(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.
Edited by
Kevin on 15-01-2026 21:54,
1 day ago(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.
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.
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.
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.
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.
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.
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.
