I have a 4020.

[masterfabr]

I can do a tool change no problem using M6TXX but when using TC,1 to load the turret ,the door opens,the turret moves into position, the head moves to top of Z and E stop kicks in. I assume the Z is trying to travel further than the stop allows. How do I correct that?

[fizzissist]

Have you ensured that the machine is in the proper home position first?

I had this problem when some moron I work with set bad home locations and did an improper shut down.

Make sure the axis markers are lined up with the indicators, and do the cold start procedure...

1) Press the MANUAL key until the enter next command prompt is displayed
or, from the quick keys menu, press the jog key.

2) Press the JOG key and align each axes at the alignment marks within .05
inches of each other.

3) Press the MANUAL key until the enter next command prompt is displayed.
Type CS and press the ENTER key.

4) Wait. The machine will find the axis origin.

5) This procedure is complete when the move to last home position screen is
displayed.
a) The last home position will not display if an auto start-up program is
in memory.
b) The auto start-up program is named O9998. (See auto start up program)
c) After the auto start-up program is finished, the move to Last Home
Position screen will be displayed.

6) Press the START button to begin motion to the last home position
established by the set commands.

Power Off
1) From the command mode, type “SETCS” and press the ENTER key.
2) Type HO and press the ENTER key.
3) Wait for the light to flash and the word “waiting” to blink on the screen.
Press the START button for the machine to move to the cold start position.
4) On the main power box, place the knife switch in the down (off) position to
power off the VMC.
Note: For SYSTEM 97, follow the power-off procedure as outlined above or;
1) Press the MANUAL button until the control is in the command mode or the
quick keys, edit, or functions menus are displayed on the screen.
2) Power off the machine.

[masterfabr]

I've done all that repeatedly.It just acts like it wants to over travel the Z and faults.

[davisboys]

There's a procedure for setting the tool change position in the manual. Probably also online somewhere. Basically setting the spindle height in relation to the carousel using the resolver....?. Once the zero position is correctly set then you should have the required 4" to change tools.

[masterfabr]

Not the problem. The head height is correctly set for the tool change.It's when the head raises to the eop of z it faults. I believe it is trying to overtravel the 4" it should be moving. Can this be a rsolver issue? Isn't that what determines an axis travel distance?

[davisboys]

First, After CS, move Z down some amount, then G0 E0 Z0 see if this sends Z to tool change position.
2nd, G0 G91 Z4.0, you know this, see if it works correctly.
3rd, move to Z-2. position, CS, then G91 Z4.0 see if it stops at correct spot.
I don't know what all this will tell you, but you might find a discrepancy which may give you a key.
I'd get a hold of Neal via PM. He knows a lot more than I do about Fadals.

[masterfabr]

I'll try that. I appreciate the info and any help you guys can give me.

[masterfabr]

OK,did a bit more checking out the issue.I finally thought about jogging Z +4.0" above the tool changer position as suggested and it over traveled and faulted.WTF? It traveled 4.75". Clear to the end of any possible travel. So I tried it at Z+2.0 and the head traveled 3.25 approx. inches.WTF again! So I checked X and Y axis at 5.0 inches and they traveled almost 9"! WTF????????? Apparently I have an issue with whatever determines the travel of ALL the axis. Any ideas?

[masterfabr]

I see a g code of G51.3 called axis scaling that allows x ,y and z to be scaled a factor of whatever you want.
Such as :

G51.3 Axis Scaling This allows the programmer to scale all or individual axis dimensions. The
G51.3 code with the R1# parameter will scale all axes. The R2# will scale the X
axis only. The R3# is used for the Y axis, and the R4# for the Z axis. The # with
the parameters represents a percentage to scale. The percentage is
represented in the decimal form. For example 2.0 would double the size, .5
would half the size.
EXAMPLE: N1 O1 (PART 1234
** Cut part **
N2 M6T1 (TOOL #1
N3 G0 G90 S2500 M3 E1 X0Y0
N4 H1 D1 Z.1
N4 G51.3 R1+2. Scale all axes by 2 times scale factor 2
** Cut part **
N4074 G51.3 R1+1. Cancel scaling or scale factor 1
N4075 G0 G90 H0 Z0


Is it modal or not? If so that might be the problem???

[davisboys]

You're going to need professional help. (yep, me too lol) Each axis has an amplifier card. Beyond that I don't know much. You could power down the machine and exercise the cards in their slots though not a great likelihood of success imho. you'd think there's a controller card(?). I don't know. Short of contacting Fadal service, you ought to PM Neal.

[davisboys]

I'm not familiar with scaling, but seems like a logical possibility. Key in the cancel and then home the machine. maybe even shut it off and start it up again..

[little bubba]

I'm betting that you have metric screws and have it set to American screws in the parameters.