Support > Knowledge Base > XL200 Series Controllers > Error Codes > 39 - Out of tolerance
The "Out of tolerance" error indicates the controller has calculated that a cut or punch operation has fallen outside of the programmed Tolerance parameter.
Causes
The cause of the "Out of tolerance" error message varies based on machine application type.
Each time the XL200 Series controller stops the material for a press operation, the controller checks to see if the stop occurred within the defined Tolerance range. If not, the "Out of tolerance" error is displayed.
The most common reason for an "Out of tolerance" message on this type of machine is due to a large shift in the time it takes for the machine to stop. By default, the XL200 Series controller tests to see how long it takes the machine to stop, then stops the machine early by that time on successive stops. The stopping time for the machine is updated for every press operation in the automatic mode.
- Changing from very long parts to very short parts (or vice versa) can cause some machines to greatly lengthen or shorten their stopping reaction times.
- Mechanical backlash can create large reaction shifts.
Remedies - Turn on dynamic braking in the inverter used to control material motion.
- Try running the machine in 2-speed mode, where the material shifts into a slow speed before stopping.
- Remove all mechanical backlash from the machine: i.e. tighten chains, replace couplers, replace worn gears, etc.
- Try using the Bump-Into-Tolerance feature.
Closed Loop Stopping
In the closed loop feed-to-stop application, the XL200 Series controller creates a motion profile that brings the material to 0 fpm (0 mpm) before firing the press. The controller waits up to 1 s for the material to get into tolerance before displaying the "Out of tolerance" error.
- Mechanical backlash can cause 2-encoder systems to "continue moving" after the servo motor has stopped.
- Tuning problems in the servo system can cause the servo motor to oscillate on stand still.
- Based on certain parameters, the press can be fired while the material is decelerating to a stop. If the press is contacting the material too soon, the servo might still be trying to drive the material into position.
Remedies - Remove all mechanical backlash from the machine: i.e. tighten chains, replace couplers, replace worn gears, etc.
- Check the tuning of the servo system. Reduce motor oscillation as much as possible. Contact AMS Controls Technical Support or the servo manufacturer for help.
- Contact AMS Controls Technical Support for help.
Closed Loop Flying Die
Contact AMS Controls Technical Support for help.