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Software Manual

MACHINEMATE ®

Error Messages
MACHINEMATE®

Progress is an ongoing commitment at MACHINEMATE INC. We continually


strive to offer the most advanced products in the industry. Therefore,
information in this document is subject to change without notice. The
illustrations and specifications in this document are not binding in detail.
MACHINEMATE INC shall not be liable for any technical or editorial omissions
occurring in this document nor for any consequential or incidental damages
resulting from the use of this document.

DO NOT ATTEMPT to use any MACHINEMATE INC product until the use of such
product is completely understood. It is the responsibility of the user to make
certain proper operation practices are understood. MACHINEMATE INC products
should be used only by qualified personnel and for the express purpose for
which said products were designed.

Should information not covered in this document be required, please contact:

MACHINEMATE INC.
Fond du Lac, WI 54937

Phone: 920-907-0001
Fax: 920-907-0181

E-mail address: info@machinemate.com

Document version: 0701

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MACHINEMATE®

Table of Contents

1. Introduction ...........................................................................................................4
1.1 CNC errors (CNC)..............................................................................................5
1.3 PLC errors (PLC).............................................................................................39
1.3 System Supervisor errors ..............................................................................41
1.4 Operator Interface errors (VMI)......................................................................50
2. Basic trouble shooting procedures...................................................................52
2.1 CNC is stuck in the Emergency Stop condition ...........................................52
2.2 CNC will not move an axis in Manual Mode (such as jogging) ...................54
2.3 CNC is stuck in the CYCLE ON condition.....................................................56
2.4 CNC has an error message during the active Part Program .......................57

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1. Introduction

This manual contains information for the various error messages from the MACHINEMATE CNC control.

The format for each section:


• An error’s number and its message on the display
Note that any _ character in the message in this document will be replaced on the CNC display
by a string from the CNC, based on the conditions at the time of the error.
• A brief description for the cause of the above error or errors.

In the HMI (Windows 2000 systems), the number will be shown at the bottom of the left icon and the
message will be displayed across a line in the message window. When the number of recent messages
exceeds the vertical size of the error window, a vertical scroll bar is provided to view all the messages.

In the MMI (Windows NT systems), the number will be shown at the bottom of the left icon and the
message will be displayed across the message bar. The right icon contains the sequence number for
the particular error message, although that number rolls over every 1000 messages. In Info | Status
treatment soft keys enable the operator to scroll through the entire list of recent messages.

In many cases, there is a common cause for a number of errors. Rather than duplicating the same
description, it is shown after the common error messages.

The error numbers are listed in order of increasing value in each section for ease of reference since no
index to these values is provided in this manual.

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1.1 CNC errors (CNC)


These error messages are assigned to CNC in the message bar (left icon).

Many of these errors involve NC part programming errors. Many of them are explained in the NC
Programming Manual; many of them are also self-explanatory (like too many digits or no signs
allowed). If the error number is in the Part Programming Manual (PPM) index, there will be a reference
to ‘check PPM index’ after the error since more information will be in that manual and it is not repeated
here.

There are several errors that result from machine parameter configuration problems. The Start Up
Manual describes in detail the configuration of many machine parameters.

Some CNC error messages can come from the NC part program so those errors would never be in this
list. If the error message number shown on the display has the format of the capital letter N followed by
a number, like (N+1230) then this is an operator message from the active program. An NC block like
this: N1230 (MSG, BAD SYNTAX) will result in an operator error message like this: CNC (N+1230)
BAD SYNTAX. The number after the N+ indicates the block number with the (MSG,. . .) that is issuing
this operator message. If an error message like this indicates some type of problem then consult the
active part program (or its subroutines) to determine why the error message block is executed. Note
that this NC operator message mechanism is often used to give the operator directions, such as
involving the part set up or a manual operation, so this message is not always an error (i.e., MSG
means an operator message).

There are several errors that involve the SERCOS drives and their configuration. The Start Up Manual
describes in detail the content of the drive configuration file as well as the SERCOS monitor tool
(provided with the CNC) that enables the operator to work with the SERCOS drives and their
configuration parameters using the MACHINEMATE control.

Note that the CNC has a feature that can run a part program in simulation – the Information –
Simulation Path Graphic display. Since this feature will run a part program in this simulation mode (no
motion will occur) with the path graphic showing the tool path, all CNC errors that involve block syntax
or run-time errors (like path compensation value causes a conflict) could occur. Each of these errors
(which have the same meaning as from the real part program execution, not in this simulation) will be
assigned to SIM in the message bar.

This is the fourth generation of the control so some of the error messages listed here actually date back
to the earlier generations and might never occur.

CNC
1 Text character(s) missing
2 Character is at wrong POSITION
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

3 NC address is not permitted

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The above error involves a programming problem. Each decimal point must have a number so
this error occurs when a decimal point value has no letter. Also, this error occurs when a
character other than A-Z accompanies a numeric value. This error can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

4 NC address does not set up


The above error involves a programming problem for the control’s configuration. This letter has
not been configured correctly in the machine parameters. Either correct the NC statement or
check this letter in the NCAddressFormat machine parameter group.

5 NC address has been programmed too often


The above error involves a programming problem. Each letter can occur only once on a line.
These errors can occur right away during an MDI or on a future block during the CNC look ahead
for syntax errors in the program. Check and fix the active part program.

6 No parameter follows
The above error involves a programming problem. Each reference to a cycle parameter (P)
requires a number after the letter P; only the letter P can be used for a parameter reference (with
the = in a non-cycle block). This error can occur right away during an MDI or on a future block
during the CNC look ahead for syntax errors in the program. Check and fix the active part
program.

7 Index not permissible or decimal number as index


The above error involves a programming problem. A cycle parameter (P) can be used as an index
in some circumstances. This error can occur right away during an MDI or on a future block
during the CNC look ahead for syntax errors in the program. Check and fix the active part
program.

8 Decimal places are valid for display only


The above error involves a programming problem for the control’s configuration. This letter has
not been configured correctly in the machine parameters. Either correct the NC statement or
check this letter in the NCAddressFormat machine parameter group.

9 Too many decimal places


The above error involves a programming problem for the letter. This letter has been configured
for a certain number of decimal places in inch or metric. Either correct the NC statement or check
this letter in the NCAddressFormat machine parameter group.

10 No signs allowed
The above error involves a programming problem for the letter. This letter has been configured
for only positive values, with no sign. Either correct the NC statement or check this letter in the
NCAddressFormat machine parameter group.

11 Too many digits


The above error involves a programming problem for the letter. This letter has been configured
for a certain number of total digits. Either correct the NC statement or check this letter in the
NCAddressFormat machine parameter group.

12 Value outside of permitted range


The above error involves a data entry error with cycle parameters. The parameters have a range of
real values and the new value is outside of that range (probably the exponent is too large positive
or too small negative).
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13 Decimal point is not permitted


The above error involves a programming problem for the letter. This letter has been configured
for no decimal places. Either correct the NC statement or check this letter in the
NCAddressFormat machine parameter group.

14 Selection of metric units allowed only before axis info.


15 NC address at wrong position (in block)
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

16 Programmed without value


The above error involves a programming problem. Each letter must be followed by at least one
number (the syntax depends on the particular letter) or there are consecutive decimal points. This
error can occur right away during an MDI or on a future block during the CNC look ahead for
syntax errors in the program. Check and fix the active part program.

17 Cycle block fault


The above error involves a programming problem for a cycle block (leading *). This error can
occur right away during an MDI or on a future block during the CNC look ahead for syntax errors
in the program. Check the active part program according to the syntax defined in the PPM.

18 Scale factor <= 0.0


The above error involves a programming problem. Check PPM index.

19 Radius is too small


20 G12/13 = complete circle is not permitted
The above errors involve a programming problem with G12/G13. These errors can occur right
away during an MDI or on a future block during the CNC look ahead for syntax errors in the
program. Check and fix the active part program.

21 Index is not permitted


22 Possible and programmed center point differ too much
23 Illegal number of axes
24 Main axis = auxiliary axis
25 No interpolation because dwell time in progress
26 Programmed dwell time too long
27 No F value has been programmed
28 Too many BCD codes programmed
29 Axis limit reached
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

30 Checksum error block no.__ Segaddr:__ block length:__


The above error indicates a corruption of the part program (or a subprogram). However, this error
will also occur if the last line (with the M30) in the program (or subprogram) does not have a
block terminator (like a carriage-return character); the error occurs if the ‘end of file’ comes
before the ‘end of block’ character. Check and fix the active part program; check PPM index.

31 Program contains M30/M02 before end:__


The above error involves a basic programming problem. The M30/M02 line (which should be the
last line) cannot have any following lines. Check and fix the active part program.

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32 Program end without M code


The above error involves a basic programming problem. The last line in any program or
subprogram must be an M30/M02 line. Check and fix the active part program; check PPM index.

33 File contains data behind program end: __


The above error involves a basic programming problem. The M30/M02 line (which should be the
last line) cannot have any following lines. Check and fix the active part program.

34 DA converter hangup in position task


The above error involves a configuration problem, where the D/A outputs are not properly
synchronized with the CNC software. T_DADELAY in the drive configuration file must define a
time at least 25% of the servo update rate (a rate which is usually 1ms or 2ms depending on the
CNC model and its block performance level). If this error occurs this time should be increased,
typically to 0.5ms for a 2ms servo rate. This timing could be affected by other hardware device
drivers that have been loaded into the CNC. If the removal of another device driver (for PC
hardware not from MachineMate, Inc.) causes this error to disappear then that hardware and its
driver are suspect.

36 Exception of type:__ at address:__ in timer message handler of CNC Interpreter


process!
37 Exception of type:__ at address:__! CNCDataServer was stopped! Please restart the
system.
The above errors are internal CNC problems. Contact MachineMate Inc. should one occur.

38 Block selection and display of NC blocks is not allowed during active NC-program!
The above error involves an operator problem. A block select cannot be done while a part
program is active. Perform a control-reset prior to the block select.

45 System computing fault


The above error is an internal CNC problem. Contact MachineMate Inc. should it occur.

47 Program does not exist


The above error involves a programming problem. A subprogram or work cycle is being called
but that program number has not been loaded into CNC memory (or perhaps the wrong program
number was called). Check the active part program and the list of program numbers in CNC
memory.

48 Only 4 subroutine levels are possible


The above error involves a programming problem with calling subprograms; there is a limit of 4
when nesting them. These errors can occur right away during an MDI or on a future block during
the CNC look ahead for syntax errors in the program. Check the active part program and/or the
subprograms it calls.

49 Axis addresses are not unique


50 G code combination is not permitted
51 Invalid address
52 Index is too big
53 Index is too small or missing
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

54 Invalid axis address


The above error involves a basic programming problem. Check PPM index.

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55 Exponent too big or too small. Value outside of displayable range


56 No further character allowed
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

57 Closing parenthesis is missing


The above error involves a programming problem; the line has a ( for the start of a comment but
is missing the trailing ). These errors can occur right away during an MDI or on a future block
during the CNC look ahead for syntax errors in the program. Check and fix the active part
program.

58 '*' can only be 1st character


The above error involves a programming problem; the * character is used for a cycle block as the
first character before the N. It cannot be used to multiply numbers in a non-cycle block. These
errors can occur right away during an MDI or on a future block during the CNC look ahead for
syntax errors in the program. Check and fix the active part program.

59 '/' only allowed as 1st character or after '*'


The above error involves a programming problem with the / character. It is used to indicate an
optional block when it is the first character on a line before the N; otherwise it is used to begin a
comment in a cycle block (a block starting with *N). These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

60 Only 100 programs possible


61 Program memory full
The above errors involve an operator problem with CNC memory. This battery-backed memory is
limited to 100 programs or to the remaining capacity after the parameter data (cycle parameters
and PLC retentive variables) and compensation tables (D-table, H-table, G5x offsets, tool table
and pitch error compensation). One or more part programs must be deleted from CNC memory to
create space. Alternately, this program (or one or more of the others in CNC memory) could be
run from a hard disk folder and not loaded into CNC memory.

62 Format error (experienced user)


The above error involves an operator error that is not properly handled by the user interface.

63 Impermissible VMI data for DP; numeric entry was not valid
The above error involves an unusual operator data entry error. The CNC expected a numeric data
entry (i.e., +,-,.,0..9) but an invalid character was also included. When this data entry was
converted into a floating point value, the conversion terminated due to the invalid character. Fix
the data entry.

64 Servo fault axis _


The above error involves a problem with a specific axis. An ‘excess following error’ (or
‘excessive lag’) condition has been detected. Either there is a binding condition preventing the
axis from its programmed motion or the configuration of machine parameters has allowed this
axis to be programmed to move faster than it is physically capable. Determine the cause and take
the appropriate action.

One possible cause of this error in an analog system is the AxisSpeedMaxAppl parameter value is
too high for the mechanical system. After activating the LAG display function, monitor the
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voltage column when moving the axis at its maximum feed rate. If the CNC will detect 10V
output even for a moment this servo fault will occur (because the D/A device cannot exceed 10V;
10V triggers the excess following error) so monitoring the voltage column will reveal how close
the drive is to this 10V limit when moving at the high feed rate. Sometimes the mechanical
system (drive/motor/gearing/inertia/load) requires the axis maximum feedrate to be limited at less
than what the axis motor is actually capable.

65 Servo interface _ defective or not existing


The above error involves a configuration problem (in the drive configuration file) with a specific
axis. Check the contents of that file.

67 Wire cut of axis _, loss of feedback


The above error is an encoder feedback problem. The CNC continually monitors the encoder
signals for a loss of feedback (which is considered caused by a ‘wire cut’). A loss of feedback is
detected when either the A and ~A pair or the B and ~B pair are found to be at the same value,
which is not allowed in the encoder’s differential signal interface. This could be caused by a
broken or intermittent wire, excessive signal noise, low encoder power supply voltage or similar
conditions. Determine the cause and take the appropriate action.

68 End of program without M code


The above error involves a basic programming problem. The last line in any program or
subprogram must be an M30/M02 line. Check and fix the active part program.

69 Block does not exist


The above error involves a programming problem. Check PPM index.

70 Subroutine does not exist


71 Feed value too big
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

72 Axis _ RMS defective, marker error d: _ a: _. Please check encoder marker or exchange
module
73 Axis _ RMS defective, wrong encoder signal change. Please check encoder or exchange
module
74 RMS card defective or missing
The above errors are encoder feedback problems (RMS is Rotary Measurement System). The
CNC continually monitors the encoder signals for a loss of feedback (see error 67 above). The
marker pulse is also monitored. A wrong ‘change’ indicates that the differential signal(s) in the
three pairs deviated from the tolerances for such signals. Determine the cause and take the
appropriate action.

75 DA output _ defective or missing


The above error is an analog output problem. In the hardware, the output from the D/A is checked
within a tolerance. This error can be caused also by another voltage being connected to the D/A
output terminal pin/wire (or perhaps strong signal noise or interference), affecting this monitor.
Determine the cause and take the appropriate action.

76 Step motor card defective or missing


77 Overload on axis (axis with overload)
The above errors are drive-related problems – these messages are not used at this time (support
for a stepper drive is a future feature).
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78 AD card defective or missing


79 AD position incorrect
The above errors are analog input problems. The above error involves a configuration problem (in
the IO configuration file) with a specific A/D module. Check the contents of that file and/or the
physical module connections.

80 Program memory defective or missing


87 E word not allowed
88 Temporary block fault
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

89 Command has not been executed correctly


90 Processing fault, please correct
The above errors are an internal CNC problem. They could occur with unexpected operator key
sequences while the CNC was busy with the last command. Either change the sequence of
operator commands or contact MachineMate Inc. should an error occur.

91 Format error
The above error involves a basic programming problem. This can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

92 Input is unknown or not allowed


The above error is an internal CNC problem. It could occur with unexpected operator key
sequences while the CNC was busy with the last command. Either change the sequence of
operator commands or contact MachineMate Inc. should an error occur.

93 Hand wheel factor too big


The above error involves a machine parameter configuration problem. There are several
handwheel parameters that could cause this error but the suggested resolution is to undo the last
changes (since the last known good set, perhaps saved to a disk file) and consider their new
values again.

94 Teach-In only during edit


The above error involves an operator problem while editing a program with the Teach Panel. A
part program must have playback activated for the teach and edit process. Either change the
selection or do not cause a conflict with the Teach Panel.

95 No change of station
The above error is an internal CNC problem. It could occur with unexpected operator key
sequence. Either change the sequence of operator commands or contact MachineMate Inc. should
it occur.

96 No D corrections, input is invalid


97 No H corrections, input is invalid
The above errors involve a programming problem. The D and H tables are standard but they can
be disabled for a specific configuration. Check your control features.

98 Danger of collision, radius is negative, change of direction

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The above error involves a problem with a D compensation value. Typically, the error comes
from the circle radius being smaller than the D value. A negative compensation value could also
cause this error. Check the compensation value and the part program path. Check PPM index.

99 NC block not correct


The above error involves a basic programming problem. This error can occur right away during
an MDI or on a future block during the CNC look ahead for syntax errors in the program. Check
and fix the active part program.

100 Preprocessing fault: memory overflow


101 Preprocessing fault: start point is invalid
The above errors involve a problem during the CNC look ahead for syntax errors in the program.
A change in the part program should resolve this look ahead problem.

102 E word not allowed, number of strokes > 32767


The above error involves a programming error with a future nibbling feature. Check and fix the
active part program.

103 Keyword incorrect, input is invalid


104 Instruction incorrect, input is invalid
The above errors involve a programming problem with cycle programming. These errors can
occur right away during an MDI or on a future block during the CNC look ahead for syntax errors
in the program. Check and fix the active part program.

105 Execution not possible, input is invalid


106 Content of parameter invalid
107 Erase of remaining path is not allowed
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

108 Code not permitted


The above error involves a programming problem. Check PPM index.

110 Slope time is too long


111 (block N....:) spline fault
112 Active preprocessing fault, no START possible
113 Circle error
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

114 Circle error at __


The above error involves a circle programming problem. Check PPM index.

115 Spiral fault at __


The above error involves a circle/spiral programming problem. Check the active part program
according to the syntax defined in the PPM.

116 Only 4 subroutine levels are possible


The above error involves a programming problem with calling subprograms (SR is subroutine);
there is a limit of 4 when nesting them. These errors can occur right away during an MDI or on a
future block during the CNC look ahead for syntax errors in the program. Check the active part
program and/or the subprograms it calls.

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117 Spline not finished


118 Wrong start point
The above errors involve a spline programming problem. These errors can occur right away
during an MDI or on a future block during the CNC look ahead for syntax errors in the program.
Check the active part program according to the syntax defined in the PPM.

119 Wrong value for I/J.


The above error involves a circle/spiral programming problem. The I/J are the incremental
distance from the block’s start positions to the circle center. Check and fix the active part
program.

120 No path correction possible


The above error involves a programming problem. A change in path compensation (D value) is
not allowed during a compensated path; the compensation value must be changed before or after
the path, not during the path. These errors can occur right away during an MDI or on a future
block during the CNC look ahead for syntax errors in the program. Check and fix the active part
program.

121 Path correction, no G92 possible


The above error involves a programming problem. Check PPM index.

122 System fault recognized. Emergency Stop generated. Reset, then test again
123 No START possible, exchange defective parts
The above errors are internal problems. Contact MachineMate Inc. should one occur.

124 Only 128 character/block, input is invalid


The above error involves a basic programming problem in the part program file. An NC statement
cannot exceed 128 characters, including the line terminator. Check and fix the active part
program.

125 Address in PROM area, value cannot be changed


126 Emergency Stop active. Only reset is possible
127 Analog step card defective
128 Not enough PROMs recognized, PROMs are defective or missing
129 Program fault
130 RAM error recognized
131 CMOS RAM error recognized
132 External program choice corrupted
133 Ext. BA selection corrupted
The above errors are internal problems. The PROM references are to the write-protected areas of
the CNC memory. Contact MachineMate Inc. should one occur.

134 Center point is wrong


The above error involves a circle programming problem, where the I, J and/or K values are the
incremental distances from the block’s start positions to the circle center. These errors can occur
right away during an MDI or on a future block during the CNC look ahead for syntax errors in the
program. Check and fix the active part program.

136 Counter overflow


The above error is an internal problem, for an obsolete system. Contact MachineMate Inc. should
it occur.

137 Voltage fault 5 V Isol.


138 Voltage fault 24 V Int.

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The above errors are hardware problems. The hardware monitors the power supplies. Check and
fix the appropriate power supply.

139 Path speed too high


141 Preprocessing fault
142 Thread cutting active
143 Spindle signal not permitted
144 Thread cutting active. NC address is not correct
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

145 NC address field _ is not valid


The above error involves a basic programming problem. The _ should be replaced in the message
by the offending letter from A to Z. If a letter from A to Z is not in the message then the block
contains some other ASCII character has been parsed to be the start of the a field (RS274 defines
a block where each field is a letter from A to Z followed by a number). Check PPM index.

147 Spline processing active


The above error involves a spline programming problem. This error can occur right away during
an MDI or on a future block during the CNC look ahead for syntax errors in the program. Check
the active part program according to the syntax defined in the PPM.

149 Servo processor is defective or missing. Please update CNC system with different
module
The above error is an internal problem, from an obsolete CNC version.

150 NC address _ is invalid. Thread cutting active


151 Error in block number
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

152 Program does not exist


The above error involves a subprogram programming problem. A Q statement has called out a
subprogram number but that program number does not exist in CNC memory. Either load that
subprogram into CNC memory or correct the number in the active part program.

153 Memory/parallel edit could not be selected


The above error involves the operator trying to enable the parallel edit feature when the CNC
conditions do not allow it.

154 Command line was busy


The above error is an internal timing problem when the operator makes consecutive soft key
commands but the first command did not complete before the second was selected. The operator
must wait for certain commands to complete before performing another.

155 Program not selected


156 First block not selected
157 Mode cannot be selected
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

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158 Data transmission aborted


159 Data transmission not active or aborted
The above errors are internal problems, from an obsolete CNC version supporting DNC.

161 Too many places before decimal point


The above error involves a programming problem for the letter. This letter has been configured
for a certain number of decimal places in inch or metric. Either correct the NC statement or check
this letter in the NCAddressFormat machine parameter group.

162 Erasing the file is not permitted


163 Writing to the files is not permitted
164 Reading the file is not permitted
The above errors involve an operator problem dealing with the program protections. Individual
programs have individual privileges for reading, writing, execution or deletion. If the operator
tries to perform an action on a file that lacks that privilege, an error results. Either the operator is
trying to do something that is not allowed or the wrong protection has been assigned to the
program.

165 Program already exists


The above error involves an operator problem dealing with the program copy command. If the
output program number for a program copy already exists in memory, this error results. Either the
operator must change the output number or delete the old program number being overwritten.

166 No line feed found


The above error involves a basic programming problem. Each line must have a line feed character
at the end; a carriage return character is optional.

167 Programmed without block number


The above error involves a basic programming problem. Every NC statement must have a block
number (N) and it must be the first letter on the line. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

168 SERCOS: Optical wave-guide ring is not closed or drives are switched off.
The above error is a SERCOS problem. The optical ring is not intact; check the connections.

169 Too many characters!


170 Character is not permitted
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

171 SERCOS: Communication error in drive _ or optical wave-guide is not closed.


The above error is a SERCOS problem. The drive has a problem or the optical ring is not intact.

174 No Sercos drive: axis _


The above error is a SERCOS problem. No drive was detected at its address (specified in the
drive configuration file). Check the drive, the SERCOS ring and/or the drive configuration file.

175 Servo debug busy


The above error is an internal problem. Contact MachineMate Inc. should it occur.

176 NC program in PROM - can only be copied cannot be edited

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The above error involves an operator problem with the system programs (e.g., canned cycles).
The operator cannot edit the system programs at any time.

177 First move to reference point


The above error involves the operator not following the normal control start up procedure. All
axes that require homing must be homed prior to running a part program. Go to Manual mode,
select Traverse to Reference Point and press Cycle Start to home all axes.

178 Execution of the program is not permitted


The above error involves a programming problem with a subprogram. A subprogram can range
from 1 to 999999; a Q0 results in this error. Correct the active part program.

179 Input field is empty


The above error results when the operator using the MDI dialog and clicks on OK with an empty
command line. The operator must have a valid NC statement before the OK.

180 Data transmission active


The above error is an internal problem, from an obsolete CNC version supporting DNC.

181 Copying of the file is not permitted


The above error involves an operator problem dealing with the program protections. Individual
programs have individual privileges for reading, writing, execution or deletion. If the operator
tries to perform an action on a file that lacks that privilege, an error results. Either the operator is
trying to do something that is not allowed or the wrong protection has been assigned to the
program.

182 Program in PROM, cannot be output


183 NC program in PROM, cannot be read, edited or deleted
The above errors involve an operator problem with the system programs (e.g., canned cycles).
The operator cannot view, edit, paste or delete the system programs at any time.

184 PLC has not taken over preceding text. New input cannot be accepted
185 Wrong GEM command structure
186 Parameter index not permitted
187 Jog during active debug not allowed
188 Called address.: __:__ in module __. Subroutine does not exist
189 Please correct - fault number: _ status: _. System computing fault, Machine parameter
data corrupted
190 Error in status word of DualPort RAM
The above errors are internal problems. Contact MachineMate Inc. should one occur.

191 Program does not exist


192 Cycle active, input invalid
193 No program active, input is invalid
194 Program is being processed, input is invalid
195 NC address invalid
196 Erasing the remainder of the path is not permitted
197 G code is not permitted - no G92 is possible
198 Circle error at __ , not a valid address of an axis
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

199 NC block not correct, NC address field _ invalid. Only reset possible
The above error involves a programming problem. Check PPM index.

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200 Parameter index too big


The above error involves a programming problem. This error can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

201 Format error


The above error involves a programming problem that is detected in a future block during the
CNC look ahead for syntax errors in the program. The second and third blocks shown in the Auto
mode active block display will be from the look ahead to help show the syntax error. Check and
fix the active part program.
Sometimes if the syntax error is not readily apparent from the display, typing the very same block
in an MDI (or each one of the two look ahead blocks in turn) can be helpful because the MDI will
reveal immediately the syntax error with a more meaningful error message, whether it is
something like ‘too many decimal places’ or ‘too many digits’.

202 Spiral fault __, center point is invalid


203 Circle error at __, center point is invalid
The above errors usually involve a programming problem. These errors can occur right away
during an MDI or on a future block during the CNC look ahead for syntax errors in the program.
Center point errors typically occur because the part program has a simple syntax error: the G2/G3
was modal (from a preceding block) but the block causing the error should have had a G1 to
indicate the move is linear and it is not relative to a previous circle center point. Check and fix the
active part program.
Another cause of these center point errors is possible but rare. If the IJK configuration (i.e., the
number of decimal places) does not match that of the axes in the circular plane (two of XYZ
depending on G17/18/19) then the correct calculation of the circle center is not possible with this
mismatch.

204 Values for I/J invalid


The above error involves a circle programming problem. Check PPM index.

205 Circle error at __, center point is invalid


206 Spiral fault __, center point is invalid
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Center
point errors typically occur because the part program has a simple syntax error: the G2/G3 was
modal (from a preceding block) but the block causing the error should have had a G1 to indicate
the move is linear and it is not relative to a previous circle center point. Check and fix the active
part program.

207 Danger of collision, change of direction


208 Spiral fault at __, path correction is not possible
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

209 Path correction, G code is not permitted


The above error involves a programming problem. Check PPM index.

210 End of program without M code


The above error involves a programming problem. The last line in any program or subprogram
must be an M30/M02 line. Check and fix the active part program.
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211 Axis limit __


The above error involves an axis programming problem. Check PPM index.

212 Acceleration too great, max. 100 percent allowed


The above error involves a programming problem with programmable acceleration, since the
range of values is from 1 to 100 (representing 1% to 100%). Check and fix the active part
program.

213 During active G21 parallel axis has been programmed


The above error involves a parallel axis programming problem. The slave axis cannot be
programmed for motion when it is in an active parallel axis configuration. Check and fix the
active part program.

214 Machine parameter defective


The above error involves a machine parameter configuration problem. There are a variety of
causes but the suggested resolution is to undo the last parameter changes (since the last known
good set, perhaps saved to a disk file) and consider their values again.

217 Servo computing fault (FP), Routine __ Error __. Program fault
218 System computing fault (FP), Routine __ Error __. Program fault
219 Position computing fault (FP), Routine __ Error __. Program fault
The above errors are internal problems. Contact MachineMate Inc. should one occur.

220 Checksum error


The above error indicates a corruption of the part program (or a subprogram). Check and fix the
active part program.

221 Mode cannot be deselected, possibly Cycle ON is active


The above error involves an operator problem while a part program is active. Certain soft keys
are not accepted while an NC block in the part program is active. Wait for the current NC block
to complete before trying it again.

222 Thread cutting active. Path speed too high


The above error involves a programming problem with the thread cutting feature. Check the
active part program according to the syntax defined in the PPM.

223 NC Address _ wrong, error in block no. __. Pitch error compensation.
The above error is a programming problem in the pitch error compensation part program
(P999999). Its syntax is described in the Start Up Manual. Check and fix that file. If the letter is
for an axis then the axis positions must be ascending and the axes must be in the order they are on
the display. If the letter is I then the problem is with the compensation value. The I values are
governed by the machine parameters PitchErrorMaxComp and PitchErrorMaxDeltaComp; these
parameters define the ranges on I so that a mistake in a comp value might be detected; with large
I values in the file these parameters must be increased.

224 Format error, error in block no. __. Pitch error compensation.
225 Pitch error compensation, block does not exist.
226 Pitch error compensation, program does not exist.
227 Pitch error compensation, program fault.
228 Pitch error compensation, end of program without M-code.
229 Pitch error compensation, checksum error.

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The above errors involve a programming problem in the pitch error compensation part program
(P999999). Its syntax is described in the Start Up Manual. Check and fix that file. The CNC
checks for this file in CNC memory (error 226 indicates the file is not there).

231 SERCOS: Configuration file cannot be opened!


232 SERCOS: Configuration file cannot be created!
233 SERCOS: Error during the automatic configuration. Sercos cycle time is too small.
234 SERCOS: Wrong number of drives!
235 SERCOS: Service channel ident __ axis _ is not free!
236 SERCOS: Program error: axis _. Invalid command option!
237 SERCOS: command error axis _
The above errors are SERCOS problems, usually caused by a mistake in the drive configuration
file. Check and fix that file.

238 NC block not correct


239 Block no. __: spline fault, path correction
240 G code prohibited, no G92 is possible
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

241 G code prohibited


The above error involves a programming problem. Check PPM index.

242 Spiral fault __ , center point is invalid


243 Circle error __ , center point is invalid
The above errors involve a circle programming problem. These errors can occur right away
during an MDI or on a future block during the CNC look ahead for syntax errors in the program.
Check the active part program according to the syntax defined in the PPM.

244 G70/G71 only at block start


245 G70/G71 only at block start
246 Format error
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

247 DA output _ defective, please check DA output wiring or exchange module


The above error is an analog servo interface hardware problem. There are hardware internal
monitors and an error condition has been detected. A DA error can be caused also by another
voltage being connected to the D/A output terminal pin/wire (or perhaps strong signal noise or
interference), affecting this monitor. Determine the cause and take the appropriate action.

248 Servo interface _ defective, clock/voltage fault. Please exchange card


The above error is an internal problem, from an obsolete CNC version.

249 Axis _ RMS defective, counter overflow


250 Axis _ RMS defective, encoder warning
The above errors are encoder feedback problems (RMS is Rotary Measurement System). The
CNC continually monitors the encoder signals for a loss of feedback and an error condition has
been detected. Check the encoder, its connection for this axis and its power supply for adequate
voltage.

251 Voltage fault 15V, machine interface _. Please exchange card

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The above error is an analog servo interface hardware problem. There are hardware internal
monitors for the power supply voltages and an error condition has been detected.

252 Block no. __: spline fault, prohibited G code. Please reset
253 Block no. __: spline fault, axis limit
254 Block no. __: spline fault, change of direction. No path correction possible
255 Block no. __: spline fault, program fault
256 Block no. __: spline fault, no path correction possible
The above errors involve a programming problem with the spline interpolation feature. Check the
active part program according to the syntax defined in the PPM.

257 Block no. __: spline fault, NC block not correct. Please reset
The above error involves a programming problem with the spline interpolation feature. Check and
fix the active part program; check PPM index.

258 Watchdog error station __


The above error is an internal problem. In almost all cases, another error message will accompany
this one. That other message will be more meaningful as it will identify what happened to cause
this watchdog error. Contact MachineMate Inc. should it occur.

259 Cycle fault in block no. __, execution not possible


260 Cycle fault in block no. __, keyword invalid
261 Cycle fault in block no. __, instruction invalid
262 Cycle fault in block no. __, index too big/small
263 Cycle fault in block no. __, contents of parameter invalid
The above errors involve a cycle programming problem. Check PPM index for each.

264 Cycle fault in block no. __, only 128 characters per block
265 Cycle fault in block no. __, program memory full
266 Cycle error in block no. __, option not installed
The above errors involve a programming problem with the cycle programming feature. The Part
Programming Manual section 6 describes programming for this capability. Check and fix the
active part program.

267 Only 100 programs possible, data transmission aborted


268 Program memory full, data transmission aborted
269 Store mode not selected, data transmission aborted
The above errors involve a problem for data transmission of data to the CNC. These errors are
from an obsolete system.

270 Axis _ RMS defective, marker error hardware. Please check encoder or exchange module
The above error is an encoder feedback problem (RMS is Rotary Measurement System) involving
the marker (or index) pulse. Check this encoder’s marker, its connection for this axis and its
power supply for adequate voltage.

271 Positioning axes: axis limit __


The above error involved a programming problem for positioning axes. A positioning axis is not
run from the part program but from the PLC and this error indicates the commanded motion
exceeded a software travel limit. Check either the PLC logic or the positioning axis motion
sequence in the active part program.

272 Oscillation: program fault


The above error involves a oscillation axis programming problem. Check PPM index.

273 Inserting blocks: cycle stop not active

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The above error involves an operation problem. Typically this error occurs when the operator
attempts to do a block select in the middle of a part program at the same time as the teach feature
is active (Manual – Playback – Teaching). The block select cannot be done when the CNC is
active (not in cycle stop) or if the Teach editor is active. Check the conditions at the time of the
operator’s block select.

274 Oscillation: NC address _ is invalid


The above error involves a programming problem for the optional axis oscillation feature. Check
and fix the active part program; check PPM index.

275 Memory overflow: please reset


276 Tool device not permitted
The above errors are internal problems. Contact MachineMate Inc. should one occur.

277 Last output is not complete. G74 is not possible


The above error involves a programming problem for G74 (move to home). Check and fix the
active part program.

278 Positioning axes: program memory full


279 Positioning axes: G code is not permitted
280 Positioning axes: program does not exist
The above errors involve a programming problem for positioning axes. A positioning axis can be
run from a number of NC statements at the start of the active part program. The capacity for these
NC blocks is part of the control configuration and cannot be changed after the installation. Check
the positioning axis motion sequence in the active part program.

281 No editing possible. Program without checksum


282 Program is being processed, input invalid.
283 Program cannot be edited or deleted. Only COPY possible
284 No program has been selected. Input is invalid
The above errors involve operator errors with part programs. Try a different selection or sequence
of operations.

285 Position program is defective or does not exist. Please update CNC system with
different module
The above error is an internal problem, from an obsolete CNC version.

286 Invalid T-word in block N + 2


287 Step width too great
288 No tool selected
289 Tool cannot be turned
290 Step width too small
291 Negative E word is not allowed with NIBBLING
292 Tool does not exist
293 Tool change is not permitted
294 Copy process is active
295 T with incompatible G code
296 Axis _ without E-word
297 Step width is too great for tool to be turned
298 Loss of synchronization with the rotary tool
299 Programmed _ value is incorrect
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

300 Table place is assigned twice

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301 No tool change possible


302 Tool number is assigned twice
The above errors involve an error in the tool table data that has resulted in a failure when the part
program attempts to do a tool select or a tool change. Check and fix the tool data table.

303 Not permitted E value


304 Matrix lock range
305 Overrun fault
306 Matrix lock range: Circular interpolation is not permitted
307 Matrix lock range: Programmed axis cannot be moved
308 Matrix lock range: Cutter path is not permitted
309 E word missing
310 E or H word with M20
The above errors involve a programming problem. These errors can occur right away during an
MDI or on a future block during the CNC look ahead for syntax errors in the program. Check and
fix the active part program.

311 Function is not implemented


312 Function is not set up
313 Programs cannot be deleted. Protection D not set.
The above error involves an operator problem for a certain CNC program. The program must
have the D protection set (enabling a delete) for the program to be deleted. Note: the other file
protections are RWE for Read enable protection, Write enable protection or Edit/Execute enable
protection.

314 Data transmission active. No editing functions are allowed


The above error involves a problem for data transmission of data to the CNC. These errors are
from an obsolete system.

315 Machine parameter __ invalid


The above error involves a machine parameter configuration problem. There are a variety of
causes but a frequent mistake is referencing an invalid axis number (in many cases, they are
numbered starting at 0, not at 1, so a reference to the highest axis number is wrong). Two
common parameters reported: TransmissionRatio is invalid if any of its index values are 0 when
M40Appl is non-zero and HandwheelNoAppl is invalid if more than one defined handwheel is
free (its axis is 0). Also check PPM index.

316 Command handshaking time out


317 Interface to PLC busy
The above errors are internal problems. Contact MachineMate Inc. should one occur.

318 Program must be selected again. Deselection was carried out by DNC command presumably
The above error involves an application problem for the PLC making a program selection. DNC
is an obsolete CNC feature.

319 Program error: Round axis _. The programmed value is outside the allowed range
320 Program error: Round axis _ (Tool rotating axis). The programmed value is outside the
allowed range
321 Program error: Round number for modulo axis _ is too big
322 Program error: Modulo axis _. The programmed value is outside the allowed range
The above errors involve a programming problem for a round axis. Check the active part program
according to the syntax defined in the PPM.

323 SERCOS: Service channel error no. __ in drive _


324 SERCOS: Service channel cannot be opened ident __ drive _
325 SERCOS: Service channel: ident __ drive _. Invalid access to element 0.

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326 SERCOS: Service channel: ident __ drive _. Ident number does not exist.
The above errors are SERCOS problems with the service channel. The use of the service channel
is optional so there is probably a configuration problem with the service channel.

327 Spacing control: Maximum offset reached


328 Real time milling radius compensation: Corner not allowed
The above errors involve the configuration of machine parameters. Change the machine
parameters associated with the feature in the error.

329 Machine parameters have not been read completely


The above error involves the machine parameter file; apparently the file is corrupted because the
file does not have the correct format. Try a previous version of that file.

330 Command file cannot be transmitted


331 Command file too long. Data transmission aborted
332 Protocol fault. Data transmission aborted
333 Blocking file cannot be transmitted
The above errors involve a problem for data transmission of data to/from the CNC. These errors
are from an obsolete system.

334 EGB: B/C axis programmed incorrectly by invalid L


335 EGB: T teeth digit is zero
336 EGB: B/C speed too great
337 EGB: M code is not permitted
338 EGB: G code not permitted
339 EGB: acceleration C too great
340 EGB: incorrect normal module
341 EGB: B/C synchronization fault
The above errors involve a programming problem for the Electronic Gear Box (EGB) optional
feature. Check and fix the active part program.

347 _
This error comes from a compile cycle add-on to the system. A compile cycle is a DLL (dynamic
linked library) that has been integrated into the CNC kernel. Typically this message will be an
error of some kind (check the message contents) or just information about the special feature or
its operation.

348 Address: __ OpAddress: __ 8087 status: __. Servo computing fault (FP)
349 Address: __ OpAddress: __ 8087 status: __. System computing fault (FP)
The above errors are internal problems, but these were for old obsolete hardware.

350 Logic analyzer expansion not present


351 Position processor _ not present
The above errors are internal errors from an obsolete system.

352 Axis _ marker error reference point cycle


The above error involved the search for an axis marker pulse during the analog axis homing
sequence. Either check the marker pulse from this axis encoder or check the machine parameters
involved with the configuration of the marker pulse.

353 Expansion stage G code not set up


354 Graphic cycle command not permitted
355 No: __ Address: __ OpAddress: __ 8087 status: __. Position calculation error (FP)
The above errors are internal problems, but these were for obsolete software or hardware.

356 Position processor no.: __ defective running up: __

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357 Watchdog position regulator no.: __ Nom.: __ Act.: __


The above errors are internal errors. Contact MachineMate Inc. should one occur.

359 Jog keys locked, because jog panel active


The above error involves the operator trying to jog an axis while the Teach Panel is active. Try a
different selection or a different sequence of operations.

360 Rotary tool, programming of a starting position is not permitted


361 Rotary tool, starting position is not permitted when nibbling
362 Rotary tool, only starting position programmed
The above errors involve a programming error with a future nibbling feature. Check and fix the
active part program.

363 Start not possible


364 Stop not possible
The above errors are internal errors for a cycle start or stop. Contact MachineMate Inc. should
one occur.

365 Tool jams


366 NC block does not exist! Please activate initial state!
367 Dynamic download active! Please activate initial state!
The above errors are internal errors that require the operator to reset the control (or activate the
initial state for G-codes). A control reset will restore the initial state of the CNC default G-codes.

376 Spindle/rotary axis: Programming of axes not allowed


377 Spindle/rotary axis: Programming of spindle not allowed
The above errors involve the optional feature for a servo that can be switched between a rotary
axis and a spindle. These errors indicate an incorrect application of the feature. Check the active
part program; check PPM index.

378 Override controls or push buttons defective


The above error indicates a failure from the internal monitor of the critical operator inputs (two
override switches and four buttons).

379 Axes control cannot be activated during interpolation!


The above error involves an activation of a parked axis during a part program using that axis. The
PLC cannot ‘activate’ a parked axis (i.e., change its state from parked to not parked) if at that
moment the CNC is ignoring that axis in the active program (the CNC only simulates the motion
from a parked axis when used in a program). The axis must be activated only when the axis has
no active command, such as from the active program. Check the active part program and/or the
PLC logic so that the parked axis does not change its parked status at an inappropriate time.

380 Tool management: General error


381 Tool management: Conversion fault of number value
382 Tool management: Conversion fault string --> digit
383 Tool management: Internal error
384 Tool management: Read error - end recognized
385 Tool management: Syntax read error
The above errors involve a syntax error in a file that is identified in its header as being tool data.
Check the file contents and update the contents accordingly. Either the data header is wrong (it is
not a tool data file) or the file contents are not correct for tool data.

386 Tool management: Table size/number of parameters read error

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The above error occurs when the tool table file being loaded into the CNC has more locations
defined than are available in the tool table or the file has invalid parameters. Fix the tool table file
to match the CNC capacity and to have the correct file format.

387 Tool management: Table size/number of parameters PLC error


388 Tool management: Table size/number of parameters CNC error
389 Tool management: CNC syntax error
390 Tool management: PLC error type of parameter/data type
391 No tool table set up
392 Tool management: Machine parameter corrupted
393 Tool management: PLC syntax error
The above errors are internal errors caused by an invalid configuration of the tool management
feature parameters. Contact MachineMate Inc. should one occur.

394 Tool management: Tool in gripper


The above message is information for the operator. It is not an error. The message indicates that
the selected tool is already in the gripper location.

395 Tool management: Tool in SPINDLE


The above message is information for the operator. It is not an error. The message indicates that
the selected tool is already in the spindle.

400 Tool management: General error


The above error is an internal error caused by an invalid configuration of the tool management
feature parameters. Contact MachineMate Inc. should one occur.

401 Life time of tools and Spare tools are finished


The above error indicates that no valid tool can be found for the selected tool. All tools of this
tool number have no remaining tool life and all tools that have been identified as possible spares
also have no remaining tool life. The tool change could not be performed. An acceptable tool
must be loaded into the tool magazine and the tool data updated accordingly for this tool number
to be selected.

402 Spare tools not found


The above error indicates that no valid tool can be found for the selected tool. All tools of this
tool number in the tool magazine have no remaining tool life and no tools were identified as
possible spares. The tool selection could not be performed so the part program cannot proceed
past this block. An acceptable tool must be loaded into the tool magazine and the tool data
updated accordingly for this tool number to be selected.

403 Tool not found


The above error indicates that no valid tool can be found for the selected tool. No tools of this
tool number with remaining tool life are found in the tool magazine. The tool selection could not
be performed so the part program cannot proceed past this block. An acceptable tool must be
loaded into the tool magazine and the tool data updated accordingly for this tool number to be
selected. Both the Operator’s Manual and the Startup Manual have descriptions of filling in initial
values in the tool table.

404 Tool management: internal error


405 Tool management: reserved
The above errors are internal errors caused by an invalid configuration of the tool management
feature parameters. Contact MachineMate Inc. should one occur.

406 Tool management: Reference point and tool in Pending

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The above error indicates that a tool magazine homing procedure has completed with a tool in the
gripper location.

407 Tool management: moving to reference point and tool active


The above error indicates that a tool magazine homing procedure has completed with a tool in the
gripper location.

408 Tool management: no type defined in machine parameter


The above error is an internal error caused by an invalid configuration of the tool management
feature parameters. Contact MachineMate Inc. should one occur.

409 Tool management: position request of PLC cannot be executed


The above error indicates that either the PLC has requested the movement of the tool magazine to
an invalid location or the PLC has requested a tool magazine move at the wrong time in the
middle of a tool change process. The PLC application must be fixed to match the tool magazine
configuration.

410 Tool management: H correction table does not correspond to machine parameter
The above error is an internal error caused by an invalid configuration of the tool management
feature parameters. Contact MachineMate Inc. should one occur.

411 Tool management: actual location is not assigned to this tool


The above error indicates that the PLC has moved the tool magazine to an incorrect location for
the current tool to be moved to. This error could occur with fixed location tooling when the
spindle tool always returns to its original magazine location. The PLC application must be fixed
to match the tool management configuration.

412 Tool management: Place to be written to is not empty


The above error indicates that the PLC has indicated to the CNC that it will move a tool into a
new tool location but the CNC has detected that location is not empty. The PLC application must
be fixed to prevent this conflict, probably by checking the tool location for the empty status
before indicating to the CNC that a tool will be moved into that location.

413 Compile cycle: Event __ not active


The above error involves the optional compile cycle feature. The furnished dll is not handling a
specific internal event properly. Replace or eliminate the compile cycle dll.

414 Keyboard-Controller defective. Error: __


The above error indicates a failure from the keyboard monitor. This is an internal error.

415 SERCOS: Service channel: ident __ drive _. Invalid access to element 1.


416 SERCOS: Service channel: ident __ drive _. Transmitted data too short.
417 SERCOS: Service channel: ident __ drive _. Transmitted data too long.
418 SERCOS: Service channel: ident __ drive _. Data cannot be changed.
419 SERCOS: Service channel: ident __ drive _. Data are presently write protected.
420 SERCOS: Service channel: ident __ drive _. Data smaller than minimum value.
421 SERCOS: Service channel: ident __ drive _. Data greater than maximum value.
422 SERCOS: Service channel: ident __ drive _. Data are not correct.
The above errors are SERCOS problems with the service channel. The use of the service channel
is optional so there is probably a configuration problem with the service channel.

426 Read-in not possible, Cycle Edit still active!


427 Cycle Edit not possible, read-in still active!

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MACHINEMATE®

The above errors indicate an operator failure during a Teach process. Please change the teach
procedure to avoid this conflict between teach and edit.

429 Execution not possible! Activate emergency stop first!


The above error indicates an operator failure to place the control in emergency stop before
making this command. To save a new set of machine parameters to CNC memory, the control
must be in emergency stop.

431 Distance-control: If distance-control is active, G74 is not allowed.


432 Distance-control: If distance-control is active, programming of 'axis-choice' is not
allowed.
433 Distance-control: Programming of 'axis-choice' allows max. 3 axes.
The above errors involve a programming problem for the Distance Regulation optional feature
(also called distance control). Check the active part program and/or PLC logic; also check the
PPM index.

434 Additive Handwheel: Programming of axes not allowed


The above error involves the programming of an axis in conjunction with an assigned handwheel
that adds an axis offset in automatic mode. Check and fix the active part program.

435 Negative diameter input is not allowed!


The above error involves a programming error in a lathe with diameter programming active.
Check the active part program; check PPM index.

436 At the moment the function can only be selected by PLC


The above internal error indicates the operator cannot (yet) perform a feature that is executable
from the PLC. Contact MachineMate Inc. should it occur.

444 Spindle/Rotary axis: encoder error


The above error involves the optional feature for a servo that can be switched between a rotary
axis and a spindle. This error indicates an encoder problem in this axis. Check PPM index.

445 S-Analog: Maximum circumference velocity exceeded


The above error involves a programming problem. Check PPM index.

446 S-Analog: Grinding wheel radius is not set


The above errors involve a programming problem with the obsolete grinding wheel feature.

447 MMS Command: Invalid variable address


448 MMS Command: Invalid length
449 MMS Command: Variable write is not allowed
450 MMS Command: Unknown variable
451 MMS Command: Invalid Event type
452 MMS Command: Invalid Event handle
The above errors involve a programming problem for a future MMS optional feature.

453 NC Block abort: Withdrawal distance too large


454 NC Block abort: No input signal
456 S-Analog: Grinding wheel parameter table is not correct
457 S-Analog: Radius programming is not allowed
The above errors involve a programming problem with the obsolete grinding wheel feature.

458 MMS Command: Required Event handle cannot be deactivated.


459 MMS Command: Required Event handle cannot be activated.
460 MMS Command: Event Interface is occupied by another Task

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MACHINEMATE®

The above errors involve a programming problem for a future MMS optional feature.

461 Grinding wheel management: incorrect axes assignment


462 Grinding wheel management: Diameter is too small
463 Grinding wheel management: incorrect compensation assignment
The above errors involve a programming problem with the obsolete grinding wheel feature.

464 Error in Digitalizing mode


465 Digitalizing mode: Change distance too large
466 Digitalizing mode: Stationary lag error
467 Digitalizing mode: Transfer error
The above errors involve the ART feature. The programming and application of ART are
described in the Start Up Manual.

468 Connection break in encoder input _ !


469 Encoder input _ RMS defective, incorrect differential signal change! Please check
encoder or change module!
470 RMS board defective or missing!
The above errors are encoder feedback problems (RMS is Rotary Measurement System). The
CNC continuously monitors the encoder feedback signals (three pairs of differential signals). A
wrong ‘change’ indicates that the differential signal(s) in the three pairs deviated from the
tolerances for such signals. Determine the cause and take the appropriate action.

471 Additive Handwheel: fixed axes not allowed


472 Additive Handwheel: Axes selection not allowed yet
The above errors involve the programming of a handwheel that adds an axis offset in automatic
mode.

473 ART train function already active. First deactivate train function!
474 ART speed factors have not been optimized
475 ART acceleration factors have not been optimized
476 Programmed frequency limit for commanded position filter is too great
477 Commanded position filter is already active. First deactivate filter!
478 Programmed frequency limit for commanded position filter must be greater than zero
479 Digitalizing: Axis number not given
480 Machine parameter error: Invalid Axis number
The above errors involve the ART feature or the accompanying command filter feature, either in
their operation or in their machine parameter configuration. The programming and application of
ART are described in the Start Up Manual.

481 Lag error during standstill on axis _!


The above error involves a problem with a specific axis. The axis position loop could not
maintain its stationary position within defined limits (by machine parameters). Either there is an
outside influence on the axis to move it from its programmed position or the configuration of
these machine parameters is not appropriate for the axis physical and mechanical environment.

482 SERCOS: Dual-Port-Memory to SERCOS-Master is erroneous


483 SERCOS: Dual-Port-Memory to SERCOS-Monitor is erroneous
484 SERCOS: Communication phase _ can't be activated
485 SERCOS: Invalid command for communication phase _
486 SERCOS: Communication was reset during phase 0
487 SERCOS: Number of drives and the ring configuration are invalid
488 SERCOS: Error in state class 1 (ZK1) in drive _
489 SERCOS: SW-Watchdog of the SERCOS-Masters is defective
The above errors are SERCOS problems. Use the SERCOS Monitor tool to manage the timing
and phase on the ring and to determine whether the problem is caused in the ring or at the
SERCOS master in the CNC.
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490 Program error: Speed of the rotary axis is too great


491 Program error: Speed of the radial axis is too great
The above errors involve the programming of an axis velocity. Check the active part program;
check PPM index.

492 NC Block abort not possible with active Filter


493 Filter may not be activated with filter active
The above errors involve the command filter feature associated with ART. The programming and
application of ART are described in the Start Up Manual.

494 S5-Interface: Unknown Telegram from S5


495 S5-Interface: No answer from S5
496 S5-Interface: Communication error
The above errors involve a problem with a proposed interface to an S5; these errors are invalid as
the feature is not implemented.

497 Axis is parked and may not be selected


The above error involves the operator selecting a parked axis for motion (a parked axis is one that
has been removed and its encoder is no longer checked for loss of feedback). Try a different axis
selection.

498 Input not possible. Internal memory is full!


499 Error by Calibrating analog-Input of axis board _.
The above errors are internal errors. Contact MachineMate Inc. should one occur.

668 User cycle Block: __. Program doesn't exist


669 User cycle Block: __. Invalid Program number
The above errors involve the programming of a user work cycle, that is configured using machine
parameters. Check the subprogram assignments to the user cycle G-codes and take the
appropriate action (change assignments or change the subprogram numbers).

670 Programmable AFC: Input signal invalid


671 Programmable AFC: I/O-Bus - Error
672 Jog keys locked, because external manual-mode active!
The above errors involve a problem with the Analog Feed Control (AFC) optional feature.

673 Sercos: error state class 1 drive _. Overload switching off


674 Sercos: error state class 1 drive _. Amplifier excess temperature switching off
675 Sercos: error state class 1 drive _. Motor excess temperature switching off
676 Sercos: error state class 1 drive _. Cooling error switching off
677 Sercos: error state class 1 drive _. Control voltage error
678 Sercos: error state class 1 drive _. Feedback error
679 Sercos: error state class 1 drive _. Error in electronic commutation system
680 Sercos: error state class 1 drive _. Excess current
681 Sercos: error state class 1 drive _. Excess voltage
682 Sercos: error state class 1 drive _. Undervoltage error
683 Sercos: error state class 1 drive _. Phase error of power supply
684 Sercos: error state class 1 drive _. Excessive control lag
685 Sercos: error state class 1 drive _. Communication error
686 Sercos: error state class 1 drive _. Position limiting value exceeded (switching off)
687 Sercos: error state class 1 drive _. Product-specific error (see display of drive)
The above errors are SERCOS drive problems, indicated to the CNC via the SERCOS class 1
diagnostic status definitions. Check the drive indicated in the error for the stated condition.

688 Thread cutting active! Spindle hold!


689 Thread cutting G34: change of direction!

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690 Thread cutting G34: change of gradient!


691 Thread cutting active! No path for the length-axis!
692 Thread cutting! Only one block with controlled running out allowed!
The above errors involve a programming problem with the thread cutting feature. Check the
active part program according to the syntax defined in the PPM.

694 Reset of drives is only possible if the Sercos ring is booted at least to phase 2
695 Reading of drive parameters is only possible if the Sercos ring is booted at least to
phase 2
696 Writing of drive parameters is only possible if the Sercos ring is booted at least to
phase 2
The above errors are SERCOS problem. The SERCOS specification requires certain tasks to be
possible only at phase 2 or later, not at phases 0 or 1.

697 Error in configuration for measuring function axis _ (see ident number 169).
The above error is a SERCOS configuration problem. For the Probing Logic function to work
with the SERCOS axis, its S-169 must be non-zero (typically a value of 403). Update the S-169
parameter in the drive.

698 Return to escape points: invalid escape point


The above error involves the configuration for a future escape point feature.

699 Loading of drive parameters is only possible if Sercos ring is in phase 2


The above error is an operator problem. The SERCOS specification requires certain tasks,
including the loading of drive parameters from a soft key, to be possible only at phase 2 or later,
not at phases 0 or 1.

705 Watchdog fault of the user interface! JOG-keys of the Teach-Panel disabled!
The above error involves a hardware problem with the serial interface to the Teach Panel. If the
connection is lost or unreliable, a remote jog is not allowed.

706 Gantry-axis initializing is active! Only gantry-axis is selectable!


The above error involves an operator problem with the gantry axis feature. When homing the
gantry axes (a specific procedure described in the Start Up Manual), another axis cannot be
selected.

708 Turning Cycle: Parameter wrong


709 Turning Cycle: Block number wrong
710 Turning Cycle: Block not found
711 Turning Cycle: Cycle blocks not allowed
712 Turning Cycle: Circular level not allowed
713 Turning Cycle: Too many blocks
The above errors involve a programming problem with the turning cycle feature. Check the active
part program; check PPM index.

714 Sercos: Not enough memory. Ring: _


715 Sercos: Internal error. Ring: _
716 Sercos: Handshake timeout in Service-channel. Ring: _ Drive: _
717 Sercos: Error Telegram missing. Ring: _ Drive: _
718 Sercos: Command in this Phase not allowed. Ring: _ Drive: _
719 Sercos: Wrong drive-address. Ring: _ Drive: _
720 Sercos: Wrong ring. Ring: _
721 Sercos: Wrong drive-count. Ring: _ Drive: _
722 Sercos: Drive not found. Ring: _ Drive: _
723 Sercos: Internal Ram overflow
724 Sercos: Error during initializing. Ring: _
725 Sercos: Last transfer not finished. Ring: _ Drive: _

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726 Sercos: Internal communication error. Ring: _ Drive: _


727 Sercos: Error during initialization of ring _ T2
728 Sercos: Error during initialization of ring _ T3
729 Sercos: Error during initialization of ring _ T4
730 Sercos: Error during initialization of ring _ TEND
731 Sercos: Internal error 0. Please note error number
732 Sercos: Internal error 1. Ring: _ Drive: _ IdentNr.: __
733 Sercos: Handshake error. Ring: _ Drive: _ IdentNr.: __
734 Sercos: Wrong Ident number. Ring: _ Drive: _ IdentNr.: __
735 Sercos: Wrong Element. Ring: _ Drive: _ IdentNr.: __
736 Sercos: Internal error, wrong offset. Ring: _ Drive: _ IdentNr.: __
737 Sercos: Internal error, wrong length. Ring: _ Drive: _ IdentNr.: __
738 Sercos: Internal error, wrong command. Ring: _ Drive: _ IdentNr.: __
739 Sercos: Command in this phase not allowed. Ring: _ Drive: _
740 Sercos: channel busy. Ring: _ Drive: _ IdentNr.: __
741 Sercos: Internal communication error. Ring: _ Drive: _ IdentNr.: __
The above errors are SERCOS problems. Some are internal drive problems and some of these are
caused by data attributes being configured wrong. Others are internal CNC problems involving
the SERCOS interface; some of these could be caused by the drive configuration file, invalid
drive data or fiber-optic connection problems (717 occurs if the fiber cable is disconnected while
running). Some of these could be caused by the SERCOS drive providing data incompatible with
the SERCOS standard definitions for the S-parameters.

742 Sercos: Timeout-error. Ring: _ Phase: _


The above error is a SERCOS problem and is usually caused by an incorrect baud rate setting in
the drive so it does not match that in the drive configuration file. The error can also be caused by
an incorrect setting for T_OFFSET in the drive configuration file; the suggested value is 0.3ms.

743 Sercos: Error during command-execution. Ring: _ Phase: _


744 Sercos: Drive not found. Ring: _ Drive: _
745 Sercos: No input signal. Ring: _
746 Sercos: Invalid receive-signal. Ring: _
747 Sercos: Error during command execution. Ring: _ Drive: _ IdentNr.: __
748 Sercos: timeout-error on busy-signal. Ring: _ Drive: _ IdentNr.: __
749 Sercos: error on service-channel. Ring: _ Drive: _ IdentNr.: __
750 Sercos: error during opening of channel. Ring: _ Drive: _ IdentNr.: __
751 Sercos: wrong access to element 0. Ring: _ Drive: _ IdentNr.: __
752 Sercos: invalid Ident number. Ring: _ Drive: _ IdentNr.: __
753 Sercos: wrong access to element 1. Ring: _ Drive: _ IdentNr.: __
754 Sercos: error data too short. Ring: _ Drive: _ IdentNr.: __
755 Sercos: error data too long. Ring: _ Drive: _ IdentNr.: __
756 Sercos: data not changeable. Ring: _ Drive: _ IdentNr.: __
757 Sercos: data fixed. Ring: _ Drive: _ IdentNr.: __
758 Sercos: data too small. Ring: _ Drive: _ IdentNr.: __
759 Sercos: data too large. Ring: _ Drive: _ IdentNr.: __
760 Sercos: data incorrect. Ring: _ Drive: _ IdentNr.: __
The above errors are SERCOS problems. Some are internal drive problems and some of these are
caused by data attributes being configured wrong. Others are internal CNC problems involving
the SERCOS interface; some of these could be caused by the drive configuration file(744 results
if the drive address does not match that in the configuration), invalid drive data or fiber-optic
connection problems (745 results from a broken fiber ring at start up). Some of these could be
caused by the SERCOS drive providing data incompatible with the SERCOS standard definitions
for the S-parameters.

761 File __ does not exist


The above error involves a subprogram programming problem. A Q statement has called out a
subprogram number but that program number does not exist in the same folder as the main
program or in CNC memory. Either correct the file name for the subroutine and load that
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MACHINEMATE®

subprogram file into CNC memory or correct the Q program number in the part program. Note
that the subroutines called from a program from a disk folder must be named Pxxxxxx. (no file
extension), where the subroutine program number is a six-digit value (so use leading zeroes to
pad out to six digits, as in P000001. for a subroutine called with Q1). The search will first be to
CNC memory then to the disk folder for the main program so beware of common program
numbers in both CNC memory and in disk folders for the part programs.
762 Read error in file __
763 File __ already exists
764 Write error in file __
The above errors involve an operator problem with the saving or restoring of many part programs
to/from a disk folder. Check the current files in the disk folder for the expected contents.

766 Block __ not found


The above error is for a GO in the part program but its target block number (shown in the
message) does not exist in the program. Check the part program and make the appropriate
change.

767 Syntax error in line:__


The above error is for a syntax error in a particular block in the part program; that block is shown
in the message. Check the part program and make the appropriate change.

768 Table syntax error in __


769 Data transfer already active
770 Invalid data transfer command
771 Invalid data transfer ID
774 Invalid data transfer type
776 Internal data transfer error
778 Invalid data transfer string
The above errors are either operator errors due to an unexpected operator sequence or internal
errors involving data transfers. Contact MachineMate Inc. should one occur.

779 Handwheel _ RMS defective, wrong encoder signal change. Please check encoder or
exchange module
780 Handwheel _ RMS card defective or missing
781 Connection break encoder input Hand wheel _ !
782 Handwheel _ Encoder input defective! Incorrect differential encoder signal change!
783 Handwheel _ RMS board defect or missing!
The above errors are encoder feedback problems (RMS is Rotary Measurement System). The
encoder handwheel is monitored continuously for proper signal timing just like the axis encoders.
A wrong ‘change’ or ‘changer’ indicates that the differential signal(s) in the three pairs deviated
from the tolerances for such signals. Determine the cause and take the appropriate action.

784 Program number P0 not allowed


785 Program end without M code after block __
The above errors are basic programming errors. Check and fix the active part program.

786 Error in Reference Point cycle axis _. Command 148 not activated
787 Error in Reference Point cycle axis _. Command 148 not set
788 Error in Reference Point cycle axis _. Command 148 not executed
789 Error in Reference Point cycle axis _. Command 172 not activated
790 Error in Reference Point cycle axis _. Command 172 not executed
The above errors are SERCOS problems during homing. The SERCOS drives are homed using
specific SERCOS command numbers from the CNC (SERCOS parameter 148 is the standard
parameter for the SERCOS command procedure to home). Check the homing parameters within
the drive indicated in the error.
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MACHINEMATE®

791 Distance coded RMS axis _. No marker found inside MarkerDistance


792 Distance coded RMS axis _. Only one marker found inside MarkerDistance
793 Distance coded RMS axis _. MarkerDistance invalid
The above errors involve the homing of an axis with a distance coded encoder feedback system
(RMS is Rotary Measurement System). The solution is to correct the machine parameters that
define this feedback configuration.

794 Reference point cycle axis _. Error occurred while resetting


795 Reference point cycle axis _. Error occurred while initializing
The above errors involve the homing cycle for a SERCOS axis. The solution is to correct either
the machine parameters that define this axis homing sequence or the internal drive parameters
involved with homing.

796 Path __ does not exist!


The above error is an internal error. Contact MachineMate Inc. should it occur.

797 Machine parameters faulty! Turning cycles only with longitudinal and transversal axis!
The above error involves a machine parameter configuration problem for the turning cycles
feature. Both the longitudinal and transversal axes must be defined in the NCAddressFormat
parameter group.

798 Thread cutting with dynamic pitch. Transversal axis may not be programmed!
799 Thread cutting with dynamic pitch. J missing!
800 Thread cutting with dynamic pitch. K missing!
801 Thread cutting with controlled running out transversal axis and J must be programmed!
802 Thread cutting with controlled running out! Not possible without transversal axis!
803 Thread cutting without longitudinal axis! Only plane thread allowed!
The above errors involve a programming problem with the thread cutting feature. Check the
active part program according to the syntax defined in the PPM.

804 Machine parameters faulty! Constant circumferential speed (G93) only with Transversal
axis possible!
The above error involves a machine parameter configuration problem for the G93 feature. The
transversal axis must be defined in the NCAddressFormat parameter group.

805 Constant surface speed only possible with Transversal axis!


806 Thread cutting. K missing!
807 Conical thread only with Transversal Axis!
The above errors involves a machine parameter configuration problem for the turning cycles
feature. Both the longitudinal and transversal axes must be defined in the NCAddressFormat
parameter group.

808 Sercos: Setup data have been changed! Initializing of timing values necessary.
The above error indicates that a change was made to the drive configuration file since the last
time the CNC started. Anytime that file changes, the operator must use the SERCOS Monitor tool
to initialize the timing within the ring.

809 Machine parameters faulty! RefpointCycle. SercosHomingType only with closed loop in
drives.
The above error involves a machine parameter configuration problem for a SERCOS axis.
SercosHomingType can specify only SERCOS with the position loop closed in the drive.

810 Positioning command from PLC for Axis _: Axis not a positioning axis or does not
exist!

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MACHINEMATE®

The above error involves an error in the PLC application that is requesting a positioning axis to
move but that axis is not a positioning axis. Either fix the machine parameter for this axis letter or
fix the PLC application.

811 Access from PLC: __. Machine parameter not found!


The above error involves an error in the PLC application that is requesting a certain machine
parameter but that parameter name does not exist. Check the PLC application code for the correct
machine parameter name.

812 Positioning command from PLC for Round axis _: Position outside the allowed range!
The above error involves an error in the PLC application that is requesting a positioning round
axis to move but that new position is not valid. Fix the PLC application.

813 Error locking memory for file __


814 Error unlocking memory for file __
815 Error freeing memory for file __
The above errors are internal problems when loading a part program file. Contact MachineMate
Inc. should one occur.

816 Missing header in file: __


The above error involves a syntax error in a part program file being loaded. There is a
requirement for a header in a part program, described in the PPM 1.10. There must a % on a line
by itself at the start of the file (typically after a blank line). Typically this line with a % is
followed by the part program number. If this % on a line by itself is missing in the file, this error
results. Check and fix the syntax of the part program file.

817 Line too long:__


The above error involves a syntax error in a part program file being loaded. Each line in a
program must be less than 128 characters. Check and fix the syntax of the part program file.

818 Invalid data type:__


The above error involves the operator selecting the wrong type of file to load. For example, if
Tool Table is the current data selection, loading a part program results in this error. Check that
the correct file is being loaded for the current data type. Perform the Data Selection soft key
action for the correct data type before this Load selection.

819 Invalid program or table number__


820 Invalid program checksum format__
821 Data end in file:__ reached. M30/M02 missing!
The above errors involve syntax errors in a part program file being loaded. Check and fix the
syntax of the part program file.

822 Invalid block number in:__


The above error involves a syntax error in a part program file being loaded. This is usually caused
by invalid characters between the N and its block number (this string of characters with the N will
be shown in the message). Check and fix the syntax of the part program file.

823 Invalid block checksum in:__


The above error involves a syntax error in a part program file being loaded and this file has the
special checksum characters (they are not required by the CNC). Check and fix the syntax of the
part program file.

824 Access denied for file:__


825 Too many open files. Cannot open file:__

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MACHINEMATE®

826 The process cannot access the file:__ because it is being used by another process.
827 Invalid operation mode! Program selection not permitted!
The above errors involve operator or programming problems with program files. Try a different
selection or change the protection on the selected file.

828 CNC Interpolator hangup! Reset Control!


The above error is an internal problem. Contact MachineMate Inc. should one occur.

829 Compile Cycle __ Machine Parameter (CPCFixArea, CPCBlockArea) are changed! This
requires a restart
The above error involves a configuration issue with the compile cycle feature. When either of
these parameters is changed (changing the amount of memory that is set aside within the CNC) a
control restart is required. Restart the CNC to make these parameter changes active.

830 Axis _ is being moved by PLC. Homing is not allowed!


The above error involves an error that could occur while the PLC application is moving one of
the interpolating axes (i.e., one of the axes normally moved during a part program). The PLC
motion must complete before the operator could command a homing cycle.

831 Axis _ cannot be released by PLC while NC program moves it!


The above error involves an error that could occur while the PLC application is moving one of
the interpolating axes (i.e., one of the axes normally moved during a part program). Fix the PLC
application so that it does not attempt its motion request during a programmed request; the axis
must be stationary for the PLC axis motion command.

832 Sercos: Warning state class 2 drive _. Overload warning


833 Sercos: Warning state class 2 drive _. Amplifier over-temperature warning
834 Sercos: Warning state class 2 drive _. Motor over-temperature warning
835 Sercos: Warning state class 2 drive _. Cooling error warning
836 Sercos: Warning state class 2 drive _. Positioning velocity > nlimit
837 Sercos: Warning state class 2 drive _. Target position outside of position limits
838 Sercos: Warning state class 2 drive _. Manufacturer warning
The above errors are SERCOS problems. Some are internal drive problems and some of these are
caused by data attributes being configured wrong. Others are internal CNC problems involving
the SERCOS interface; some of these could be caused by the drive configuration file, invalid
drive data or fiber-optic connection problems.

839 Angled-Wheel transformation error: Number of Angled-Wheel axes less than 2


840 Angled-Wheel transformation error: Transformation matrix is singular
841 Angled-Wheel transformation error: Drive _. Angles are outside of the allowed range
The above errors involve a programming problem with the angled wheel feature for grinding
applications. Check the active part program according to the syntax defined in the PPM.

842 Oscillation: Axis is oscillating, Programming not possible during active oscillation.
843 Oscillation: Amplitude _ is too small
844 Oscillation: frequency value for sinusoidal oscillation missing
845 Oscillation: feedrate for linear oscillation missing
846 Oscillation: No axis is programmed
847 Oscillation: frequency value for sinusoidal oscillation invalid
The above errors involve a programming problem for the optional axis oscillation feature. Check
the active part program according to the syntax defined in the PPM.

848 Programming error: Only four axes possible


The above error results when the parallel axis feature is programmed (G21) to have more than 3
slave axes for one master axis. The feature’s limit on a parallel axis is up to 3 axes can follow the

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MACHINEMATE®

master programmed axis. Change the machine parameters CharacterApplTab[] index 6 settings
for the axes to that there are fewer slave axes for the same master.

849 EGB-Machine parameter faulty: No spindle function for Hob. Spindle function must be
applied to use the same output
850 EGB-Machine parameter faulty: No Hob axis or not rotating axis
851 EGB-Machine parameter faulty: No Table axis or not rotating axis
The above errors involve a configuration problem for the Electronic Gear Box (EGB) optional
feature. The gear hob requires a correct axis configuration with the hob being both a round axis
and a spindle and with the table being a round axis. Check the machine parameters for the
respective axes.

852 EGB: DriveOn Signal for Table axis or Hob missing


The above error involves a PLC problem for the Electronic Gear Box (EGB) optional feature. The
DriveOn signal is the signal from the PLC to the CNC to close the position loop for a specific
axis and in this case the CNC is missing one that is required for the EGB. Check the PLC
application for the conditions that affect these PLC signals.

853 EGB: Invalid value for G95, movement not possible


854 EGB: Only linear movement possible with G95
855 EGB: Test fast Traverse not possible with active EGB
The above errors involve a programming problem for the Electronic Gear Box (EGB) optional
feature. Check the active part program according to the syntax defined in the PPM.

856 Angled-Wheel transformation error: G_ is not allowed in two step mode


The above error involves a programming problem with the angled wheel feature for grinding
applications. Check the active part program (the offending G-code is in the message) according to
the syntax defined in the PPM.

857 G92 setting from PLC is not possible: NC program is active


The above error involves a PLC application problem. The PLC attempted to set a G92 offset
while an NC program is active. Check the PLC application for the conditions involved in its G92
command.

858 An error occurred while setting G92 offset


The above error involves a PLC application problem. The PLC attempted to set a G92 offset
when the CNC was in a condition that such a command was invalid. Check the PLC application
for the conditions involved in its G92 command.

859 Machine parameter _[_] is zero _


The above error indicates a machine parameter with a zero value when a non-zero value is
required. Fix the machine parameter value for the one identified in the message.

860 Axis limit _ in _, line N_. Axis position: _


The above NC programming error results from the CNC detecting an axis is commanded to move
past one of its software travel limits. The message indicates the axis overtravel direction (+ or -)
as well as the NC statement that will have this result. The programmed axis position (perhaps
including programmed compensations) in error is also shown. Check the active part program and
the NC block indicated to resolve this NC programming error.

861 Machine axes offset G_ is not allowed during active parallel axes function
The above NC programming error results from the CNC detecting a machine axis offset
command (G99) while the parallel axis function was active (G21). Check the active part program
to resolve this NC programming error.
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862 Axis _ lag limit is reached


The above error results for a configurable axis lag (or following error) limit. The PLC application
can request the CNC perform a different check on the axis lag limits and this error message
indicates that the axis lag has reached the configured limit. Check the possible causes for an
excessive axis lag (like binding). If this message still occurs, then check the proper values in these
configuration machine parameters and/or check the PLC application for the conditions involved
in its lag check command.

863 Cancel active block is currently active. No further requests are possible
864 Cancel active block: operation failed
865 Cancel active block: backward motion active. Operation not possible.
The above error involves a PLC application problem. The PLC commanded the CNC to cancel
the active NC block but the CNC could not perform the command. Check and fix the PLC
application for the conditions involved in its cancel active block command.

866 Release without retreat: operation failed


The above error involves a PLC application problem. The PLC commanded the CNC to move an
interpolating axis but not to have it return to the programmed path and the CNC failed to perform
the command. Check the PLC application for the conditions involved in its interpolating axis
motion command.

867 Teach panel communication error


The above error involves a communication problem with the teach panel. The Teach Panel was an
option for Windows NT systems.

868 Spindle orientation not possible. Spindle _ without feedback.


The above NC programming error results from an M19 when the active spindle has no feedback.
Check the active part program to resolve this NC programming error.

869 Thread cutting not possible. Spindle _ without feedback.


The above NC programming error results from a thread cutting G-code when the spindle has no
feedback. Check the active part program to resolve this NC programming error.

870 Error from System Supervisor, details see Message Box!


This error message serves as an entry in the log book when a pop-up dialog from the System
Supervisor has reported a serious error. Check the contents of the active message box to
determine the fault and an appropriate recovery.

871 Const. cutting speed not possible. Autom. gear selection is active.
The above NC programming error results from the G96 (constant surface speed) when M40
(automatic gear selection for spindle gear box) is active. With a spindle gear box and constant
surface speed programming, the correct gear range must be explicitly declared in the part
program (via M41 to M46) prior to the G96. Check the active part program to resolve this NC
programming error.

872 Set axis position: axis _ is a slave axis in a gantry pair. Operation is not possible!
873 Set axis position: function deactivated during execution!
874 Set axis position: position of axis _ exceeds software limits. Operation is not
possible!
875 Set axis position: PLC movement of an axis is active. Operation is not possible!
876 Set axis position: axis _ is a SERCOS axis with position control in drive. Operation
is not possible!

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The above errors result when the PLC application has tried to set an axis position when such an
action by the PLC is not allowed. Check the active PLC application and the condition indicated in
the message to resolve the PLC problem.

877 Axes allocation: either a NC program or MDI or jogging mode is active. Operation is
not possible!
878 Axes allocation: PLC movement of an axis is active. Operation is not possible!
879 Axes allocation: Homing is active. Operation is not possible!
880 Axes allocation: function is not enabled!
The above errors result when the PLC application has tried to change an axis allocation when
such an action by the PLC is not allowed. Check the active PLC application and the condition
indicated in the message to resolve the PLC problem.

881 Set axis position: either a NC program or MDI or jogging mode is active. Operation is
not possible!
The above error results when the PLC application has tried to set an axis position when such an
action by the PLC is not allowed. Check the active PLC application and the condition indicated in
the message to resolve the PLC problem.

882 Cancel active block and finish active block are not allowed together
883 Cancel active block is allowed in AUTO mode only
The above errors result when either the operator or the PLC application has tried to execute the
Cancel Active Block command at the wrong time or under the wrong circumstances. Check the
active PLC application and the conditions for the PLC command to resolve the PLC problem. The
operator commands should not be an issue for these errors unless the factory default soft key
assignments for these commands have been changed by the integrator.

884 Axes' allocation: MDI-mode is active. Function not allowed!


885 Axes' allocation: Cycle-on state. Function not allowed!
The above errors result when the PLC application has tried to change an axis allocation when
such an action by the PLC is not allowed. Check the active PLC application and the condition
indicated in the message (in MDI or in cycle) to resolve the PLC problem.

886 Program error %1: %2 not allowed during G95 active!


The above NC programming error results when an invalid NC block is detected with G95
(inches/rev or mm/rev). Check the active part program to resolve this NC programming error.

887 Interpreter Restart on first block is not possible


The above error results when either the operator or the PLC application has tried to restart the
block interpreter in the middle of the program but actually the CNC was at the first block in the
program. If the error was not caused by an operator error then check the active PLC application to
resolve the PLC problem.

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1.3 PLC errors (PLC)


These error messages are assigned to PLC in the message bar (left icon). Those having a number less
than 500 should be coming from the CNC’s handling of the PLC application.

PLC
1 PLC program and symbol file do not fit
2 PLC symbols invalid
The above errors involve a PLC application problem. Edit the project to fix the problem.

3 No PLC program loaded


The above error (reported during the CNC start up) indicates there is no active PLC application.
One must be loaded for the CNC. Run the PLC programming tool and open/download the correct
PLC application project.

4 PLC breakpoint reached, System stopped


5 PLC stopped because of user command
The above errors involve the operator doing a stop or breakpoint with the PLC application. The
PLC application should never be stopped as that breaks the internal integration between the CNC
and PLC. Other debug techniques should be used in this CNC environment.

6 PLC calculation error (FP). PLC Task : __ status: __


The above error involves an internal PLC problem. It is likely that a PLC programming error is
causing the internal error so check any recent changes to the PLC logic.

7 PLC: Retain variables have been cleared


The above message is not error but is just information. During the CNC start up, the PLC had to
clear its retain variables (those in memory backed up by a battery), typically due to a change in
the CNC memory allocations (which can be changed by certain machine parameter values, which
require a restart after a change).

8 PLC - program compiled with wrong Systemvars. Please recompile with correct version of
libraries
The above error involves a PLC application problem. The two required PLC object libraries
(cnclib and plclib) are not included in the active PLC application’s project. Add them to the
active PLC application and download it again.

9 PLC - program - code is too big


The above error involves a PLC application problem. Edit the project to fix the problem.

10 <POU name>.<variable name>


The above error involves an integration problem with a DDE client for the PLC application. If the
external DDE client (like a MM Visualizer project) requests an invalid variable (either a wrong
name or it has been misspelled), the CNC will display that invalid variable name in this message.
To resolve this problem, either fix the name in the PLC application or fix the named being
referenced in the external software program or project; the PLC’s DDE server and the external
DDE client must reference the same variable name. Note that this error message is just the name
of the variable being requested via DDE. If the variable is in the PLC project global variables,
then the <POU name> (in front of the period) within the message will be empty.

12 Internal error during symbol table processing


13 Stack fault of realtime tasks
The above errors involve a PLC application problem. Edit the project to fix the problem.

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14 Unknown variable name for PLC server or type mismatch: __


The above error involves an operator display configuration problem. At the moment this error
occurs, the html file generating the display content must contain a reference to the PLC variable
shown at the end of the message. Edit the html file (wrong PLC variable name) or the PLC
project (wrong data type for the PLC variable) to fix the problem.

Many other error messages can be assigned to PLC in the message bar. All error messages that are
sent to the CNC from the PLC application via the WRITE_ERROR_MESSAGE function are assigned to
the PLC group, with the error number (500 or higher) and its accompanying error message coming from
the PLC application. The PLC Interface Manual (section 7.2) also describes how these PLC error
messages can be handled using a language-dependent text file. Since these error messages come
from the PLC application and not from the software that is part of the MACHINEMATE CNC distribution,
their content is beyond the scope of this manual.

Note that these PLC messages can be provided within the PLC application or they can be provided in a
text file that accompanies the CNC software. Either technique of programming the PLC application will
associate a PLC error number with its error message.

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1.3 System Supervisor errors


These error messages result in an error dialog, as the problem involves the CNC system (often in the
configuration files or in the hardware), not a particular error that the operator can read and then clear.
Most of these errors require either 1) the engineer performing the installation to fix the configuration
file(s) or the accompanying hardware or 2) the maintenance to fix the hardware problem. The error
numbers are included here for reference; each error will be displayed in a dialog without an
accompanying number.

Many of these errors are caused by drive or I/O configuration problems that are solved by changing the
corresponding configuration file. The Start Up Manual describes in detail the content of these
configuration files.
System supervisor
1 System Warning:__ __
The above error is a warning about a CNC hardware condition. The message contains the
problem encountered.

2 Battery Voltage Error on __ board:__ All buffered data may be destroyed on shut down.
Please check battery!
The above error is a warning that the internal battery is too weak to maintain the contents of the
CNC memory. Replace the CNC battery at your earliest convenience after backing up the
contents of CNC memory (Setup – Backup; Restore will restore the saved data).

3 Voltage Error __V on __ Board Nr:__ Please Check Power Supply!


The above error is from the internal hardware monitors for correct voltages. The error message
indicates the module number that detected the error. Take the appropriate action to resolve the
problem.

4 Temperature higher than __°C The control is set to emergency stop!


The above error is from the internal hardware monitor for correct temperature. Take the
appropriate action to resolve the heat problem within the CNC computer.

5 Error on __ Nr:__ Rack Nr:__ TestPattern:__ ReadPattern:__


The above error is a communication problem with a MIO in the system. The error message
indicates the module number that detected the error. Check the cabling, the CNC card with the
Superbus output or the MIO reported in the message.

6 24V Output Error on PCI-SERCOS board:__. Missing 24V or output overload Test
pattern:__. Please check power supply!
The above error is from the internal hardware monitors for voltage to the PCI-SERCOS output
bytes. This error indicates there is no 24V connection to the SERCOS output bytes (the 24V
connection is monitored only if the built-in bytes are configured in the IO configuration file; if the
bytes are not used then do not configure them in this file). Either the 24V connection is missing
(check the wiring) or the 24V supply is too low (check the power supply).

7 Watchdog error CNC __, trigger missing, CNC hangup! The system was stopped! Please
restart the system!
The above error is an internal error. Contact MachineMate Inc. should one occur. Note that this
error can be accompanied by other error(s). For example if the CNC application encounters an
exception and subsequently stops because of that error, this error accompanies that error (error

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68). That other error message can indicate the reason for the ‘CNC hangup’ reported here and so
that other error message is actually more important.

8 Watchdog error PLC, trigger missing, PLC program hangup! The system was stopped!
Please restart the system!
The above error is an internal error. Contact MachineMate Inc. should one occur. Note that this
error can be accompanied by other error(s). For example if the PLC application does a ‘divide by
zero’ and subsequently stops because of that programming error, this error accompanies that
error. That other error message can indicate the reason for the ‘PLC program hangup’ reported
here and so that other error message is actually more important.

9 IO-BUS Error Voltage Error at __ Output Module Nr:__ BusAddress:__ Test Pattern:__
Please check module for output 24V supply missing or overload!
The above error is from the internal hardware monitors for temperature and voltages. Typically
either the 24V connection is missing (check the wiring) or the 24V supply is too low (check the
power supply). However, if an IO unit output byte is not used and its 24V supply is not connected
there is a software signal available to the PLC to disable this particular check (see
IGNORE24ERRORS in PLC Interface manual); we recommend connecting the 24V power to
unused output bytes. Also, if the 24V supply voltage is removed from the output bytes during an
emergency stop condition then the PLC can use this signal to disable the 24V voltage test for this
brief time (check the electrical diagram and/or PLC logic). Note that in the case of a 24V supply
failure only one of these error messages will be provided rather than one from every module.

10 IO-BUS Error at __ Module Nr:__ BusAddress:__ Test Pattern:__ Read:__ Please check the
hardware, solve the problem and restart the system!
The above error is a communication problem with an IO module in the system. Check the
cabling, the CNC card with the IO connector or the IO module reported in the message.

11 IO-BUS Warning! Ambient temperature __ Module Nr:__ BusAddress:__ above 55 C Test


Pattern:__
The above error is from the internal hardware monitors for module temperature. Take the
appropriate action to resolve the problem.

12 IO-BUS Error No connection of __ device to the network!


13 IO-BUS Error Error on __ network or master device! Error code: __
14 IO-BUS Error Error on __ slave device __! Error code: __
15 IO-BUS Error No __ master device found or device not ready!
The above errors are communication problems with an IO module in the fieldbus network. Check
the cabling, the CNC card with the IO connector or the IO module reported in the message. If this
error occurs during the initial startup, then check the IO configuration file for this IO bus type as
well as the fieldbus master card’s configuration (done with its software tool, not with the
MachineMate CNC).

16 Module __ Invalid module number or module id:__


17 Module __ Invalid number of In Bytes __ must be __
18 Module __ Invalid Number of Out Bytes __ must be __
19 __ module __ InByte number __ already used for module __!
20 __ module __ OutByte number __ already used for module __!
21 Module __ Invalid rack number:__d
22 Module __ InByte Number __ already used
23 Invalid In Addr:__ at rack:__ module:__
24 Invalid Out Addr:__ at rack:__ module:__
25 Module __ OutByte Number __ already used
26 missing module number in module definition No:__
27 missing board parameter in module definition No:__
28 PCI Sercos IO Module __ INByte __ already used by module __!
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29 Module __ has always 3 InBytes instead of __


30 PCI Sercos Module __ OUTByte __ already used by module __!
31 Module __ has always 2 OutBytes instead of __
32 Module __ has always 16 InBytes instead of __
33 __ without modules configured
34 __ without module configuration
35 __ without modules configured
36 Bustype:__ without module configuration
37 Line:__ Configuration error missing IO-Bus Type!
38 Line:__ too many IO Modules
39 __ cannot be combined with __ Modules
40 Line:__ Configuration error Invalid ID or Len code!
41 Line:__ Configuration error Invalid InByte number!
43 Line:__ Conflict with automatic configuration of __'s!
The above errors are caused by errors in the IO configuration. The Start Up Manual describes in
detail the IO configuration file. Check the contents of that file (the line number is often in the
message) to fix the problem.

44 __ AUTO configuration, no modules found! The control will be started with


EMERGENCY_STOP set!
45 IO Configuration error!
48 Invalid IO configuration will cause unsafe and dangerous operation of your machine!
Nevertheless do you really want this actual IO configuration used for operation?
55 __ Configuration Error
59 Invalid IO configuration will cause unsafe and dangerous operation of your machine!
The above errors are caused by errors in the IO configuration or by hardware errors/failures in the
IO system. Whenever a change in the IO configuration is detected, based on the configuration
recorded during the last CNC session, the operator is warned about the change. The operator
should know if the hardware has changed or whether a hardware failure has resulted in the change
in configuration.

61 __ module __. Input address __ too large.


62 __ module __. Output address __ too large.
63 __ module __. Input address __ too large.
64 __ module __. Output address __ too large.
The above errors are caused by errors in the IO configuration. The Start Up Manual describes in
detail the IO configuration file and the byte address must be less than 256. Check the contents of
that file to fix the problem.

67 Software may not run on this machine! Do you want to continue nevertheless?
The above error could result if the MachineMate software were loaded on an incompatible PC
platform. MachineMate Inc. cannot guarantee the CNC performance on unknown hardware.

68 An exception of type __ in task __ on Station __ at address __, the system was


stopped! Please restart your system!
69 System overload __, the system was stopped! Please restart your system!
70 Real time task hangup detected in task:__ of Station __, the system was stopped!
Please restart your system!
74 Close is not allowed with this version of __-__!
The above errors are internal errors (coming from software development and debug). Contact
MachineMate Inc. should one occur.

75 Unexpected data format __


76 Hardware access error: Invalid board address, the system was stopped! Please restart
your control!
The above errors are internal errors caused by an incorrect set of installation parameters or the
hardware configuration has changed and no longer matches that of the original installation.
Contact MachineMate Inc. should one occur.
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77 No connection to drive Interface on __ no. __. Please restart your control!


78 IO-Bus communication with __ no. __ disturbed. Please restart your control!
79 __ no. __ is not present on the configured IOBUS address!
The above errors are caused by errors in the IO configuration if the error occurs during startup or
by hardware errors/failures in the IO system if the error occurs after the system was successfully
configured. The Start Up Manual describes in detail the IO configuration file. Check the contents
of that file to isolate the cause of the problem.

80 Line __ Invalid Inbyte or Outbyte length!


81 Number of configured __ modules:__ differs from number of modules __ found!
82 __ Module Nr.:__ configured type __ differs from type of modules __ found!
The above errors are caused by errors in the IO configuration or (less likely) by hardware
errors/failures in the IO system. The Start Up Manual describes in detail the IO configuration file.
Check the contents of that file to isolate the cause of the problem.

83 Error with +-15V Voltage Supply in __ Module Nr:__ BusAddress:__ Test Pattern:__
Please check module for voltage supply!
The above error is from the internal hardware monitors for module voltages. The error message
indicates the module number that detected the error. Take the appropriate action to resolve the
problem.

84 Endless Loop in PLC task no.__ assumed. Check your PLC program!
The above error is an internal error (coming from control integrator’s PLC software development
and debug). Fix the PLC application. Each PLC thread must complete each scan within its
allotted time. If an algorithm must wait for an event, the PLC code must check the event each
scan rather than looping within one scan.

85 IO-BUS Error! Ambient temperature __ Module Nr:__ BusAddress:__ above 60 C Test


Pattern:__
The above error is from the internal hardware monitors for module temperature. The error
message indicates the module number that detected the error. Take the appropriate action to
resolve the problem.

86 System Error in display part of Supervisor! Exception of type:__ at address:__


88 Timeout Error at SendMessage!
89 Timeout Error at ReceiveMessage!
90 Mapping onboard DPM failed!
91 Bus Master device not ready!
The above errors are internal errors (coming from software development and debug). Contact
MachineMate Inc. should one occur.

92 Error opening drive configuration file __


94 Illegal analog channel in drive configuration file line:__
95 Illegal SM-Board no in drive configuration file line:__
96 No SM-Board defined in drive configuration file!
97 Line: __. Max. 8 channels per SM-Board allowed!
The above errors are caused by errors in the drive configuration file. The Start Up Manual
describes in detail the drive configuration file. Check the contents of that file (the line number is
often in the message) to fix the problem.

98 Error at CreateFileMapping of: __


99 Error at MapViewOfFile of __
100 Error at UnmapViewOfFile of __

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The above errors are internal errors (coming from software development and debug). Contact
MachineMate Inc. should one occur.

101 Unknown keyword in line: __!


102 Line __, missing system data!
103 Syntax error! Missing '=' in line:__ __
104 Syntax error in line:__ __"
105 __ __ too long max. __ Bytes:__!
106 Invalid parameter type in line:__!
107 Invalid number of Parameters in line:__ __ __.
108 Line __ too many RINGS.
The above errors are caused by errors in the drive configuration. The Start Up Manual describes
in detail the drive configuration file. Check the contents of that file (the line number is often in
the message) to fix the problem.

109 __ requires Windows NT 4.0!


110 __ already running!
111 CPU is not an Intel processor!
112 Processor is not member of Pentium or Pentium II family!
113 Features of CPU Processor are not sufficient to run __!
The above errors could result if the MachineMate software were loaded on an incompatible PC
platform. MachineMate Inc. cannot guarantee the CNC performance on unknown hardware.

114 Illegal Ax-channel number in __


115 Mapping ISA Mem for analog board failed
116 Error opening RT Scheduler __ Software will be stopped!
117 Start of RT Interrupt failed!
The above errors are internal errors that can occur during installation or the first execution of the
CNC software. They are caused by an incorrect set of installation parameters or the hardware
configuration has changed and no longer matches that of the original installation. Contact
MachineMate Inc. should one occur.

118 Should Process: __ be started?


119 Process: __ was not started! Continue with next?
The above are startup messages caused by specific registry entries (to be used for customer dll
development and debug). Either respond appropriately to the expected prompt or change the
associated registry entry to disable these dialogs.

120 CNC Process not initialized!


121 Version conflict, Process aborted!
122 Invalid board address, mapping error, hardware cannot be accessed! Process aborted!
123 Default machine parameter file cannot be opened!
124 Read error with default machine parameter file!
125 Insufficient buffered memory size:__H Bytes. Requested Size:__H Bytes.
126 Error loading system NC-program:__. NC-program with number: __ already exists!
127 Allocation error for memory of machine parameter file!
The above errors are internal errors that can occur during installation or the first execution of the
CNC software. They are caused by an incorrect set of installation parameters or the hardware
configuration has changed and no longer matches that of the original installation. Contact
MachineMate Inc. should one occur.

128 Error on open of machine parameter save file!


129 Error writing machine parameter to save file!
130 Error on open of system data save file!
131 Error writing system data to save file!
132 Load error on machine parameter file: __!

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The above internal errors are caused by a problem in the host operating system environment that
does not allow the CNC to open the two parameter files or to save its backup copy of those two
files. Contact MachineMate Inc. should one occur.

133 The CNC's buffered part program memory is corrupt! A dump of corrupt memory was
created:__! memory was cleared!
The above internal error is caused by a corruption of the CNC part program memory. This is
usually caused by the loading of a part program with significant syntax errors that were not
properly handled during the operator’s loading of that file. The CNC memory contents will have
to be restored from the original disk files using the Load soft key for each data type.

134 Insufficient revision of 8Ax-Analog Boards!


The above internal error is caused by the detection of an obsolete analog engine ISA board with
Windows NT. Contact MachineMate Inc. should it occur.

135 No memory hole found!


The above internal error is caused by an incorrect BIOS configuration for an analog engine ISA
board with Windows NT. Contact MachineMate Inc. should it occur for the BIOS setting.

136 RS422 error on __ no. __!


137 Handwheel - wrong signal transition change on __ no. __!
138 Watchdog turned off on __ no. __! Please restart your control!
139 Clock Fault on __ no. __. Please restart your control!
140 Spindle voltage error on __ no. __!
142 Mapping CPU internal memory failed!
143 No more free memory tables to initialize CNC hardware!
144 Processor resources are in use, CNC software can not initialize!
145 This version of RTSchedule doesn't match version of RunControl.exe!
146 Real Time System overload __, the system was stopped! Please restart your system!
147 Configured PCI master device was not found!
148 Error on initializing RTScheduler! Software will be stopped!
149 Invalid Version of RTScheduler! Software will be stopped!
150 The hardware configuration of your control was changed! Continue nevertheless?
The above errors are internal errors that can occur during installation or the first execution of the
CNC software. They are caused by an incorrect set of installation parameters or the hardware
configuration has changed and no longer matches that of the original installation. Contact
MachineMate Inc. should one occur.

156 Syntax error in Line:__:


The above error is caused by syntax errors in the either the drive or IO configuration files. The
Start Up Manual describes in detail the drive and IO configuration files. Check the contents of
those files (the line number is in the message).

157 No PCI-Sercos Board found! Application will be stopped!


The above error is an internal error that can occur when no CNC engine card (either the SERCOS
PCI card or the Superbus PCI card) is detected. Either: the board is not properly seated in the
motherboard, the board has failed, or the installation parameters do not match the actual axis
interface hardware configuration.

158 No 4/8Ax-MFB Board found! Application will be stopped!


The above error is an internal error that can occur when no ISA CNC analog engine card is
detected with Windows NT. Either: the board is not properly seated in the motherboard, the board
has failed, or the installation parameters do not match the actual axis interface hardware
configuration.

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159 Resource conflict in operating system at hardware initialization! Application will be


stopped!
The above internal error could occur during installation or the first execution of the CNC
software. It is caused by an incorrect set of installation parameters or the hardware configuration
has changed and no longer matches that of the original installation. Contact MachineMate Inc.
should it occur.

161 __-board timer doesn't work correctly! Timer uses IRQ__! Please check interrupt
configuration! IRQ__ must be configured for exclusive use by __!
The above internal error is caused by an incorrect BIOS configuration for an analog engine ISA
board. Contact MachineMate Inc. should it occur for directions on the BIOS setting.

163 __ Board(s) configured, but __ Boards found!


164 Configuration error in line __ of IO-Configuration File
165 Axis channel number __ configured, but no axis hardware available.
166 __ axes configured, but no axes modules available.
The above errors are caused by syntax errors in the either the drive or IO configuration files. The
Start Up Manual describes in detail the drive and IO configuration files. Check the contents of
those files to isolate the cause of the problem.

167 IO-Configuration Warning! You use __ modules without cable length configuration! Your
bus speed will be reduced to standard speed!
The above error is caused by the omission of the BUSLENGTH parameter in the IO and drive
configuration files when the 4ENC4A MIO is used. The Start Up Manual describes in detail the
IO and drive configuration files. Check the contents of the file(s) to fix the problem.

168 Driver cannot get enough memory for real time operation!
169 Error in line __. Unknown unit for BUSLENGTH:
170 Line:__ Error with automatic configuration!
171 Axis __ used for analog output. Outaddress __ is already used from module __!
172 Axis __ used for analog output. Axis not available.
The above errors are caused by syntax errors in the either the drive or IO configuration files. The
Start Up Manual describes in detail the drive and IO configuration files. Check the contents of
those files to isolate the cause of the problem.

174 5V RMS defect at __ Module Nr:__ BusAddress:__ Test pattern:__ Please check hardware
and restart system!
The above error is from the internal hardware monitors for voltages. The error message indicates
the module number with the error. Take the appropriate action to resolve the problem. Note that if
there is no 5V power needed for the encoders (a 2-pin connector) then the 5V power might not be
connected so then the drive configuration file should have 5V_RMS_MONITOR=OFF to disable
this monitoring of the 5V supply.

175 Error opening serial keyboard driver __ Software will be stopped!


176 COM port number for __ serial keyboard not defined in __ drivers registry.
177 Serial Keyboard __ not connected to __ Port
178 Serial Keyboard __ at __ Port does not respond to initialization
179 Communication error with serial keyboard __ at __ Port
The above errors result in problems with the serial keyboard, caused by either a change in the
host operating system or hardware configuration, or the hardware configuration has changed and
it no longer matches that of the original installation. Correct the host operating system
configuration or contact MachineMate Inc. should one occur.

180 Invalid Buslength in line __

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The above error is caused by syntax errors in the either the drive or IO configuration files. The
Start Up Manual describes in detail the drive and IO configuration files. Check the contents of
those files (the line number is in the message) to isolate the cause of the problem.
182 __ Error __ during Initialization
185 No Businterface Board found!
186 Configured PCI slave device was not found!
The above errors are caused by syntax errors in the IO configuration file for a fieldbus network.
The Start Up Manual describes in detail the IO configuration file. Check the contents of that file
to isolate the cause of the problem. Alternately, the CNC system was configured for a specific
fieldbus network and it has not detected its PCI card; check the fieldbus PCI card’s installation in
the computer’s motherboard.
187 Error on initialization of system supervisor!
The above error is an internal error that can occur during installation or the first execution of the
CNC software. It is caused by an incorrect set of installation parameters or the hardware
configuration has changed and no longer matches that of the original installation. Contact
MachineMate Inc. should this occur.

191 Invalid module number in line: _


The above error is caused by a syntax error in the either the drive or IO configuration files. The
Start Up Manual describes in detail the drive and IO configuration files. Check the contents of
those files to isolate the cause of the problem.
192 System data file corrupted: Invalid string length!
193 System data file corrupted: Invalid array size _!
194 System data file corrupted: Invalid data type _!
The above error is an internal error that could occur during a start up of the CNC software. It is
caused by a corrupted mmsystem.app file. Contact MachineMate Inc. should this occur.

196 5V internal power supply defect at _ Module Nr:_ Please check hardware and restart
system!
The above error is from the internal hardware monitors for voltages. The error message indicates
the module number with the error. Take the appropriate action to resolve the problem.

198 No Medium found in external device!


199 No valid file system or partition on the medium!
200 No external device found
The above errors come from the CNC trying to access a USB disk device (such as a pen disk or
memory stick). Take the appropriate action to resolve the problem.

201 USB Communication Error!


202 USB Module: error on +/- 12V power supply _
203 USB Module: error on 5V power supply _
204 USB Module: error ambient temperature > 60C _
205 USB Module: warning ambient temperature > 55C _
206 USB Module: 24V Output error: Problem with power supply or shortcut in output
diagnosis:_
The above hardware errors come from the LL CNC trying to access an IO module via its internal
USB connection. Take the appropriate action to resolve the LL hardware problem.

207 DriveCfg file line:_, Error invalid character '_' for axis assigned!
The above error is caused by a syntax error in the drive configuration file. A servo is limited to
the letters A to Z (with S reserved for a spindle and L for a laser channel). Check the contents of
this file for the invalid character and the line noted in the message.

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208 Error getting hardware interrupts from PCI Sercos board


209 Error connecting to interrupt IRQ_ in __ board driver!
The above errors come from the CNC trying to access a PCI interrupt from a PCI card. This is
usually caused by an incorrect configuration. Take the appropriate action to resolve the problem.

210 Error in Sercos Drive Parameter file: _\nSection: [_]\nline: __


The above error is caused by a syntax error in the drive configuration file. There can be a special
section in this file to define changes to drive parameters and this error indicates a syntax error in
that section (whose name is in the error). Check the contents of this file for the error in the line
noted in the message.

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1.4 Operator Interface errors (VMI)

These error messages are assigned to VMI in the message bar (left icon). These errors involve the
operator interfaces (including the Teach Panel) and the peripherals involved with the Windows NT
operator interface (like the serial interface to the Teach Panel).

Most of these errors will never occur on the Windows 2000 systems. They are included in this manual
just for completeness.

VMI
811 Serial driver for external panel not found
812 Serial driver opening error
813 Serial driver closing error
The above errors involve an installation problem for the Teach Panel. Either there is a problem
with the CNC distribution for the installation or there is a software conflict with the support for
COM2 in the control. The installation has to be done again or find the software conflict.

814 File cannot be saved on another device!


815 Wrong file name
816 Incorrect external device has been selected
The above errors involve a file problem for the program being edited using the Teach Panel. Try a
different device or a different file name for the device.

817 Step is too big


818 Block not found
819 Invalid block number
The above errors involve an operator problem while editing a program with the Teach Panel. The
step increment is a parameter used for each new block. The block number errors involve the edit
process. Change the parameters used for teaching a program.

821 Block is worked off. No change possible


822 File deleting error. Permission denied
824 Empty file is not saved
825 Teaching file not saved
826 Backup file creation is not possible
The above errors involve an operator problem while editing a program with the Teach Panel. Try
a different sequence of operations during the teaching.

827 Serial driver sending error


The above error involves a serial interface problem to the Teach Panel. Either there is a problem
with the CNC distribution for the installation or there is a software conflict with the support for
COM2 in the control. The installation has to be done again or find the software conflict.

828 File closing is not possible. M30 missing


829 Active program saving is not possible
832 Teaching editor not closed
833 It isn't possible. CNC-teaching editor is active
834 It isn't possible. External device is active
835 Backup file creation is not possible. P999998 already exists
836 Teaching mode is already active for another station
837 Backup file P999998 already exists! Overwrite?
840 No backup file P999998!
841 File protected

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The above errors involve an operator problem while editing a program with the Teach Panel.
P999998 is the temporary file created during the edit process. Fix the part program (error 828) or
try a different sequence of operations during the teaching.

850 Wrong scale for path graphic


851 Wrong offset for path graphic
852 Part program not selected
853 Axis not selected
854 Wrong input
The above errors involve an operator selection problem. Try a different selection for the
operation.

855 Illegal CNC station required by PLC


The above error involves a problem with the PLC trying to change the station selection for the
operator. Check the PLC logic for a station selection.

901 This function cannot be selected at present


904 Unknown command (coming from CNC or COM)
905 This input is currently not allowed
914 Input is not executed by the CNC
943 Device not selected
952 Read-in or output is active, first abort!
The above errors involve an operator problem with the soft keys. Try a different selection for the
operation, appropriate. Some of these errors can be generated also when the PLC makes a request
for a feature found in a different, later version of the CNC software than is present.

966 Hotkey is missing or not allowed


967 Hotkey file with same name already exists
968 Macro has been stored and may be used
969 Macro storage has been aborted
The above errors involve an operator problem while defining a User-defined soft key. Either
change the hot key definition or delete the keyboard macro of the duplicate name.

992 Station selection not accepted by CNC/PLC


The above internal error involves a problem with the operator changing the station selection. It is
caused by an incorrect set of installation parameters or the request is not consistent with the CNC
options. If the request is correct for the CNC options, then contact MachineMate Inc. should it
occur.

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2. Basic trouble shooting procedures


This informal section describes several basic troubleshooting procedures with the CNC. Each basic symptom is
shown in as the main section title followed by its explanation and the suggested procedure for solving the
problem.

2.1 CNC is stuck in the Emergency Stop condition

The CNC will be in the Emergency Stop condition due to either of two triggers:
1) The CNC has detected a condition that requires an emergency stop.
There are a number of triggers for this including an axis loss of feedback (also called a ‘wire cut’) or a
part program exceeding the velocity limits for an axis (also called an ‘axis servo fault’). All of these
triggers should be accompanied by an error message at the moment the event occurs.
2) The PLC has indicated to the CNC that an emergency stop is required.
If PLC sets the INEMERGENCn signal to FALSE then the CNC immediately enters the Emergency Stop
state. The CNC will not respond with any error message but its status changes with ON_EMERG at
TRUE. The error message must come from the PLC logic. The INEMERGENCn state can be check by
monitoring the INFO – Interface Display – CNC Interface – Inputs in INGENERAL1.
The possible triggers of an emergency stop by the CNC should always result in an error message; these various
triggers are described below.
If the symptom has the CNC in emergency stop and an error message is shown then the cause of that error
message must be determined. If the source of the error message is not PLC then the Error Message Manual can be
helpful for that investigation. If the PLC wrote the error message (via the WRITE_ERROR_MESSAGE function)
then that PLC logic must be consulted.
If there is any doubt whether a message might have been displayed but then cleared from the display please check
the fault history log. This history is found in INFO – Log book (though it can be configured to ignore certain
errors).
The CNC will remain in the Emergency Stop condition (i.e., ON_EMERG remains TRUE) until it successfully
performs the control reset action. This control reset is commanded in several ways:
1) The operator selects the Initial State soft key on the Automatic – Program Process 2 display.
2) The operator simultaneously depresses both the Ctrl and Reset buttons on the front panel keypad.
3) The PLC issues a control reset command using the IN_EXTMODE signal word at a value of 6. There is
often a front panel switch associated with this action, such as the Machine Start push button on a
MachineMate Machine Tool Builder’s Panel.
4) If there is an external PC keyboard available, the operator simultaneously presses both the Ctrl and R
keys.

If the ON_RESET is seen to go on/off when monitoring the INFO – Interface Display – CNC Interface – Outputs
in ONGENERAL1 and if Emergency Stop does not change to Cycle Off (on Manual, Automatic or Info displays)
then there must be a condition in the system that requires the CNC to remain in the emergency stop state.
1) There can be no power supply errors in the system, whether in the CNC box or in external IO boxes.
These power supply errors should result in an error message. A restart of the system is required to
recover.
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Note that the 5V power supply monitor can be disabled in the drive configuration file (see 3.3 in the Start
Up Manual).
Note that the 24V power supply monitor for the 24V output bytes on the 2416 MIO and the 2416LX BIO
modules can be disabled from the PLC logic (with the signal IGNORE24ERRORS; this signal is
described in 7.6.2 in the PLC Interface Manual). The 24V logic power pin (pin 2) on each 2416 MIO
power connector always requires 24V.
Note that the 24V power supply monitor for the SERCOS built-in 24/16 IO on the 50-pin connector is
enabled whenever that IO connection is defined in the IO configuration file (see 2.4.4 in the Start Up
Manual). When IO byte numbers are defined for this connector the 24V power supply pins on the
connector are monitored.
2) The SERCOS ring cannot be in a failure mode, such as bad ring timing, missing drive address, etc.
These SERCOS errors should result in an error message. Some SERCOS errors can be cleared by the
control reset. The severity of the error determines whether a restart is required.
3) The analog servos and encoders that are configured cannot be in a failure mode, such as a wire cut or loss
of feedback condition.
These analog interface errors should result in an error message. The AXISOK LED (on the 4ENC4A
MIO or 4AXLX BIO) should be illuminated for those axes that have a valid encoder connection on
startup. An encoder wire cut or loss of feedback error condition requires the restart of the CNC software
to reset both the software and the hardware detection circuit (except in the unique case of a parking axis
whose feedback error can be reset by the PLC command to reset this hardware monitor for the parking
axis when the axis is unparked; i.e., IN_PARKxx is set back to FALSE). This e-stop result also includes
when no 4ENC4A module is found for the analog drive connections defined in the drive configuration
file.
4) The PLC logic must not be requesting an emergency stop, so INEMERGENCn must be TRUE.
If the PLC sets INEMERGENCn to FALSE then the CNC will remain in emergency stop. If the
INEMERGENCn is FALSE while ON_RESET is TRUE then the emergency stop condition will remain
at the conclusion of the control reset processing. The INEMERGENCn signal should not be held in the
FALSE state. No message is provided by the CNC due to this PLC signal because that message must
come from the PLC logic. If this signal is ever set to FALSE then there should be an associated
WRITE_ERROR_MESSAGE command in the PLC logic for the operator to be informed of its cause.

The respective possibilities should be checked as noted above. Since this symptom can be caused by PLC logic
that did not successfully perform the WRITE_ERROR_MESSAGE function when the emergency stop condition
was triggered (item 4) all PLC logic associated with INEMERGENCn being set to FALSE must be checked.

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2.2 CNC will not move an axis in Manual Mode (such as jogging)

The CNC has these requirements before an axis will move in Manual Mode:
1) The CNC is not in emergency stop.
ON_EMERG must be FALSE. A control reset should put the control in a Cycle Off mode. Please
reference the section above regarding emergency stop conditions.
2) The axis must have its position loop closed and the axis drive must be enabled.
The PLC must set the IN_DRONxx to TRUE for each axis whose position loop is closed (where
IN_DRON01 is for the first axis, etc.). The INFO display Status column Drive ON line shows the letters
for those axes with their position loop closed.
With analog axes, there is usually a 24V output signal for the PLC to enable each drive (either an output
directly to the drive or perhaps to a relay that electrically enables the drive). With SERCOS axes, this
IN_DRONxx signal will enable the drive using the fiber optic ring when it is TRUE.
3) The axis must have its manual motion enabled.
The PLC must set the IN_DRENxx to TRUE for each axis that can be moved in Manual Mode (where
IN_DREN01 is for the first axis, etc.). Sometimes this PLC logic could inhibit motion during defined
circumstances (like a light curtain). The INFO display Status column Feed line shows the letters for those
axes with their motion enabled.
4) The CNC is not in a feed hold condition.
The CNC indicates a feed hold condition (ON_CYCLE_STOP set to TRUE) with the status on top of the
Manual, Automatic and Information display pages with CYCLE STOP (or Cycle Halt) shown.
The CNC feed rate override percentage must be more than 0%. A feed rate override percentage of 0% is
the same as a feed hold – nothing will move. This percentage is shown on the Manual display.
The PLC must have the IN_STOPn set to TRUE indicating the PLC does not require a feed hold. The
CNC indicates this status of ‘not feed hold’ with ON_CYCLE_STOP being FALSE.
Note that if an operator presses a Cycle Stop push button thereby changing the CNC condition from Cycle
Off to Cycle Stop then the CNC is in the feed hold condition. The recovery from this feed hold condition
in a Manual mode and in a jogging mode (either continuous, incremental or handwheel) is either pressing
the Cycle Start push button or by performing the control reset action. Either action will change the CNC
condition from Cycle Stop to Cycle Off in Manual Mode (unless the PLC directs the continued Cycle
Stop condition with IN_STOPn set to FALSE).
If the Manual mode has Movement to Reference Point active then a cycle start initiates the homing
sequence.
5) The jog soft keys must be available (jog continuous, jog incremental, handwheel) to jog.
An axis cannot be jogged while in the homing mode. The first three soft keys in Manual Mode will be
disabled on power up when homing is required. The soft keys become available after homing is
completed.
If an axis must be jogged before homing has completed then the hand release command is required
(Manual, Auxiliary functions, Hand release). Note that no software travel limits are in effect until the
homing cycle has completed. This operator action of hand release is required since the operator must
recognize that in this mode there are no soft travel limits so jogging into a hardware overtravel condition
is very possible since the CNC cannot prevent it. Homing establishes the machine coordinate system for
the CNC. Homing also disables the hand release mode.
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6) The axis is not at its software travel limit.


The CNC will allow an axis to jog up to its software travel limit but not beyond. Upon reaching the
software travel limit the CNC will prevent further motion in that direction. No error message is provided
because this is considered the correct behavior (i.e., stopping at the defined software travel limit). The
INFO display will indicate this condition (of being at the software travel limit) in the STATUS column:
Axis Limit followed by the axis letter.
The software travel limits become active only after a successful homing cycle. If an axis is not required to
home then the defined software travel limits are always active. If an axis is required to home but it has not
yet been homed then it has no software travel limits for jogging (i.e., the hand release mode).
7) The PLC is not issuing a conflicting command that would interfere with the HMI jog (or homing).
The PLC can set IN_EXTMODE to a value to issue a command to the CNC. If the operator is trying to
jog an axis with the front panel and not with external switches or buttons then IN_EXTMODE must be 0
to indicate the PLC has no active command. Depending on the control, there might be operator switches
that direct PLC logic that uses IN_EXTMODE so those switches must not interfere with the HMI
jogging.
8) The PLC must issue the correct jogging command when jogging by switches – when this is a PLC jog,
not an HMI jog.
If this attempt at jogging an axis is being done with external switches or buttons (as on the Handheld
Pendant) then the sustained value in IN_EXTMODE must be correct for the desired axis motion. If the
PLC is supposed to issue the command for an axis to move then the value in IN_EXTMODE is critical. A
value of 0 indicates no active command so nothing will be moved for the PLC, a value of 3 moves the
first axis in the positive direction at the slowest of four defined rates, a value of 5 moves the first axis in
the negative direction at the slowest of four defined rates, a value of 7 enables the first axis to follow the
handwheel MPG at the smallest of four defined increments and so on. The definitions for the
IN_EXTMODE values are in the PLC Interface Manual (2.3.9).
9) To home the axes, homing mode must be active before pushing Cycle Start.
If the CNC is in homing mode (Movement to Reference Point is shown at the top), upon the Cycle Start
push button the CNC status changes to Cycle On and the CNC performs the homing sequence. The status
will change back to Cycle Off when the homing sequence has completed.
If the CNC is not in homing mode (e.g., Continuous Jog or some other mode is shown) then the Cycle
Start does not start a homing cycle. In this case, please select the fourth soft key in Manual mode to get
into homing mode (which updates the mode at the top) if another mode is active when homing is desired
before pushing the Cycle Start push button.

The respective possibilities should be checked as noted above. After selecting the axis jog mode (either
continuous or incremental) and selecting the desired axis with its soft key, the activation of the Jog + or the Jog –
push buttons should move the axis in that direction. At the moment the Jog + or Jog – push button is activated the
CNC status should change from Cycle Off to Cycle On indicating it is now busy with this jogging activity. When
the jog push button is released the CNC status should return to Cycle Off indicating it is done.

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2.3 CNC is stuck in the CYCLE ON condition

The CNC has these requirements before its condition changes from CYCLE ON to CYCLE OFF:
1) The CNC must complete all the axis motion for the block.
INFO indicates when axes are moving in a plus or minus direction.
The signals ON_CMNDPxx and ON_CMNDMxx also indicate this condition to the PLC (with one signal
for each direction for each axis).
Note that the feed rate override percentage of 0% results in a feed hold condition, preventing any axis
motion. This percentage is shown on the bottom of the Manual and Automatic displays. No message is
provided to the operator when he has caused the feed hold condition by the feed override position.
Note that the PLC must have IN_ENABLE set to TRUE to allow axis motion in Automatic Mode.
Sometimes this PLC logic could inhibit motion during defined circumstances (like a light curtain).
2) The CNC must have all axes in position when G73 is active.
The INFO display Status column In position line shows the letters for those axes that are ‘in position.’
The signals ON_INPxx also indicate this condition to the PLC (with one signal for each axis).
If this ‘out of position’ at the end of a block is the case, caused by too much lag or following error, there
are two solutions: either increase the ‘in position’ zone by increasing the value in the machine parameter
InpositioningArea or increase the KV for the axis (its position loop gain) to decrease its following error
by decreasing the value in GainSpeedFactor. This scenario is described in 13.9 in the Start Up Manual.
When G72 is modal the block’s motion is completed when the axis interpolation is completed.
3) The PLC must signal it has completed its processing of the block.
The PLC must have the IN_TRANSF set to TRUE indicating the PLC is done with the active block. If
this signal is FALSE then the CNC remains in CYCLE ON to indicate the block is still ‘in progress.’
4) If the spindle is involved, like with an M19 orient or a G33 threading, then the spindle has certain
requirements before the block is done.
The M19 is not completed until the spindle can be held in position on its marker pulse (with M19S0; a
different S value is a different orientation). The same two parameters for an axis in position (see above)
are involved in controlling a spindle in position.
Note that with a G33 operation the observed spindle behaviors are different based on a particular machine
parameter setting. If G33SpindleControlAppl is 0 (where the axes just follow the spindle) then the CNC
will slow the spindle so that it can catch the marker; at the moment the marker is detected the G33 activity
proceeds with the axes following the spindle feedback. If G33SpindleControlAppl is 1 (where the spindle
is treated like another servo and so it is interpolated with the axes; this setting requires very good spindle
performance) then the CNC will orient the spindle; at the moment the orient has completed the G33
activity proceeds with the spindle accelerating up to its programmed speed and the axes following the
spindle feedback. The correct setting of this machine parameter depends on the spindle performance as a
servo (i.e., can it be run like a rotary axis? The temporary set up of a spindle as a rotary axis is even
suggested in the Start Up Manual for checking the correct machine parameter values for the spindle to run
as a servo.).
The respective possibilities should be checked as noted above.

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Conditions during an MDI cycle start


An MDI block with no active program behaves slightly different than a block within a part program. The MDI
block can change the Cycle On status to Cycle Off when the axis interpolation has finished even though it has not
really completed the end of block checks because there is no subsequent block pending. However if another Cycle
Start is activated (even if there is not another MDI block) then the CNC confirms whether the current block is
done before it tries to do the next (which could be empty). If there is a problem with that last MDI block such that
the CNC has not actually finished the processing of the active block (i.e., one of the conditions noted above) then
the Cycle On condition will return to the display.
An MDI entry will be ignored by the control when both the PLC has IN_TRANSF set to FALSE and there is no
active program. Because the PLC has indicated it cannot complete the current block (if any) by its IN_TRANSF
signal being FALSE the CNC does not allow another MDI to be queued until the PLC indicates it is ready. If the
operator ignores this condition, enters another MDI block and then another cycle start occurs while IN_TRANSF
is FALSE, the MDI block will be ignored (it will be erased from the display but it will return after IN_TRANSF
is TRUE when the active block has completed) and the control will indicate this status with Cycle On (i.e., the
PLC is not done with its processing of the previous NC block so another cannot be started).

2.4 CNC has an error message during the active Part Program
The CNC will provide an error message when something is wrong with the active part program. There are two
steps involved in determining the cause of the problem:
1) Determine the source of the error message. This is at the left end of the line in the error window, prior to
the error number and message. A check mark will precede the source if this is the last error (though the
operator can click on different messages or scroll through them with the Info – Status Treatment soft
keys).
CNC:
If the error message is a pop-up dialog (often with the System Supervisor title), not one in the error
message window at the bottom of the CNC display, then this is a CNC error message. These pop-up error
messages are commonly caused by system problems (like those detected by hardware monitoring circuits)
that have nothing to do with the active part program. Since these problems typically cause an emergency
stop, these conditions are described at the start of this document.
If the error message is shown with the source of CNC then this is a CNC error so proceed to the next step.
PLC:
If the error message is shown with the source of PLC then the error originated in the PLC logic. Typically
this implies a machine or control condition is not correct. These errors will not be in the MachineMate
Error Message Manual because the PLC logic is the responsibility of the integrator not MachineMate Inc.
Identifying the cause of a problem in the PLC logic will take one of several courses:
a) Use the Info – PLC Interface display to investigate the current input and output conditions in light of
the error message. Perhaps the incorrect machine or control condition will be visible if the condition
was not transient.
An example of this type of error could be a hardware overtravel error message. Inspecting the PLC
inputs would reveal which input has the incorrect state.

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b) Use the Setup - PLC Programming – PLC Online – Login to animate the current PLC logic. The
current values for all variables will be shown to the operator, perhaps enabling the cause of the error
message to be determined.
An example of this type of error could be a tool change hang up error message. Inspecting the PLC
logic would reveal which step in that sequence the PLC logic encountered a problem.
c) Consult with the PLC programmer, who associated each error message with a particular condition.
SIM:
If the error message is shown with the source of SIM then the error originated in the Info – Simulation
path graphic feature, not from running the main part program in Automatic mode. This Info feature has a
simulated CNC running a selected part program with the tool path graphic display showing the results.
This is like another built-in CNC and its error checking procedures are the same as those in Automatic
mode. Proceed to the next step. In the Error Message Manual, a source of SIM is like CNC.
2) Determine the cause of the CNC error message.
The Error Message Manual provides a simple suggestion for every error message from the CNC. The
cause of an error during an active part program is either something in the control or in the part program.
If the CNC error number in parentheses starts with the capital letter N (like N+1230) then this is a part
program operator message and that N-number is the NC block number with the (MSG,) statement. Check
the conditions preceding that block number with the (MSG) in either the main program or its subroutines.
If the (MSG) block also has an M0 (operator stop) then it will be the active block (proceed to the next
step). The (MSG) block is sometimes used to pass set up directions to the operator. An (MSG) block will
display an operator message but it is up to the operator to determine whether that message indicates an
error or is just information.
An example of an error in the control would be an axis loss of feedback error, where an error in the
encoder feedback from an axis was detected by the control hardware. An error such as this is not related
to the part program content. Often such control errors result in an emergency stop (so such conditions
were discussed at the start of this document).
An example of an error for the active part program would be an NC block syntax error (e.g., a number out
of range or a sign with a letter that is always unsigned) or a programmed axis position has been detected
beyond the software travel limit. An error such as any of these is related to the part program content.
Proceed to the next step.
3) Determine the NC block in the part program that caused the CNC error message.
The CNC will show three blocks of the active part program on the Automatic and Info displays. Typically
the top block is the active block and the next two shown are the next two in the file. If the active block
caused the error message then it will be at the top of the three blocks on the display.
However, when an error is detected by the block look ahead processing then the bottom two blocks will
be updated with the content involved in the error from the block look ahead. With a look ahead error,
often the three blocks shown will not have consecutive block numbers due to this attempt to show the
problem found in a future block, where the top block remains the active block but the following two
blocks point to a programming error in the ‘future’ (i.e., from the block look ahead feature). Depending
on the severity of the programming error sometimes the CNC will just cycle stop (i.e., a feed hold in the
active block) or the CNC will emergency stop.
There is not a definitive rule as to whether an error from the block look ahead is in the second of the three
blocks or from the third block. This comes from the actual error number/message. For example, a
programmed axis position detected beyond a software travel limit (error 860) is typically shown in the

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middle block. If the problem arose due to the conflicting conditions in consecutive blocks then typically
the problem arose in the third block due to its preceding block that is shown in the middle.
However, there are several errors involved with modal conditions where the block in the third position
violates one of those rules so the previous block is shown in the second position to help the operator. For
example, when G2 or G3 is modal there will be an I, J or K (one or two of these letters) in each block to
define the arc center for the axis motion along that arc. If a subsequent block has none of I, J, K or even
no G-code (like G1 to change from circular interpolation to linear) then the CNC will assume the
previously defined arc will continue into this block but if the block’s axis positions are not on that arc
then the error message will indicate the problem with the arc but the block shown in the third position will
be the block that seems incorrect for those modal conditions (with the block before it in the part program
being shown in the middle position).

Cycle starting the part program after a look ahead error


When a block look ahead error is detected and it is not too serious, the CNC will stop in a cycle stop. In
most cases on such an error, the control is now forced into a single block condition and the operator will
be able to cycle start and run each block up to the problem block – but the problem block is inhibited and
the program will not execute that block. Sometimes, if there is some confusion about which is the
problem block in look ahead, this behavior can be helpful. However since the CNC is forced into this
single block mode, it might not be practical if the cutter is in contact with the part and the program is in
single block mode. Depending on the particular error, it is not always possible to cycle start up to the
problem block, based on the actual part program content (especially its modal G-codes).
Every new program should be tested before an actual part is cut. This detection of programming errors in
block look ahead is one of the many reasons why that test run is strongly recommended.

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