Yaskawa YASNAC PC NC Maintenance Manual

YASNAC PC NC Maintenance Manual

Contents

Chapter 1: General Installation and Electrical Connection ................... 1-1

1.1 Component Arrangement............................................................ 1-1

1.2 General Specifications ................................................................ 1-5

Chapter 2: Routine Inspection ............................................................... 2-1

2.1 Routine Inspection ...................................................................... 2-1

2.2 Battery......................................................................................... 2-1

2.3 Servo Motor ................................................................................ 2-3

2.4 Fan .............................................................................................. 2-4

2.5 Touch Screen .............................................................................. 2-5

2.6 Control Panel .............................................................................. 2-6

Chapter 3: Maintenance Instruments..................................................... 3-1

Chapter 4: Troubleshooting ................................................................... 4-1

4.1 Maintenance Data ....................................................................... 4-1

The VS-626M5..................................................................................... 4-80

4.2 Notes For Safe Operation ......................................................... 4-80

4.3 Receiving .................................................................................. 4-86

4.4 Installation ................................................................................ 4-90

4.5 Wiring ....................................................................................... 4-93

4.6 Operation ................................................................................ 4-128

4.7 Digital Operator ...................................................................... 4-133

4.8 Maintenance And Inspection .................................................. 4-147

4.9 Troubleshooting ...................................................................... 4-149

Chapter 5: Adjustments ......................................................................... 5-1

Chapter 6: Module/Unit Replacement ................................................... 6-1

6.1 CPU Rack ................................................................................... 6-1

6.2 CRT Display Unit....................................................................... 6-8

6.3 Floppy Disk Drive Unit ............................................................ 6-17

6.4 NC Power Supply ..................................................................... 6-18

6.5 Handheld Remote Machine Pendant......................................... 6-19

6.6 Noise Filter ............................................................................... 6-20

Chapter 7: Memory Option.................................................................... 7-1

7.1 Part Numbers .............................................................................. 7-1

7.2 RAM DIMM Installation ............................................................ 7-1

Chapter 8: Fixed File Operations............................................................ 8-3

8.1 NC Data Handling ...................................................................... 8-3

8.2 Yasnac PC NC CPU Rack BIOS Setup .................................... 8-59

8.3 PLC Label in Diagnosis and Parameter Screens ...................... 8-69

8.4 CNC Card Software Update ..................................................... 8-72

8.5 Manual Page Customization ..................................................... 8-82

8.6 Properties File Customization................................................... 8-84

Chapter 1: General Installation and Electrical Connection PC NC Maintenance Manual

Chapter 1: General Installation and Electrical Connection

This section addresses the basic system: configuration, specifications, enclosure design, electrical connections, and installation.

1.1 Component Arrangement

The YASNAC PC NC unit is composed of two boards: JCP20 and JFC20 (JZNC-JFC10). (Refer to the figure below.) The PC NC unit is inserted into a PC extended bus (ISA) inside the personal computer (PC) case. The I/O module, servo unit, spindle drive, and motor are the same as those of the YASNAC J100 CNC UNIT.

Figure 1.1: The YASNAC PC NC Unit

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PC NC Maintenance Manual Chapter 1: General Installation and Electrical Connection

FDD

PC NC case

ISA bus

JFC10

+24V

power

Mouse

Monitor with Touch screen

Keyboard

Feeding

servo unit

Spindle

drive unit

Machine

Feeding

motor

Spindle motor

I/O Module

Figure 1.2: The YASNAC PC NC System Structure Diagram

High voltage

1-2

Device

machine side

Chapter 1: General Installation and Electrical Connection PC NC Maintenance Manual

CPU RACK UNIT

ATX MOTHER BOARD

IDE I/F

KBD

COM2

FDD

COM1

PS/2 MOUSE

LPT1

PCI

ISA

FAN1

CPU FAN

FAN3

Connection Between Devices

DATA

HDD

PWR

DC OUT

VIDEO CARD

VIDEO

JFC20

JCP20-1

PC POWER

CASE FAN

SUPPLY

INPU T

CN01 CN02 CN03 CN04 CN05

CN11 CN12 CN13 CN14

OUTOUT

(PO W E R SIGNAL)

NC POWER

SUPPLY

INPU T OUTPUT

PGS

GOOD

24VDC FOR MACHINE I/O

CN1~6

I/O BOARD

FOR MACHINE SIGNAL

(FC8 X X )

CN11

CN13

SENSOR SIGNAL

CONVERTER UNIT

5CN

CRT

KEYBOARD

MOUSE

FDD

CONTROL

SERVO ON

SHUT DOWN

MACHINE CONTROL SIGNALS

CN14

CN12

SERVO UNIT

SG DC -**A J A

4CN 1CN

Z AXIS

52CN 51CN

SG DC -**A J A

4CN 1CN

Y AXIS

52CN 51CN

SG DC -**A J A

4CN 1CN

X AXIS

52CN 51CN

C1MR-M5N

4CN 1CN 52CN 51CN

C1MR-MR5N

PWRDATA

TOUCH

SCREEN

MACHINE OP. PANEL I/O

CN5

I/O BOARD

FOR MACHINE

OP. PNL.

(JSP02/04)

CN3

3CN

2CN

3CN

2CN

3CN

2CN

REACTOR

R/S/T

A1/A2

X0100**

TB3

CN1

CN7 ,8,9

MACHINE PANEL

UAASK*-**FZ*INVERTER UNIT

SIGNALS

SGMG-

**A2AB*

HPG

INPUT POWER UNIT

AC230V

NFB

TB2

TB1

SVM

A1/A2

Figure 1.3: Detail Connection of PC NC Unit With Various Devices.

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PC NC Maintenance Manual Chapter 1: General Installation and Electrical Connection

Connector Layout NC Side

The following figure provides a detailed Connectors Layout of the YASNAC JZNC-JFC10 board.

Servo controller connector (CN01)

I/O module connector (CN02)

Power good signal connector (CN03)

Interruption setting short pin (S11)

emory address setting rotary swi t ch (S12)

I/O module power output verification LED

I/O module power output connector (CN04)

Servo controller I/O connector (CN11)

Power On/Off co nne cto r (C N12)

Fuse (HM03, 0.3A) (F1)

RS232C connector (CN14)

Direct IN/OUT connector (CN14)

System load switch (S1)

I/O module power input connector (CN05)

I/O module power input verification LED

ttery power reply supply connector (CN06)

Battery

Figure 1.4: Detailed Layout of the YASNAC JZNC-JFC10 Board

System load switch (S1)

(from top: 1, 2, 3, 4)

Battery alarm LED

LITHIUM

System load rot ary switch (S1)

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Chapter 1: General Installation and Electrical Connection PC NC Maintenance Manual

Connector Layout (PC Side)

Figure 1.5: Connector Layout of the PC NC CPU Rack (top view)

1.2 General Specifications

The enclosure must be designed to meet all of the following conditions.

Table 1.1: Specifications

Item Specifications

Ambient Conditions Temperature* Storage and

Transportation Operating

(around enclosure)

Humidity 20% to 80% RH (with operation)

Vibration during operation Less than 4.9m/s Others Free from dust, coolant, or organic solvent PC NC Unit input power supply +24VDC+ Power Supply Unit

UPS000004

-15

C to +65oC

PC NC unit I/O module Servo Amplifier 14” Color monitor with touch screen

10% to 90% RH (with non-operation)

10% 180V-264VAC

Input power supply voltage: 180V ~ 264VAC Frequency: 47Hz to 63Hz Momentary interruption: 0.5 cycle (0VDC)

C to +53oC

Note: Avoid installing the control panel in a location subject to direct sunlight, near heat generating

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PC NC Maintenance Manual Chapter 1: General Installation and Electrical Connection

devices, or outdoors, even if the ambient temperature is within the specified range.

Design of the enclosure should be made on the basis that the average temperature increase of air within the enclosure (containing the PC NC unit and other compo-

nents) should be 10oC below the external air temperature.

(1) Temperature Increase within the Enclosure (Average Temperature Increase)

The internal temperature increase (sheet metal enclosure) is generally as follows: where,

∆Τ: Internal temperature increase (oC) P: Heat generation in enclosure (W) qe: Enclosure heat percolation ratio (W/oC) k: Heat transit ratio of sheet metal (W/m2oC) 6W/m2oC: With internal cooling fan 4W/m2oC: Without internal cooling fan A: Efficient heat diffusion area of enclosure (m2) Area capable of diffusing heat in surface area of the enclosure (Excluding area contacting other devices)

Example: Allowable heat generation in the enclosure with internal circulating fan

1200

All dimensions in millimeters

800

700

Figure 1.6: Enclosure Dimensions

Efficient heat diffusion area is independently located, so bottom area is excluded.

A=4.16m

If the heat generation in the enclosure is supposed to be 246W (113W in the

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Chapter 1: General Installation and Electrical Connection PC NC Maintenance Manual

CNC portion, 104W in the servo portion, and 29W in the I/O portion):

∆Τ=

246

6 x 4.16

k A

= 9.9 (oC)

Therefore, the above value is within the temperature increase value. When it exceeds 10oC, separate cooling countermeasures must be arranged.

(2) Heat Exchanger Cooling Capacity

Yaskawa can provide heat exchangers where the cooling capacity is insufficient even with a circulating fan mounted in the enclosure.

Table 1.2: Heat Exchangers

Heat Exchanger Cooling Capacity External Dimensions (mm)

REX1550

HEATEX02

100W /10 250W /10

295 width x 890 height x 50 depth 440 width x 924 height x 50 depth

The heat generation indicated in the above table is the allowable heat generated when the internal temperature increase in the enclosure is limited to under 10oC.

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PC NC Maintenance Manual Chapter 1: General Installation and Electrical Connection

Example: Allowable Heat Generated in the Enclosure with Heat Exchanger The amount of internal heat generated to make the internal temperature under

10oC when the enclosure is equipped with a HEATEX02 Heat Exchanger is expressed by the following equation:

.A.

P= k

∆Τ+ 250 W/10oC

= 6 x 4.16 x 10 + 250 = 499 W/10

Therefore, the amount of internal heat generated must be less than 499W.

(3) Mounting Heat Exchanger

The heat exchanger must be mounted on the enclosure provided by the machine tool builder, as shown in the figure below. Mount the exchanger so that the internal air is drawn from the upper portion and discharged through the lower portion, while the external air is drawn in from the lower portion and discharged through the upper portion.

Internal air

Enclosure

External air

Heat exchanger

Figure 1.7: Mounting of Heat Exchanger on the Machine Builder’s Enclosure

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Chapter 1: General Installation and Electrical Connection PC NC Maintenance Manual

(4) Heat Generation by Respective Units

Table 1.3: Heat Generation

Unit Type

PC NC rack JZNC-JPCRKM_-_ — — — 14” Color CRT with

Touchscreen I/O Module JANCD-FC810* 29 29 0

Converter CIMR-MR5N23P7 84 44 2.5

Spindle Inverter CIMR-MR5N23P7 84 44 2.5

Reactor UZBA-B 20A 0.53 mH 35 35 0

JZNC-JPCOP-_ _ _ — — —

JANCD-FC860* 29 29 0 JANCD-FC861* 14.5 14.5 0

CIMR-MR5N25P5 84 44 CIMR-MR5N27P5 119 61 CIMR-MR5N2011 152 70 CIMR-MR5N2015 204 88 CIMR-MR5N2018 273 108 CIMR-MR5N2022 335 132 CIMR-MR5N2030 392 160

CIMR-MR5N25P5 185 58 CIMR-MR5N27P5 244 77 CIMR-MR5N2011 307 89 CIMR-MR5N2015 454 119 CIMR-MR5N2018 565 144 CIMR-MR5N2022 717 180 CIMR-MR5N2030 869 219

UZBA-B 30A 0.35 mH 45 45 0 UZBA-B 40A 0.265 mH 50 50 0 UZBA-B 60A 0.18 mH 65 65 0 UZBA-B 80A 0.13 mH 75 75 0 UZBA-B 90A 0.12 mH 90 90 0 UZBA-B 120A 0.09 mH 90 90 0 UZBA-B 160A 0.07 mH 100 100 0

Total Heat

Generation (W)

Internal Heat

Generation (W)

Minimum Wind

Velocity for

Cooling

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PC NC Maintenance Manual Chapter 1: General Installation and Electrical Connection

Table 1.3: Heat Generation (Continued)

Unit Type

SGDC-05AJ A 28 10 2.5 SGDC-10AJ A 48 12

Servo Unit

SGDC-15AJ A 73 15 SGDC-20AJ A 108 18 SGDC-30AJ A 148 22 SGDC-50AJ A 208 28

1. The heat generated by the CNC unit varies depending on the addition of options. The heat generated by the I/O module varies with I/O status.

2. Internal heat generation is the heat remaining inside of the enclosure when the fin of the servo is exposed outside of the enclosure, and when the external air is applied to the fin at greater than 2.5m/s

3. The thermal design of the enclosure to house the servo unit varies with machine specifications, but is acknowledged to use a value of 70% of the load factor.

Total Heat

Generation (W)

Internal Heat

Generation (W)

Minimum Wind

Velocity for

Cooling

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Chapter 2: Routine Inspection PC NC Maintenance Manual

Chapter 2: Routine Inspection

This chapter includes the requirements to maintain optimum operating conditions over

time.

2.1 Routine Inspection

The table below details routine inspection of the PC NC.

Table 2.1: Routine Inspection

Area Inspect Item Frequency

Battery Verify battery alarm

LED is on.

Servo motor Vibration and noise Daily ON Feel by hand; listen by ear.

Motor contamina-

tion and damage Fan Air flow Monthly ON and OFF Feel by hand; listen by ear. Touch screen Clean Daily ON and OFF Use clean rag.

Calibrate Monthly ON Use Calibration Screen. Control panel Verify doors are

tightly closed.

Verify tight fit, no

gaps in the side

plates, and door

gaskets are not

worn.

* With the exception of inspections made while the NC is in the energized state (i.e., external cleanliness,

vibration, noise, etc.) , turn of f the source p ower suppl y to the NC before undertaking routine maint enance service. To remove power completely from the NC, turn off the main circuit breaker on the power panel of the machine.

At power on ON If alarm LED is on, replace battery.

Daily (or as required)

Daily OFF Visual inspecti on

Monthly OF F Visu al ins pe ction

System

OFF/ON*

ON and OFF Visual inspection

Remarks

2.2 Battery

To determine whether the battery must be replaced, and replacement directions, follow the steps below.

1. Press the Power OFF button.

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PC NC Maintenance Manual Chapter 2: Routine Inspection

2. Turn OFF the door interlock switch, if provided. (The power can be turned ON with the door open.)

3. Open the door to view the NC rack.

4. Turn the power ON. If the Battery Alarm LED is displayed in the Message Bar on the top portion of the screen, the battery must be replaced within 16 hours. Do not use commercially-available batteries. Contact a Yaskawa customer service representative.

5. If the battery must be replaced, turn the power OFF. Remove the battery from the battery holder.

6. Place the new battery in the holder and set the connector. (Note: the direction of the connector is unimportant; however, poor connection may result in a lack of conduction.). Refer to the figure below.

Correct Correct Incorrect

Figure 2.1: Battery Connection

Figure 2.2: Replacement Battery

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Chapter 2: Routine Inspection PC NC Maintenance Manual

Note: • Replace the battery as soon as possible after the power goes OFF to avoid

data loss.

• Do not turn the power ON and OFF in rapid sequence.

• Wait 4 to 5 seconds after the power has been turned ON before turning the power OFF.

7. With the power ON, ensure that the “Message Alarm” display on the CRT and the red LED at the front of the JZNC-JFC10 PCB is OFF.

Note: If the “Message Alarm” display on the CRT or the red LED on the front are

still illuminated, the probable cause is improper battery connection, or a defective battery. When alarms 2121 or higher (encoder battery errors) occur, DGN #35024 (*BALM) is not output. When DGN #35024 (*BALM) is output, the LED goes on only when the CMOS backup battery is exhausted. This battery differs from the encoder batter.

2.3 Servo Motor

Inspect the servo motor daily as follows.

Table 2.2: Servo Motor Inspection

Inspect Item Remarks

Vibration and noise Vibration can be checked by resting the hand on the motor.

Noise can be checked by using a listening stick. Contact maintenance personnel immediately when any abnormality is found.

Motor contamination and damage Visually check the motor exterior. If dirt or damage are

observed, inspect the motor by removing the machine cover. Refer to the machine manufacturer’s manual.

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PC NC Maintenance Manual Chapter 2: Routine Inspection

2.4 Fan

Verify the CPU rack cooling fan is running by placing a hand on the outside case in the path of the airflow.

Figure 2.3: CPU Rack and Fan

If the cooling fan speed falls below 2000rpm, a “Slow Fan” warning message appears. When this occurs, open the CPU rack and check the fan for any obstacles that may inhibit the fan rotation. If no obstacles are present, call a Yaskawa customer service representative.

If the CPU rack cooling fan speed falls below 1800rpm, a “Fan Alarm of CNC Unit” message appears. When this occurs, Cycle Start is not possible. Open the CPU rack and check the fan for any obstacles that may inhibit the fan rotation. If no obstacles are present, call a Yaskawa customer service representative.

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Chapter 2: Routine Inspection PC NC Maintenance Manual

2.5 Touch Screen

Clean the touch screen daily. Select PC Settings from the Utilities Menu. Select the Touch Screen Cleaning button. When the screen below appears, proceed to clean the touch screen.

1. Ensure there are no metal or other hard particles on the touch screen that may scratch the screen.

2. Use a general purpose liquid glass cleaner and a clean rag.

3. Never spray glass cleaner directly onto the touch screen. Always spray onto the clean rag.

4. Wipe the touch screen completely.

5. When finished, press the Escape key.

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PC NC Maintenance Manual Chapter 2: Routine Inspection

2.6 Control Panel

Details of the standard cabinet are explained below. Questions on customized cabinets should be referred to the manual issued by the machine manufacturer.

Follow the steps below for routine daily maintenance of the control panel.

1. Inspect the door(s) daily to ensure tight closure. The control panel is constructed as a dust-proof, sheet-steel enclosure with gasketed doors to keep out dust and oil mists. Keep the door(s) tightly closed at all times.

2. Following inspection of the control with the door open, close the door and fasten the door locks (two per door) securely using the key provided (Number YE001). When opening (counter-clockwise rotation) or closing (clockwise rotation), 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.

Left-hand Hinge Door Right-hand Hinged Door

closed position

Note: If the optional door interlocking switch is provided, opening the door shuts

The following monthly maintenance must be performed.

1. Inspect the gaskets on the rims of the front and rear doors for openings or damage.

2. Inspect the inside of the enclosure; clean it if necessary.

open position

closed position

open position

Figure 2.4: Open and Closed Positions

off the main power supply and stops all operations.

3. Look for any opening in the door base when the doors are tightly shut.

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Chapter 3: Maintenance Instruments PC NC Maintenance Manual

Chapter 3: Maintenance Instruments

Measuring instruments, tools, and replacement parts are described in this chapter.

Table 3.1: Measuring Instruments

Name

Tester

or multi-purpose digital meter

Allowable Measuring

10 to 33VAC (at 40 to 100Hz) Tolerance: ±2%

Several mV to 100VDC Tolerance: ±2%

Up to multiples of 10MΩ To measure currents

The only required tools are those listed below.

• Phillips screwdrivers (large, medium, and small)

Range

Purpose

To measure AC power voltages

To measure DC power voltages

• Standard screwdrivers (medium and small)

• ROM extractor: IC extractor model GX-6

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PC NC Maintenance Manual Chapter 3: Maintenance Instruments

Maintenance/replacement parts are:

• Fuse model HMO3, 0.3A; approximate mass: 0.4g

• NC card fuse

• CPU rack fuse: 1A 250V 3AG fast-acting type glass body cartridge fuse; or

250V 3AG fast-acting type glass body cartridge fuse

Note: The current CPU rack fuse is 1A Littlefuse #312001, but will change to

3A Littlefuse #312003 fuse per ECO #N-9910-020.

• Motherboard battery: coin-type 3V lithium battery, part # Mitsubishi #CR2032, or Maxell #CR2032

3-2

Chapter 4: Troubleshooting PC NC Maintenance Manual

Chapter 4: Troubleshooting

4.1 Maintenance Data

To locate the cause of problems or when contacting your Yaskawa customer service representative for advice, users must precisely understand the actual situation. To minimize the downtime, check the following points carefully.

CAUTION

• When an alarm occurs, eliminate the fault and assure operation safety before resetting it. Failure to observe this caution could result in equipment malfunction.

• For details on the machine-related sequence, refer to the machine tool manual.

Checking the Status of Problems

(1) Understanding the Situation

To identify the nature of the problem, first check the following items.

• Type of operation that causes a problem. Do other types of operations not cause problems?

• Q Details of problems How, frequency (always or sometimes), and when?

• Unusual situation when the problem occurred.

• Was there an unusual external occurrence (such as power failure or lightning) when the problem occurred?

• Timing of problem occurrence. Did the problem occur during or after the operation of the keys, or in a specific operation mode?

(2) Check Items

(a) Problems related with axis feed and spindle drive

Check the following items.

• Indication status of the LEDs on the drive unit

• Fuses and breakers

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PC NC Maintenance Manual Chapter 4: Troubleshooting

• Timing of problem occurrence – when the power is turned ON, during acceleration, during deceleration or during fixed speed spindle rotation, etc.?

(b) Problems related to part program

Record the program block data, offset data, workpiece coordinate system offset data, coordinate system setting data, etc.

Checking the NC Information

Aside from the specific problem, the following information must be obtained regarding the hardware environment.

• Machine tool builder’s name

• Delivery date of machine tool

• Type and model name of the machine tool

• Type and model name of the NC and units

Example

NC unit YASNAC PC NC

Servo drive SGDC-AJA

Servo motor SGMG

Spindle drive CIMR-M5N20155

Spindle motor UAASKD-11HB11

Display of Alarm Information

If an alarm occurs, the top priority alarm number and alarm comment are displayed in the normal display area disregarding the selected mode and the screen.

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Chapter 4: Troubleshooting PC NC Maintenance Manual

Cause of Alarm and Corrective Action

The following shows the listing of YASNAC PC NC alarms.

Table 4.1: Alarm Numbers and Classification

Number Contents Stop Mode Output How To Reset

0000 to 0049

0050 to 0099

0100 to 0499

1000 to 1099

2000 to 2199

3000 to 3299

8000 to 8049

9000 to 9049

No number indication BAT indication BAT, AXIS

No number indication Warning message

Errors related to edit and operation Occurring in the background mode also.

Errors related to edit and operation Not occurring in the background mode.

Program error Block stop Input error

Program error DNC, COMS total, etc.

Machine related error OT, reference point return, machine ready, in-position, etc.

Servo and spindle related alarm ESP, CPU mutual monitoring

Memory check error Watchdog timer error Offline error

Error occurring in background editing (basically the same as with 0000 to 0049)

Battery error Encoder alarm

Key operation error, edit operation error (not serious operation error)

Block stop Input error

alarm

Block stop Input error

alarm

Block stop Input error

alarm

Stop after deceleration, or immediate stop

Immediate stop, or se rve, OFF

Immediate stop, or serve OFF

Not stopped Back-

Not stopped No output Changing the battery

Not stopped Warning Next key operation

Alarm Reset operation after removing the

Alarm Reset after removing the cause.

Alarm For maintenance

ground error output

Reset

Reset Power OFF for #0050 and #0051

Reset

cause. With the alarm caused by the machine ready signal, if it occurs in the first power ON operation, it is automatically reset.

With the SVOFF alarm, it is automatically reset by the SVON.

CPU halt Switching to the maintenance screen

Reset or with reset soft-key

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PC NC Maintenance Manual Chapter 4: Troubleshooting

Troubleshooting (1)

(1) Alarm Number 1099 (High Temperature)

Table 4.2: Countermeasures - Alarm #1099 (High Temperature)

Cause Check Item Countermeasures

Ambient temperature of the NC rack exceeded the specified value* due to the failure of the cooling fan. * 70ºC ± 3ºC when mea-

sured above CPS-18.

Internal temperature of the power supply unit is high.

Ambient temperature of the l NC unit is high.* *: Allowable temperature

range for operation is 0 to 40ºC.

Open the NC unit door to check whether the cooling fan is operating correctly.

• Ensure that air is blowing out through the ventilation port of the cooling duct.

• Ensure that the ventilation port of the cooling duct is not blocked.

Allow the power supply unit to cool by turning OFF the power with the PC NC unit door opened. If the alarm occurs even after the power supply unit has been cooled for 30 minutes, the power supply unit is faulty.

Measure the ambient temperature.

• If the NC unit is placed in direct sunlight, the NC unit temperature may exceed the allowable limit.

If the fan is faulty, it must be replaced. Contact your Yaskawa customer service representative. If the cooling duct is blocked, remove the interfering object and start the cooling fan.

The power supply unit must be changed. Contact your Yaskawa customer service representative.

This is not the failure of the NC unit. Remove the cause.

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Chapter 4: Troubleshooting PC NC Maintenance Manual

(2) Alarm Numbers 2061 to 2068 (Reference Point Return Area

Error)

Table 4.3: Troubleshooting - Alarm #2061 ~ 2068 (Reference Point Return Area Error)

Cause Check Item Countermeasures

The reference point return start point is at the zero point side of the deceleration limit switch.

Approach feedrate is too fast.

Deceleration limit switch (DECLS)

#3073 DO (1st axis) #3073 D1 (2nd. ax is) #3073 D2 (3rd axis) #3073 D3 (4th axis) #3073 D4 (5th axis)

If reference point return is started from a point located at the reference point side of DECL (point C) as shown below, an alarm occurs. Note: This error check is not made before the

execution of manual reference point return after the power is turned ON.

Compare the setting for the approach feedrate parameter with the parameter list.

Execute reference point return again while observing the I/O signal monitor screen

Return the axis to a position on the deceleration LS or away from it and, then execute reference point return once again.

Change the setting for parameters pm2521 to pm2525 to an appropriate value.

Table 4.4: Troubleshooting - Alarm Numbers 2071 ~ 2078, 2081 ~ 2088

Cause Check Item Countermeasures

Alarm in manual reference point return operation

Alarm in automatic reference point return operation

(3) Alarm Numbers 2071 to 2078, 2081 to 2088 (Reference Point

Return Position Error)

(Reference Point Return Position Error)

Determine w h e the r th e er r or occurs every time.

G28: Determine whether the alarm

occurs every time.

G27: Check the point specified in the

program to determine whether it agrees with the zero point.

4-5

Contact a Y askawa customer service representative.

Review the program.

PC NC Maintenance Manual Chapter 4: Troubleshooting

(4) Alarm Numbers 2101 to 2108 (P-SET Error)

The P-SET alarm occurs if the error between the position specified in the program and the actual machine position is lar ger than the value set for parameterspm1321 (1st axis) to pm 1325 (5th axis) in the following modes of operation.

At the completion of positioning in G00, G27, G28, G29, G30, etc., error detect ON (1/O monitor parameter #3004 D4 = 1), and G04 (dwell).

If error pulses have been accumulated, check the number of accumulated pulses on the Error Pulse Display Screen before contacting a Yaskawa customer service representative.

(5) Alarm Number 3000 (Servo Power Not Ready)

Table 4.5 Troubleshooting - Alarm #3000 (Servo Power Not Ready)

Cause Check Item Countermeasures

Secondary power supply is not applied

With the secondary power ON, I/O input specification is not turned ON (for automatic servo power ON)

Emergency stop signal stays ON.

The secondary power ON signal is turned OFF due to some other alarm.

If the NC RESET switch is depressed after depressing the POWER ON button once, or after clearing the emergency stop or alarm state, the alarm message is displayed. This does not indicate the occurrence of an alarm.

Verify the following on the I/O monitor screen: #3005 DO = 1 (SVON) #3503 DO = 1 (SVONS)

Determine whether alarm Number 3002 is displayed (#3503 D4 = 1) on the screen.

Check the alarm indication for other alarms.

Press the POWER ON button again.

Contact your Yaskawa customer service representative.

Reset the emergency stop input signal.

Take appropriate measures by referring to the alarm code.

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Chapter 4: Troubleshooting PC NC Maintenance Manual

(6) Alarm Number 3001 (Control Not Ready)

The PC NC executes self-diagnosis after power ON. This alarm occurs when the positioning error checked during this self-diagnosis exceeds the values set for parameters pm 1321 (1st axis) to pm1325 (5th axis).

Table 4.6: Troubleshooting - Alarm Number 3001 (Control Not Ready)

Cause Check Item Countermeasures

Machine axes have moved. Select the error pulse display screen

from the present position display

PG signal remains output. PG or AC servo must be

screen in the common process and check the error pulse value.

Contact a Yaskawa customer service representative.

changed. Contact a Yaskawa customer service representative.

(7) Alarm Numbers 3041 to 3048 (Excessive Follow-up Error)

If the follow-up error between the co mmand values and the ac tual position values exceeds 120% of the error in rapid traverse (100%) operation, this alarm occurs. Check the values set for parameters pm1671 to pm1675, pm1681 to pm1685 and contact a Yaskawa customer service representative.

(8) Alarm Number 3051 (Excessive Follow-up Error: Spindle)

If the follow-up error between the co mmand values and the ac tual position values exceeds the value set for parameter pm1351, this alarm occurs. Check the values set for parameter pm1351 and contact a Yaskawa customer service representative.

(9) Alarm Numbers 3061 to 3068 (Overload)

Table 4.7: Troubleshooting - Alarm Numbers 3061 ~ 3068 (Overload)

Cause Check Item Countermeasures

Cutting conditions Determine whether the alarm occurred during

machining.

Guideways are not lubricated properly, causing heavy axis movements.

Inspect the guideways to determine whether they are lubricated properly.

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Turn OFF the power and allow the servomotor to cool. Then change to lighter machining conditions and restart the operation.

Contact the mac hine tool builder, or a Yaskawa customer service representative.

PC NC Maintenance Manual Chapter 4: Troubleshooting

(10) Alarm Numbers 3081 to 3088 (Broken PG Cable)

The A and B phase signal cables are checked for breakage.

Table 4.8: Troubleshooting - Alarm Numbers 3081 ~ 3088 (Broken PG Cable)

Cause Check Item Countermeasures

Signal cables between the NC and the AC servo drive unit are broken or loose.

Faulty PG cable breakage detection circuit.

Error in motor type parameter setting

Ensure that the cable connectors are plugged into the connectors securely.

Determine whether the alarm occurs in the first pressing of the POWER ON button even when the cables are connected c orrectly.

Determine whether the motor type setting parameters (pm 1061 to pm 1065) has been set to “0”.

If they are loose or disconnected, re-connect them correctly.

Contact your Yaskawa customer service representative.

Correct the setting for the motor type parameters (pm1061 to pm1065).

(11) Alarm Number 3091 (Broken Spindle PG Cable)

The A, B, and C phase signal cables are checked for breakage.

Table 4.9: Troubleshooting - Alarm Number 3091 (Broken Spindle PG Cable)

Cause Check Item Countermeasures

Signal cables between the NC and the AC servo drive unit are broken or loose.

Faulty PG cable breakage

-detection circuit

Faulty PG If an alarm occurs during low speed

Ensure that the cable connectors are plugged into the connectors securely.

Determine w hether the alarm oc curs in the first pressing of POWER ON button even when the cables are connected correctly.

operation, the PG may be faulty.

If they are loose or disconnected, re-connect them correctly.

Contact a Yaskawa customer service representativ e.

(12) Alarm Numbers 3121 to 3125 (Excessive Speed)

This alarm is detected if the motor speed exceeds 1.2 times the maximum motor speed.

Contact a Yaskawa customer service representative.

(13) Alarm Numbers 3161 to 3165 (Absolute Error)

Malfunction of the absolute encoder is detected. Contact a Yaskawa customer service representative after checking the following:

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Chapter 4: Troubleshooting PC NC Maintenance Manual

• Whether the alarm occurs immediately after the control power is turned ON.

• Whether the alarm is cleared when the power is turned OFF and then turned ON again.

• Whether the battery alarm occurs at the same time.

(14) Alarm Numbers 3181 to 3185 (Position Error)

Malfunction of the PG pulse (counter in the absolute encoder) is detected. Contact your Yaskawa customer service representative after checking the following:

• Whether the alarm occurs immediately after the control power is turned ON.

• Whether the alarm occurs frequently during operation.

(15) Alarm Numbers 3201 to 3205 (Servo Drive Unit Communication

Error)

Communication error between the NC and the AC servo drive unit is detected. Contact your Yaskawa representative.

(16) Alarm Numbers 3301 to 3305 (Overcurrent)

Contact your Yaskawa customer service representative after checking the following:

• Whether the alarm occurs immediately after the control power is turned ON.

• Whether the alarm occurs after turning ON the main power.

(17) Alarm Number 3311 to 3315 (MCCB Trip)

• Contact your Yaskawa customer service representative after checking the following:

• Whether the alarm occurs immediately after the control power is turned ON.

• Whether the alarm occurs after turning ON the main power.

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