Polar 115X - Error 653

Dear all master, I am wonder anyone experience this and share solution? Thanks.

 

NO REFERENCE POSITION IMPULSE (653)

 

Hi sir
This problem is displayed when
- No electrical reference pulse is detected during the reference run
- No electrical reference pulse is detected in the switching phase of the
mechanical reference switch
- No electrical reference pulse is detected when moving over the reference
position stored.
- During the reference run, neither the mechanical nor the electrical reference
point is detected.
To fix this issue do this diagnosis
- Make a reference run and move the backgauge along the entire width of the
table, if the position of the mechanical reference point switch has been modified
- Check functioning and position of sensor B 341
- Check cabling B 341
- Check pulse generator and clean veey wellwith dielectrique or jupiter
- check S1 electrical interlocking of rear-table guard (neither cut nor
backgauge movements are possible)
- Check backgauge motor, electrical connections and it's cabling.
Good luck

 

We have checked everything but still the same issues, until we changed the SAP-02 board.
After its running for a while, the new error "654" pop up
Any master know the solution? Thank you.

 

Error can sometimes be misleading …
I think your find the inverter for the backguage motor is faulty or brake is not releasing so supply failed or adjustment if it’s not driving…motor
No encoder pluses is more likely that its not turning via the motor.
If it is scanning correctly so backguage motor is turning but it stops just after rear limit when it moves fwd. error 654 then look at rear limit switch and momentary hold operated carefully when moving fwd then release it can fool the machine to reference correctly

 

During an active backgauge run: if no or too few counting pulses are received from
the signal transducer the above error message will be output.
This is done whenever the actual speed of the backgauge falls below the nominal
speed by 1/8.
- Verify setting of frequency converte.
- Mechanical stiffness of backgauge drive, check table spindle.
- C014: with Lenze Motor=2, others=0.n
- Check / adjust backgauge drive motor with brake, brake is moving on small
measurements.
- Check and/or replace the backgauge drive motor with brake. (If the brake
is shaking when dealing with short cutting position, replace the brake)
- Frequency converter is defective
- Check / replace pulse generator
- Check cable routes / connections
- Check / replace SAP- board
- Check / replace CPxx- board
- Check proper connection of main terminals from backgauge motor
- Parting of cable to the limit switches in the clamp (S6, S218, S218b)
- Check fuse F8
- Check correct adjustment of S13 and switching cam
- Check correct grounding of backgauge
- Check tight fit of spindle extension
- Adjust 0V by means of potentiometer on board SAP.
- Check plug no. 26 for Freq. Converter / SAP.
- Frequency converter setting, parameter step, try C016 with 8-20%.
- Verify cable routes and connections (connectors 23/ 24 may be reversed).
- Check position B 341.

 

The progression from error 653 to 654 suggests that while the initial issue with the reference pulse was addressed, there is now a problem with the backgauge's signal transducer or associated components
The pulse generator may not be sending sufficient pulses due to:

Incorrect alignment.
Mechanical damage or dirt.
Internal malfunction of the transducer.
The wiring between the signal transducer and the control board (SAP board) might be:
Loose.
Damaged.
Intermittently failing.
The motor might not be reaching the desired speed, indicating issues such as:
Faulty motor connections.
Motor controller or drive failure.
Mechanical resistance in the backgauge
The backgauge may encounter physical resistance, leading to reduced speed:
Check for any obstructions or worn rails.
Inspect lubrication and ensure smooth operation.

Steps for Troubleshooting and Correction

Recheck the alignment and condition of the signal transducer (pulse generator).
Clean it thoroughly with dielectric cleaner or isopropyl alcohol.
Ensure it is securely mounted and properly positioned.
Inspect all cables connected to the signal transducer for damage, loose connections, or wear.
Use a multimeter to check continuity in the cables.
After replacing the SAP board, ensure it is calibrated to match the specific machine parameters
Monitor the motor for smooth operation.
Verify electrical connections and look for signs of wear or overheating.
Test the motor drive unit for proper functionality.
Manually move the backgauge across its range to detect any resistance.
Clean and lubricate the rails and guides.
If all components seem fine, but the error persists, the issue could be:

A defective replacement SAP board.
Deeper electrical or logic-level issues in the control system.