Professional Documents
Culture Documents
Maintenance Manual
for
MDS-A, MDS-B & MDS-C1
AC Servo Amplifier & Spindle Controller
(Mitsubishi BNP-B2046C)
Publication # CMDSMA1100E
3/2001
CAUTION
All Mazak machine tools are engineered with a number of safety devices to protect
personnel and equipment from injury or damage. Operators should not, however, rely
solely upon these safety devices, but should operate the machine only after fully
understanding what special precautions to take by reading the following documentation
thoroughly.
Certain covers, doors or safety guards may be open or removed to more clearly show
machine components. These items must be in place before operating the machine.
Failure to comply with this instruction may result in serious personal injury or damage to
the machine tool.
This manual was considered complete and accurate at the time of publication, however,
due to our desire to constantly improve the quality and specification of all Mazak
products, it is subject to change or modification.
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Notes:
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SAFETY PRECAUTIONS
The machine is provided with a number of safety 6) Do not deface, scratch or remove any caution
devices to protect personnel and equipment from plate. Should it become illegible or missing,
injury and damage. Operators should not, order another caution plate from the supplier,
however, rely solely upon these safety devices, specifying the part number shown at the lower
but should operate the machine only after fully right corner of the plate.
understanding what special precautions to take by • BEFORE POWERING UP
reading the following documentation thoroughly.
DANGER:
• BASIC OPERATING PRACTICES
Cables, cords or electric wires whose insulation
DANGER: is damaged can produce current leaks and
1) Some control panels, transformers, motors, electric shocks. Before using, check their
junction boxes and other parts have high condition.
voltage terminals. These should not be touched WARNING:
or a severe electric shock may be sustained. 1) Be sure the instruction manual and the
2) Do not touch any switches with wet hands. programming manual are fully understood
This too, can produce an electric shock. before operating the machine. Every function
WARNING: and operating procedure should be completely
1) The emergency stop pushbutton switch clear.
location should be well known, so that it can be 2) Use approved oil resistant safety shoes, safety
operated at any time without having to look for goggles with side covers, safe clothes, and
it. other safety protection required.
2) Before replacing a fuse, turn off the main 3) Close all NC unit, operating panel, electric
incoming power switch to the machine. control panel doors and covers.
3) Provide sufficient working space to avoid CAUTION:
hazardous falls. 1) The power cable from the factory feeder switch
4) Water or oil can make floors slippery and to the machine main circuit breaker should
hazardous. All floors should be clean and dry have a sufficient sectional area to handle the
to prevent accidents electric power used.
5) Do not operated any switch without a thorough 2) Cables which must be laid on the floor must be
understanding of the actions about to be taken. protected from hot chips, by using rigid or
other approved conduit, so that short-circuits
6) Avoid accidental operation of switches.
will not occur.
7) Work benches near the machine must be
3) Before first time operation of the machine after
strong enough to hold materials placed on
unpacking it or from being idle for a long period
them to prevent accidents. Articles should be
of time (several days or more), each sliding
prevented from slipping off the bench surface.
part must be sufficiently lubricated. To do so,
8) If a job is to be done by two or more persons, push and release the pump button several
coordinating signals should be given at each times until the oil seeps out on the sliding
step of the operation. The next step should not parts. The pump button has a return spring, so
be taken unless a signal is given and do not force it to return.
acknowledged.
4) Oil reservoirs should be filled to indicated
CAUTION: levels. Check and add oil, if needed.
1) In the event of power failure, turn off the main 5) For lubrication points, oil specification and
circuit breaker immediately. appropriate levels, see the various instruction
2) Use the recommended hydraulic oils, lubricants plates.
and grease or acceptable equivalents. 6) Switches and levers should operate smoothly.
3) Replacement fuses should have the proper Check that they do.
current ratings. 7) When powering the machine on, turn on the
4) Protect the NC unit, operating panel, electric switches in the following order: first the factory
control panel, etc. from shocks, since this feeder switch, then the machine main circuit
could cause a failure or malfunction. breaker, and then the control power on switch
5) Do not change parameters or electrical located on the operating panel.
settings. If changes are unavoidable, record 8) Check the coolant level, and add coolant, if
the values prior to the change so that they can needed.
be returned to their original settings, if
necessary.
S-1
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S-2
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CAUTION:
CAUTION: 1) Thoroughly read and understand the safety
1) During automatic operation, never open the precautions in the instruction manual.
machine door. Machines equipped with the 2) Thoroughly read the whole maintenance
door interlock will set the program to single manual and fully understand the principles,
step. construction and precautions involved.
2) When performing heavy-duty machining, • MAINTENANCE OPERATION
carefully prevent chips from being accumulated DANGER:
since hot chips from certain materials can 1) Those not engaged in the maintenance work
cause a fire. should not operate the main circuit breaker or
• TO INTERRUPT MACHINING the control power "ON" switch on the
WARNING: operating panel. For this purpose, "Do not
When leaving the machine temporarily after Touch the Switch, Maintenance Operation in
completing a job, turn off the power switch on Progress!" or similar warning should be
the operation panel, and also the main circuit indicated on such switches and at any other
breaker. appropriate locations. Such indication should
be secured by a semi-permanent means in the
• COMPLETING A JOB reading direction.
CAUTION:
2) With the machine turned on, any maintenance
1) Always clean the machine or equipment. operation can be dangerous. In principle, the
Remove and dispose of chips and clean cover main circuit breaker should be turned off
windows, etc. throughout the maintenance operation.
2) Make sure the machine has stopped running, WARNING:
before cleaning. 1) The electrical maintenance should be done by
3) Return each machine component to its initial a qualified person or by others competent to do
condition. the job. Keep close contact with the
4) Check the wipers for breakage. Replace responsible person. Do not proceed alone.
broken wipers. 2) Overtravel limit and proximity switches and
5) Check the coolant, hydraulic oils and lubricants interlock mechanisms including functional parts
for contamination. Change them if they are should not be removed or modified.
seriously contaminated. 3) When working at a height, use steps or ladders
6) Check the coolant, hydraulic oil and lubricant which are maintained and controlled daily for
levels. Add if necessary. safety.
7) Clean the oil pan filter. 4) Fuses, cables, etc. made by qualified
manufacturers should be employed.
8) Before leaving the machine at the end of the
shift, turn off the power switch on the operating • BEFORE OPERATION & MAINTENANCE BEGINS
panel, machine main circuit breaker and factory WARNING:
feeder switch in that order. 1) Arrange things in order around the section to
• SAFETY DEVICES receive the maintenance, including working
1) Front cover, rear cover and coolant cover. environments. Wipe water and oil off parts and
provide safe working environments.
2) Chuck barrier, tail barrier and tool barrier (NC
software). 2) All parts and waste oils should be removed by
the operator and placed far enough away from
3) Stored stroke limit (NC software). the machine to be safe.
4) Emergency stop pushbutton switch. CAUTION:
• MAINTENANCE OPERATION PREPARATIONS 1) The maintenance person should check that the
1) Do not proceed to do any maintenance machine operates safely.
operation unless instructed to do so by the 2) Maintenance and inspection data should be
foreman. recorded and kept for reference.
2) Replacement parts, consumables (packing, oil
seals, O rings, bearing, oil and grease, etc.)
Should be arranged in advance.
3) Prepare preventive maintenance and record
maintenance programs.
000X717-KY 11/98
S-3
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aaaaaaaaaa
aaaaa
! WARNING
ALWAYS TURN THE MAIN CIRCUIT BREAKER TO THE “OFF” POSITION & USE AN APPROVED
LOCKOUT DEVICE WHEN COMPLETING MAINTENANCE OR REPAIRS.
LOCKOUT PROCEDURE
1) THE LOCKOUT PROCESS MUST BE PERFORMED BY AUTHORIZED PERSONNEL ONLY.
2) INFORM ALL EFFECTED PERSONNEL OF YOUR INTENT TO LOCKOUT AND SERVICE THE
SPECIFIED MACHINE.
3) SHUT OFF MACHINE POWER USING NORMAL SHUT DOWN PROCEDURES.
4) TURN OFF THE MACHINE AND INDIVIDUAL BUILDING CIRCUIT BREAKERS. MAKE SURE ALL
STORED ELECTRICAL ENERGY IS RELIEVED. (EG: SPINDLE & AXIS SERVO CONTROLLERS)
5) CONNECT THE LOCKOUT DEVICE AS SHOWN IN FIGURE 1, AND ATTACH THE APPROPRIATE
TAG AT THE MACHINE CIRCUIT BREAKER. THE TAG MUST IDENTIFY THE PERSON
RESPONSIBLE FOR THE LOCKOUT. THIS WILL ENSURE THAT POWER CANNOT BE
RESTORED BY ANYONE ELSE.
6) TEST THE MACHINE TO VERIFY THAT MACHINE SYSTEMS DO NOT OPERATE IN ANY WAY.
ONCE TESTING IS COMPLETE, MAKE SURE ALL SWITCHES ARE IN THE “OFF” POSITION.
CONFIRM THAT THE LOCKOUT DEVICES REMAIN PROPERLY INSTALLED.
7) COMPLETE THE REQUIRED MAINTENANCE OPERATIONS.
8) MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.
9) REMOVE THE LOCKOUT DEVICE. MAKE SURE ALL PERSONNEL ARE AT A SAFE LOCATION
BEFORE RESTORING MACHINE POWER.
PADLOCK
FIGURE
S-4
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INSTALLATION PRECAUTIONS
The following subjects outline the items that 6) In pouring grout, fasten the leveling block
directly affect the machine installation and start- base plates with the collar retaining screws
up. To ensure an efficient and timely installation, to prevent the base plates from dropping.
please follow these recommendations before When the grout has completely hardened,
calling to schedule a service engineer. level the machine properly, and tighten M24
nuts to secure the machine to the
foundation.
• ENVIRONMENTAL REQUIREMENTS
Note:
Avoid the following places for installing the
machine: The machine must be anchored to the
foundation with J-bolts, expansion bolts or
1) Avoid exposure to direct sunlight and/or near a other suitable method.
heat source, etc. Ambient temperature during
operation: 0° thru 45°C (32°F to 113°F). The machine accuracy and alignment
specifications quoted by Mazak can usually
2) Avoid areas where the humidity fluctuates be obtained when the minimum foundation
greatly and/or if high humidity is present; requirements are met. However, production
normally 75% and below in relative humidity. A of close tolerance parts requires the use of an
higher humidity deteriorates insulation and appropriate certified foundation. Foundations
might accelerate the deterioration of parts. that do not meet certified specifications may
3) Avoid areas that are especially dusty and/or require more frequent machine re-leveling and
where acid fumes, corrosive gases and salt are re-alignment, which can not be provided
present. under terms of warranty.
4) Avoid areas of high vibration. If any of these conditions cannot be met,
5) Avoid soft or weak ground (minimum load contact the nearest Mazak service office
bearing capacity of 1025 lbs./ft2) immediately.
• FOUNDATION REQUIREMENTS
For high machining accuracy, the foundation
must be firm and rigid. This is typically
accomplished by securely fastening the
machine to the foundation with anchor bolts. In
addition, the depth of concrete should be as
deep as possible (minimum 6 - 8 inches). Note
the following:
1) There can be no cracks in the foundation
concrete or surrounding area.
2) Vibration proofing material (such as asphalt)
should be put all around the concrete pad.
3) Form a “cone” in the foundation for J-bolt
anchors, or use expansion anchors.
4) With the foundation anchor bolt holes open
pour the primary concrete at a minimum
thickness of 6 - 8 inches. Typically, the
concrete must have a minimum compression
rating of 2500 lbs. @ 250 lbs. compression
and strengthened with reinforcing rods. When
the concrete has cured, rough level the
machine, and install the J-bolts, leveling blocks,
etc., and pour grout into foundation bolt holes.
5) Mix an anti-shrinkage agent such as Denka
CSA with concrete, or use Embeco grout to fill
the foundation bolt holes.
S-5
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• WIRING
1) Use only electrical conductors with
performance ratings equivalent or superior.
2) Do not connect any power cables for devices
which can cause line noise to the power Desirable Independent Grounding:
distribution panel, such as arc welders and high
frequency machinery.
3) Arrange for a qualified electrician to connect NC Earth resistance:
the power lines. Machine Less than 100 ohms
4) Incoming supply voltage should not deviate
more than ±10% of specified supply voltage.
5) Source frequency should be±2 Hz of nominal Common Grounds:
frequency.
Resistance to ground
= 100 ÷ the number of
[ CAUTION ] devices connected to
the grounding (ohms)
VERIFY THE ACTUAL MACHINE ELECTRICAL
Note: Never ground equipment as shown below:
POWER REQUIREMENT AND THE MAIN
TRANSFORMER RATING (IF APPLICABLE), AS
• GROUNDING
1) An isolated earth ground with a resistance to
ground of less than 100 ohms is required.
Typically, a 5/8” copper rod, 8 feet long, and
no more than 5 feet from the machine, is
sufficient. Building grounds or multiple
machines grounded to the same ground rod,
are not acceptable.
2) The wire size should be greater than AWG
(American Wire Gauge) No. 5 and SWG
(British Legal Standard Wire Gauge) No. 6.
000X713-KY 11/98
S-6
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! CAUTION
S-7
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WARNING
!
MAZATROL CNC CONTROLLERS PROVIDE PARAMETER SETTINGS TO LIMIT SPINDLE
RPM. THESE SETTINGS ARE BASED ON THE MAXIMUM SPEED SPECIFIED BY THE
CHUCK/ACTUATOR MANUFACTURER.
REFERENCE THE CNC PARAMETER MANUAL SUPPLIED WITH THE SPECIFIC MACHINE
TOOL TO IDENTIFY THE REQUIRED PARAMETERS TO CHANGE.
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.
WARNING
!
MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO
PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE.
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.
S-8
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WARNING
!
MAZAK MACHINES ARE ENGINEERED WITH A NUMBER OF SAFETY DEVICES TO
PROTECT PERSONNEL AND EQUIPMENT FROM INJURY AND DAMAGE.
NOTE: THE MAXIMUM INSERT WEIGHT FOR MAZAK MACHINES IS 20 gf. (0.04 lbs.).
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.
S-9
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WARNING
!
BEFORE STARTING OPERATION, CHECK THAT THE WORKPIECE IS SECURELY MOUNTED
IN A VISE OR A SUITABLE FIXTURE. BE CERTAIN THAT THE MOUNTING IS SUFFICIENT
TO WITHSTAND CUTTING FORCES DURING WORKPIECE MACHINING.
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.
WARNING
!
CONFIRM PROPER WORKPIECE FIXTURING/CLAMPING, TOOL SETUP AND THAT THE
MACHINE DOOR IS SECURELY CLOSED BEFORE THE START OF MACHINING.
VERIFY ALL SAFETY PRECAUTIONS OUTLINED IN THIS MANUAL BEFORE USING THE
FOLLOWING CUTTING CONDITIONS:
- CUTTING CONDITIONS THAT ARE THE RESULT OF THE MAZATROL FUSION 640
AUTOMATIC CUTTING DETERMINATION FUNCTION
IF ANY QUESTIONS EXIST, CONTACT THE NEAREST MAZAK SERVICE CENTER FOR
ASSISTANCE.
S-10
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CENGDB0551E
DOOR INTERLOCK SAFTY SPEC.
Determined by YMW Eng. H.Q. ‘99/9/1
Revised by YMC Prod. Eng. ’99.10.28
MACHINING CENTER
SET UP SWITCH
DOOR MODE
O (OFF) I (ON)
OPEN MANUAL Prohibit to move axis. Limit the rapid override. Max is 12%.
Prohibit to start spindle running. Prohibit to run chip spiral conveyor.
Prohibit to operate manual ATC. Can run spindle JOG.
Prohibit to operate manual Pallet Changer. Can run spindle Orient.
Prohibit to run chip spiral conveyor. Can operate manual ATC.
AUTO Prohibit cycle start. Prohibit cycle start.
Prohibit to run chip spiral conveyor. Prohibit to run chip spiral conveyor.
CLOSE MANUAL Door is always locked. Door lock can be released by pushing “DOOR UNLOCK SW” on operator panel.
I But, it can not release in operating ATC/Pallet changer/Axis/Spindle.
V Prohibit to move axis. Limit the rapid override. Max is 12%.
OPEN Prohibit to start spindle running. Chip spiral conveyor would stop.
Prohibit to operate manual ATC. Can run spindle JOG.
Prohibit to operate manual Pallet Changer. Can run spindle Orient.
Prohibit to run chip spiral conveyor. Can operate manual ATC.
AUTO Door is always locked. Door lock can be released by pushing “DOOR UNLOCK SW” on operator panel.
But, it can not release in auto operation running except single block stop or feed hold stop or M00 program
stop or M01 optional stop and spindle stop. If not, Alarm displayed “Door open invalid”.
If release the lock by note(*1), Alarm will occur Prohibit cycle start.
then stop the all motion. Chip spiral conveyor would stop.
Chip spiral conveyor would stop.
TURNING CENTER
SET UP SWITCH
DOOR MODE O (OFF) I (ON)
Can operate CHUCK, TAILSLEEVE , Can operate CHUCK, TAILSLEEVE ,
STEADY REST for Loading workpiece. STEADY REST for Loading workpiece.
Can NOT operate Spindle, Axis, Turret, Can not operate Spindle running, but
MANUAL Coolant, ToolEye, Partscatcher, Can operate Spindle JOG and Spindle Orient.
Chip Conveyor. Limitation of speed for axis movement .
(Override is 10% max.)
OPEN
1 step index only for turret.
Can operate CHUCK, TAILSLEEVE , Can operate CHUCK, TAILSLEEVE ,
AUTO STEADY REST for Loading workpiece. STEADY REST for Loading workpiece.
Can not run Auto-operation. Can not run Auto-operation.
CLOSE MANUAL Can not open the front door in Spindle running, Axis moving, Auto-running( Cycle start, Feed hold ) due to
-> & Mechanical locking system. (Except Single Block Stop or M00 program stop or M01 optional stop)
OPEN AUTO But, if release the lock by note(*1), Alarm will occur then stop the all motion.
MANUAL No Limitation. No Limitation.
CLOSE AUTO No Limitation. Can not run Auto-operation.
*1 : Door lock mechanism can not be released in machine stop by NC power OFF.
If it is necessary to release the lock such as emergencies, the lock can be released by operating the
supplementary lock release mechanism of the main body of the safety door lock switch.
*2 : Override Limitation of Rapid speed of AXIS
Machining Center : 12%. Turning Center : 10%.
*3 : Chip Conveyor and Coolant should stop in the door open.
PED-EDS-001 S-11
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CENGDB0551E
APPENDIX
DOOR UNLOCK
MACHINE SET UP
SWITCH
SWITCH
PED-EDS-001 S-12
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MACHINE DOCUMENTATION
CUSTOMER EVALUATION The Other Thoroughbred From Kentucky
Your opinion is important to enable us to issue documentation that will fit your needs.
Thank you for taking the time to supply this information.
Date:
Machine Type: Machine Serial#: NC Type:
Customer: Reported By:
Address: Position:
Telephone#:
Manual Publication #: Excellent Good Adequate Fair Poor
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SF-202Xa
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Notes:
Introduction
The numeric control unit is configuredof the control unit, operation board,servo amplifier,
spindle amplifier, powersupply + servo drive or spindle drive, servomotor, and spindle motor,
etc.
In this manual, the following items are generically called the "servomotor".
Servomotor
Spindle motor
In this manual, the following items are generically called the"servo amplifier".
Servo amplifier
Spindle amplifier
Power supply + servo drive or spindle drive
t-
E Ro
so
L11 / Ro
L21 / s o
L11
I L2 1
I
M6478-ES
For Safe Use
/1\ WARNING
Do not open the front cover whole the power
is ON or during operation. Failure to observe this
A could lead to electric shocks.
Do not operate the unit with the front cover removed. The high voltage terminals and charged
A sections willbe exposed, and can cause electric shocks.
Do not remove the front cover even when the power is OFF unless carrying out wiring work or
A of the servo amplifier is charged, and can cause electric
periodic inspections. The inside
shocks.
Wire the servo amplifier and servomotor after installation. Failure to observe this could lead to
A electric shocks.
Do not damage, apply forcible stress, place heavy items or engage the cable. to
Failure
observe
A this could lead to electric shocks.
2. Fire prevention
I A CAUTION
Install the servo amplifier, servomotor and regenerative resistor on noncombustible material.
A Direct installation on combustible material or near combustible materials could lead
to fires.
Shut off the power onthe servo amplifier sideif a fault occurs in the servo amplifier. Fires could
A be caused if a large current continues to flow.
Shut off the power with an error signal when using the regenerative resistor. The regenerative
A resistor could abnormally overheat and cause a fire due to a fault in the regenerative transistor,
etc.
.
I Outline ................................................................................................................... I-?
1.1 Features ............................................................................................................. I-1
1.2 System configuration .......................................................................................... 1-3
.
2 System Start Up ......................................................................................................... 1-7
.
3 Addition and Replacement Methods of Units and Parts........................................ 1-9
3.1 Unit replacement ................................................................................................ 1-9
3.2 Servomotor encoder ............................................................................................ 1-12
3.2.1 OHUOHA typeencoder ............................................................................. 1-12
3.2.2 OSWOSA type encoder ............................................................................. I-?4
3.3 Battery unit ......................................................................................................... 1-17
3.4 Unit fan ............................................................................................................... 1-18
.
4 Daily Maintenance ...................................................................................................... 1-20
4.1 Tools formaintenance ........................................................................................ 1-20
4.2 Periodic inspection .............................................................................................. 1-20
.
5 Maintenance Parts ..................................................................................................... 1-22
. .................................................................................................................
6 Noise Filter 1-25
I1.MDS-A-CV MDS-B-CV MDS-A-CR Power Supply Section *
.
I Troubleshooting ......................................................................................................... 11-1
1.1 Status display ..................................................................................................... 11-1
1.2 Troubleshooting per power supply alarm ........................................................... 11-4
1.3 Power supply warnings ....................................................................................... 11-17
I11.MDS-A-Vx MDS-B-Vx Servo System Section
.
1 MDS-CI-VlN2 Servo Drive Unit................................................................................ 111-1
1.1 Points changed from B Series ............................................................................. 111-1
1.1.1 Compatible detectors and compatible motors ............................................ 111-1
1.1.2 2-system compliance (standard amplifier (MDS-B-VlN2) mode and
high-gain amplifier (MDS-9-Vl4N24) mode)............................................. 111-2
.
2 Adjustment Procedure .............................................................................................. 111-3
2.1 Initial adjustment ................................................................................................. 111-3
2.1.1Confirmation of parameters ....................................................................... 111-3
2.1 -2 Adjustment of optimum acceleration/deceleration time constant .............. 1114
2.1.3 Adjustment of speed gain .......................................................................... 111-6
2.1.4 Zeropointreturn ........................................................................................ 111-8
2.1.5 Adjustment of absolute position detection ................................................. 111-9
2.2 Adjustmentdetails .............................................................................................. 111-11
2.2.1 Vibration or vibration sounds occur ........................................................... 111-11
2.2.2 The cutting surface precision is poor. The roundness is poor ................ 111-1 2
2.2.3 Overshooting occurs during positioning . A limit cycle occurs................. 111-13
2.2.4 Accumulated feed occurs with pulse feed ................................................. 111-14
2.3 Adjustment of special functions .......................................................................... 111-1 5
2.3.1 High precisioncontrol mode ...................................................................... 111-1 5
.
3 Troubleshooting (MDS-A/B Series) .......................................................................... 111-1 7
3.1 Status display ..................................................................................................... 111-17
3.2 Troubleshooting per servo alarm ........................................................................ 111-23
3.3 Precautions.......................................................................................................... 111-52
4.Troubleshooting (MDS-CI Series)
............................................................................ 111-53
4.1 Servo warnings and servo alarms ....................................................................... 111-53
.
5 Appendix ................................................................................................................... 111-84
5.1 Changing from closed loop to semi-closed loop ................................................. 111-84
5.2 Servo system configuration table ....................................................................... 111-86
I
IV. MDS-A-SP MDS-B-SP Spindle System Section
I.Adjustment Procedure .............................................................................................. iv-1
1.1Trialoperation ..................................................................................................... Iv-1
1-2 Adjustment of orientation .................................................................................... rv-2
1.2.1
Operation .................................................................................................. 1v-2
1-2.2 Operation sequence .................................................................................. 1v-3
1.2.3 Encoderorientationstop positions ............................................................ 1v4
1.2.4 Parameter block diagram for orientation ................................................... 1v4
1-2.5 Preparation for adjustment of motor built-in encoder orientation .............. 1v-5
1-2.6 Preparation for adjustment of encoder orientation .................................... 1v-6
1.2.7 Preparation for adjustment of magsensor orientation ............................... 1v-8
1-2.8Adjustment of orientation .......................................................................... I
V 0I
-
1-2.9 Adjustment of sew0 rigidity ....................................................................... 1v-11
1-2.10 "Delay/advance control" and "PI control" application ................................ 1v-11
1.2.11 Troubleshooting during orient error ........................................................... IV -
2I
1.3 Synchronous tap adjustment .............................................................................. 1v-15
1-3.1 Synchronous tap operation adjustment ..................................................... IV -
5I
1.3.2 Troubleshooting for synchronous tap error ............................................... 1v-18
2.Troubleshooting ......................................................................................................... N-19
2.1 Introduction ......................................................................................................... Iv-
9I
2.2 First step of troubleshooting ............................................................................... Iv-
9I
2.3 Second step of troubleshooting .......................................................................... rv-21
2.4 Alarm and warning table .............................................................................. :...... 1v-23
2.5 Approach per phenomenon ................................................................................ 1v-24
2.5.1 When alarm or warning is displayed on the 7-segment display ................ 1v-24
2.5.2 When alarm or warning is not displayed on 7-segment unit ..................... 1v-38
2.6 Periodic inspection .............................................................................................. 1v-43
2.6.1 Inspection of controlunit ........................................................................... 1v-43
2.6.2 Inspection of motor .................................................................................... 1v-44
3. Disassembly and Assemblyof Motor ............................................. ......................... 1v45
3.1 Disassembly and assembly of SJ type AC spindle motor ................................... N-45
3.2 Disassembly and assembly of SJ-N type AC spindle motor ............................... 1v-53
4. Installation of Orientation Position Detector ......................................... ................. 1v-62
4 .I Magnesensor 1-point orientation ........................................................................ 1v-62
4.1.1Magnetand sensor ................................................................................... 1v-62
4.1.2 Orientation of magnet and sensor head .................................................... 1v-63
4.1.3 Caution on installation of magnet .............................................................. 1v-67
4.1.4 Caution on installation of sensor head ...................................................... 1v-67
4.1.5 Types and outside dimensions of magnesensor........................................ 1v-69
4.2 Encoder orientation (4096 points) ...................................................................... 1v-71
4.2.1
Configuration ............................................................................................. 1v-71
4.2.2Outside dimensions ................................................................................... 1v-72
5. Contour Control (C-axis Control) Encoder .............................................................. 1v-73
5.1Separate stand-type encoder ............................................................................. 1v-73
5.1.1 Name: OSE9OK + 1024 BKO-NC6336HOl ............................................ 1v-73
5.1 -2 Outside dimensions ................................................................................... 1v-73
5.1.3 Connectors ................................................................................................ 1v-73
5.1.4 Mechanical specifications .......................................................................... 1v-74
5.1.5 Handling, installation and operation of encoder ........................................ 1v-75
5.2 Built-in encoder ................................................................................................... 1v-76
5.2.1 Model : MBE-9OK ...................................................................................... 1v-76
5.2.2 Model : MHE-9OK ...................................................................................... 1v-76
6.Appendix ................................................................................................................... 1v-77
6.1Parameter list ..................................................................................................... 1v-77
ii
3. Injury prevention
A CAUTION
Do not apply a voltage other than that
specified in Instruction Manualon each terminal. Failure to
or damage, etc.
observe this item could lead to ruptures
Do not mistake the terminal connections. Failure to observe this item could lead to ruptures
or
A damage,
etc.
4. Various precuations
Observe the following precautions. Incorrect handling of the unit could lead to injuries and electric
faults,
shocks, etc.
(1) Transportation and installation
/1\ CAUTION
A correctly transport the product according its
toweight.
Use the servomotor's suspension bolts only when transporting the servomotor.
Do not
it is installed on the machine.
transport the servomotor when
Do not holdthe connected power supplyor cables when transporting the servomotor.
Follow this Instruction Manual and install the unit in a place where the weight can be borne.
Secure the specified distance betweenthe sew0 amplifier and control panel, or between the
servo amplifier and other devices.
Do not installor run a servo amplifieror servomotor that is damaged or missing parts.
Do not let conductiveobjects such as screwsor metal chips, etc., or combustible materials such
as oil enter the servo amplifier
or servomotor.
Ill
A CAUTION
A Store and use the units under the following environment conditions.
Conditions
Environment
Servo amplifier Servomotor
0°C to+55"C 0°C to +40"C
Ambient temperature
(with no freezing) (with no freezing)
Ambienthumidity I TO followseparatespecifications
I (with
no
dew
8O%RH or less
condensation)
Storage temperature To follow separate specifications -15°C to +70°C
A Securely fix the servomotor to the machine. Insufficient fixing could lead to the servomotor
slipping off during operation.
A Never touch the rotary sections of the servomotor during operations. Install a cover, etc.,
on the shaft.
A Do not apply a load exceeding the tolerable load onto the servomotor shaft. The shaft could
break.
a When storing fora long time, please contact the Service Center
or Service Station.
IV
(2) Wiring
A CAUTION
Correctly and securely perform the wiring. Failure tosodo
could lead to runawayof the
A servomotor.
Do not install a condensing capacitor, surge absorber
or radio noise filter on the output side
of
A the servo amplifier.
Correctly connect the output side (terminals
U, V, W). Failure to doso could lead to abnormal
A operation of the servomotor.
Do not directly connect a commercial power supply to the servomotor. Doing so could lead to
A faults.
A When using an inductive load such as a relay, always connect a diode as a noise measure
parallel to that load.
When using a capacitance load such as a lamp,
ahways connect a protective resistor as
a noise
A measure serial to that load.
When connecting a DC relay for the control output Servo amplifier
Control output
observe this could cause the signals notbeto
output due to a fault
or the protective circuit to fail.
2 Do not connect/disconnect the cables connected between the units while theispower
Securely tighten the cable connector fixing screw
cause the cable tof a l l off while the power is
When use of a shielded cable
ON.
ON.
or fixing mechanism. An insecure fixing could
A Always separate the signals wires from the drive wire and power line.
Use wires and cables that have a wire diameter, heat resistance and flexibility that conforms to
A the system.
so that the battery unit is not mistakenly wired.
Check the cables sufficiently before wiring
A The battery in the battery unit could short circuit and be charged due to incorrect wiring, and
could lead to battery ignition, heating, rupture
or generation of toxicgas.
I CAUTION I
Check and adjust each program and parameter before starting operation. Failure todo so could
A
A
lead to unforeseen operation of the machine.
Do not make remarkable adjustments and changes as the operation could become unstable.
V
(4) Usage methods
CAUTION
A Use the spindle motor, spindle amplifier and regenerative resistor with the designated
or trouble.
so could lead to fires
combination. Failure to do
8 The brakes (magnetic brakes) assembled into the servomotor are for holding, and must
used for normal braking.
be not
A There may be cases when holding is not possible due to the magnetic brake's or the
life machine
construction (when ball screw and servomotor are coupled via a timing belt, etc.). Install a stop
device to ensure safety on the machine side.
A After changing the parameters or after maintenance and inspecbon, atways test the operation
before starting actual operation.
A Do not enter the movable range of the machine during automatic operation. Never place body
parts near or touch the spindle during rotation.
A Follow the power supply specification conditions given in the separate specifications manual for
the power (input voltage, input frequency, tolerable power failure time, etc.).
(5) Troubleshooting
/1\ CAUTION
If a hazardous situation is predicted during power failure or product trouble,ause
servomotor
A with magnetic brakes or install an external brake mechanism.
Use a double circuit configuration
A Shut off with NC brakecontrol PLC output.
signal. Servomotor t
I RA1 EHG
VI
(6) Maintenance, inspection and part replacement
A CAUTION
Always backup the servo amplifier programs and parameters before starting maintenance
or
inspections.
If the batterylow warning is issued, save the machining programs, tool data and parameters
with an input/output unit, and then replace the battery.
or
When storing the battery unit, avoid places subject to direct sunlight, high temperatures
high humidities. Failure to observe this could lead to leaking
or rupture of the internal battery.
A
1 CAUTION
A Plug thegaps on the battery unit with non-conductive material such as cellophane tape before
disposing.
Disposal in the original state allow other metal chips entering the internal battery, and lead to
ruptures or fires.
The drawings givenin this Specifications and Maintenance Instruction Manual show the covers and safety
partitions, etc., removedto provide a clearer explanation. Always return the covers
or partitions to their
respective places before starting operation, and always follow the instructions given
thisIn
manual.
VI I
. ..-
I. MDS-A Series
MDS-B Series
Servo/Spindle System Configuration Section
I
1. Outline
I Outline
The MDS-A Series is a drive system that corresponds to the MELDAS M500 Series NCthat has been
developed to totally connected the servo drive and spindle drive sections. The MDS-B Series is the
successor to the MDS-A Series, and has been developed to satisfy European Safety Standards. This
Series has the following features.
The MDS-C1 Series is a drive system compatible with the NC system. This high-performance, compact
series is compatible with the MDS-B Series (some changes have been made).
1.I Features
Compact and lightweight
The converters that were conventionally built in each servo and spindle drive have been integrated
into one unit. The drive system volume, installation area and weight have been drastically reduced
with the incorporationof high density mounted electronic parts IGBT-IPM (Intelligent Power Module)
and the high performance heat radiating fin.
Standardization of dimensions
The outline has been standardized *to the book end type, and by unifying the height and depth
dimensions, installation in cabinets has been made easy. Furthermore, by matching the shape with
the NC unit, an integrated appearance with the NC has been realized.
1-1
1. Outline
2) Compact
The fin outline has been downsized by incorporating high-efficiency fins and a loss
low compact
IPM, and a thin type drive unitis realized.
3) Reliability
Heat generation has been reduced loss IPM, and the strength of the inner
by incorporating a low
support structure has been increased by integrating the terminal block with the wiring condu
This has improved the reliability compared to the conventional B Series.
A WARNING
I
b
Always ground the spindle driver and spindle motor with Class
3 or higher grounding.
I
/1\ CAUTION
1. Correctly connect the power phases(U, VI W) of the spindle amplifier and spindle motor.
Failure to doso could cause the spindle motor to malfunction.
2. Do not apply a voltage other than that specified to each terminal. Failure to observe this could
lead to rupturesor trouble.
/I\ CAUTION
1. Shut off the power on the spindle amplifier side if a fault occurs in the spindle amplifier. Fires
could be caused if a large current continues toflow.
2. Shut off the power with afault signal. The regenerative resistor could abnormally overheat and
cause a fire due toa fault in the regenerative transistor, etc.
1 3. Configure the magnetic brake operation circuit as a double circuit
so that tit will function with
the emergency stop switch even when the power supply is OFF, and alarm has occurred or
i
1
whentheservoONsignal is OFF.
Wire the power and main circuit as shown on the next page. Always use a no-fuse breaker
for (NF)
the power input wire.
1-3
. .. .
.
I
.- .
I.Outline
A CAUTION
<Control mode changeover>
(1) The 2-system compatible software is compatible from Version A1(BND-582WOOO-Al).
Version A0 is not compatible with the standard amplifier mode.
It is compatible only with the
high-gain amplifier mode.
(2) Whether to start the servo amplifier in the standard amplifier compatible mode or the high-
gain amplifier compatible mode is judged by the servo parameters SVOO9 to SV012 and
SV033 setting values setin the machine.
(3) When the control mode has been changed to the high-gain amplifier (MDS-B-VI4N24) mode
afterremountingfromthestandardamplifier(MDS-B-VlN2),theparametersmustbe
changed for the high-gain amplifier and the servo parameters must be adjusted.
Refer to the section"111. Servo System, section 1.1.2 2-system compliance" for
details.
' A CAUTION
<Servo alarm "7F">
The actual mode is changed between the standard amplifier mode and high-gain amplifier
mode when the 200V power is turnedON. Thus, if the above servo parameters are changed,
the alarm"7F" will occur, and the restarting of the power will be requested.
Alarm "7F" is a status flag that occurs when the amplifier mode state changes. It does not
indicate an amplifier fault like the other alarms. (Alarm "7F" is not counted as a fault.)
The system is shipped from the factory with the high-gain amplifier mode. Thus, the amplifier
state after the machine is installed will be as follows.
Standard amplifier parameters + First time200V power is turnedON.
Alarm "7F"
+Second and subsequent time 200V power is turned ON.
Normal connection
High-gain amplifier parameters+First and subsequent time 200V poweris turnedON.
Normal connection
When using the standard amplifier mode (using the standard amplifier parameters), the 20OV
power must be turned ON again after the machine is installed. "7F" will appear in the alarm
history, but as"7F"does not indicate an amplifier fault, clear the alarm history and erase the
"7F"record.
If alarm "7F" is detected even afterthe 200V power is turnedON again, an error willbe
detected in the internal memory circuit (EEPROM). The amplifier mustbe replaced in this
case.
Refer to the section "III. Servo System, section I.I
.2 2-system compliance" for details.
1-4
1. Outline
<MDS-AIB series>
Standard connection
-lz
60Hz
Note 1. Starting from production in April 1995, a Prior to April 95 to Following April 96
grounding bar is enclosed with each unit March 95 March 96
when shipped. Connect the grounding (MDS-B Series)
wire as shown above, and make sure that R L1 I R L1
the grounding wiresare not tightened al
1 S I L2 I s I L2 I
together. Ec T L3 I T L3
Note 2. Always install a surge killer on both ends P L+ I P L+
of the contactor coils. N L- I N L-
Note 3. The terminal block names have been t Ro
al L11 I R o L11
changed in two stages as shown in the I-
table. so L21 I so L21
G GIC3 e
1-5
I.Outline
<MDS-Cl series>
Standard connection
30
POOVAC =Hz
200-23OVAC 6OHz
Please read the "MDS SeriesSpecifications BNP-C3000" together with this manual when
servicing the MDS system.
2. System Start Up
/1\ WARNING
1. Do not touch the switches with wet hands. Failure to observe this could lead to electric shocks.
2. Do not operate the unit with the front cover removed. The high voltage terminals and charged
sections will be exposed, and can cause electric shocks.
3. Do not open the front cover whole the power
ONisor during operation. Failure to observe this
could lead to electric shocks.
A CAUTION
1. Always check the parameters before starting. Depending on the machine, unforeseen
operation could take place.
2. Do not touch the servo amplifier fins, regenerative resistor or servomotor,
, while
etc.
the power
is turned ON or immediately after turning the power
OFF. Some parts are heated to high
temperatures, and touching these could lead to burns.
. The procedure for starting up the entire system is explained in this chapter.
Refer tothe section for each unit for the individual adjustment procedures.
(1) Connect the units according to the connection drawing. (Refer to 1.2 System configuration wiring
system drawing. Refer to the specifications for details.) Observe the cautions in the specifications
when installing each unit, motor and detector.
(2) Set the rotary switches on each unit. (Refer to the settings below. Refer to the specifications for
details.)
(3) Confirm the wiring and input voltage, etc., and turnON the power while the NC emergency stop is
applied. Confirm that theLED displays on each unit are normal. (Refer to following page.)
(4) Confirm that the servo and spindle parameters are set as specified on the NC screen. (Refer to the
specifications for the parameter definitions and setting methods.)
( 5 ) Release the NC emergency stop and confirm that the movement is normal.
(6) Make adjustments according to each unit section.
* If any instabilrty such as runaway of the sew0 axis is sensed with the first machine, lower the
parameter SV013ILMTI value. The limiterwill be applied on the torque and the damage to the
machine canbe reduced.
* Rotaryswitchsettings
1)Powerregenerative type power supply unit [ Setting 0 : Contactor used
I: Contactor notused
2) Resistanceregenerativetypepowersupply unitSetting 0
I
3) Sewokpindle unit Setting 0 : 1staxis
1 : 2nd axis
1
6 : No. 7 axis
1-7
-
2. System Start Up
Status display
MDS-A-VI (V2)
MDS-B-V1 (V2) MDS-B-SP
MDS-Cl-VI
-CV
MDS-C1
(V2) MDS-CI-SP
Servo drive unit
30 200/23OVAC ON 30 200/23OVAC ON 30 200/23OVACON
In initialization
NC pbwer ON
I
rwer ON
I
NC power ON
I Alarm is
displayed
when alarm
occurs
Initial data
communication
with NC
iInitial data
communication
with NC
BS OFF I
I
I Emergency
st0 'P Alarm is
EmergenIcy stop
I
T]
Alarm code ReadyON Reaby ON
is displayed displayed
whenalarm 1 when alarm
RDY ON
SV OFF
occurs
RDY ON
SV OFF
Wl
I I
pp SV ONON
Normal operation
NC power OFF
NO^& operation
NC power OFF
v
Normal operation
NC p-r
I OFF
BS ON
RDY ON
or emergency
stop
+
I NC p&er ON
-L
NC po&r ON
/i\ CAUTION
1. Correctly transport the product according to its weight. Doingso could lead to injuries.
2. Do not stack the products above the tolerable number.
3. Install the unit on non-combustible materials. Installation directly on combustible matters or
near combustible objects could lead to fires.
4. Follow this Instruction Manual and install the unit in a place where the weight can be borne.
5. Do not get on top of or place heavy objects on the unit. Doingso could lead to injuries.
6 . Use within the designated environmental condition range.
7. Do not let conductive objects such as screwsor metal chips, etc.,or combustible materials
such as oil enter the servo amplifier
or servomotor.
8. Do not block the intakeor exhaust ports of the servomotor provided with a cooling fan. Doing
so could lead to trouble.
9. The servo amplifier and servomotor are precision devices, so do not drop them or apply strong
impacts to them.
10. Do not installor run a servo amplifier
or servomotor that is damaged or missing parts.
11. When storing for a long time, please contact the Service Center or Service Station.
or parts, always turnOFF the main power and confirm that the
Before adding or replacing units
CHARGE lamp onthe power supply unitis not lit.
- A CAUTION
1. Do not hold the front cover when transporting the servo amplifier. The unit could drop.
2. Always observe the installation directions. Failure to doso could lead to faults.
3. Secure the specified distance between the spindle amplifier and inner side of the control panel
and the other devices. Failureto do so could lead to faults.
1-9
3. Addition and Replacement Methodsof Units andParts
c)c)
11._111 UIII
L 1 1
L21
NCl
%I %I
L1
21
rU1V1W7@1
L1
21
LlL2L30 L1 L2 L3 0
c>
1-10
3. Addition and Replacement Methodsof Units and Parts
L2 1
KI
:w
L1
2 11 ‘Iw
L1
2 11
1-11
3. Addition and Replacement Methodsof Units andParts
A CAUTION
The MDS-Cl Series is not compatible with the
OHE/OHA encoder (motor end).
Installation method
1) Install theM4 screw on the coupling. Make sure that the screw does not protrude on the inside.
2) Remove one ortwo rubber bushings for the motor.
3) Install the O-ring on the encoder spigot section.
4) install the motor detector and insert the key in the shaft. Make sure that there
is no dirt or burrs
in the key hole at this time, and push the in key
completely.
5) Install the encoder on the motor. Match the coupling keyway and shaft key position at this time
before inserting. The encoder connector position must be fixed to the motor connector position
or the designated position.
6) Fix the encoder with fourM4 P screws. Align the encoder flange markings and the motor flange
punch position.
7) Install the rubber bushing.
Note) Prevent the coupling screw from loosening.
* The current position will be lost after replacement in the OHA25K-85 type, and initializing
will be required.
O-ring S75
(2)OHE25K-6,OHA25K4
Installation method
1) Remove the cover screws with aM5 hexagonal wrench and remove the cover.
2) Install the encoder on the motor. Align the motor shaft pin and encoder shaft groove,
and the
encoder flat spring's slotted hole and motor flange pin.
3) Fix the flat spring to the motor with the
M5 screws. (Three positions)
1-12
3. Addition and Replacement Methodsof Units and Parts
4) Insert the M6 box screw through the hole on the encoder cover, and fix with six wrenches. Fix
the motor shaft at this time, and tighten the screws
so that the screws will not loosen.
5) Place the seal enclosed with the encoder onto the hole on the encoder cover.
6) Cut thetwo wires from the encoder and wires
the form the motor to a length that is suitable, and
connect each with joint amplifiers.
7) Remove the cannon connector housing with a special tool, pass through the motor cover hole,
and assemble the housing (including the rubber packing). Fix to the motor cover withM3
four
screws.
8 ) Install the motor cover
to the motor.
970-901table Shell 2
Name Of tool
Rear
nuttightening
spanner
97D-9011
Manufacturer DDK
Chicago Office
245 West Roosevelt Road, Bldg. 15
Unit 3,West Chicago, IL60185,U.S.A.
Phone: 708-293-7335 Fax: 708-293-7337
Mountingldismounting of insert
Shell table
(97D-9012)
1-13
3. Addition and ReDlacement Methods of Units and Parts
,a ,
O-ring S75 4445 X 0.8 X 15 screw
t
\
Detector
HA motor
Mounting method
I ) Install the O-ring(S75) on the detector flange.
2) Install aM4 hexagonal socket screw on the coupling.
3) Align and insert the motor shaft key in the detector
bellow keyway.
4) Align the position mark on the detector and the motor markings.
5 ) Install the detector on the motor. (Use
M5 x 0.8 screws.)
6) Tighten the screw on the keyway to fix the key.
7) Tighten the detector's rubber plug.
(Note) The detector and bellow position
is determined so do not remove the bellow from the
detector.
Installation method
1) Install the O-ring on the encoder spigot section.
2) Install the encoder on the motor. At this time, align the motor's Oldham position (Oldham
installation screw hole position) and encoder's Oldham mark position. Install the Oldham space
betweenthis.Fixtheencoder'sconnectorpositiontothemotorconnectorpositionor
designated position.
3) Fix the encoder with four
M4 P screws. Align the encoder flange markings and the motor flange
punch position.
* Thecurrentpositionwillbelostafterreplacement in the OSAl04S/I 05s type,and
initializing will be required.
3. Addition and Replacement Methodsof Units and Parts
MOtOf
4
Encoder mark position
Mark
4-M4 X 14
O-ring S75 (When using IP65, replace with the new packing M769D009H01.)
Installation method
1) Remove the cover screws with M5 a hexagonal wrench and remove the cover.
2) Install the encoder on the motor. At this time, align the motor shaft pin (Oldham installation
screwholeposition)andtheencoder'sOldhammarkposition.InstalltheOldhamspacer
between this.
3) Fix the motor with fourM4 screws.
4) Connect the two connectors from the encoder with two the connectors from the motor.
5 ) Remove the cannon connector housing with a special tool, pass through the motor cover hole,
and assemble the housing (including the rubber packing). Fix to the motor cover with four M3
screws.
6) Install the motor cover to the motor.
Motor
1 Encoder 1
--
Motor cover
packing.
\ When using IP65,
replace with the
new
Oldham spacer
4-M4X 18
t
4-M5 box screw
3. Addition and Replacement Methodsof Units and Parts
~ ~~
Mounting/dismounting of insert
3. Addition and Replacement Methodsof Units and Parts
o Applicable
battery : Li battery
o Battery back up time : 7 years (at 265 workdays, 100 holidays)
* The back up time will be reduced if there are more holidays or if the
ambient temperature is high.
U W
166
__ ~~ -~
[Replacement procedure]
1. Turn OFF the NF for the input power supply 200/23OVAC, pull out the cable, and remove the
battery unit.
2. Replace the battery unit, and connect the cable.
3. Turn ON the power and confirm the operation.
Note) The backup timeof the built-in backup capacitor in the absolute value detector
OHA25K-
4, -85 and -ET is 20 hours when delivered, and will decrease
by half to ten hours
after five
years of use. Complete the operation within that time.
3. Addition and Replacement Methodsof Units and Parts
L
I
I
I 71 / I
I
13
Remove the two
screws.
1-19
4. Daily Maintenance
4. Daily Maintenance
A WARNING
1. Always wait at least ten minutes after turning the power supplyOFF before starting
maintenance and inspection.
Failure to doso could lead to electric shocks.
2. Maintenance and inspection must be doneby a qualified technician. Failure to observe this
could lead to electric shocks. Contact your nearest Service Center or Service Station for
repairs and part replacement.
NOTICE
Never perform a megger test (insulation resistance measurement) on the spindle amplifier control
circuit.
The following measurement instruments are required to confirm that the correct power is being
supplied to the servo amplifier and that the servo amplifier wiring
is correct.
(2) Tools
Screwdrivers (Large and medium Phillips type, small flat head)
I Item
Inspection
frequency
Inspection details Remedies
Cooling fan Monthly 1. Can the fan be rotated easily by hand?Clean or replace the
(fhn built-in unit) 2. Does the fan rotate properly when the fan
and additional power is ON?
cooling fan
3. Is the fan dirty with oil or dirt?
(outside unit)
4. Do the bearings make abnormal
sounds?
ITerminal block
screws
Cables and
As
necessary
As
I . Are the screws loose?
2. Are the screws dirty with oil or dirt?
Tighten and clean
the screws
1. Is there any damage or scratches, etc.7Replace the cable
connectors 2. Are the connectors loose? Tighten the
necessary
~ ~
connectors
~ _ _ ~~
Batter Jnit Every 1. The battery life is 7 years under normal Replace the unit
7 years use. This will differ according to the
usage environment (temperature,
usage frequency, etc.).
Motor Sound, Monthly Is there any abnormal sound or vibration?
vibration
Tempera- Monthly Are the motor bearings or frame hot when
ture touched by hand?
Insulation TwiceQear Is the resistance1MS2 or higher when
insulated with a500V megger tester
between the motor frame and motor
terminals (U, V, W). (Remove the motor's
I
cannon plug before measuring).
5. Maintenance Parts
5. Maintenance Parts
qeplacement Remarks
Part Q'ty time
I
1-23
5. Maintenance Parts
As a high frequency chopper current thatis PWM controlled flows to the AC servo/spindle, the leakage
current will be larger than a motor run with a commercial power supply. Select the leakage breaker
according to the following explanation and securely ground both the amplifier and motor.
I 1 u, v, w
I 1 1 1
111
200/230VAC -
+
a
@ Motor
The commercial frequency compositionof the leakage current for theMELDAS MDS-A Series spindle
and servo system is approximately 6mA for one spindle axis and 1mA for oneservo axis. However, when
selecting the leakage breaker, differences in the motor power line length, distance with the grounding
and motor size, etc., must be considered, and should be calculated as a max. of 15mA per spindle axis
and 2mA per servo axis.
Furthermore, if other inverter equipmentis connected to the same power line, the leakage current for that
equipment must also be considered, and so select and install the leakage breaker in the position marked
@ above.
Select a leakage breaker (for inverters) that removes the high frequency elements with a filter, and that
detects only the leakage current within the commercial frequency range (approx. 50 to 60Hz).
If a leakage breaker that is too sensitive towards the high frequency elements is used, the breaker may
malfunction.
Note) There is one spindle axis and three servo axes in theMDS Series, and if the total of the leakage
current from the equipment on the same power line is 7mA, select a leakage so breaker
that the
following calculated value is within the rated non-operative sensitivity current.
15mA + 2mA X 3 + 7mA = 28mA
When using a leakage tester to investigate the cause of leakage breaker malfunction, etc., selec
of 50range
one thatis not affected easily by the high frequency and which has a measurement to
60Hz.
Example) LC-30F manufactured by Soko Denki
Note) Always ground the machine with class3 grounding for safety purposes.
6. Noise Filter
6. Noise Filter
(1) Selection
If radio noise needs to be reduced, select one of the following noise filters according to the type of
power supply unit being used.
~~~~ ~~ ~ ~~
(3) Specifications
~ ~ ~~~
1-25
6. Noise Filter
LF-300 Series
4-4.5
- -~
A B C D E F G H I
LF-330 180 170 60 29 120 135 150 35 65
200 220 240 40 80
200 220 240 40 80
160 200 60 30 ~ 300 320 340 50 I00
(mm)
LF-K Series
-
H kFi
Terminal F G H
Name A B C D E
plate
LF-380K M6 670 TE-K22
400 380 560500 170 6.50 9X6
1-26
11. MDS-A-CV
MDS-B-CV
MDS-A-CR
Power Supply Section
1. Troubleshooting
1 Troubleshooting
1.I Status display
A WARNING
1. Do not touch the switches withwet hands. Failure to observe this could lead to electric shocks.
2. Do not operate the unit with the front cover removed. The high voltage terminals and charged
sections will be exposed, and can cause electric shocks.
3. Do not open the front cover whole the power isor during operation. Failureto observe this
ON
could lead to electric shocks.
/I\ CAUTION
1. Always check the parameters before starting. Depending on the machine, unforeseen
operation could take place.
2. Do not touch the sew0 amplifier fins, regenerative resistor
or servomotor, etc., whilethe power
is turnedON or immediately after turning the power OFF. Some parts are heated to high
temperatures, and touching these could lead to burns.
The power supply state is displayed on the 7-segmentLED on the top of the power supply. When an
alarm occurs,the alarmNo. will display on 7-segment LED on the servo/spindle drive connected with the
communication cable(CN4) and on theNC diagnosis screen.
If the sewo/spindle alarms#60 to #7F display on the diagnosis screen, a power supply alarm has
occurred. The power supply alarm will display as the alarm for the axis connected to the power
supply communication cable (CN4). At the same time, the same alarm No. will display on the
spindle/sento drive unit's 7-segment
LED. An example is shown below.
I1 - 1
1. Troubleshooting
-El
b I ReadyOFFFrom2OOVAC(24VDC)ONtorelease of emergencystop.
I
C
I Servo OFF Displayed for approx. 1 see. after emergency stop is released and then
changes to d display.
d Servo ON Indicates that emergency stop is released and operation is possible.
: Flicker Alarm or warning has occurred
No.)
: Alarm display codeuhis display code differs from the alarm
I1 - 2
I.Troubleshootinn
E r Idr&
Alarm display model
Meaning Detection timing
A-CV I B-CV ICl-CVl A-CR
nstantaneous
stop
(24VDC)
Constantly
after
power is
turned ON PR
'over
module
overcurrent
Constantly
after
power is turned ON PR
-requency
error
Constantly
after
power is turned ON PR
63 0 Auxiliary
regeneration
error
Constantly
after
power
turned
is ON PR
6 4 1 4 I I I I Jot used
iushWhen
error
ready
relay
OFF - ready
PRON
Jot used
OFF
ready
When
phase
3pen - ready ON PR
Constantly
Natch
dog
power
after tumed
is ON AR
OFF
ready
When
3round
fault - ready ON PR
circuit
dain
error
When ready
OFF - ready ON PR
'arameter
When
error NC power is turned ON PR
Vlemory
Immediately
errorturned
power
after
is ON AR
VD converter
error/power
Immediately
after
power is turned
AR
OWconstantly error ;upply
Instantaneous stop/extemal
During ready ON NR
emergency stop
Over-regeneration
Constantly
turned
power
after
is ON PR
RegenerativeresistoroverheatConstantlyafterpower is turned ON PR
75 L 0 0 0 0 Overvoltage
Constantly
power
after is turned ON NR
76 M 0 0 error
External emergency stop
settina I When NC power is turned ON
I AR
77 n 0 0 0 0
E8 0 0 0 0
Auxiliary regeneration
frequency over I Constantly after power is turned ON
I -
E9 P 0 0 0 ready
During
warning
Instantaneous
stop ON -
E A q 0 0 External
emergency
stop
input
When NC power is turned ON -
E6 r 0 0 ready
Over-regeneration
During
warning ON -
[Alarm No.] Alarm No. displayed on the drive unit connected to the power supply unit
[LED display] LED displayed on power supply unit
[Release]AR : Released whenpowersupplyunitpower is turned ON again.
PR : Released when NC power is turned ON again.
NR: Released with NC reset key.
I1 - 3
1. Troubleshooting
A CAUTION
When an alarm occurs, remove the cause of the alarm, confirm that an operation signal
is not
being input, and secure the safety. Then reset the alarm to resume operation.
When an alarm occursin the spindle amplifier, the base will be off
shutand the motorwill coastto a stop.
Turn the powerOFF with an external sequence.
[Meaning] This is a overcurrent in the power module in the power A-CV C1-CV A-CRB-CV
supply- 0 0 0
[Detection] Constantly after power is turned ON
L ~~
Investigate the load state, The total of all motors' loads Lower motor load and operation
of each frequency.
exceeds power supply rated start/stop frequency
motor. caDacitv.
] Not exceeded. Perform investiaation item3.
Investigate whether the power s pply is normal.
1) Is rated power supply Power capacity is insufficient. Increase the power supply
capacity secured? caDacitv.
2) Confirm that the poweris Power is less than 17OV. Increase the power supply
170V or more even during capacity.
motor acceleration/ Power is higher than 17OV. Perform item 3).
deceleration.
3) Observe the power voltage 1. Distortion in voltage waveform. Eliminate the waveform distortion.
with a synchroscope. 1. Increase the power capacity or
( A l s o during acceleration/ power cable size.
deceleration) 2. Improve the other
semiconductor units where
waveform distortion is
occurring.
(Add anAC reactor.)
2. When there is a partial drop.
I1 - 5
I.Troubleshooting
I1 - 7
I.Troubleshooting
[Meaning] The power supply software process did not end within A-CV B-CV Cl-CV A-CR
the designated time. 0 0 0 0
[Detection] Constantly after power is turned ON
t
Investigation item Investigation results Remedy
1 Measure the insulation 1OOkQ or less Motor defect or cable ground fault.
between theU W terminals of Replace motor and cable.
all motors and the grounding q o o k ~ or more Perform investigation item2.
with a megger tester.
2 Is motor or cable covered with Oil isfound. Take measuresso that oil does
oil? not come in contact.
Clean the motor's cannon
connector and inside the terminal
box.
If the error occurs again, perform
investigation item3.
Oil is not found. Perform investigation item3.
3 Perform the insulation 1Mi2 or less Replace motor or cable.
measurement again. 1Ma or more Replace the unit.
I.Troubleshooting
EMG I
Switch, etc.
I1 - 9
I.Troubleshooting
(1I)
Alarm No. Maincircuiterror I ODeration
unit I
[Meaning]
[Detection] When ready OFF -
Charging to the main circuit is not normal.
ready ON
A-CV B-CV Cl-CV A-CR
0 0 0 0
Defect
I
Short circuit or infinite I
supply side
Short circuit or several 1 0 0 0 I
Short circuit or infinite I
Disconnect only thePN wiring
on the power supply. Short circuit or several 1 OOR I
Measure the positions(1) and
(2) with a tester.
11- 10
I.Troubleshootinn
2)
(IAlarm No. Parameter
error
[Meaning] The power supply unit (CR) capacity and the
regenerative resistance type (rtyp) set in the
parameter PRYP are not set to an adequate
combination.
[Detection] When NC power is turned ON
Servo/spindle parameter :
svo36 sP041 PlYP
F E D C B A 9 8 7 6 5 4 3 2 1 0
5
wl External regenerative resistancetype lptypl Power supply type
(Set type from following table) (Set type from following table)
Power supply type PtyP
CR-10 81
CR- 51 82
CR-22 83 ,
CR-37
CR-55
CR-75
89 CR-90
11-11
1. Troubles hooting
Remedy
results
Investigation
item
lnvestigation
Check
power
the
supply 7- F is flickering. A/D converter
error.
segment LED display: - Perform same remedies as for
alarm 6E memory error.
Other alarm codeis flickering. Refer to each alarm section.
0 is displayed. Perform investigation item2.
F is displayed. Perform investigation item2.
I
8 is displayed. Refer to alarm68 watch dog
alarm.
b, c, d are displayed. Perform investigation item3.
Other display Refer to alarm 68 watch dog
alarm.
Investigate
rotary
theswitch
Setting isReplace
01.orunit.
the
setting.
Setting is not 0 or
Correctly
1. set
the
rotary
switch.
mistaken.
wiring
is
driver
Replace
The
Check
cable.
the
the
communicationcablewiring.There is noshield.
wiring
The
is OK. Perform
investigation
item 4.
replacing
Try
driver
the OK replacement.
after Cable
defect.
communication cable.
~
NG
even
after
replacement.
Replace
the
unit.
I.Troubleshooting
operation
eased.
I I
the
I I
when
is
occur
Theregenerationloaddisplay
I
I
I1 - 13
-
1. Troubleshooting
srform investigation
item 3. I
Note) Do not touch the
resistor or case
directly. It ishot and
can cause burns.
Confirm the alarm history. The alarm has occurred.
The over-regeneration there is no abnormality, ease the
warning or over-regeneration
alarm has occurred. The alarm has not occurred.
Is the resistor installation regenerative resistor.
correct? Install in a well-ventilated
place.
Cool with a fan, etc.
Confirm theCN22 (B) The wire is cut. Replace with correct wiring.
connector pins 1 and 2. There is no conductivity in the Replace the resistor.
Confirm whether there is a resistor's terminal relay.
short circuit caused by the The wire is correct. Replace the unit.
resistor's terminal or wire.
I1 - 14
yl_ "..
I.Troubleshooting
I1 - 15
1. Troubleshooting
I1 - 16
1. Troubleshooting
(2) Alarm
history
display
Instantaneous
stop
warning LED display
[Meaning] An abnormal instantaneous stop occurredfor 25ms or
more. An alarm did not occur because the main circuit
voltage did not drop. This may cause an
or power
instantaneous stop alarm, overvoltage alarm
module error.
[Detection] Duringready ON
11-17
, .
... . .j.. .
#
1. Troubleshooting
(4) Alarm
history display Over-regeneration LED display 11-1
[Meaning] 80% of the over-regeneration alarm level was reached.
[Detection] Duringready ON
t Investigation item
Perform the investigation
items for alarm73 over-
regeneration.
Investigation results Remedy
111. MDS-A-VX
MDS-B-VX
Servo System Section
1. MDS-C1-Vl/V2 Servo Drive Unit
(1) Compatibledetectors
Note that some detectors are not compatible with the C1 Series.
0: Connectable, x: Not connectable
MDS-8- MDS-B- MDS-C1-
Detector type Detector model
V1N2 Series
_ _ V14N24
.~ Series V1N2 Series
~
OHE-25K-ET, OHA-25K-ET
I o l x
0 0
l x 0
detector I High-speedserial
I
OSE104-ET, OSAl04-ET
OSA1054ET. OSElO5-ET
~~ ~~
0 0 0
(2) Compatiblemotors
1) HCmotor : (INC specification) HC***-E42/E51,
(ABS specification) HC***-A42/A51
2) HC R motor : (INC specification) HC***R-E42/E51f
(ABS specification) HC***R-A42/A51
3) HANmotor : (INC specification) HA***N/INC high-speed serial encoder,
(ABS specification) HA***N/ABS high-speed serial encoder
4) HA L motor : (INC specification) HA***L/INC high-speed serial encoder,
(ABS specification) HA***L/ABS high-speed serial encoder
5) HA-LH S1 motor : (INC specification) HA-LH**Sl/INC high-speed serial encoder,
(ABS specification) HA-LH**Sl/ABS high-speedserial encoder
6 ) HA-FFmotor : (ABS specification) HA-FF***
7) HC-MFmotor : (ABS specification) HC-MF***
8 ) HA compact motor : (INC specification) HA053NC, 13NC/INC high-speed serial encoder,
HA-FE**
(ABS specification) HA053NC, 13NC/ABS high-speed serial encoder,
HA-FH**
111 - 1
1. MDS-Cl-VlN2 Servo Drive Unit
A CAUTION
When the control mode has been changed to the high-gain amplifier
(MDS-B-Vl4N24) mode
after remounting from the standard amplifier (MDS-B-V1/V2), the parameters must be changed
for the high-gain amplifier and
the servo parameters mustbe adjusted.
-
one of the following
SVOO9 = 4096 or more, conditions is satisfied. svoo9=* svoo9=* svoo9=*
svm'0 Sv012
SVOlO = 4096 or more, svo1o=* svo1o=* svo1o=*
Servo s v o 1 1 = 768 or more, and S V m = 4096 or more* svol1=* svo11=* svol1=*
para- ~ ~ 0 =1768 2 or more. svo12=* SVOl2=* svo12=*
meters svol
SV010= =
768 or mo18, and
or more,
SVOl2 = 768 or more
svO33 (SSF2)/bii8 0 0 1 0 1
svO33 ( S S F 2 ) b i i 0 0 0 1 1
High-gain mode
Standard Highgain High-gain
Control mode Standard mode
mode modemode
A CAUTION
The actual mode is changed between the standard amplifier mode and high-gain amplifier mode
when the 200V poweris turned ON. Thus, if the above servo parameters are changed, the alarm
"7F"will occur, and the resettingof the power will be requested. Alarm"7F"may also occur when
the poweris turned ON for thefirst time after the machine is installed.
If alarm "7F"occurs, turn the
power ON again. The alarm"7F"will not occur after the second and subsequent power ON unless
1 the above servo parametersare set.
(4) Display of servo monitor type for highgain mode and standard amplifier mode
(Servo Monitor screen)
Whether the system is running in the high-gain mode or standard amplifier mode can be confirmed
with the type displayed on
the Servo Monitor screen.
~~ ~~~~ ~ ~~
Unit type For standard amplifier mode For high gain mode
MDS-C1-VI -000 c1v1sooo ClV1-000
MDS-C1- V 2 - 0 0 0 0 c1v2soooo ClV2-0000
MDS-C1-V145S c 1Vsl4S c1v 1 4 s
MDS-C1 -V2-7070S c1v2s7s7s ClV2-7S7S
MDS-C1 -V2-351 OS C1 V2s3510 ClV2-3510
MDS-C1 -V2-3520S c1v2s3520 C1 V2-3520
I11 - 2
2. Adjustment Procedure
2. Adjustment Procedure
2.1 Initial adjustment
/1\ CAUTION
Do not make remarkable adjustments and changes of the parameters as the operation could
become unstable.
I
DIAGNOSIS][SERVO
UNIT TYP
<x> <Y> <2>
3/3
UNIT NO
S W VER
CONTROL
MOT DT
MAC DT
MOTOR
WORK TIME
ALM HlST
I11 - 3
~
. ., .
2. Adjustment Procedure
The rapid traverse acceleration/deceleration time constants are adjusted according to the following
settings as theydiffer according to the load inertia, friction and motor capacity.
(1) Set the acceleration/deceleration time constant initial value. The basic setting equation is shown
below.
Ts = 1000 (2nN/60) (J, + JL) / (0.8 Tm - TF) (ms)
Ts : Acceleration/deceleration timeconstant (rns)
N : Motor speed duringraFidtraverse(rpm)
J, : Motorinertia(kg0crn.s )
JL : Load
inertia (kg*cms2)
, ,T : Maximum output torque for amplifier (during motor combination) (kgocm)
TF : Motor shaft conversion load torque during rapid traverse (kgocm)
in the NC
(2) The rapid traverseacceleration/decelerationmode is selected and the time constants set
device parameter axis specifications screen.
(3) After reciprocating with rapid traverse for about five times, adjustacceleration/deceleration
the time
constant so that the MAX current 1 value on the servo monitor screen(1/3)is within the optimum
maximum current value range givenin Table 3.1.
Note) If the maximum current value exceeds the optimum maximum current value given in
Table 3.1, the acce'leration/decelerationconstant mustbe increased.
The max. current1 indicates the maximum value (stall current conversionYO(absolute
value)) from whenthe NC power is tumed ON, so the NC power mustbe turned OFF
when repeating rapid traverse operation to confirm the current.
The max. current 2 indicates the absolute valuetheof max. current in2 sec.intervals, so
the powerdoes not need tobe turned OFF when adjusting while looking at this value.
Motor current
J
0 I
l I
Max. current 1
t
0
. Max. current 2
< >
2 sec.
2. Adjustment Procedure
Table 3.1 Max. output torque per motor and optimum max. current
I Standard
2000rpm
motor
I
! Standard
1
3000rpm
motor
Optimum max. Optimum max.
Motor Tmax Motor Tmax
current current
HA40N to 400 14.2 HA053N 355 0.7 210 to 240
25.5 HA80N325 to 365 HA13N 1.4 210 to 240
OON 42.0 HA1 230 to 260 HA23N 2.8 205 to 230 i
The VGNl (SVOOS) optimum value and maximum value will change according to the load so inertia
refer to the following diagram and set the initial
VGNl (SVOOS) value. The following diagram shows
the values when the motor and load are linked, so the motor may vibrate even with a lower setting
when gears are used, or due to the coupling method ball screw
and twisting even
if linking is used. In
that case, lower the value to that which
is SO lower than the value where vibration occurs, and reset.
0 1
0
- 1 2 3
Load inertiascale (load inertialmotor inertia) - 2 3
Load inertia scale (load inertialmotor inertia)
2. Adjustment Procedure
unitsingle
Motor <HC**>
500 I
HC202 HC203
HC352 HC353
400 -H a 5 2 HC453
HC702 HC703
HC902
300
Standard
VGNl
200
\ HC53
100
HClO2
HC152
0 I
1 2 3 4 5
Command speed
current
The vibration may occur due to the machine resonance, and if the frequency is known may be
eliminated by settingthe frequency in the machine resonance suppression frequency
FHz (SV038)
without loweringVGNl (SVOOS). If the vibration is eliminated with this setting, raiseVGNl (SV005)
again, and confirm the limit.
If the optional adaptive filter
is mounted, turnON servo parameter"27. SSFl bit F"and the machine
resonance will be eliminated automatically.
I11 - 7
--_ ...... . ~
2. Adjustment Procedure
I) The reference for the zero point position is the last Z phase passed before reaching the dog
OFF stop, and theNC creates the hypothetical grid for each grspc from Zthe phase.
2) The position stopped at after the distance(L) from the dog OFF position to the next grid+ the
grid shift amount(G28sft) is moved is the zero point.
7 Motor speed
0 \
I
Z phase
Dog
'I I
I
Zero point reference G28sf t
2 phase c 3
NC hypothetical grid I I
(Note) After zero point return, the high speed zero point return mode (not usingZ phase) will be
applied from the second return, so turn OFF the power beforestarting each zeropoint return.
(Dog-type zero point return can be performed without turning the powerOFF each time by
turning ON the automatic dog method or manual dog method in the NC user parameter's
axis parameter.)
2. Adjustment Procedure
111 -9
2. Adjustment Procedure
1) Currentmonitor
OFF and ON several timesin the emergency
Turn the NC power and MDS Series input power
stop state and confirm the following:
Check that the relationof the power OFF position and power ON position is not greatly
deviated. (However, there maybe a difference due to sequential axes or unbalanced axes.)
below, so 4094,4095 -
Confirm that ABSn, Rn and Pn do not move greatly. (However, Pn will change as shown
0, 1 movement can be considered.)
Encoder
X division
type
OHA25K
Rn N+ 1 rN+3
N+ 2
N-
c b
1 motor rotation
Write down the ABSn, Rnand Pn values displayed when the zero point position is set. The
absolute position detection can be confirmed with the following equation when absolute
position deviation occurs.
(Substitute the noted ABSn, Rn and Pn values as ABSO,RO and PO.)
The above values will be displayed on the monitor screen,so confirm that the left side equals
the right sidewith the following equation.
ABSn = (Rn - RO + (Pn - PO)/x} *PIT*PCl/PCZ/hterpolation unit
Machine position= ABSn X Interpolation unit
2. Adjustment Procedure
(1) A fine vibration is felt when the machine is touched, or the machine makes
a groaning sound.
I Lower 5. VGNl by 50 at a time. (Lower limit50)
Lower 11. IQG by50 at a time. (Lower limit 128)
Lower 12.IDG by 50 at a time. (Lower limit256)
Set 27. SSFl vfctl(bit 4), vfct2 (bit5) in the following order.
9 1
4) Set 27. SSFl vf
ctl (bit 4), vfct2 (bit5) in the following order.
vfctl (bit4) vfct2 (bit5)
3)
I11 - 11
2. Adjustment Procedure
-
If differing compensation amounts - -
are required in the- + direction and+
compensation gain for- + direction in 16. LMC1, and the +
-- direction, set the
- direction compensation gain in
41. LMC2.
Q Too large
111 - 12
2. Adjustment Procedure
~~~ ~
~~~ ~~ ~~
(3)The load fluctuation is large during cutting and vibration or surface precision defects occur.
(Especially during heavy cutting)
I) Raise 5. VGNI by 20 at a time.
(The limit is when vibration or sounds occur when stopping or during rapid traverse.)
2) Raise 8. VIA by 200 at a time. (Upper limit
2000)
-
If the droop does not overshoot, the motor is
overshooting. Adjust the machine system.
itself
not overshooting and only the machine system is
-
screen is not overshooting, the overshooting is not occurring near the scale, and only the machine
system is overshooting. Adjust the machine system.
I11 - 13
.
2. Adjustment Procedure
(1) Command several pulses, and confirm that the droop corresponding to the command pulse is
occurring by checking the droop on the sew0 monitor screen.
Droop is occurring Droop is not occurring
!
1) Raise 5 . VGNl by 50 at a time. 1) Movement has been made to near the
(The limit is when vibration
or sounds position detector (scale, ball screw end
occur when stoppingor during rapid detector) in the motoror full closed loop.
traverse.) The following machine system is
2) Raise 8. VIA by 200 at a time.
(Upper limit2000)
Perform the same measures as 1.2.3 (2)
-
accumulated feed.
Adjust the machine system.
L 5).
2. Adjustment Procedure
Whenperforminghigh
precision
control,
the
various
parameters
for
performing
acceleration/
deceleration before interpolation, feed forward control and SHG control, etc. must be set.
(1) Outline
The delaycausedbytheNCsidecommandtimeconstants is removedwithacceleration/
decelerationbeforeinterpolation.Thedelaycausedbytheposition loop ontheservosideis
corrected only withfeed forward control in the
M300 Series, but the correction has been stabilized in
the M500 Series by combining SHGcontrol andfeed forward control.
1900
125
281 225
I900
I Speed control \
Always observe the above relation for the three parameters related to position control.
Setting the same value asPGNl and setting SHG control will double the conventional control's
position loop gain and
be effective.
As the response duringacceleration/deceleration in SHG control is smoother than the
if PGNl = 33 (l/S) in the conventional position control, further gain
conventional position control,
up may be possible with SHGcontrol.
I11 - 15
Y..yuuT(D ,
2. Adjustment Procedure
Setting limits
All axes must be matched for the SHG control parameters (PGNl , PGN2, SHGC) and feed
forward gain (fwdg). (For interpolation axis)
Equivalent FF (YO)
= 100 f w d L 33 )2
50 )2'x( 2.PGN1
SHG
Nom
control fwdJ Equivalent feed fonuard gain
(%) Equivalent FFGis the
~
comparison of when
1 No.1 40 95 PGNl=33 SHG control
2 No.2 40 97
is not being used.
3. Troubleshooting (MDS-A/B Series)
/1\ WARNING I
I. Do not touch the switches with wet hands. Failure to observe this could lead to electric shocks.
2. Do not operate the unit with the front cover removed. The high voltage terminals and charged
sections will be exposed, and can cause electric shocks.
3. Do not open the front cover whole the powerON
is or during operation. Failure to observe this
could lead to electric shocks.
A CAUTION
1. Always check the parameters before starting. Depending on the machine, unforeseen operation
could take place.
2. Do not touch the servo amplifier fins, regenerative resistor
or servomotor, etc., while the power is
turned ON or immediately after turning the power
OFF. Some parts are heated to high
temperatures, and touching these could lead to bums.
The state of the drive unit is displayed on the 7-segment display on the drive unit and the NC servo
monitor screen.
Confirm one of these displays before troubleshooting.
Caution: The machine's power distribution box door must be opened to confirm the drive unit's 7-
segment display. Take special care not to touch the conductive parts at this time.
(1) 7-segmentdisplay
The drive unit state is indicted with the 7-segment display on the drive unit.
When an alarm occurs, the alarm No. will be displayed. If several alarms occur simultaneously for
No. will be displayed.
one axis, the latest alarm
Servo OFF
F# - 9*
F# -. E*
9*
E*
Servo ON
Warning
(* is 0 to F. Note "E6","E7" and "EA" are status displays).
F# -. ** ** Alarm occurrincr
# : Axis No.
* : Warning No.
** : Alarm No. (Refer to <Servo alarm> <Warning> Tables on following pages.)
I11 - 17
3. Troubleshooting (MDS-A/B Series)
The status display after initializing will repeat lighting and going out per axis and show the axes
in
order. An exampleis shown below.
(Example 2) With the above axis. Displayof emergency stop signal input from NC.
r
-
. (
L i
) (Not lit)
L axis state M axis state
(Example 4) With the above axes. Display of motor overheat alarm (No.
46) in L axis. (Emergency
stop is applied onM axis)
> - r n
(Not (Flicker)
L axis state
l
i
d
)
-(Flier)
E 7
(Flicker)
M axis state '(Not lit) 7
-
plry
11
Abbr.
ASE sewion
Name
error
Meaming
AR c
Alarmtwaming
check Per
i
d
f l f 2 f 3 f 4
0 - - -
The memoryIC (SRAM or FLROM) check sum was c
12 ME Memory error AR 0 - - -
illegal.
The software data processingwas not completed
13 SWE processing within the normal time. Includes peripheral G/A PR c - 0 0 0
error
errors.
The differential inputof the U, V, or W phase of the
16 RDl ,de position detection pole position detectiin signal of the OHE type PR A - 0 0 -
mr
- detector wre both "H"or "L".
The AD converterfor current detection did not
17 A9E converter error PR A - o - -
- function correctly during initialization.
The absolute positionor pole position datafrom the
18 VVAT
communication OHA type detector or serial pulse encoder was not PR A - o - -
r m
corredly sent.
&rial detector The initial communication with the serial encoder
1A I;El mmunication error installed on the ball screw end was not possible.
PR A - 0
SUB)
An error was detectedin the data stored in the
1B ;cpu > P U error (SUB) EEROM of the serialpulse encoder installed on the PR A - 0 0 0
- ball screw end. (Alarm output by the detector.)
Deteriorationof the LEDs in the serial pulse
1c bled ED error (SUB) encoder installed onthe ball screw end was PR A - 0 0 0
- detected. (Alarm outputby the detector.)
An error was detected in the per rotation position
1D aat )ata error (SUB) data of the serial pulse encoder installed on ballthe A -
PR 0 0 0
screw end. (Alarm output by the detector.)
The thermal protectorbuilt in the detector operated
detector thermal A PR- 0 0 0
1E ;OH€ in the serial pulse encoder installed
on the ball
wmr (SUB)
screw end. (Alarm output by the detector.)
hrnmunication error Communication withthe detector in the serial pulse
1F i
t
re encoder installed on
the ball screw end was cutoff.
PR A - 0 0 -
SUB)
of the A, B or 2 phase signal
The differential input
20 JSl 40 signal detected1 from the motor end installation detectorwere both PR A - 0 0 -
- "H" or "L". (Software detectionin B Series.)
The differential inputof the A, B or Z phase signal
21 rls2 rlo signal detected2 from the machine end installation detector were both PR A - 0 0 -
"H"or "L". (Software detection in B Series.)
The absolute position datain the absolute position
25 W E AR A - o - -
- position lost
I\b6olute detector was lost.
A powt3r module erroroccurred in theaxis that is not
26 NAE Not used axis error being controlled set as
"F*' by theaxis setting rotary PR c - 0 0 0
switch in the 2-axes integrated drive unit.
I11 - 19
3. Troubleshooting (MDS-AlB Series)
Dis-
I r T Alann/waming
I
play
Abbr. Name
Deterioration of theLEDsinthe
Meaming
serial pulse 1
lelease
t
2c SLED ScaleLEDerrorencoderinstalledonthemotorendwasdetected. PR
(Alarm output by the detector.)
An error was detected in the per rotation position
2D SDAT Scale dataerrordata of the serial pulseencoderinstalledonthe PR
motor end. (Alarm output by the detector.)
Communication withthe OHA type detector or
communication PR
2F STRE serial pulse encoder installed on the motor end and
error
the detector was cut off.
31 os OveFSpeed ~~ ~
The motor speed reached 1.2 times
~
the
rated speed. PR
Power module An overcurrentwas detected in the IPM used in the PR
32 PMOC
overcurrent servo drive's
circuit.
main
A CRC erroroccurred in the communication data PR C
34 DP CRC error
from the NC. -
35 DE Data error
The movement command data from the NC is PR A
abnormally large. -
The cyclic data transmissionfrom the NCwas PR
36 TE Transmission error C
terminated. -
There is error in the servo parameters transmitted A
37 PE Parameter error PR
from the NC duringservo drive initialization. -
There was an errorin the communication protocol
38 TP1 Protocol error1 PR C
with the NC. (Frame error)
There was an error inthe communication protocol PR A
39 TP2 Protocol error 2
with the NC. (Information error) -
3A oc Overcurrent
An
excessive
current flowed to the motor. PR A
Overheating of the IPM used in theservo driver's PR A
38 PMOH Power module Overheat
main circuit was detected.
(1)
. . A skip of the detector feedback signal pulse
occurred in the OHE type or OHA type detector
used in thesemi-closed loop system and ball
42 FE 1 Feedback error 1 screw
end closed loop
system. PR
(2) A skip of the detector feedback signal pulse in
the low-speed serial type absolute position
linear scale.
A deviationoccurred in the feedback amount from
43 FE2 Feedbackerror 2 the motorenddetectorandmachineenddetectorin PR
the closed loop system.
46 OHM Motor oveheat The motor or detedor thermal
protector
operated. NR
The motor current operatedin the range set with
50 OL 1 Overload
the
1 overload
detection level (parameter OLL) and NR
-
~ _ _ _ _ ~
overload time constant (parameter OLT).
A current commandwith a maximum output current
51 Overload 2 NR
- OL2 exceeding 95% continued for 1 secondor more.
The actual position to the command exceeded the
52 OD1 Excessive error 1 excessive errorwidth 1 (parameter OD1) when the NR
servo was turned ON.
_ _ ~~
-
58 CLEO Collision
detection 0 I
A collision detection type 1 error was detected
durina the GO modal (rapid traverse).
~ ~~
NR
r
Release Class
I Alarmhuaming
check Deriod
f l f 2
Acollisiondetection type 2 errorwasdetected. I NR A - -
An error occurred in the power supply unit. (Refer to
<Sew0 warnings>
Dis-
plsr
90
--I Name Meaming
PR I A
Alarmhvaming
check period I
91
I
The absolute position serial data
sentfromthe
serial type absolute
position
linear
was not properly
OHA type detectorand low-speed
scale.
II - I
I
A
93 wAM
I
Absolute
position
fluctuation
tumed
The absolute position counter cannot
absolute position data fluctuated when NC
was ON.
be set as the
the power
IPRIA
96 MPE
1'
MP scale feedback
error
In the MP scale absolute detection system, an
excessive deviationin the motor end installation
detector and MP scale feedbadc amount was
detected.
- A
97
I
MP scale offset error
In the MP scale absolute position detection
system, an error was detected in the offset data
read when theNC power was tumed ON.
PR A
9€ WAN
9f wAB
I
High-speed serial mu)ti-
rotation counter
Batteryvow
IAn error was detected in the multi-rotation counter
in the serial pulse encoder installed on the motor
end or ball screw end.
The voltage of the battery supplied to the absolute -
- A
A
position detector dropped.
El WOL
I
Overload
warning
An 80% level of the overload 1 alarm was detected.
(If operation is continued, the overload1 alarm may
occur.) - IC
E3
E4
WAC
W E
Absolute position The absolute position counter value
absolute position mustbe initialized.
is illegal.The
Alarmhnaming
Dm-
Abbt. Name Meaming Release Class check ,
play
~
f l f Z f 3 f 4
E6 AXE Removing control axis The axis removal command is input from the NC. - A - 0 0 0
E7 NCE NC emergency stop The emergency stop command is input from the NC. - c - 0 0 0
E8- A warning was generated with the power supply
EB unit.
(Refer to the power supply unit item for
details.)
[Release]
AR : The alarm is released by turning the servo drive unit power
OFF and ON.
PR : The alarmis released by turning theNC power OFF and ON.
NR : The alarmis released by NC reset.
is lowered passed the reset
(However, overload alarm"50cannot be released until the load
level (50% of the current value on the monitor screen.))
- Automatically restored when the warning state is eliminated.
[Class]
c : Detects both axes even during the Z-axes integrated drive unit.
A : Detects each axis independently.
[Alarm/waming checkperiod]
fl : When servo drive unit power is turned
ON.
f 2 : When NC power is turned ON (emergency stopON)
ON)
f 3 : During normal operation (servo
f4 : During axis removal (ready
ON, sew0 OFF)
(Note' : Warning "93" may occur after axis removal while installing the axis again.)
3. Troubleshooting (MDS-NB Series)
When an alarm occurs in the spindle drive, the servo will Oturn
F F and the motor will coast to a stop. Turn
the power OFF with an external sequence.
To release the alarm, remove the cause and then turn the power ON.
111 - 23
3. Troubleshooting (MDS-A/B Series)
, ,
confirm cooling fan
Grounding not enforced .....
add grounding measures.
are both"L".
2) When the states of theU, V and W phases are all "H" or
"L".
Alarmcheckeriod
(6) Alarm No. Initial
communication
error
[Meaning] Initialcommunicationwiththedetectorwasnotpossibleina - 0 - -
system using the OHA type detector (motor endor ball screw
end installation)or serial pulse encoder.
I11 - 25
,
3. Troubleshooting (MDS-A/B Series)
,
(Alarm outputby the detector.)
Aqn;hy;31ri;d,
(11) Alarm No. Serial pulseencoderthermalerror
weaning] The thermal protectorbuiltin the detectoroperatedin the - 0 0 0
serial pulse encoder installed on the
ball screw end.
(Alarm output by the detector.)
-
I11 26
3. Troubleshooting (MDS-A/B Series)
111 - 27
. .I"
3. Troubleshooting (MDS-A/B Series)
(16) Alarm
period
check
Alarm No.
error
axisusedNot
[Meaning] A IPM alarm is occurring in an axis that is set"F"
asin the unit
axis settingrotary switch and which is not being controlled.
(Alarm only for 2-axes integrated drive unit)
~ ~~~~
Check for abnormalities in the No special abnormalities were Replace the detector (linear
unit's peripheral environment. found. scale.)
(Ex. ambient temperature, An abnormality was found in the Take measures according to the
noise, grounding.) ambient peripheral environment.cause.
Ex. High temperature _....
confirm cooling fan
Grounding not enforced.....
add grounding measures.
I11 - 29
-.-, .,, ,
3. Troubleshooting (MDS-A/B Series)
(18) Alarm No. 1281 Absolute position overspeed Alarm check period 1
, ,
Ex. High temperature .....
confirm cooling fan
Grounding not enforced.. ...
add grounding measures.
111 - 30
3. Troubleshooting (MDS-A/B Series)
I11 - 31
~*.... .
(23) Alarm No. (2D( Serial
weaning]
pulse
encoder
serial
pulse
data
encoder
3. Troubleshooting (MDS-A/B Series)
error
An error was detected in the per rotation position data of the
connected
the
motor
to end.
(Alarm output from the detector)
, kimph~kqri;d,
- 0 0 0
I I monitor screen.
The setting is less than 80% of
the maximum value.
than 80% of the maximum value.
Perform investigation
- item 6.
111 - 32
3. Troubleshooting (MDS-A/B Series)
I11 - 33
3. Troubleshooting (MDS-A/B Series)
No. Alarm
(27) Alarmcheck CRC error period
f4
weaning] A CRC error occurredin the communication data from the NC. f l f2 f3
- 0 0 0
~~
Check for abnormalities in the No special abnormalities were I Replace the MCP card on theNC
unit's peripheral environment. found. side.
(Ex. ambient temperature, An abnormalitywas found in the Take measures according to the
noise, grounding) ambient peripheral environment.cause.
Ex. High temperature.....
confirm cooling fan
...
Grounding not enforced..
add grounding measures.
,
large.
k 4 z w p h ~ ~ 3 ~ r i ~ ,
(29) Alarm No. Transmission
error
[Meaning] The cyclic data transmission from the NC was terminated. - 0 0 -
Alarm(30) eriod1371
No.check
Alarm
Parameter
error
weaning] There is error in the servo parameters transmitted from the
n. during NC - 0 - 0
~~ ~~~~
3
Remedy
The illegal parameter No. is is incorrect. Set the correct parameter. The setting
displayed on the NC diagnosis The setting is correct. Perform investigation item3.
Screen, so adjust the sento The parameterNo. is other than Perform investigation item2
parameter with the parameter 1 to64. when parameter No. is 101.
adjustment procedures.
The servo parameter (PIT) Illegal or setting range is Refer to the parameter settings
(RNG) (PC?)(PC2) combination and supplementary explanations exceed
is illegal or the setting range is in the specifications, and reset to
exceeded. the correct value.
The settingis correct. Perform investigation item3.
3 Perform the items for alarm
No.
"34"-
side cannons) tosee if they are Not disconnected. Perform investigation item4.
loose.
Turn thepower OFF and check A connection defect was found. Replace the detector cable.
the detector cable connection Connection is normal. Perform investigation item5 .
with a tester.
Check the thermal relay terminal No conductivity or resistance is Perform investigation item6.
conductivity in the detector's high.
cannon Wnnecfor with a tester. Normal (short circuit) Perform investigation item7
(Excluding MDS-B Series)
Between pin Nos. 'T' and 'V'
If the thermal connection is as No conductivityor large Replace the motoror detector.
shown belowfor OHE25K-6, resistance in the motor and
OHA25K-4, OSE104/105 and detector thermal.
OSAl04/105, so cut the wire Normal Perform investigation item7.
between the motor and detector
with a joint amplifier, and check
the thermal conductivityfor each.
For OHE25K-85,0HA25K-85,
OHE25K-108 and OHA25K-108,
the thermal is only on the
detector side, so the detector is
defective if there is no
conductivity.
Replace with anothernormal axis The alarmis on the unit side. Replace the unit.
unit, and check ifthe defect is on Occurs evenif unit is replaced. Perform investigation item 7.
the unit.
Check for abnormalities in the No special abnormalities were Replace the motor.
unifs peripheral environment. found.
(Ex. Ambient temperature, Take measures according to the An abnorm
noise, grounding) ambient peripheral environment. cause.
Ex. High temperature .....
confirm cooling fan
Grounding not enforced..
...
add grounding measures.
I11 - 37
3. Troubleshooting (MDS-AIB Series)
!
Standard setting values
OLL: 60 (unit: sec.)
n l
UL I .
T-~ c n
I J W
111 - 38
3. Troubleshooting (MDS-NB Series)
ISupplementary explanation]
1) MDS-B Series
The unit was run in the region
of the thermal characteristics
shown with 'slanted lines below.
With the MDS-B Series, continuous protection characteristics were realized by changing the overload
alarm detection process.
Note 1) The overload 1 detection region canbe changed with the parameters(SV021: )LT, SV022: OLL) in the same manner
as MDS-A. However, as long as there is no particular reason, use the standard parameters.
Note 2) With this alarm, as the overload detection method has been changed, the alarm occurrence time and the value
displayed at "Overload(YO)" on the servo monitor screen may differ fromMDS-A the Series even when usingthe same
operation pattern.
Note 3) To prevent operationfrom being resumed immediately from the overload state, this alarm cannot be reset until the
control power( L l l , L12) continuity stateis not continued for several minutes after the alarm occurs.
The condition for resetting the alarm is that the "Overload (YO)''
display value must drop to50% or less. The time to wait
for this alarm to reset will differ accordingto the servo parameters (OLT and OLL), but is approximately five minutes
with the standard parameters.
If the control poweris turned ON again immediately after the alarm has occurred, the alarm will notbe reset due to the
above operation.Wait at least 5 minutes in the continuity state, and then carry out NC reset or turn the power ON
again.
0.1
&LL-SO t OLL
0 50 150 2 00 250 300 350
Motor current (YOto stall rating)
I00
Q
W
E
F 10
0.1
1
0
I11 - 39
3. Trou bleshootinq(MDS-NB Series)
2) MDS-A series
loo -
50 -
Operation nut possible
h range due to current
0
limit
3
Y
Q)
E
i=
10 -
5 .
1 I Fixed value
0.5
I I 1 I
100 200 300 400 500
(39)
Alarm No. Overload 2 Alarm check Deriod
[Meaning] A current command that is 95% or more of the amplifier's
maximum output current value continued for Isecond or
more.
~~~ ~~ ~
I11 - 41
- ".. . ..I
3. Troubleshooting (MDS-A/B Series)
[supplementary explanation1
1) MDS-B Series
The unit was run in the region below.
of the thermal characteristics shown with slanted lines
100
h
0
Q)
v
u)
10
i=
0.1
IO
100
111 42-
3. Troubleshootina (MDS-A/B Series)
2) MDS-Aseries
100
overload 1
Overload 2
50
Y
E
i=
10
0.5
I I 1 I b
100 200 300 400 500
I11 - 43
oI__. .. .
3. Troubleshooting (MDS-A/B Series)
Motor
r Level
0
Time
r Level
0
Time
r Level
X
Time
A
Level
The actual machine position deviated an amount exceeding the value set in OD1 from the ideal
machine position for the command position.
This will occurif the actual machine position enters the shaded area
shown below.
Position
I11 - 45
.. -.
(41) Alarm No.
weaning)
1531 Excessive
error
3. Troubleshooting (RADS-NB Series)
2
The actual position to the command exceeded the value set in
parametersettingvalue OD2 (excessiveerrorwidthduring
servo OFF) duringsew0 OFF.
-
, li~rph~~3~ri;d,
0 -
-
I
reached the current limit value the current limit value.
or 90% of the limit value .during
normal rapid traverse
- The current is less than
the current limit value.
perform investigation item4.
90% of Perform investigation item4.
acceleration/deceleration.
4 Adjust the collision detection The alarm does not occur. -
function again, and try The alarm occurs. Perform investigation item5.
operation. (Refer to the separate
collision detection function
specifications.)
5 Does the machineor current Is vibrating. Eliminate the vibration by
vibrate? adjusting the gain, etc., and then
perform investigation item4.
Is not vibrating. Perform investigation item 6.
6 Try increasing the detection The alarm does not occur. If the problem is not solved by
level. replacing the unit, try increasing
the level.
The alarm occurs. , Replace the unit.
I11 - 47
3. Troubleshooting (MDS-A/B Series)
II
replacing the unit, try increasing
the level.
level* The alarm occurs. Redace the unit:
is on the drive unit side or power The alarmis on the power supplyReplace the power supply unit.
supply side. side.
I
~ ~~ ~-
111 - 49
3. Troubleshooting (MDS-A/B Series)
,
Investigation item Investigation results Remedy
1 Perform the items 3 and following
for alarmNo. "25"
(53) Alarm
MP No. scale feedback error li~~;h~kqri;d,
weaning] In the MP scale absolute detection system, an excessive
deviationinthemotorendinstallationdetectorand MP scale - 0 0 0
feedback amountwas detected.
1
111 - 50
3. Troubleshooting (MDS-A/B Series)
( 5 6 ) Warning No.
eriod
check
Alarm
drop
voltage
Battery
[meaning] The voltage of the battery supplied to the absolute position
pped. detector - 0 0 0
1
k
voltage.
Perform the items3 and following
for alarm No. "25'
I11 - 51
3. Troubleshooting (MDS-A/B Series)
3.3 Precautions
(1) When changing the motor and amplifier combination due to troubleshooting, avoid running the
motor with an amplifier that has a capacity larger than the designated amplifier. The motor may be
demagnetized.
However, checkingin the emergency stop stateis no problem.
Running the motor with an amplifier having a capacity smaller than that designated
is no problem.
4. Troubleshooting (MDS-C1 Series)
A CAUTION
1. This servo system uses a large capacity electrolytic capacitor. When the
CHARGE lamp on
the front of the power supply (MDS-C1
unit is still a voltage in the
-CV)in the system is lit, there
unit. Take care to prevent electric shocks and short circuits. (The voltage will remain for
several minutes after the power
is turned OFF.)
2. The continuity inside the driver cannot be checked due to the structure.
3. Do not carry out a megger test as the driver could be damaged.
<Matters to confirm>
1. What alarm No. is displayed?
2. Can the error or fault be repeated? (Investigate alarm history)
3. Is the motor and servo driver temperature and ambient temperature correct?
4. Are the servo driver, control unit and motor grounded?
5. Did the problem occur during acceleration, deceleration or constant speed operation?
What was thespeed?
6. Is there any difference in the state during forward run and reverse run operation?
7 . Was there a instantaneous power failure?
8. Did theproblem occur when a certain operationor command was carried out?
9. How often does the problem occur?
10. Does the problem occur when the load is applied or removed?
11. Has the driver unit been replaced, any part been replaced, or any remedial measure been
taken?
12. How many years have passed since operation was started?
13. Is the power voltage normal?Is there any great fluctuation according to the time zone?
11 F1 (flicker)
F +axisNo.
37 (flicker)
Alarm No.
(flicker)
F1
F + axis No.
lit (flicker)
37 Not
Alarm No. I
I
LED display during servo alarm
F1 9F F1 lit 9F Not
F + axis No. Warning No. F + axis No. Warning No.
I11 - 53
*
-
. .
4. Troubleshooting (MDS-CI Series)
~~~~ ~~~ ~~
I I
~~
I11 - 54
4. Troubleshooting (MDS-Cl Series)
I11 - 55
4. Troubleshooting (MDS-C1 Series)
72 I t A2
73 1. J /ovler-.regeneration I PR 1 R, A3
74/ K /Regerrerative&storover)leat PR R A4
75 1 L - 1 I NR I V/R A5
76 M I F - w a w m m ARI
A6 V
77 N ~PowlermaduleOr)/fin (R) overheat
I I
PR 1 V/R
I
A7
I
Bn In READY OFF (n is control axis No.) Dn (In servo ON (nis control axis No.)
Cn In SERVO OFF (n is control axis No.) Fn lcontrol axis No. display (n is control axis No.)
Note 1) For R S , PR: Reset by turningNC power OFF, AR: Reset by turning servo driver power OFF.
*: This is a warning display, and the servow i l l not turnOFF.
Note 2) For A/C, A: Alarm occurring for each axis, C: Common alarm in driver, SP: Spindle alarm, SVJ: MDS-A-SVJ alarm,
AV: MDS-A-Vx alarm, BV: MDS-B-Vx alarm, VL: MDS-B-Vx4L alarm, V: Power regeneration p o w e r supply alarm,
R: Resistor regenerationpower supply alarm
111 - 56
4. Troubleshooting (MDS-CI Series)
error
I
Rebtive position
circuit error (SUB)
I FE2
I Feedbackerror 2
IExcessive deviation was detected in the feedback amount of the
An FB IC
error
was
detected
the
insemi-closed 1000. I I
motor end detector and machine end detector within the closed loop. PR A
I11 - 57
4. Troubieshootina (MDS-C1 Series)
Servo warnings
No. Abbr. Name Details RS NC
9o wsT Low-speed serial initial Initial communication with the absolute position linear was scale
not PR A
communication error possible.
An error was detected in the communication with the detector in the
91 WAS L0W-S-d serial absolute position detection system usingthe OHA25K-ET/absolute * A
communication error position linear scale.
An error was detected in the data from the detector in the absolute
92 WAF Low-speed serial protocol position detection system using the OHA25K-ET/absolute position * A
error linear scale.
Fluctuation exceedingthe tolerable valuewas detected in the PR A
93 WAM Absolute absolute position detected when the NC power was turned ON.
Excessive deviationwas detected-inthe feedback amount of the.
96 MPE MP scale feedback error motor end detector andMP scale In the MP scale absolute posltlon * A
detection system.
An error was detected in the offset data readin when the NC power
97 MPO MP scale offset error was tu& ON within the MP scale absolute position detection PR A
system.
An error was detected in the multi-rotation counter of
9E High-speed serialmulti- OSElO4/OSA104/OSE105/OSA105/OSE1W-F/OSA104- * A
rotation counter error ET/OSE105-ET/OSA105-ET. The absolute posltlon cannot be
guaranteed.
9F WAB The voltageof the battery supplying to the absolute position detector
*
Batteryvoitage drop has dropped. A
El WOL Overload warning A level 80% of the overloadalarm 1 was detected. * A
E3 WAC -lute position counter Deviation of the absolute position and relative position
was detected. * A
warning
E4 WPE Parameter error warning A parameter exceedingthe setting range was set. * A
E6 AXE Control axis removal warningThe controlaxis is removed. * A
E7 NCE N C emergency stop The NC is in the emergency stop state. * c
4. Troubleshooting (MDS-C1 Series)
At NC power ON
I11 - 59
4. Troubleshooting (MDS-Cl Series)
Alarm No.
17 I N D convertererror:
Anerroroccurred in thedriveunit's A/D converter.
I Alarm check period
s I I
Investigation item Investigation
results Remedy
1 Confirmtherepeatability. 1Always occurs. Replace the drive unit.
2
I Check for abnormalities in the
unit's peripheralenvironment.
(EX. ambient temperature,
I No specialabnormalitieswere
found.
Replace the drive unit.
I11 - 61
-*~ j .
. . ,,
4. Troubleshooting (MDS-Cl Series)
5 Check for abnormalities in tke No special abnormalities were Replace the detector.
unit's peripheral environment. found.
(Ex. ambient temperature, An abnormallty was found in the Take measures accordingto the
noise, grounding) ambient peripheral environment.cause.
Ex. High temperature .....
confirm cooling fan
Grounding not enforced.....
add grounding measures.
Alarm No. Serial detector initial communication error (SUB): Alarm check,period ,
1A Initial communicationwith the detector was not possible
in the fl f2 f3 f4
system usingOHA25K-ET or a high-speed serial detector at the - -
0 -
machine end.
Investigation item Investigation results Remedy
1 Investigate the items for alarm
No. 'I18".
1
Alarm No.
1E The linear scale connected to the machine end detected an error
in the ROWRAM.
Or, the thermal protector built in the high-speed serial detector
connected
ROM-RAMI
(SUB): to
errorthe machine end activated.
thermal ;arihy;kfe[%
1
I Investigate the items for alarm
NO.Y B . I
Alarm No. Serial detector communication error
(SUB): Alarm check period
1F Communication with the high-speed serial detector connectedflto f3 f4 '
the machine end was disconnected.
- 0 0 0
Investigation item Investigation results Remedy
1 Investigate the items2 and
following for the alarmNo. "18".
I11 - 63
4. Troubleshooting (MDS-Cl Series)
I Alarm No.
21
No signal 2: Alarm check period
An A, B or Z phase error was detected in the closed loop system.1 1
Investigation item Investigation results Remedy
:heck the servo parameter "4", "5", or
" 8 1 is set for the Correctly set.
" 9 t
Turn the powerOFF and check Connection is defective. Replace the detector cable.
the detector cable connection Connection is normal. Perform investigation item 4.
with a tester.
Try connecting with another The alarm is on the unit. Redace the drive unit.
normal axis unit and check
~~
Check the repeatability. Does not recur. Perform investigation item7, and
Perform zero point return again. if there is no error, continue to
~~
use.
Always recurs. Perform investigation item6 .
Returns to normal once, but
recurs periodically.
Try connecting with another I Thealarmisontheunit. ReDlace the drive unit.
noml axis unit and check The alarm is on the detector. Perform investigation item7.
whether the defect is on the unit
detector
or
side
side. I ~~~ ~~~
Check for abnormalities in the No special abnormalities were Replace the motor (detector).
unit's peripheral environment. found.
(Ex. ambient temperature, Take measures according to the
noise, grounding) ambient peripheral environment. cause.
Ex. High temperature .....
confirin cooling fan
Grounding not enforced..
~. ~
1 1
I I
Alarm No. Scale CPU error: ;arihjcTT;{
The CPU in the absolute position linear scale connected to the
27 I
machine
end operating
correctly.
is not - I
I11 - 66
4. Troubleshooting (MDS-Cl Series)
Alarm No. Absolute position detection circuit error (SUB): Alarm check period
29 The absolute position linear scale connected to the machinefl
end p2 f3 f4
detected an error in the scale or scale circuit. - 0 0 0
Investigationstem Investigation results Remedy
1 Investigate the items for alarm
No."28".
Alarm No. Relative position detection circuit error (SUB): Alarm check period
2A The absolute position linear scale connected to the machinefl end p2 f3 f4
detected aspeed exceeding the absolute position linear scale's
maximum movement speed. - 0 0 0
I1 ! Investigation item
Check whether the machine was
I Investigation results
The machine was operating.
Remedy
Perform investigation item 3.
operating when the alarm The machine was not operating. Perform investigation item2.
OCCUTTed.
2 Check whether movement is Is moving Perform investigation item 3.
normal atlow speeds. Is not moving Check the cautionary items
before turning the powerON.
Check the wiring
Check the parameters
3 Tug the connector tocheck if the Was disconnected(loose). connect.Correctly I
absolute position linearscale Was not disconnected. Perform investigation item 4.
connector (unit side and scale
side)is disconnected. I ~ ~~~~
II
4 Turn the p o w e r OFF and check A connection defect was found. Replace the-detector cable.
the detector cable connection Connection was normal. Perform investigation item5.
with a tester.
I5 I Tw c o n n a n a with another I Thealarmisontheunit. Replace
drive
unit.
the I
II
~
normal axis u h and check The alarm occurs with the Perform investigation item6.
whether the defect is on the unit absolute position linear scale.
side or dewor side. ~ ~~
6 Check for abnormalities inthe No special abnormalities were Replace the-motor (absolute
unifs peripheral environment. found. position linear scale).
(Ex. ambient temperature, An abnormality was found in the Take measures according to the
noise, grounding) ambient peripheral environment. cause.
Ex. High temperature ..... .
confirm cooling fan
Grounding not enforced.....
add grounding measures.
I11 - 67
4. Troubleshooting (MDS-Cl Series)
error:I Data
Alarm No. checkI
Alarm period I
2D I
IAn error was detected at a position within one rotation
Remedy
I I
I
I
Communication with the high-speed serial detector connected to
the motor end was disconnected.
Remedy
I I
I11 - 68
-. ...
" e
,._"
4. Troubleshooting (MDS-C1 Series)
>heck the servo parameter The settings are incorrect. Correctly set.
setting values. The settings are correct. Perform investigation item5.
Refer to the adjustment
procedures.
Tug the detector connector (unitWas disconnected (loose). Correctly connect.
see if it has
3nd detector side) to not disconnected. Perform investigation item6.
lisconnected.
rum the powerOFF and check A connection defect was found. Replace the detector cable.
e
' detector cab' mnnecfjon ' Connection was normal. Perform investigation item7.
with a tester.
Check the repeatability. Does not recur. Perform investigation item9.
Recurs Deriodicallv. Perform investigation item9.
Always recurs. Perform investigation item8.
Try connecting with another The alarm is on the unit. Replace the drive unit.
normal axis unit and check The alarm is on the detector. Replace the motor (detector).
whether the defectis on the unit
side or detector side.
Check for abnormalities in the No special abnormalities were Wait.
unit's peripheral environment. found.
(Ex. ambient temperature, An abnormality was found in the Take measures according to the
noise, grounding)
ambient peripheral environment. cause.
Ex. High temperature .....
confirm cooling fan
...
Grounding not enforced..
add grounding measures.
I11 - 69
....* " - .. .
4. Troubleshooting (MDS-Cl Series)
- 0 0 1 0
Investigation item Investigation results Remedy
Tug the connection connectors The connectors are Correctly connect.
between the NC and drive unit, disconnected (loose).
battery unit and drive unit, and Not disconnected. Perform investigation item2.
between drive units to see if they
are loose. Check that an
excessive force is not being
applied on the connector section.
Turn the powerOFF and check A connection defect was found. Replace the communication
the connection of the cable.
communication cable in item1 Connection is normal. Perform investigation item3.
with a tester. Try replacing with a
normal cable.
C h k k whether the NC and drive Was changed. Try returning to the original
unit software version was software version.
recently changed. Not changed. Perform investigation item4.
Replace with another normal The alarm is on the unit side. Replace the drive unit.
unit, and check whether the errorThe driver is not the cause. Perform investigation item5.
is on the NC side or unit side.
Check for abnormalities in the No special abnormalities were Replace the MCP card on the NC
unit's peripheral environment. found. ~~
side.
(Ex. ambient temperature, An abnormality was found in the Take measures according to the
noise, grounding) ambient peripheral environment. Cause.
Ex. High temperature .....
confirm cooling fan
Grounding not enforced.. ...
add grounding measures.
~~
Alarm No.
An
NC error was detected
35 communication
NC.
~~ ~
in the
Data movement command data from the
error: yr;hryT;:1 - -
I
Investigation item Investigation results Remedy
1 alarm
Investigate the items for
No. "34".
Check whetherthe servo Illegal or setting range is Refer to the parameter settings
parameter (PIT) (RNG1) (RNG2) exceeded. and supplementary explanations
(PC1) (PC2) combination is in the specifications, and reset to
illegal, or whether the setting the correct value.
range hasbeen exceeded. The settingis correct. Perform investigation item3.
Check the items for alarmNo.
I
Alarm No. NC communicationprotocolerror 1: Alarm check period
An error was detected
in the communication frame sent from the
fl f2 f3 f4
NC.
Investigation item investigation results Remedy
1 Investigate theitems for alarm
No. "34".
111 - 71
4. Troubleshooting (MDS-CI Series)
1
46 No-
A'ann I Motor overheat:
An errorwasdetectedinthetemperatureofthemotorbeing
Alarm check period
f l I 42 I f3 I f4
I driven.
Or,thethermalprotectorbuilt in thehigh-speedserialdetector
I connected to thema 3r end activated.
I-I I I
0 0 -
Investigation item lnvestiaation results
w
Remedy
Check the repeatability. Recurs within one minute startof Perform investigation item 3.
UP-
Recurs periodically after Perform investigation item2.
operating for some time. ~~~ ~
Check the motor temperature The motoris hot. Lessen the operation pattern.
when the alarm occurs. 1
If the problemis not solved,
perform investigation item 3.
The motoris not hot. Perform investigation item3.
Tug the detector cable The connectors are Correctly connect.
connectors (unit side and motor disconnected (loose).
side cannons) tosee if they are Not disconnected. Perform investiggtion item 4.
loose.
Turn the powerOFF and check Connection is defective. Replace the detector cable.
the detector cable connection Connection is normal. Perform investigation item5.
with a tester.
If the thermal connection is as No conductivity or large Replace the motor or detector.
shown below for OSEl04/105 resistance in the motor and
and OSA104/105,so cut the wire detector thermal.
between the motor and detector Perform investigation item7.
with a joint amplifier, and check
the thermal conductivity for each.
Replace with another normal axis The alarmis on the unit side. Replace the unit.
unit, and checkif the defect is on Occurs evenif unit is replaced. Perform investigation item7.
the unit.
Check for abnormalities in the No special abnormalities were Replace the motor.
unit's peripheral environment. found.
(Ex. Ambient temperature, An abnormallty was found in theTake measures according to the
noise, grounding) ambient peripheral environment. cause.
Ex. High temperature ..._.
confirm cooling fan
Grounding not enforced.. ...
add grounding measures.
I11 - 72
4. Troubleshooting (MDS-C1 Series)
Check the servo parameter The setting is not the standardCorrect to the standard setting
(OU) (OLT) setting values. setting value. value if special specifications are
Standard setting valuesOLL: 150 not being used.
The value is the standard settingPerform investigation item2.
~ ~~
value.
Check the motor temperature The motor is hot. Ease the operation pattern.
when the alarm occurs. L
If the problem is not solved,
perform investigation item
3.
The motor is not hot. Perform investigation item
3.
Check whether the motor
is Hunting is occurring. Refer to the adjustment
hunting. procedures and readjust.
Check the cable wiring and
connector connections.
Check for mistaken
parameter settings.
Adjust the gain.
L
If the problem is not solved,
perform investigation item4.
Hunting is not occurrina. Perform investigation item
4.
Replace with another normal axisThe alarmis on the unit. Replace the drive unit.
unit and check whether the Problem still occurs even after Perform investigation item
5.
defect is on the unit. unit is replaced.
Check whether the current value
The value is abnormal. Check the machine system.
displayed on theNC Servo The value is correct. Perform investigation item
6.
Monitor screenis abnormally
large when stoppedor during
operation.
Check for abnormalities in the No special abnormalities were Replace the motor (detector).
unirs peripheral environment. found.
(Ex- ambient temperature, An abnormality was found in theTake measures according to the
noise, grounding) ambient peripheral environment. cause.
Ex. High temperature .....
confirm cooling fan
...
Grounding not enforced..
add grounding measures.
I11 - 73
- -UP_.. .,
4. Troubleshooting (MDS-C1 Series)
1 yy;hy;ejri;: 1
Alarm No.
51 A current command95% or more of the driver's maximum
performance continued for1 sec. or more.
~~ ~
Overload 2:
~~
- - -
Investigation item Investigation results Remedy
Check whether the PN poweris The voltage is supplied. Perform investigation item3.
being supplied to the driver. The voltage is not supplied. Perform investigation item
2.
Check the axis for which the
alarm is occurring and the
axis farthest from the power
supply-
Confirm that the power supply is no voltage at the PN Check the power supply unit. There
unit CHARGE lamp is lit and terminal. (The lamp is not lit.)
check the PN terminal voltage. There is a voltage at the PN Check the PN wiring between the
terminal. units.
The maximum value exceeds the
Check whether the current value Lengthen the acceleration/
displayed on the NC Servo level indicatedwith an x in the deceleration time constant, and
Monitor screen is abnormally table on the previous page. lower to80% of the limit value.
large during acceleration/ A correct value is displayed. Perform investigation item4.
deceleration.
Perform the items 3 and following
for alarmNo. "50.
~~~ ~~ ~~ ~
turned ON. - 0 -
Investigation item Investigation results Remedy
1 Check whether the PN power is is supplied. Perform investigation item 3. The voltage
being suppliedto the driver.
Check the axis for which the
alarm is occurring and the The voltageis not SUPPlid- PerForm investigation item2.
axis farthest from the power
supply-
2 Confirm that the power supply Check no vottage
There isthe at the unit.
power suppljr PN
unit CHARGE lamp is lit and terminal. (The lampis not lit.)
check the PN terminal voltage- There is a voltage at the PN Check the PN wiring between the
terminal. units.
3 Checktheservoparameter The setting is not the standard Correct to the standard
(OD1) setting value. setting value. specification valueif special
specifications are not being used.
The setting is the standard Perform investigation item4.
setting value.
I11 - 74
4. Troubleshooting (MDS-Cl Series)
I
lsupplementary explanation
The actual machine position deviated an amount exceeding the value set in OD1 from the ideal
machine position for the command position.
This will occurif the actual machine position enters the shaded area shown below.
Command positic
\
Position
OD 1
I
OD 1 >
I11 - 75
___L ..
4. Troubleshooting (MDS-Cl Series)
r Alarm No.
53
error
I
The difference of
Excessive
parameter SV026: OD2when the servo was turned OFF.
1
2: the ideal position and actual position exceeded
rajrn;hT;3pr;:
I
- I
0 I
- I
-
Investigation item Investigation results Remedy
:heck the servo parameter The setting is not the standard Zorrect to the standard setting
lOD2) setting value. setting value. lalue if special specifications are
lot being used.
The setting is the standard 'erform investigation item2.
setting value.
:heck if the machine is moving Is moving. :heck the machine and
juring sew0 OFF. nechanical brakes.
Is not moving. >erform investigation item
3.
Tug the communication cable Is disconnected (loose). Zorrectly connect.
zonnector from the NC to the Not disconnected. 3erform investigation item4.
terminator (unit side and NC
side) to see if it is disconnected.
Turn the powerOFF, and check A connection defectwas found. Replace the communication
the communication cable =able.
connection with a tester. Connection is normal. Perform investigation item5.
Try changing with a normal
cable.
Replace with another normal axisThe alarm is on the unit. Replace the drive unit.
unit and check whether the Problem still occurs even after Replace the NC side MCP card.
defect is on the unit. unit is replaced. 1
solved,
If the problem is not
____
perform investigation item6.
Tug the detector cable connectorIs disconnected ( l o o s e ) . Correctly connect.
(unit side and motor side cannon)
Not disconnected. 7.
Perform investigation item
to check ifit is disconnected.
Turn the powerOFF, and check A connection defectwas found. Replace the detector cable.
the detector cable connection Not disconnected. Perform investigation item
8.
with a tester.
Check for abnormalities in the No special abnormalities were Replace the motor.
unit's peripheral environment. found.
(Ex. ambient temperature, An abnormallty was found in the Take measures according to the
noise, grounding) ambient peripheral environment. cause.
Ex. High temperature .....
confirm cooling fan
...
Grounding not enforced..
add grounding measures.
4. Troubleshooting (MDS-C1 Series)
I11 - 77
4. Troubieshootina (MDS-C1 Series)
I I
~~ ~ ~~~~
I I
2 Checktheparameters.
Is SV060 (TLMT) set to"OH? I' Thesetting is incorrect. 1 Change SV060 (TLMT) to "0".
I
3 Check whether the current has The currentis 90°h or more of
reached the current limit value the current limit value. I
Increase the time constant, and
performinvestigationitem 4.
or 90% of the limit value during The current is less than 90°h of Perform investigation item 4.
I
~-
normal cutting feed
acceleration/deceleration.
~~
occur.
Adjust the collision not
detection
the current limit value.
does
The alarm ~ ~~
I ~~~
I I
function again, and try The alarm occurs. Perform investigation item5.
operation. (Refer to the separate
collision detection function
specifications.)
5 Does the machine or current Is vibrating. Eliminate the vibration by
vibrate? adjusting the gain, etc., and then
perform investigation item4.
Is not vibrating. Perform investigation item 6.
11
6 Try increasing the detection
level.
The alarm does not occur. If the problem
the level.
is not solved by
replacing the unit,try increasing
A
I
- No. Amplifier power reset request: Alarm check period
7F An error was detected when the control mode (high gain mode, fl f4
standard mode) was selected.
Or, an error was detected in EEPROM
the if this error is detected -
again after the power is reset.
I11 - 79
- ,.. ...,
_",
4. Troubleshootina (MDS-C1 Series)
8C
Ala-No- II HR unit scale judgment error:
The MDS-B-HR connected to themachineendcould
the connectedscale's analog wave cycle.
i lnvestiaation
item investiaation results Remedy
I s c o n n e c t e d (Ioose). Correctlv connect.
MDS-B-HR connector (unit side, Is not disconnected.
HR side and linear scale side) is
disconnected.
2 Turn the power OFF and check The connectionis defective. Replace the detector cable.
the connectionof the detector Connection is normal. Perform investigation item3.
cable (between driver andI/F
unit, and between I/F unit and
scale) with a tester.
Interchange with another correctAlarm occurs in unit. Replace the drive unit.
axis unit (or MDS-B-HR), and Alarm occurs in MDS-6-HR Perform investigation item4.
check whether the faulty section (linear scale).
is in the unitor MDS-B-HR
(linear scale).
Check for abnormalitiesin the No special abnormalities were Replace MDS-B-HR (linear
unit's peripheral environment. found. scale).
(Ex. ambient temperature, An abnormality was found in the Take measures according to the
I noise,
grounding) ambient peripheral environment. cause.
Ex. High temperature.....
confirm cooling fan
Grounding not enforced.. ...
add aroundina measures.
111 - 80
4. Troubleshooting (MDS-C1 Series)
Aa
ln No. I HR unit CPU error: 1 Alarm
Deriod
check 1
80 I The CPU forthe MDS-B-HR connectedtothemachineendis ' fl f2 f i f4 1
I not operating correctly. 1
0
- 1
- I
- 1
-
Investigation item I Investigation
results Remedy
Tug the connector to check if the Is disconnected (loose). Correctly connect.
MDS-B-HR connector (unit side Is not disconnected. Perform investigation item2.
and HR side) is disconnected.
Turn the powerOFF and check The connection is defective. Replace the detector cable.
the connection of the detector Connection is normal. Perform investigation item3.
cable (between driver andI/F
unit) with a tester.
Interchange with another correct Alarm occurs in unit. Replace the drive unit.
axis unit, and check whether theAlarm occurs inMDS-B-HR. Perform investigation item 4.
faulty section isin the unitor
MDS-B-HR.
Check for abnormalities in the No special abnormalities were Replace MDS-B-HR.
unit's peripheral environment. found.
(Ex. ambient temperature, An abnormality was found in theTake measures according to the
noise, grounding) ambient peripheral environment. cause.
Ex. High temperature .....
confirm cooling fan
Grounding not enforced.. ...
add grounding measures.
Ahrm No. Low+peed serial initial communication error: Alarm check period
90 Initial communication with the absolute position linear
scale was fl p2 f3 f4
not possible. - 0 0 0
Investigation item Investigation results Remedy
1 Investigate the items for alarm
No. " 5 8 .
I11 - 81
4. Troubleshooting (MDS-C1 Series)
I
unit's peripheral environment.
(Ex. Ambient temperature,
noise, grounding)
found.
,
1 1
Alarm No.
9E An error was detected in the multi-rotation counter with the
high-speed serial detector connected to the motor end and ball
- 0 0 0
screw end. serial multi-rotation
High-speed counter error: Fr;hrF3pT;f
Investigation item Investigation results Remedy
1 Investigate the items 3 and
following for alarm No."25'
4. Troubleshooting (MDS-Cl Series)
I11 - 83
5. Appendix
5. Appendix
5.1 Changing from closed loop to semi-closed loop
To move the axis with the semi-closed loop for troubleshooting due to a defect in the closed toop or for
temporary operation, changeover with the following procedure.
1. Leave the parameter SVOI7 SPEC bit 5 setting as it is, and change the other bits to
0.
2. Set parameter SVOl9RNGI according to the motor shaft end detector type.
HA053/13
For 10
Forothermotors100(Motorenddetector : OHA25K,OHE25K, OSAl04,OSEl04)
1000 (Motor end detector : OSAlO5, OSElO5)
5. Turn the NC power OFF andON and confirm the axis movement.
Note 1) Write down the parameter data before changingso it can be applied when returning to closed
loop.
Note 2) Always perform set the reference point again when returning to the closed loop in the
absolute position detection system.
I11 - 84
~,.._. . -.
. _-._-
5. Appendix
bit7=l
Detector bit7=l
~ ~~ ~~~
I
......................3)
.......(HAOW1
.10 I
I
...... 100
100 Ball screw pitch
(OHE25WOSE104) .....................................
(OHA25WOSA104)
......................................
O0 ~~~~&~ Ball screw pitch
....................................
I o
l
t
0
..........................................................................
0(OSEIoa o
l
too (OSE105)
I Scaleresolution 1OOO (OSA105)
/OR
1OOO (OSA105) Scale resolution
hl myp I
m25 ooxx
(oHE~~WOSEI I 4ow6oxx
04) (OSE25WOSE104) (OHE25WOSE104)
.....................................................................
I 8oXX
I.....................................
...................................... 50W60XX
(OHE25WOSE104) (OHE25WOSE104)
SO>ovAOXX
............................................................................
Is2xx
I h....
22xx (OsA105) 52>Ov6= 92>OvA2>0<
(OSE105)
(OSE105) (OSE105)
111 - a5
I l- FIB cable 1
~~ ~
Amplifier Detector
System Confi guration Capacity Motor enddetector Machine end Motor Machine
Servo amplifier
-
end end
r
Type Motor detector
or OHE25K-6
HA40N
1 E l Motor shaft enddetector
MDS-AB-V1-•
OSE10410SE 105
more
Max. tracking capacity: HA23N'OHE25K-85
5MPPS OSEl04SIOSE105S HA33N - CN2
Min.
resolution : 0.0036' OHE25K-108 Low inertia
IHA40N
1
I
MDS-AB-VI-0
Max. tracking capacity: OHE25K-ET
5MPPS OSEl04ET CN2 CN3
Min.
resolution : 0.0036' OSAl04ET
Max. speed : 3000rpm
MDS-AIB-V2-0
1 1
HA053
u- U
I
/061104/0SE105 mz3N scales with a 1p
MDS-AB-VI-0 OHE25K-85
Max. tracking capacity specification, 0 . 5 ~
(according to maker) OSEl04S/OSElO5S HA33Nspecification
pulse FIB
CN2 CN3
Min. resolution OHE25K-108
inertia
possible.
Low
(according to maker) OSEl04S/OSE105S motor (Ex. MP
scale
MDS-AIB-V2-0
(Mitsubishi
HA053
Heavy
Built-in encoder Industries)) -
orOHA25K-4
HA40N
-
Q
0
0
1 Motor shaft detector
end
Max. tracking capacity:
I
MDS-NB-V1-0 OSAl04/0SA105 Imore 1
HA23NOHA25K-85
5MPPS OSAl04S/OSAlO5S HA33N CN2
Min.
resolution : 0.0036"
Max.
speed : 3000rpm MDS-NB-V2-0 OHA25K-108
inertia
Low
I
1 1 I
U
U
I OHE25K-6 IHA40N or I
1 Motor shaftdetector
end OSEl0410SE105 mG3N
MDS-NB-V1-0
Max. tracking capacity: OHE25K-85
OHA25K-ET
5MPPS OSEl04SIOSEl05S HA33N
OSAl04ET CN2 CN3
Min.
resolution : 0.0036' OHE25K-108
Low inertia OSAl05ET
speed
Max. : 3000rpm
I . .. ..- 1 -
I OHE25K-6 IHA40Nor I
OSE10410SE105
more
MDS-AB-VI-0
Max. tracking capacity: OHE25K-85 HA23N
Absolute
linear
value
0.83MPPS
CN2 CN3
Min.resolution : l p OHE25K-108
Max.
speed : 50mlmin. (Mitsutoyo)
MDS-A/B-V2-0
Tv. MDS-A-SP
MDS-B-SP
Spindle System Section
1. Adjustment Procedure
1 Adjustment Procedure
1.I Trial operation
Link the motor and machine, and check the control status while breaking in the machine.
IV - I
.l_l .. , .
1. Adjustment Procedure
There are three types of orientation stop that can be selected by setting parameter 1- .
1. PRE ........____............
(a)Spindleapproachesthestoppositionintherotationdirectionwhich is
same as that of ongoing rotation.
2. Fonward run ..........._ (b) Spindle always approaches the stop position in the forward run direction.
3. Reverse run ............ ( c ) Spindle always approaches the stop position in the reverse run direction.
OHC J I
I I
IV-2
1. Adjustment Procedure
Operation sequence
When orient command signal ORC turns O N , motor speed changes from steady run speed to
position loop changeoverspeedandatthesametime"stoppositioncommand"(multipoint
orientation) is read.
Whenmotorspeedreachesthepositionloopchangeoverspeed,controlmodechangesfrom
"speed control" mode to "position control" mode (position loop gain parameter (Note1)).
(Position loop changeover speed is automatically set in accordance with position loop gain setting.)
When control mode changes to position control mode, the distance to the stop is position
calculated
and spindlespeed is decelerated in accordance with the deceleration pattern set by parameter1-1
to stop.
When the spindleentersthe"in-position"rangesetbyparameter , orientedcompletesignal
ORCF turns ON.
The zeropoint can be shifted by setting parameter =
I] .
When orient command signal (ORC) is turned OFF, motor speed returns to the previously set
reference speed.
Motor speed
d
I
ORC
stop position
command
12b i t
I
GRl. CR2, GR3
QRCF b-
Note) 1-1 1-1
is used for magnesensor/motor built-ine n d e r type orientation, and for
encoder type orientation.
IV-3
.~ .
1. Adjustment Procedure
The stop positions willbe asshown below depending on the direction that the encoder is installed.
Case 1 Case 2
Encoder
Installation
Motor p&
direction Arrow A
Normal
orientation
Forward run
COOH
(270" )
Forward
run 0 Reverse run
800H 8obH
(180' 1 080' 1
block
Position
control Speed c o n t r o l blodc
r
I I
1- : Parameter name
I 1
From CNC +
Power
> n n
amplifier
&
[ X I
'
J
-
Position feedback - .
Spindle Speed feedback
motor
- GRB 1 - 6
CRA 1 - 6
- 0- Encoder
Bit5 or Bit6 p[
x-
IV-4
1. Adjustment Procedure
[Related Parameters]
I Parameter No. I Abbrev. I Name Ivalue
Default I
Position loop gainfor magnesensor or motor
SPOOl PGM 100
built-in encoder orientation
I SP004 I OINP I Orientation
in-Dosition
width I 16 I
SP005 OSP Orientation changeover speed limit value 0
SPO06 CSP Deceleration rate during orientation 20
SP007 OPST Orientation position shift amount 0
SP025 GRAl No. of gear teeth on spindle side1 1
GRA2 SP026
No. of gear teeth on spindle side 2 1
SP027 GRA3 No. of gear teeth on spindle side 3 1
GRA4 SP028
No. of gear teeth on spindle side 4 1
I SP029 I GRBl I No.motor
side
ofon
teeth
aear 1 I 1 I
I SP030 I GRB2 I No.motor
side
ofon
teeth
clear 2 I 1 I
SP031 GRB3 No. of gear teeth on motor side 3 1
GRB4 SP032
No. of gear teeth on motor side 4 1
SP097 SPEC0 Orientation specifications 0000
Speed loop gain proportional item during
SP098 VGOP 63
orientation
SP099 VGOl Speed loop gain integral item during orientation 60
Speed loop gain delayladvance item during
SP100 VGoD 15
orientation
SP105 IQGO Current loop gain magnification during orientation
1 100
SP106 IDGO Current loop gain magnification during orientation
2 100
SP107 CSPZ Orientation deceleration rate2 0
SP108 CSP3 Orientation deceleration rate3 0
SP109 CSP4 Orientation deceleration rate4 0
SP119 Orientation position loop gainH coil
MPGH 0
compensation magnification
Orientation position loop gainL coil
SP120 MPGL 0
compensation magnification
I I I
~~ ~~~
[Preparation]
1) Confirm that the parameters are set to the values given above.
IV-5
1. Adjustment Procedure
[Related Parameters]
Parameter No. Abbrev. Name Default value
SPO02 PGE Position loop gain during encoder orientation 100
SPO04 Orientation in-position width OlNP 16
SP005 OSP Orientation changeover speed limit value 0
SP006 CSP Deceleration rate during orientation 20
SP007 Orientation position shift amount OPST 0
SP025 GRAl No. of gear teeth on spindle side 1 Ito 32767
SP026 G W No. of gear teeth on spindle side 2 1 to 32767
SP027 GRA3 No. of gear teeth on spindle side 3 1 to 32767
SP028 GRA4 No. of gear teeth on spindle side 4 Ito 32767
SP029 GRBI No. of gear teeth on motor side 1 1 to 32767
P
SP030 GRB2 No. of gear teeth on motor side 2 Ito 32767
SP031 GRB3 No. of gear teeth on motor side 3 1 to 32767
SP032 GRB4 No. of gear teeth on motor side 4 1 to 32767
SP096 EGRA Encoder clear ratio 0
SP097 SPEC0 Orientation specifications 0000
1
Speed loop gain proportional item during 63
SP098 VGoP
orientation
SPO99 VGOI Speed loop gain integral item during orientation 60
Speed loop gain delay/advance item during 15
SPIOO VGoD
orientation
SP105 IQGO Current loop gain magnification during orientation
1 100
SP106 IDGO Current loop gain magnification during orientation 2 . 100
SP107 CSP2 Orientation deceleration rate 2 0
SP108 CSP3 Orientation deceleration rate 3 0
SP109 CSP4 Orientation deceleration rate4 0
Orientation positionloop gain H coil 0
SP119 MPGH compensation magnification
Orientation position loop gain L coil
SP120 MPGL 0
compensation magnification
SP121 Deceleration rateH coil magnification during 0
MPCSH
orientation
IV-6
1. Adjustment Procedure
[Preparation]
1) The accurate gear ratio (or pulley ratio) from the motor shaft to the encoder rotation axis is
required.
Confirm
that
the
correct No. of gear teeth
is
set
in 1- to
ISP032 (GRBI) 1.
.ISP025 (GRA1) I to I SP028 (GRA4) I = A x cxE
Note) IsPo25 (GRA1) Ito I SPO32 (GRB4) may be set by the user, so make sure that these
are set accurately to correspond to the machine.
. 2) Confirm that the parameters are set to the values given above.
IV-7
I.Adjustment Procedure
[Related Parameters]
.
I Pat.eter I Abbrev. I Name
1 1 1 SP099
SP100
Speed loop gain integral item during orientation
Speed loop gain delay/advance item during
orientation
Current loop gain magnification during
60
15
100
orientation 1
I SP106 I IDGO Current loop gain magnification during
orientation 2
100
_ _ _ ~
Orientation deceleration rate2 0
SP108 CSP3 Orientation deceleration rate 3 0
SP109 CSP4 Orientation deceleration rate4 0
IV-8
1. Adjustment Procedure
[Preparation]
1) The accurate gear ratio(or pulley ratio)from the motor shaft to the magnesensor rotationisaxis
required.
Confirm
that
the
correct No. of gear
teeth is set
in 1- to
. 1-
1-
Note) 1to- 1 may be set by theuser, so make sure that these
are set accurately to correspond to the machine.
2) Confirm that the parameters are set to the values given above.
Spindle
+ E A
TT-
(A-F: No. of gear teeth)
IV-9
I.Adjustment Procedure
Orientation
Refer to the following table and set the corresponding orientation set.
~ ~~
Adjustment
Phenomena m
p
s
o
o
s1
Overrun at stop
I
!
alarm
Long orientation time
Hunting at stop
Excessive
error I
\
I \
- I
~
Note 1) : increase
-/ setting
value.
: Do not change setting value.
s-- : Decreasesettingvalue.
Note 2) The excessive error alarm will also occur when the detector direction
SP097
(SPECO) is incorrectly set.
1-1
Adjust 1{ - 1-
} first and then adjust .
To execute the shortest orientation time per gear setting, adjust 1-1 1, - and
1- in the same manner.
To set the shortest orientation time coil
perwhen using the , 1-
coil changeover motor, adjust
,1- ISP121 (MPSCH) Iand 1 SP122 (MPCSL) 1 in the Same manner.
If the
gear
ratio is excessive
error
alarm
occurs
andcannotbe
remedied with
the
above
adjustments,
Ifthe spindle rotates slowl in the forward/reverse run direction and does not stop during magnesensor
orientation, change the ISP0970] detector installation direction bit.
IV- 10
1. Adjustment Procedure
Carry out adjustments with the following procedures to raise the servo rigidity.
Raise the position loop gainto the extent that overrun does not occur during orientation.
For motor built-in encoder orientation and ma nesensor orientation:
Raise the 1- value.
For encoder orientation : Raise the I SPOO2 (PGE) 1 value.
Raise
the 1- and
values
with
the
same
proportion
the
degree
to
that vibration does not occur during orientation sto
1-
For example, if is set to80, set 1 - f to 80.
I I
The value of SPlOO (VGOD) can be increased to raise the impact response during stopping.
However, if this value istoolarge,thetorque for thepositiondeflectionwilldrop.Thus,the
movement couldbe adversely affected suchas the orientation stop position being inconsistent, etc.
PI control will be applied
if this value is set to0.
IV- 11
-._ .~
1. Adjustment Procedure
Improves when the position Readjust SPOO1 (PGM) and The same applies
eters to the followin
SPOO1
,loop (PGM)
gain and
paray
ISP002 (PGE) Iare halved.
The orient stop direction
is in
one direction (CCW orCW).
1-1
Set bit 0 and
1 to 0 h e ) .
Iv- 12
1. Adjustment Procedure
The stop
- position
- isOFF.
Cause Check items Remedy Remarks
Machine factor The stop positionis notOFF on There is backlash or slippage For encoder
the encoder axis. between the spindle and orientation
encoder.
The gear ratio between the
spindle and encoderis not 1 :1
or 1:2.
There is backlashor slippage For motor built-in
between the spindle and encoder
motor. orientation.
The gear ratio between the
spindle and motoris not 1: 1.
~ ~~~~ ~~~~~ ~~
(4) The stop positiondoes not change even when the position shift parameter is changed.
Check items Remedy Remarks
The parameter The gear ratio between the If the gear ratio on the left is
setting valueis spindle and encoderis 1:2 used between the spindle and
inappropriate (encoder rotates once per two encoder, the position shift
spindle rotations), andthe amount per spindle rotation is
position shift was changed to 2048 and not4096.
2048.
IV- 13
, .
1. Adiustment Procedure
loop gain
Increase the current
loop gain
Decrease the current
IV- 14
1. Adjustment Procedure
<Preparation>
Before adjusting the synchronous tap, carry out operation with thespeedcommand or orient
adjustment, and thenfollow the steps below.
<Parameter>
(1) Setting the spindle controller
#
:PO37
r Parameter
SFNCS spindle
Description
>ossibilities of orient type and synchronous taptype combinations and setting
I
unction lalU0S.
3
Closed type Semi-closed Setting
type value
No orient X X X 0
I
I
I
IOrient type
II
I
Motor built-in
encoder
Encoder
orient
lI 0x lI x0 l I o l o
I I I
X X
4 1
I I 1
I Magnesensor
orient l x l x l o l o
0..... Possible, X ..... Not possible
IV- 15
1. Adjustment Procedure
:User parameter>
tap Valid
Synchronous tapis validated. When not valid, the conventional
zycle will run.
:Machine parameter>
3asic speci- )it3 of Set whether the synchronous tap uses the time constant set 0:Time
ications nparl method orslope set method. constant set
mrameters 1:Slope set
a p t1 Sets the position command time constant for the time constant 1toset1500
synchronous tap. (m-1
If the start up timefall max.Standard:
ortime to rotate to the considerable tap
s p e e d with theS command is t, set the following: 1000
Servo 'GNlSP
I When tap precision is priority : tap-tl = t x 2 (ms)
When tap cycle timeis prionty: tap-tl = t X 1.2 (ms)
set.the 1 to 200
Sets the position loop gain during synchronous tap. Always
mrameter :svo49) same value as for the spindle parameter PGT. Standard: 10
[Z axis)
Spindle NC ;gear Sets the gearratio between the spindle and spindle encoder. 0
Darameters Always set to0 (1:Iwhen
) not using the spindle encoder (semi- Standard: 0
closed type).
;tap 1 Sets the max. spindle speed during theslope set tap cycle at gears0 to 99999
;tap 2 00, 01, 10, 11. (wm)
;tap 3
;tap 4
stap 1 Sets the time constant tothe max. tap speed during the slope set 0 to 5000
;tap 2 tap cycle at gears00, 01, 10, 11. The setting method is the same(msec)
;tap 3 as taptl above.
;tap 4
Spindle PGT Sets the position loop gain during synchronous tap. Always set 1the to 100
parameters same value for(Z axis) parameter PGNlSP. Standard: 10
SPECT bit 5 . ....... Sets the detector (spindle encoder) rotation direction -
during synchronous tap. Set0 for semi-closed.
bit 3.-...... Set to1for a strong excitation during synchronous tap.
The response to impact loads wil increase. Normally0.
bit 0 ........ 0: Closed (when there is an encoder on the spindle)
1: Semi-closed (when there is no encoder on the
spindle)
bit 4 ..... ... Decides the motor command direction (spindle rotation
direction at G84) during synchronous tap.
bitE=O .... Performs zero point return at the beginning of the
synchronous tap mode.
bitE= 1.... Enters the position loop immediately after deceleration
and stopping without performing zero point return.
GRAl- The gear ratio of each gear step mustset becorrectly with the no. -
GRA4, of teeth.
GRBl- Motor
Motor
shaft
side No. of teeth (GRB1-GR64) Spindle
GRB4 speed x Spindleside No. of teeth (GRA1-GRA4) = speed
EGEAR Sets the gear ratio between the spindle and spindle encoder. 0
Always set 0 (1:1) when not using the spindle encoder (semi- Standard: 0
closed type).
1. Adjustment Procedure
<Points of caution>
1) When the spindle is driven with belt the or the timing belt in the semi-closed method (with no spindle
encoder) thebelt may slipor stretch and make precise synchronized tapping difficult.
When driving with the belt, use the spindle encoder, and carry out synchronized tapping in the closed
method. In this case, use the encoder type orient for orientation.
2) When the spindle and encoder are connected with a speedofratio 2:l in the closed method (with the
spindleencoder),setthespindleparameterto 1.
Carry out the cutting test with the floating tap chuck installed.
Refer to troubleshooting for
1) Is there any stretchingor shrinking of the tapper? synchronous tap error.
2) Is precisetap machining carried out?
Carry out the cutting test without the floating tap chuck Refer to troubleshooting for
installed. synchronous tap error.
1) Is precise tap machining carried out?
1. Adjustment Procedure
Cause I mmedy
~ 1 1 Excessivedifferencealarm(alarm 52) 1 I) The spindle parameter1-1 bit 5 synchronous tap
in reverse.
detector direction is set
2) The spindle motor cannot follow the command as the tap
time constantis too short.
Multiply the longer of theS command's rising time or
falling time by 1.2 or more, and set.
1) The spindle motor cannot follow the command as the tap
time constant is too short.
Multiply the longer of theS command's rising time or
falling time by 1.2 or more, and set.
3 The spindle rotation movement amount
does not match the command value.
1) The spindle parameter 1-
bit 0 close/semi-close
setting is wrong.
2) The spindle parameter gear ratio to 1-1 1,-
to [=I settings do not match the machine
gear ratio. -
IV- 18
2. Troubleshooting
2. Troubleshooting
1. Always wait at least ten minutes after turning the power supply
OFF before starting maintenance
and inspection.
Failure to do so could lead to electric shocks.
2. Maintenance and inspection must be done by a qualified technician. Failure to observe this could
lead to electric shocks. Contact your nearest Service Center or Service Station for repairs and
part replacement.
2.1 Introduction
If any trouble occurs with the control unit, perform the preliminary checks described below and then
proceed to the troubleshooting described later.
The following preliminary checks are very important when you consult with service engineer.
Preliminary check
I NOTICE
1. Which alarm is displayed on the unit alarm display? Confirm the past alarms on the unit's 7-
segment displayor on the NC diagnosis screen. (Refer to the alarm and warning in list2.4.)
2. Is the troubleor failure repeatable?
3. Are ambient and inner-panel temperatures normal?
4. When did the trouble occur (during acceleration,
or deceleration, or steady-speed operation)?
What was the speed?
5. Is rotation direction correct?
6. Did instantaneous power failure occur?
7. Does the same trouble occur in a specific operation, or when a specific command is given?
8. How frequently does the trouble occur?
9. Does the trouble occur when load is applied,
or when load is removed?
10. Were emergency procedures performed?
11. How many years has the control system been used?
12. Is supply voltage normal?
Does it change from time to time?
IV- 19
2. Troubleshooting
If the above status confirmation is carried out sufficiently, the faulty section should be apparent.
The most likely troubles or failures
of MDS-A-CV, SP can be largely divided into the following two groups:
I
Unit trouble Trouble in power supply unit
Trouble in spindle drive unit
Trouble B Trouble
with
detector Failure inspeed detect encoder
from NC
Trouble in parameter, transfer data
Trouble with power supply
Trouble with motor
Other troubles (mismatching input sig,nal conditions, cable disconnection, etc.)
2. Troubleshooting
Note 1) "Start signal CW, CCW' should be turned ON after "ready' signal and speed command been
have
input.
IV - 21
, . .., I Y .
2. Troubleshooting
~~
Trouble I11
~~
Check iteins Remedy
Operation is not In this case, the comprehensive analysis
correct sometimes. must be accomplished to determine the
The orientation cause (load condition, operation mode,
stop position etc.).
deviates. Refer to the causes below.
An alarm displays, ( I ) The input power stopped ( I ) Perform a detailed investigation of
but after turning the instantaneously or dropped, and the
power OFF and . .Dower fluctuation, etc.
the inwt
instantaneous stop alarm displayed. I
ON or resetting, ~~
(2) Check if malfunction occurred in (2) Find the noise source, and install a
the operationis
control circuit, due to large noise. surge killer, etc.
restored.
The unit is capable of withstanding Review the unit's grounding,
noise (in power supply) of detector shields and grounding, etc.
1600V/1ps. ~~
IV - 22
2. Troubleshooting
Name
M L;1ItZ- 3UI I I UI M I V I GI tSI I UI UclcIUlI CU II I L I IC 3p11 IUIG UI I V G
12 ME1 Memoryerror 1 PR
control card ROM.
13 SWE 'Oftware pr-ss The
software
data
process
did
not
end
within
the
set
time.
PR
error
The current detectionAD converter did not function correctly
AD€
17 AD error PR
during initialization.
L I 1 - 3 4
No signal
(spindle
The
. signal
- wasnot
input
from
the
spindle
encoder (for DE>
encoder) I orientation, C axis), or was not at the normal level. I E\
c).l
L3 UQL
Excessive speed The speed command and
motor
speed
deflection
exceeded PR
deflection the specified value and the state continued
____ ~~~
for a specified time.
31 OS Overspeed The motorspeed exceeded 115% of the set
max.
speed.
PR
Power module A currentexceedingthesetvalueflowedintotheIPMusedby DR
32 PMOC I I .
overcurrent the spindle drive's main circuit.
34 DP CRC error 1 A CRCerroroccurredinthecommunicationdatafromtheNC. PR
, Themovementcommand from the NCwasexcessivelylarge DD
Note) If the above protective functions activate, the alarmNo.w i l l be displayed on the 7-segment LED built into the
spindle drive, andthe following will occur.
Operation PR : The base currentof the spindle drive will be shut off, the external contactor will turn OFF,
and the spindle motorwill coast to a stop.
Operation NR : The spindle motorwill decelerate and stop with the regenerative motor, and then the base
current wil be shut off.
Operation AR : Only a warning wil display, and operation canbe continued.
IV - 23
2. Troubleshooting
Investigation item
~ ~~~~~
Investigation results Remedy
1 Check the spindle parameter "1*'is set to Bit
0 even though Correctly set.
(SP037: SFNCS) setting value. encoder orientationis not used.
No special problem. Perform investigation item
2,
and remedy.
2 Tug the connector to check if Is disconnected (loose). Correctly connect.
the detector connector (spindleIs not disconnected (loose). Perform investigation item3,
drive unit side and detector and remedy.
7
side) is disconnected.
3 Turn the power OFF and check A connection defect or broken Replace the detector cable.
the detector cable connection wire is found. Correctly connect.'
with a tester.
When usingMBE-9OK for the C Connection
axis detector, peiform
investigationitem 4, and
remedy.
In other cases, replace the
7
spindle drive unitor detector.
4 When using theC axis built-in The waveformis not correct. Readjust.
detector MBE-SOK, check the Replace the detector.
output waveform. The waveform is correct. Replace the spindle drive unit.
IV - 25
2. Troubleshooting
IV - 27
-....
2. Troubleshooting
i
occurred.
Perform investigation item 2,
Occurs ON. after and remedy.servo
~
(SPO34, SP040, SP055, SP257 The correct values are set. Perform investigation item
3,
and following) setting values. and remedv.
If the alarm occurs during The load amountis 120% or Decrease the load.
cutting, check the load amount. higher.
The load amountis 119% or Perform investigation item
4,
lower. and remedy.
Check the UVW wiring
between the spindle drive unit
and motor.
1) Are the terminal screws 1) The screws are loose. Correctly tighten.
loose?
2) Do the wires short-circuit 2) There is a short-circuit. Replace the cable.
between phases?
3) Is there a ground fault
in one 3)There is a ground fault. Replace the cable.
of the phases?
Open both ends of the cable There is no special problem. Perform investigation item
5,
when checking2)and 3). and remedy.
Check the motor insulation. The resistance value isMS
1Z or Replace the motor.
Check between each motor less.
and ground with a megger
tester. ’ The resistance value 1
more.
isMQ or Perform investigation item
and remedy.
6,
Check the power voltage. The powervobge drops below Review the power capacity.
170V during acceleration/
deceleration and cutting.
The power voltage is constantly Perform investigation item
7,
~~ ~~~~~~ ~
and remedv. 171V or more.
Investigate the wiring and
installation environment.
1) Is the unit correctly 1) The grounding is incomplete. Correctly ground.
grounded?
2) Is there any equipment 2)The alarm occurs easily Take noise prevention
generating noise near the when certain equipment measures for the left equipment.
unit? ~~~~
operates. ~ ~~ ~
Investigation item
Perform the same investiga-
tions items and remediesas for
alarm NO. 1341 .
IV-30
2. Troubleshooting
II
3 Check the parameters. Valid. Invalidate.
Is the coil changeover valid for (The SPO34 [mkch] bit set
is to1.) (Set the SP034 [mkch] bit to0.)
sPecial motor specifications?
IV - 31
2. Troubleshooting
I ~ ~
Investigation
~ ~
item
~~~~
I Investigation results
~~~ ~
I Remedy
Investigate the repeatability. Occurs immediatelyafter turning Perform investigation item
2,
power ON. and remedy.
Occurs several minutes after
operation starts.
a
Occurs after operating for Perform investigation item
5,
while. ~ and remedy.
2 I Tugthe speed detectorcable I
Is disconnected ( l o o s e ) . I correctlyconnect.
connector on the spindle drive ' No special problem. Perform investigation item
3,
unit tosee if it is disconnected. and remedy.
3 Check thespeed detector cable A connectiondefect is found. I Correctlyconnect.
connection.
Iv-34
2. Troubleshooting
Check
parameter
spindle
the value.
setting
the
Change
(sPoo3:FGco, SP130 -
-
SP133: PGCI PGC4, SP165: NG evenif the setting value is Return the setting value to the
pG2c, SP166:PG3C) setting increased. original value, perform
values. investigation item1 1 , and
I remedy.
Check the other spindle is not set. Correctly set. The correct value
parameters sp166s No special problem. Replace the spindle drive unit or
SP257 and following) readjust or replace the position
detector.
Check the spindle parameter OK if the bit 5 setting value is Change the bit5 setting value.
(SP177: SPECS) bit 5 setting. changed.
NG evenif the bit 5 setting Return the bit5 setting value to
value is changed. the original value, perform
investigation item 13, and
remedy.
Check the spindle parameter's OK if the setting valueis Change the setting value.
spindle synchronous time increased.
constant. NG evenif the setting value is Return the setting value to the
increased. original value, perform
investigation item 14, and
remedy.
Check the spindle parameter OK if the setting value is Change the setting value.
(SP010: PGS, SP189: PG2S, increased.
sp190:PG3S) setting values- NG even if the setting value
is Return the setting value to the
increased. original value, perform
investigation item 15, and
remedv.
Iv-35
- . .
2. Troubleshooting
The tracking error amount (droop amount) be cancalculated with the following equation.
If this value exceeds each excessive error width setting, this alarm
wil occur.
(21)Alann No. ml
[Meaning] The pulse miss value was higher than the parameter set value
(SPI 14: OPER) when
orientation positioning was completed.
IV - 37
2. Troubleshootins
(2) An alarm is not displayed but the motor only rotates slowly. The sound from the motor
is loud.
I
~ ~~ ~~
IV - 39
." .
2. Troubleshooting
IV - 41
.. .
2. Troubleshooting
(9) The motor speed does not rise above a certain speed.
Check whether the load has The load has increased. Repair the machine side.
increased suddenly. No special problem. Perform investigation item 3,
and remedy.
Check that the motor bearings The bearings do not rotate Replace the spindle motor.
can be rotated normally by smoothly.
hand. The bearings rotate smoothly. Perform investigation item 4,
and remedy.
Tug the connector to check if Is disconnected (loose). Correctly connect.
the speed detector connector Is not disconnected (loose). Perform investigation item 5,
(spindle drive unit side and and remedy.
speed detector side) is
disconnected.
Turn the power OFF and check A connection defect or broken Replace the detector cable-
the speed detector cable wire is found. Correctly connect.
connection with a tester. Connection is normal. Perform investigation item 6,
(Especially checkthe shield ~
and remedy.
wirina.)
Check the speed detector The waveformis not correct. Adjust so that it is correct.
waveform. (Refer to Page IV-35)
Replace the detector.
The waveform is correct. Replace the spindle drive unit.
2. Troubleshooting
1. Always wait at least ten minutes after turning the power supply
OFF before starting maintenance
and inspection.
Failure to doso could lead to electric shocks.
2. Maintenance and inspectron must be done by a qualified technician. Failure to observe this could
lead to electric shocks. Contact your nearest Service Center or Service Station for repairs and
~ part
replacement.
The periodic inspectionis particularly important to ensure high-performance operation of equipment, and
trouble-free long useof equipment.
I To prevent major accidents, make sure the power is interrupted completely before starting the
inspection. Make sure that the CHARGE lamp on the power supplyisunit OFF.
I NOTICE I
I Never perform a megger test (insulation resistance measurement) on the spindle amplifier control
circuit.
IV - 43
2. Troubleshooting
Cablesand PCB
Terminal box cover
/
_ _ Remove the coverof terminal
(1) /
Fan case'
'\ Leadprotectionpacking
L. . . -.
IV - 45
., .
3. Disassembly and Assembly of
Motor
Cooling fan
For typessmaller than frame
No.132
Fan motor
-- -
Fan
IV - 47
.."_. ." .
3. Disassembly and Assemblyof Motor
Cooling fan.
~ - , . - ......
Finger guard
--\\
IV - 48
.-- -. ..
3. Disassembly and Assemblyof Motor
IV - 49
3. Disassembly and Assembly of Motor
-
Bearinns
Apply sealing
compound. Bracket fixing bolt
Remove the bearing case
cover fixing screws and the
bracket fixing hexagon socket
head bolts and remove the
bracket on the opposite drive
side.
When the bracket on the
opposite drive side is installed
again, apply sealing compound
to the fittingsurface.
f
1
I
i
/
Shaft stop ring
IV - 50
3. Disassembly and Assemblyof Motor
( 5 ) To install bearing onto shaft, all fitting surfaces should Press here.
be thoroughly cleaned and smoothed.
I Pipe Bearing
I
Installation withhammer
IV - 51
.*-
3. Disassembly and Assembly of Motor
1. PCB volumelayoutdrawing
Check terminals
PA : A phasesignal
PB : B phasesignal
AGA : Ground
Volume
VRI : A phase 0 position adjustment
vR2 : A phase gain adjustment
VR3 : B phase 0 position adjustment
VR4 : B phase gain adjustment
2. Confirmation method
(1) Set the spindle parameter SP038 (SFNC6) Fbitto "1" and turn the NC power OFF and ON.
(Enter the open loop.)
( 2 ) Input the forward run command, and gradually raise the motorspeed to 1800rpm.
(3) Measure theA and B phase waveforms with a synchroscope.
(4) Confirm that the waveformis as shown below.If not as shown below, adjust with VRI to VR4.
( 5 ) If the waveform cannot be adjusted with VRI to 4, readjust the gap between the sensor and
gear teeth.
1) If voltage level does not decrease below
i1.6V: Increase the gap
2 ) If voltage level does not increase above
& .4V:
I Decrease the gap
(6) Next, reverse run the motor and measure the waveform at 1800rpm.
( 7 ) Set the SP038 (SFNCG) bittoF"0"after completing the confirmation and adjustments, and turn
the NC power OFF andON.
-1.55 -1.63
A phase/B phase output signal waveform A phase/B phase output signal waveform
during forward run during reverse run
3. Disassemblv and Assemblyof Motor
Fan case
(3) Remove the external PCB fixing pan head screw PCB
connector from the connector t‘
I
! Lead protection,
- -. packing
IV - 53
3. Disassembly and Assemblyof Motor
The motor cableis under the amplifier. The motor cable protrudes from the amplifier.
3. Disassemblv and Assemblyof Motor
For frameNo. 90
IV - 55
, 1 1
3. Disassembly and Assembly of Motor
Fan -motor
..
IV - 57
3. Disassembly and Assemblyof Motor
Conditions:
Position with the SensorV-type base
side and the motor base positioning
ring protrusion.
Preparation:
Clean (air blow) the sensor block
mounting face (motor base) and the
sensor V-type base side.
Method:
with bolts
Lightly fix the Sensor block
(so that the block can be moved.)
Tighten the boltso that the Sensor
block is pressed against the mounting
face andso that theV-type base side
contacts the motor base positioning
ring as shown in the figure.
Caution:
Take careso that the sensor base
of
does not slip from the tightening
the bolts.
Do not apply strength to the flexible
plate.
removal jig.
Caution: The removed drum
Condition:
Heat
fitting
(heatedtemperature: below 150°C)
Method: Confirmthatthedrumisatthespecifiedtemperature.
Hold the drumwith leather gloved hands and quickly insertit.
Caution:There mustnot be a magneticfield of over 50G insidetheheatingdevice.
Cotton gloveswill slip.
~ Confirmation: Is thedrumcompletelyinserted?
IV - 59
_.& . .
3. Disassembly and Assembly of Motor
Bearings
Apply
sealing
compound.
Bracket
fixing bolt
(1) Remove the bearing case
cover fixing screws and the
bracket fixing hexagon socket
head bolts and remove the
bracket on the opposite drive
side.
(2) When the bracket on the
opposite drive side is installed
again, apply a sealing
compound to the fitting
surfaces.
IV - 60
3. Disassembly and Assemblyof Motor
pipe Bearing
( 7 ) If press machineis not available, lightly hammer the pipe to drive the bearing in.
Use care not to hammer the outer of the bearing.
ring
I
Bearing Pipe
IV - 61
___5_ ... ”
4. Installation of Orientation Position Detector
Direction of Rotating
disk rotation
plate
.
Amplifier
output
+8-
i +sv ;
1-1 7 h
Between CN6 (7)to (17 )
8
MS signal : Signal voltage output isOV when the centerof magnet comes to the sensor head, and
maximum at both ends of the magnet.
Spindle is stopped with this signalOV. at
(Note that the target voltagewill fluctuate a max.of & 2.5V depending on the position shift
setting.)
LS signal : Signal voltage is constant within the magnet zone (width).
This signal is used to verify that spindle remains stopped within the magnet zone.
IV - 62
4. Installation of Orientation Position Detector
The magnet and sensor head should be installed in the specified orientation.
Standard type
High speed standard type
............. The center reference hole of magnet and the reference notch
of sensor head should come to
the same side.
m,
m,
Refer to1- and [UNACCEPTABLE EXAMPLE11.
High speed miniature type
.._..........The reference notch of sensor head should be positioned in reference with polarity
S)(N.
of
magnet.
,14-1
Refer to 1- and [UNACCEPTABLE EXAMPLE21.
High speed ring type
............. The reference notch of sensor head should be positioned in reference with(N.polarity
S)of
magnet.
-I,
Refer to 1- and [UNACCEPTABLE EXAMPLE31.
Reference
'111
notch View from "A'
IV - 63
y u c -
4. Installation of Orientation Position Detector
Reference
notch
Reference
hole n
MagnetisinstalledontheoppositedriveMagnetisinstalledonthedriveside.
side.
13 - 1 1-1
In regard to , the magnet and sensor head canbe changed to the following
position as long as the reference hole and reference notch are aligned. With this, normal
orientation canbe carried out.
(However, the parameter SP097SPEC0 magnesensor detection polaritybit mustbe
changed in this case.)
n
Reference hole
Reference natch
[UNACCEPTABLE EXAMPLE1 I
If the magnet reference hole and sensor head reference notch are not aligned; intense vibratio
will occur when the sensor head is at end of magnet (orientation is impossible.)
Reference hole
Ref&ence notch
4. Installation of Orientation Position Detector
Drive side
Opposite
drive side
15 - 1 As long as the relation between location of the sensor head reference notch and the polarity
of the magnet are aligned, the sensor head and the magnet can be installed as shown
below in , and
normal
orientation
can
be
carried
out.
(However, the parameter SP097 SPEC0 magnesensor detection polarity bit must be
changed in this case.)
- Opposite
drive side Drive side
notch
View from “A’
notch
IUNACCEPTABLE EXAMPLE 21
If the sensor head reference notch is not alianed DroDerlv in reference to of the maanet,
Dolarity
intense vibration occurs when the sensor head is at the end
of the magnet, and orientation is
imoossible.
Drive side
U
-
T
notch View from “ A ‘
Reference notch
IV - 65
. ..
4. Installation of Orientation Position Detector
n Opposite
drive side Drive side
Drive Opposite
drive side
T
Referen
notch View from “ A
Reference notch
A
(CASE1 As long as the relation between location of sensor head reference notch and the polarity
of
the magnet are aligned, the sensor head and the magnet can be installedbelow as shown
in
1,- and normal orientation canbe carried out.
(However, the parameterSP097 SPEC0 magnesensor detection polarity bit must be
changed in this case.)
n Opposite
drive side
b A Reference notch
V i from “A”
\UNACCEPTABLE EXAMPLE31
W
V i from “ A
IV - 67
. ,
4. Installation of Orientation Position Detector
-p I
T MO 3
MO 3
Direction f rotation
z
FaceA \ permis!
f i
Magnet
Table 1
BKO-Cl810H03 BKO-Cl730H06
Standard High speed standard
Radius (R)mm Max. gap mm Min. gap mm Max. gapmm Min. gap mm
40 11.5f 0.5 2.7f 0.5 10 f 0.5 1.22f 0.5
50 9.5f 0.5 2.8f 0.5 8 f 0.5 1.31 f 0.5
60 8.5f 0.5 3.0f 0.5 7 f 0.5 1.5f 0.5
70 8.0k 0.5 3.4f 0.5 7 f 0.5 2.38f 0.5
Table 2
BKO-Cl810H03 BKO-Cl730H06
Standard High speed standard
Radius (R)mm Gap mm Gap mm
40 6 k 0.5 5 f 0.5
50 6 k 0.5 5 f 0.5
60 6 f 0.5 5 & 0.5
Table 3
BKO-CI730H09 High speed miniature
Radius (R)mm Max. gapmm Min.gap mm
40 6.25f 0.5 3.3f 0.5
50 6.0f 0.5 3.7f 0.5
60 5.75f 0.5 3.85f 0.5
* .
70 5.5f 0.5 3.87 0.5
IV - 68
4. Installation of Orientation Position Detector
For oriented spindle stop, the following combinations of amplifier, sensor and magnet
are available.
Permissible Combination
Type Model
speed [RPMI Amplifier Sensor Magnet
Standard 0 to 6000 MAGSENSOR BKO-C1810H01-3 H01 H02 H03
High-speed
standard
I 0 to 12000 I MAGSENSOR
BKO-C1730H01.2.6 1 H01 I H02 I H06 I
High-speed
miniature
I 0 to 12000 I MAGSENSOR BKO-C1730H01.2.9 I
I
H01 I
I
H02 I
I
H09 I
High-speed ring 0 to 25000 MAGSENSOR BKO-C1730H01.2.11 I H01 I H02 I H41
High-speed ring 0 to 25000 MAGSENSOR BKO-C1730H01.2.12 H01 H02 H42
High-speed ring 0 to 30000 MAGSENSORBKO-C1730H01.2.13 H02 H01
H43
High-speedring I 0 to 30000 I MAGSENSOR BKO-C1730H01.2.14 1 H01 I H02 I H44 1
Note: Combination of amplifier, sensor and magnetis possible within thesame modelgroup (C1810 or
C 1730).
Outside dimensions:
0 Amplifier HOI
-+
0 Sensor HO2
Reference
Connector
For MKO-C1810H02, R04-P-8M is used.
For BKO-C1730H02, TRCl16-12A10-7M
is used.
IV - 69
4. Installation of Orientation Position Detector
Magnet
Pennissi-
ble speed Outline drawing
[RPMI
0 to 6000
2.
7.5
Weight: 4W 1.!3g
0 to 25000
Sen
notch /-
Reference
Polarity (N,S) is indicate ontheside w a l l ofcase.
Sensor head should be installed so that the reference
'
notch of sensor head comesthe oncase side.
Refer to page82 and followingfor details.
Magnet Unit: mm
Type
BKO-C1730Hll
0 to 30000
BKO-C 1 730H
12
BKO-C1730H13
BKO-C1730H14
IV - 70
4. Installation of Orientation Position Detector
4.2.1 Configuration
N/C
Spindle
IV- 71
4. Installation of Orientation Position Detector
Name plate
\ +
1.153
Key dimensions
Connector
Encoder: x
Controller cable:
MS3106A20-29S
135
Unit: mm
1chB C M
5. Contour Control (C-axis Control)Encoder
4 onnector
Encoder: MS3102A20-29P
Controller cable:MS3106A20-29S (user should prepare this connector)
5.1.3Connectors
(1) Connectorside: MS3102A20-29P Controller cable side: MS3106A20-29S
(2) Connection(Notsupplied)
IV - 73
(.- . . ".
5. Contour Control (C-axis Control) Encoder
Function
Ich A phase
. ~ p
2ch Z phase
~~
C l c h B phase
I
D I I
I E I CaseGND I
I I
I G I 3ch D phase I
I I
I
I T I 4ch phase
ov
Admitted electrical speed is 166 rpm for signal in 3 channel (C, D phases, , b phases)
(1) Rotationalcharacteristics
a.
Inertia : Max. 100 gcm2
b. Shaft frictional torque : Max. Ikpcm
c. Shaft angular acceleration : Max. 10 rad/sec2
d. Permissible max. speed : 7,030 rpm
(2) Mechanicalconstruction
a. Bearing : Reoiling
not
isrequired
for 100,000 hr of operation
at
2,000
rpm,
and
20,000 hr of operation at 6,000 rpm.
b. Shaft
runout : Max.
0.02mm at 15mm from shaft end
c. Permissible load : 10 kg (5 kg during operation)
in
thrust
direction
20 kg (10 kg during operation) in radial direction
Weightd. : Max. 2 kg
e. Error in perpendicularity of flangesurfaceagainst shaft 1 Max. 0.05 mm
f. Eccentricity
flange
engagement
in : Max. 0.05 mm
(3) Environment
a. Operating temperature range : -5°C +55"C
b. Storage temperature range : -20°C +85"C
c.
Humidity : 95%PH (at45'C) for 8 hours
d. Vibration : 5 to 50 Hz, 1.5 mm full amplitude,30 min. for eachaxis
e. Mechanicalimpact : 30G,1Imsec., I O times for each axis
5. Contour Control(C-axis Control) Encoder
1. Installation of encoder
It is recommended that flexible coupling be used to connect the encoder to the spindle shaft to
secure the encoder life and performance.
(2) Recommendedcoupling
Example I Example 2
Manufacturer TOKUSHU SEIKO EAGLE
Model Model M1 FCS38A
Resonance frequency 1,374 Hz 3,515 Hz
Error in position detection 0.8 X deg. 1.2 X deg.
Permissible speed 20,000rpm 10,000 rpm
I Eccentricity 0.7 mm 0.16 mm
Misalignment Angular 1.5deg.
1.5 deg.
displacement
Outside Max. length 74.5 mm 33 mm
dimensions M=. diameter 057 mm 038 mm
2. Cable
A CAUTION
When manufacturing the detector cable,
do not mistake the connection. Failure to observe this
could lead to runaway of the encoder, andto injuries.
IV - 75
5. Contour Control (C-axis Control) Encoder
@ and @,
(2) In the connector(MS3106A20-29S) on the encoder side, short-circuit between pins
-
or @ . (Use a short wire of 0.75 sq. 1.25sq.)
3. Others
(1) The encoder is a precision device, so take care not to apply strong shocksit.to
(2) Mistaken wiring may cause trouble. Confirm the connector name and pin Nos., etc., before
wiring.
01 I
01 I
SP068 VIGWB 0
SP069 VlGN 0
.-
5 SP038 SFNC6 I SP070 I FHz I 01 I
E SP039 ATYP I SP071 I I 01 I
SP072
.-
g SP041
PTYP SP073
SP042
CRNG SP074
SP043 TRNG 0 SP075 0
I SP012 I TRANS SPO44 0 SP076 FONS 0
SP077 TDSL 14
t
11
I 1 6i
w SP078 0
cI SPOl5 I 01 I
4
i 4
I SP017 I TSP I 6000 I I 20
S618 ZSP ~
SPO19 CSNl
SP020 SDTS I SPO84 1 I 01 I
SP021 TLMl SP085
SP022 VGNPl 63 SP086
12
SP057
SP090 VGHl 60
SPO91 OFSN 0
I-Sx[ 1 i I 1
SP031
SP032
GRB2
GRB3
GRB4
SP062
110
SP093
Class Name Abbr.
Standard
setting
Abbr. Name
Setting Class
Standard
setting
Setting Name I Abbr. I Standard
setting
I
Setting
.-
ca
I SP321 I RPML I 0000 I I
1 I 1 0 01 I
8
SP323
NPL
d
NBL SP324 OOOO SP356
VPWML
Y SP322 NRL
U5 SP325 NFL 0000 SP357
Y,
E SP326 PML OOOO SP358
~~
SP359 1 ~~
I OOOol
SP360 0000
SP297 0000 SP361 0000
SP298 0000
SP299 0000 SP363 I I ooool
SP300 0000
I
SP302 I NICNT I 0000 I I
0000 SP303 NlCT - SP335 KDlL OOOO SP367 I I OOOOI
NCSN 0000 SP336 KQPL 0000
0000 SP305 NWR1 SP337 KQlL
0000 NWR2 SP338 IDSML SP370 0000
~1
SP307 NWR3 0000 SP339 IQSML SP371
I ooi 1
SP308 NEVO 0000 SP372
SP309
I SP310
I SP311
NEVl 0000
/spy2/
I SP341 I KVQSL I
SP343
TMLRL
TMLDL
OOOOl I SP373
SP374 I
sp375 1
I
I
OOOol
OOOol
I SP312 SP344 TMLSL
I SP313 SP377 EDOL 0000
I SP314 SPO 0000 SP378 SPOL oooo
I~ ~ 3 1I %SBS I ooool I SP379 SBSL oooo
I SP316 I SIQ I ooool I SP380 SlQL oooo
SP317 DPO 00o0 SP381 DPOL oooo
SP318 DBS oo00 SP382 DBSL oooo
k
P 3
E 1DIQ I ooool I SP383 DlQL OOOO
I SP320 I BSD OOOol SP384 BSDL OOOO