Kongsberg C-series cutting machine troubleshooting guide

Perform security system reset (models after September 2018): Pressing the "Servo On" button will also reset the security system. The old model needs to be reset by pressing 'Pause' first. After successful reset, the warning light will turn on normally, and then press "Start" to complete the reset to zero.

2.3 Frequent triggering of security systems

Check if the gap between the bottom of the crossbeam and the tabletop is too small (standard about 70mm). If the tabletop is placed with too thick material or the vacuum bed is deformed, it may accidentally trigger the light beam.

Check the cleanliness of the photoelectric head. Wipe the transmitting/receiving window with a soft, lint free cloth to avoid dust accumulation and misoperation.

Servo and motion axis malfunction

3.1 "X1/X2/Y servo error" appears during power on self-test

This usually means that the corresponding servo amplifier board is damaged or the motor encoder feedback is lost.

Attempt to power off and wait for at least 5 seconds before restarting. If the fault persists, check the LED status code on the amplifier board (refer to TG driver or Kollmorgen manual). Common cause: The internal fuse of the amplifier is blown (F2-F5).

If the fuse is intact, contact Kongsberg technical support to replace the amplifier.

3.2 “X1/X2/Y fuse error”

Directly check the fuse (T10A 250V) of the corresponding shaft motor driver. If it melts again after replacement, it indicates that there is a short circuit in the motor or cable, and the insulation resistance of the winding needs to be measured.

In addition, the wiring harness inside the cable drag chain at the end of the crossbeam may be damaged due to long-term bending, resulting in intermittent short circuits. Check if the outer skin of the power line and encoder line in the drag chain is worn.

3.3 Axis motion shaking or inaccurate positioning

Mechanical reasons: The guide rail and rack require regular lubrication. Lubricate the guide rail with Tellus R10 oil every week; Fill the gears with grease every month using a grease gun (through the grease fitting on the cover plate). If there is dry glue or debris on the rack, clean it and re lubricate it.

Parameter reason: Check if the maximum speed of "Jog Settings" in iPC has been accidentally modified. For the C series, the continuous jog speed is directly determined by the maximum speed value, and the percentage is invalid. If the servo parameters (such as gain) have been modified, please restore the factory backup.

Milling unit (HPMU) malfunction

HPMU (High Power Milling Unit) is the core of high value-added machining and also the component that is most prone to problems.

4.1 "Inverter not started yet"/milling cutter spindle not rotating

Wait after safety reset: There is a delay of approximately 10 seconds between the safety system reset and the inverter readiness. If the alarm appears immediately, be patient and wait.

Check communication: Confirm that the serial line connection between the main inverter (IBAG) and the front-end PC is normal. If a USB to COM converter is used, check if the COM port number is correctly set in the iPC. HPMU requires the use of native COM ports.

Check the coolant and cooler: HPMU is a liquid cooled spindle. Chiller malfunction will prohibit starting. Check the error codes on the cooler display screen (such as E03: low water flow, E05: low water temperature). When starting in winter, wait for the cooler to heat up to above 19 ℃. Check whether the coolant pipeline is bent or leaking.

Check the air source: HPMU clamp requires 7 bar air pressure for opening and closing. When the air pressure is insufficient, the spindle will not start. Check the air conditioning valve.

4.2 Milling cutter cutting through table or into conveyor belt

Reason 1: The milling cutter slides downwards in the chuck. After each tool change, the clamp must be tightened with a wrench, and a retaining ring should be used to limit the insertion depth. Clean the inner cone of the handle and chuck to avoid oil stains that may cause a decrease in clamping force.

Reason 2: Tool height measurement error. Re execute the 'Table Top Reference' function (remove material and measure on cutting pads or conveyor belts). Then recalibrate the Tool Height of each milling cutter. For thick materials, it is recommended to add a bias value of+0.2~0.5mm in the "Tool Height Calibration" to prevent penetration.

Reason 3: Insufficient vacuum causes the material to lift during milling. Check the vacuum zone selection - close the vacuum zone that is not covered by the material to enhance adsorption. If using a conveyor belt, ensure that the belt joints are flat.

4.3 Abnormal noise or rough surface during milling

Blunt blade or mismatched speed: Replace milling cutter. When the diameter of a single blade milling cutter is greater than 4mm, the maximum speed shall not exceed 40000 RPM. Short blade knives use high speed, while long blade knives automatically slow down.

Main shaft bearing wear: If the vibration increases with running time and the coolant is normal, it may be the end of the main shaft bearing life. It is recommended to replace the spindle every 2000-4000 hours of operation. The manual states: "Indication of worn beads may be increasing noise, increasing vibrations, or decreasing surface finish