Problem:

Whenever machine is powered down and powered backup you keep getting a . . .
 
"DS0300 : APC ALARM : NEED REFERENCE RETURN"
 (31i controls)
or
"300 APC ALARM : Nth-AXIS ORIGIN RETURN"
(18i or earlier controls)
 
Cause:  Servo axis absolute position retaining batteries are bad
 
Solution:  Replace batteries
 
Explanation:  Murata turning centers have two sets of retaining batteries. One set retains the
absolute positioning of each servo axis. This is the information that tells the machine where it is
positioned at all times.
 
When the machine is turned off, the batteries supply a current to the encoder which stores all the
positioning information while powered down. These batteries are usually (8) "D" Cell batteries
installed in (2) battery cases located on the backside of the machine.
 
If at any time while the machine is powered down these batteries lose their charge, all
information stored on the encoders will be lost. You must then go through the process of re-
establishing the home positions for all of your different axis which can be time consuming and
unnecessary.

We recommend changing these batteries once a year or whenever you get a "LOW BATTERY
ALARM," whichever comes first.
What causes zero return position to change or loss of it on any CNC?

1. Crash- causes motor coupling to slip or drive miscalculate position

2. Chips piled in area of deceleration dog (switched machines only)
3. Zero return switch(switched machines only)- If Limit switch-does it move freely (clean
it) If prox switch, then wipe chips off Face
4. Backup Battery needs replacement keeps encoder position when power is shut off
(Warning Most machines require replacement with power up)
5. One revolution pulse on the encoder happens to be really close to the drop off point of
the decel dog(Switched machines only)

How to determine what type of zero return type you have?

After initial power up. Then perform zero return. Do the axes decelerate in the end when you
zero return this machine? If Yes you have zero return decel switches. If No you have absolute
encoders no decel switches.

Troubleshooting the different axis zero return types

With Decel switches (switched):

1. Check that it is hitting the decel dog properly. Keep in mind if you move switch or
dog your zero return position will change and you may need to do a gridshift. Inspect and
clean Limit switch or Prox/decel dog and area around the decel dog of any chips. If its a
limit switch push the plunger to see if its sticky (clean with WD40 if necessary). If ok then
check the Prox or limit switch for power to and from switches with a meter, Make sure you
are not testing hard overtravel limit switches instead of zero switch.
2. The one revolution pulse might be to close to the drop off point of the deceleration
dog Disconnect motor coupling then rotate motor only 1/2 turn then retighten and try zero
returning.
Also check if there is any conditions that must be satisfied to be able to zero return? Does
the axis need to be in a certain area? do you have to zero return any axis first? is the
tailstock back? turret clamped? etc.
3. If the CNC is crashed (something slips) or loss of power while its machining. The
CNC control can get goofed up. Power down then back up and zero return and see if it
corrects itself. If not you may have to reset it.
4. If it does not decel it is not seeing the limit switch. Check the power and input diagnostic
in the control by putting metal in front of the prox or activating the limit switch.

NOTE: Remember switched machines after the initial zero return. Will not recalculate the zero
return again unless the power is turned completely off at main breaker then back on. Only then it
will recalculate the zero return. Also Keep in mind if you move switch or dog your zero return
position will change and you may need to do a gridshift.

Without decel switches (Absolute encoder switchless):

Once the zero return is set, that's it. You must reset it through a procedure to reset it. Some
controls are fooled if the axis is moving when the power is off or loss of power while its
machining. (NOTE:Do not disconnect encoder cable from drive to check connections unless you
know how to reset zero return. You will loose zero return position if it is set.)

Soft overtravel machine alarm occurs when zero returning:

There are 3 ways to get by this in order to complete the zero return. Reasons for this problem can
vary. Most controls have a way to bypass the soft overtravels without changing any parameters
and will usually reset by cycling power. The another way is to change the overtravel temporarily
to allow for a completed zero return and then change back the parameter. The last way is to push
the axis by hand with power off to get the axis closer to zero return position.
Causes:

This usually occurs on a Z-axis of vertical machining center or X-axis of turning centers. These
axes tend to drift down if brake does not stop axis quick enough before power down. A crash can
also cause this to happen. This will also occur if axes are moving and the main breaker is cut off
when they are in motion. Problem is when the power is off it does not track axis movement.

Fanuc controls only. Turn the control power off. Power on the control pressing letter (P) and the
cancel (CAN) key and keep them depressed until the CRT Display comes up plus an additional 5
seconds. Then release P and Cancel keys . (Do not hold in any other keys or risk loosing
parameters, programs and more) Once powered up fully perform Zero Return. This procedure
bypasses the soft limit, and will reset after completing a zero return. If the axis overtravels again
after deceleration, more than likely you have a bad Zero return Switch if its not an absolute pulse
coder.

Resetting zero return position (Different ways CNC OEM's set zero return up)?

Procedure varies from machine to machine, model to model. Here are Four different zero return
setting types:

1. There is a Parameter for each axis called gridshift that can be changed to a value.
(switched machines)
2. Special machine tool builder procedure that will automatically bump up against a hard
stop and backs off a certain distance.
3. Special procedure that you place the axis where you think zero return should be. Then
perform procedure to call that position home. Some will also require the axis to be moved
to find the one rev pulse.Here is an example of a procedure for fanuc controls setting zero
return position.
4. Special procedure that you place the axis just before usually 1/4-1/2 inch where you think
zero return should be. Then perform procedure that will move the axis to the one
revolution pulse and count the gridshift value and stop.

How does an encoder determine zero return?

Most encoders must find the one revolution pulse of the encoder first. The gridshift value is
counted off of this pulse. The machine must be told at what point to begin looking for this one
rev pulse. Here are 2 types: switched and switchless.

On switched machines with a zero return dog the the prox or limit reads this dog. Then once it
goes past this dog and drops off, it begins looking for this pulse then begins counting the
gridshift. On switched machines you will not loose zero return as long as you do not disconnect
the mechanical linkage or disturb the switch or dog you can just zero return the machine as usual.

On switchless machines once the zero return is complete the battery backup holds this position in
memory, so if battery is lost you will have no choice but to reset Zero Return.
Excess following error alarm Troubleshooting and repairing

What does excess following error mean?

When an axis can not physically keep up with the commanded control speed

Troubleshooting excess following errors

Causes for following error

1. Mechanical problems that are causing a load on the axis. Either bearings, axis brake,
lubrication, counter balance weight etc.
2. Old or aging drives can also be the cause.

Troubleshooting following errors

Many of the newer controls have a diagnostic in which you can look at that shows the physical
following error when the axis is moving. Try jogging at various speeds and view the following
error. Notice there is a jump when the axis first starts-this is common. View the following error
ounce the axis reaches its speed and holds steady. Compare to another axis for a comparison.
Make sure you check an axis that corresponds to if it is horizontal or gravity is pulling down on
it. Many vertical axis problems with a following error problem can be related to counterballance
weights and axis brakes. Also try moving in small increments with the hand wheel and
handwheel the axis back and forth to see how quickly the following error steadies out. It should
steady out after about one bouce from positive 1or 2 to negative 1 or 2 and hold steady or not
bounce at all. If it bounces multiple times it tells you you most likely you have a bind or load in
the axis. If this is the case and it is a horizontal axis consider putting the machine in Estop and
powering off the machine and grab onto to the ballscrew and turn it by hand to see how it feels.

To access the screen to view the following error for Fanuc controls 15, 16,18,21,and above press
the system key then press the DGN softkey. Page down till you get to 300. Here you should see
a description for excess servo error.

Repairing

As a temporary fix to get a machine running there is often a parameter that can be adjusted to
allow a larger following error limit. However accuracy of the machine will also be affected when
this is adjusted. Another temporary fix may be to drop down your rapid or feedrates depending
on where the following error alarms occurs in the program.

Beyond that find and repair the problem otherwise I gaurantee it will return at a later date.
What causes zero return position to change or loss of it on any CNC?

1. Crash- causes motor coupling to slip or drive miscalculate position

2. Chips piled in area of deceleration dog (switched machines only)

3. Zero return switch(switched machines only)- If Limit switch-does it move freely (clean
it) If prox switch, then wipe chips off Face

4. Backup Battery needs replacement keeps encoder position when power is shut off
(Warning Most machines require replacement with power up)

5. One revolution pulse on the encoder happens to be really close to the drop off point of
the decel dog(Switched machines only)

How to determine what type of zero return type you have?

After initial power up. Then perform zero return. Do the axes decelerate in the end when you
zero return this machine? If Yes you have zero return decel switches. If No you have absolute
encoders no decel switches.

Troubleshooting the different axis zero return types

With Decel switches (switched):

1. Check that it is hitting the decel dog properly. Keep in mind if you move switch or
dog your zero return position will change and you may need to do a gridshift. Inspect and
clean Limit switch or Prox/decel dog and area around the decel dog of any chips. If its a
limit switch push the plunger to see if its sticky (clean with WD40 if necessary). If ok then
check the Prox or limit switch for power to and from switches with a meter, Make sure you
are not testing hard overtravel limit switches instead of zero switch.

2. The one revolution pulse might be to close to the drop off point of the deceleration
dog Disconnect motor coupling then rotate motor only 1/2 turn then retighten and try zero
returning.
Also check if there is any conditions that must be satisfied to be able to zero return? Does
the axis need to be in a certain area? do you have to zero return any axis first? is the
tailstock back? turret clamped? etc.

3. If the CNC is crashed (something slips) or loss of power while its machining. The
CNC control can get goofed up. Power down then back up and zero return and see if it
corrects itself. If not you may have to reset it.

4. If it does not decel it is not seeing the limit switch. Check the power and input diagnostic
in the control by putting metal in front of the prox or activating the limit switch.
NOTE: Remember switched machines after the initial zero return. Will not recalculate the zero
return again unless the power is turned completely off at main breaker then back on. Only then it
will recalculate the zero return. Also Keep in mind if you move switch or dog your zero return
position will change and you may need to do a gridshift.

Without decel switches (Absolute encoder switchless):

Once the zero return is set, that's it. You must reset it through a procedure to reset it. Some
controls are fooled if the axis is moving when the power is off or loss of power while its
machining. (NOTE:Do not disconnect encoder cable from drive to check connections unless you
know how to reset zero return. You will loose zero return position if it is set.)

Soft overtravel machine alarm occurs when zero returning:

There are 3 ways to get by this in order to complete the zero return. Reasons for this problem can
vary. Most controls have a way to bypass the soft over travels without changing any parameters
and will usually reset by cycling power. The another way is to change the over travel temporarily
to allow for a completed zero return and then change back the parameter. The last way is to push
the axis by hand with power off to get the axis closer to zero return position.

Causes:

This usually occurs on a Z-axis of vertical machining center or X-axis of turning centers. These
axes tend to drift down if brake does not stop axis quick enough before power down. A crash can
also cause this to happen. This will also occur if axes are moving and the main breaker is cut off
when they are in motion. Problem is when the power is off it does not track axis movement.

Fanuc controls only. Turn the control power off. Power on the control pressing letter (P) and the
cancel (CAN) key and keep them depressed until the CRT Display comes up plus an additional 5
seconds. Then release P and Cancel keys . (Do not hold in any other keys or risk loosing
parameters, programs and more) Once powered up fully perform Zero Return. This procedure
bypasses the soft limit, and will reset after completing a zero return. If the axis overtravels again
after deceleration, more than likely you have a bad Zero return Switch if its not an absolute pulse
coder.

Resetting zero return position (Different ways CNC OEM's set zero return up)?

Procedure varies from machine to machine, model to model. Here are Four different zero return
setting types:

1. There is a Parameter for each axis called gridshift that can be changed to a value.
(switched machines)

2. Special machine tool builder procedure that will automatically bump up against a hard
stop and backs off a certain distance.
 3. Special procedure that you place the axis where you think zero return should be. Then
perform procedure to call that position home. Some will also require the axis to be moved
to find the one rev pulse.Here is an example of a procedure for fanuc controls setting zero
return position.

4. Special procedure that you place the axis just before usually 1/4-1/2 inch where you think
zero return should be. Then perform procedure that will move the axis to the one
revolution pulse and count the gridshift value and stop.

How does an encoder determine zero return?

Most encoders must find the one revolution pulse of the encoder first. The gridshift value is
counted off of this pulse. The machine must be told at what point to begin looking for this one
rev pulse. Here are 2 types: switched and switchless.

On switched machines with a zero return dog the the prox or limit reads this dog. Then once it
goes past this dog and drops off, it begins looking for this pulse then begins counting the
gridshift. On switched machines you will not loose zero return as long as you do not disconnect
the mechanical linkage or disturb the switch or dog you can just zero return the machine as usual.

On switchless machines once the zero return is complete the battery backup holds this position in
memory, so if battery is lost you will have no choice but to reset Zero Return.