8. Tool Breakage Monitoring Alarm

Error:

“Punch breakage detected”

“Tool length deviation”

Steps

Inspect tool physically.

Re-teach tool length.

Check spring and stripper movement.

Reset tool data and recalibrate.

7. Sheet Detection Error

Error:

“Sheet missing”

“Material sensor blocked”

Steps

Clean optical sheet sensors.

Check sensor alignment.

Verify 24V supply.

Test sensor manually with metal piece.

6. Servo Drive Fault (Axis Drive)

Error:

“Drive ready missing”

“Overcurrent in X/Y axis”

“Encoder fault”

Steps

Note exact drive fault number on Siemens drive.

Power OFF machine for 5 minutes.

Check:

Motor cables

Encoder cables

Grounding

Swap encoder cable (if spare) to confirm.

Replace drive only after confirming motor OK.

5. Hydraulic Pressure Fault

Error:

“Hydraulic pressure low”

“Pump not building pressure”

Causes

Low oil level

Clogged filter

Pump motor failure

Solenoid valve stuck

Steps

Check oil level in tank.

Replace or clean hydraulic filters.

Check pump motor current.

Manually energize pressure solenoid.

Measure system pressure with gauge.

4. Overload in Punch Drive

Error:

“Punch overload”

“Ram drive fault”

“Hydraulic pressure too high”

Causes

Tool collision

Thick material vs wrong tool

Worn guide bush

Hydraulic relief valve stuck

Steps

Remove tool and inspect for damage.

Check correct material thickness in program.

Inspect punch guide and stripper.

Check hydraulic pressure values.

Reset overload, run slow test stroke.

3. Clamp Error / Sheet Not Clamped

Error:

“Clamp open”

“Clamp position error”

“Sheet not detected”

Causes

Pneumatic leak

Clamp proximity sensor faulty

Hydraulic pressure low

Steps

Check air pressure and filter-regulator-lubricator (FRL).

Inspect clamp cylinder for oil/air leaks.

Verify clamp sensors in diagnostics screen.

Manually actuate clamp and confirm feedback.

Replace sensor if no signal change.

(Generic across TruPunch 1000/3000, TC200/TC500, TruMatic punch-press)
2. Turret Indexing Error

Error:

“Turret not in position”

“Turret reference missing”

“Tool station not found”

Causes

Turret encoder error

Mechanical blockage

Low air pressure

Index motor overload

Troubleshooting Steps

Remove sheet and tools (safety first).

Check air pressure (6 bar typical).

Jog turret manually in maintenance mode.

Clean turret sensors and index marks.

Check encoder coupling for slippage.

Perform Turret Re-reference procedure.

(Generic across TruPunch 1000/3000, TC200/TC500, TruMatic punch-press)

1. Axis Not Referenced / Reference Run Error

Error:

“Axis X not referenced”

“Reference run failed”

Alarm: Axis not in home position

Causes

Power loss during motion

Encoder not giving signal

Limit switch dirty or damaged

Servo drive fault

Troubleshooting Steps

Switch to Manual / Jog mode

Move the affected axis slowly away from limits.

Perform Reference Run (Homing) from control panel.

If still failing:

Check limit switch LED status in diagnostics.

Inspect encoder cable and connector.

Reset servo drive and reboot control.

If motor does not move → check drive enable and 24V supply.