Zero return problems alarms and troubleshooting CNC information

What causes zero return position to change or loss of it on

any CNC?
1.

Crash- causes motor coupling to slip or drive miscalculate

position

2.

Chips piled in area of deceleration dog (switched machines

only)

3.

Zero return switch(switched machines only)- If Limit switch-does

it move freely (clean it) If prox switch, then wipe chips off Face

4.

Backup Battery needs replacement keeps encoder position

when power is shut off (Warning Most machines require
replacement with power up)

5.

One revolution pulse on the encoder happens to be really close

to the drop off point of the decel dog(Switched machines only)

How to determine what type of zero return type you have?

After initial power up. Then perform zero return. Do the axes decelerate
in the end when you zero return this machine? If Yes you have zero
return decel switches. If No you have absolute encoders no decel
switches.

Troubleshooting the different axis zero return types

With Decel switches (switched):
1.

Check that it is hitting the decel dog properly. Keep in mind if

you move switch or dog your zero return position will change and
you may need to do a gridshift. Inspect and clean Limit switch or
Prox/decel dog and area around the decel dog of any chips. If its a
limit switch push the plunger to see if its sticky (clean with WD40 if
necessary). If ok then check the Prox or limit switch for power to
and from switches with a meter, Make sure you are not testing hard
overtravel limit switches instead of zero switch.

2.

The one revolution pulse might be to close to the drop off

point of the deceleration dog Disconnect motor coupling then
rotate motor only 1/2 turn then retighten and try zero returning.
Also check if there is any conditions that must be satisfied to be
able to zero return? Does the axis need to be in a certain area? do

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you have to zero return any axis first? is the tailstock back? turret
clamped? etc.
3.

If the CNC is crashed (something slips) or loss of power

while its machining. The CNC control can get goofed up. Power
down then back up and zero return and see if it corrects itself. If not
you may have to reset it.

4.

If it does not decel it is not seeing the limit switch. Check the
power and input diagnostic in the control by putting metal in front of
the prox or activating the limit switch.

NOTE: Remember switched machines after the initial zero return. Will
not recalculate the zero return again unless the power is turned
completely off at main breaker then back on. Only then it will recalculate
the zero return. Also Keep in mind if you move switch or dog your zero
return position will change and you may need to do a gridshift.
Without decel switches (Absolute encoder switchless):
Once the zero return is set, that's it. You must reset it through a
procedure to reset it. Some controls are fooled if the axis is moving when
the power is off or loss of power while its machining. (NOTE:Do not
disconnect encoder cable from drive to check connections unless you
know how to reset zero return. You will loose zero return position if it is
set.)

Soft overtravel machine alarm occurs when zero returning:

There are 3 ways to get by this in order to complete the zero return.
Reasons for this problem can vary. Most controls have a way to bypass
the soft overtravels without changing any parameters and will usually
reset by cycling power. The another way is to change the overtravel
temporarily to allow for a completed zero return and then change back
the parameter. The last way is to push the axis by hand with power off to
get the axis closer to zero return position.
Causes:
This usually occurs on a Z-axis of vertical machining center or X-axis of
turning centers. These axes tend to drift down if brake does not stop axis
quick enough before power down. A crash can also cause this to
happen. This will also occur if axes are moving and the main breaker is
cut off when they are in motion. Problem is when the power is off it does
not track axis movement.
Fanuc controls only. Turn the control power off. Power on the control
pressing letter (P) and the cancel (CAN) key and keep them depressed
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until the CRT Display comes up plus an additional 5 seconds. Then

release P and Cancel keys . (Do not hold in any other keys or risk
loosing parameters, programs and more) Once powered up fully perform
Zero Return. This procedure bypasses the soft limit, and will reset after
completing a zero return. If the axis overtravels again after deceleration,
more than likely you have a bad Zero return Switch if its not an absolute
pulse coder.

Resetting zero return position (Different ways CNC OEM's

set zero return up)?
Procedure varies from machine to machine, model to model. Here are
Four different zero return setting types:
1.

There is a Parameter for each axis called gridshift that can be

changed to a value. (switched machines)

2.

Special machine tool builder procedure that will automatically

bump up against a hard stop and backs off a certain distance.

3.

Special procedure that you place the axis where you think zero
return should be. Then perform procedure to call that position
home. Some will also require the axis to be moved to find the one
rev pulse.Here is an example of a procedure for fanuc controls
setting zero return position.

4.

Special procedure that you place the axis just before usually 1/41/2 inch where you think zero return should be. Then perform
procedure that will move the axis to the one revolution pulse and
count the gridshift value and stop.

How does an encoder determine zero return?

Most encoders must find the one revolution pulse of the encoder first.
The gridshift value is counted off of this pulse. The machine must be told
at what point to begin looking for this one rev pulse. Here are 2 types:
switched and switchless.
On switched machines with a zero return dog the the prox or limit reads
this dog. Then once it goes past this dog and drops off, it begins looking
for this pulse then begins counting the gridshift. On switched machines
you will not loose zero return as long as you do not disconnect the
mechanical linkage or disturb the switch or dog you can just zero return

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the machine as usual.

On switchless machines once the zero return is complete the battery
backup holds this position in memory, so if battery is lost you will have no
choice but to reset Zero Return.

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