mitsubishi FREQROL-SF Troubleshooting Manual

AC SPINDLE

USA-E99991-075-*

DRIV

TROUBLESHOOTING

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ADVANCED

MITSUBISHI

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ELECTRKZ

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

20 41

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

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

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)

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

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

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).

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.

While the power is supplied to the equipment or when the

equipment is operated, circuit board.

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.

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?

How often does the trouble or fault occur?

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

temporary repair conducted against the trouble or

fault?

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 Troubleshooting

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

time,

The equipment which has normally worked does

not abruptly work.

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

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).

1.2.1

1.2.2

1.2.3

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

Alternatevely, circuit board is not correct.

When the power is turned on, the display on

the operation panel does not indicate

tions in the status display mode (as shown in

the following figure).

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

shown in the following figure).

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

Situation

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

Spindle alarm 15 01

5 The motor does not rotate.

The motor speed do not conform with that being

specified.

The motor vibrates with a large noise during

rotations.

The motor overshoots at speed or hunts.

The cutting force degrades.

The orientation of the spindle is not correctly 1 3

performed.

EcikiZ

ferenced

1.3.3

1.3.4

1.3.5

1.3.6

1.3.7

1.3.8

. .

The acceleration/deceleration time becomes

lonq.

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

or zero speed signal is not issued.

13 The tapping work is not correctly performed.

The threading work is not correctly

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

1.2.1.

Shift

REFERENCE

Unit

rpm

-I

DOWN UP

Represents the motor speed.

POSITION

___

Shift

LOAD

Description

SPEED

REFERENCE

SPEED

POSITION

DROOP

LOAD

SPEED REFERENCE INPUT

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

‘,

The following table lists the contents of the

sequence diagnosis.

Item

Sequence

Display

k, ,j - j III!

MM__

\ ,I,

l-l ] - j

Description

Represents the ready state.

Represents the non-ready

EXTERNAL SIGNAL 3

Check the contents of the external signal 1

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

0 1

: ' 'j

RDY

k. J

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.

Servo Ready 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

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.

-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

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

-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

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

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

1:Gear

1 1

D/I L

Continued on the next page.

Display

Description

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

D/O

D/O H

6543210

7 6

D/O L

5 4 3 2

-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

when the equipment is operated or installed.

The external wiring is incorrect or broken

The signal ON/OFF sequence is incorrect.

-The ground wiring is

not conducted.

The

incorrect.

The switch and setting

pins are incorrectly

set.

Cause

ElPROM

number is

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

Replace the broken wire

with a new one.

Change the signal sequence.'

Correctly connect the

ground wirings (see

Appendix

Replace the incorrect

ElPROM

Correctly set the switches

and setting pins.

Continued on the next page.

1).

with a correct one.

Item 1

Cause

Check

Remedy

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

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.

be increased (the alarm No.

23 occurs).

The motor does not correctly rotate only

when the orientation

D‘ v,

and motor is correct.

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

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

the NC CRT screen.

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.

The spindle does not rotate.

on the

ROM is defective or incorrectly attached.

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

No data is transferred from NC in bus linkage state.

Check that the spindle parameters

Check that the connection constants

slimit

and smax are not 0.

(MCW

and inching) of the

connection parameters are not 0.

para-

-14-

1 Troubleshooting

1.2.2 The motor which has normally rotated stops abruptly.

Item

The fuse or Alternatively, the NF

(CBl)

The power voltage is out of the range.

An input signal from the sequencer is

mal.

The input signal from the NC is abnormal.

Cause Check

F3)

is blown.

is tripped.

(Fl,

F2, and/

abnor-

Remedy

Check the conductivity using

a circuit tester (see

Appendix 5).

Check the power voltage using0 Adjust the related control

the circuit tester.

(See Table 1.3)

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

Check each bit of a control0 Conduct the same

input by referencing Section

1.1.2 which describes the

status display and diagnosis.

At the same time, check the

same items as the Item 3 above.

forward rotation,

1.1.1(2).)

Replace the fuse

and/or

(See Section 2.1).

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.

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.

(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.

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

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-

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

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.

(Note) This trouble

The equipment malfunc-

tions with a too large

noise.

(Power supply line)

Cause

over-

vib-

often occurs when orientation is correctly conducted.

in-

Check that an instantaneous

power failure occurred in another facility in the same

plant.

Rotate the motor at a slow

speed and check that the motor load changes through

(See Section

Check the backlash between

the spindle encoder and

spindle.

Check the voltage waveform

of the amplifier input pins Xl, x2,

oscilloscope.

While removing suspicious

noise sources one by one,

check the voltage waveform and find the real noise source.

Check

1.1.1

and X3 with an

The orien-

Although an alarm

Remedy

Check the cause of the

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

Remove the cause of the load

change.

Adjust the related control

1.1.2)

so that the backlash becomes

small.

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.

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

Correctly connect the ground

wires of the power supply,

amplifier, and motor.

(See Appendix

Correctly connect the shield

ground wire of the signal line

(CON21

built-in encoder referencing Appendix 1-4.

1.)

to the motor

(PLG)

-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

supplied.

The fuse

F3)

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

is blown.

The power

N15A,

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

The power supply inside0 Disconnect the connectors

the printed circuit

board SF-CA card is

shortcircuited.

(Fl,

F2, and/or 0 Check that the indication

(PSA, PlSA,

P24)

outside

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

and X3 of the amplifier using a circuit tester.

lights.

Check the electric continuity

using the circuit tester.

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

Replace the fuse

and/or

turn (See Section

LED1

(See

Open the shortcircuited

tion of a circuit outside the SF-CA card.

(See Appendix 1.2).

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-

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

All the dip switches

~~5-1

Sw5-4

printed circuit board

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.

PIN I PIN

on the

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

Disconnect the connectors

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

(See Appendix

Check the switch position of

switch SW5 by referencing Reference

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.)

Correctly set the dip

switches

(See Appendix

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

turned on.

When the equipment is

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

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

CNlB)

circuit board SF-TL card are not correctly connected.

Cause

CSl

on the

on the printed

(CNlA

I,-r-rr-rTl

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

Check the position of the

rotary switch

TL card by referencing Sec-

tion 3.1.3.

(See Appendix

Even after the power of the

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

Check the position of the

rotary switch TL card by referencing Reference

1.1.3.

(See Appendix

Check

I-

on,

the

I-

III

CSl

6t31.1

I-

CSl

6t31.1

fol-

dis-

on the

SF-

Remedy

Turn on the power of the

NC.

Correctly set the rotary

switch

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

correctly connected.

All the positions of the dip switches

SW5-4

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

off.

CNlA

SW5-1

and

Even after the power of the

C is turned on, the display

on the operation panel is as

CNlB

follows.

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

NC is turned on, the display

on the operation panel is as follows.

I I I

Check the positions of the

switch SW5 by referencing Reference

Especially, check

1.1.1(l).

-18-

Correctly connect the

nectars CNlA

Correctly set the positions

of the dip switches

sw5-4.

(See Appendix

Continued on the next

and

6(l).)

CNlB.

SWS-1

con-

page

1 Troubleshooting

1.3 Checking method and

remedy of trouble

classification

Item

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

An alarm occurs.

The transmission of parameters is required.

Cause

defec-

Check Remedy

Even after the power of the

NC is turned on, the play on the operation panel

is as follows.

The above Items 1 to 5 cannot

Replace the printed circuit

Check that the display on

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

-I

dis-

Replace the printed circuit

boards with the new ones.

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

Check that the bus cable

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

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.

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-

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.

1 Troubleshooting

1.3 Checking method and

remedy of trouble classification B

Alarm No.

Abbr.

ME1

ME2

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)

NSS IC MAC012 ERROR

OSE

BRT

cot

SPEED CONTROL ERROR

EXCESS

B,,,L-,,&

CONVERTER CURRENT flows in the converter.

POWER PHASE LACK

OVER-

j-a +%$I

4 / ; .,,4 .y

CPUE

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

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

;

specifc

Continued on the next page.

value

be-

21 -

Alarm

uo.

Abbr.

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)

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

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-

(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.

Check the voltage at the

;plifier

input terminals Xl,

and X3 using a circuit

teiter.

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

Check the voltage waveforms

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

Check that the input voltage

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

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

Check the cause of which the

input voltage drops and take

proper countermeasures.

Check the cause of the

instantaneous power failure and take porper counter-

measures.

Increase the power capacity.

Replace the SF-PW module

with a new one.

(2) Alarm

No.l20l!Zll

Memory Error 1

[The integrify of the contents Of

M are compared with those of RAM

during initialization.]

Item Cause

Check

EPROM is not installed

in the correct position.

Visually check that ROM's 1,

2, and 3 are installed at

correct positions on SF-CA card.

(See Appendix

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

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

Install each ROM in the cor-

rect position.

thl

Straighten the pins being

bent and securely insert

them into the socket.

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

(CNlA)

Check the looseness of the

connector.

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.

Visually check that the

signal cable is correctly shielded by referencing

Appendix 1.

The printed circuit

board SF-TL card is defective_

The NC side printed

circuit board

MC632 is defective.

~~611

Replace the SF-TL card with

a new one and check that the

equipment correctly works.

(See Appendix

Replace the MC611 or MC632

cards with new ones and check that the equipment correctly

work.

(See

"M300

Series Maintenance

Manual".)

3(2).)

6(3)1

Securely connect the connec-

tor and tighten the screws.

Replace the cable with the

new one.

Correclty connect the

ground wires.

Correctly shield the signal

cable.

Replace the SF-TL card with

a new one.

(See Section 2.4.3.)

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

error

Item

A component (especially,

A/D

(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

Replace the SF-CA card with

the new one and check that

the equipment correctly

Check that the NF is turned

off.

Replace the SF-CA card with

the new one.

(See Section 2.4.4.)

Turn on the NF.

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

SF-CA card does not correctly work.

007)

on the

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 -

+ 189 hidden pages

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