AXIS CONTROLLER NOT RESPONDING TO NC ALARM TROUBLESHOOTING

Before performing invasive testing, rule out mechanical connection issues.

1. Power Down: Completely shut down the machine and disconnect main power.
2. Backplane Reseat: Gently remove the 1010 card and inspect the gold-plated pins on the card edge and the corresponding slots in the 1060 motherboard backplane. Look for oxidation, debris, or "burned" pins. Reseat the card firmly.
3. Front-End Connectors: Ensure the bullet connectors (J2 for resolver/encoder, etc.) are tight. Vibration in a high-speed production environment can cause these to back out, resulting in "Servo Fault" or "Feedback Error" codes.

Step 2: Diagnostic "Load-Test" of the Low-Voltage Supply

The ELE-1071 power supply must maintain rigid ±12VDC and +5VDC rails. If these rails sag under load, the 1010 card's internal logic will experience "brownouts," leading to intermittent communication errors.

1. Multimeter Test: With the machine powered, measure the voltage at the test points on the power supply.
2. Isolation Method: If the voltage is low, unseat the axis controller cards one at a time while monitoring the ±12V rail.
3. Identification: If the voltage returns to spec after pulling a specific card, that card is likely drawing excessive current due to a shorted internal component.

Step 3: Card-Slot Swap Test (The Definitive Test)

If the fault persists, determine if the issue is Card-Specific or Slot-Specific.

• Swap Procedure: Swap a suspect 1010 card with a known-good card from another axis (e.g., swap X and Y).
• CRITICAL REQUIREMENT: The Jumper IC (J4) must stay with the SLOT, not the card. Each 1010 card is configured for a specific axis by physical jumpers. If you swap a card into a new slot without ensuring the jumper configuration matches that slot's requirements, you will cause an axis runaway or "Logic Jumper Incorrect" error.
• Results: * If the fault follows the card, the card is defective.
  • If the fault stays with the slot, the issue is likely your 1060 motherboard backplane or cabling.

Step 4: Advanced Diagnostics via CNC Menu

Utilize Fadal’s internal diagnostic software to communicate with the card:

• Function 2 (Axis Controller Test): This test probes the axis slots. If an axis is populated but reports a "No Response" or "Failure" counter increment, the card is failing to handshake with the CPU.
• Error Code 20/21: "Move Transfer Fault" or "Spurious Interrupts" are often indicators of a failing 1010-6G card or a communication breakdown with the 1030 Interface board.

Authority on Fadal Diagnostics

At CNCPros International, we have diagnosed thousands of Fadal control faults over the last 28 years. We know that these 1010-6G cards are robust, but they are not immortal. If you have performed these steps and the error remains, the logic gates on your PCB-0217 have likely reached the end of their operational life.

Is your machine failing to clear an axis fault? Don't guess with your control rack logic. Reach out to our expert Order Desk at 1-208-888-9236. We can help you verify your jumper configurations and confirm whether a new PCB-0217 is the exact fix you need to restore your machine to peak operational status.