AC Spindle Servo Unit S Series Maintenance Manual GE Fanuc Automation GFZ-65015E/01The product described in this publication may employ hazardous voltages or might create other conditions that could, through misuse, inattention, or lack of understanding, result in personal injury, or damage to the product or to other equipment. It is imperative, therefore, that personnel involved in the installation, maintenance, or use of this product understand the operation of the product and the contents ofthis publication. ‘This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware and software, nor to provide for every possible contingency in connec- tion with installation, operation, and maintenance. Features may be described herein which are not present in all hardware and software systems. Neither GE Fanuc Automation Corporation nor any of its subsidiaries assumes any obligation of notice to holders of this document with respect to changes subsequently made. Neither GE Fanuc Automation Corporation nor any of its subsidiaries makes any representation ‘or warranty, expressed, implied, or statutory with respect to, and none assumes any responsibilty for the accuracy, completeness, sufficiency, of usefulness of the information contained herein. ‘No warranties of merchantability of fitness for purpose shall apply. Copyright 1987 GE Fanuc Automation North America, In.This manual describes following products: Series name Model name § series AC spindle servo unit Model 18, Model 1.58, Model 28, Model 38, Model 6S, Nodel 83, Model 128, Model 158, Model 18s, Model 228TABLE OF CONTENTS I. § SERIES AC SPINDLE SERVO UNIT 1. GENERAL se... 1.1 Configurations . L.1.1 Models 1s ~ 33 sone 1.1.2 Models 68 - 228 . a 1.2 Major Components ... east 2.1 AC Spindle Motor 2.2. AC Spindle Servo Unit 2.3 Maintenance Tools ........ 2.4 Major Maintenance Parts 3. 3 ROUBLESHOOTING Power Voltage Check’ Power On Indicator Lanp Pit is not Lit Alarm is Tadicated Notor does not Rotate or its Rotation is Abnormal. Vibrations or Noises 4s too Large during Rotation pee Noise is Produced from Motor during Deceleration .. sain Speed Overshooting or Hunting Occurs Gutting Force is Low ... Orientation is not Correct 0 Acceleration/Deceleration Time is Long INSTALLATION +++ Installation Procedure . Power Connection .... +1 Power voltage and capacity check +2. Protective earth connection ..++ +3. Power connection .., AC Spindle Motor Connection . Single Cable Conmection 2 2 2. 5. SETTING AND ADJUSTING , 5.1 Jumper and Variable Resistor on Spindle Control PCB (models 18 - 38). 2 Jumper on Spindle Control Circuit (models 65 - 22S) seeeeeeeesee 3 Parameter Setting Method . 4 Number and Content of Parameter 5 Setting Rank (models 15 - 38) . 6 7 Setting Rank (models 65 - 228) Setting and Adjusting Spindle Orientation Control Circuit (option) ....+5 EPLACING FUSE AND PCB Replacing Fuse .. Replacing Spindle Control Circuit and Control Cireuit PCB Replacing Spindle Orientation Control Cireuit PCB Replacing Transistor Module . eo he 7._ SPINDLE ORIENTATION CONTROL CIRCUIT . 7.1 Configuration . 7.2 Adjusting Spindle Orientation Control Circuit of Position Coder System ....7.21 Setting and adjusting spindle orientation control circuit in 2-step spindle speed change or less .. 7.3 Adjusting Spindle Orientation Control Circuit of Magnetic Sensor Type . ‘APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX Mounting magnetizing element and magnetic sensor... Setting and adjusting spindle orientation control circuit in 2-step speed spindle for standard type ..+++++ Setting and adjusting spindle orientation control circuit in 2-step speed spindle for high speed type ..ssssseeeeee Checking method of spindle position loop gain. 1 CONNECTION DIAGRAM ...sseeeseeeeneee 2 CABLE ROUTING 3 CABLE SPECIFICATIONS ........0.e000+ 4 CONFIGURATION OF SPINDLE CIRCUIT . 5 LOCATION OF UNIT . 6 LOCATION OF PCB... 7 MAJOR PARTS 8 MAGNETIC SENSOR SIGNALS CHECKING METHOD .. 9 PARAMETER LIST ., 40 45 45 45 33 58 61 22 15 7 78 ar 83 85 861. S SERIES AC SPINDLE SERVO UNIT1. GENERAL This manual describes maintenance of § series AC spindle servo units (models 1S, 1,58, 28, 38, 6S, 8S, 12S, 158, 185 and 228). 1.1. Configurations 1.11 Models 18-38 Models 18 ~ 38 of S series AC spindle servo units consist of the following units. 1) Spindle control unit (basic) 2) Resistor unit (basic) 3) Spare fuse (basic) 4) Connector for connection (basic) 5) Spindle orientation control circuit (option) 6) AC line filter (option) 1) Power transforner (option) AC spindle servo unit Spindle control unit | vote 3) AC spindle | | mor FI Resistor unit Fuse Connector ¥ 2200/220/230 VAC | i S-phase power ened AC line filter | | Nosfuse breaker {| Nose breaker | {___}owen | _seoyaistaso vac Feel L 1 Power ansformer + (Option) Le Note 1) An overcurrent protector (no-fuse breaker, etc.) is provided by the MTB for the input circuit of S series spindle servo unit. Note 2) Cool the spindle control unit using a fan motor having a specific wind speed. Refer to Descriptions manual. Note 3) For the POR configuration refer to Appendix 2.1.1.2 Models 6S - 228 Models 65 - 225 of S series AC spindle servo units consist of the following units. 1) Spindle control unit (basic) 2) Spare fuse (basic) 3) Connector for connection (basic) 4) Power transformer (option) 5) Spindle orientation control circuit (option) 6) Unit adapter (option) AC spindle servo unit r + ae t. fs | [ srnazconvota | ote) oie sal : a Jee] | ACininate a al ae hot ! ' { Fuse Connector tL 4 + Spindle orientation cont 1 Fanmotor (Note 3 1 Unitedapter phase power — 200/220/230VAC_ fF” Sel ¥ o-tuse breaker J (ote 1) =1 Power transformer! (Option) Note 1) An overcurrent protector (no-fuse breaker, etc.) is provided by the HTB for the input circuit of § series spindle servo unit. Note 2) Cool the spindle control unit using a fan motor having a specific wind speed. Refer to Descriptions manual. Note 3) For PCB configuration refer to Appendix 2.1.2 Major Components Table 1.2 (2) Major components Rom Model | Order specification Unit PCB Specification | type 1s ‘A06B-6059-H002#N501 | A06B-6059-H002 | A16B-1100 | A06s~6059-n501 | 9801 8000rpm 0200 (resi) 1.58 A06B~6059-H002H508 | A06B-6059-H002 + ‘A06B-6059-H508 | 9808 8000rpm A16B~1100 0240 2s ‘A065~6059-H002#U502 | A06B-6059-HOO2 | (PCB2) | A06B-6059-#502 | 9802 8000rpm 38 ‘A06B-6059-H003#H503 | A06B-6059-H003, A06B-6059-H503 | 9803 6000rpm 68/a3 | 406B-6059-1203#H523 | A06B-6059-1203 | a20B-1003 | Ao6B-6059-H523 | 9823 6000rpm 0010 (PcBL) 6s ‘A06B-6059-H206#H511 | AD6B-6059-N206 + ‘A06B-6059-H511 | 9811 6000rpm ‘4208-1003 0020 8s ‘A06B-6059-H208#H512 | AOGB-6059-HO28 | (PCB2) | AD6B~6059-H512 | 9812 4500rpm 8s A06B-6059-H208#1513 | A06B-6059-H028 A06B~6059-H513 | 9813 6000rpm 128/48 | A06B~6059-H208#K524 | AD6B~6059-H208 A06B-6059-H524 | 9824 4500rpm 128/48 | A06B-6059-H208#H525 | A068-6059-4208 A06B~6059-H525 | 9825 6000rpm 128 A06B-6059-H212#H514 | A06B-6059-11212 A06B-6059-H514 | 9814 4500rpm 12s ‘A06B-6059-H1212#515 | AQ6B-6059-H212 A06B-6059-H515 | 9815 6000rpm 15s A06B-6059-H2154H516 | AD6B-6059-H215 | 4208-1003 | AD6B-6059-H516 | 9816 4500rpm -0010 (PCB1) 158 ‘A06B-6059-N215#H517 | AD6B-6059-H215 + ‘A06B~6059-H517 | 9817 6000rpm 208-1003 -0120 188 ‘A06B-6059-H218#H518 | AD6B-6059-H218 | (PCB2) | Ad6B-6059-H518 | 9818 4500rpm 228 ‘A06B-6059-H222#H520 | A06B-6059-H222 A068-6059-H520 | 9820 4500rpm.Table 1.2 (b)_ Major components (option) (models 18 - 38) Name order specifications PCB Orientation ARIZ (Position coder, 2-stage speed change) A06B-6059-J110 208-008-0242 Orientation BRIT (Position coder, 2-stage speed change) A06B~6059-J111 A20B-0008-0243 Orientation CR (lagnetic sensor, 2-stage speed change) A06B-6059-J120 A16B~1300-0110 Orientation GR (Magnetic sensor, 2-stage speed change) ‘A06B-6059-J121 420B-0008-0111 ‘Table 1.2 (c) Major components (option) (models 6S - 225) Name Order specifications PCB Orientation ASIT (Position coder, 2-stage speed change) A06B~6059-J130 A20B-0008-0242 Orientation BSIT (Position coder, 2-stage speed change) A068-6059-J131 A20B~0008-0243 Orientation CSTI (Magnetic sensor, 2-stage speed change) A06B~6059-J140 208-008-0032 Orientation GSIL (Magnetic sensor, 2-stage speed change) AD6B~6059-J141 A20B-0008-00332. DAILY MAINTENANCE AND MAINTENANCE TOOLS Check and clean the following items once every 6 months or so for using the AC spindle motor and AC spindle servo units under a normal condition for a long time, Take the check frequency into consideration according to the contamination degrees in each item, 2.1. AC Spindle Motor If the ventilation hole, cooling fan, and fan finger guard (net) of the AC spindle motor become dusty, the radiation efficiency of the motor drops. Clean the AC spindle motor by using the factory air and a vacuum cleaner. 2.2. AC Spindle Servo Unit Since a cooling fan is mounted at the upper part of the servo unit, its nearby resister and other parts become dusty after a long-time use. If they are dusty, clean them using the vacuum cleaner or the like. 2.3. Maintenance Tools Use tools indicated in Table 2.3 (a) for adjustments and tools indicated in Table 2.3 (b) for repairing troubles. Table 2.3 (a) Tools used for adjustments Name Specification Use AC voltmeter 1 = 300 V +#2% or less AC power voltage measurement @,© screwdrivers | @ large, medium size © large, medium, small size Table 2.3 (b) Tools used for repairing troubles Name Specification Use AC voltmeter 1 = 300 V 41% or less AG power voltage measurement. DC voltmeter 1 nV ~ 500 V 41% or less DC power voltage measurement and offset voltage check Circuit tester Resistance value check @®,© screwdrivers | @ large, medium size © Jarge, medium, small size 2.4 Major Maintenance Parts For maintenance parts, see appendix 7 Najor maintenance parts.3. TROUBLESHOOTING Perform troubleshooting, referring to each item in Table 3 according to trouble conditions if @ trouble occurred, Table 3. Sort of trouble conditions ren Trouble conditions tea 1 | Power voltage check 3.1 2 | Power ON indicator lamp PIL does not light. 3.2 3 | Alarm (AL-[][]) is displayed on the PCB. 3.3 4 | Number of rotation is not as specified. 34 5 | Motor does not rotate, 3.4 6 | Vibrations and noises are noticeable during rotation. 3.5 7 | An abnormal noise is produced from motor during deceleration| 3.6 8 | Motor speed overshoots or hunting occurs. 3.7 9 | Cutting power drop 3.8 10 | Spindle orientation is not correct. 3.9 11 | Acceleration/deceleration time is longer than specified. 3.10 Note) When replacing the spindle control PCB or the control PCB, follow the cautions described in section 6.2. Refer to Appendix 2. 3.1. Power Voltage Check Check AC power voltage and DC power voltage on the spindle control PCB. Test points and standard values are as specified in Table 3.1. Tablo 3.1 Power voltage check AC power voltage check Check at INPUT terminals R,S,T (See 4.2) PCB on the spindle control DC power voltage check Voltage| Test points Standard value 424.V | 424V-0V | About 25 v 44% 415v | HSV-0V | +15 Vv 442 sv | t5v-ov | 45 v 42% -1sv | -1s5v-av | -15 v azTest points (refer to Appendix 6.) Note) 3.2. Power On Indicator Lamp PIL is 1sv etsy ey isy 24ve CE 2 psa cur] (&S Spindle control PCB for models 18 -35 Be careful that the 200 and 300 VDC on CNS for models 6S ~ 228, not Lit Table 3.2 Check procedure and remedy Spindle control PCB for models 65 -225 VAC is output on CNB connector for models 1S - 38 fuse PUR, FUS or FUT is blown. Ttem Causes Check procedure Remedy 1 | AC power is not Check it at power supplied. input terminals R,S,T. 2 |For models 65 - 228, | See Appendix 5. Replace fuse FUR, FUS or FUT. not plugged correctly, (N4, 5: models 1s - 38 CN ~ 6: models 68 - 228 guide groove appears on the PCB connector surface. 3 | Por models 18 - 38, | Check if alarm indi- | Check whether the pulse fuse FI or F2 is cations of fuses F2 generator cable or blown. and F3 appear. position coder cable For models 65 ~228, _| See Appendix 5. for orientation is open, fuse F2 or F3 is Replace the fuse Fl, F2 blown, or F3, When the fuse is blown even if replacing it, replace the PCB. 4 | PCB connectors are Check if the connector | Insert connectors correctly. Refer to section 6.Item Causes Check procedure Remedy PCB power circuit is defective, Lamp PIL is lit by +5 V and -15 Vv. Check power voltage according to Table 3.1. Replace PCB. Refer to section 6. 3.3. Alarm is Indicated Alarns on AC spindle motor and servo unit are indicated on Five digits of seven-segment on the servo unit PCB. indications and alarm signals is shown in Table 3.3 (a). (b). Teble 3.3 (a) Alarm (modals 18 -38) Correspondence between seven-segment Alarm No. Meanings Contents Remedy AL-O1 Motor overheat | This lamp lights when Cool the motor internal temperature of and reset the notor is higher than the alarm. specified value. AL-02 Excessive ‘This lamp lights when the | Reset alarm. deviation of notor speed is largely speed deviated from the command speed. AL-03 Defective Detects that regenerative | Reset alarm regenerative current has flown longer after removing current, than the allowable time. the problem. Al=0% _ AL-05 c= AL-06 overspeed ‘This lamp lights when the | Reset alarm. (Analog motor exceeds 115% of the detection) rated speed. AL~07 overspeed This lamp lights when the | Reset alarm, (Digital motor exceeds 115% of the detection) rated speed. AL-08 Overvoltage ‘This Lamp lights when Reset alarm. voltage largely exceeds the rated working voltage range due to a tap selection failure, etc. AL-10 Detects Lower betects the input power Remove the voltage. voltage lessened. problem and reset the alarm. = 10-Alarm No. Meanings Contents Remedy Al-11 Excessive high | Detects over DC voltage of | Remove the voltage of DC power. problem and Link reset the alarm. AL=12 Abnormal current | Detects over current of Remove the of DC Link circuit. problem and Defective reset the alarm. transistor AL-13 ~ 15 - Al-16 - 23 | Defective arithmetic circuit and peripheral circuit No indica~ | Defective ROM tion Table 3.3 (b) Alarm (models 6S - 228) Alarm No. Meanings Contents Remedy AL-O1 Motor overheat | This lamp lights when Cool the motor internal temperature of and reset the motor is higher than the alarm, specified value. AL~02 Excessive This lemp Lights when the | Reset alarm. deviation of motor speed is largely speed deviated from the command speed. AL~03 424 V fuse is +24 V fuse of the control | Replace a fuse blown, power is blown. and turn on the power again, AL-04 Open phase of A phase of input power is | Remove the input power open. problem and turn fon the power again. 1-05 =— AL+06 Overspeed This lamp lights when the | Reset alarm. (Analog notor exceeds 115% of the detection) rated speed. AL-07 Overspeed This lamp Lights when the | Reset alarm. igital motor exceeds 115% of the detection) rated speed. AL-08 Overvoltage Voltage extremely excesses | Reset alarm. the rated voltage. sabeAlarm No. Meanings Contents Remedy AL=09 Overheat of Temperature of radiator Cool the rediator such as semiconductor is radiator and extremely high. reset an alerm. AL~10 Lower voltage of | Detects lower voltage of Remove the input power input power. problem and turn on the power again. AL-LL Excessive high | Detects over DC voltage of | Remove the voltage of DC power. problem and Link reset the alarm. AL=12 Abnormal current | Detects over current of Renove the of DC Link circuit. problem and Defective reset the alarm, transistor AL-13 Defective Abnormal transmission Remove the arithmetic between microcomputer and | problem and cireuit peripherals reset the alarm. Ale 14 Defective ROM Detects defective ROM. Replace ROM. Alr15 Defective Detects defective optional | Remove the optional circuit | circuit and erroneous problem and connection to optional reset the alarm, circuit. 1) Alarm No. O1 (AL~01) Motor is overheated. Item Causes Check Remedy 1 | Built-in fan motor of spindle motor is defective, Replace fan motor, 2 | Overload operation Check it using a load meter. Re-examine cutting conditions and tools. 3 | Motor cooling system is dirty. Clean it using compressed air or vacuum cleaner. 4 | Disconnection or poor contact of wiring Check connections between motor and servo unit. Confirm the connection of connector for signal. (Note) Note) Refer to Appendix 2. -2-2) Alarm No, 02 (AL-02) Speed is deviated from the command value. Trem Causes Check Remedy 1 | overload Check it using a load | Re-examine cutting neter. conditions and tools. 2 | Transistor module is | Transistor collector- | Replace transistor defective. emitter is open. module. (Note 1) 3 | Blow out or poor Check fuses F4A ~ F4M | Connect fuses securely, connection of the for blown out or and replace blown out driver protective missing. fuses, if any. fuse on PCB. 4 | Speed feedback signal | Check the speed feed- | Check the motor speed is defective. back signal level. detector or signal (ote 2) cable. 5 | Wiring failure (disconnection, poor Check if connection cables are normally on the power supply. contact, etc.) connected. Note 1) Refer to section 6.4. Note 2) Speed feedback signal check Observe the speed feedback signal using an oscilloscope under the rota~ tion command off (motor stop, drive power off) condition after turning Observe it at the following check terminals, while Slowly turning the wotor by hand. Tee palate Normal vaveforms PAO Siesnatciae 75-07 Sane 6 show above mov 2.5 40.2 Woe nov Sane as shown above Pao sa (CW rotation) Soot Te Te Check within ON/OFF duty is 50Z. (PAP and PBP signals are inverted in CCW direction.) -13-3) Alarm No. 03 (AL-03) = Models 18 ~ 38: Defective regenerative circuit Item Causes Check Remedy 1 Transistor TR1 on the regenerative circuit is defective. Cheek collector (C), emitter (E) and base (B) of transistor. Refer to section 6.4, Replace transistor TRI. - Models 68 - 228: #24 fuse is blown. Item Causes cheek Remedy 1 Fuse Fl on PCB is blown, Replace fuse Fl. 4) Alarm No. 04 (AL-04) Open phase of input power (no dels 68 - 228) Item Causes Check Remedy 1 | High impedance on Ac | - Alarm AL-04 lights | - Replace the power power supply side. only when the motor supply having low (Example) speed is reduced power impedance, Two transformers are from high speed. (iote 1) connected in series or = Looseness of input vhen a variable auto~ cable connector. transformer is Example: connected. Open phase due to loosened screws. 2 | transistor module is Replace transistor defective. module. (Note 2) 3 | Mec or AC reactor is Replace the defective defective. Detection resistor RS or R6 is open. part. Note 1) Power impedance checking method. “ | ==Calculation formla BO ~ EL Bo * 100 (2) < 7 (x) where E0: Voltage when the motor stops operating. Bl: Voltage during acceleration of motor or voltage just before the motor speed begins lowering with a load applied. Input power specifications Name Specifications Nominal rated voltage | 200/220/230 vac Allowable voltage -15% ~ +10% fluctuation width Power frequency 50/60 Hz Power impedance Voltage fluctuation due to load (120% load at 30 minute rating): Less than 7% Note 2) Refer to section 6, 5) Alarm No. 06 (AL~06) Overspeed (analog detection) Item Causes Cheek. Remedy 1 | PcB setting failure or | Check PCB for normal | Change setting of PCB. adjusting failure setting and adjustment.) Confirm parameter F-5. 2 | Wrong specification of | Check specification Replace ROM. ROM (memory IC) referring to Table 1.2 (a). 3 | PCB is defective. Replace PCB, Refer to section 6. 6) Alarm No. 07 (AL-07) Overspeed (digital detection) Same as in alarm No. 06 (AL-06). 7) Alarm No. 08 (AL-08) Overvoltage Trem Causes Check Remedy 1 | Ac power voltage Check power voltage. | Stabilize the input exceeds the rated voltage. value. = 15 =8) Alarm No. 09 (AL-09) Radiator is overheated. (models 68 ~ 228) Item causes Check Remedy 1 | Cooling fan is Check if fan is Replace fan. defective. stopping. 2 | Overload operation. | Check load by using a | Re-examine the cutting Joad meter, condition. 3 | dusty and dirty. Clean using compressed air or vacuum cleaner. 9) Alarm No. 10 (AL~10) 10) Alarm No. 11 (AL=11) Input power voltage drops. This elatm indicates abnormally low AC power voltage (-15% or less). Overvoltage of DC link eireuit. (Regenerative circuit is faulty ... Regeneration failure) = Tren Causes Check Remedy 1 High power impedance. Examine AC power specification. Refer to section 4.2. 2 | PoR is defective. Replace PCB. (Note) 3 | Defective transistor Replace transistor module (TMI), module. (Note) 4 | Resistor R10 is open. Repair resistor R1O. 11) Alarm No. 12 (AL~12) Note) Refer to section 6. Overcurrent flows to DC link circuit. Tem causes Check Remedy 1 Output terminals or internal circuit of motor is shorted, Check connections, 2 | Transistor module is | Check the transistor | Replace transistor defective. nodule. module. (Note) 3. | PCB is defective. Replace PCB. (Note) Note) Refer to sections 6.2 12) Alarm No, 13 (AL~13) Replace PCB. - 6.4. CPU alarm. (models 6S ~ 22) Refer to section 6. 2 ge13) Alarm No, 14 (AL-14) ROM is defective. (models 68 - 22S) Item Causes Check Remedy 1 | ROM is not mounted at | Check if ROM is Mount ROM properly. all or not properly | unplugged from the mounted. socket or if its leads are broken, 2 | ROM is defective, Check series No. of Replace ROM having ROM, correct specification, See Table 1.2 (a). 14) Alarm No. 15 (AL-15) Defective optional circuit (models 6S - 225) Item Causes Check Remedy 1 | Defective optional PCB Replace PCB. (Note) Refer to section 6.3, 2 | Optional PCB con- Check and correct the nection is improper. connection. Refer to Appendix 1. 3.4 Motor does not Rotate or its Rotation is Abnormal Item causes Check procedure Remedy 1 | Defective phases of | Alarm lamp lights on | Repair phases. motor power line spindle servo unit when| Refer to Appendix 2. rotation command is given. Alarm lamp does not Apply higher voltage light. of speed conmand, 2 | Command signal Check signal cable connection failure Connection. 3 | Parameter is not Set parameters F-01 and proper. F-02 correctly, Refer to section 5.4. 4 | ROM is not proper. Check series No. of Set ROM correctly, ROM. See Table 1.2 (a). Snipe3.5. Vibration or Noise is too Large during Rotation Teem Causes Check procedure Remedy 1 | Motor is defective, Replace motor. 2 | PcB is defective, Run the motor idly. Replace PCB. When the connector CN2 | Refer to section 6. from AC spindle servo unit while rotating the motor, overheat alarm (AL-O1) occurs, and the motor runs idly. (Nore) If vibrations and noises are reduced during idle run as compared with normal rotation time, the control circuit is defective. Note) To perform idle run contact with the NIB whether idle run is considered. Some of sequences makes brake enable. 3.6 Noise is Produced from Motor during Deceleration During deceleration of the motor, energy is regenerated to the power supply through the regenerative control circuit. If the regenerative energy is excessive, the tegenerative current limit circuit operates to change the motor current waveform, causing an abnormal noise to be produced from the motor. In such @ case, lessen parameter F-20 until no abnormal noise is produced. Lessening F-20 makes the deceleration period long. 3.7. Speed Overshooting or Hunting Occurs Trem Causes Check procedure Remedy 1 | overshooting Enlarge F-21 or F-22. | Readjust. Refer to (Note) section 5.4, 2 | spindle hunting Readjust. Refer to section 5.4, Note) Adjust F-21 for "HIGH" clutch, and F-22 for "LOW" clutch, 3.8 Cutting Force is Low Item Causes Check procedure Remedy 1 | ROM is not proper, Check it referring to | Replace ROM. Table 1.2 (a). 2 | Torque limit command | Chock signal. is applied. 3. | Loosened helt Check belt tension. as3.9. Orientation is not Correct Item causes Check procedure Remedy 1 Setting or adjusting failure of orientation control circuit. Check if circuit is set and adjusted as specified in data Refer to section 7. (position coder or magnetic sensor) is defective. waveform of the position detector. sheet. 2 | Orientation control Replace PCB. Refer to circuit PCB is section 6. defective. 3. | Spindle control PCB is | Adjust deceleration Adjust PCB. Refer to not adjusted properly. | time of spindle control | section 7. circuit. Adjust parameter F-20 to shorten the decelera~ tion period. 4 | Position detection Check the output signal | Replace the position coder or magnetic sensor. correctly, set too low, the deceleration period becomes long. Refer to section 3.6. 3.10 Acceleration/Deceleration Time is Long Ttem Causes check procedure Remedy 1 | Torque limit command | Check signal. is applied. 2 | Defective receiver Change torque limit Replace receiver part part activates the parameter F18 to (HY2) or PCB. torque limit. adjust acceleration period. 3 | PCB is not adjusted If parameter F-20 is | Readjust F-20. Refer to section 5.4. AAT4, INSTALLATION 44 Installation Procedure Observe the checking procedure shown in Table 4,1 at the installation. cireuit. Table 4.1. Installation procedures Item Description Remarks 1 | Check if specifications of motor, | Check if motor corresponds to servo unit, options, etc. are units, PCB, and ROM correctly correct. according to Table 1.2. 2 | Check appearance for damage Check resistors, and parts on the PCB. 3 | Check the working AC power supply | See Table 4.2.1. for voltage, voltage fluctuation, power capacity (kVA) and frequency. 4 | Connect the earth wire, power Refer to sections 4.2, 4.3, 4.4 cable and drive power cable. and Appendix 1. 5 | Check setting and adjustment Refer to section 5.1. results, 6 | ‘urn on AC power supply, and make | Refer to Appendix 6. sure that green lamp PIL. lights on PCB. 7 | Give rotation command to check the normal rotation and reverse rotation movement. 8 | Check the operation over the entire velocity range. 9 | Adjust spindle orientation Refer to section 7. ~ 20 -4.2. Power Connection 42.1. Power voltage and capacity check Measure the AC power voltage before connecting the power supply, and take the following measure according to power voltage. Table 4.2.1 (a) Checking AC power voltege AC power voltage | Nominal voltage Measures 170 ~ 253 vac Connect directly. Higher than 254 vac | 380 V to 550 V | Set input voltage to 200 VAC using insulation transformer. The input power specification of the AC spindle servo unit is as specified in Table 4,2.1 (b). Use a power source having the power capacity having a sufficient allowance so that no trouble due to voltage drop occurs with the maximum load. "i 42:18) Input poner scion of AC ine ui Nominal rated voltage 200/220/230 VAC, 3 phases ‘ilowable voltage Eluctwa- | “152 vo H102 then coed 90 fe /6oke He Power | woeor sodei | 15] 1.59]25 [38] $57 55 [es [127 [zs] ss]ies fas capacity | capacity with soeainute | 4] 7{7| 9] 9 frz|ar| a7 bee fos [oe for rating (kVA) 4.2.2 Protective earth connection Connect the protective earth to connection terminal @ before connecting the power supply. Use the protective earth having sufficient capacity as compared with the feeder circuit breaker capacity. 4.23 Power connsction Connect the power cable after protective earth connection. The power phase rotation is not specified for AC spindle servo unit. The cooling fan motor employs three-phase power. When connect the input power to the unit, check the proper phase connection. 4.3 AC Spindle Motor Connection Connect the AC spindle motor according to the connection diagram in Appendix 1, If the drive power cable connection sequence is in error, vibration are produced the motor does not rotate or alarm (AL-02) occurs to stop the motor. Always connect protective earth "Cc", 4.4 Single Cable Connection Gonnect the signal cable according to the connection diagram in Appendix 1. Sa125. SETTING AND ADJUSTING 5.1. Jumper and Variable Resistor on Spindle Control PCB (models 1S - 3S) Refer to Appendices 5 and 6 for part locations of the unit and PCB, Always confirm the location of parts on PCB before power on. Table 5.1 (a). Jumpers (models 18 - 38) Setting ae Jumper Contents State aiteeee s1 | Switches mode of Test mode TEST DRIVE control circuit Operation mode DRIVE s2 | Selects from right | Detector | Detector Depends upon 53 table according to I (cpm) | 11 (rpm) model, the speed at rated command (VCMD = 10 V) 6000 D Detector T: 4500 8000 c Gear of 256 teeth Detector II: 6000 10000 to B Gear of 128 teeth 12000 8000 to | 15000 to A 10000 20000 sh | Switches gain Normal operation OFF orF SS mode Switches gain ow ‘Table 6.1 (b)_ Variable resistor (models 15 - 35) Variable Yaris Contents Setting at shipment RVL Maximum speed in CCW Depends upon model. direction RV2 Maximum speed in GW direction RV Offset of speed detection Adjust TS3 to 0 mV 40.1 mV ac circuit rotation command OFF Rvs Voltage of +5 V +5. V 40.10 RVS Adjusts gain at switching of | 50% gain RV6 Gain of speed detection Model. Value Max. speed circuit for low speed s (rpm) | (rpm) Adjusts speed at 25 mV +2 nV | 35 15 43 6000 of VCMD for each model = 1s, 1.58, 28 | 20 44 80005.2. Jumper on Spindle Control Circuit (models 6S - 22S) Refer to Appendices 5 and 6 for parts location of the unit and PCR. Always confirm the location of parts on PCB before power on. Table 5.2 Jumpers (models 68-228) ae Setting at Jumper Contents Position ittgmene si | Drive mode DRIVE DRIVE Test mode rest 82 | Increases 10% of power voltage of | +10 No setting 45 Decreases 10% of power voltage of | -10 5 85 | MOFFI (CN3 - 15) and MOFF2 EXT INT (CN3 - 16) signals are used. MOFF1 and MOFF2 signals are not INT used. 86 | Option setting S6A: ON +24 V | Optional S6B: ON 45V | setting is S6C: ON -15 V | not set. OFF: Not apply | OFF 5.3 Parameter Setting Method The setting switch and the display part are arranged on the PCB like the figure below. Refer to Appendix 6, These switches enable to confirm and set parameters. eaaaa Setting switch Ione] (bara) SET 1) To confirm the current paraneter a) The speed is usually displayed at the display part (Five digits). The current parameter number can be displayed when "NODE" is on. The parameter number is displayed as tuo digits of "F-XX", Display part2) a To confirm the setting data a) Select the parameter number of data to be checked in the Following manner, b) Continuously turn 4 switches "NODE", "+ UP", "¥ DOWN" and "DATA SET” ON at the same time for more than one second. ©) The display part changes from the blank to "FFFFI 4) Off all switches, e) The current parameter is displayed when "MODE" is on. £) When "+ UP" is on with "MODE" on, the parameter number is incremented by 1. g) When "+ UP" is continuously on with "MODE" on, the parameter number increases continuously. h) When "¥ DOWN" is on with "MODE" on, the parameter number is decremented by 1. 4) When "} DOWN" is continuously on with "NODE" on, the parameter nunber decrenents continuously. 4) With "MODE" off, the data is displayed (4 digits) after approx. 0.5 second. k) After approx. 10 seconds the data display is selected, the speed display is selected. When all switches are off in any mode, the speed is finally displayed. Jo alter the data a) Select the parameter to be changed according to the steps (2)-(b) to (i). b) Turn "MODE" off: The data of parameter is displayed after approx. 0.5 second. c) Torn "+ UP" on: The data is incremented by 1. 4) Turn "t UP" on continuously: ‘The data is incremented continuously. e) Turn "+ DOWN" on: The data is decremented by 1. £) Turn "¥ DOWN" on continuously: The data is decremented continuously. g) The motor is controlled using the displayed data. h) When replacing the data with the modified data, keep turning "DATA SET” on for one second or more. i) The display part changes from the blank to "88888" and modification of the data completes. 4) When changing the data once again, follow the steps from (3)-(a) above. k) The speed is indicated automatically after about 10 seconds. For para~ meters F-13, F-14 and F30, speed is displayed after 2 seconds. 5.4 Number and Content of Parameter » 2) Motor speed indication Display data (Five digits) F-00 The speed of the motor is displayed. (rpm) Parameter No. Contents of data Use/no use of the machine ready signal (MRDY) Display data ae (Five digits) Contents of dar, 5 F-O1 0001 0, 1 (Standard setting: 0) Parameter No. Explanation: Machine ready signal (MRDY) is used L Machine ready signal (MRDY) is not used: 0 he3) Use/no use of speed override (models 68 - 228) Parameter No. Display data (four digits) Contents of data 4) Range of speed override (models 6S - 228) F-02 0001 0, 1 (Standard setting: 1) Explanation: Use speed override 1 Not use speed override: 0 Parameter No. Display data (Four digits) Contents of data F-03 0001 0, 1 (Standard setting: 1) Explanatio to 0. 5) Maximum speed Note) When F-02 is set to 0; speed override is not used, F-03 should be set Upper limit of speed override (up to 1202): 1 Upper limit of speed override (up to 1002): 0 (models 68 - 228) Parameter No. Display data (Four digits) Contents of data F-05 0 ~ 3 (Depend upon motor) Explanation: [65> 225 is = 35 (xpn) (xpm) ROEEInE: Up to 5000 | Up to 10000 ° up to 6000 | Up co 12000 1 Up to 15000 2 up to 20000 3 6) Output limit pattern Parameter No. Display data (Four digits) Contents of data F-06 0000 0 to 6 (Standard setting: 0) Explanation: This function is not available for a conventional type. In the following cases, select a pattern which is appropriate respectively. A, When the output is limited only at acceleration and deceleration, the motor accelerates and decelerates slowly, and operates at the rated output during steady rotation (Setting data: 1 or 4) (function similar to software start and stop) B, When the motor accelerates and decelerates at the maximum rated output and the output is limited during stable rotation (Setting data: 2 or 5) S34