Emergency stop. (with photos and videos)
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  1. #1
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    Exclamation Emergency stop. (with photos and videos)

    Guys, i got a problem here, and i dont know next move to solve it. Hope, that it is not serious.

    Machine: mazak variaxis 630 5x with mazatrol fusion 640m control, without palletes and chip conveyor.

    History: machine wasnt working for more than 5 years (one test part was done). During transportation, axis werent fixed correctly. Z motor was removed and mounted back after transportation. Oil is full. Lubricant not connected.

    What was done: MRJ2 tool magazine battery changed and abs restored. control battery changed and data restored.

    What we have: Machine is in emergency state and not mooving.

    Here are some photos with description.

    after start i got this


    the diagnosis looks like this


    holding MF1 + RESET, temporary removes all errors and machine starts, but after release, all errors are back and machine shuts down.
    holding mf1+reset, dont allow to move axis (pressing the buttons while holding mf1+reset, shuts down the machine).
    E-stop buttons are released.


    air preasure alarm was gone after we connected air. Tool holder sensor error appears after a few seconds (My guess, that the turret gone in the z axis limit switch during transportation, or something happened after they removed the z axis drive, but im not shure).
    And we got load on z axis while holding mf1+reset.

    errors in mrj2 soft


    in electrical cabinet
    E7 and F1-F2-F3-F4-F5-F6 on the servos.
    Err. on the small servo
    and error led on the renishaw
    VIDEO OF CABINET

    and we got a red led behind the screen (i forgot how it signed. something like "sw alarm")

    Guys, any ideas how to find a problem will be nice. Im stuck at this moment and dont want to rummage where im not shure.
    Need help! Thanx in advance.

  2. #2
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    Totally off the wall but.......could the plastic film on the key pad cause the problem?

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    Does Mazak help you if you call them on the phone? They have a Russian tech center:

    Официальный сайт Yamazaki Mazak

    The problem should be pretty minor, but you need some expertise to diagnose it. Those two yellow alarms and the white alarm are related to auto-power on and warmup. It can't find the assigned warmup program. The E-stop problems could be as simple as that.

    Also, do you have all the doors closed, and the setup and program edit keys turned to the red when you're doing your MF1+reset?

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    Sensor half is a sometimes PITA. Use some sort of manual process to move the tool holder. When I get the sensor half error on my magazine I rotate the magazine manually and it goes away.

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    Quote Originally Posted by Joe788 View Post
    Does Mazak help you if you call them on the phone? They have a Russian tech center:

    ž„и†иалŒн‹й сай‚ Yamazaki Mazak

    The problem should be pretty minor, but you need some expertise to diagnose it. Those two yellow alarms and the white alarm are related to auto-power on and warmup. It can't find the assigned warmup program. The E-stop problems could be as simple as that.

    Also, do you have all the doors closed, and the setup and program edit keys turned to the red when you're doing your MF1+reset?
    russian mazak wants 3000 EURO for registering a used machine + 1300 EURO for thier specialist to come. Not an option for the owner.

    About warm up i know, is that possible that emergency alarm cause of that?
    Doors are closed, and the program edit keys turned to the right position (i have tryed in all positions). e-stop buttons are released in front panel and in tool magazine.

    And yea, i almost shure, that it is minor problem, but i have not much experience in mazaks, and to find a better specialist is almost impossible here. (
    What else can I try to find out the reason?

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    Was it moved from the location where it was set up?

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    If you look on the door of the electrical cabinet, does it have a little control panel for auto power-on/warmup?

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    Quote Originally Posted by Scruffy887 View Post
    Was it moved from the location where it was set up?
    yep. but it is 2002 YOM so it has no location detector.
    Quote Originally Posted by Joe788 View Post
    If you look on the door of the electrical cabinet, does it have a little control panel for auto power-on/warmup?
    on the door? O_o. no. may be in? in, there are lots of stuff. )

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    Quote Originally Posted by ChatJokey View Post
    yep. but it is 2002 YOM so it has no location detector.
    on the door? O_o. no. may be in? in, there are lots of stuff. )
    Here's what mine looks like, right on the door to the electrical cabinet. This is on a Matrix machine though, not Fusion:




    Here's the page from the Matrix manual. There's a good chance your parameters will be the same as the Angulax with the M640MX control. Do you have the manuals? I don't have a Fusion 5X control, and a lot of the parameters are slightly different between different control models, as you can tell.



    If parameter R2117 is set to 0, just set it to 1. Then create program number 1, and just put a dwell and an M30. Power off and back on and see what happens.

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    Thanx a lot for such info. I'll try to remove yellow warnings in near future and see what happens. I got manuals and i know how to do it, got no time for it yesterday. I thought that machine couldnt e-stop because of this.

    And there is no such control panel on the e-cabinet doors on this machine. (

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    You're probably right that the machine won't e-stop because of it, but usually when there's an E-stop, there's some other alarm along with it that's causing it. Since this is your only other alarm, I'd start there.

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    It is a red mushroom, you can see that the system is not a machine and maybe is becouse of lubricant

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    E-stop signal needs to be a complete circuit or it will not clear. Sometimes auxiliary stuff not plugged in (chip conveyor, pallet station, etc) will cause the fault as newer machines have several E-stop buttons on those items.

    For example, if the chip conveyor has an E-stop button and the conveyor is not plugged into the machine, the E-stop circuit is not complete and machine no worky. Also, need to make sure all the E-stop buttons are pulled out.

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    Ok. Ill try everything that you have suggested tomorrow. Thanx

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    Does the machine have a manual pulse generator or Chip coverage ? If the machine didnt have those itemthen it will cause e Stop on the machine. those Item have an estop button on them. If You didnt have it then look in the electrical manual for the diagram to the wiring then you can bypass it!

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    I've seen the unhooked chip conveyer causing the same problem on other machines, but you noted that it's not hooked up.

    I'd go to the ladder and search for the line that throws the Estop error message and see what contact is causing the alarm. IT's most likely a simple connection that has been missed. Could be on a conveyer, access door, tool magazine, anything in the Estop chain.

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    Quote Originally Posted by Stuart Caruk View Post
    I've seen the unhooked chip conveyer causing the same problem on other machines, but you noted that it's not hooked up.

    I'd go to the ladder and search for the line that throws the Estop error message and see what contact is causing the alarm. IT's most likely a simple connection that has been missed. Could be on a conveyer, access door, tool magazine, anything in the Estop chain.
    Thanx a lot for advice. I'll try.

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    my guess is that the estop alarm is coming from the MRJ drive that has the ERR on it. go to the diagnos version page and see if all the mrj drives are comunicating with the control.

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    Quote Originally Posted by Justin_Terry View Post
    my guess is that the estop alarm is coming from the MRJ drive that has the ERR on it. go to the diagnos version page and see if all the mrj drives are comunicating with the control.
    its not mrj drive. It got only one mrj2 under tool magazine, with no errors.

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    Silly question..... Does your machine have a relocation detector on it? It's of the vintage where they were installed. Once the machine is moved and powered up, your SOL unless a Mazak service tech comes onsite to reset the detector. It's designed to fink on you if the machine was moved from its original location to comply with a government mandate.


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