-lock on teeth).
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- Locking sensor faulty
5.2 Signal of locking sensor is not active when the turret is locked:
- Problems with pressure (only hydraulics)
- Connection/wiring of sensor wrong (remote control application)
- Locking sensor faulty
5.3 Signal of unlocking sensor is active when the turret is locked:
- Problems with pressure (only hydraulics)
- Connection/wiring of sensor wrong (remote control application)
- Unlocking sensor faulty

Alarm family 6
6.0 Time-out at reference search:
- Zero sensor faulty (always Off)
- Wrong position of reference cam
- Connection/wiring of sensor wrong (remote control application)
- Disk cannot turn around
6.1 Time-out at searching end of the reference cam:
- Zero sensor faulty (always Off)
- Connection/wiring of sensor wrong (remote control application)
- Disk cannot turn around

Alarm family 7
7.0 Tool is called before the zero cycle:
- Error in programming of CNC logics
- Operator did not call the reference cycle
7.1 Parity error on position code:
- Error in programming of CNC logics
- Wiring problems (PBIT** and PARITY)
- Outputs from CNC/PLC slow (when the PSTART signal is given, the
output value may be wrong)
7.2 An unexisting tool has been called:
- Error in programming of CNC
- Turret not correctly configured (check the number of positions entered by
PTAB01 and PTAB02 – LK1 and LK2 signals in the junction box)
- Wiring problems
7.3 Variation of code position encountered, however the PSTART signal has
not been received within 5 – 20 seconds:
- Error in programming of CNC
- Wiring problems (PSTART signal not connected)
7.4 Time limit for continuous rotation of disk has exceeded:
- Turret has been activated in Maintenance or Service mode for a long
time period
- Indexing frequency too high
7.8 PTAB01 and PTAB02 signals of configuration inputs are not configured
7.7 (Positions number):
- Input error at PTAB01 and PTAB02 (LK1 and LK2 in the junction box)
- Powering of 24 V DC signals is not present for more than 500 ms as to
the 24 V DC reference voltage on the drive-control circuit board
(configuration has not been loaded correctly)
7.11 Memory test failed
7.12 Switch off temporarily and then switch on again. If the alarm persists,
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7.13 probable fault on the device
7.14
7.15
Index

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Troubleshooting

No serial connection has been established:

• Make sure that the cable is connected to the correct PC serial port.
• Make sure that at least the 24V powering unit is connected to the
electronic unit of the turret.
• Check the set-up values of the serial port:
Baud rate: 19200
Parity: none
Bits: 8
Stop bits: 1

The software is too slow:

On old PCs with little memory or slow processor there might be a slow-down
during monitor refreshing.

Some signals (for example the EVLOCK signal) always remain off:
This is due to the reduced time available, at which the signal remains in the
active state (less than 1 sec.).
As the software reads the information from the control unit at regular intervals, it
may occur that the software is reading the data when these are not active. You
must wait for the right moment in order to have the data read in.

The state of the controller is always 'undervoltage':

The electronic unit requires 3-phase voltage of 230 or 400 Vac before doing
positioning.

The state 'Emergency’ cannot be changed:

It must be taken into account that the mode must be different from 0 (mode
1,2,3,4,5,6,7) in order to work with the PC.

Index

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