Synchronization Error

Problem

If the machine is not operating and the” information light” at the rear status panel of the machine and the firmware LED on the logic board flashes with the following eight-bit pattern as described here:

Where 0 indicates a short pulse which is 1/4 second and 1 indicates a long pulse which is 1 second long.

This error results from a significant difference between the rotary encoder and linear encoder of an axis. This error can occur on all three axes but the debugging procedure is always the same.

Solution

The following items provide step by step instructions on how to break down the cause of the issue:

1. This can easily occur if the drives are adjusted or replaced because the ratio between the encoders needs to be calibrated. Recalibrate the volume to measure the ratio.

2. Check that the drive is mechanically aligned, smooth, no slop/slipping, etc.

   • If the fault is occurring on an Excel XY-axis during long, high-speed moves, the most likely mechanical cause is incorrect preload on the capstan idler bearing.

   • If the fault is occurring on an Excel XY-axis during long, low-speed moves, the most likely mechanical cause is band misalignment.

   • If the fault is occurring on a Vertex machine or Z-axis, there is an egregious drive issue, unless it is an electrical issue. Check for axial play in the lead screw or the coupling.

3. Check all the encoders, encoder interpolators, and encoder cables.

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