ALARM 50 — OVERLOAD 1

Check the overload parameters (Servo: SV021, SV022; Spindle: SP021, SP022). If they are not set to the standard values (Servo: 60/150, Spindle: 60/120, IPM: 300/100), adjust them to match the standard specifications.

Monitor the load on the NC screen during operation. For servo axes, if 'Max.current 3' stays at maximum or overload rises rapidly, mount a smaller workpiece or increase the acceleration/deceleration time constant. For spindles, if the load meter exceeds 120% continuously, lower the cutting amount or extend the cycle time. Do not forcibly turn OFF the power to reset if the overload is 50% or higher.

Verify the motor brake operation. Check the brake relay and the motor brake connector (CN20). If the motor brakes are not releasing properly during operation, correct the faulty wiring or replace the relay.

Investigate the mechanical load using the NC Servo Monitor. If the load is unexpectedly high, check for interference with the positioning pin (turn servo OFF when stopped if necessary), inspect for a bent ball screw, or look for guide faults, and resolve any mechanical binding.

Check for machine resonance or hunting. If resonance occurs during machining, set an optimal notch filter and lower the speed loop gain VGN1 (SV005, SP005). If the shaft hunts when stopped, increase VGN1 (SV005, SP005) and lower the speed loop lead compensation VIA (SV008, SP008).

Check the spindle PLG output waveform using an oscilloscope. If the waveform is abnormal, adjust the PLG output waveform. If using a TS5690 encoder where the waveform cannot be checked, reinstall the encoder sensor.

Confirm the tooling condition and motor capacity. If the tool service life is reached, replace the tool or use a cutter with more teeth. If the motor capacity is fundamentally insufficient for the job, permanently reduce the acceleration/deceleration rate or the cutting load.

If parameters, load, mechanical parts, and encoders are normal but the Overload 1 alarm persists, the hardware is faulty. Replace the MDS-E drive unit. If the alarm continues after replacing the drive unit, replace the motor.