0102 Spindle Keylock High gear
Sheet 4 plug 2 pin-d
This error indicates a 24 volt signal from the high gear proximity switch present at the control interface when there should be zero volts. If the error can be cancelled by pressing the ERROR pushbutton on the control the fault is probably a malfunction of the proximity switch; refer to paragraph (d). If the error can't be cancelled, continue with paragraph (a)
a) With the spindle stopped, try to rotate the spindle from the spindle nose. A free turning spindle would indicate that high gear was engaged, and the error is correct; refer to paragraph (b). If the spindle is difficult to turn, medium or low gears are engaged therefore the error is false; refer to paragraph (d).
b) Monitor the triac outputs in the rear of the control, they are numbered from 1 to 16 from left to right on the bottom row, 17 to 32 on the next row, etc. Triac 10 is the 110 volts AC output to the high gear solenoid valve through fuse 10. The red LED should indicate if the triac is switched-on. Check for 110 volts AC at fuse 10, if a voltage is present the triac or 'Digital Output' board is faulty; refer to paragraph (c). If there is no 110 volts output at fuse 10 refer to paragraph (d).
c) Switch-off the control and transpose the 'DO' boards situated in the lower rack, left of centre. Power-up the machine and retry; if a different, unrelated error displays the 'DO' board is faulty and will need replacing. If the 0102, 0002 or 1102 error returns the triac is faulty; switch-off and replace triac 10, or if a spare isn't available change with another triac e.g. triac 5, to test.
d) Gain access to the rear of the column by manually jogging X and Y axes to a convenient position. Remove the cover to terminal box 12 mounted on the rear of the spindle motor. While the 0102, 0002 or 1102 error is displayed check for 24 volts DC on terminal 424. If 24 volts is present the high gear proximity switch is faulty. The switch, the front one of 3, is mounted on a plate to the right of the spindle motor. If there's zero volts on 424 the 'Digital Input' board is suspect; refer to paragraph (e).
e) Switch-off the control and transpose the 'DI' boards situated in the lower rack to the left. Power-up the machine and retry; if a different, unrelated error displays the 'DI' board is faulty and will need replacing. If the same 0102 error returns the fault may be with the 'Watchdog' board (WD 50x) in the control or corruption of the memory. If another control is available the 'Watchdog' boards can be exchanged to test. If the memory is to be reloaded remember to punch-out programme and tool information first (although an up to date back-up tape should always be held).