1047 Er

RBPC 1200
Error messages
Error manual
M1047
Rev. NC
Preface
This manual is part of a set of manuals for the RBPC 1200 pipe-cutting machine. In this manual you
will find the RBPC 1200 programming instructions.
The complete set of manuals consist of the following manuals:
The operators manual This manual describes the operation of the cutting machine, this
manual also contains a number of important notes for safe use
of the pipe cutting machine.
The programmers manual This manual describes the programming of all the profiles of the
machine in relation to the position, marking point, where the
profile will be cut.
The technical manual This manual contains the maintenance schedule of the RBPC
1200 together with calibration instructions. The manual also
contains assembly drawings, electrical schemes and connection
lists.
For safe operation and to ensure the reliability of the pipe cutting machine it is necessary that all the
above manuals are available to all the people who work with the machine and to those who are related
to the machine, like maintenance and service engineers and the work preparation engineers.
It is important that everybody who works with the RBPC 1200 pipe cutting machine is aware of the
safety notes as described in the chapter ‘Safety’ in the operators manual.
For reliability and safe operation of the RBPC 1200 it is necessary that the maintenance is executed
as described in the technical manual.
This manual describes all error messages for all Hgg Profiling Equipment bv machines, that means
that there are messages in this manual which will not be seen on your machine.
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Contents
1. AMPLIFIER ERROR....................................................................................................................................5
2. FOLLOWING ERROR..................................................................................................................................6
2.1. X-, Y-, Z-, I-, H-, C AND CH MOTOR........................................................................................................6
2.2. SENSOR AND PIPE MODE............................................................................................................................7
3. MOTOR WARNING AND MOTOR OVERDUE ERROR.......................................................................8
3.1. FALSE OVERDUE ERRORS...........................................................................................................................8
4. MOTOR OVERHEATED..............................................................................................................................9
4.1. FALSE OVERHEAT ERRORS.........................................................................................................................9
5. END SWITCH ERRORS.............................................................................................................................10
5.1. SOFTWARE END SWITCHES......................................................................................................................10
5.2. Z-MOTOR END SWITCHES.........................................................................................................................10
5.3. I-MOTOR END SWITCHES..........................................................................................................................10
5.4. Y-MOTOR END SWITCHES........................................................................................................................10
5.5. FALSE END SWITCH ERROR MESSAGES....................................................................................................12
5.6. MISSING END SWITCH ERROR MESSAGES.................................................................................................12
5.7. DOUBLE END SWITCH MESSAGES.............................................................................................................12
6. INITIALIZATION ERRORS......................................................................................................................13
6.1. Y AXIS HOME ERROR...............................................................................................................................13
6.2. CUTTING HEAD INITIALIZATION ERROR...................................................................................................13
6.2.1. Z axis initialization error................................................................................................................13
6.2.2. I axis initialization error.................................................................................................................14
6.3. GENERAL HOME SEARCH ERRORS:...........................................................................................................14
7. SENSOR SYSTEM ERRORS......................................................................................................................15
7.1. GENERAL SENSOR CHECK........................................................................................................................15
7.2. HEIGHT SENSOR BLOCKED.......................................................................................................................15
7.3. FLOATING MODE ERRORS........................................................................................................................16
7.4. DEVIATION ERRORS.................................................................................................................................16
8. EMERGENCY BUTTON PRESSED.........................................................................................................17
8.1. FALSE ‘EMERGENCY BUTTON PRESSED’ MESSAGE..................................................................................17
9. CHUCK ERRORS........................................................................................................................................18
9.1. CHUCK ERRORS........................................................................................................................................18
9.2. CHUCK OPERATION ERRORS:...................................................................................................................19
9.3. PIPE BLOCKED IN THE CHUCK..................................................................................................................19
10. AMPLIFIER CHECK..............................................................................................................................21
10.1. X MOTOR.............................................................................................................................................21
10.1.1. No display.......................................................................................................................................21
10.1.2. resolver break status.......................................................................................................................21
10.1.3. over-current status..........................................................................................................................21
10.2. MOTORS Y, H, AND CH......................................................................................................................21
10.2.1. None of the leds is turned on...........................................................................................................22
10.2.2. The resolver break led is on............................................................................................................22
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10.2.3. The over-current led is on...............................................................................................................22

10.2.4. The DBR active led is on.................................................................................................................22
10.3. MOTORS Z AND I.................................................................................................................................23
10.4. C MOTOR.............................................................................................................................................23
10.4.1. None of the leds is turned on...........................................................................................................23
10.4.2. The over-current led is on...............................................................................................................23
10.4.3. The DBR active led is on.................................................................................................................24
11. ENCODER SIGNAL CHECK.................................................................................................................25
11.1. ENCODER SIGNAL FAILURE..................................................................................................................25
11.2. ENCODER VOLTAGE AND STATUS........................................................................................................26
12. RESOLVER CHECK...............................................................................................................................28
13. MOTOR CHECK.....................................................................................................................................29
14. MOTORS RUNNING TOO HEAVY.....................................................................................................30

14.1. X MOTOR.............................................................................................................................................30
14.2. Y-MOTOR.............................................................................................................................................30
14.3. Z MOTOR..............................................................................................................................................31
14.4. I MOTOR...............................................................................................................................................31
14.5. H MOTOR.............................................................................................................................................32
14.6. C MOTOR.............................................................................................................................................32
14.7. CH MOTOR...........................................................................................................................................32
15. ERROR NUMBERS.................................................................................................................................33
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1. Amplifier error
The amplifier error is caused by an error signal that comes from the amplifier.
Error number Error text Motor number

6105 Amplifier error X-motor 1
6205 Amplifier error Y-motor 2
6305 Amplifier error Z-motor 3
6405 Amplifier error I-motor 4
6505 Amplifier error H-motor 5
6605 Amplifier error C-motor 6
6805 Amplifier error CH-motor 8
 Check the amplifier as described in chapter 9.’
If the amplifier shows ‘drive healthy’ status and the machine shows amplifier error, an error has
occurred for a short while and now the system is ok.
This might happen if a motor is in break action for a long time. It happens for example when you are
slowly rotating a pipe with a heavy eccentric weight. The pipe wants to rotate due to the eccentric
weight and the X-motor has to slow down this rotation. In this case you need to balance the weight of
the pipe better.
If the error is not caused by excessive break action

 Check the resolver cable for an internal disconnection or shortcut to earth, especially at the places
where cables move like in the cable chains. Keep in mind the disconnection or shortcut might not
be present all the time.
 Replace the motor
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2. Following error
2.1. X-, Y-, Z-, I-, H-, C and CH motor

6101 Following error X-motor 1
6201 Following error Y-motor 2
6301 Following error Z-motor 3
6401 Following error I-motor 4
6501 Following error H-motor 5
6601 Following error C-motor 6
6801 Following error CH-motor 8
A following error means one of the CNC controlled motors did not reach the programmed position or
could not keep up with the programmed speed or acceleration. If you only get the error message at a
specific point of a special profile and not with an ordinary profile the error might be caused by a
software problem, in this case you have to contact your supplier.
The error is caused by one of the following parts:

 The encoder feedback.
 The amplifier
 The motor
 Cabling
 The load on the motor might be too much
To find out where the error lies

 Operate the motor with the remote control keys
 Check if the motor is moving
 Check if the motor position on the remote control changes
The motor moves (a little) but the motor position on the remote control does not change
The encoder signal is incorrect, any motor movement must be visible in a change in position on the
display.
 Check the encoder signals as described in chapter 11. ’Encoder signal check’.
The motor does not move
The motor must be blocked mechanically or the motor / cables is defect

 Check the motor as described in chapter 13. ’Motor check’
 Check the amplifier as described in chapter 10. “Amplifier check’
 Check if the motor is blocked as described in chapter 14. ‘Motors running too heavy’
The error occurs when the motor is running

The motor cannot keep up with the acceleration or maximal speed commanded by the motion
controller.
 Check if the motor load is too high as described in chapter 14. ‘Motors running too heavy’
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The error could not be located with the instructions above:

Check all parts of a motor axis that were not already checked
 Check if the motor is blocked as described in chapter 14. ‘Motors running too heavy’
 Check the encoder signals as described in chapter 11. ’Encoder signal check’.
2.2. Sensor and pipe mode

6501 Amplifier error H-motor 5
6701 Amplifier error sensor 7
When the cutting arm is in ‘PIPE’ mode a following error on the H-motor or sensor may indicate a
problem with the following of the pipe surface.
The error may occur in the following situations;

 The sensor pin drops of the pipe.
 The sensor pin is moved too quickly, for example due to a big welding seam.
 The sensor pin vibrates because the pipe surface is not very smooth.
 The sensor pin vibrates due to melted particles on the pipe surface from a previous cut.
In the above situation the error is not caused by a machine error.
 Check the H-motor in normal mode as described above

 Check the encoder signal of the sensor as described in chapter 11. ’Encoder signal check’.
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3. Motor warning and motor overdue error

6160 X-motor overdue 1
6260 Y-motor overdue 2
6360 Z-motor overdue 3
6460 I-motor overdue 4
6560 H-motor overdue 5
6660 C-motor overdue 6
6860 CH-motor overdue 8
A motor overdue error indicates that a motor is taking too much power over a period of 10 to 30
seconds. The error has two levels. Above the first level a motor warning will be displayed on the
remote control, the machine can still be operated normally. Above the second level a motor overdue
will be displayed and the machine is stopped.
The motor load status can be displayed on the remote control, activate <shift>, press<dist> until motor
power percentage is displayed. The value is the percentage of the nominal load of the motor. You can
set the two levels under F9 ‘Calibration’, select the ‘Edit’ field of a motor.
An overload to 200% for a servomotor is allowed but the values are set so they will not be exceeded in
normal conditions.
A motor warning indicates that the motor is running heavier, check out the reason since the motor
might soon come to the second level and then the machine shuts down.
 Check if the motor is mechanically ok as described in chapter 14. ‘Motors running too heavy’
3.1. False overdue errors
The motion controller cannot actually measure the load of the motor. The displayed motor load
percentage is based on the actual torque command from the motion controller. If the motor is
functioning ok the commanded torque should also be generated by the motor.
This system only works as long as motor and amplifier are ok. As soon as one of these has a problem
you might get false overdue errors. The error message says a motor is overloaded but in fact the
torque command from the motion controller is not generated at all because of a defective amplifier,
motor or cable.
In this case you have to set the fatal error level to 200%, the overdue error is now disabled
You will now probably get another error message that shows you the real error.
If not:
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4. Motor overheated
All AC servomotors have an temperature sensor in the motor, as the motor temperature exceeds the
maximum temperature an error will be shown

X-motor overheated 1
Y-motor overheated 2
H-motor overheated 5
CH-motor overheated 8
Normally this error will not be shown since you should already have had the motor overdue error.
Locate the overheat problem as follows:
 Check if the motor indeed is overheated, in this case the temperature should be over 50ºC, if not
check for false overheat errors.
 Check the motor overdue levels as described in 3. ‘Motor warning and motor overdue error’, if the
level was set wrong threat the overheat error as an overdue error.
 Check if the motor cannot cool down properly because of the surroundings of the motor
4.1. False overheat errors
The machine shows overheat error but the motor is not too warm (over 50ºC).
The overheat error comes from a sensor in the motor, therefor the error can also be caused by
problems with the cables, sensor or related electronics.
 Check if the motor indeed is overheated, the temperature should be over 50º
 Check if the motor power connector is properly connected to the control unit.
 Measure the impedance between the overheat contacts, this should be about 0 at normal
temperatures.
 Check the relays of the overheat contact in the control unit.
 Check the led status of the digital input board, ‘on’ means no over temperature.
 Check the overheat contact with the diagnostic program as described in the technical manual.
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5. End switch errors

6203 Y-neg end switch 2
6204 Y-pos end switch 2
6303 Z-neg end switch 3
6304 Z-pos end switch 3
6403 I-neg end switch 4
6404 I-pos end switch 4
6503 H-neg end switch 5
6504 H-pos end switch 5
6803 CH-neg end switch 8
6804 CH pos end switch 8
An end switch error indicates that a motor has reached its positive or negative end. The motor can
only be moved away from the end switch.
Usually an end switch error does not indicate a machine problem.
5.1. Software end switches
Software end switches are end positions set by the motion controller. If the end position is reached an
normal end switch error is displayed. The software end switches are used for the Z and I motor and
they are set after initialization of the cutting head.
The I-motor has software and hardware end switches, both are active at the same time.
5.2. Z-motor end switches
The Z-motor has no physical end switches, only software end switches are used. As long as the
cutting head is not initialized the software end switches are not set. The Z-motor will run to the
mechanical end and show a following error.
 A Z-motor end switch error during cutting indicates a software problem, contact HGG.
 You cannot have a false z end switch error.
5.3. I-motor end switches
The I motor has a set of hardware and software end switches, they are active at the same time. As
long as the cutting head is not initialized the software end switches are not set. The I-motor will run
onto the hardware end switches.
The hardware end switches are used to check the winding mechanism of the cable chain in the top
part of the cutting head. Normally the end switches detect the positions ‘cable chain fully winded’ or
‘cable chain fully un-winded’. If the cable chain does not wind up properly you will get a I end switch
error.
5.4. Y-motor end switches
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The Y-axis has two normal end switches, left and right. The Y-axis also has an end switch to detect
the main drive unit. The switch as pressed as long as the cutting head may hit the main drive unit.
Only in top position the cutting trolley may pass the main drive unit. The limit switch has a double
function, it is also used as home switch as described in chapter 6.1. ‘Y axis home error’.
The end switch is adjusted to allow enough space between cutting head and main drive unit for de-
acceleration, even when the cutting trolley approaches the main drive unit at maximal speed.
If you want to cut really close to the chuck you need to press ‘DIS LIM’ from the main drive unit to
disable this limit switch.
The error messages for coming too close to the main drive unit are:
5600 Cutting head near maindrive

6207 Stopped by chuck limit switch"
All of the above errors indicate that the chuck limit switch is pressed
 The end switch should be pressed over the full length of the main drive unit.
 Check if the home switch is functioning as described in chapter 5.5. ‘False end switch error
messages’ and 5.6. ‘Missing end switch error messages’.
 Check if the I limit end switches are functioning as described in chapter 5.5. ‘False end switch
error messages’ and 5.6. ‘Missing end switch error messages’.
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5.5. False end switch error messages
When an end switch error message is displayed, the end switch should actually be pressed. If the end
switch is not pressed you have a false error message.
 Check if the end switch is actually pressed.

 Check if the end switch physically functions, can you operate the switch manually
 Check if the end switch is actually switching, this should be visible on the led of the opto isolator at
the back top section of the control unit. The led is ‘on’ if the end switch is not pressed
 Check if the end switch is adjusted properly.
 Check the end switch power supply P+24V PGND
 Check the cabling of the end switches for disconnections.
 Check the connector to the control unit
 Check the function of the end switch with a multimeter.
 Check the actual status with the diagnostic program as described in the technical manual
5.6. Missing end switch error messages
If a machine runs into a mechanical end stop without an end switch error message:
 Check if the end switch is adjusted properly.

 Check if the end switch physically functions, can you operate the switch manually
 Check if the end switch is actually switching, this should be visible on the led of the opto isolator at
the back top section of the control unit. The led is ‘on’ if the end switch is not pressed
 Check the end switch power supply P+24V PGND
 Check the cabling of the end switches for shortcuts.
 Check the function of the end switch with a multimeter.
 Check the actual status with the diagnostic program as described in the technical manual
5.7. Double end switch messages
If you get a positive and negative end switch error for one motor at the same time you have a false
end switch error message. The error is most likely caused by a failure of the +24V power supply to the
end switches, the problem might also be caused by the internal +/- 15V power supply in the control
unit.
 Check for false error messages as described above

 Check the 24V DC power supply to the endswitches.
 Check the +/- 15V power supply inside the control unit
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6. Initialization errors
6.1. Y axis home error
6000 Unable to detect y-home position
The Y-axis has one home switch at the back of the cutting trolley, the home switch switches on a strip
that indicates the position of the main drive unit. The switch is also used as a limit switch as described
in chapter 5.4. ‘Y-motor end switches’.
During the home search the switchpoint of the home switch is located and than the motor is moved to
the actual zero position.
 The home switch should be pressed over the full length of the main drive unit, if the switch is not
pressed, the cutting head may not hit the main drive unit as it goes down.
6.2. Cutting head initialization error
The following error messages may appear depending on the progress of the initialization procedure
1900 Task init error motor Z

1901 Task init error motor Z
1902 Task init error motor I
1903 Task init error motor I
6208 Task fail error
7200 Cuttinghead home failure
7201 Cuttinghead home failure
If you get these error messages together with other Z-motor or I-motor related error messages first
check out these other error messages.
Cutting head initialization is done for the Z and I axis at the same time. To locate an error it is better to
work with one axis at the time. Activate <shift> and press <I-ini> or <Z-ini> to initialize one axis at the
time
6.2.1.Z axis initialization error
The Z-axis has one home switch at the back of the cutting head, rotate the cutting head to the 180º
position for good access to the home switch.
During the initialization process first the switching point is located and than the motor is moved to the
actual zero position. The distance between the switching point and zero position is stored at the
calibration settings of the machine.
To eliminate any play during the initialization procedure the axis may reverse direction several times,
depending on the start position.
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 The switch must be activated from the switchpoint to the mechanical end.
 The switch must be de-activated from the switchpoint to the other mechanical end.
6.2.2.I axis initialization error
The I-axis has one home switch at the bottom plate of the cuttinghead.
During the initialization process the cutting head is first moved to the negative end limit. From this
point the switchpoint of the home switch is located and than the motor is moved to the actual zero
position. The distance between the switching point and zero position is stored at the calibration
settings of the machine.
6.3. General home search errors:
The following error messages are general home search errors:
6150 Home search failure, X motor

6250 Home search failure, Y motor
6350 Home search failure, Z motor
6450 Home search failure, I motor
6550 Home search failure, H motor
4031 Timeout for home, * motor
4032 Home not found, * motor
If this error comes together with other motor errors first check out these errors.
The home switch switchpoint could not be found.

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7. Sensor system errors

The sensor system is used to keep de distance between cutting head and pipe constant. A linear
sensor detects the positions of the sensor frame. The position of this linear sensor can be displayed
on the remote control. A spring is used to pull the system down, a pneumatic cylinder is used to bring
the system to top position. The cylinder is used to deactivate the sensor system (floating mode) and to
test the function of the system at startup.
In ‘pipe’ function the linear sensor is used as an active feedback to the H-motor. The motion controller
tries to keep the sensor position constant.
 The sensor pin is pushed up by the pipe.
 The linear sensor value changes.
 The motion controller moves the H-motor.
 The cutting arm and sensor system goes up.
 The linear sensor value changes back.
Because sensor system and H-motor work together a height sensor error might be caused by a failure
of the H-motor.
The linear sensor has a home flag output that is used to initialize the sensor system, this is not an end
switch but part of the encoder signals that come from the linear sensor.
7.1. General sensor check
You can manually move the sensor system from top to bottom.
 The sensor position on the display should change from about 0 to 25
 The home flag should change from top to bottom
The system must rotate absolutely free, it may not be in contact with any parts of the cutting arm other
than sensor pin, spring and bearings.
If the sensor value does not change

 Check if the sensor system actually drives the linear sensor pin
 Check if you can manually push in the linear sensor pin
 Check the linear sensor encoder signals as described in chapter 11. ‘Encoder signal check’.
7.2. Height sensor blocked
The following errors may appear
1930 Height sensor blocked error

This means the sensor system does not come free.

 Check if the sensor is blocked mechanically.
 Check if the H-motor is functioning, press <UP>
 Check the sensor encoder signals as described in chapter 11. ‘Encoder signal check’.
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7.3. Floating mode errors
1935 Float error

1940 Height sensor following error
The floating mode is cancelled by the motion controller:

.
When this error comes during the ‘pipe’ function as soon as the pipe is reached:
Check the mechanical adjustment of the sensor system
Check the ‘H sensor offset’ in the configuration setting
If the above is ok, the error is probably caused by a following error. See chapter 2.2. ‘Sensor and pipe
mode’.
7.4. Deviation errors
1920 Height sensor deviation error

1921 Height sensor deviation error
The floating mode is cancelled by the motion controller:

.
The error occours in sensor mode when the sensor system is out of ist working area, either fully
pressed or fully out. The height motor could not compensate the movement of the sensor system
quickly enough. You will get this error message if the sensor system falls down if it runs off the end of
the pipe. The error can also be caused by oscillation of the sensor caused by pipe rotation or for
example an heavy weld on the pipe surface.
 Check the mechanical adjustment of the sensor system

 Make sure the pipe runs smoothly
 Make sure the pipe surface is smoothly
If the above is ok, the error is probably caused by a following error. See chapter 2.2. ‘Sensor and pipe
mode’.
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8. Emergency button pressed
As soon as the emergency button is pressed power is removed for the following parts:
 AC motor amplifiers
 DC motor amplifiers
 Valves
 Remote control
 24V DC power supply
 +15/-15V DC power supply
 5V DC power supply
 12V transformer
 110V transformer
Only the computer stays turned on.
You can resume by resetting the emergency button and press the space bar of the keyboard. The
machine will automatically be turned on again. If the emergency button was pressed during cutting you
can resume cutting from the place it has stopped.
There is however the risk that motors have moved while the power was down. Since the power was
down the motion controller has not seen this movement. If you continue you have to make sure that all
motors are still in the correct location. If you are not sure it is better to restart from the beginning.
8.1. False ‘emergency button pressed’ message
The emergency system consists of an emergency relays that is activated by the computer and can be
deactivated by one of the emergency buttons. All emergency buttons are placed in series.
As the emergency relays is deactivated everything is switched off by hardware, (not by software)
including the 24V DC power supply.
The computer checks the presence of the 24V-power supply, as this power fails the computer
assumes the emergency button was pressed. This automatically indicates that a problem with this 24V
DC power supply might cause a false error message.
Check for a false error message:

 Check if all emergency buttons are reset.
 Check if all cables are connected to the control unit.
 Check if the impedance of the emergency buttons at the emergency relays, the impedance of all
emergency buttons should be below 5.
 Check the emergency cables for disconnections.
 Check if the 24V DC power comes up. You have a couple of seconds after the computer starts to
turn on the machine. After the error message is displayed you cannot have 24V DC since the
computer has turned it off again.
 Turn on the machine manually with the diagnostic program as described in the technical manual.
Turn on the ‘K4 power supplies’ and check the input ‘24V power’ status.
 Check the digital input board.
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9. Chuck errors
The chuck uses one motor to rotate and clamp the pipe. Switching from rotation to clamping is done
with two pneumatic cylinders; one cylinder is used to lock the spiral plate inside the chuck with the
chuck body (the spiral lock) and one to lock the chuck body to the main drive unit frame (the chuck
lock). The claws of the chuck are opened or closed by rotating the spiral plate while the chuck body is
locked.
Both cylinders have end switches to detect the position of the cylinder shaft. The shaft position must
always be either fully in or fully out until one of the end switches is activated.
The two modes are:
Rotation:
The chuck lock is free so the chuck body can rotate freely.
The spiral lock is set so the spiral plate inside the chuck body cannot rotate in respect to the chuck
body, both rotate together so a clamped pipe will remain clamed during rotation.
Clamping:
The chuck lock is set so the chuck body cannot rotate.

The spiral lock is free so the spiral plate can rotate while the chuck body is stationary. In this case the
claws will go in or out.
Switching from clamping to rotation and back can only be done at one specific position of the chuck
body. This position can be set in the configuration settings, see maintenance manual.
9.1. Chuck errors
1951 Spiral cylinder blocked

1951 Chuck cylinder blocked
The cylinder has not moved far enough, the shaft is not fully in our out, none of the end switches is
activated. The shaft is now in an illegal position.
Actions see below.
1955 Spiral cylinder blocked

1955 Chuck cylinder blocked
The cylinder has not moved at all, the shaft is still in the original start position. One endswitch is
activated but the control cannot move the shaft to the other position. The shaft is not in an illegal
status but it cannot be moved to the other side.
Chuck cylinder problems:
 Check if the air pressure on the chuck is high enough (7 BAR)

 Remove the pipe from the chuck
 Check if the chuck operates fine without a pipe
 Check if the cylinders can move in and out properly with the I/O test program as described in the
maintenance manual
 Check if the end switches are adjusted correct and operate properly with the I/O test program
 Check if the chuck body comes into the correct switch position, see adjustment of the chuck in the
maintenance manual.
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9.2. Chuck operation errors:
6209 Clamping locked, press CHK LOCK
This is a software lock for the chuck to prevent unexpected movements of the chuck and accidentally
operation of the chuck that might cause unsafe situations.
You can only open or close the chuck if the CHK LOCK is deactivated. The led on the CHK LOCK
button indicates the status of the chuck lock. Press the CHK LOCK button, the led will go out and the
chuck is unlocked. Now you can open or close the chuck. If the chuck is not used for 5 seconds the
lock will be activated again automatically.
9.3. Pipe blocked in the chuck
If a pipe is clamped in the chuck and you get error messages during operation of the chuck you will not
be able to remove the pipe from the chuck. This can be caused by a chuck problem but it can also be
cause by one of the following external problems:
Clamping side setting:
The chuck uses more force to release the pipe than to clamp the pipe, therefor you have to specify
how a pipe is clamped. This can be set in the machine settings. Inside means clamped at the inside of
the chuck (at the outside of the pipe), outside means clamped at the outside of the chuck (at the inside
of the pipe), .
If the clamping side setting is wrong the chuck uses less power to release the pipe than it has used to
clamp the pipe. The force might be insufficient to release the pipe.
Make sure you make no mistakes in the procedure below, you might clamp the pipe
furthermore which will make it even harder to remove the pipe later.
 Set the clamping side correctly

 Set the chuck force to 100%
 Try to release the pipe from the remote control
Blocked due to improper clamping or pipe/chuck height adjustment
If the pipe clamped in the chuck is forced up or down during rotation because it was not clamped
properly or if the pipetrolley or chuck height was not set properly, the pipe might move in the claws of
the chuck, this may increase the clamping force on the pipe. If the force is too high the motor is not
powerful enough to open the chuck and the pipe is blocked in the chuck.
 Set the clamping side correctly

 Set the chuck force to 100%
 Try to release the pipe
Gently try to push the pipe in line with the chuck with one of the pipe trolleys. (do not leave one side of
the pipe unsupported while the other side is clamped in the chuck) , repeat the above procedure.
Manual removal of the pipe in the chuck
If the pipe cannot be remove with the above procedures the only option is to manually remove the pipe
 Unscrew the three jaws from the chuck and force the pipe out..
 In extreme situations you will have to use a manual cutting torch and cut off the pipe so it will
come lose.
10-8-2000 19
Error manual
M1047
Rev. NC
This ca
To determine the cause of the errors you have to remove the pipe from the chuck manually you get
chuck error messages if you operate the chuck while a pipe is clamped in the chuck
10-8-2000 20
Error manual
M1047
Rev. NC
10. Amplifier check
If the amplifier status is ‘Drive healthy’ you may assume the amplifier is ok.
10.1. X Motor
Brief description
Amplifier type is Digitax , motor is AC brushless with resolver feedback and encoder simulation to
motion controller. The amplifier is operated in torque mode.
The amplifier is located at the front of the control unit.
The Digitax drives has the following display on the front side
10.1.1. No display
The amplifier probably has no main power

 Check the automatic fuse F1 below the amplifier
 Check the main power of the amplifier, this should be 3* 410V AC
The amplifier has main power

 Replace the amplifier.
10.1.2. resolver break status
 Check the resolver as described in chapter 12. ‘Resolver check’
10.1.3. over-current status
This only indicates a fault if the status stays on more than 5 seconds. It indicates that the motor has
too much load mechanically or a shortcut in the motor or cables.
 Check the motor as described in chapter13. ‘Motor check’

 Check the motor as described in chapter14. ‘Motors running too heavy‘, X-motor
10.2. Motors Y, H, and CH
Replace ‘*’ in the next section with the motor number that you are working on.
Brief description
10-8-2000 21
Error manual
M1047
Rev. NC
Amplifier type is Maxax 100 or Maxax 300, motor is AC brushless with resolver feedback and encoder
simulation to motion controller. The amplifier is operated in torque mode. In this mode all
potentiometers at the front are unused.
You can exchange a Maxax 100 with Maxax 300, in this case you cannot operate the motor, only
check if the amplifier is defective.
The Maxax drives have the following status led on the front side
Green Drive healthy

Red Resolver break
Red Over-current
Yellow DBR active
10.2.1. None of the leds is turned on

 Check the automatic fuse F* below the amplifier
 Check the main power of the amplifier on the bottom connector labeled L1-Z* and Z-2*, this should
be 230V AC

 Exchange the amplifier with an amplifier from an axis with no problem to see if the amplifier is
defective.
10.2.2. The resolver break led is on
 Check the resolver as described in chapter 12. ‘Resolver check’
10.2.3. The over-current led is on
This only indicates a fault if the led stays on more than 5 seconds. It indicates that the motor has too
much load mechanically or a shortcut in the motor or cables.

 Check the motor as described in chapter 13. ‘Motor check’
 Exchange the amplifier to see if the error is cause by the amplifier.
 Check the motor as described in chapter 14. ‘Motors running too heavy‘
10.2.4. The DBR active led is on
This indicates the internal electronical break system of the amplifier is activated. Normally this only
happens on a strong deceleration of the motor, the led should go out as the motor has stopped.
 Check is the main power of the amplifier is ok., between L1-Z* and Z-2*, this should be 230V AC
 Exchange the amplifier and see if the DBR active led also comes then connected at another
location.
10-8-2000 22
Error manual
M1047
Rev. NC
10.3. Motors Z and I
Replace ‘*’ in the next section with the motor number that you are working on.
Brief description
The amplifier for both motors is an maxon line driver. The motors are 24V DC with encoder feedback
to the motion controller. The amplifier is used in current mode
The amplifiers are located at the back of the control unit.
 Check the main power of the amplifier: +24V and PGND

 The green led and no red led must be illuminated at the amplifier
 If this is not the case the amplifier must be replaced
10.4. C Motor
Brief description
The amplifier is MaxiMaistro 4Q DC amplifier. The motors is 180 V DC with tag generator feedback to
the amplifier, there is no feedback to the motion controller. The amplifier is operated in torque mode.
The amplifier has the following status leds
Green Drive healthy
10.4.1. None of the leds is turned on

 Check the automatic fuse F6 below the amplifier
 Check the main power of the amplifier, this should be 3*128V AC
 Check the 380V / 128V transformer

 Replace the amplifier.
10.4.2. The over-current led is on
10-8-2000 23
Error manual
M1047
Rev. NC
This only indicates a fault if the led stays on more than 5 seconds. It indicates that the motor has too
much load mechanically or an shortcut in the motor or cables.
 Check the motor as described in chapter 13. ‘Motor check’

 Check the motor as described in chapter 14. ‘Motors running too heavy‘
10.4.3. The DBR active led is on
This indicates the internal electronical break system of the amplifier is activated. Normally this only
happens on a strong deceleration of the motor, the led should go out as the motor has stopped.
 Is the main power of the amplifier is ok., between L1-Z* and Z-2*, this should be 230V AC
 Exchange the amplifier and see if the DBR active led also comes then connected at another
location.
10-8-2000 24
Error manual
M1047
Rev. NC
11. Encoder signal check

The encoder signals are a position feedback of the motors to the PMAC motion controller
Any motor axis movement must be visible as a change in position on the remote control. Even when
the motor only rotates very little and stops, this should be visible on the remote control
 Use the remote control to operate the motor.
If the motor cannot be moved with the remote control, not even a view rotations, you need to manually
rotate the motor. This must be done as follows:
X-, Y-, H- and CH-motor:

 Turn off the machine.
 Disconnect the main motor power connector.
 Dismount the motor.
 Turn on the machine, you will now get an overheat error.
 Manually rotate the motor axis.
Z- and I- motor:
Remove the motor fuse F23 or F24
Height sensor
The height sensor system drives the linear sensor that generates encoder pulses just as a motor does,
manually move the sensor system with the sensor pin. The sensor system should now drive the pin of
the linear sensor. Check if the linear sensor pin actually moves in and out.
 Rotate the motor, the position should change

 Move the motor back to the original location, the position should go back to the start position
If the above is correct you may assume the encoder signal is correct.
11.1. Encoder signal failure
If the encoder signal does not change when the motor moves there must be an encoder failure.
If you have problems with several motors first check the following:
 Check the power supply of the encoder opto isolation board O+5V and OGND
 Check the flatcable connections to the terminator board and PMAC.
 Exchange the two opto isolation boards (set the jumpers correctly)
X-motor
This motor has a resolver feedback to the amplifier, the amplifier simulates an encoder.
 Check the resolver signal of the motor as described in chapter 12. ‘Resolver check’.
If the resolver signal is ok.

 Check the cabling from amplifier to opto isolation board
 Check the encoder signal status as described in chapter 11.2. ‘Encoder voltage and status’
 Check the flatcables to the terminator board and PMAC.
10-8-2000 25
Error manual
M1047
Rev. NC
 If all connections are ok, the X-amplifier must be defective
Y- H- and CH motor
These motors have a resolver feedback to the amplifier, the amplifier simulates an encoder.
 Check the resolver signal of the motor as described in chapter 12. ‘Resolver check’.
If the resolver signal is ok.

 Exchange amplifiers to see if the amplifier is defective.
 Place the encoder connector to another drive to see if encoder signals can come trough
 Check the cabling from amplifier to opto isolation board

Z-and I- motor
These motors have an encoder that provides direct position feedback to the motion controller.
 Exchange the Z and I connectors in the cutting head to see if the motor is defective.
 Check for a disconnection in the encoder cable
 Check for a shortcut to another pin in the connector
 Check for a shortcut to earth (disconnect the encoder cable from the control unit)
 Check the O+5V and OGND on the connector in the cutting head
 Compare the voltage on the encoder lines in the control unit and in the encoder box, they should
be the same.
Height sensor
The height sensor has an encoder that provides direct position feedback to the motion controller.
 Check for a disconnection in the encoder cable

 Check for a shortcut to another encoder signal
 Check for a shortcut to earth (disconnect the encoder cable from the control unit)
 Check the O+5V and OGND in the encoder box
 Compare the voltage on the encoder lines in the control unit and in the encoder box, they should
be the same.
11.2. Encoder voltage and status
The encoder signals are two block shaped signals, channel A and channel B. For a good checkup you
need an oscilloscope but also with a multimeter you can already check a lot
10-8-2000 26
Error manual
M1047
Rev. NC
The status and voltage can be checked as follows:
X-, Y-, H- and CH motor
(Replace * with the motor number)
These motors have normal and inverted encoder outputs.
 The voltage of the signals +CHA-* – CHA-*, +CHB-* and –CHB-* to OGND must be below 1V or
above 4V when the motor is stationary
 If the +CHA or +CHB is +0V, than –CHA or –CHB must be 5V and vice versa
 If the motor is rotating the signals should switch from 0V to 5V, if the motor rotates very slowly you
can see this on your multimeter, otherwise you will measure about 2.5V (the average)
Z-, I-motor and height sensor
(Replace * with the motor number)
These motors have only normal encoder outputs (no inverted outputs are present).
 The voltage of the signals +CHA-* and +CHB-* to OGND must be below 1V or above 4V when the
motor is stationary
 The voltage of the signals -CHA-* and -CHB-* to OGND must be 0V
 If the motor is rotating the signals should switch from 0V to 5V, if the motor rotates very slowly you
can see this on your multimeter, otherwise you will measure about 2.5V (the average)
10-8-2000 27
Error manual
M1047
Rev. NC
12. Resolver check
The resolver provides a position feedback of the rotating magnet on the motor axis to the amplifier.
This signal is used to create a rotating field that makes the motor rotate. The resolver consists of 3
coils called sin, cos and ext.
The signal is converted to an encoder signal for a position feedback to the motion controller.
The amplifier checks the functioning of the resolver, if the amplifier does not show a resolver break
signal you may assume the resolver is ok.
Check the resolver on the disconnected resolver connector of the amplifier:
 Check if one of the resolver signals is in contact to earth

 Check if you can measure the three coils of the resolver, the impedance between +sin/-sin, +cos/-
cos, +exe/-exe should be between 0 and 20
 Exchange the amplifier to see if the amplifier or the resolver is the problem.
Too much axial pressure on the motor axis can cause a resolver break signal.
 Dismount the motor and check the resolver status on the amplifier again.
 If the status still is resolver break replace the complete motor.
10-8-2000 28
Error manual
M1047
Rev. NC
13. Motor check
X-, Y-, H-, and CH-motor
The motor type is AC brushless, the motor consists of 3 stationary coils and a rotating magnet. The
coils are place in triangle.
Check the motor signals on the disconnected motor connector of the amplifier
 Check if one of the motor cables U, V or W is in contact with earth

 Check if you can measure the 3 motor coils, the impedance between U-V V-W and U-W should be
close to 0, all three should be just about the same.
 Check for a shortcut in the motor cable.
Z and I motor
The motor type is 24V DC, the motor consist of a rotating coil and a fixed magnet.
Check the motor signals on the disconnected motor connector of the DC line driver
 Check if the motor fuses F23 and F24 are ok

 Check if one of the motor cables +AMPL* and –AMPL* is in contact with earth
 Check if you can measure the motor coil, the impedance between +AMPL* and –AMPL* should be
close to 0.
C-motor
The motor type is 110V DC, the motor consist of a rotating coil and a fixed magnet.
Check the motor signals on the disconnected motor connector of the amplifier
 Check if one of the motor cables + and – is in contact with earth

 Check if you can measure the motor coil, the impedance between + and – should be close to 0.
 Check the slide contacts at the side of the chuck.
10-8-2000 29
Error manual
M1047
Rev. NC
14. Motors running too heavy

The general approach is to remove the motor and check if the motor is running ok with no load and
than to check is you can manually move the system in order to find out where the system is blocked.
If you find that the motor is running ok without any load and also the mechanical system is running ok.
In this case the motor does not have enough force due to a motor failure, you have to replace the
motor.
14.1. X motor
The X-motor might be running heavy due to a pipe clamped in the chuck, check the following:
 Is the weight of the pipe very much out of balance
 Is the pipe straight
 Does the pipe have a big welding seam.
 Is the pipe leveled out properly
 Does the chuck center height match with the pipe center height
 Can the pipe rotate properly on the pipe trolleys or roller ball gutter.
To locate the block:

 Remove the pipe from the chuck
 Check if the claws have run into something
 Remove the front cover and check for a block at the front side of the main drive unit.
The chuck does not rotate at all
 Dismount the X-motor

 Check if the motor rotates without the gearbox
 Check if you manually can rotate the incoming axis of the gearbox.
 Check the front of the main drive unit for failures while the chuck is rotating. (at the slider contacts)
 Check the main bearing of the chuck.
 Check if the gearbox axis and / or pinion are touching the back of the chuck while rotating.
 Unscrew the gearbox, make sure the pinion can rotate freely
 Check if you now manually can move the incoming axis of the gearbox.
 Check is the gearbox is running when the motor is mounted.
 Check if you can rotate the chuck manually
 Dismount the chuck and check the main bearing
14.2. Y-motor
The most likely problem with the Y-motor are the sliders and the linear guiding rail.
 Remove and check the two sliders of the cutting trolley.

 Check the rail for rust.
 Check for particles that lie between the rail and the rack, also check between the two sliders under
the cutting trolley.
 Check for particles in the teeth of the rack
 Check if the two bottom wheels run properly.
 Unscrew the Y-gearbox and pull it out of the rack
 Check if you can manually move the cutting trolley
 If you manually move the cutting trolley (3 Km/H) it should not stop within 20 cm
 Check if all rail are in line properly
 Check if all rack sections are in line properly
 Is the rear frame set up properly, is the upper beam horizontal
10-8-2000 30
Error manual
M1047
Rev. NC
 Check if the pinion is running now it is out of the rack

 Dismount the motor and check if the motor is running
 Check if you can manually rotate the incoming axis of the gearbox.
14.3. Z motor
The Z-motor has a low backlash gearbox, at low temperatures the grease may become too thick which
causes the gearbox to run heavy. Try to operate the motor at a temperature of about 15ºC to see if
this causes the problem.
Lower part
Are both calibrations pins removed.

Check if the torch can rotate a little, there should be some stretch in the belt to allow a little movement.
Remove the heat shield and check for dirt at the bottom.
Check if the belt connection block is running onto the machined edges of the cuttinghead arm.
Upper part
 Check the mechanics visually for damage or lose particles.

 Remove the Z-motor.
 Check if the outgoing axis of the gearbox is running.
 Check if you manually can move the tilting system by pushing to the cutting head arm, since the Z-
motor is removed the system can now be blocked by the lose belt.
 Remove the gearbox from the motor.
 Check if the motor runs without the gearbox.
 Check if you can easily rotate the incoming axis of the gearbox.
14.4. I motor
The I-motor has a low backlash gearbox, at low temperatures the grease may become too thick which
causes the gearbox to run heavy. Try to operate the motor at a temperature of about 15ºC to see if
this causes the problem.
 Check if you can manually rotate the cutting head by pulling at the top part.
 Remove the bottom plate of the cutting head
 Check for lose particles in the teeth ring or I-motor pinion
 Check if the pinion was mounted too low. In this case it has touched the bottom plate.
 Check if the pinion was mounted too high, in this case it has touched the bottom of the cutting
head.
 Check if the cable chain at the top of the cutting head can rotate properly.
 Check if the winding unit for the cable chain is functioning properly
 Remove the I-motor.
 Check if you manually can rotate the cutting head.
 Remove the gearbox from the motor.
 Check if the motor runs without the gearbox.
 Check if you can easily rotate the incoming axis of the gearbox.
10-8-2000 31
Error manual
M1047
Rev. NC
14.5. H motor
 Check the vertical guiding rails for rust, wear or damages.

 Check the spindle for rust, wear or damages.
 Check the vertical sliders.
 Hang the cutting arm in a crane.
 Remove the H-motor, the cutting arm may come down on its own weight.
 Check if the H-motor runs without the spindle.
 Gently lower the crane is steps of 5 cm.
 If the cutting arm comes down on its own weight there is no mechanical problem.
 Check the rolllerball bearing on the spindle, at the back of the cutting arm.
 Check the top spindle bearing.
 Check the bottom spindle bearing.
 Remove the spindle and check if the spindle is straight.
 Replace the vertical sliders one by one.
14.6. C motor
 Make sure the force is set to maximal

 Dismount the 3 slider boxes with the claws
 Check the boxes and chuck for wear and damage
 Make sure the boxes can slide properly in the chuck
 Check if you can manually rotate the spindles
 Check is the spindles rotate when the boxes are removed
 Open the cover of the chuck in front of the clamping motor
 Open the gearbox and check for wear and damage
 Remove the C-motor
 Check if the motor is running without the gearbox
 Check if you manually can rotate the incoming axis of the gearbox
 Replace the motor again
 Remove the spindle gearboxes one by one and check if the C-motor can rotate
 Remove the chuck
 Check the big bearing inside the chuck.
14.7. CH motor
 Remove the CH-motor

 Check if the motor is running without the gearbox
 Check if you can rotate the incoming axis of the gearbox manually
 Unscrew the bolts of the spindle nut at the bottom of the main drive unit
 Lift the chuck with a crane, the spindle nut comes free.
 Check if you can rotate the spindle nut
 Check is you can rotate the CH motor
 Dismount the gearbox
 Remove the spindle
 Check if you can rotate the outgoing axis of the gearbox
 Check the two bearing at the top of the spindle, below the gearbox.
10-8-2000 32
Error manual
M1047
Rev. NC
15. Error numbers
Error no Page Error no. Page
1 6550.......................................................................14
6560.........................................................................8
1900.......................................................................13
6601.........................................................................5
1901.......................................................................13
6605.........................................................................4
1902.......................................................................13
6660.........................................................................8
1903.......................................................................13
6701.........................................................................7
1930.......................................................................16
6801.........................................................................5
1931.......................................................................16
6803.......................................................................10
1932.......................................................................16
6804.......................................................................10
1935.......................................................................17
6805.........................................................................4
1940.......................................................................17
6860.........................................................................8
4
7
4031.......................................................................14
7200.......................................................................13
4032.......................................................................14
7201.......................................................................13
5
E
5600.......................................................................11
Emergency button pressed....................................18
5601.......................................................................11
5602.......................................................................11 M
6 Motor overheated....................................................9
6000.......................................................................13
6101.........................................................................5
6105.........................................................................4
6150.......................................................................14
6160.........................................................................8
6201.........................................................................5
6203.......................................................................10
6204.......................................................................10
6205.........................................................................4
6207.......................................................................11
6208.......................................................................13
6250.......................................................................14
6260.........................................................................8
6301.........................................................................5
6303.......................................................................10
6304.......................................................................10
6305.........................................................................4
6350.......................................................................14
6360.........................................................................8
6401.........................................................................5
6403.......................................................................10
6404.......................................................................10
6405.........................................................................4
6450.......................................................................14
6460.........................................................................8
6501.....................................................................5; 7
6503.......................................................................10
6504.......................................................................10
6505.........................................................................4
10-8-2000 33
Error manual
M1047
Rev. NC
10-8-2000 34

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The complete set of manuals consist of the following manuals:

10.2.3. The over-current led is on...............................................................................................................22

13. MOTOR CHECK.....................................................................................................................................29

14. MOTORS RUNNING TOO HEAVY.....................................................................................................30

Error number Error text Motor number

 Check the amplifier as described in chapter 9.’

If the error is not caused by excessive break action

2.1. X-, Y-, Z-, I-, H-, C and CH motor

Error number Error text Motor number

The error is caused by one of the following parts:

To find out where the error lies

The motor does not move

The motor must be blocked mechanically or the motor / cables is defect

The error occurs when the motor is running

The error could not be located with the instructions above:

2.2. Sensor and pipe mode

Error number Error text Motor number

The error may occur in the following situations;

In the above situation the error is not caused by a machine error.

 Check the H-motor in normal mode as described above

3. Motor warning and motor overdue error

3.1. False overdue errors

Error number Error text Motor number

Locate the overheat problem as follows:

4.1. False overheat errors

5. End switch errors

Error number Error text Motor number

Usually an end switch error does not indicate a machine problem.

5.1. Software end switches

5.2. Z-motor end switches

5.3. I-motor end switches

5.4. Y-motor end switches

5600 Cutting head near maindrive

5.5. False end switch error messages

 Check if the end switch is actually pressed.

5.6. Missing end switch error messages

 Check if the end switch is adjusted properly.

5.7. Double end switch messages

 Check for false error messages as described above

6.1. Y axis home error

6000 Unable to detect y-home position

6.2. Cutting head initialization error

1900 Task init error motor Z

6.2.1.Z axis initialization error

6.2.2.I axis initialization error

6.3. General home search errors:

The following error messages are general home search errors:

6150 Home search failure, X motor

The home switch switchpoint could not be found.

7. Sensor system errors

7.1. General sensor check

If the sensor value does not change

7.2. Height sensor blocked

The following errors may appear

1930 Height sensor blocked error

This means the sensor system does not come free.

7.3. Floating mode errors

1935 Float error

The floating mode is cancelled by the motion controller:

7.4. Deviation errors

1920 Height sensor deviation error

The floating mode is cancelled by the motion controller: