Mitsubishi FREQROL-SF Manual de programación

AC SPINDLE

DRIV

TROUBLESHOOTING

./’

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ADVANCED

AND

EVER AOVAkCfNG

MITSUBISHI

ELECTRKZ

USA-E99991-075-*

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Status display and diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1

Status display and diagnosis from spindle amplifier.

1.1.2

Status display and diagnosis from NC . . . . . . . . . . . . . . .

1.2 Checking method and countermeasures of trouble

classification A .._..................................

1.2.1

When the amplifier is turned on at the first time,

it does not correctly work

. . . . . . . . . . . . . . . . . . . . . . . .

1.2.2 The motor which has normally rotated stops

abruptly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.3

The equipment does not work in occasions.

The

orientation stop position deviates. Although an

alarm appears, after turning on and off the power

or resetting the equipment, the equipment normally

works

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Checking method and remedy of trouble classification

1.3.1

1.3.2

1.3.3

1.3.4

1.3.5

1.3.6

1.3.7

1.3.8

..I................................................

When the power is turned on, the display of the

operation panel does not appear at all . . . . . . . . . . . . .

When the power is turned on, the display on the

operation panel does not indicated the speed in

the status display mode (as shown in the following

figure)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

An alarm appears ont he display on the printed

circuit board (SF-CA card) of the amplifier . . . . . . . .

The motor does not rotate . . . . . . . . . . . . . . . . . . . . . . . . . .

The motor does not rotate at a speed being

specified

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The motor vibrates and is getting noisier during

rotations . . . .

.._...._._........_...................

The motor overshoots in speed or hours . . . . . . . . . . . . .

The cutting force degrades . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.9 The orientation of the spindle is not correct . . . . . .

1.3.10 The acceleration/deceleration time increases . . . . . . .

1.3.11 The speed detection signal, up to speed signal,

or zero speed signal is not issued . . . . . . . . . . . . . . . . .

1.3.12 The tapping operation cannot be correctly performed. 55

1.3.13 The threading operation cannot be correctly

performed

. . . . . . . . . . . . . . . ..I...........

. . . . . . . . . . . . .

2. Checking and replacing parts ............................

2.1

Replacing fuses ......................................

2.2

Replacing thermal protectors .........................

2.3

Replacing amplifier cooling fan ......................

2.4

Replacing printed circuit board ......................

2.4.1 Replacing SF-PW module .............................

2.4.2

Replacing SF-OR or SF-10 card ......................

2.4.3

Replacing SF-TL card ...............................

2.4.4

Replacing SF-CA card ...............................

2.5 Checking transistor module (This method is the same

both in the power side and regeneration side)

........

2.6

Checking diode stack .................................

2.7

Replacing transistor module and diode stack

..........

2.8

Replacing motor cooling ..............................

2.9

Adjusting and replacing motor built-in encoder

.......

2.9.1

Adjusting printed circuit board ....................

2.9.2

Replacing encoder and printed circuit board

........

3. Spindle orientation control circuit . . . . . . . . . . . . . . . . . . . . .

3.1

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Spindle orientation using magnesensor (1 point) . . . . 80

3.1.2

Spindle orientation using encoder . . . . . . . . . . . . . . . . . .

(4096 points,

with index function)

3.2

Control circuit and parameter setting . . . . . . . . . . . . . . . .

3.2.1 Where the speed selection signal function is

provided (SF-OR card)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Where the equipment is linkedwith the NC through

the bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3 Where the equipment is linked with the NC using

analog or digital signals ..........................

3.3 Mounting position detector ...........................

3.3.1

In the case of magnesensor type ....................

3.3.2

In the case of encoder type ........................

104

3.4

Adjustment ...........................................

106

3.4.1

In the case of magnesensor .........................

106

3.4.2

Encoder type .......................................

110

3.5

Operation mode and motions ...........................

113

3.5.1

In the case of magnesensor .........................

113

3.5.2

Encoder type .......................................

115

4. Adjusting synchronous tap ...............................

117

4.1

Setting parameters ...................................

117

4.2

Checking operation ...................................

118

Appendix 1

Machine Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Appendix l-l

Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Appendix l-2 Connection with motor (for standard motor) . . . 122

Appendix l-3

Machine connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

(without orientation (standard))

Appendix l-4

Machine connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Appendix l-5

Machine connection(Bus linkage with NC) . . . . . . 124

(Magnesensor orientation (1 point)

specification)

Appendix l-6

Machine connection(Bus linkage with NC) . . . . . . 125

(with encoder synchronous tap, orientation

(4096 points) specification/indexing

funtion)

Appendix l-7

Machine connection . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

(with encoder orientation rather than NC)

(with 4096 point orientation/indexing function)

Appendix 2

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

Appendix 2-l

Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

(without orientation (standard)

Appendix 2-2 Cable connection .............................

128

Appendix 2-3 Cable connections (Bus linkage with NC)

...... 129

Appendix 3

Appendix 4

Appendix 5

Appendix 6

Appendix 7

Appendix 8

Appendix 9

Cable and Connector Specifications

.............

130

Main Circuit Configuration .....................

138

Spindle Part Layout ............................

139

(Excluding printed circuit boards)

Control Circuit Printed Circuit Board Part

Layout .........................................

144

Major Part Table ...............................

148

Display Lamps (LED diodes) .....................

154

Check Terminals ................................

155

Appendix 10 Parameter Setting List and Short Pin Switch . . .

Appendix 11

Structural Components . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix 12

Maintenance Instruments . . . . . . . . . . . . . . . . . . . . . . .

Reference: Setting and Adjustment

1.1 Set switches, set pins, and variable resistors

.......

1.1.1

SF-CA card .........................................

1.1.2

SF-GR card .........................................

1.1.3

SF-TL card .........................................

1.2

Setting parameters ...................................

1.2.1

Display and set switches (on SF-CA card)

...........

1.2.2

Setting parameters from spindle amplifier

..........

1.2.3 Setting parameters from NC (On 9" CRT screen)

......

1.3

Adjusting speed and load meter .......................

1.4 Setting and adjusting spindle orientation control

circuit ..............................................

169

172

175

176

179

180

182

183

185

204

214

1 Troubleshooting

Troubleshooting

If any trouble occurs, before checking the cause, make sure

to read and follow the contents of Table 1.1, "Precautions"

for safety,

Table 1.1 Precautions for safety

After turning off the power, do not immediately touch

the controller. After checking that the power indica-

tion lamp LED 10 (SF-CA card) puts off, conduct the main-

tenance and inspection work (waiting for 3 minutes or

more).

An electric shock may result in a death accident.

Regardless of whether the power supply is grounded or

not,

since each component of the equipment may be

exposed to a high voltage, carefully select and use test

apparatus.

When installing any test apparatus on a portion to be

tested,

take care not to touch any portion being grounded.

Generally, when conducting a test, do not ground the case

of any test apparatus.

Thus,

because a high voltage may

be applied between the test apparatus case and the

ground,

when operating the equipment while adjusting/

repairing it, take care of it.

While the power is supplied to the equipment or when the

equipment is operated, do not attach/detach any printed

circuit board. Otherwise, the equipment may be damaged.

Do not put on a loose close which may be caught by the

rotating portion of the equipment.

Next,

thoroughly check the contents of Table 1.2, "Check

Items upon Occurrence of Trouble". They will help you contact

with Service Department of Mitsubishi Electric.

-l-

1 Troubleshooting

Table 1.2 Check items upon occurrence of trouble

Check what alarm the alarm display of theamplifier indi-

cates.

In addition, check old alarms in the alarm mode

of the indication lamp (see Appendix 8).

At which of phase R, S, and T a fuse is blown?

(Control circuit input fuse)

Does the trouble or fault repeatedly occur?

Is the ambient temperature and temperature in the

panel normal? (Is that 55°C or less?)

During what situation does the trouble or fault occur?

During acceleration, deceleration, or constant speed?

At what speed it occurs?

Does the trouble or fault differ between the forward

rotation and reverse rotation?

Is there an instantaneous power failure?

Does the trouble or fault occur when a special opera-

tion or instruction is executed?

How often does the trouble or fault occur?

At what load situation does the trouble or fault occurs?

Whether a load is applied or removed?

Is a suspicious part replaced with a new one or a

temporary repair conducted against the trouble or

fault?

How many years has the equipment been operated?

Is the power voltage normal?

Does it vary remarkably depending on the time zone?

By referencing the trouble classification shown in Table 1.4,

check the power voltage listed in Table 1.3 before conducting

troubleshooting and countermeasures.

-2-

1 Troubleshooting

Table 1.3 Checking power voltage

Checking Amplifier input pins

AC power voltage Xl, X2, X3, and E See Appendix l-l

Checking DC power

supply voltage on Checking DC output

voltage at check See Appendixes 5,

printed circuit pins on SF-PW card

h(4),

and

g(4).

board

Table 1.4 Trouble classification

E;$-

cation

Situation

When the amplifier is powered on at the first

time,

it does not normally work.

1.2.1

The equipment which has normally worked does

not abruptly work.

1.2.2

The equipment does not work in occasions.

The orientation stop position deviates from

the specific position. Although an alarm

1.2.3

lights,

it is recovered by turning off and

then on the equipment or by resetting it.

When the power is turned on, the display of

the operation panel does not appear at all.

Alternatevely, the DC voltage of the printed

1.3.1

circuit board is not correct.

When the power is turned on, the display on

the operation panel does not indicate

rota-

tions in the status display mode (as shown in

1.3.2

the following figure).

The display on the amplifier printed circuit

board (SF-CA card) indicates an alarm (as

shown in the following figure).

1.3.3

Continued on the next page.

-3-

1 Troubleshooting

:kEi-

;ifi-

Situation

EcikiZ

ation

ferenced

The NC CRT (spindle monitor screen) indicates

an alarm (as shown in the following figure).

1.3.3

Spindle alarm 15 01

5 The motor does not rotate.

1.3.4

The motor speed do not conform with that being

specified.

1.3.5

The motor vibrates with a large noise during

rotations.

1.3.6

The motor overshoots at speed or hunts.

1.3.7

The cutting force degrades.

1.3.8

The orientation of the spindle is not correctly 1

performed.

11 The acceleration/deceleration time becomes

1.3.10

lonq.

The speed detection signal, up to speed signal, 1

or zero speed signal is not issued.

13 The tapping work is not correctly performed. 1.3.12

The threading work is not correctly 1.3.13

performed.

-4-

1.1 Status display and diagnosis

The status display and diagnosis are executed with the

display and switches on the SF-CA card. When linking

an NC and bus line, the status display and diagnosis can

be executed on the NC CRT.

1.1.1

Status display and diagnosis from spindle amplifier

For instructions for operating the display and switches,

see Reference

1.2.1.

(1) Status display

Shift

-I

___

Shift

DOWN UP 3

SPEED REFERENCE POSITION SPEED

LOAD

REFERENCE

The following table lists the contents of the four types

of status display modes.

Item

Code

SPEED

REFERENCE

SPEED

POSITION

DROOP

LOAD

SPEED

REFERENCE

I-

INPUT

Unit Description

rpm Represents the motor speed.

rpm

Pulse

rpm

Represents the motor reference

speed.

Represents remaining pulses on the

deviation counter. In the case of

reverse side pulse (negative number),

the decimal point indicator lights.

Represents the load status assuming

that 30-minute rating output is

100%.

Bus linkage with NC . . . 2-port data

of speed reference inputted from NC

S analog . . .

12-bit conversion value

of A/D converter

Digital control . . . 12-bit value

-5-

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