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P-COOL - Troubleshooting Guide

5.6 P-COOL - Troubleshooting

Last updated: 08/05/2024

P-COOL - Troubleshooting Guide

Introduction

The Programmable Coolant Nozzle is a multi-position nozzle that automatically directs coolant precisely at the cutting tool.

Symptom Table

Symptom Possible Cause Corrective Action
Alarm 196 COOLANT SPIGOT FAILURE The P-COOL could not obtain the commanded position in the allotted time.  Make sure there are external reasons for the nozzle to move slowly. Check for drag in the swivel fitting. 
There is no voltage to the P-COOL.  Measure the power to the P-COOL.
The P-COOL. moves up and down without stopping.  Make sure the cabling is undamaged, and the connector pins are sealed properly. 
There is low coolant flow from the nozzle.  Chips have clogged the P-COOL nozzle or the filters.  Remove chips from the P-COOL nozzle and the filters. 
Chips have clogged the check valve or the coolant hoses.  Remove chips from the check valve and coolant hoses.
HMC Mills: The PCOOL spigot moves in the opposite direction.  Parameter 209.09 SPIGOT KEY INVERT is not set correctly.   Make sure that Parameter 209.09 is set correctly.  This parameter inverts the direction the spigot moves when the CLNT UP / CLNT DOWN buttons are pressed. 
P-COOL will not position correctly or skips positions. The switch inside the P-COOL that tracks the P-COOL's position is damaged and does not count correctly. 

Use M34/M35 to move the spigot up and down in 1 position increments. A 0.05 second dwell will be needed with each movement.

HSG-A 4-4-2023
Alarm 9806 SHORT CIRCUIT Short circuit on P-Cool Cable or P-Cool Motor.

Do a visual inspection of the cable assembly for any cable cut, pinch or damage that could cause the cable to fail. Then do a continuity test of both ends of the cable assembly. 

IMPORTANT: If the cabe is not damaged and passes the continuity tests, an error report MUST be taken and added to the machine history for troubleshooting the motor. If an error report is not taken there is a risk of warranty being rejected.

P-COOL Spigot Failure

Make sure the connectors for the P-COOL cable that connects through the connector bracket at the spindle head, and to P35 on the I/O PCB, are not contaminated and are properly seated. Check for damage to the cable. Run the program for 12 seconds. If the program is not working, reset the machine.

Run this program in MDI mode:

M34;
G04 P1. ;
M35;
G04 P1. ;
M99 ;

Find the connection for the P-COOL on the spindle-head connector bracket. While the program runs, use a multimeter with needle-tip probes touse a multimeter with needle-tip probes to measure the voltage across pins 1 and 2. The voltage must measure 12 VDC. Do not measure the voltage with the cable disconnected.

If there is voltage, check for continuity in the cable between the P-COOL and the connector bracket. If there is no continuity, the cable is at fault. If there is continuity, the P-COOL assembly is at fault.

If there is no voltage, refer to:

Clogged Spigot, Filter and/or Check Valve

Make sure the ball valve for the coolant loop on the spindle head is fully open.

Remove any chips that are stuck in the P-COOL nozzle.

Clean or replace the filter element. Check the area around the coolant pump intake for chips.

  1. Auxiliary Filter - The bag filters in the Auxiliary Filter tanks need to be cleaned or replaced. The Auxiliary Filter is an option. Your machine might not have this option.
  2. Standard Filter - The Standard Filters need to be cleaned. Remove chips from the basket filter in the coolant tank.

Remove the coolant check-valve. Check it for blockage [1]. Make sure the trap door opens and closes freely. If the trap door does not close, coolant flows back into the tank. This delays the flow of coolant by a few seconds.

Disconnect both ends of the coolant hoses. Remove any kinks. In the opposite direction of the coolant flow, blow air through the hoses to remove any chips. If you find chips in the hoses, check the coolant nozzles and washdown hoses for chip buildup. Connect the coolant hoses.

Refer to the Standard Coolant - Tank - Maintenance procedure.

Electrical Diagram