TABLE OF CONTENTS
XMILL-580DC Robotic Arm Consideration
When moving the robotic arm in the XTCERA controller menu - the arm will not jog unless the JAW is left in the OPEN position.
Errors and Resolutions
XTCERA Controller Error : Axis Driver Alarm: Error Code 5
This error message can be caused by the XMILL server needing a refresh. Turn off the machine and turn it back on to resolve the issue.
If the same error message appears, the back cover of the machine needs to be removed to get the specific error code to identify the root cause. We then need to forward the code to XTCERA Support for further investigation.
XTCERA Controller Error : Abnormal Length of Tool Checking
This error happens when the automatic Tool Length Checker (TLC) finds that the tool is outside the range set in the machine settings.
This issue can sometimes occur due to debris or dust on the sensor or the tool. However, more often than not, it is caused by the tool length value being outside the limits set in the machine’s controller.
To check for a range error, go to Manual and select ‘TLC’.
After running the TLC, check the Tool Info and take note of the tool length value. Repeat the TLC process 2-3 times; if the tool length value in the Tool Info screen stays the same, it’s likely a range error.
If the value does change on each TLC run, make sure that both the sensor in the machine chamber and the tool are clean of dust and debris.
Changing Tool Length Range Limits - Fixing The Range Error
Go to Settings by pressing the Check button twice until the icon changes from Check to Settings
Scroll down to around P950 to P1000. This section houses the Tool Length Max and Min value.
Double-click the affected tool, enter 888 as the admin password, and then input the correct minimum or maximum range.
Tool Length Minimum and Maximum Values
For XTCERA tools, the normal tool length range is from -2 to 2. If the tool length displayed in the Tool Info exceeds this range, it clearly indicates that the bur is likely broken or the sleeve is misaligned. If you are using third-party tools, it's essential to test the appropriate range by performing a TLC run.
XTCERA Controller Error 9: File loading failed in list
This error occurs when attempting to load the NC file onto the XTCERA machine, regardless of whether the file is corrupted or saved locally on the machine's built-in computer.
Cause 1: This issue is due to the expiration of the Controller License.
Resolution:
Please contact XTCERA Support for assistance. Ensure you have the TeamViewer details of the XTCERA machine controller readily available, as they will need this information to help resolve the issue.
Cause 2: It can be caused by soft limit violation on one of the axis
Resolution: Check MillBox simulation for collision, this normally happens with Special machining 90 degree milling. Re-nest the part and check simulation if there will be any collisions.
XTCERA Controller Error 5: Auto Disk Change Failed
Things to check: Please check whether another disk is present in the designated slot of the disc magazine. In the example below, disk 3 should be the one currently loaded. Confirm that there is not another disk occupying its position in the magazine.
Resolution:
If there is another disk loaded, ensure that the space in the magazine is cleared.
If no disk is present, check to make sure there are no tools on the spindle. If the spindle is clear, power cycle the XMILL machine, as the machine server may have encountered an error.
Turn off the machine and wait for one minute before turning it back on.
Once the machine is powered back on, click "Start" and confirm that normal operations have resumed.
Calibration
Collisions on 580 DC - What to do + Auto Calibrate Failed, error code: 201
In the event of a significant collision on the 580DC, the machine may become misaligned and go out of calibration. If you experience a manual collision while jogging against the machine or the arm, it is crucial to refrain from performing any tool swaps until the machine has been recalibrated. Continuing with tool swaps in this state could lead to damage to the tool or the Automatic Tool Changer (ATC) tool holder.
If you fail calibration and are presented with the following error:
Auto Calibrate Failed, error code: 201
You will need to implement a temporary zero shift on the machine’s controller, depending on the extent of the deviation indicated by the alarming axis.
As you can see, we experienced a collision along the X-axis that temporarily halted the machine and resulted in an approximate calibration shift of 2mm. The controller is programmed to issue an error message whenever the measured calibration value exceeds a variance of 1mm from the expected position.
To address this issue, our first step was to adjust the machine's zero point into a range suitable for automatic calibration. We then shifted the X-axis zero by -1.1mm, bringing the adjustable amount within the controller's acceptable limit. Following this adjustment, we received an "auto calibrate success" message. Upon reviewing the logs, we confirmed that the automatic calibration shifted the X position by -0.910mm.
Despite this adjustment, we still have an outstanding shift of 1.1mm to reach the target. Therefore, the next step is to shift the zero point back by 1mm, recalibrate the machine, and then assess the results.
Manual Calibration of 500+ XTCERA Machine
Insert the wax blank (D98-12mm) into the clamp.
Ensure that T1 (2mm) is securely in the collet.
Load the “X-NC500ABCD.nc” file from the “500 standard nc” folder on disk D and click ‘Start’..
Measure the XL values of cubes A, B, C, and D. Discard the lowest and highest values, then use the two middle values of the four cubes to calculate the average.
Measure the XR values of cubes A, B, C, and D. Discard the lowest and highest values, then use the two middle values of the four cubes to calculate the average.
Measure the Z values of cubes A, B, C, and D. Discard the lowest and highest values, then use the two middle values of the four cubes to calculate the average.
Important Note
The acceptable range for XL and XR is 0.95mm - 1.05mm, and for Z, it is 8.95mm - 9.05mm. If your measurements fall within these ranges, calibration is not necessary.
Record the previous G54 and G55 values from the iTool application to prevent any mishaps during calibration.
Open the iTool 500 3.0 application on your desktop and launch the on-screen keyboard from the Start menu.
Enter the calculated XL, XR, and Z values for the X/Z axes, then click Compute, followed by Revise.
Enter the ZD and ZB values for the A axis and click Compute, then Revise. (Note: Cube D’s Z value should match the A axis’ ZD value, and Cube B’s Z value should equal the A axis’ ZB value.)
Reference Video
How to Remove Collet
Kindly view this video for guidance on removing the collet from XTCERA machines. This technique is applicable to all machine types, and you can find the required tools in the white accessory box. Please note that using grease on the collet is not recommended, as it has led to unsatisfactory results in past tests.
Reference Video
Was this article helpful?
That’s Great!
Thank you for your feedback
Sorry! We couldn't be helpful
Thank you for your feedback
Feedback sent
We appreciate your effort and will try to fix the article