Yaskawa MX 3 User Manual

YASNAC MX3

CNC SYSTEM FOR MACHINING CENTERS

Before initial operation, read these instructions thoroughly, and retam for future reference

YASKAWA

												CONTENTS
1.		OUTLINE	1									7.	SETTING		AND	ADJUSTMENT			FOR	MODULE	bO
1.1		COMPONENT		ARRANGEMENT								7.1	MU20	BOARD		60
1.2		CONSTRUCT! ON			3							7.2	SP20	BOARD		61
1.3		MAJOR COMPONENTS					4					7.3	SR20	BOARD		SR20	- [--------161
																	~. -- ---~
2.		ROUTINE	INSPECTION SCHEDULE							7		7.4	1021	61
												7.5	AREA	NO SETTING			AND	I/O ADDRESS PORT				63
2.1		TAPE READER 8
2.2		CONTROL PANEL				8						8.	NC DATA		HANDLING		64
2.3		AC SERVOMOTOR				9						8.1	SYSTEM		NO. SETTING			(<<6219)		64
2.4		BATTERY	9									8.2	DISPLAYING			AND WRITING PARAMETERS					64
3.		MAINTENANCE		INSTRUMENTS					10			8.3	DISPLAYING			AND WRITING			KEEP_MEMORY		66
												8.4	TAPE INPUT OF SETTING DATA AND PARAMETER
4.		TROUBLESHOOTING				11						DATA	66
												8.5	PUNCHING-OUT OF SETTING DATA AND
4.1		TROUBLE	IDENTIFICATION						11
												PARAMETER		DATA		67
4.2		TROUBLESHOOTING				BY	ALARM CODES				12	8.6	SUMMARY OF STORING DATA AND EDITING
4.3		TROUBLESHOOTING				WITHOUT			ALARM CODES			OPERATIONS			67
												30
4.4		MAINTENANCE OF			ACGC		49					9.	APPENDIX		69
4.5		SUPPLY VOLTAGE			CHECK			51				9.1	ALARM NO. LIST				69
4.6		STATUS DISPLAY BY ON-LINE DIAGNOSTICS										9.2	LIST OF SETTING				NUMBERS		102
FUNCTION (DGN)				52								9.3	LIST OF		PARAMETER NUMBERS					108
5.	ADJUSTMENTS			UPON		INSTALLATION				54		9.4	STORED		LEADSCREW		ERROR COMPENSATION				130
6.	MODULE/UNIT			REPLACEMENT				PROCEDURE			57	9,5	LIST OF		STANDARD		INPUT/OUTPUT SIGNALS					134
												9.6	LIST OF		ADDRESS CHARACTERS					143

6.1CPU UNIT 57

6.2OPERATOR'S PANEL 58

6.3OPTIONAL MODULES 59

														'r
										INDEX
	Subject											Chapter	Section	Page
A	AC SERVOMOTOR											2	2.3	9
	AOGC ALARM	INDICATION										4	4.4.2	49
	AOGC TROUBLESHooTI NG •											4	4.4.1	49
	ADJUSTMENTS UPON INSTALLATION											5		54
	ALARM 075. 076. 077 (RS232C Faulty)											4	4.2.3	14
	ALARM 170. 172. 173. 174 AND							175	(Memory	Error)		4	4.2.4	17
	ALARM 179 (Temperature Alarm inside the Panel) •											4	4.2.5	18
	ALARM 310 (Servo Power Supply Not Applied) •											4	4.2.9	22
	ALARM 320 (Control Not Ready)							. • . ••				4	4.2.10	23
	ALARM 325 (Servo CPU Error)							• • • • • •				4	4.2.16	28
	ALARM 329 (Bui It·in			Type PC CPU Error! •								4	4.2.17	28
	ALARM 330 (Emergency Stop) • • • •											4	4.2.11	23
	ALARM 820 (ROM/RAM Check Error)											4	4.2.18	29
	ALARM NO. LIST· •••••••••											9	9.1	69
	ALARMS 010	AND 011	(Parity Error)									4	4.2.2	13
	ALARMS 231. 232. 234 AND 235 (Zero Point Return Area
	Error! • • • • • • • • • • • • • • • • • • • • • • • •											4	4.2.6	19
	ALARMS 241. 242. 243. 244						AND 245 (Zero Point Return
	Area Error!	• • • .		. •		•	•	• . . • • •		• • • •	. • .	4	4.2.7	20
	ALARMS 271. 272. 273. 274						AND 275		(P-SET	Error)	•••	4	4.2.8	22
	AbARMS 331. 332. 333. 334 AND 335 (Servo Fuse Blown) .											4	4.2.12	24
	ALARMS 341. 342. 343. 344. 345 AND 346 (Servo Error) .											4	4.2.13	25
	ALARMS 351. 352. 353. 354						AND 355		(Motor Overload) .			4	4.2.14	26
	ALARMS 361. 362. 363. 364. 365 AND 366												4.2.15	27
	(PG 0 i sconnec ti on		Error) .				.	. . .	• .			4
	APPENDIX· • . • • •			•	. •		• • . • ••					9		69
	AREA NO SETTING AND 110 ADDRESS PORT·											7	7.5	63
B	BATTERy···········											2	2.4	9
C	CHECK AC POWER SUPPLY				VOLTAGE							4	4.5.1	51
	CHECK DC POWER SUPPLY VOLTAGE											4	4.5.3	52
	COMPONENT ARRANGEMENT											1	1.1	1
	CONSTRUCT ION· • •		•	•	•	•	•	•				1	1.2	3
	CONTROL PANEL . .		•	.	•	•	•	•				2	2.2	8
	'CPU ERROR"	DISPLAY		(Without				Alarm Codes)				4	4.3.3	31
	CPU UNIT· • . • . ••• . •											6	6.1	57
	CRT SCREEN DOES NOT DISPLAY											4	4.3.4	32
	CYCLE START FAILURE			••••								4	4.3.9	39
o	0ISPLAY METHOD· . •			. •		•	•					4	4.2.1	12
	DISPLAYING AND WRITING KEEP MEMORY·											8	8.3	66
	DISPLAYING	AND WRITING			PARAMETERS							8	8.2	64
E	EDIT DOES NOT FUNCTION·					•••••						4	4.3.13	44
F	FAULTS NOT	DISPLAYED AOGC					ALARM INDICATION·					4	4.4.3	49
	"FIN" WAIT MODE BY SPINDLE RELATED INSTRUCTION·											4	4.3.15	46
H	HANDLE MODE OPERATION FAULTY· ••••• . ••											4	4.3.5	32
	INDICATION	LAMP OF	POWER SUPPLY UNIT· . . ••									4	4.5.2	52
	INITIAL DIAGNOSTIC ERROR DISPLAY AT POWER ON·											4	4.3.2	31
	1021' . . . . . . . . .							. . •• .....				7	7.4	61

II

INDEX (Con t' d)

Subject

LLIST OF ADDRESS CHARACTERS ... • . L[ST OF PARAMETER NUMBERS . . . . . .

L[ST OF SETT[NG NUMBERS . . . . . . .

L[ST OF STANDARD [NPUT/OUTPUT S[GNALS

MMA[NTENANCE [NSTRUMENTS . . . . .

MA[NTENANCE OF ACGC . . . . . • . . MAJOR COMPONENTS' . . • . . . . . .

MANUAL JOG MODE OPERATION FAULTY· . MANUAL RAP[D MODE OPERATION FAULTY·

MANUAL ZERO RETURN OPERAT[ON FAULTY MB20 BOARD· . • ... •• ....

MODULE/UNIT REPLACEMENT PROCEDURE

NNC DATA HANDLING' ....... .

9" CRT SCREEN [S DARK. . . . . . .

oOPERAT[NG PROCEDURE TO DISPLAY [NPUT/OUTPUT SIGNALS

OPERATION IS NOT AVAILABLE WITH Gal, G02 OR G03 • OPERATOR'S PANEL' . . . . . . . . • • • . . OPTIONAL MODULES' . . .. • .

OUTLINE ..... .

OUTL[NE OF DISPLAYS

PPARAMETER DATA DISPLAY' PARAMETER TYPES . . . .

POWER CANNOT BE SUPPLI ED .

PUNCHING~OUT OF SETTING DATA AND PARAMETER DATA

RRECOGNITION OF NC SYSTEM· .. RECOGNITION OF TROUBLE STATUS

RS232C DOES NOT FUNCTION WELL

ROUTI NE INSPECTION SCHEDULE •

SSETTING AND ADJUSTMENT FOR MODULE . . SKIP FUNCTION (G31) OPERATION FAILURE

SOFTWARE VERSION INDICATION SP20 BOARD· .... • .

SPINDLE DOES NOT ROTATE .......... • ..

SR20 BOARD	SR20	~	~ ~ ~ . .	. • . . .	. . . . . • .
STATUS DISPLAY		BY ON~LINE		DIAGNOSTICS FUNCTION (UGN) .
STORED LEADSCREW ERROR COMPENSATI ON					• . • • . .
SUMMARY OF	STORING DATA AND EDITING OPERATIONS,
SUPPLY VOLTAGE CHECK· . . . . . . .					. . . . . •
SYSTEM NO.	SETTING		(16219) . . . . . . . . . .

TTAPE INPUT OF SETTING DATA AND PARAMETER DATA TAPE MODE OOES NOT FUNCTION

TAPE READER . . . . . .

TROUBLE IDENT[FICATION' . . . .

TROUBLESHooTl NG . . . . . . . .

TROUBLESHOOTING BY ALARM CODES'

TROUBLESHOOT[NG WITHOUT ALARM CODES

W WR[TING PARAMETER DATA • ... • .

Chapter Section Page

9	9.6	· 143
9	9.3	· 108
9	9.2	• 102
9	9.5	• 134
3		10
4	4.4	49
1	1.3	4
4	4.3.6	34
4	4.3.7	36
4	4.3.8	37
7	7.1	60
6		57
8		64
4	4.3.12	43
4	4.6.2	53
4	4.3.10	40
6	6.2	58
6	6.3	59
1		1
4	4.6.1	52
8	8.2.2	65
8	8.2.1	65
4	4.3.1	30
8	8.5	67
4	4.1.2	11
4	4.1.1	11
.. 4	4.3.14	45
2		7
7		60
4	4.3.16	47
4	4.4.4	50
7	7.2	61
4	4.3.1	41
7	7.3	61
4	4.6	52
9	9.4	••• 130
8	8.6	67
4	4.5	51
8	8.1	64
8	8.4	66
4	4.3.17	48
2	2.1	8
4	4.1	11
4		11
4	4.2	12
4	4.3	30
8	8.2.3	65

ill

This manual is primarily intended to give operators maintenance instructions for YASNAC MX3.

The information contained in manual does not provide all details to be met concerning maintenance and troubleshooting. If uncertainties be encountered for particular maintenance operation, refer to the following YASNAC MX3 documents for additional information:

YASNAC LX3/MX3 PC SYSTEM (TOE-C843-9.1) YASNAC MX3 SPECIFICATIONS (SIE-C843-9.30) YASNAC MX3 OPERATOR'S MANUAL (TOE-C843-9.30) YASNAC MX3 CONNECTING MANUAL (TOE-C843-9.32)

1. OUTLINE

The YASNAC MX3 provides you with an internal self-diagnosis function (DGN). System maintenance can easily be accomplished with DGN and other main functions as listed below;

(1) Microprocessor always monitors the machine operations internally and can display the status with function keys. If any failure occurs, NC immediatelY stops with the blinking of alarm displays. Also the same precedure

1.1 COMPONENT ARRANGEMENT

can be executed on machine sequence for the application of built-in type programmable controller.

(2)ON/OFF SIGNAL of input to NC/Output from NC can be displayed with DGN.

(3)Setting value of various parameters such as accel/decel time constant and rapid speed.

MACHINE

~

9" CRT

ACGC

0 _

Zo

,

CONTROL

PANEL

i::~

(OPTIONAL)

STATION

..

S

w

~ t

AC SERVO

'X-AXIS

"' ...

DRIVE

-<2; MOTOR

"'

r-- ~

=J

"s

UNIT

o~

...w ,..

CONTROL UNIT

r-

~ ...

I-

-

~o.

00 .

o.=>

AC SERVO

Y-AXIS

0"'~

u

DRIVE

POWER

-

UNIT

~!~J MOTOR

~

INPUT

UNIT

GENERAL

~f--

AC SERVO

M

Z-AXIS

PURPOSE

DRIVE

~j

MOTOR

I/O MODULE

l-.

UNIT

~

SPINDLE

SPINDLE

CONTROL CABINET

DRIVE

"

MOTOR

UNIT

Fig.

1.1 Component Arrangement of

YASNAC MX3

- 1 -

1.1 COMPONENT	ARRANGEMENT	(Conl'd)
YASNAC· MX~J====			:c:-: :-:: ,
Ii:	-CPS-l0N"SUl',--,PL~YCi'UNIf,'~CNl -f1iTf--'4-~~-----
	poWER
. !		eN 12'(}-::!---==---	{A)
t)!1		l
1	:~'7""'!.""-1'.!C~N!!li·39-"T-=---
<	"-

HANDLE TYPE

OPTIONAL ENCODER

(OPTIONAL)

NOTE: Circled "e" values shows cable No. (Refer to YASNAC

MX3 Connecting Manual:

TOE-<:843-9. 32).

III	8	POIIITS	III 40 PQIIITS	OUT 4	pOlIlTS
OUT	~	POUltS		(REED	lEUY)

Fig. 1.2 Conneclion Diagram

- 2 -

1.2 CONSTRUCTION

586-176

Approx				POWER SUPPLY UNIT
Weight: 10 kg
			" ---- PC20 BOARD
				BOARD
		L------------------I020 BOARD
	L-________________________________,M":on MAIN BOARD
	Fig. 1.3 CPU Module

(2)

KEYBOARD UNIT

¢ ~ ~

CRT UNIT

MDI MODULE

Fig. 1.4 g"eRT	Unit	Fig. 1.5 Tape Reader Unit
(rear	view)

- 3 -

1.2 CONSTRUCTION	(Cont'd)
(3)	RELAY UNIT
	SPINDLE
	DRIVE UNIT

•

\	--CPU
	MODULE
A

9" CRT UNIT

.1

I

MACHINE

PANEL

.1F~

,-

586--173

Fig. 1.6 Example of Uni t Assembly wi th IIigh Vol tage Uni ts

1.3 MAJOR COMPONENTS

(1) YASNAC MAJOR COMPONENTS

Table 1.1 YASNAC Major Components

Tape Reel

Memory Board for EKtension

Control Stalron..

SP	Board
SR	20 Board
Manual Pulse				OTN5520	(Option)
(SiMultaneous 3-axls Cont-		JANCD-SP21

-4-

(2)

ACGC Major

Components

Table 1.2 ACGC Major Components

Name

Type

Code No.

Remarks

14" CRT

Unit

C-5470YE

CRT6

Keyboard

Un i t

HMK-9993-02

SI-I677

Main

key

(Hoci zon ta I)

Keyboard

Un i t

IlMK-2293-03

SI-I678

Main

key

(Vertical)

Keyboard

Unit

HMK-9993-20

SI-I679

Soft

key

Power Supply

Unit

VST-5-522/ST

AVR738

CPU Module

JANCO-CGOlD

OTN5390

Graphic

Module

JANCO-CG02

OTN4290

Memory

Module

JZNC-I1UL lU -t:J

JANCO-CG03

OTN5100

Memory

Unit

JANCO-CG04

OTN5110

These units are incor-

JANCO-CG05

OTN5120

JANCO-CG06

OTN5130

porated

into memory module

JANCO-CG09

OTN5510

Ba ttery

Un i t

JZNC-BAT02

DUN13060

(3)

AC Servo Units

Table

1.3

AC Servo Units

Servopack

App lied Mo tor

Code

No.

Optical

Encoder

Type

Motor Type

p/rev

CACR-SR05SBIAF

DUAI5920

USAFED-05FAl

6000

CACR-SR05SBIBF

DUA16020

USAFED-05FBl

5000

CACR-SR05SBIDF

DUA16120

USAFED-05FOl

4000

CACR-SRIOSBIAF

DUAI5940

USAFED-09FAl

6000

CACR-SRIOSBIBF

DUA16040

USAFED-09FBl

5000

CACR-SRIOSBIOF

OUA16140

USAFEO-09FOl

4000

CACR-SR15SBIAF

DUA15950

USAFEO-13FAl

6000

CACR-SR15SBIBF

DUA16050

USAFEO-13FBl

5000

CACR-SR15SBlDF

OUA16150

USAFEO-13FDl

4000

CACR-SR20SBIAF

DUA15960

USAFEO-20FAl

6000

CACR-SR20SBIBF

OUA16060

USAFEO-20FBI

5000

CACR-SR20SBlDF

DUA16160

USAFEO-20FDl

4000

CACR-SR30SBIAF

OUAI5970

USAFEO-30FAl

6000

CACR-SR30SBIBF

DUA16070

USAFEO-30FBl

5000

CACR-SR30SBIOF

OUA16170

USAFEO-30FDl

4000

CACR-SR44SBIAF

OUA15980

USAFEO-44FAl

6000

CACR-SR44SBIBF

DUAI6080

USAFEO-44FBl

5000

CACR-SR44SBIOF

OUA16180

USAFEO-44FDl

4000

- 5 -

1.3 MAJOR COMPONENTS (Cont'd)
(4) Spindle Drive Units VS-626l1T ill
		Table 1.4				Spindle Drive Units
		Dri ve Un i t Type				l1otor Type	Installation
		CIl1R-MT ill -3. 7K			UAASKA-04CAI		Flange l10unted
					UAASKA-04CA3		Foot l10unted
		CIl1R-I1Till-5.5K			UAASKA-06CAI		Flange Mounted
					UAASKA-06CA3		Foot l10unted
		CIMR-MTill-7.5K			UAASKA-08CAI		Flange Mounted
					UAASKA-08CA3		Foot Mounted .
		CIMR-MTill -11K			UAASKA-llCAI		Flange Mounted
					UAASKA-llCA3		Foot Mounted
		CIMR-I1Till-15K			UAASKA-15CAI		Flange l10unted
					UAASKA-15CA3		Foot Mounted

- 6 -

2. ROUTINE INSPECTION SCIIEDULE

The following table shows the minimum requirements to be observed for maintenance time in

order to keep the equipment in optimum condilion for an exlended period.

Table 2.1

Inspection

Schedule

Wi th

Wi th

Items

Frequency

the

the

Remarks

system-

sys tem-

off

on

Cleaning of

reading

As

required

0

Including light source

head

part.

Tape

Cleaning of

tape

As

required

0

Reader

tumble box

Lubrica ting of tension

As

required

0

,

arm shaf tend

Tight closing of doors

Dai Iy

0

Control

Checking

for

loose fit

Panel

and gaps of side plates

Monthly

0

'and worn

door

gaskets

AC

Vibration

and

noise

Dai Iy

0

Feel

by

hand, and do

the

audible inspection.

Servo-

Mo tor con tam i na ti on

Dai Iy

or

0

0

motor

Inspect

visually.

and breakage

as

required

Battery

At

POWER ON

0

0

See if alarm for BATTERY

is displayed on CRT screen.

Except for those checks which can be made with the NC in the energized state, such as checks for external cleanliness, vibration, and noise, be sure to turn off the power supply to the NC before starting to undertake routine maintenance service.

For this, turning off the power supply by pushing the POWER OFF button on lhe NC operator's station is nol sufficient, because after this button is pushed, still several areas in the housing are energized, and are potenlially dangerous.

- 7 -

OPEN POS ITION

2.1 TAPE READER

(1)Cleaning the tape reader head (As required)

(a)Remove tape rubbish and dust from the glass with a blower brush. If the glass is stained with oil or oily dust, wipe it using agauze or soft cloth with absolute alcohol. Also clean the tape guide and the tape retainer.

(b)Remove the dust, if any, on LED (light

source) on top with a blower brush.

(2) Cleaning of tape tumble box (As required) Clean the braided nylon leading tape with a clean, soft cloth.

(3) Lubricating of tension arm shaft(As required)

For the control with 6-inch or 8-inch diameter reels, lubricate the shaft end of tension arm, when the tension arm does not move smoothly.

LUBRICATING

Q

TENSION ARM

\

(In the case of 8-inch diameter reel)

Fig. 2.1

NOTE

When trouble occurs in feeding or winding tape with 8-inch diameter reels, open the front door and brush away dust around the photo-coupler by using a blower brush.

2.2 CONTROL PANEL

(1)Checks on doors for tight closing (Daily)

(a)The control panel is constructed as a dustproof, sheet-steel enclosure with gasketed

doors so as to keep off dust and oil mists. Keep each door tightly closed at all times. Tension arm shaft available as an option.

(b) After inspecting the control with door open, close the door and fasten door locks (2 per door) securely using the key provided (No. YE001). When opening or closing, insert the key all the way into the keyhole and turn

until it clicks (approximately a quarter-turn). The key can be removed from an open or closed position.

				@J
~5~ii~ON~~						CLOSED
				~-CLOSED
CWSED	"-.::!			~			POSITION
OPEN		POS ITION
Wi th		the door		Wi th	the door
lock		on	righ t	lock	on	left
side of			the	side of		the
door		(Lef t- hand		door	(Right-hand
Hinged			Door)	Hinged		Door)
			Fig.	2.2
			NOTE
If the optional door interlocking
switch is provided, opening the door
shuts	off		the main	power supply and
stops	all operations.
(2) Checks	gaps or i mpa irmen t 0 f				to ta II y-

enclosed structure.

(a) Check gaskets on the rims of front and

rear doors.

(b)See if the inside of enclosure IS dusty. Clean it, if necessary.

(c)Check for any opening In the door base with the doors shut tightly.

YASNAC control panel can be used stably for a longer period by executing the above procedures.

-8-

2.3 AC SERVOMOTOR

(1) Vibration and noise (Daily or as required)

Vibration can be checked by resting the hand on the motors, and for noise, using a listening stick is recommended. If any abnormality is found, contact maintenance personnel immediately.

(2) Motor contamination and impairment (Daily or as required)

Check the motor exterior visually. If dirt or damage should be observed, inspect the motor by removing the machine cover. Refer to the machine tool builder's manual.

2.4 BATTERY

Make sure that "BAT" or "AlB" on the rightlow position of CRT screen is not displayed. If it is displayed, the battery must be replaced within a month.

When replacing, never remove the old battery with power OFF, otherwise the data stored in memory are cleared. Battery cannot be obtained in the market. Contact your YASKAWA representative.

Replacing Procedure

(1) Depress POWER OFF pushbutton to shut off the power supply to the operator's station.

(2) Turn OFF the door inter lock sw itch key when a door interlock switch is provided. Then the power supply can be turned ON with the door opened.

(3) Open the door and remove the CPU module cover (type JANCD-MB20) so that the module can be seen.

(4) Depress POWER ON pushbutton (only for primary power supply).

(5) Check to see if lLED on memory board is illuminated. Fig. 2.3 shows the arrangement of LED and the battery. If illuminated, replace the battery with new one.

Battery Type: JZNC-GBAOI

(6)With the power on, remove the old battery.

(7)Put the new battery in the holder and set the connector. See Fig. 2.4. Battery connection.

(8)With the power on, make sure that blink display of CRT screen or LEDl goes off. IF they are still illuminated, it is due to the improper battery connection or defective battery.

JANCD-MB20D

LEDI

f:j

eJOo

Fig. 2.3 Arrangement of LED and Battery

o 0

CORRECT	CORRECT	WRONG
Fig.	2.4 Battery Connection

-9-

3. MAINTENANCE INSTRUMENTS

(1) Measuring instruments

Name		Allowable measuring range					Purpose
		10 to 30 VAC (at 40 to 100 Hz)			To	measure	AC power	voltages
		Tolerance :	±2% or	less
Tester		Several mV to 100 VDC			To	measure	DC power	voltages
or
Multi-purpose		Tolerance :	±2% or	less
digital meter

Several >2 to approx. multiple of 10M>2 To measure currents flowing

Tolerance : ±5% or less through DC motors, etc.

.

(2) Tools

Phillips screwdrivers; large, medium and small Standard screwdrivers; medium and small

(3) Chemicals

Cleaning agent for tape reader (absolute alcohol)

-10-

YASNAC MX3 (ENCM-LP332) CACR-SR053SB USAFED-05MA

VS-626MT m (CIMR-MTm 7. 5K) UAASKA-08CA3

4.TROUBLESHOOT! NG

4.1 TROuBLE IDENTIFICATION

Try to fully analyze the circumstances in which the trouble occurred. This is necessary for identifying the trouble and/or for having your YASKAWA representative called in to correct the trouble. Verifying the following poin ts will minimize the down time of your system:

4.1.1 RECOGNITION OF TROUBLE STATUS

(1)What operation will cause the trouble? (Is other operation performed normally?)

(2)When does the trouble occur: every time or frequently?

(3)Was there no external disturbance such as power interruption or lightning when trouble occurred?

(4)Did it occur during or after operation of mode switches such as EDIT or memory. or function such as IP~M I(parameter) orl DGN I(diagnose) or key switch on C~T panel?

(5)Ensure the following points if the trouble occurred as related to feed and/or spindle operation:

Check of LED on the drive unit ON/OFF check of fuse or MCCB

Time of trouble occurrence such as at power application.

at acceleration. at deceleration.

at steady-state runnine.

(6) Does it depend on part program?

If so. record also part program. offset and coordinate system settings.

4.1.2 RECOGNITION OF NC SYSTEM

recognize the status of machine and equipment regardless of the detail of trouble.

The NC unit is provided with an interlock

swi tch. When the operator opens the door. the NC unit power supply is tripped by MCCB and the interlock switch is released.

Do not start the check operation unLil the interlock switch is released.

(I) Name of machine manufacturer

(2)Time of delivery

(3)Name and type of machine

(4)Name and type of NC unit and others (Example)

NC unit

Servo drive

Servo motor

Spindle drive

Spindle motor

(5) System No. of NC software Check procedure

Keep depressinglORGlbutton on operator's panel at the time of power application. Then. the screen as shown in Fig. 4.1 appears on the CRT.

YASNAC MX3

~Servo system No.

II I I III I I

ain system No.

III I II I II

I I I I I I I I I /---PC system No.

L-______________~

Fig. 4.1 NC Screen at Power Application

(6) Ensure that the parameters are the same as Ensure the following points so as to correctly those specified in the list attached to the NC

uni t.

- 11 -

4.2 TROUBLESHOOTING BY ALARM CODES

This description covers the troubles displayed by alarm codes that were recognized by diagnostic function of NC unit during normal operation.

Refer to Appendix 1 "List of Alarm Codes.' Some additional explanations are given for especially difficult troubles.

4.2.1		DISPLAY		METHOD
If	an alarm condition occurs, a display "ALM"
or	"A/B"		(for	battery alarm) blinks on the
bottom		line of		the CRT screen regardless of
the mode or function.						In this case, detailed
information of				the alarm condition will be
displayed by the following operations:
Depress		the (ALM)			key.
This will			cause up		to	4 pairs of alarm codes

and alarm messages to appear in order of importance, with the most serious one at the top. Note: In an alarm state, the alarm screen

appears taking priority over any other display. There is no need to operate the (PAGE) key.

Alarm disp lay area diagnosed

f by He unit.

Alarm and message disp lay area by

fmach~ne sequence

Fig. 4.2 Alarm Codes and Messages

Eliminate the cause of the alarm and depress thelRESETlkey, and the alarm state and the alarm display will be reset. Notice that the alarm code "820" is displayed regardless of the selected function key.

The alarm codes are categorized as in Table

4.1.

Table 4.1

Type of

Alarm

Alarm No.

Spindle OperatIon

000

to 099

Stop at

block end

Tape format errOr alarm

100

to 199

Stop at

block

end

Macro,

operation, external

input/output

error,

sequence error

(1)

200

to 299

Decelerated

to

stop

Overtravel.

reference

poInt

return.

po~ltlonlng,

MHOY

300

to 399

Decelerated

to

slop

Servo, emergency stop, overload FG,RPG

400

to 499

Decelerated

to

stop

Sequence error (2)

500

to 599

Unused

600

to 699

Sequencer message

700

to 799

Unused

800

to 899

NC

sys tem stop

CPU error, RAM error,

ROM error

Contact

your

YASKAWA representative.

900

to 999

--

Off-line error (for our maintenance)

NOTE:

Alarm

No.

180:

sequence error

(I), 400: sequence error (2)

and 600 to

699: sequencer ~essages are the troubles concerned with machine sequence.

Refer to the maintenance manual prepared by machine manufacturer for details.

- 12 -

4.2.2

ALARMS 010

AND 011

(Parity Error)

Cause of Trouble

Check

l1ethod

Solution

Alarm 010

1)

In

case of

tape

operation:

• Clean

tape

reader.

(TH

error)

The number

of data holes for each

Check tape itself if the

character is checked on the NC tape.

feed hole is faulty and/or

An alarm is issued when the number is:

the nap is raised on the

Even:

For

EIA

tape

hole.

Odd:

For

ISO

tape

Failure of

tape reader

(The description that follows applies

itself

to

the

EIA

code.)

o

0~.. ~..•~~0./. :~

0.(~

000

0

0

o

.•••

••••.•

••• •.•

•• f •••••••.•

o

o

0 0

0

000

0

0

0

0

00

0

0

0

o

0

000

00

0

0

0

0

F.COICN IGOX 12 J

456C

MJOlE

I.SK -ji

\,",,--~)'

It"

'"

But

EOR

2)

Failure of machining program area

Failure of I1B20 board or

in case of memory operation or at time

of expansion memory board

of

EDIT.

(111121

board)

.

item 4.3.14 •

Refer to

3)

RS232C communication error

• Framing error

. Overrun

Alarm 011

In

case of

tape operation:

If the tape cannot perform

(TV

error)

The

tape should be capable of TV check.

TV check, use it

by setting

(Number of characters for one block

ISETI16002 D. = 0 (TV check

should

be

even, including

EOB.)

OFF) or make it so that it

can perform

TV check.

Others

1)

Disagreement between

numbers

of

Check

the

specification of

Alarm 010

RS232C baud rates and stop bits

RS232C

equipment.

2) Communication error of RS232C

Check

parameters.

(e.a.

too

high

noise level)

Refer

to Par.

4.3.14.

Check

cable grounding.

- 13 -

4.2.3ALARM 075, 076, 077 (RS232C Faulty)

075:RS232C interface; disagreement between number of bits and number of baud rates

RS232C

No effect with

• 0 9999· keyedin and depressing

IOUTI key.

Setting da ta wri tten

correct! ?

YES

Parameter written proper I ?

076:RS232C interface; transmission failure

077:RS232C interface; 10 characters or more were read after stop code was issued.

	NO		#6003
			D.=L	D5=0 OUT
			Do=L	D.=O IN
			#6028	(OUT)
	NO		#6026	(IN)
			Baud	rate setting.
			Stop	bi t set ting.

Control code setting.

Cable

NO

connections Check wiring. correct?

YES

Detailed investigation is required.

(Contact your YASKAWA representative.)

Fig. 4.3

- 14-

· Setting of _Appl icdble Jnterface

Set the data trdnsmlSSlon baud rate, stop bil length and control code sending command specificatIons wilh parameters as shown in Tables 4.3 and 4.4.

(a) Selection of RS232C Interface Porl

Select the port of RS232C inlerface by selting 16003.

Isl RS232C and 2nd RS232C cannot be selected

simuI taneously.
	Table 4.2 Seleclion of RS232C					Inlerface Port
			Interface	Input		Outpu l
			1st RS232C	«6003D.		«6003D.
			2nd RS232C	«6003D,		16003D5

Select above bits by parametler selting "I".

(b) 1st RS232C Interface

Baud rate val~e setting for 1st RS232C interface is shown in Table 4.3.

		Table 4.3 Baud Rate Value Setting
						Input								#602t			#602t				B602E	16026
														D3			D.				D,			D.
						Output								B602~			#602f				B6021	#6028
														D3			D.				D,			D.
					50					0					0				0			0
					100					0							0		0			1
						1I0								0			0		1			0
	Baud				150									0			0		1			1
					200									0			1		0			0
	Rate				300									0			1		0			1
	Value				600									0			1		1			0
					1200								0				1		1			1
					2400					1							0		0			0
					~~~					1							0		0			1
					9600					1					0					1			0

SettIng			of stop bi t length
		Input			I		Two bl ts for stop bl t
				160260.
					=1:
		Output		#602~D.	=0:		One bit for stop bIt
Setting of control code sending command
		Input		#602605	=1:		Does	not send	control
							code.
		Output		16028D5	=0:		Sends	control	code.

(c) 2nd RS232C Interface

Baud rate value setting for 2nd RS232C interface is shown in Table 4.4.

	Table 4.4				Baud Rate							value Setting
			Input			#602						16027			#602	#6027
								D3				D.			D,	D.
			Output				B602~					1602~			B60~	16029
								D3				D.			D,	0.
			50			0						0			0	0
			100			0						0			0	1
			110			0						0			1	0
												a
	Baud		150			0									1	1
			200			0						1			0	0
	Rate		300			0						1			0	f----g-
	Value		600			0						1			1
																0
			1200			0						1			1	1
			2400			1						0			0	0
															0	1
			4800						1			0
			9600			1						0			1	0

- 15 -

4.2.3 ALARM 075, 076, 077 (RS232C Faulty) (Cont'd)

Setting of stop bit length

Input

#60270.

=1:

Two bits

for

stop

bit

Output

#60290.

=0:

One bit

for

stop

bit

Setting of control code sending command

Input

#60270 5

=1:

Ooes

not send control

code.

Output

#60290 5

;0:

Sends

control code.

Table 4.5 RS232C

Voltage

Level

VO<-3V

VO>t3V

Function

OFF

ON

Signal

Status

Mark

Open

Logic

1

1

Table 4.6 Connection Cable(A) for Terminal Connection

RS232C Interface

NC Side (DB-25P)

External

Connection

Equipment

Symbol

Signal

Pin No.

Symbol

FG

Frame grounding

1

0

0

FG

SO

Send data

2

O~/

SO

RO

Receive data

3

v

-

/\

~u

~

RS

Request send

4

o~

RS

CS

Capable of send

5

Iv- \\

~

CS

~

OR

Oa ta se t ready

6

\

-0

IJR

SG

Signal grounding

7

\

-v

SG

\

ER

Equipment ready

20

\

-0

10 BUSV

La

ER

- 16-

fig. 4.4 shows connection example of standard RS232C tape reader.

failure of battery unit (battery alarm display)

JANCD-MB20 module, -MM20 module or -MM21 module (optional) is not correctly connected. failure of above modules

Contact your YASKAWA representative in any of above cases.

UB- 2c,P

Type

fig. 4.4 Example of 1st RS232C Interface

Notes:

1. Use 1st RS232C interface when the built-in type tape reader (PTR) is used.

In this case, RS232C interface freely usable by customers is 2nd RS232C interface only.

2. Keep cable length from tape reader to main board (JANCD-MB20 Type) less than 3m. Contact your YASKAWA representative in advance if it is necessary to exceed 3m.

4.2.4 ALARM 170, 172, 173, 174 AND 175 (Memory

Error)

170:MEM ERROR (OFS)

Tool offset value total check error

172:MEM ERROR (SET)

Setting area total check error

173:MEM ERROR (PRM)

Parameter area total check error

174:MEM ERROR (KEEP)

Keep memory total check error

175:MEM ERROR (MACR)

Macro total check error

These alarms indicate that tool offset value, setting data, parameters, keep memory data and/or macro data were rewritten for some reason.

The following points may be considered as their cause.

- 17 -

4.2.5 ALARM 179 (Temperature Alarm inside the Panel)

Cause

of

Trouble

Check

Method

Sol ut ion

Ambient

temperature

of

Open

NC

panel door

and ensure tha t the

. l/eplace

the fan

if

CPU

module

exceeded

fan

runs normally.

I

faulty.

the

specified

value

Ensure that air comes out of exhaust

Call our service person-

(70'( ±3'C)

by

meas-

port at the cooling duct.

nel your

YASKAWA

uring at top of CPS-

Ensure

that

air intake port of cool ing

rep resen ta ti ve.

ION

as a

resul t of fan

duct

is

not

blocked.

If cooling

duct

IS

fai lure.

clogged,

remove

the

cause of

clogging and

restart

the

operation.

Failure of

power

·Turn OFF power supply, open the door

The power supply unit must

supply unit(CPS-ION)

of NC panel

and

cool

it for

abou t

be

NC placed.

(Temperature detector

30min.

If

the

alarm still

lights.

Contact your

YASKAWA

is built

inside the

represen ta ti ve.

power supply

unit.)

Ambient temperature

of

·Measure the ambient temperature.

Reduce the

effects of

NC panel is too high.

·The temperature may rise if NC panel

temperature

rise by

(Applicable

temperaturE

is exposed

to direct

rays of the sun.

shielding the NC

unit,

range is

O'C

to 40·C.)

iI

etc.

- 18 -

4.2.6

ALARMS

231, 232,

234 AND

235

(Zero Point Return

Area

Error)

Cause of

Trouble

Check

Method

Solution

Zero

point

return

start

Try zero point return again

while

Return it to the opposite

position was

at

zero

observing

the deceleration LS,

direction of the zero point

point

side

rather

than.

IDGN/11306

D. (X)

and try the zero point

at deceleration

LS

side.

#l306

Ds(Z)

return

again.

As shown by below an alarm results when

zero point return is made between DECLS

and zero point. Note that this error

check can be performed only after power

supply is turned OFF and the manual

return to zero point has been completed.

DECLS

II

' \' - ,, - ,

(DECELER-I--:-----,;""----'.1

ATION

~ 1

ZERO

POINT

0 '(ZERO

RETURN

AREA

ERROR)

LIMIT

I

,

SWITCH)

ZERO

Jlli

n

I

POINT

RAPID

5-OT H-OT

SIGNAL

JOG

21:::.

20~;

Comfirm the deceleration

LS

by IDGNI

Ul328 Do

(X-axis)

D.

(Y-axis)

Dz

(Z-axis)

D3

(4-axis)

D.

(S-axis)

Generated in the speci-

Check the difference

(.€)

be tween

pos i -

Adj us t

the dece Iera t ion

fications

of

arbirtary

tions

of zero

point

pulse

in

the

section

limit switch dog.

phase C zero

point

re-

"a" of the deceleration limit switch and

turn. This is why an

·0" -> "I". An

alarm occurs

when

the

alarm is to occur in

former position is smaller (several mil-

order to prevent the delimeters).

celeration

limit

switch

from being passed be-

fore

establishment of

arbitrary

zero point

when

the position

of

the

deceleration

limit

1111

swich

(0->1)

is

near

PULSE

the

posi ton

of zero

ARBITRARY

point pulse detected at I

ZERO POINT

I

#6480

PULSE

TO

the

first

time of

the

I

RAPID

#6485 5-0T H-DT

JOG

SHIFT

LENGTIi

21;:- ~ 20~

first

zero

point

return

after

power

supply

is

turned ON.

- 19-

Cause of Trouble

Check Method

Solution

The trailing edge (C-

Measure

IOGNI

#1382 and

#1288

- #1292

AdJ us t

the

dog pos i t ion

point) of the decel-

D., moving the C-point

by

the

manual

for

the

deceleration limit

eration limit switch

handle.

The position slippage equiv-

swi tch,

so that C-point in

is too close to the

alent to one rotation of the motor

the figure may come to the

zero point signal.

corresponds to

this.

center

point between the

zero

point

pulses.

Point-C in the figure is

illustrated in the How-to-

confirm column when

the

deceleration limit

switch

dog

is narrow.

The

zero point'pulse

Use IDGNI

#1288 -

#1292

O. or osci 1-

Trouble

has

occurred on

was

in error.

loscope

to

measure

the

waveform.

one

of

the

following:

•

Motor (PG)

AC servo

• MB20 servo

Contact your YASKAWA

represen ta t ive.

The zero point return

If the reference point return is operat-

Set a parameter value which

travel distance para-

ed without turning power OFF when IPRMI

does

not cause an alarm.

meter is too small, or

#6316 -

#6320

is changed,

(e.g. at the

approach speed 2 valus

reference point return adjustment time,)

is

too high.

an alarm will be issued.

IMake the

IPRMI

#6316 -

#6320

value high

lor IPRMI

#6304

- 16308

value

low.

- 21 -

4.2.8 ALARMS 271. 272. 273. 274 AND 275

(P-SET Error)

P-Set Error results when difference between command position and machine position does not fall within parameters #6156 (X-axis). #6157

(Y-axis). #6158 (Z-axis). 16159 (4-axis). or 16160 (5-axis) at the time of completing positioning with GOO. G27. G28. G29 and G30. Check is also required at the time of G04 (dowell) .

Cause of

Trouble

Check Method

Solution

Machine runs

too heavy.

Measure the load current. Observe

Lighten machine

load.

torque motor in case of AC servo.

Servo error

pulse

Check error

pulse.

Adjust zero point of servo.

exceeds setting range.

Refer to Par. 4.3.4.5

If it cannot be adjusted.

Display Number of Servo Lag Pulses in

replace M820 or Servo Pack.

Operator's

Manual.

Contact your YASKAWA re-

presen ta ti ve.

4.2.9 ALARM 310

(Servo

Power Supply

Not Applied)

Cause of Trouble

Check Me thod

Solution

Secondary power supply

This is a normal result when depressing

Depress POWER ON

bu tton

is

not appl ied.

NC RESET after initial power application.

again.

or resetting emergency stop alarm. etc.

In

case of automat~c

Ensure that

it is set to

Check

wiring and

sequence.

servo power app

I . ,i

IDGNI#l322 D ,l.

lca-

7

tion I/O input spec-

if ica tion is

not ac-

tivated by secondary

power supply.

Emergency stop

input.

Check if ALM330 displays. orIDGN/#1281

Reset

emergency

stop input

D,~l.

Secondary power supply

Check for other alarm display.

Take corrective action

was

tripped by other

according to alarm code.

alarm.

- 22-

4.2.10 ALARM 320 (Control Not Ready)

This type of alarm results when posi tion lag does not fall wi thin the range of RPM fl6156

(X-axis), fl6157 (V-axis), fl6158 (Z-axis), fl61S9 (4-axis) and fl6160 (S-axis) after power application and self-diagnosis.

Cause of Trouble

Check Me thod

Solution

Faulty zero point

Select ISET 1fl6219=4,

then, ERROR PULSE

Perform zero point adjust-

adjustment of servo.

display screen fromlPOSldisplay and

ment of servo.

read the values of

X-. Y-, Z-,

4thand

Machine is running.

5th-axis.

This is a problem of the

machine side rather than

failure of NC unit.

Contact machine manufac-

turer.

PG signal keeps feed-

Replace PG or servo.

ing.

Contact your YASKAWA

represen ta t ive.

I1B2O failure.

Replace 11820.

Con tact your YASKAWA

represen ta ti ve.

4.2.11

ALARM 33J (Eaergency Stop)

Cause of Trouble

Check Method

Solution

Eaergency stop button

After ensuring II);NI#l281 D.=O

(during

Rese t the emergency stop

depressed, or, machine

emergency stop), check continui ty of

button. Release it from

end LS

is out of place. emergency stop button or machine end LS

machine end LS according

shown below. For correct connection.

to

instruction manual

refer to connection diagram prepared by

prepared by machine manu-

by machine manufacturer.

facturer.

MB20

Wiring

is not proper.

CNS-IO~,

+2~V

(eNS-ill

ESP

Machine End L5

CN S - 1'1 '/_-Q.~I.lD-~-'-~-B4nj-~"ibg---1

-"-'--~('"

=

=

Machine End Release

Example of Emergency Stop Connection

- 23-

4.2.11

ALARM 330 (Emergency Stop)(Con t'd)

Cause of Trouble

Check Method

Solution

Fai lure of MB20

This is MB20 failure if alarm 330 lights

Replace MB2O.

even atIIXiNII1281=1 when CN5-10 and CN5-

Con tact your YASKAWA re-

19 short-circuit.

presen ta ti ve.

Drop of +24V power

Check

+24 VOC power.

If the voltage is

Replace CPS-ION (power

helow

+20 V, it

indicates possible

supply unit).

trouble.

Contact your YASKAWA re-

presentative.

4.2.12

ALARMS 331. 332,

333, 334 AND 335

(Servo Fuse Blown)

Cause of Trouble

Check Method

Solution

Servopack fuse is

IIXiNIAl~ 0,=1 X-axis alam

Turn off power supply to

blown or MeB tripped.

.1289 0,=1 Y-axis alarm

machine.

#1290 0.=1 Z-axis alam

Check if Servopack fuse is

#1291 0,=1 4th-axis alarm

blown or MeB tripped.

#1292 0,=1 5th-axis alam

Con tac t your YASKAWA re-

Alarm 390 (Servopack alam) should also

presenta ti ve.

he displayed sinrul taneously.

IIXiNI A1281 Oz=1

Erroneous wiring

Check if CNI-43 (X-axis) CN2-43 (Y-axis),

Correct wiring according

CN3-43 (Z-axis), CN63-43 (4th-axis) and

to Connection

Manual Par.

CN64-43 (5th-axis) drop

to 0 V.

13. Servo Uni t

Feed Connec-

tion

- 24 -

4.2.13

ALARMS

341, 342,

343, 344, 345

to

command value exceeds

parameter 36150

AND 346

(Servo

Error)

(X-axis), #6151 (Y-axis), 36152 (Z-axis),

Servo error

results when the lag of machine

U6153 (4-axis) and U6154 (5-axis).

Trouble

Check Method

Solution

Motor

load

is

too

·Observe motor current or

torque

mon i tOI

If

machine remove,

trouble

large and

movement

if alarm occurs during idle running

and

restart operation.

command is

too small.

81/E1 direction at jog or rapid mode

E.g.

after turning ON the power.

·Excessive drilling

·Check oil film on slide surface of

load

machine and

check oil

level in

tank.

·Machine requires

lubricant.

·Program error causes

tool/work contact.

Torque

is

not

applied.

·Check torque limit signal.

·Correct torque limita-

·Check torque monitor

and

motor

current.

tion.

·Replace Servopack.

·Replace the motor.

D/A circuit

failure

Measure check

terminal

ON-M) of

Replace main board

(MB20)

(output continues)

Servopack with servo power OFF.

of

CPU

unit.

It is

faul ty

if

the voltage

exceeds

several 10 mV

at

this status.

,

Servopack

failure

When servo power is on,

the machine runs

Replace Servopack.

(speed

command

con tin-

away,

causes alarm and

stops.

ues.)

Wiring

failure

Refer

to Connection Manual

Par. 13. Connection of

Feed Servo Unit.

The setting of

PG

Feed at low speed such as in hurdle mode,

Refer

to the relation

magnigication

is in

etc.

It will

be mormal

if

the actual

between the number of PG

error.

move

distance

equals the position dis-

pulses, gear ratio, ball-

play change distance.

type screw pitch,

etc. to

set the correct PG lIIagnfi-

cation

to parameters

36056

- U6060.

- 25 -

4.2.13

ALARMS 341, 342,

343, 344, 345 AND 346 (Servo Error) (Cont'd)

Trouble

Check Method

Solution

Kp(position loop

gain)

Determine if Kp value from the POS(ER)

When the value is lower

is not correctly

display at the time of jog and rapid

than a value set as stand-

adjusted

and it causes

feed is

correct.

ard by the machine tool

excessive

position lag.

maker,

enlarge parameters

F=mm/min

#6406

-

#6410.

For the

Kp=16.7

F

KP adjustment

technic,

X

POS(ER)

refer

to Par.

3.

(S-I)

5 "Adjustment at installa-

tion

tillle".

For detailes,

contact the

machine

tool maker.

4.2.14

ALARMS 351,

352,

353, 354

AND 355 (Motor Overload)

Trouble

Check Method

Solution

Cutting condition

is

Did it occur during drilling and/or

Wait until

temperature of

too severe (Servopack

threadcutting?

servo

motor cools down.

alarm lights and

alarm

Check if it recurs at idle running or

Then,

restart

operation by

390 activates simul-

dry run.

alleviating the condition

taneous ly.)

after clearing alarm with

alarm

reset button of

Servopack.

Machine runs heavily

Check the oil film

on the

guide face.

Check oil

tank

and oi I

due to shortage of

pipe according to instruc-

lubricant on the guide

tion manual of

machine.

face

of machine.

(Servopack alarm

lights

and alarm 390 activa-

tes simultaneously.)

Disconnection or con-

. Ensure that alarm lamp of

Check

wiring status

tact

failure of signal

Servopack

does not light.

between

NC

unit and

between NC unit and

·IDGNI U288

Dz=O(X)

causes

alarm.

Servopack according to

Servopack

11289 Dz=O(Y)

causes

alarm.

Connection

Manual.

#1290

Dz=O(Z)

causes

alarlll.

#1291

Dz=O (4)

causes

alarm.

#1292 Dz=O (5)

causes

alarm.

Servopack

failure

Servopack alarm activates

instantly

Replace Servopack.

after power ON even if wiring is correct.

Contact your YASKAWA re-

It may cause an alarm by motor overload

presentative.

without causing Servopack alarm.

- 26 -