3015 Very high current in axis drive.
Sheet 4 Plug 2 Pin-B

a) Visually check if any of the overload units AM O/L1, AM O/L2 or AM O/L 3 mounted adjacent to the Axis Drive Unit in the Power Distribution Panel have tripped. If an overload has tripped go to paragraph (e)

b) If none of the overloads have tripped-out check for 24 volts at terminals 400 and 403 with a voltmeter (TB1 in the power distribution panel). If there is no 24 volts, indicator-fuse 4 in the PDP may be faulty.

c) If none of the overloads have tripped-out and there is 24 volts at terminal 400 but not at terminal 403 then one of the overload units are faulty. To determine which one test for 24 volts at wires numbered 421 and 402 connected to AM O/L 2. If 24 volts is present at 402, then AM O/L 3 is faulty. If 24 volts is present at 421 but not at 402, then AM O/L 2 is at fault. If 24 volts is not present at 421, then AM O/L 3 is faulty. Replace or repair any faulty overload unit. Remember to datum all the axes before running a programme.

d) If none of the overloads have tripped and there is 24 volts at both 400 and 403 then the fault lies from terminal 403 through to Plug 2, Pin-B and the 'Digital Input Board' in the control. Switch off the control and transpose the DI boards situated in the lower rack to the left. Power-up the machine. If the fault disappears, or a different, unrelated error code shows-up, then the DI board is faulty and a replacement is required. If the same error code persists switch off the machine, remove plug 2 and check the continuity from pin-B to terminal 403. There may be a spare wire in the cable loom to utilize if wire 403 appears to be broken. If the wiring is O.K. 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).

e) If one of the overloads has tripped-out check the windings of the offending axis choke (refer to the electrical diagram sheet 2) with a multimeter switched to resistance. Disconnect terminals U, V, W and N related to the axis to check. If any discrepancy is found (comparisons can be made with another axis), the choke must be repaired or replaced.

f) If the choke windings are O.K., disconnect the two wires numbered 281- X axis, 286-Y and 291 for Z axis to the offending axis motor at the ALC contactor and the D terminal on the drive unit. With a multimeter or 'Megger' check the resistance from one of the motor wires to Earth. The reading should be in Mega-ohms for a good motor. If the reading is low (10K ohms or less) it indicates a build-up of carbon around the brush-gear, damaged brush-holders, a faulty commutator or windings. The same check can be made with the motor brushes removed. If the reading is then considerably higher than with the brushes fitted (Mega-ohms), then the commutator or windings are faulty and the motor needs repair or replacement.

g) If the motor has been removed for repair it will be necessary to check and adjust the axis reference position. Remember to datum all the axes before running a programme.