mitsubishi FREQROL-SF Troubleshooting Manual

AC SPINDLE

USA-E99991-075-*

DRIV

TROUBLESHOOTING

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ADVANCED

MITSUBISHI

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EVER AOVAkCfNG

ELECTRKZ

1.

Troubleshooting

1.1

1.1.1

1.1.2

Status display and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .

Status display and diagnosis from spindle amplifier.

Status display and diagnosis from NC . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Checking method and countermeasures of trouble

classification A .._..................................

1.2.1

When the amplifier is turned on at the first time,

it does not correctly work

. . . . . . . . . . . . . . . . . . . . . . . .

1.2.2 The motor which has normally rotated stops

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Although an

after turning on and off the power

1.2.3

abruptly The equipment does not work in occasions. orientation stop position deviates.

alarm appears,

or resetting the equipment, the equipment normally

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

1.3.1

works

Checking method and remedy of trouble classification B

.

..I................................................

When the power is turned on, the display of the

operation panel does not appear at all . . . . . . . . . . . . .

1.3.2

When the power is turned on, the display on the

operation panel does not indicated the speed in

the status display mode (as shown in the following

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3

figure)

An alarm appears ont he display on the printed

circuit board (SF-CA card) of the amplifier . . . . . . . .

1.3.4

1.3.5

The motor does not rotate . . . . . . . . . . . . . . . . . . . . . . . . . .

The motor does not rotate at a speed being

specified

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The

. . . . . . . . .

1 5 5

10

13

15

16

17

18

20 41

43

1.3.6

1.3.7

1.3.8

The motor vibrates and is getting noisier during

rotations . . . .

.._...._._........_...................

The motor overshoots in speed or hours . . . . . . . . . . . . .

The cutting force degrades . . . . . . . . . . . . . . . . . . . . . . . . .

44 46 47

1.3.9 The orientation of the spindle is not correct . . . . . .

1.3.10 The acceleration/deceleration time increases . . . . . . .

1.3.11 The speed detection signal, up to speed signal,

or zero speed signal is not issued . . . . . . . . . . . . . . . . .

1.3.12 The tapping operation cannot be correctly performed. 55

1.3.13 The threading operation cannot be correctly performed

. . . . . . . . . . . . . . . ..I...........

. . . . . . . . . . . . .

48 53

54

57

2. Checking and replacing parts

2.1

2.2

2.3

2.4

2.4.1

2.4.2

2.4.3

2.4.4

2.5 Checking transistor module (This method is the same

2.6

2.7

2.8

2.9

2.9.1

2.9.2

Replacing fuses Replacing thermal protectors Replacing amplifier cooling fan Replacing printed circuit board

Replacing SF-PW module

Replacing SF-OR or SF-10 card Replacing SF-TL card Replacing SF-CA card

both in the power side and regeneration side) Checking diode stack Replacing transistor module and diode stack Replacing motor cooling Adjusting and replacing motor built-in encoder

Adjusting printed circuit board Replacing encoder and printed circuit board

......................................

.................................

............................

.........................

......................

.............................

......................

...............................

........

..........

..............................

....................

........

.......

58 59 59 59 61 61 62 63 64

65 68 70 71 74

74 77

3. Spindle orientation control circuit . . . . . . . . . . . . . . . . . . . . .

3.1

3.1.1 Spindle orientation using magnesensor (1 point) . . . . 80

3.1.2

3.2

3.2.1 Where the speed selection signal function is

3.2.2 Where the equipment is linkedwith the NC through

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spindle orientation using encoder . . . . . . . . . . . . . . . . . .

(4096 points,

Control circuit and parameter setting . . . . . . . . . . . . . . . .

provided (SF-OR card)

the bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with index function)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 80

82

84

89

3.2.3 Where the equipment is linked with the NC using

analog or digital signals ..........................

3.3 Mounting position detector

3.3.1

3.3.2

3.4

3.4.1

3.4.2

3.5

3.5.1

3.5.2

In the case of magnesensor type ....................

In the case of encoder type ........................

Adjustment ...........................................

In the case of magnesensor .........................

Encoder type .......................................

Operation mode and motions ...........................

In the case of magnesensor .........................

Encoder type .......................................

...........................

96 97

97 104 106

106

110 113 113 115

4. Adjusting synchronous tap ...............................

4.1

4.2

Appendix 1 Appendix l-l

Appendix l-2 Appendix l-3

Setting parameters ...................................

Checking operation ...................................

Machine Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Connection with motor (for standard motor) . . . 122

Machine connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

(without orientation (standard)) Appendix l-4 Appendix l-5

Machine connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Machine connection(Bus linkage with NC) . . . . . . 124

(Magnesensor orientation (1 point)

specification)

Appendix l-6

Machine connection(Bus linkage with NC) . . . . . . 125

(with encoder synchronous tap,

orientation

(4096 points) specification/indexing

funtion)

Appendix l-7

Machine connection . . . . . . . . . . . . . . . . . . . . . . . . . . .

(with encoder orientation rather than NC) (with 4096 point orientation/indexing function)

117 117 118

120

126

Appendix 2 Appendix 2-l

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(without orientation (standard)

1

127 127

Appendix 2-2 Appendix 2-3

Cable connection .............................

Cable connections (Bus linkage with NC)

...... 129

128

Appendix 3

Appendix 4 Appendix 5

Cable and Connector Specifications

Main Circuit Configuration .....................

Spindle Part Layout ............................

.............

(Excluding printed circuit boards)

Appendix 6

Control Circuit Printed Circuit Board Part

Layout .........................................

Appendix 7

Appendix 8

Appendix 9

Appendix 10

Appendix 11

Appendix 12

Reference:

Major Part Table ...............................

Display Lamps (LED diodes) .....................

Check Terminals ................................

Parameter Setting List and Short Pin Switch . . .

Structural Components . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Instruments . . . . . . . . . . . . . . . . . . . . . . .

Setting and Adjustment

1.1 Set switches, set pins, and variable resistors

1.1.1

1.1.2

SF-CA card SF-GR card

.........................................

.......

130

138

139

144

148

154

155

169

172

175

176 176 179

1.1.3

1.2

1.2.1

1.2.2

SF-TL card .........................................

Setting parameters

Display and set switches (on SF-CA card)

Setting parameters from spindle amplifier

...................................

...........

..........

1.2.3 Setting parameters from NC (On 9" CRT screen)

1.3

Adjusting speed and load meter

.......................

1.4 Setting and adjusting spindle orientation control circuit

..............................................

......

180 182

183 185 204 214

214

1 Troubleshooting

Troubleshooting

1.

If any trouble occurs, before checking the cause, make sure to read and follow the contents of Table 1.1, "Precautions"

for safety,

Table 1.1 Precautions for safety

o

After turning off the power,

the controller. tion lamp LED 10 (SF-CA card) puts off, conduct the maintenance and inspection work (waiting for 3 minutes or more).

0

An electric shock may result in a death accident.

Regardless of whether the power supply is grounded or not, exposed to a high voltage, apparatus. When installing any test apparatus on a portion to be tested, Generally, when conducting a test, of any test apparatus. be applied between the test apparatus case and the

ground, repairing it, take care of it.

o

While the power is supplied to the equipment or when the

equipment is operated, circuit board.

o

Do not put on a loose close which may be caught by the

rotating portion of the equipment.

since each component of the equipment may be

take care not to touch any portion being grounded.

when operating the equipment while adjusting/

After checking that the power indica-

Thus,

do not attach/detach any printed

Otherwise,

do not immediately touch

carefully select and use test

do not ground the case

because a high voltage may

the equipment may be damaged.

1

Next,

Items upon Occurrence of Trouble". with Service Department of Mitsubishi Electric.

thoroughly check the contents of Table 1.2, "Check

They will help you contact

-l-

/

1 Troubleshooting

/

Table 1.2

Check items upon occurrence of trouble

Check what alarm the alarm display of theamplifier indicates.

In addition, check old alarms in the alarm mode

of the indication lamp (see Appendix 8).

At which of phase R, S, and T a fuse is blown?

(Control circuit input fuse)

Does the trouble or fault repeatedly occur?

Is the ambient temperature and temperature in the

panel normal?

(Is that 55°C or less?)

During what situation does the trouble or fault occur? During acceleration, deceleration, or constant speed? At what speed it occurs?

Does the trouble or fault differ between the forward

rotation and reverse rotation?

Is there an instantaneous power failure?

Does the trouble or fault occur when a special opera-

tion or instruction is executed?

9

How often does the trouble or fault occur?

10

At what load situation does the trouble or fault occurs? Whether a load is applied or removed?

Is a suspicious part replaced with a new one or a

11

temporary repair conducted against the trouble or

fault?

12

13

How many years has the equipment been operated?

Is the power voltage normal? Does it vary remarkably depending on the time zone?

By referencing the trouble classification shown in Table 1.4, check the power voltage listed in Table 1.3 before conducting

troubleshooting and countermeasures.

-2-

1

1 Troubleshooting

~1

Table 1.3

Checking AC power voltage

Checking DC power

supply voltage on printed circuit board

Table 1.4

E;$-

cation

When the amplifier is powered on at the first

1

time,

The equipment which has normally worked does

2

not abruptly work.

A.

The equipment does not work in occasions. The orientation stop position deviates from

3

the specific position. lights, then on the equipment or by resetting it.

Checking power voltage

Amplifier input pins Xl, X2, X3, and E

Checking DC output voltage at check pins on SF-PW card

Trouble classification

Situation

it does not normally work.

Although an alarm

it is recovered by turning off and

See Appendix l-l

See Appendixes 5,

h(4),

and

g(4).

1

r-

1.2.1

1.2.2

1.2.3

When the power is turned on, the display of the operation panel does not appear at all.

1

Alternatevely, circuit board is not correct.

When the power is turned on, the display on

the operation panel does not indicate

2

tions in the status display mode (as shown in

B

the following figure).

)-

The display on the amplifier printed circuit board (SF-CA card) indicates an alarm (as

shown in the following figure).

3

the DC voltage of the printed

rota-

::

Continued

on the next page.

1.3.1

1.3.2

1.3.3

-3-

1 Troubleshooting

:kEi-

;ifiation

B

Situation

The NC CRT (spindle monitor screen) indicates an alarm (as shown in the following figure).

4

Spindle alarm 15 01

5 The motor does not rotate.

The motor speed do not conform with that being

6

specified.

The motor vibrates with a large noise during

7

rotations.

8

The motor overshoots at speed or hunts.

9

The cutting force degrades.

The orientation of the spindle is not correctly 1 3

10

performed.

EcikiZ

ferenced

1.3.3

1.3.4

1.3.5

1.3.6

1.3.7

1.3.8

g

. .

The acceleration/deceleration time becomes

11

lonq.

The speed detection signal, up to speed signal, 1 3 11

12

or zero speed signal is not issued.

13 The tapping work is not correctly performed.

The threading work is not correctly

14

performed.

1.3.10

. .

1.3.12

1.3.13

-4-

1.1 Status display and diagnosis The status display and diagnosis are executed with the

display and switches on the SF-CA card. an NC and bus line,

the status display and diagnosis can

be executed on the NC CRT.

When linking

1.1.1

Status display and diagnosis from spindle amplifier

For instructions for operating the display and switches,

see Reference

(1) Status display

SPEED

The following table lists the contents of the four types of status display modes.

Item

SPEED

Code

I'

1.2.1.

Shift

REFERENCE

Unit

rpm

-I

DOWN UP

Represents the motor speed.

q

POSITION

___

Shift

LOAD

Description

3

SPEED

REFERENCE

7

REFERENCE

SPEED

POSITION

DROOP

LOAD

SPEED REFERENCE INPUT

1-

1,

-

1:

L

I-

_

rpm

Pulse

%

rpm

Represents the motor reference

speed.

Represents remaining pulses on the deviation counter.

In the case of reverse side pulse (negative number), the decimal point indicator lights. Represents the load status assuming

that 30-minute rating output is 100%.

Bus linkage with NC . . . 2-port data

of speed reference inputted from NC

S analog . . .

12-bit conversion value

of A/D converter

Digital control . . . 12-bit value

-5-

(2)

Diagnosis

Shift

1 Troubleshooting

1.1 Status display and diagnosis

-

Shift

DOWN

LP

‘,

0

The following table lists the contents of the

sequence diagnosis.

I

Item

Sequence

1

Display

1

k, ,j - j III!

MM__

\ ,I,

II

l-l ] - j

Description

Represents the ready state.

Represents the non-ready

3

EXTERNAL SIGNAL 3

Check the contents of the external signal 1

0

external signal 2 signal 3

(STSl)

(CTM2)

of input signals and external

and external signal 4

(STS2)

of output

signals by comparing them with the following table.

(Note) On the NC spindle monitor display

(ALM/DGN3),

the external signal 1 and external signal 4 are checked as a control input and control output, respectively.

-6-

(CTMl)

and

(a) External signal 1

(CTMl)

Check the contents of signals by each digit of LED using the following table.

selectselect

(b) External signal 2 (CTM2)

Check the signal contents by each digit of LED using

the following table.

[2/1;10/

LED Digit Servo Ready

SVON

ON

0 1

:!

3

J

1

: ' 'j

n

RDY

ON

k. J

I_

1

Troubleshooting

1.1 Status display and diagnosis

(c)

External signal 3

(STSl)

Check the signal contents by each digit of LED using the following table.

1

Servo Ready ON

f

0

ON

-8-

1 Troubleshooting

1.1 Status display

(d)

External signal 4

(STS2)

Check the signal contents by each digit of LED

using the following table.

and diagnosis

@

There are three types of warnings as listed in the

EO

IPF

E4E7WPE

NCE

table.

INSTANTANEOUS POWER FAILURE

PARAMETER

SETTING ERROR

NC EMERGENCY STOP

Warning which is issued when the power voltage temporarily drops.

/cl'

i.. y

12vJr Lp> /- "",/.A /c_* [,A

Warning which is issued when a parameter value exceeds the allow-

able range

OWarning which is issued when an

emergency stop signal is inputted

from the CNC in bus linkage with

the M300 series CNC.

owarning which is issued when an

emergency stop signal is inputted

from the outside while the external emergency stop signal is validated with the related para-

meter being set.

C

-9-

1 Troubleshooting

1.1 Status display and diagnosis

(Note 1) Motion B - The motor decelerations and stops

with regenerative braking and then base

shut-off takes place.

Whether to open

the trouble signal contact FA-FC can be

selected with a parameter.

Nos.

Motion C

11 and

Only the alarm lamp lights, but

-

12",

Appendixes l-4 and l-5.)

(See

"CON Pin

the operation continues.

(Note 2) An example of the display is as follows.

1.1.2

1-4

I-1 111

rm.

@

The parameter error No. represents which parameter

;'

_ .-1'

DA,&

NC emergency stop

is defective when the alarm No. 37 (PE, parameter

error) occurs.

(Note 1) If a multiple of parameters is defective, check

and correct the parameters in accordance with the parameter error Nos. until the alarm No. 37 does not occur.

(Note 2) An example of display is as follows:

19 :'

’ ^

Am.

Status display and diagnosis

Pressing the

E,

is one of function selection keys and the

D))

key

which is one of menu keys causes the following spindle monitor screen

(ALM/DGN

3) to appear.

l-l

I-

,,I :I

D.,l

which

Indicating parameter

error No.

from NC

[SPINDLE MONITOR]

GAIN DROOP

Srpm

RPM LOAD RATE ALARM NO.

D/I L D/O L

ALARM SERVO

(FB)

H H

00 00

76543210

00000100 00000001 00000100 00000010

SPINDLE

MONITOR PLC-I/F

ALM/DGN

10.0

675 100 100

40

3

-lO-

Display

Description

Represents the position loop gain state. It represents 0 when no position loop is formed.

GAIN

Position loop gain is obtained from the equation

Motor speed

=

Followed delay error

(rad/s)

(rad/)

The standard value is 10.

An error of real spindle rotation angle against

POSITION DROOP

referred spindle rotation angle is named droop. The unit is in pulses. When no position loop is

formed,

the position droop is 0.

RPM Represents the real motor speed.

(Motor speed)

The unit is in rpm. Represents a ratio of load against the rating

MOTOR RATE

output.

The unit is

output is 100%. The motor rate is in the range

The 30-minute rating

8.

0 to 120%.

Represents the contents of alarms which occurred in the spindle amplifier this time and last time

ALARM NO.

with code numbers.

However,

the last alarm is

(Spindle alarm) the smallest number alarm which differs from

this time alarm.

For details of the contents

of alarms, see 1.3.3. Represents an input command to be issued to the

spindle amplifier corresponding to bits.

D/I

7

6 5 4 3 2 10 7 6 5 4 3 2

1

1:Gear

13

1 1

D/I L

10

Continued on the next page.

-

11

-

Display

Description

Represents a control output being outputted from the spindle amplifier corresponding to bits.

D/O

D/O H

7

6543210

-

7 6

D/O L

5 4 3 2

10

-12-

1 Troubleshooting

1.2 Checking method and countermeasures of trouble classification A

1.2.1 When the amplifier is turned on at the first time, it

[tern

The amplifier is knocked and damaged

1

when the equipment is operated or installed.

The external wiring is incorrect or broken

2

The signal ON/OFF sequence is incorrect.

3

-The ground wiring is

not conducted.

4

The

5

incorrect.

The switch and setting

pins are incorrectly

6

set.

Cause

ElPROM

number is

l-

Visually check there is an abnormal portion on the amplifier.

Visually check the external wiring.

Check that the indication lamp LED 1 on the SF-PW card lights

(see Appendix

Check the sequence among the NC ready ON signal, spindle ampli-

fier CON1 ready signal

SETZ),

reverse rotation signal, and orientation signal taking care of the following items.

DThe

NC ready ON signal and spindle amplifier CON1 ready signal ready when both the signals are turned on.

BIt

takes 1 command of the forward rotation signal,

or orientation signal is received after the ready ON

state.

BWhen

both the forward rotation signal and reverse rotation signal are turned on at a time, the motor does not rotate (it becomes the DC exciting state).

BWhen

the forward rotation

or reverse rotation signal is

inputted when the speed reference is 0, DC exciting State.

BUnless

Check the ground wirings of the power, shield ground wiring of the detector command.

Check that the conforms with the amplifier mode name and motor type name.

Check the set positions of the

switches and setting pins by comparing them with the attached setting pin list (Reference

1.11.

the forward rotation

signal,

or orientation signal is input-

ted the motor is in the free run state where the base

shut-off takes place.

Check

6(411.

forward rotation signal,

(SETl, SET21

set

or more until tht

reverse rotation signal

the motor becomes the

reverse rotation signal

amplifier, and motor and

E'PROM

(SETl,

become

signa

number

-13-

Remedy

D

Replace the broken wire

with a new one.

0

Change the signal sequence.'

D

Correctly connect the

ground wirings (see

Appendix

o

Replace the incorrect

ElPROM

o

Correctly set the switches

and setting pins.

Continued on the next page.

1).

with a correct one.

1

Item 1

Cause

Check

Remedy

The parameters are0 Check the parameters by comparing oCorrectly set the incorrectly set.

7

them with the parameter list

vided by the machine manufacturer

pro-

meters.

(Reference 1.2).

The motor speed cannot DCheck that the phase sequence of . oCorrect the phase sequence.

a

be increased (the alarm No.

23 occurs).

The motor does not correctly rotate only

9

when the orientation

D‘ v,

and motor is correct.

1

Check and readjust the spindle orientation control

referencing Chapter 7.

and W between the amplifier

circuyt

stop takes place (a

runout

occurs).

The alarm disply

10

of the amplifier

)

Check the cause and take the proper remedy by referencing

Section 1.3.3 which describes the contents of alarms.

lights.

An alarm appears on

11

the NC CRT screen.

0

Check the cause and take the proper remedy by referencing

Section 1.1.2 which describes the status display and diagnosis.

The

LED3(red)

amplifier lights.

12

The spindle does not rotate.

13

on the

0

ROM is defective or incorrectly attached.

0

The power supply (SF-PW Module) is defective.

o

No data is transferred from NC in bus linkage state.

o

Check that the spindle parameters

o

Check that the connection constants

slimit

and smax are not 0.

(MCW

and inching) of the

connection parameters are not 0.

para-

by

-14-

1 Troubleshooting

1.2.2 The motor which has normally rotated stops abruptly.

Item

The fuse or Alternatively, the NF

(CBl)

1

The power voltage is out of the range.

2

An input signal from the sequencer is

mal.

3

The input signal from the NC is abnormal.

4

Cause Check

F3)

is blown.

is tripped.

(Fl,

F2, and/

abnor-

Remedy

0

Check the conductivity using

a circuit tester (see

Appendix 5).

0

Check the power voltage using0 Adjust the related control

the circuit tester.

(See Table 1.3)

0

Check each bit of the

external signals 1 and 2 in

the diagnosis mode of the amplifier indicator. received. For example, the bits of ready ON, and reverse rotation signals.

(See Section

0

Check each bit of a control0 Conduct the same

input by referencing Section

1.1.2 which describes the

status display and diagnosis.

0

At the same time, check the

same items as the Item 3 above.

forward rotation,

1.1.1(2).)

0

Replace the fuse

and/or

(See Section 2.1).

0

After replacing the fuse

with a new one or resetting

the NF, tion takes place, see Section 1.2.3.

so that the input power votlage is in the specified range.

0

Check the input signal where

bits are abnormal so that the signal is correctly

measures as the Item 3 above,

F3)

with a new one.

if the same situa-

(Fl,

F2,

counter-

The signal from the

encoder which contains a motor is abnormal.

5

(Note)

The parameter 00 is valid just after 1 is set. Since the parameter 00 is cleared when the power is turned off or the equipment is reset, after setting 1, immediately

input the speed reference and start command.

0

Set the parameter of the

amplifier as follows.

(Note) _

In an open loop state, input the speed reference and

start command to rotate the0 If the above adjustment motor at a slow speed and check the signal from the encoder. (See Section 2.9.) printed circuit board with

I 8 t-1

l-1 ,_I

I I I

:

0

Adjust the related control

by referencing Section 2.9

which describes the

ing procedure of motor built-in encoder so that the output signal is in the specified level.

not be conducted, replace the sensor section and

new ones.

adjust-

-15-

can-

1 Troubleshooting

1.2

Checking method and countermeasures of trouble tion

calssifica-

A

1.2.3

The equipment does not work in occassions. tation stop position deviates. appears,

after turning on and off the power or resetting

the equipment, the equipment normally works.

[tern

An instantaneous power

failure or voltage

1

drop of the input power occurs. (Alarm No.101

The machine is

loaded instantaneously due to affect of rations and so forth. the status display.

2

(Note) This trouble

The equipment malfunc-

tions with a too large

noise.

(Power supply line)

3

Cause

over-

vib-

often occurs when orientation is correctly conducted.

in-

o

Check that an instantaneous

power failure occurred in another facility in the same

plant.

0

Rotate the motor at a slow

speed and check that the motor load changes through

(See Section

o

Check the backlash between

the spindle encoder and

spindle.

o

Check the voltage waveform

of the amplifier input pins Xl, x2,

oscilloscope.

o

While removing suspicious

noise sources one by one,

check the voltage waveform and find the real noise source.

Check

1.1.1

or

and X3 with an

The orien-

Although an alarm

Remedy

0

Check the cause of the

instantaneous power failure and take the proper measures so that the same situation will not occur.

o

Remove the cause of the load

change.

o

Adjust the related control

1.1.2)

so that the backlash becomes

small.

o

Place a serge killer near

the noise source.

(For example, 200 VAC, DCR-2-12003-5041, made by

MATSUO)

counter-

The equipment malfunc-D Check the signal waveforms

tions by noise which

enters a signal from

the motor built-in encoder.

4

at check pins

AGA)

for phase A signal and

CH45-CH9

B signal using an

scope.

(See

9(l).)

(Note) When measuring the

(or

Appendixes

waveforms, turn off the

power of the amplifier before using the check pins.

CH44-CH9 (or

AGA)

for phase

6(l)

OscillO-

and

o

Correctly connect the ground

wires of the power supply,

amplifier, and motor.

(See Appendix

o

Correctly connect the shield

ground wire of the signal line

(CON21

built-in encoder referencing Appendix 1-4.

1.)

to the motor

(PLG)

by

-16-

1.3

Checking method and remedy of trouble classification B

1.3.1 When the power is turned on, tion panel does not appear at all.

the display of the opera-

Item Cause

The AC power is not

1

supplied.

The fuse

F3)

of the control power lamp LED1 on the SF-PW module

is blown.

2

The power

N15A,

the printed circuit outside of the SF-CA card in board SF-CA card is the order of shortcircuited.

3

The power supply inside0 Disconnect the connectors

the printed circuit

board SF-CA card is

4

shortcircuited.

or

(Fl,

F2, and/or 0 Check that the indication

(PSA, PlSA,

P24)

outside

D

Check the input pins Xl, X2,o Supply the power.

and X3 of the amplifier using a circuit tester.

lights.

o

Check the electric continuity

using the circuit tester.

0

Disconnect the connectors

which are connected to the

and so on by referencing Appendixes 1-4 or 1-5, turn on the power again, and then check that the indication

lamp LED1 on the SF-PW module

lights.

which are connected between

the SF-CA card and SF-PW module (CON21 to

on the power again, and check

that the indication lamp

lights.

Check

(See Appendix

CONl,

6(4)

CON3,

CON24),

Remedy

o

Replace the fuse

and/or

.)

turn (See Section

LED1

(See

o

Open the shortcircuited

tion of a circuit outside the SF-CA card.

(See Appendix 1.2).

D

Replace the printed circuit

board SF-CA card with a new

one.

F3)

with a new one.

Section 2.1.)

(Fl,

2.4.4)

F2,

por-

o

The control power SF-PWo Check that 200 VAC power is module is defective.

5

All the dip switches

~~5-1

to

Sw5-4

printed circuit board

6

are not placed in the

OFF position.

-

When the equipment is

not

linked with the NC through the bus, the setting pins PIN1 and attached setting pin list PIN2 on the SF-CA card are not placed as 1.1.1(4).

follows.

7

3

2

1

PIN I PIN

on the

2

supplied to the input nals of the SF-PW module.

0

Disconnect the connectors

(CON21 to the power again, and check that the indication lamp LED1 does not light.

(See Appendix

o

Check the switch position of

switch SW5 by referencing Reference

0

Compare the positions of the

setting pins on the SF-CA card with those on the

by referencing Reference

CON24),

6(4).)

1.1.1(l).

-

17-

termi-

turn on

Replace the control power

with a new one.

(See Section 2.4.1.)

o

Correctly set the dip

switches

(See Appendix

o

Correctly set the setting

pins.

SWS-1

to SWS-4.

6(l))

1.3.2 When the power is turned on, tion panel does not indicate display mode (as shown in the following figure).

the display on the opera-

the speed in the status

Item

When the equipment is

linked with the NC through the bus, the power of the NC is not

1

turned on.

When the equipment is

linked with the NC through the bus, the rotary switch printed circuit board

2

SF-TL card is not placed in the correct position.

When the equipment is

connected with the NC through the bus, the bus cable connectors and

3

CNlB)

circuit board SF-TL card are not correctly connected.

Cause

CSl

on the

on the printed

(CNlA

I,-r-rr-rTl

o

While the display on the

operation panel is as

lows, and check that the display indicates the speed (as shown in the above figure).

Even after the power of the

' EC

play on the operation panel

turn on the NC power

is turned

is as follows.

Ill

o

Check the position of the

rotary switch

TL card by referencing Sec-

tion 3.1.3.

(See Appendix

o

Even after the power of the

NC is turned on, the display on the operation panel is as follows.

D

Check the position of the

rotary switch TL card by referencing Reference

1.1.3.

(See Appendix

Check

--

I-

on,

the

I-

I

III

CSl

6t31.1

I-

CSl

6t31.1

fol-

dis-

on the

i

on the

SF-

Remedy

D

Turn on the power of the

NC.

D

Correctly set the rotary

switch

o

Correctly connect the

nectars CNlA

CSl.

and

con-

CNlB.

When the equipment is linked with the NC through the bus, the connectors on the printed circuit board SF-TL card are nqt

4

correctly connected.

All the positions of the dip switches

SW5-4

on the printed circuit board SF-CA card are not turned

5

off.

CNlA

SW5-1

and

to

o

Even after the power of the

N

C is turned on, the display

on the operation panel is as

CNlB

follows.

D

Check the connections by

referencing Appendixes l-6 to l-9. that a termination resistor is connected to the connector

CNlB.

Even after the power of the

0

NC is turned on, the display

on the operation panel is as follows.

I

I I I

o

Check the positions of the

switch SW5 by referencing Reference

Especially, check

I

1.1.1(l).

-18-

t

1-

II

o

Correctly connect the

nectars CNlA

I

o

Correctly set the positions

of the dip switches

sw5-4.

(See Appendix

Continued on the next

and

6(l).)

CNlB.

SWS-1

con-

to

page

1 Troubleshooting

1.3 Checking method and

remedy of trouble

classification

B

Item

The printed circuit board SF-CA card or SF-TL card is tive.

6

An alarm occurs.

7

The transmission of parameters is required.

8

Cause

defec-

Check Remedy

o

0

Even after the power of the

NC is turned on, the play on the operation panel

is as follows.

0

The above Items 1 to 5 cannot

0

Replace the printed circuit

0

Check that the display on

o

Even after the power of theo Check that the rotary switch

NC is turned on ,the display on the operation panel is as

1 I I I I I

be applied.

boards SF-CA card and/or SF-TL card with new ones and check that the correct display appears.

the operation panel is as follows.

:-::I_:

follows.

czfzlxi-_11

1-

-I

3

dis-

7

Replace the printed circuit

boards with the new ones.

0

Check the cause and take the

proper countermeasures by referencing the description relating to alarm display, Section 1.3.3 (on display of the amplifier) and Section

1.3.4

(On NC CRT).

"CSl"

on the SF-TL card is

placed in thecorrectposition

0

Check that the bus cable

CAM11 is securely connected to the connector SF-TL card.

o

Replace the SF-TL card with

a new one.

CNlA

on the

The equipment waits for

the IT start of the servo amplifier. on the operation panel is as start up.

9

o

Even after the power of theD The amplifier of the servo

NC is turned on, the display

follows.

I-

I I I I

motor does not correctly

Check an alarm of

the servo amplifier.

- 19-

1.3.3

An alarm appears on the display on the

board (SF-CA card) of the amplifier.

1-e

As an example:

,

8-1 ,_ c

, I-

,

3

printed circuit

Alternatively,

an alarm appears on the

NC CRT.

As an example: Spindle alarm 15 32

The contents of the alarm which appears on the spindle

amplifier are the same as those which appear on the NC

CRT.

The contents of alarms are listed in the following table.

The details of each alarm are described in the following.

(Note) If the alarm No.12

(MEl)

memory error 1 occurs, it should be reset by turning off the power of the spindle amplifier.

On the other hand, other alarm Nos. should be

reset by turning off the NC power.

-

20

-

1 Troubleshooting

1.3 Checking method and

remedy of trouble classification B

Alarm No.

10

12

13

15

17

20

21

Abbr.

UV

ME1

ME2

BE

NSl

NSZ'

,

UNDER VOLTAGE

MEMORY ERROR 1

EXTERNAL CLOCK ERROR

MEMORY ERROR 2

P.C.B

IC MAC007 ERROR

NO SIGNAL 2

(SPINDLE

Name

ERROR

ENS)

Description

The input power voltage drops to a value less

than the specification assured value or an instantaneous power failure occurs for 15 ms or more.

The internal memory for controlling the ler is not correclty read and written.

(It is checked when the power of the controller

is turned on.)

The system clock which is sent from the NC is defective.

The 2-port memory for communication which is

used for linkage with the M300 series CNC through the bus does not correctly work.

Any part on the controlling printed circuit board does not correctly work.

The part ICMACOO7 on the controlling printed cir-

cuit

board does not correctly work.

A signal is not input from the orientation

coder or the signal is not in the correct level.

control-

en-

Motion

(Note)

A

22

23

24

25

26

NSS IC MAC012 ERROR

OSE

BRT

cot

PL

SPEED CONTROL ERROR

EXCESS

B,,,L-,,&

CONVERTER CURRENT flows in the converter.

POWER PHASE LACK

OVER-

j-a +%$I

4 / ; .,,4 .y

27

-

31

32

33

CPUE

OS

oc

ov

CPU ERROR

(DIVISION ERROR)

OVERSPEED

INVERTER OVERCURRENT

OVER VOLTAGE

'

The part IC MAC012 on the controlling printed

circuit board does not correctly works.

The difference between the referenced speed and motor speed is 50 rpm or more and it takes for

12

set

or more.

fli@-

current which exceeds the specific value flows

in the main circuit.

An overcurrent which exceeds the

One or more of 3 phases is missed in 3-phase

power.

,‘.,_

-< .’ ‘ c- (’

A division error occurs in CPU operation

cause of incorrect parameters being set.

The motor speed exceeds 115% of the maximum speed

An overcurrent which exceeds the specific value

flows in the controller.

The voltage of the main circuit condenser exceeds

the specific value because of regenerative energy

in motor deceleration state.

I.

>i/ ‘I

/,

,, I

;

specifc

Continued on the next page.

value

be-

A

-

21 -

Alarm

uo.

34

35

Abbr.

DP

DE

Name

DATA PARITY

DATA ERROR

Description

Parity error occurs in bus linkage with the M300 series CNC.

In bus linkage with the M300 series CNC, the shift command which exceeds the specific value is issued from the CNC.

Pl"CJ."ll

(Note)

A

36

46

52

57

Motion A - The base shut-off occurs in the controller, the main circuit

TE

PE

OPE

TRANSFER ERROR

PARAMETER ERROR

OPTION CARD ERROR

turned off,

trouble signal contacts FA-FC are open.

and the motor stops in the free-run state.

In the bus linkage with the M300 series CNC, data is not correctly transferred.

A parameter value which exceeds the allowable

range is set. the controller is turned on.)

The ambient temperature is abnormal or the main

circuit devices are overheated because an load is applied or the air cooling fan stops.

The motor is overheated because an overload

is applied or the motor cooling blower stops.

lowing error exceeds the

In the bus linkage with the M300 series CNC, any fault occurs in an other servo axis.

Any function which is not provided with the option card is selected.

(It is set when the power of

sbecific

value.

COntaCtor

In additon, the

over-

is

A

(Note)

For the main circuit contactor

For the trouble signal contacts FA and FC :

: See Appendixes l-4 and l-5

- 22 -

(contact

See Appendixes l-4 and 1-5

(CON1 pins 11 and

MC11

12)

(1)

Alarm

No.lO(UV)

Under Voltage

[The voltage drop of the input voltage

(3-phase,

ZOO/220 V)

to the amplifier

is detected. (Voltage between phase

Xland

phase

X,)1

_

Item

Cause Check

The AC input votlage of the amplifier drops to a voltage which is less than 170 V.

An instantaneous power

failure which lasts for 15

msec

(the input votlage to a value which is than 170 V for 15

or more occurs

drop2

less

msec

or more).

The power capacity is

insufficient.

The control power

(SF-PW module) is defec-

tive.

0

Check the voltage at the

;plifier

input terminals Xl,

and X3 using a circuit

teiter.

0

Check the voltage waveforms at the amplifier input terminals Xl, X2, and X3 using an oscilloscope.

0

Check the voltage waveforms

at the amplifier input terminals Xl, X2, and X3 using an oscilloscope.

0

Check that the input voltage

drops while the spindle motor is in the acceleration/ deceleration state or while an overload is applied.

0

Check that the voltage bet-

ween ACDOW and DO24 of the block A in the SF-PW module is + 5V.

(See Appendix

6(4).)

Remedy

0

Check the cause of which the

input voltage drops and take

proper countermeasures.

0

Check the cause of the

instantaneous power failure and take porper counter-

measures.

o

Increase the power capacity.

o

Replace the SF-PW module

with a new one.

(2) Alarm

No.l20l!Zll

Memory Error 1

[The integrify of the contents Of

RO

M are compared with those of RAM

during initialization.]

Item Cause

Check

I

EPROM is not installed

in the correct position.

0

Visually check that ROM's 1,

2, and 3 are installed at

correct positions on SF-CA card.

1

(See Appendix

I

0

There is an imperfect

connection between pins

of EPROM and the socket.

Visually check that pins of

ROM's 1, 2, and 3 are not

bent and they are correctly

inserted into the sockets.

The printed circuit board SF-CA card is

0

Replace the SF-CA card with

a new one and check that the

defective. new one correctly works.

- 23 -

6(l).)

-II-II-II

Remedy

o

Install each ROM in the cor-

rect position.

e

thl

D

Straighten the pins being

bent and securely insert

them into the socket.

o

Replace the SF-CA card with

the new one.

(See Section 2.4.4).

(3) Alarm No.15

(ME2)

Memory Error 2

[The integrity of the contents of

the 2-port RAM which communicates

with the NC during initialization

is checked.1

Item

The connector which is linked with the

NC through the bus is not securely connected.

Cause Check Remedy

D

(CNlA)

Check the looseness of the

connector.

o

Check that the set screws of

the connector are not loosen.

(See Appendixes l-6 to l-9

and

2-3.)

The cable

is connected with the NC

(CAM11)

which0 Replace the cable with a new

one and check that the equip-

through the bus is ment correctly works.

defective.

(See Appendix

The ground wires of theo Visually check that the

amplifier, and motor

NC,

are not correctly con- connected by referencing nected.

The signal cable is not

correclty shielded.

ground wires are correctly

Appendix 1.

0

Visually check that the

signal cable is correctly shielded by referencing

Appendix 1.

o

The printed circuit

board SF-TL card is defective_

The NC side printed

circuit board

MC632 is defective.

6

~~611

or

Replace the SF-TL card with

a new one and check that the

equipment correctly works.

(See Appendix

o

Replace the MC611 or MC632

cards with new ones and check that the equipment correctly

work.

(See

"M300

Series Maintenance

Manual".)

L

3(2).)

6(3)1

D

Securely connect the connec-

tor and tighten the screws.

o

Replace the cable with the

new one.

o

Correclty connect the

ground wires.

o

Correctly shield the signal

cable.

o

Replace the SF-TL card with

a new one.

(See Section 2.4.3.)

D

Replace the MC611 or UC632

cards with the new ones.

MC632: M310 MC611: All other

- 24 -

(4) Alarm

[Whether a component (especially A/D converter) on the printed circuit board is normal or abnormal

is checked.

No.l7(BE) P.C.B

1

error

Item

A component (especially,

A/D

1

2

(5) Alarm

Item

converter) on the printed circuit board SF-CA card is defective. works.

The power of the

ment is turned on while

the NF in the unit is turned off.

[The internal codes of the IC MAC007

on the SF-CA card are checked.]

Cause Check Remedy

equip-

No.20(NSl)

IC MAC007 Error

Cause Check

D

Replace the SF-CA card with

the new one and check that

the equipment correctly

D

Check that the NF is turned

off.

o

Replace the SF-CA card with

the new one.

(See Section 2.4.4.)

o

Turn on the NF.

o

To check only the control

circuit without appearance of alarm No.17, set the parameter X58 CVHS to However,

the normal operation mode,

make sure to set the

CVHS to the ing regeneration) on the SF-CA card continuously lights.

to return back to

"0".

LED1

(which lights dur-

Otherwise,

Remedy

"1".

158

The IC (MAC printed circuit board

1

SF-CA card does not correctly work.

007)

on the

o

D

Replace the SF-CA card with a

new one and check that the board SF-CA card with the equipment correctly works. new one.

Replace the printed circuit

(See Section

2.4.4.)

- 25 -

1 Troubleshooting

1.3

Checking method and

remedy of trouble

r

classification B

(6) Alarm

[The signals of

Item Cause Check

1

2

NO.~~(NS~)

spindle orientation encoder are checked

during orientation and synchronous tapping

state.1

The cable the spindle orientation encoder is defective. oscilloscope. (See Appendix 3

The encoder for the

spindle orientation is same manner as Item 1 above. new one.

defective.

NO Signal 2 (Spindle

phases

(MR-ZOLF)

A, B, and C of the

toD Observe the signal waveform

from the encoder using an

o

Check the check pins on the

printed circuit board SF-TL card.

.

Between

.

Between CH2 and DGA, for

.

Between CH3 and DGA, for

(See Appendixes

o

Replace the cable with a new

one and check that the equipment correctly works.

(See Appendix 1 - 7.)

o

Check the wave form in the

o

Replace the encoder with a

new one and check that the

equipment correctly works.

(See Appendix 7.)

phase A phase B phase

9(3).)

ENC)

CHl

and DGA, for

2

6(3)

and

Remedy

o

Replace the cable to the

encoder with the new one.

(2j.l

*

D

Replace the encoder with the

The printed circuit board SF-TL card is from the encoder at CONB defective.

3

The 5V power is not

supplied from the NC NC side. side to the encoder.

4

o

Observe the signal waveform

on the SF-TL card using the oscilloscope and check that

it is normal.

(See Appendix 1 -

o

Check the 5V power on the

o

Replace the cable with a new

one and check that the ment correctly works.

7.1

equip-

o

Replace the printed circuit

board SF-TL card with a

new one.

(See Section

o

Repair the power supply on

the NC side. Refer to M300 series Maintenance

o

Replace the cable with a new

one.

o

If the 5 V power is not

plied from the NC side

(namely, connected with the NC), shortcircuit the pin 5 on the SF-TL card to pins 2 and 3 (no power supply form the

NC).

2.4.3.)

manual

sup-

when CONAA is not

- 26 -

(Note) The correct output waveform of the encoder is as follows:

@

When the spindle of the machine rotates counterclockwise at approx. 500 rpm

while the bit 8 of the parameter

Phase A

ORSZ

is 0:

Phase

@

When the spindle of the machine rotates clockwise at approx. 500 rpm and when

the bit 8 of the parameter OSR2 is 0,

occurs.

(7) Alarm

[The internal codes of the IC MAC012

Item Cause Check Remedy

1

No.22(NSS)

are checked. 1

The IC (MAC 012) and the related circuits on the printed circuit board SF-CA card do not correctly work.

B

2

___.

IC MAC012 Error

I

o

Replace the SF-CA card with ao Replace the printed circuit

new one and check that the board SF-CA card with the equipment correctly works.

(See Appendix

the same waveform as the above figure

new one.

6(l))

(See Section 2.4.4.)

- 27 -

>‘I / c

4

,P+

(13) Alarm

[The difference between the speed reference

4

No.23(OSE)

value and real speed is checked and if the deviation which is 50 rpm or more lasts

for 12 sec. or more, an alarm occurs.1

c

Speed Control Error Excess

/)

0

ir

Item

The phase sequence of wires U, V, are connected between

the amplifier and the

motor is incorrect.

One of the wires U, V, and W which are

netted

amplifier and the motor

is broken.

The motor is overloaded.

The printed circuit board SF-CA card is defective.

The integration gain parameter VKI (amplifier parameter X37; NC

meter:

loop is set to 0.

Cause

and W which

between the

#23)

of the speed

con-

para-

Check

o

Increase the reference speedD Correctly connect the wires

and check that the motor rotates at a low speed.

o

Visually check the phase

sequence of wires U. V, and W.

o

Check that the motor does not

smoothly rotate.

o

Remove the wires U, V, and W

on the amplifier side and check that there is no electric discontinuity in the wires U, V, and W.

o

Check whether the motor iso Review the cutting condition

overloaded using a load meter or load display in the status display mode.

(See Section 1.1.1)

D

Replace the SF-CA card with ao Replace the printed circuit

new one and check that the board SF-CA card with the equipment correctly works.

D

Check the parameters beingo Set the parameters to the

set by referencing Section

1.1.1

or 1.1.2.

U, V,

amplifier and the motor.

0

Replace the power wire which is broken with a

and tool being used.

new one.

(See Chapter 2.)

standard values by refer-

encing Reference 1.2.2 or

1.2.3.

0

If the motor unstably

rotates,

to correct values by refer-

encing Alarm No. 31 Item 2.

Remedy

and W between the

new one.

set the parameters

The volume on the printed circuit board

for the motor built-in encoder (in the motor terminal box) is not correctly adjusted.

o

Check that the motor rotates

at several speed display is

o

Set the parameters of the

amplifier as follows and put the speed reference and start command to rotate the motor at a low speed. parameter 00 becomes valid just after it is set to Since the parameter is cleared when the power is turned off or reset, after it is set to speed reference and start command.

ten

rpm and the

"0".

"l",

input the

in-

The

"ll..

- 28 -

0

Adjust the volume

and VR4 so that the

VR3, output waveforms of phases A and B are in the

ard value range by referencing the section ing to adjustment and replacement of motor built-in encoder (Section

6.9).

Continued on the next page.

VRl, VR2.

standrelat-

1 Troubleshooting

1.3

Checking method and remedy of trouble

classification 0

Item

The printed circuit

board in the motor built-in encoder speed display indicates

(motor terminal box) is

defective.

7

Cause

Check Remedy

o

Check the signal waveform at

the check pins on the printed circuit board SF-CA card using an oscilloscope.

Phase A signal: Phase B signal:

(See Appendixes

9(l).)

(Note) Before using the check

pins,

amplifier should have been turned off.

0

Check that the motor rotates

at several ten rpm and the

o

Like the same manner as the

Item 6 above, in the open loop state, rotate the motor at a low speed.

0

Like the same manner as the

Item 6,

waveform of the check pins on

the SF-CA card using an oscilloscope.

0

By referencing the descrip-

tion relating to adjustment and replacement of the motor built-in encoder described in Section 2.9, observe the

waveforms between PA and PGA

and between PB and PGA using an oscilloscope and check that they can be in the standard value range using

volume resistors VR3 and

the power of the

check the signal

VR4).

CH44-CH9

(or AGA)

CH45-CH9

(or AGA)

6(l)

and

(VRl, VR2,

"0".

0

Replace the printed circuit

board in the motor terminal box and adjust the controls

by referencing Section 2.9.

The sensor in the motoro Check that the output built-in encoder is forms between PA and PGA and defective.

a

(9)

(10)

Alarm

No.24tBRT)

No_25(COC)

Breaker Trip

Converter Overcurrent

between PB and PGA on the encoder printed circuit board cannot be adjusted in the standard value range even after the printed circuit board has been replaced in the manner described in the

Item 7 above.

- 29 -

wave-

o

Replace the entire motor

with a new one.

o

If the motor cannot be

replaced, replace it together with the sensor and printed circuit board by referencing Section

2.9.

(111

Alarm

No.32(OC)

Inverter Overcurrent

Item Cause

The input power voltage waveform is defective.

1

Check

o

Observe the voltage waveforms

at the input terminals Xl, X2, and X3 of the amplifier using an oscilloscope.

0

Check that the voltage wave-

forms are as follows even in the acceleration or

tion state.

(al

If the waveform is

tially lost:

It should be

If the peak value drops:

(bl

t.-

100 us or less.

<-.

decelera-

par-

-L

It should be 2 to 3% or less.

Remedy

Increase the power capacity.

0 0

Thicken the size of the

cable between the input power supply and amplifier.

0

Check other semiconductor

devices which generate

distorted waveforms and install surge killers and so force.

(For example, MATSUO made,

rating 200 VAC, 12003-5041, etc.)

DCRZ-

The input power

ante

is high.

(Example,

that two transformers

2

are connected in series or a variable transformer is con-

netted)

The input power quency remarkably

3

changes.

The motor selection parameters

4

are not correctly set.

The transistor module

is defective.

5

in the cases

#Ol

imped-

auto-

fre-

and

102

0

o

Check that the alarm occurs

only when the motor speed decelerates from a high

speed.

0

Check that the input voltage

temporarily drops to 170 V power supply and amplifier.

or less when the motor

decelerates.

0

Check the voltage frequencies

at the input terminals Xl,

and X3 of the amplifier

x2,

using a frequency counter.

o

Check that the parameters are0 Correctly set the

correctly set by referencing

Reference 1.2.2.

0

Check that this alarm occurs

even after the equipment is unit of the amplifier with

reset.

0

Disconnect the cable between

the amplifier and motor and check that this alarm occurs when only the amplifier is operated.

(See Appendix l-2.1

-

30

-

Replace the power supply

with an other one whose

power impedance is low.

0

Tighten the screws of

nections

0

Check the cause of the fre-

quency

the related controls so

that it is in the specification range.

meters.

(See Reference

0

Replace the main circuit

a new one.

between the input

variation and

1.2.3.)

Continued on the next page.

con-

adlust

para-

1 Troubleshooting

1.3 Checking method and remedy of trouble

classification B

Cause

The diode stack is defective.

The surge absorbers and

condensers are defective.

The current detection circuit is defective.

8

The motor is overloaded.

9

Check

o

Check the diode stack in the

same manner as the Item 5

above.

o

Check them in the same manner

as the Item 5 above.

0

Observe the waveforms at the

following check pins using an oscilloscope and check that the peak value exceeds 10 V.

Between CH39 and AGA:

Regenerative converter

side

Between CH42 and AGA:

Converter side

Between CH43 and AGA:

Inverter side

(See Appendix

0

Check that the motor is over-

loaded using a load meter or the load display in the status display

Section

1.1.1).

9(l).)

mode (see

Remedy

0

Replace the main circuit

unit of the amplifier with a new one.

(Note)

See Section 2.6 and

2.7.

0

Replace the main circuit

unit of the amplifier with a new one.

0

Replace the printed circuit

board SF-CA card with a new one.

(See Section 2.4.4.)

(Note) Normally, the peak

voltage is in the range

from 6 to 7 V while the

motor accelerates or

decelerates.

D

Review the cutting condition

and tool being used.

The cable connections between the amplifier and motor are incorrect.

10

The wiring of the motor

is rare-shortcircuited or earth-grounded.

11

3

Visually check the cable con-

nections.

0

Check that the screws of the

cable connection terminal are loosen.

Disconnect the cables between the amplifier and motor and check the insulation resistance between the following leads.

Between U and W; between V and W; between U and W; between each of U, V, and W and E

3

Correctly connect the

cables.

s

Tighten the screws being

loosen.

)

Replace the motor with a

new one.

-

31

-

1 Troubleshooting

1.3 Checking method and remedy of trouble

classification

B

(12) Alarm

Item

1

2

(13) Alarm

Item

1

No.26(PL)

[When R and T of phases R, S, and T are

normal, checked.]

One of phases R, S, and T is lacked when the power is turned on.

One of the fuses

and F3 has been blown

when the power is turned

on.

No.27(CPUE)

[This alarm occurs when an CPU operation where

a value is divided by 0 is executed or the result of division is overflowed.)

The parameter relating

to gear ratio is

correctly set.

Power Phase Lack

whether there is phase S is

Cause

D

Check the voltage between any

two phases of R, S, and T at the input power terminals

and X3 using a circuit

X2, tester.

o

Check the electric continuity

of each fuse using the

cuit

tester.

D

Check the parameter by

encing

Reference 1.2.2 for that which is set from the amplifier and Reference 1.2.3 for that which is set from the NC.

Cause

Fl,

F2,

CPU Error (Division error)

in-

Check

Sl,

cir-

refer-

Remedy

o

Check the cause of the phase

lack and take proper

countermeasures.

Replace the fuse being blown

0

with a new one.

(See Section 2.1.)

Remedy

o

Correctly set the parameter.

(Note) Compare the parameter

in the parameter list on the cover of the amplifier with that being set.

(See Appendix 10)

The connector which is linked with the

2

NC through the bus is

loose.

The cable

is linked with the NC

3

through the bus is

defective.

The following parameterso Check the parameters by

relating to the gain of the speed loop are

4

correct.

When a special motor iso Compare the

used (when

5

are set), the motor constants

incorrect.

(CNlA)

(CAMll)

VKP,VKI,ORSl.

181

whichD Check the cable in the same

in-

X01

and 02

to

XAF

are

o

Check the cable in the same

manner as the alarm No. 15

(k=2).

manner as the alarm No. 15

(-2).

referencing Reference 1.2.3.

the parameter list on the amplifier cover with those being set.

(See Appendix 10.)

parameters.in

- 32 -

o

Securely connect the

tor and the set screws.

o

Replace the cable with a new

one.

o

Correctly set the parameters.

(Note) Compare the parameters

in the parameter list on the amplifier cover with those being set.

(See Appendix 10.)

D

Correctly set the parameters

connec-

1 Troubleshooting

I

1.3 Checking method and remedy of trouble

classification

B

I

(14) Alarm

(The real speed of the motor is checked

Item Cause Check

1

No.31(0S)

and when it exceeds 115% of the motor

maximum speed,

The reference speed exceeds 115% of the maximum speed. speed being set.

The speed control system oObserve and check the signal

is unstable and an shoot occurs.

Overspeed

this alarm occurs.)

o

Compare the reference speed

with the following maximum

Parameter being set from the amplifier:

Parameter being set from the NC: #17(TSP)

(See References

and

over-

between the speed signal terminals SMO and OM using an oscilloscope (See dixes l-4 and l-5).

1.2.3(3).)

#31(TSP)

l-2.2(2)

Appen-

-~-

0

Decrease the reference

speed.

o

Correctly set the parameter

for motor maximum speed.

0

Decrease the parameter

values of the speed loop gain VKP and VKI (amplifier parameter parameters

(Note) To check the occurrence

Remedy

Y36

and

#22

and X23).

--

#37

or NC

The motor built-in coder is defective.

3

The printed circuit board SF-CA card is

4

defective.

en-

o

If the signal output is

saturated when it exceeds 10 V because a too high speed is set, age rises to around 115% in the speed mode of the status display (see Section or using the NC CRT monitor.

D

In the same manner as the

alarm encoder output signal

form using the oscilloscope.

o

Rotate the motor using the

reference speed which is

slower than and check that the frequencies of the signals of the

phase

following relation.

f(Bs) = +

o

Replace the SF-CA card with

a new one and check that it correctly

check that the

1.1.1)

No_23(OSE),

A or B satisfy the

works.

check the

the

middle speed

x

(motor

speed(rpm)

wave-

volt-

(b) If the alarm does not

occur, decrease the parameter values of VKP and VKI.

o

In the same manner as the

alarm

replace the motor built-in

encoder with a new one.

No.23(OSE),

adjust or

1

o

Replace the printed circuit

board with a new one.

(See

Section 2.4.4.)

!

-

33

-

(15) Alarm

No.33(OV)

OVerVOltage

[The voltage in the converter circuit is

checked and if it exceeds 400 V, this alarm occurs.)

Item

The input power voltage

Cause Check

0

In the same manner as the

waveform is abnormal.

1

0

The input power

ante

is high. alarm

imped-

In the same manner as the

2

o

An instantaneous power

In the same manner as the

failure occurs in the

input voltage or the input power.

3

voltage drops when the motor decelerates.

alarm No.24, No.25, and

No.32, check the waveform.

check the input power.

alarm

No.24/NoW25/No.32,

No.lO(LJV),

check the

Remedy

0

See the alarm

No.24/No.25/

No.32.

0

Increase the power capacity.

0

Thicken the size of the

cable between the input power supply and the ampli-

fier.

0

Improve other components

which generate distorted waves by installing surge killers and so forth.

0

See the alarm

No.24/No.25/

No.32.

0

Replase the power supply

with that whose impedance

is low.

o

Tighten the screws of the

cable connections between

the input power and amplifier.

o

See the alarm

o

Check the cause of the

No.lO(UV).

instantaneous power failure

or voltage drop and improve

the power condition.

The printed circuit board SF-CA card is

4

defective.

0

Replace the SF-CA card witho Replace the printed circuit

a new one and check that the board SF-CA card with a equipment correctly works.

The main circuit unit0 Check the regenerative

is defective.

5

transistor module by

encing

Section 2.5.

- 34 -

refer-

new one.

(See Section 2.4.4.)

o

Replace the amplifier main

circuit unit with a new one.

(Note) See Section 2.7.

(16)

Alarm

No.13() External Clock Error

[This alarm occurs when the system clock

which is sent from the NC is defective.]

(17)

Alarm

No.34(DPl

Data Parity

[The parity of the data

whick

is trans-

mitted from the NC is checked.]

(18)

Alarm

No.35(DE)

Data Error

[This alarm occurs when the position refer-

ence of the synchronous tap which is transmitted from the NC is too large.]

(19)

Alarm

No.36(TE)

Transfer Error

[This alarm occurs when data from the NC

is not completed.]

Item Cause

The connector which is linked with the

1

NC through the bus is

(CNlA)

0

In the same manner as the

alarm connector.

Check

No.l5(ME2),

loosed.

The cable

is linked with the NC

2

through the bus is

(CAM111

which

o

In the same manner as the

alarm

No.lS(ME21,

connector.

defective.

The NC,

3

motor are not correctly alarm

amplifier, and

o

In the same manner as the

No.l5(ME2),

grounded. grounding.

The signal cable is not correctly shielded.

4

o

In the same manner as the

alarm

No.lS(ME21,

shielding of the signal cable.

The termination resistor o Check that the termination

of the bus connection is abnormal.

resistor is correctly installed.

(See Appendixes 1-6 to l-9.)

5

0

Replace the termination

resistor with a new one and check that the equipment correctly works.

check the

Remedy

0

Tighten the connector and

mounting screws.

o

Replace the cable with a

new one.

a

Correctly ground them.

o

Correctly sheild the signal

cable.

D

Replace the termination

resistor.

(See Appendix

3t21.1

The bus interface

cuit

6

of the printed

cuit

board SF-TL card is

defective.

cir-

o

Replace the SF-TL card with a 0Replace the printed circuit

new one and check that the board SF-TL card with a equipment correctly works. new one.

(See Section 2.4.3.)

on

- 35 -

Item

The bus interface

cuit cuit

card on the NC side is defective.

A travel command which

exceeds the specification value is issued

from the program.

8

(20)

Alarm

(This alarm occurs when a parameter which

exceeds the allowable range is set.1

Cause

of the printed board M?611/MC632

No.37(PE)

cir-

Parameter Error

o

Replace the

with a new one and check that

the equipment correctly works

o

Check that the spindle speed

reference exceeds

6192

(Parameter

GRA

Check

MC6ll/MC632

xlOr

GRA

= number of gear teeth

(rpm)

on spindle side)

card

.

Remedy

0

Replace the

card with a new one.

I

o

Correct the program.

MC611/MC632

I

Item

1

Cause Check

1

A parameter which exceeds the allowable range is set.

I I

o

Check that the parameter be-

ing set accords with that in the parameter list by refer-

encing Reference 1.2.2 for

the parameter being set from the amplifier and Reference

1.2.3 for that the NC.

beinu

set from

Remedy

o

Correctly set the parameter

value.

-

36

-

“.4

P

(21)

Alarm

No.45(OHF)

[This alarm occurs when the thermal protect

which is installed in the controller exceeds

the temperature being set.]

(Ambient temperature:

Fin temperature

Controller Overheat

:

6O='C

1OO~C'

-L

IL:

0

Item Cause

The fan which cools the

fin is defective. rotates.

1

The ambient temperature of the amplifier is high.

2

The equipment is

loaded.

3

The thermal protector

(THSZ)

which is

led on the fin is defective. Alternatively, the thermal which detects the ambient temperature of

4

the amplifier is defec-

tive.

THSl

ture = 60°C

(Ambient temperature)

THS2

ture =

(Fin temperature)

protector(THS1)

setting tempera-

100°C

Check

o

Check that the fan normally0 Replace the cooling fan with

D

Measure the ambient

ature of the amplifier in the high voltage panel.

over-o Check the load condition

instal-

ing a load meter or the load display (see Section in the status display mode.

o

Check that

frequently started and

stopped.

o

Check that electricity

does not flow between the ends of the thermal protector by referencing Appendix

"Main circuit block

4,

gramn

"Spindle amplifier component layout".

(Note) Separately check

the

and Appendix 5,

and

THSZ.

temper-

.

1.1.1)

equipment is

THSl

us-

dia-

Remedy

a new one.

(See Section 2.3.)

o

Unless the cooling unit in

the high voltage panel

rectly

works, replace it

with a new one.

o

If the ambient temperature

exceeds the cooling power.

D

Review the cutting condition

and tool.

o

Decrease the frequency of

start and stop operations.

o

Replace the thermal protec-

tor

(See Section 2.2.)

THSl

55'C,

strengthen

or

THSZ.

cor-

The alarm detection

cuit

5

6

in the printed

cuit

board SF-CA card is

defective.

The cooling fan is dirty

by dust and the cooling

effect is degraded.

o

Replace the SF-CA card with

circir-

a new one and check that the equipment correctly

works.

visually or by touching the

0

cooling fan, check the degree of dirt.

- 37 -

o

Replace the printed circuit

board SF-CA card with a

new one.

(See Section

o

Clean the cooling fan using

a factory utility air or vacuum cleaner.

2.4.4.)

1

I

1.3

Checking method and remedy of trouble

classification

B

(22) Alarm

[This

Item

1

No_46(OHM)

alarm

tor which is installed in the motor exceeds the temperature being set

The motor cooling fan

defective.

The motor cooling systen

is dirty.

Check that the air in-

take portion of the

motor cooling fan is

clogged with foreign

matter or machine com-

ponents.

The motor is overloaded.

occurs when the thermal protec-

Cause

Motor Overheat

(145"Cl.l

o

Visually check that the fan

is

motor normally rotates.

0

Visually or by touching the

cooling system, check the degree of dirt.

o

Visually check the position

of the foreign matter or components.

0

Check the load of the motor

using a load meter or the load display in the status display mode

1.1.1).

0

Check that the motor is fre-

quently started and stopped.

Check

(see Section

Remedy

3

Replace the motor cooling

fan with a new one.

(See Section 2.8.)

D

Clean the cooling system

using the factory utility air or vacuum cleaner.

D

Remove the foreign matter.

D

Change the position of the

machine components.

D

Review the cutting condition

and tool.

D Decreas

start and stop operations.

the frequency of the

The motor built-in thermal protector is defective.

The following cable connections are defective.

Motor Amplifier

side

OHS1 -

OHS2 - CON2 pin 2

side

CON2 pin 3

I

o

After stopping the motor and

turning the cooling fan to fully cool the motor, check that the motor leads OHS2 is shortcircuited.

(When they are shortcircuited

the thermal protector is normal.)

o

Check the wire breakage or

connector imperfect contact using a circuit tester.

OHS1

and

D

Shortcircuit

of CON2 on the amplifier side as a temporary repair and continue the operation.

(See Appendixes l-4 and

D

At a convenient time, re-

place the motor with a new one.

D

Replace the signal cable

with a new one.

D

Repair the connector's

imperfect contact or replace the connector with a new one.

OHS1

and OHS2

l-5)

- 38 -

(23) Alarm

[This alarm occurs when the position error

N0.52(0D)

becomes too large in synchronous tapping mode

(for 8 rotations against the reference value.)]

Over

Droop

Item

The parameter which is set from the

1

amplifier is not rectly set.

The bits 8 and E of the

parameter ORS2

2

amplifier; NC) are not correctly

set.

The orientation encoder

is defective.

3

The reference time

constant is small.

4

Cause

#16(~~)

#03 (PLG)

cor-

(#30

for

Check Remedy

D

Check the parameter being set

by referencing Reference

1.2.2(2).

D

Check the parameter being set

by referencing Reference

1.2.2 (2) and

0

In the same manner as the

alarm signal waveform from the encoder.

0

Measure the acceleration time o

using a stop watch or observe acceleration time constant the speed signal terminals parameter CSN (amplifier SMO and OM using an scope and check that the acceleration time is shorter than the reference constant time.

No.21(NS2),

(See Appendixes 1-4 and l-5.)

1.2.3(3).

check the

oscillo-

o

Correctly set the parameter value.

o

Correctly set the parameter values.

0

Replace the encoder with a

new one.

Increas

parameter meter

the value of the

#33

#19(PR)).

or NC

para-

(24)

Alarm

Item

1

2

3

4

No,56(OA)

The servo axis alarm

occurs.

The cable CAM11 whicho Replace the cable CAM11 and

is linked with the NC through the bus is rectly works. defective.

The connectors

CNlB)

on the printed circuit board SF-TL card are not correctly

netted.

The termination resistor

is defective.

Other Axis Fault

Cause

(CNlA

and

con-

Check

o

Check that the servo axis

alarm occurs.

check that the equipment

(See Appendix

o

Visually check the following

connections.

CNlA -

CAM11 cable

CNlB -

termination resistor

0

Check that the connector

screws are loosen.

o

Replace the termination

resistor which is connected to the connector check that the equipment correctly works.

(See Appendix

3(2).)

CNlB

and

Remedy

o

Remove the cause of the

servo axis alarm.

0

Replace the cable CAM11 with

cor-

the new one.

o

Correctly connect the CAM11

cable and termination

tor in place.

0

Tighten the connector screws

0

Replace the termination

resistor with a new one.

resis-

39 -

(25) Alarm

Item

1

No.57(OPE)

The option card does

not conform with the specification.

Option Card Error

Cause Check

D

Check that the order list

conforms with the option card name.

----~-

Remedy

D

Check the specification.

.

- 40 -

1 Troubleshooting

1.3.4

Item

Trouble analysis

1

The control signal cable o Check that the cables are

or power cable is

2

correctly connected or is broken.

The input power voltageo Measure the voltages at theD Improve the power condition

is abnormal.

3

The control power supplyD Measure all the DC output

(SF-PW module) is

4

tive.

The motor does not rotate.

Cause Check

0

in-

defec-

When a rotation command iso Review the cause and take a

issued, on the display on the spindle amplifier printed circuit board (SF-CA card).

D

When no alarm occurs:

correctly connected and they are not broken.

input terminals Xl, X2, and so that the input power X3 of the amplifier using a voltage is in the allowable circuit tester.

(See Table 1.3.)

voltages of the SF-PW module using a circuit tester.

(See Appendix

an alarm is indicated

6(4).)

Remedy

proper action by referencing Section 1.3.3.

0

Go to the Item 2 or later.

0

Correctly connect them.

D

Replace the broken cable

with a new one.

range.

o

Replace the control power

supply (SF-PW module) with

a new one.

(See Section 2.4.1.)

o

The printed circuit board SF-CA card is as follows, defective.

5

The external emergency

stop signal or reset signal is input.

6

(Note)

The parameter 00 becomes valid just after it is set to 1. Since the parameter is cleared when the power is turned off or the equipment is reset, just after 1 is set,

input the speed reference and start

Set the amplifier parameterer

o

Check that the bit 2

input a reference

amnrrnn

speed in the open loop state to cause the motor to rotate, and check that a reference sine wave occurs on the

oscilloscope.

l%z;:%AGA

CH14 - AGA

(See Appen-)

dix 9(l).

(emergency stop) of the external signal is turned on or the portion between CON1 pins No.47 and No.48 (emergency stop) or portion between pins No.19 and No.20

(alarm reset) is turned on.

U-L

e

coannand.

(Note)

o

Replace the printed circuit

board SF-CA card with a new one.

(See Section 2.4.4.)

0

Correctly connect the

nal signal cable.

exter-

-41-

Cause

The

PIN1

printed circuit board SF-CA card are incorrectly set.

and PIN2 of the

Check

o

Check that the control power

(SF-PW module) is normal and the amplifier display (LED) does not indicate any mes-

sage.

o

Check how the

are set.

(See Reference

PIN1

and PIN2

1.1.1(4).)

Remedy

o

Correctly set the

PIN2 on the SF-CA card.

PIN1

I

and

- 42 -

1.3.5 The motor does not rotate at a speed being specified.

Item

1

2

3

4

5

Cause Check

The phase sequence ofo the wires U, V, and W of the motor are not matched with that of the amplifier.

The output voltage ofo Measure the voltage between the amplifier is balance.

The three phases of theD Measure the voltage between input power voltage are unbalance. fier input terminals Xl, X2

The external speed reference is incorrect. speed reference and check

The motor built-in coder is defective.

un-

en-

Increas

speed reference and check that the motor rotates only at a low speed.

any two points of the wires U, V, and W of the amplifier using a circuit tester.

any two points of the and X3 using a circuit tester. tion.

o

Increase the value of the

that the motor speed portionally increase.

SF-CA card)

o

Check the signal waveform by

referencing the alarm No.23

the value of the

ampli-

pro-

(Between CH46 and AGA of

(OSE).

Remedy

o

Match the phase sequence of

the motor with that of the

amplifier.

D

Check the cause of the

balanced output voltage and

improve the power condition.

o

Check the cause of the

balanced input power voltage

and improve the power

o

Correctly set the value of

the external speed

ence.

o

See the alarm No.23

D

Replace the encoder or the

printed circuit board with a new one.

un-

condi-

refer-

(OSE).

o

The parameter of the motor maximum speed is with the following maximum set to a low value. speed being set.

6

The motor is overloaded.

7

The override command is

input.

8

Compare the reference speed

o

Amplifier parameter: X31 (TSP.

o

NC parameter:

9" CRT screen

. . .

NC parameter: X49

14" CRT screen

. . .

(See References

1.2.3t31.1

o

Check the load using a load

meter or the load display in

the status display mode

(see Section 1.1.1).

o

Check the override command

using the speed display in the status display mode of the amplifier (see Section

1.1.1).

#17 (TSP)

1.2.2(2)

(TSPl

and

0

Correctly set the parameter

value.

o

Review the cutting condition

and tool.

D

Turn off the override

mand.

com-

- 43 -

1.3.6

(Note) To distinguish between a fault of the mechanical portion including the

The motor vibrates and is getting noisier during rotations.

motor and that of the amplifier including the speed reference, take the

following procedure.

(i)

Rotate the motor at a high speed and press the pushbutton switch

PBl

(see Appendix

rotate in the free run state.

(ii) In the free run state,

than the normal operation of the motor, mechanical portion is normal.

6(l))

on the SF-CA card to cause the motor to

when the vibration and noise become smaller

it is supposed that the

Item

1

2

3

4

Cause

o

The motion balance of the machine is bad.

The motion balance ofo Check that the motor the motor is bad.

The mounting screws which fasten the motor

to the machine are fasten the motor to the loosen.

The reference sine wave-

forms of the control

circuit are disordered.

Rotate the motor at a higho Improve the motion balance

speed, rotate in the free run state, the machine. and check that the mechanical portion including the motor is bad.

o

Remove the coupling between

the motor and machine, separately rotate the motor, and check the mechanical portion is bad.

ficantly vibrates and ates noise in the Item 1 above.

o

Check that the screws

(flange portion or leg) which

machine are loosen in the

Item 1 above.

Observe that the waveforms

0

are balanced at the following check terminals on the printed circuit board SF-CA (See Section

card using an oscilloscope.

.

Between CH14 -

.

Between

.

Between CH23 -

(See Appendixes

9(l).)

Check Remedy

cause the motor to

signi-

gener-

CH9 SAGA):

CH15 - CH9:

Phase W

CH9:

Phase

6(l)

Phase V

and

of the rotation portion of

o

Replace the motor with a new

one.

o

Securely tighten the screws.

o

Replase the printed circuit

board SF-CA card with a new

one.

U

2.4.4.)

The insulation

ante

of the amplifier is

degraded.

5

resist-o Remove the wires of the

phases R,

input power and measure the

following portions using a

500 V megger.

(However,

connected to the ground terminal should be removed.)

(a) Between main circuit

ground (The main circuit consists of each terminal of Xl, x2, x3, u, v, W,

MSl,

S, and T of the

the wires which are

and

MS2.b

-44-

-

o

Check the portions whose

insulation is degraded and clean and/or dry them to restore the good insulation.

o

If it is difficult to re-

(E)

store the good insulation, replace the printed circuit board or the entire

fier with a new one.

ampli-

1 Troubleshooting

1.3 Checking method and remedy of trouble

classification

B

Item

Cause

Check

(b)

Between control circuit

common control circuit the OM terminal of the terminal board SF-CA card.)

(c)

Between main circuit

control circuit common

(between each terminal of

the main circuit and OM

terminal)

(Note) The insulation resist-

(See Appendixes l-l and

-

ground (The

ance should be

more.

common

TBl

is

on the

-

20MR

or

6(l).)

Remedy

- 45 -

1.3.7 The motor overshoots in speed or hunts.

p2izz&q

Item

The speed loop gain parameter is incorrectly set.

1

The speed loop gain is

too high.

2

Cause Check Remedy

0

Check that the speed loop

proportional gain speed loop differentiation gain

(VKI)

60 as their standard values, respectively.

o

Amplifier parameter No:

136

and X37.

o

NC parameter:

. . .

NC parameter:

(See'

1.2.3.)

o

Set the parameters VKP and

VKI to low values and check that they are nearly the that the motor does not hunt or overshoot.

0

For the amplifier parameters:

see Reference

0

For the NC parameters, see

Reference

are set to 63 and

9" CRT screen

14"

CRT screen

References 1.2.2 and

1.2.3(3).

(VKP)

and

#22(PRJ,#23(PR)

#54(PR),#55(PR)

1.2.2(2).

Set both the parameter

values to the standard values.

0

Set both the parameters so

same low values.

-

46

-

1.3.8 The cutting force degrades

Item

The ROM No. is

1

correct. Appendix 11 Table 1.1.

The torque limit

mand is issued.

2

The torque limit meter is incorrectly

set.

3

The belt is loosen.

4

Cause Check

in-

com-

para-

o

Check the ROM No. using

0

Check that CON1 pin No.5

(TLl)

or

turned on by referencing

Appendix l-4 or l-5.

o

Check the parameter TLM

value by referencing

ence 1.2.2(2)

o

Amplifier parameter

o

NC parameter:

. . .

NC parameter:

. . .

0

Check the tension of the

belt.

No.21(TL2)

9" CRT screen

14"CRT screen

or

#21 (PR)

#53 (PR)

is

Refer-

1.2.3(3). No.#35.

Remedy

o

Replace the ROM with a

correct one.

o

Turn off the limit command

input release the torque limit.

0

Correctly set the parameter

value.

o

Correctly put on the belt.

TLl

and TL2 to

-

47

-

1.3.9 The orientation of the spindle is not correct.

(a) The orientation speed is not obtained.

I

tern

Cause

The orientation command

is not issued.

1

Check

o

On the NC spindle screen,

check that the control input L bit 6 of

ALM/DGN3

(see

o

Check the signal which is

sent from the operation panel to the NC.

Remedy

Section 1.1.2) is not set to

"

1 " .

o

On the spindle amplifier dis- o Since the cable is

check that the external

play, signal 1 Section 1.1.1) is not set to

(CTMl)

bit 6 (see

-1".

tive,

replace it with a new

one.

Q

In case of analog

connection:

Connection cable to CON1

@

In case of bus

con-

nection:

Connection cable to

(CAM111

(See Appendixes 1 and 2)

o

Since the printed circuit

board is defective, replace

it with a new one.

In case of analog con-

0

nection:

SF-CA card

@

In case of SF-CA card:

SF-TL card or SF-CA card

(See the note of the

Item 2 and Section 2.4)

defec-

CNlA

-48-

(b)

The motor rotates at the orientation speed but does not stop.

Item

1

Cause

The detector sensor or encoder) is defective.

(magne-

Check

o

Rotate the motor in the

ner that it does not form the orientation and check that the position back signal is normal.

In case of magnesensor:

0

(On the SF-OR or

-

Waveform

E%;~zd

-

Waveform bet-

E%;~“”

-

Check that the above wave-

forms are normal.

@

In case of encoder:

(SF-OR or SF-TL card)

.

Waveform

ween

OM

-

Waveform bet-

ween CH3 and OM

Check that the above wave-

forms are normal.

(Note) The OM terminal is

located on the SF-CA card terminal board (lower right

portion).

(See Appendix (See the note of the alarm

No.21,

Appendix

bet-

+

bet-

CH2 and

Section 3.5, and

9(2) 131.1

per-

SF-TLcard)

///iJ$~~

j

gm-

l-----L

6(l).)

man-

feed-

‘c;,

Remedy

0

Readjust the related

rols by referencing the description of the tion control circuit

(Section 3).

0

If it is impossible to

adjust the controls, replace

the detector with a new one.

orienta-

L

cont-

re-

The following printed circuit board is

tive.

@

In case of analog

linkage:

2

SF-OR card or CA card.

@

In case of bus

linkage:

SF-TL card or

CA card

defec-

SF-

o

In the same manner as the

Item 1 above, forms at the check terminals on the SF-OR card or SF-TL card.

check the

-49-

wave-

D

Readjust the related

rols by referencing the cription of the orientation control circuit (Section

o

If it is impossible to

adjust the controls, replace the printed circuit board with a new one.

(See Sections 2.4.2 and

2.4.3.)

Continued on the next page.

cont-

re-

des-

3).

Item

Cause

In the orientation operation using an encoder, not supplied to the encoder.

5 V power is

Check

o

Disconnect the connector CONE

which is connected to the encoder and check that 5V power

is applied between the pin 4

(or pin 5 or 6) and pin 20. (See Appendixes l-7 and l-8).

o

Check the position of the

shortcircuit ring of the pin.

0

In the case that power is

supplied from the spindle

amplifier:

. The side A of the PIN 3 is

shortcircuited (on the SF-OR card).

.

The portions 2 and 3 of the

PIN 5 are shortcircuited

(on the SF-TL card).

@

In the case that power is

supplied from the NC:

-

The side B of the PIN 3 is

shortcircuited (on the SF-OR card).

-

The portions 1 and 2 of the

PIN 5 are shortcircuited

(on the SF-TL card).

(See References

1.1.3(3).)

1.1.2(l)

and

Remedy

0

When 5 V power is applied,

replace the cable which is

connected from the CONB to

the orientation encoder with a new one.

0

When 5 V power is not

applied and when the position of the shortcircuit ring is correct:

0

Replace the control power

SF-PW module with a new one.

(See Section

Alternatively, replace the SF-OR card (or SF-TL card) with a new one.

@

Check the NC power.

Alternativelv. reolace the SF-OR card with a new one.

5.3.1(S).)

(or

SF-TL card)

The orientation parameter is incorrectly

set.

4

0

Check that the parameter

(#41OSL)

the spindle amplifier accords with the orientation type.

which is set from

1: Encoder 2: Magnesensor

o

Correctly set the parameter.

- 50 -

(c)

Although the motor performs the orientation stop,

the stop state is abnormal.

Item

The orientation control circuit is abnormally set or defective.

(Note) The following

defective situations

1

2

3

can be considered.

@

The motor stops with

a hunting.

@

The servo rigidity

is weak.

@

The motor over-

shoots in speed.

The detector

sensor or encoder) is defective.

The following printed

circuit board is tive.

0

In case of analog

linkage:

SF-OR card or SF-CA card

@

In case of bus

linkage:

SF-TL card or SF-CA card

Cause

(magne-

defec-

Check Remedy

o

In the same manner as the

Item 1 of the position feedback signal is normal.

o

In the same manner as the

Item 1 of that the position feedback signal is normal.

o

In the same manner as the

Item 1 of that the position feedback signal is normal.

(b),

check that control circuit by

(b)

above, check

(b)

above, check

o

Readjust the orientation

ing Section 3.

0

Readjust the spindle orien-

tation

control circuit by

referencing Section 3.

0

If it is impossible to re-

adjust such a circuit, replace the detector with a new one.

o

Readjust the spindle orien-

tation

control circuit by

referencing Section 3.

0

If it is impossible to

adjust such a circuit, place the printed circuit board with a new one.

(See Section 2.4.2 and

2.4.3)

referenc-

rere-

The backlash of the

portion where the coder is mounted is large.

4

en-

o

In the multiple point orien-

tation

operation, check that

the stop position of the

ward orientation differs from

that of the reverse orientation.

o

Set the following address and

data on the amplifier display

in the status display debug

mode.

(See Reference

Check that the display data of the forward orientation is

the same as that of the reverse orientation and there is no electrical problem. An

example of display data is as

follows.

-

51

1.2.1.)

-

for-

o

Decrease the backlash of the

portion where the encoder is mounted.

Continued on the next page.

Item

5

Cause

The parameter of the

gear ratio is

rectly

set.

incor-

Check

o

Check that the stop situation

depends on the gear being used.

D

Check that the servo rigidity

is weak.

Remedy

0

Parameters relating to gear ratio are as follows:

GRAl, GRAZ, GRBl,

o

NC parameter: #25(PR)to#32(PR

9" CRT screen

. . .

NC parameter:

. . . 14"

D

Spindle

GRA3, GRA4,

GRBZ,

GRB3. GRB4

#57(PR)to #64(PR

CRT screen

parameter:139

and

#40

(See References 1.2.2 and

1.2.3.1

.

- 52 -

1.3.10

The acceleration/deceleration time increases.

Item

1

2

3

Cause

The torque limit commandD Check that the CON1 pin No.5

is issued.

The Ea ROM No. is incorrect.

The parameter

value is too large.

(#33CSN)

(TLl)

or No.21(TL2) are

turned on by referencing

Appendix l-4 or 1-5.

o

Check the E' ROM No. by

referencing Appendix 11 Table 1.1.

o

Check the parameter by

referencing Reference

Check

1.2.2.

Remedy

o

Turn off the limit command

input TLl and TL2 to release the torque limit.

o

Replace the ROM with a cor-

rect one or change the related parameter.

o

Correctly change the para-

meter value.

-

53

-

1.3.11

The speed detection signal, up to speed signal, or zero

speed signal is not issued.

Item

1

2

3

4

Cause

The motor does not tate.

The motor speed does not D In the same manner as the accord with that being

specified. related signal.

The output circuit ofo Check that the external the SF-CA card is tive.

The cable which is

netted

to the connector

CON3 is defective.

ro-D Check that the external

defec-

con-o In the same manner as the

signal 4 speed detection) or bit 5

(UTS

up to speed) is not turned on in the diagnosis mode on the status display.

(See Section

Item 1 above, check the

signal 4 speed detection), bit 5

(UTS

up to speed), or bit 4

(2s

zero speed) is turned on.

Item 3 above, external signal 4 bit 2, bit

5, or bit 4 is turned on in the diagnosis mode of the status display.

Check

(STSZ)

bit 2 (SD

1.1.1(21.)

(STSZ)

bit 2 (SD

check that the

Remedy

o

In the same manner as

tion 1.3.4, quired countermeasures.

0

In the same manner as

tion 1.3.5, countermeasures.

o

Replace the SF-CA card with

a new one.

(See Section 2.4.4.)

o

Replace the cable with a ner

one.

take the

take the proper

Sec-

re-

Sec-

- 54 -

1.3.12

(a)

In case of synchronous tapping:

Item Cause Check Remedy

The tapping operation cannot be correctly performed.

The parameter relating to the synchronous tapping is incorrectly set.

1

The spindle speed is

high.

2

The spindle orientation

encoder or printed

cuit

board (SF-TL card)

is defective.

3

cir-

0

Compare the following

meters which are set on the NC CRT display with the meter list on the machine and check them.

-

Fundamental specification

parameter:

.

Axis 2 specification

meter:

.

Spindle parameters:

(See Reference

o

Compare the S command of the

machining program with the S command of the machining speed being set by the program. machine manufacturer.

o

Check that the waveforms at

the check terminals

CH2,

and

card are normal.

(See the instructions for

checking waveforms in the case of encoder @ as described in Section 1.3.9(b) Item

1.)

1.2.3.)

CH3)

on the SF-TL

para-o Correctly set the parameter

para-

(CHl,

values.

o

Decrease the value of the

o

Replace the detector or

printed circuit board with a new one.

(See Section 2.4.2 or

2.4.3.)

The cable between the spindle orientation

4

coder and the amplifier is defective.

o

In the same manner as the

en-

Item 3 above, forms at the check terminals

(CHl,

CH2,

SF-TL card.

and

-

55

check the

CH3)

on the

-

wave-

o

Replace the cable with a new

one.

(b)

In case of un-synchronous tapping:

1 Troubleshooting

1.3 Checking method and remedy of trouble

classification

B

[tern

The speed of the spindle motor deviates for 10

rpm or more. open loop state, input the

1

The up to speed signal or zero speed signal is the status display diagnosis

2

not issued.

The orientation encodero In the same manner as the of the spindle is tive.

3

cause

defec-

Change the parameter value

0

of the amplifier for the speed reference and start

command, at a low speed, and check the signal of the motor built-in encoder (in the same manner as the check method of the Item 6 of the alarm

o

Check the external signal in

mode by referencing Section

1.3.11.

Item 1 of the alarm No.21

OJS2),

form.

o

Replace the encoder with a

new one and check that the equipment correctly works.

(See Appendix 7.)

Check

rotate the motor

No.23(OSE)).

check the signal wave-

Remedy

@

When the signal waveform

in the open loop state

deviates:

replace the printed

cuit

board SF-CA card

with a new one.

@

When the signal waveform

in the open loop state does not deviate, in cordance with the Items 6, 7, and 8 of the alarm No.23 the variable resistor in the motor built-in encoder and (ii) replace the printed circuit board or sensor with a new one.

o

Take proper countermeasures

by referencing Section

1.3.11.

o

Replace the encoder with the

new one.

(OSE), (i)

adjust

cir-

ac-

- 56 -

1.3.13

The threading operation cannot be correctly performed.

Item Cause Check

The orientation encodere In the same manner as the

of the spindle or the printed circuit board

1

(SF-TL card or SF-OR

card) is defective.

The cable between the

orientation encoder of

2

the spindle and the amplifier is defective. on the SF-TL card or SF-OR

The speed of the spindle D In the same manner as the motor deviates for 10

rpm or more. check the signal of the

3

Item 3 of Section

check that the waveforms at

the check terminals CH2, and card or SF-OR card are normal.

o

In the same manner as the

Item 1 above,

forms at the check terminals card.

step 1 of Section 2.3.12(b), motor built-in encoder.

CH3)

on the SF-TL

check the

1.3.12(a), (CHl,

wave-

Remedy

o

Replace the detector or

printed circuit board with a new one.

(See Section 2.4.2 or

2.4.3.)

o

Replace the cable with a

new one.

0

In the same manner as the

Item 1 of Section

@

replace the printed

cuit

board SF-CA card

with a new one or

@

replace the motor built-in

encoder with a new one.

2.3.12(b), cir-

- 57 -

Checking and replacing parts

2.

Checking and

2

replacing parts

When replacing cuit board SF-CA card (see Section in the note.

I]

How to replace the

(1) Using the ROM extractor listed in Table

(2)

(3) Last,

Remove the E2PROM Appendix new card in the following manner.

Appendix 12, "Maintenance instruments",

E2PROM from the new amplifier (or SF-CA

it.

Then,

CA card) and mount it on the new amplifier (or SF-CA card).

amplifier (or SF-CA card) on the old amplifier (or CA card).

(i)

the entire amplifier or (ii) printed cir-

2.4.41,

(ROM31

6(l))

remove the E2PROM from the old amplifier (or

mount the E'PROM which was extracted from the new

from the old card and mount it on the

E2PROM:

on the SF-CA card (see

perform the items

1.1(c)

remove the card) and store

of

SF-

How to extract

:

ROM extractor

E*PROM:

Widen the arms of the

0

ROM extractor in the arrow direction as shown

in the left-hand figure and insert both the hooks

under the ROM.

-

Arm

/-

/

Narrow the width of the

0

arms, the ends of the ROM, and gradually extract the ROM extractor in the straight direction per-

pendicular to the printed

circuit board (without swinging it horizontally and vertically).

place them on both

- 58 -

How to insert

E2PROM:

0

Lightly insert one side

of the pins of the E2PROM into the socket.

are completely inserted into the socket holes, equally push the top side of the

E2PROM.

The sections that follow describe how to replace the fuses,

thermal protectors,

boards,

and motor cooling fan and how to check the transistor

amplifier cooling fan, printed circuit

module and diode stack.

2.1 Replacing fuses

By referencing Appendix 5, houses the printed circuit board SF-CA card, manually re-

move white fuses

(Fl,

the control circuit filter replace them with new ones.

2.2

Replacing thermal protectors By referencing Appendixes

leads which are soldered, replace the thermal

THSl . . .

THS2 . . .

Fixed on Fixed on

2.3 Replacing amplifier

By referencing Appendix

fasten the cooling fan on the bottom plate in the following manner.

open the hinge panel which

and

F3)

F2,

(FILl)

5(l)

which are inserted into on the small panel, and

to

(41,

unsolder the two

loosen the mounting screws, and

protectors with new ones.

the small panel with screws. the heat radiation fin with screws.

cooling fan

5(l)

to

(41,

remove parts which

- 59 -

Checking and

2

replacing parts

2.1

Replacing

fuse

(i)

(ii)

(iii)

(iv)

(VI

Remove the leads for the cooling fan from the terminals RO and SO on the terminal block

TBll.

Loosen the mounting screws on the terminal block TBll and remove the terminal plate from the bottom plate. Loosen the mounting screws of the cement resistor RO

(1 or 2 pieces) and remove the cement resistor(s).

For the amplifier where the electromagnetic relay

RA1

is mounted on the bottom plate, loosen the mounting screws and remove the electromagnetic relay from the bottom plate. Extract the base plate where the cooling fan is mounted

from the amplifier main unit.

(See the following

figure.)

Terminal block fixing

screw hole

Protection bush

(vi)

( vii)

Cooling fan

fixing screw

e

side where the cooling fan

late is not stuck.

Extract the leads from the protection bush hole. Loosen the cooling fan mounting screws and replace

the cooling fan with a new one.

(Note) When mounting the cooling fan, the side where

the cooling fan name plate is not stuck is

located as shown in the figure.

-

60

-

(viii) When assembling the amplifier cooling fan, perform

the reverse procedure as the disassembling procedure.

(Note) After the cooling fan is replaced with the

new one,

check that the cooling fan name plate

is observed from the outside of the amplifier.

2.4 Replacing printed circuit board

Checking and

2

replacing parts

Replacing printed

2.4 circuit board

2.4.1

Replacing SF-PW module

Black

Screw

A/--

r

SF-PW

(Power

Cavityi

supply&," r(;r

r---~ r_--~ T--__--' L___J L-_-J L____

u

SF-CA card

(i)

By referencing Appendix 2-1 or 2-2, keep the follow-

, /’

Connector

(rear side)

/ -~-~

,/'

--Cavity

SF-PW

(Power supply)

0

/II

/

Hinge panel

The

SF-CA card has

(

been removed.

ing connectors and cable connections as they are.

On SF-CA card . . . . .

CONl,

CON2, CON3, TB2

Screw

/

-__ - -

0

1

Screw

On SF-OR card . . . . .

CON4, CONB, CONAA, CONC

(On SF-OR10 card)

on SF-TL card . . .

Or,

CNlB,

(ii) By referencing Appendix 5,

remove the leads from the following three terminals on the terminal board

RO,

SO . . . . .

E

. . . . . . . . .

White leads (Remove either of them.) Green lead

TBll.

-61-

CONB, CONAA

open the hinge panel and

(iii)

Remove the five nails on the SF-CA card (left figure)

and loosen the two screws.

2.4.2

(iv)

Raise and remove the SF-CA card from the hinge panel.

Last,

insert your fingers into the cavities (2 positions) on the hinge panel and remove the entire SF-CA card from the hinge panel.

(VI

By referencing the right figure, loosen the four screws which fasten the SF-PW (power supply) and

remove it.

(vi)

After replacing the SF-PW (power supply)

semble the parts in the reverse order of assembling procedure.

(Note) When mounting the SF-CA card, push the connec-

tor by your fingers from the front side of the card so that the connector on the rear side of the SF-CA card is securely connected to the SF-CA card.

Replacing SF-OR or SF-OR10 card

Connector (Rear side)

/

,---1*I-,

0

i______;

0

module, the dis-

as-

Screw

A7

,'

/

0 0

( i)

By referencing Appendix 2-l or 2-2, remove the con-

nectors (CON4, CONB, CONAA, and CONC).

(ii)

Loosen the five screws and remove the SF-OR (or

ORlO)

card.

-

62

-

SF-

(iii) After replacing the SF-OR (or

the parts being disassembled in the reverse procedure as the assembling procedure.

(Note) When mounting the card, by pushing the connec-

tor (rear side) from the front side with your

fingers and check that the connector is securely

connected to the card.

SF-ORlO)

card, assemble

2.4.3

Replacing SF-TL card

.

Connector (Rear side)

/

/”

/

Termination resistor-y)

L

\

“c3

(

i) By referencing Appendix 2-3, remove the connectors

(CNlA,

(ii)

Loosen the five screws and remove the SF-TL card.

CONB,

CONAA) and termination resistor

/'

.'

/'

Screw

/

(CNlB).

(iii) After the SF-TL card is replaced, assemble the parts

being disassembled in the reverse order of the

assembling procedure.

(Note) When mounting the card, by pushing the connec-

tor (rear side) from the front side with your

fingers and check that the connector is securely

connected to the card.

-

63

-

2.4.4

Replacing SF-CA card

SF-PW

(Power supply)

r_._-) r_-_~ r---

Cavity+-

L__-_I L-----l L___-J

@@-

Screw

Connector(Rear

--Cavity

side)

II

SF-CA card

0

(;;;"eY_.

(i)

By referencing Appendixes 2-l to 2-3, remove the

I7

I-V

Nail

0

following option card from the SF-CA card. SF-OR card or SF-OR10 card or SF-TL card

(ii)

Remove the connectors

(CONl,

CON2, and CON3) on the

CA card and the connections on the terminal block TB2.

(iii) Remove the five nails on the SF-CA card and loosen

the two screws.

(iv) Raise the SF-CA card from the lower side and remove

it from the hinge panel. Last,

insert your fingers into the hinge panel cavi-

ties (2 positions) and remove the entire SF-CA card

from the hinge panel.

(v)

After the SF-CA card is replaced, assemble the parts

being disassembled in the reverse order of the assem-

bling procedure.

(Note)

When mounting the card, by pushing the connec-

tor (rear side) from the front side with your

fingers and check that the connector is securely

connected to the card.

SF-

(vi)

Adjust

meter.

the offset volume

-64-

vR2

and VR3 using A DC volt-

Volume No.

Description

Check pin val

Adjustment

ue

VR2

VR3

(Note) When replacing the SF-CA card, first remove the

2.5

Checking transistor module (This method is the same both

in the power side and regeneration side.)

(a) 75 A or less

U phase current feedback

zero adjustment

V phase current feedback

zero adjustment

E2ROM from the old card and then mount it on the

new card.

(b)

100 A or more

CH40-OM

CH41-OM

f5

mV or

less

0

‘>

L,

1,:

1

(I

Ii

I

ti

2

(Note) The following figure shows the relationship between

the terminal symbols and circuit diagram of the above transistor module.

0

Cl

T

- 65 -

(i)

On the terminal block TB3, remove the wires U, V,

and W which are connected to the motor.

(ii) In the same manner as Section 2.4.4, to open CON101

to 103,

remove the SF-CA card from the hinge panel.

(iii) In accordance with the following criteria, check the

electric continuity of each terminal and determine

whether the transistor module is good or bad.

(Note) Even if part of the transistor module is defec-

tive, one. should be replaced,

replace the entire amplifier with a new In addition, if the transistor module

to prevent the transistors

from being damaged by your static electricity, ground yourself and replace it by referencing Section 2.7.

-

66

-

Criterion list

(when x 10 R range of the circuit tester is used)

Terminal to be checked

Between Cl and C2El

Between Cl and

Gl

Between

Gl

and

C2El

Between

C2El

and E2

Between

C2El and G2

Between G2 and E2

Between

Bl

and Cl

Between B2 and C2El

I

Circuit tester terminal

Cl

: @

terminal

Cl

: 0

terminal

Cl

: @

terminal

Cl

: 0

terminal

: @

Gl

G2El: @

G2El: 0

C2El: @

C2El: 0

G2

Bl

B2

I

terminal

: @

terminal

terminal Several

terminal Indefinite

: Q

terminal

: 0

terminal Indefinite

: @I

terminal Indefinite

: 0

terminal

:

@

terminal

: 0

terminal

OK

Several

1Ofi

Indefinite Indefinite

Indefinite

Several

1OOR

Indefinite

10R

Several

1OOR

10R

Indefinite

Sevl?ral

-- - ----

1no

--“I

No good

Shortcircuited, indefinite Shortcircuited, several 100 Shortcircuited, several

100R

Shortcircuited,

several 100 Several 100 indefinite Shortcircuited, several 100

Shortcircuited,

indefinite

Shortcircuited,

several

100R

Shortcircuited, several 100 Shortcircuited,

several 100

Shortcircuited,

indefinite Shortcircuited, several 100 Shortcircuited, several 100 Shortcircuited, indefinite Shortcircuited, several 100 Shortcircuited,

1

indefinite

R

,

R

I

(Note)

@

terminal: Red lead of circuit tester

@

terminal:

Black lead of circuit tester

-

67

-

2.6

Checking diode stack

(a)

PT type

(Note) The following figures show the relationship bet-

ween the terminal symbols and circuit diagram of

the above diode stack.

lb) PD

type

Copper bar

/'

b

h

(i)

(ii) Check the electric continuity of each two terminals

Remove the leads which are nals P and N.

in accordance with the criterion list and check that the diode stack is good or no good.

(First,

N-1

check the electric continuity between P and

-68-

connected to the

termi-

(Note) Even if part of the diode stack is defective,

Criterion list

(when x 10 R range of the circuit tester is used)

1

Terminal to be

checked

Between P and R

Between P and S

Between P and T

Between N and R

Between N and S

Between

N and T

Between P and N

replace the entire amplifier with a new one. If it is necessary to replace the diode stack, by referencing Section 2.7, replace it with a new one.

Circuit tester terminal

-

A.

'nal

nal

P

: @ termii

P

: @

termi:

P

: @

terminal Indefinite

P

: 0

termi:

N

: @

termi:

N

: 0

termi:

nal

nal nal

nal

P

: @

terminal

P

: @

terminal

OK

Indefinite

Several

10R

Indefinite

Several

10R

102

Indefinite

Several

109

Indefinite

Several

1052

Indefinite

Several

1OOR

No good

Shortcircuited, several Shortcircuited, indefinite Shortcircuited, several Shortcircuited,

1022

G_;l_FG_;c_

IllUczLIIIILt:

Shortcircuited,

several

Shortcircuited,

indefinite Shortcircuited,

Shortcircuited, several Shortcircuited, indefinite Shortcircuited, several Shortcircuited, indefinite Shortcircuited,

--rr--_-.I

Shortcircuited, several Shortcircuited, indefinite

1OOQ

1002

1005

10012

1OOR

1 nnn

lOOti

(Note)

0

terminal: Red lead of circuit tester

@

terminal: Black lead of circuit tester

- 69 -

2.7

Replacing transistor module and diode stack

(i) Disconnect the leads which are connected to the

transistor module or stack and remove them from the

heat radiation fin.

(Note) Since part of the terminals G and E of the

transistor module is of the insert type, when removing them,

take care of it.

(ii) Equally apply silicone grease on the rear side of

the module or stack.

(iii)

At the specified tightening torque (see the following

table),

mount the devices in the same direction as

. .

the old ones and then connect the leads.

(Note) Put on the tube on the terminal G of the

sis

tor module.

Tightening torque table

Recommended

torque(kg-cm)

17 ? 2

Diode

Model

PT768

PD608

Maximum

Screw size tightening tightening

torque

(kg-cm)

M5 x 0.8

20

PD1008

Tran-

sis-

tor

UM75CDY-10

UMlOOCDY-10

UM150CDY-10

M5 x 0.8

20

17 f 2

tran-

(Note)

Since the diodes and transistors used in the

equipment conform with the detail specific-

ations,

they which are replaced or prepared

for spares should be purchased from Mitsu-

bishi.

-

70

-

2.8 Replacing motor cooling (a) In the case of 132

frames or less

(1) Remove the hex socket

bolts which fasten the

finger guard.

Remove the P flat head

(2)

screw which is located at the center of the cooling fan and only

the fan can be dismounted.

Cut the four leads of

(3)

the cooling fan which

are connected in the

terminal box.

the P flat head screw which fastens the fan motor main body and

the fan motor main

unit can be dis-

mounted from the fan

case.

Remove

-71

-

(4) Assemble the parts

the reverse order of the disassembling procedures (1) to (3).

In the case of 160

lb)

frames or more:

Remove the three hex.

(1)

socket bolts which fasten the fan case and pull the fan case in the rear direction and the fan case with the cooling fan can

be dismounted.

in

Fan

Finger guard

/

(2) Remove the hex.

socket bolts which fasten the finger

guard.

-

72

-

(3)

Cut the three leads of

the cooling fan which

are connected in the

terminal box.

Remove

the P flat head screw which fastens the cooling fan from the

inside of the fan case

and the cool fan can be dismounted from the

fan case.

(4) Assemble the parts in

the reverse order of

-

73

-

2.9

Adjusting and replacing motor built-in encoder

2.9.1 Adjusting printed circuit board

Motor built-in

encoder

Shaft

( i)

Observe the waveforms at the same time for phases

A and B at the check pins on the above printed cir-

Printed circuit board in motor terminal box

cuit board using an oscilloscope.

Phase A output . . . . . . Between PA and PGA

Phase B output . . . . . . Between PB and PGA

(ii) Rotate the motor in the forward direction (counter-

clockwise viewed from the shaft end) at a low speed

so that the waveform can be easily observed and adjust the following four volumes until the follow-

ing output waveforms can be observed.

Volumes

VRl

VR2

T7D7

” 1x-I

VR4

Adjustment

function

Zero level adjustment of chase A Amplitude adjustment of phase A

Zero level adjustment of phase B Amplitude adjustment of ohase B

Amplitude(V)

t

,’

Phase A

Phase

B

-

74

-

(iii) Rotate the motor in the reverse direction (clockwise)

and check that the following waveforms can be observed at the nearly same speed as (ii) above.

IAmplitude

I

(iv) Press the pushbutton switch

and Appendix closed loop.

6(l))

Rotate the motor at the maximum speed

(V)

Phase

B

PBl

\

Phase A

(see Reference

to reset the equipment to the

1.1(2)

and check that the amplitudes of the signal outputs

for the forward rotation and reverse rotation are

?

0.8 V or more.

(v) Check that the motor speed is the middle speed of

the base speed (approx.

1500 rpm) and the envelopes

of the signal waveforms of the phases A and B are

0.3 V or less. The following figure exemplifies a waveform of phase A.

rAmplitude(V1

-

75

.

-

Checking and

2

replacing parts

Adjusting and

re-

2.9 placing motor built. in encoder

(vi) Rotate the motor from a

speed and check that it in the forward rotation

low speed to the maximum does not generate noise both and reverse rotation.

(Note 1) If the printed circuit board is defective:

If the items for (ii) to (vi) cannot be adjusted on the printed circuit board which is

mounted on the motor,

replace the board with a

new one and try to adjust the same items.

(Note 2) If the gap between the sensor in the motor and

the detection gear is incorrect: By referencing Section 4.2, replace the set of sensor and printed circuit board with new ones and try to readjust the items (ii) to

(vi)

again.

-

76

-

2.9.2

Replacing encoder and printed circuit board

(1) Remove the connector of

the sensor from the printed circuit board

in the terminal box.

(2) Remove the three hex.

socket bolts which fasten the fan case and pull the fan case in the rear direction.

At the time, the fan

case with the cooling

fan can be dismounted.

(3) Remove the two P flat

head screws which

fasten the sensor fix-

ing plate to dismount the mounting plate with the sensor. At

the time,

take care not to collide the sensor with the detection gear.

Sensor

Mounting plate mounting screw

Sensor mounting plate

(4) To adjust the sensor

position,

loosen the

sensor mounting screw while the sensor mounting plate is

fastened and adjust

the gap between the

detection gear and

the sensor using a

thickness gauge (the

gap is marked on the

sensor mounting

plate).

At the time,

check that the sen-

sor's match mark

(marking-off lines) matches that of the mounting plate and

tighten the sensor

mounting screws.

(See the right-hand

figure.)

Thicknes;

gauge

Se;lsor

ing screw

mount-

Ii

Det&tion

!

1

gear

-

77

Mat&

the match marks

(marking-off lines)

-

Checking and

2

replacing parts

Adjusting and

2.9 placing motor in encoder

(5) Apply screw lock paint on the sensor mounting screws and

plate mounting screws.

rebuilt-

(6) When assembling the fan case,

into the terminal box to prevent them from getting caught.

fully extend the sensor leads

-

78

-

3. Spindle orientation control circuit This chapter describes the maintenance, installation, and

adjustment procedures for the electric orientation (fixed position stop) function which is provided to the spindle of an NC machine.

- 79 -

Spindle orientation

7

a

control circuit

3.1 Structure

3.1.1 Spindle orientation using magnesensor (1 point) (a) Where speed selection signal function is provided:

External

signal

Option card

Spindle

Controller

-I

Option card

Sf?-

OK

Orientation

Speed selection signal

CONC

1

CON2

-L

Magne-

y----

I

i-_-A

:

c

z

F

Ul

Spindle

L__._

I

-

80

-

(b)

Where the equipment is lined with the NC through the bus:

Externa signal

To last axis

CNlB of MR-S

Controller

Option card

s

F -

‘I‘ I_

CNlA

Control

section

---_

Option card

SF-TL

Magnesensor Spindle

Orientation

rr

Orientation position command (data)

command(bit)

r

N.

I

c

CN

A

1

CON2

Bus line

Magne-

-

81

-

3.1.2 Spindle orientation using encoder (4096 points,

(a) Where the equipment is linked with te NC using analog

or digital signals:

with index function)

----_____

Controller

Option card

SF-?'I.

n

-i-l

command

Orientation command

t

CON1

CONC

I

Orientation

position command

(12 bit binary)

nn+ion card

aF-OR

r

Ml9 MO6

N/C

I

CON2

R

u

I

(Note) When the direction of the motor rotation differs from

that of the encoder rotation, the bit 8 and bit E of the parameter 0RS2 (amplifier

parameter

#30).

-

it is necessary to change

82

-

Spindle

(b)

Where the equipment is linked with the

External signal

----_--_

To last axis

CNlB of MR-S

servo amplifier

Controller

Terminatio

resistor

Option card

-1

NC through the bus:

_-_-

r

1

Option card

SF-TI.

l-71

L

E-

CN I A Bus line

CONAA

-

n

CONB

CON2

’

1

Orientation position command (data)

I

Spi

N/C

.

ndle

(Note) When the direction of the motor rotation differs from

that of the encoder rotation, the bit 8 and bit E of the parameter ORS2 (amplifier parameter

#30;

NC parameter

it is necessary to change

116 (PR)).

- 83 -

3.2 Control circuit and parameter setting

3.2.1 Where the speed selection signal function is provided (SF-OR card):

(1) Setting parameters

Although the contents of the parameters which are set by the amplifier are listed in Reference

l-2.2(2),

only the parameters relating to the orientation function are listed in the following.

For instructions of setting parameters, see Reference

1.2.2(l).

t

03 PLG

Parameter

Positio" loop

encoder type

The setting depends on the number of pulses of the encoder.

0: 1024 pulses

1: 90000

Description Setting range (unit)

(

encoder orientation

tapperless

pulses(for

1

axis c control)

Decimal notation

21

22 PG2 2nd

24

25 OSP orientation

26 CSP Creep speed

27 PST

Orientation

PGl

1st deceler-

ation point

Orientation

deceler- loop starts is set.

ation

Orientation

zRz

in-position

range

Spindle speed

Position

shift

point

Encoder orientation:

Angle from which creep speed starts is set.

Magnesensor orientation:

Time taken for start of creep speed after passing over liner zone is set.

Angle at which creep speed for position

Positioning range within which 'orientation complete" signal is output is set.

(NC display standard setting: 1.00)

Orientation speed is set.

Creep speed is set.

Oriented spindle stop position is set.

Encoder:

Magne-

sensor

Stop position is set within

360 deg.

360/4096.

:

Stop position is set within

range from -5 deg. to +5 deg.

with increment

for 0 deg.)

Standard setting: 180

Standard setting: 133

Standard setting: 20

Standard setting: 16

Standard setting: 200

Standard setting: 20

with increment of

lo/1024

Standard setting:2048

(2048

Encoder

0 -

359tdeg.I

Encoder

1 - 5760

(l/l6

deg.)

For parameter on NC play.

0 -

359(deg.)

0 - 1000 rpm

Encoder Magnesensor

0 - 4095

Magnesensor

0 -

5OOms

0 - 40 (deg.)

Magnesensor

1 - 512

(l/16

deg.)

0 - 39

1536 - 2560

dis-

(deg.)

-84-

Spindle orientation

?

3

control circuit

Control circuit and

_ m

~3,‘

parameter setting

2F

Parameter

jriented spindle :ontrol

stop 1

l-

:ontrol :ation

(When

Oriented

spindle

stop magnific-

ation.

4-bit

combina-

tlon

0:

1:

2:

3: 4:

5: 6:

7:

8:

9: A: B: C: D: E: 3 F:

type (such as gain) during

stop is set.

spindle

dedicated machine,

6601.)

KI

I I I

I

[times]

0.6

0.7

0.8

0.9 1

1.2

1.4

1.6

1.8 2

2.2

2.4

2.6

2.8

3.2

Description

Standard setting:4400

GDz

is small like a

it should be set to

Oriented

spindle stop

Kp

magnific-

ation

T--

4-bit combination

[times]

0:

0.6

1:

0.7

2:

0.8

3:

0.9 4: 1 5:

1.2 6:

1.4 7:

1.6 8:

1.8 9: 2 9:

A:

2.2

B:

2.4

C:

2.6

D:

2.8

E:

3 E:

F:

3.2

0:

Delay/

advance

1:

PI

orien-

44it

combination

I rad/s I

0:

0.55

1:

1.1

2:

1.65

3:

2.2

4:

2.75

5:

3.3

6:

3.85

7:

4.4

8:

4.95

5.5

A:

6.05

B:

6.6

c:

7.15

D:

7.7

8.25

F:

8.8

Setting range (unit)

Hexadec imal notation

[Note)

The Kp magnification should be set

to the magnification for X36 VKP. The Ki magnification should be set to the magnification for

-

a5

-

137

VKI.

-

l-

Parameter

l-

#

-

The spindle orientation direction, detector installed direction, and motor rotation direction are set.

[Magnesensor orientation]

(0120 when the detector installation

direction is reversed)

[Encoder orientation]

(0020 when the detector installation

direction is reversed)

Description

Standard setting: 0020

Standard setting: 0120

Setting range (unit)

30

152

pindle stop

'ontrol

2

i:t

1:Semiclose

0:Faint exci-

tation

1:Intense ex-

citation

(+)direction

l:(-)direction

Normally: 0

1:(-j

Elose(with

spindle encoder)

(without spindle encoder)

(Note)The

Z-bit combination

00:

PRE

01:

CCW(Mckor

forward rotation)

10: cw

11: Prohibited PRE... Same as

0

:

ir

I EMG,

01

dtput

1:In

EMG, in-position

output is held.

(Motor

reverse rotation)

in-position

is not held.

In

31OMT/3lOL.T,

it is set to "1" .

1

position loop

means the synchro-

Hexadecimal notation

nous tap.

(+)direction

lriented

1:

(-jdirection

-

Type of spindle orientation is set.

41

ISL

orientation .ype

ipindle

0: Motor built-in encoder 1: Encoder 2: Magnesensor

Hexadecimal notation

-

- 86 -

-

#

42

l-

-

)SL

Parameter

sit assign-

lent

Description

I

\

-f

I

Speed refer- ,

ence

mput

\II

0: Open emitter

tor

I

Position command, oriented spindle

stop 0:

open

emitter

1: open collec-

tor

f

Load meter

0 :I

output

1: Load meter

output 3v

Aiarm

put in case of external

0: Presence

1: Absence

E

ternal

in

NC

mode

0: Invalid 1: Valid

M‘3C

:hine

ready

signal in NC

mode

0: Invalid 1: Valid

1ov

Setting range (unit)

code out-

EMG

Hexadecimal notation

Cl

c2

-

c3

c4

)Ml

-

,M2

'Gl

magnifi-

:ation

for

-espective

rear

'G2

magnifi-

:ation

for

.espective [ear

'he

magnification for

oration Live

.OH

idjust rear.

!he leceleration

-espective

10H (16D)

adjust orientation for the respective gear.

point for orientation) for

gear is set.

F

Cl

c2

(1601

magnification for

c3

c4

Gear 01

F

Gear 11

is regarded as 1 time.

orientation for the respective

If 0 is set,

point for orientation) for

gear is set.

F

Gear 01 Gear 00

F

Gear 11

is regarded as 1 time.

If 0 is set,

#21PGl

(first

87

Gear 00

87

Gear 10

it becomes 1 time.

Y22PG2

(second

87

Gear 10

it becomes 1 time.

-

87

-

decel-

respec-

0

Set to

0

I

0

1

Set to

&

to 15 times

(16

times)

&

to 15 times

(16

times)

(2)

Check terminals

Spindle orientation

3

control circuit

3 2

Control circuit and

.

Darameter

settina

See Appendix

g(2).

-

88

-

Spindle orientation

3

control circuit

3 2

Control circuit and

parameter setting

3.2.2 Where the equipment is linked with the NC through the bus (SF-TL card):

(1)

Setting pins

Although all setting pins are described in Reference

1.1.3(3),

only the setting pins relating to the orien-

tation are listed in the following.

No.

PIN 1 PIN 2

IBare

board

drawing No.

52 is not

used.)

Name

CONNA output

selection

Setting

I ! ,

I',\

I

I.I'IL

I',\

I

'I"

J

I

Description

Outputs an encoder

feedback signal from

CONB to CONAA.

Outputs a feedback

sig-

nal from the CON2 motor detector to CONNA. However,

the phase Z outputs the linear zone of the magnesensor.

outputs a feedback

sig-

nal from the CON2 motor detector to CONAA.

No power is supplied

from NC.

PIN 5

Orientation encoder power

-89-

4

L

I

,',\',

Power is supplied from NC.

(2) Setting parameters

There are two types of parameters: one of which is set

from the amplifier and the other is set from the NC CRT

(being asterisked).

the same as those in Section

The contents of the parameters are

3.2.1(l).

For instructions for setting parameters, see Reference

1.2.3. The following table lists parameters which are set from the NC CRT.

- 90 -

@

Spindle parameter

(l/2)

screen

#

11

@I

#

No.

1 21

2 22 PG2

4 24 ZRZ tion,

5 25 OSP

Parameter

Encoder gear

sgear

ratio

Spindle parameer

CParameter

Parameter

Spindle orienta-

PGl &iz;;e;;F

tion point

Spindle orienta-

~~~~ie:~d

tion point

Spindle Encoder Magnesensor orienta-

position range

Spindle

;;;;nta-

speed

Sets the gear ratio between spindle and encoder.

(2/2)

No.

of parameter error

Encoder spindle orientation:

The spindle rotational angle at which creep speed starts is set.

Magnesensor spindle orientation:

The time in which creep speed starts after passing through linear zone is set.

Angle at which creep speed run changes to position control loop is set.

The error range within which spindle entation complete signal is output is set.

in-

Spindle orientation speed is set.

screen

Description Setting range (unit)

0:

l/l

1:

l/2

2:

l/4

3:

l/8

Description

Standard setting: 180

Standard setting: 133

Standard setting: 20

ori-

Standard setting: 1.00 0 -

Standard setting: 220

Setting range (unit)

Encoder

0 -

359cdeg.J

359tdeg.I

0 - 1000

Magnesensor

0 - 500 ms

0 -

40tdeg.I

39tdeg.j

(rpm)

6 26 CSP

Creep

speed

The creep speed is set.

Standard setting: 20

-91 -

0 - 1000

(rpm)

-Parameter No.

-

I

a

Y

-

27

7

-

-r

-

‘ST

-

Parameter

shift

Position

of parameter error

T

[Encoder orientation]

Oriented spindle stop position is set. The stop position is set within 360 deg.

with increment of Data change during orientation stop state is valid from the next orientation.

[Magnesensor orientation]

The stop position is set within range

from -5 deg. to +5 deg.

When 0 deg. is 2048, in the + direction, 2048 - n. stop can be changed.

2048 + n;in the - direction,

Description

360/4096.

Setting value:2560

512 divi-

sions(n)

value:2048

-512 divi-

\

Setting value:1536

Data during orientation

l-

Encoder

0 -

Setting range (unit)

Magnesensor

4095

(pulse)

1536 - 2560

1

28

a

3RC

-

Not used.

Set to

no".

- 92 -

#

No.

Parameter

Description

Spindle orientation

2

Setting range (unit)

2F

1

Control type (such

as gain) during

orien-

tation stop is set.

(When spindle

GD2

is small like a

dedicated machine,

Standard

it

setting:4400

should be set to

6601.)

BjA9876543210

Oriented spindle stop

KI

magnific-

ation

I I

\

4-bit combination

[times]

0:

0.6

1:

0.7

2:

0.8

3:

0.9 4: 1 5:

1.2 6:

1.4 7:

1.6 8:

1.8 9: 2

A:

2.2

B:

2.4 c:

2.6

D:

2.8 E:

3

F:

3.2

magnification

I

Oriented spindle

stop Kp

I

4-bit combination

[times]

0:

0.6

1:

0.7

2:

0.8

3:

0.9

4:

1

5:

1.2

6:

1.4

7:

1.6

a:

1.8

9:

2

A:

2.2

B:

2.4

C:

2.6

D:

2.8

E:

3

F:

3.2

r

0:

Delay/

advance

1:

PI

UT selec-

Y

[rad/sl

$4

0

$: $6

rn"

*

4-bit

combina-

tion

Irad/sl

0:

1:

2: 3: 4: 5: 6: 7: a:

9: A:

8:

c: D: E: a.25

F: a.8

tion

Hexadecimal notation

0.55

1.1

1.65

2.2

2.75

3.3

3.85

4.4

4.95

5.5

6.05

6.6

7.15

7.7

(Note) The Kp magnification should be set

to the magnification for

(36

VKP.

The Ki magnification should be set

to the magnification for

-

93

-

137

VKI.

Continued on the next page.

Spindle orientation

7

#

No.

Parameter

Oriented

;i

30 0RS2 spindle stop

control 2

Description

The spindle orientation direction, detector installed direction, and motor rotation direction are set.

[Magnesensor orientation]

Standard setting: 0020

(0120 when the detector installation

direction is reversed)

[Encoder orientation]

Standard setting: 0120

(0020 when the detector installation

direction is reversed)

I

[

Setting range (unit)

Hexadecimal notation

!4 ,P.

38 TYP

Position

loon

IN type

01:

CCw(Hotor

forward rotation)

10: cw

“’

0:

(+)direction

l:(-Jdirection

O:(+)direction

1:

(-)direction

Position loop, IN type Sets the process for switching from speed

O:Close(with

encoder)

1:Semiclose

encoder)

0:Faint exci-

tation

1:Intense ex-

citation

Normally: 0

(Note)

11: Prohibited

PPJS...

0:In

EMG, in-Position

output is not held.

l:In

EMG, in-Position

output is held.

The position loop

means the synchro-

nous tap.

(Motor

reverse rotation)

same as

direction.

In

31OMT/31OLT,

it is set to

"1".

loop to position loop.

0: To perform position loop/zero return

operation after orientation operation.

1: Not to perform position loop/zero

return operation.

1

- 94 -

(3)

Display lamps

See Appendix

(4)

Check terminals

See Appendix

8(2).

g(3).

-

95

-

mitsubishi FREQROL-SF Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Troubleshooting

1.1 Status display and diagnosis The status display and diagnosis are executed with the

Checking method and remedy of trouble classification B

Checking and replacing parts

3. Spindle orientation control circuit This chapter describes the maintenance, installation, and

3.1 Structure

3.2 Control circuit and parameter setting