Problem- 2003 Fadal TRM Motor Overload

[TriumphMachine]

I ran the X-Axis manually to a limit and it tripped the emergency stop switch.
When i reset the switch and pressed the "JOG" key it does its regular "wait 2 seconds axis drives being reset" and then it trips again with the following error message:

Emergency Stop Take Appropriate Action
x Axis Fault(s) as Follows:
Error #1
Motor Overload

I checked my Manual and looked up the error message.
It tells me that if this message pops up and the emergency stop button is not depressed ( which it is not) then I should power off the machine and press the rest buttons on the motor overload relays to see if they are tripped.

Then it tells me the Motor Overload Relays can be recognized by their white rest buttons. they are located in both control enclosures ( I only have one but i think that is because the manual if for all VMC's and i have a TRM.

First i can't find any sort of relay individual to each axis. the only two i can find are black barrel style fuses with a white button the has "5" on the button and says "Push to Re-Cirk-It" ( i'll try to post a picture of them )

I have pushed these but i am still getting the error message.

Can someone help me identify the Motor overload relays?
If i have found them then what is my next step if they are not the problem.

also i have the Fadal MP Controller and i think AC Motors but i'm not posative how to tell.

Thanks in advance.

Cory

[iess525]

It sounds like you may have damaged the X-axis amplifier.

[TriumphMachine]

So, i am going in tomorrow morning to work on the machine some more.

I do not completely understand how the machine stop limits work but is it possible that i'm in some sort of limbo where i am constantly hitting a manual limit and because of that it keeps tripping the E-stop and not letting me jog away from it?

i think i am going to try an zero the x axis where its at and if that doesn't work then remove the motor and try to physically back the x axis off an inch or so and see if that does anything.

This is a newly acquired machine and i am new to this ( a lot of the stuff i work on doesn't involve a computer ) so if i'm am about to go and do something stupid please do write a quick message or if you have any half way related info i would be very grateful.

Thanks again

Cory

If i can't figure anything out i may also try to post some pictures of the machine tomorrow.

[Al_The_Man]

Motor overloads are generally located on the 3 phase contactor itself above or feeding each drive, There is a button marked either reset or test usually.
Al.

[TriumphMachine]

Originally Posted by iess525 It sounds like you may have damaged the X-axis amplifier.

how exactly could i check to see if i damaged the amplifier?
each axis has its own amplifier right?
could i have damaged the axis from jogging to a limit or was it just an unrelated event before the amp went?

Thanks

[iess525]

If the machine is referenced (coldstarted) in the right place, the software in the axis will limit its travel. If you don't cold start in the right place, it will hit the mechanical limit. If you hit the mechanical limit, the amplifier may get damaged or the motor will overheat.

Power the machine off and turn the ballscrew by hand and get out of the mechanical limit. You should not have to take the motor out.

[TriumphMachine]

Originally Posted by Al_The_Man Motor overloads are generally located on the 3 phase contactor itself above or feeding each drive, There is a button marked either reset or test usually. Al.

Thanks Al,

I will check for it first thing in the morning

Cory

[iess525]

Originally Posted by TriumphMachine how exactly could i check to see if i damaged the amplifier? each axis has its own amplifier right? could i have damaged the axis from jogging to a limit or was it just an unrelated event before the amp went? Thanks

Send me a message with your phone number and I will call you tomorrow.

[TriumphMachine]

Originally Posted by iess525 If the machine is referenced (coldstarted) in the right place, the software in the axis will limit its travel. If you don't cold start in the right place, it will hit the mechanical limit. If you hit the mechanical limit, the amplifier may get damaged or the motor will overheat. Power the machine off and turn the ballscrew by hand and get out of the mechanical limit. You should not have to take the motor out.

Well hopefully i haven't done any thing to harmful to it.
Can i move the ball screw just by grabbing it and turning it or is there a neutral of some sort on the motor. ( i guess i will have to look tomorrow ).

I will post an update as to what happens after i try everything.

Thanks

Cory

[TriumphMachine]

Well i came in this morning and backed the x axis off manually with a 3/4 socket and an extension, Found the "TEST" reset button on the main power switch, gave that a push for good measure and the machine started right up. i homed it and zeroed out each axis.
I had to cold start it and i don't quite know why or what that means but i am happy that i can go back to learning it and stop trying to fix it.

A BIG thanks to everyone who responded and to iess525 for calling me today to ensure that i got everything back up and running properly.

[iess525]

Glad you got it up and working. Let me know if you need anything else!