AG Spindle Servo Unit S Series1.1.2 Models 6S-22S Models 6S-22S of S series AC spindle servo units consist of the following units. 1) Spindle control unit (basic) 2) Spare fuse (basic)

AG SpindleServo Unit

S Series

Maintenance Manual

©E Fanuc Automation

GFZ-65015E/01

iWARNING

The product described in this publication may employ hazardous voltages or might create otherconditions that could, through misuse, inattention, or lack of understanding, result in personalinjury, or damage to the product or to other equipment. It is imperative, therefore, that personnelinvolved in the installation, maintenance, or use of this product understand the operation of theproduct and the contents of this publication.

This document is based on information available at the time of its publication. While efforts havebeen made to be accurate, the information contained herein does not purport to cover all detailsor variations in hardware and software, nor to provide for every possible contingency in connec¬tion with installation, operation, and maintenance. Features may be described herein which arenot present in all hardware and software systems. Neither GE Fanuc Automation Corporation norany of its subsidiaries assumes any obligation of notice to holders of this document with respect

to changes subsequently made.

Neither GE Fanuc Automation Corporation nor any of its subsidiaries makes any representation

or warranty, expressed, implied, or statutory with respect to, and none assumes any responsibility

for the accuracy, completeness, sufficiency, or usefulness of the information contained herein.

No warranties of merchantability of fitness for purpose shall apply.

Copyright 1987 GE Fanuc Automation North America. Inc.

This manual describes following products:

Series name Model name

S series AC spindle servo unit Model IS, Model 1.5S, Model 2S,Model 3S, Model 6S, Model 8S,Model 12S, Model 15S, Model 18S,

Model 22S

TABLE OF CONTENTS

I. S SERIES AC SPINDLE SERVO UNIT

I . GENERAL1.1 Configurations ...

1.1.1 Models IS - 3S1.1.2 Models 6S - 22S

1.2 Major Components

33345

2. DAILY MAINTENANCE AND MAINTENANCE TOOLS2.1 AC Spindle Motor2.2 AC Spindle Servo Unit

2.3 Maintenance Tools2.4 Major Maintenance Parts

77777

83. TROUBLESHOOTING3.13.23.33.43.53.63.7 Speed Overshooting or Hunting Occurs3.8 Cutting Force is Low3.9 Orientation is not Correct3.10 Acceleration/Deceleration Time is Long

Power Voltage CheckPower On Indicator Lamp PIL is not LitAlarm is IndicatedMotor does not Rotate or its Rotation is Abnormal

89

101718Vibrations or Noises is too Large during Rotation

Noise is Produced from Motor during Deceleration 1818181919

4. INSTALLATION4.1 Installation Procedure4.2 Power Connection

Power voltage and capacity checkProtective earth connectionPower connection

4.3 AC Spindle Motor Connection

4.4 Single Cable Connection

202021

4.2.14.2.24.2.3

2121212121

225. SETTING AND ADJUSTING5.1 Jumper and Variable Resistor on Spindle Control PCB

(models IS - 3S)

5.2 Jumper on Spindle Control Circuit (models 6S - 22S) ....5.3 Parameter Setting Method5.4 Number and Content of Parameter5.5 Setting Rank (models IS - 3S) .5.6 Setting Rank (models 6S - 22S)

5.7 Setting and Adjusting Spindle Orientation Control Circuit(option) .

222323243434

35

366. REPLACING FUSE AND PCB

6.1 Replacing Fuse6.2 Replacing Spindle Control Circuit and Control Circuit PCB

6.3 Replacing Spindle Orientation Control Circuit PCB

6.4 Replacing Transistor Module

36363637

397. SPINDLE ORIENTATION CONTROL CIRCUIT7.1 Configuration .7.2 Adjusting Spindle Orientation Control Circuit of

Position Coder System

39

40

7.2.1 Setting and adjusting spindle orientation control circuit

in 2-step spindle speed change or less

7.3 Adjusting Spindle Orientation Control Circuit ofMagnetic Sensor Type

7.3.1 Mounting magnetizing element and magnetic sensor7.3.2 Setting and adjusting spindle orientation control circuit

in 2-step speed spindle for standard type

7.3.3 Setting and adjusting spindle orientation control circuit

in 2-step speed spindle for high speed type

7. 3. A Checking method of spindle position loop gain

40

4545

45

5358

APPENDIX

61APPENDIX 1 CONNECTION DIAGRAM

APPENDIX 2 CABLE ROUTING 72

75APPENDIX 3 CABLE SPECIFICATIONS

APPENDIX 4 77CONFIGURATION OF SPINDLE CIRCUIT

78APPENDIX 5 LOCATION OF UNIT

81APPENDIX 6 LOCATION OF PCB

83APPENDIX 7 MAJOR PARTS

85APPENDIX 8 MAGNETIC SENSOR SIGNALS CHECKING METHOD

86APPENDIX 9 PARAMETER LIST

I. s SERIES AC SPINDLE SERVO UNIT

1. GENERALThis manual describes maintenance of S series AC spindle servo units (models IS,1.5S, 2S , 3S, 6S , 8S, 12S, 15S, 18S and 22S) .1.1 Configurations

1.1.1 Models IS -3S

Models ISunits.1) Spindle control unit (basic)2) Resistor unit (basic)3) Spare fuse (basic)4) Connector for connection (basic)5) Spindle orientation control circuit (option)6) AC line filter (option)7) Power transformer (option)

3S of S series AC spindle servo units consist of the following

AC spindle servo unitr

I

"----** U—* Spindle control unit (Note 3)|PMC sequence

I circuitAC spindle

motor HIICNC1

Resister unitIL J

Fuse ConnectorL J

i iFan motort iL Spindle orientation control circuitJ

(Note 2)

I200/220/230 VAC

3-pltase power r~ i

*—i AC line filterI I

r—"ii

_____i —No-fuse breaker i

|No-fuse breakerI (Note 1)I

r380/415/460 VAC

Power transformerI__ I (Option)

Note 1) An overcurrent protector (no-fuse breaker, etc.) is provided by the MTBfor the input circuit of S series spindle servo unit.

Note 2) Cool the spindle control unit using a fan motor having a specific windspeed. Refer to Descriptions manual.

Note 3) For the PCB configuration refer to Appendix 2.

3 -

1.1.2 Models 6S-22SModels 6S - 22S of S series AC spindle servo units consist of the followingunits.1) Spindle control unit (basic)2) Spare fuse (basic)3) Connector for connection (basic)4) Power transformer (option)5) Spindle orientation control circuit (option)6) Unit adapter (option)

AC spindle servo unit

r i

Spindle control unit (Note 3)r—- r*PMC sequence jcircuit

AC spindle

motor =1CNC

ConnectorFuseL

I J

' Spindle orientation control circuit i

j- "1I

Fan motor i Unit adapter ii ii

(Note 2)

I

200/220/230 VAC f i3-phase power iIT i

r-*~.L

___:

II No-fuse breaker

I (Note 1)No-fuse breaker 1 I

Ii

__i_ _ 380/415/460 VAC

Power transformer i (Option)L_

Note 1) An overcurrent protector (no-fuse breaker, etc.) is provided by the MTBfor the input circuit of S series spindle servo unit.

Note 2) Cool the spindle control unit using a fan motor having a specific windspeed. Refer to Descriptions manual.

Note 3) For PCB configuration refer to Appendix 2.

- 4 -

1.2 Major Components

Table 1.2 (a) Major components

ROMModel Order specification Unit PCB

Specification Type

A06B-6059-H002//H501 A06B-6059-H002 A16B-1100-0200

(PCB1)

A06B-6059-H501 9801IS8000rpm

A06B-6059-H002//H508 A06B-6059-H002 A06B-6059-H508 98081.5S8000rpm

+A16B-1100

-0240(PCB2)A06B-6059-H002//H502 A06B-6059-H002 A06B-6059-H5022S 9802

8000rpm

A06B-6059-H003//H503 A06B-6059-H003 A06B-6059-H503 98033S6000rpm

A06B-6059-H203//H5236S/A36000rpm

A06B-6059-H203 A06B-6059-H523 9823A20B-1003-0010

(PCB1)

A06B-6059-H206//H511 A06B-6059-H206 A06B-6059-H5116S 9811+6000rpm A20B-1003

-0020(PCB2)A06B-6059-H208//H512 A06B-6059-H0288S A06B-6059-H512 9812

4500rpm

A06B-6059-H208 //H5138S A06B-6059-H028 A06B-6059-H513 98136000rpm

A06B-6059-H208#H52412S/A84500rpm

A06B-6059-H208 A06B-6059-H524 9824

12S/A86000rpm

A06B-6059-H2O8//H525 A06B-6059-H208 A06B-6059-H525 9825

A06B-6059-H212//H51412S A06B-6059-H212 A06B-6059-H514 98144500rpm

A06B-6059-H212//51512S A06B-6059-H212 A06B-6059-H515 98156000rpm

A06B-6059-H215//H51615S A06B-6059-H215 A06B-6059-H516A20B-1003-0010

(PCB1)

98164500rpm

A06B-6059-H215//H51715S A06B-6059-H215 A06B-6059-H517 9817+6000rpm A20B-1003

-0120(PCB2)A06B-6059-H218//H51818S A06B-6059-H218 A06B-6059-11518 9818

4500rpm

A06B-6059-H222//H52022S A06B-6059-H222 A06B-6059-H520 98204500rpm

- 5

Table 1.2 (b) Major components (option) (models IS - 3S)

Orderspecifications

Name PCB

A06B-6059-J110Orientation ARII(Position coder, 2-stage speed change)

A20B-0008-0242

Orientation BRII(Position coder, 2-stage speed change)

A06B-6059-J11 1 A20B-0008-0243

A06B-6059-J120 A16B-1300-0110Orientation CR(Magnetic sensor, 2-stage speed change)

Orientation GR(Magnetic sensor, 2-stage speed change)

A06B-6059-J121 A20B-0008-0111

Table 1.2 (c) Major components (option) (models 6S - 22S)

Orderspecifications

Name PCB

Orientation ASH(Position coder, 2-stage speed change)

A06B-6059-J130 A20B-0008-0242

Orientation BSII(Position coder, 2-stage speed change)

A06B-6059-J131 A20B-0008-0243

Orientation CSII(Magnetic sensor, 2-stage speed change)

A06B-6059-J140 A20B-0008-0032

Orientation GSII(Magnetic sensor, 2-stage speed change)

A06B-6059-J141 A20B-0008-0033

6 -

2. DAILY MAINTENANCE AND MAINTENANCE TOOLSCheck and clean the following items once every 6 months or so for using the AC

spindle motor and AC spindle servo units under a normal condition for a long

time.Take the check frequency into consideration according to the contamination

degrees in each item.

2.1 AC Spindle MotorIf the ventilation hole, cooling fan, and fan finger guard (net) of the AC

spindle motor become dusty, the radiation efficiency of the motor drops.

the AC spindle motor by using the factory air and a vacuum cleaner.Clean

2.2 AC Spindle Servo UnitSince a cooling fan is mounted at the upper part of the servo unit, its nearby

resistor and other parts become dusty after a long-time use. If they are dusty,

clean them using the vacuum cleaner or the like.

2.3 Maintenance ToolsUse tools indicated in Table 2.3 (a) for adjustments and tools indicated in

Table 2.3 (b) for repairing troubles.

Table 2.3 (a) Tools used for adjustments

Specification UseName

AC power voltagemeasurement

1 - 300 V +2% or lessAC voltmeter

© , © screwdrivers © large, medium size

© large, medium, small size

Table 2.3 (b) Tools used for repairing troubles

Specification UseName

AC voltmeter AC power voltagemeasurement

1 - 300 V +1% or less

DC power voltagemeasurement and offsetvoltage check

DC voltmeter 1 mV - 500 V +1% or less

Resistance value checkCircuit tester

© large, medium size

© large, medium, small size

© , © screwdrivers

2.4 Major Maintenance PartsFor maintenance parts, see appendix 7 Major maintenance parts.

7

3. TROUBLESHOOTINGPerforin troubleshooting, referring to each item in Table 3 according to troubleconditions if a trouble occurred.

Table 3 Sort of trouble conditions

Referenceitem

Trouble conditionsItem

Power voltage check1 3.1

Power ON indicator lamp PIL does not light.2 3.2

Alarm (AL-QO) is displayed on the PCB.3 3.3

4 Number of rotation is not as specified. 3.4

Motor does not rotate.5 3.4

Vibrations and noises are noticeable during rotation.6 3.5

An abnormal noise is produced from motor during deceleration.7 3.6

Motor speed overshoots or hunting occurs.8 3.7

Cutting power drop9 3.8

10 Spindle orientation is not correct. 3.9

Acceleration/deceleration time is longer than specified.11 3. 10

Note) When replacing the spindle control PCB or the control PCB, follow thecautions described in section 6.2. Refer to Appendix 2.

3.1 Power Voltage CheckCheck AC power voltage and DC power voltage on the spindle control PCB.points and standard values are as specified in Table 3.1.

Test

Table 3.1 Power voltage check

Check at INPUT terminals R,S,T (See 4.2)AC power voltage check

DC power voltage checkon the spindle controlPCB

Voltage Standard valueTest points

+24 V - 0 V About 25 V +4%+24 V

+15 V +4%+15 V - 0 V+15 V

+5 V +2%+5 V +5 V - 0 V

-15 V +4%-15 V - 0 V-15 V

- 8 -

Test points (refer to Appendix 6.)

U CN8 U

CN6[~o] OV |~o] OV

I CN9 1 I CN9 JC CN N5

5

24V®+5 V ® ® OV

+1 5V® 0-15V®- 1 5V

® +5V® + 1 5V

CCNN© OV

® OV4

4

24V®

1 CN1 | flN2j | CN1 | |CN3~| [CN2]ncNBfi

Spindle control PCB for models IS - 3S Spindle control PCB for models 6S •22S

Note) Be careful that the 200 VAC is output on CN8 connector for models IS - 3Sand 300 VDC on CN8 for models 6S - 22S.

3.2 Power On Indicator Lamp PIL is not Lit

Table 3.2 Check procedure and remedy

Item Causes Check procedure Remedy

1 AC power is notsupplied.

Check it at powerinput terminals R,S,T.

2 For models 6S - 22S,fuse FUR, FUS or FUTis blown.

See Appendix 5. Replace fuse FUR, FUSor FUT.

For models IS - 3S,

fuse FI or F2 is

blown.For models 6S -22S,fuse F2 or F3 is

blown.

3 Check if alarm indi¬cations of fuses F2and F3 appear.See Appendix 5.

Check whether the pulsegenerator cable orposition coder cablefor orientation is open.Replace the fuse FI, F2or F3. When the fuseis blown even ifreplacing it, replacethe PCB.

4 Check if the connectorguide groove appearson the PCB connectorsurface.

PCB connectors arenot pluggedcorrectly.CN4, 5 : models

IS - 3SCN4 - 6: models

6S - 22S

Insert connectors

correctly.Refer to section 6.

- 9 -

Check procedureCauses RemedyItem

Replace PCB.Refer to section 6.

PCB power circuit is

defective.Lamp PIL is lit by +5 V

and -15 V.Check power voltageaccording to Table 3.1.

5

3.3 Alarm is IndicatedAlarms on AC spindle motor and servo unit are indicated on five digits ofseven-segment on the servo unit PCB. Correspondence between seven-segmentindications and alarm signals is shown in Table 3.3 (a), (b).

Table 3.3 (a) Alarm (models 1S - 3S)

Alarm No. Meanings Contents Remedy

Motor overheat This lamp lights wheninternal temperature of

motor is higher than thespecified value.

Cool the motorand reset thealarm.

AL-01

This lamp lights when themotor speed is largelydeviated from the commandspeed.

AL-02 Reset alarm.Excessive

deviation ofspeed

Defectiveregenerative

current

AL-03 Detects that regenerativecurrent has flown longerthan the allowable time.

Reset alarmafter removingthe problem.

AL-04

AL-05

AL-Ob Overspeed

(Analogdetection)

This lamp lights when themotor exceeds 115% of therated speed.

Reset alarm.

AL-07 Overspeed(Digits1detection)


Reset alarm.

Overvol tage This lamp lights whenvoltage largely exceeds therated working voltage rangedue to a tap selectionfailure, etc..

AL-08 Reset alarm.

A1.-09

Detects lowervoltage.

Detects the input powervoltage lessened.

AL-10 Remove theproblem andreset the alarm.

10

RemedyAlarm No. Meanings Contents

Detects over DC voltage ofpower.

Remove theproblem andreset the alarm.

Excessive highvoltage of DClink

AL-11

Detects over current ofcircuit .


Abnormal current

of DC linkDefectivetransistor

AL-12

AL-13 - 15

Defective arithmetic circuit and peripheral circuitAL-16 - 23

Defective ROMNo indica¬tion

Table 3.3 (b) Alarm (models 6S - 22S)


Motor overheat This lamp lights wheninternal temperature ofmotor is higher than thespecified value.

AL-OI Cool the motorand reset thealarm.

AL-02 This lamp lights when themotor speed is largelydeviated from the commandspeed.

Excessivedeviation ofspeed

Reset alarm.

+24 V fuse is

blown.AL-03 +24 V fuse of the control

power is blown.Replace a fuseand turn on thepower again.

AL-04 Open phase ofinput power

A phase of input power is

open.Remove theproblem and turnon the poweragain.

AL-05

AL-06 Overspeed(Analogdetection)


Reset alarm.

AL-07 Overspeed(Digitaldetection)


Reset alarm.

AL-08 Overvoltage Voltage extremely excessesthe rated voltage.

Reset alarm.

11


Overheat ofradiator

AL-09 Temperature of radiatorsuch as semiconductor isextremely high.

Cool theradiator andreset an alarm.

AL-10 Lower voltage ofinput power

Detects lower voltage ofinput power.

Remove theproblem and turnon the poweragain.

Excessive highvoltage of DClink

AL-11 Detects over DC voltage of

power.Remove theproblem andreset the alarm.

Abnormal currentof DC linkDefectivetransistor

AL-12 Detects over current ofcircuit .


Defectivearithmeticcircuit

AL-13 Abnormal transmissionbetween microcomputer andperipherals


AL-14 Defective ROM Detects defective ROM. Replace ROM.

Defectiveoptional circuit

AL-15 Detects defective optionalcircuit and erroneousconnection to optionalcircuit.

Remove the

problem andreset the alarm.

1) Alarm No. 01 (AL-01) Motor is overheated.

Item Causes Check Remedy

Built-in fan motor ofspindle motor is

defective.

1 Replace fan motor.

Overload operation2 Check it using a loadmeter.

Re-examine cuttingconditions and tools.

3 Motor cooling systemis dirty.

Clean it usingcompressed air orvacuum cleaner.

4 Disconnection or poorcontact of wiring

Check connectionsbetween motor and servounit .

Confirm the connectionof connector forsignal. (Note)

Note) Refer to Appendix 2.

12 -

2) Alarm No. 02 (AL-02) Speed is deviated from the command value.

CheckItem Causes Remedy

Check it using a loadmeter .

1 Overload Re-examine cuttingconditions and tools.

2 Transistor module is

defective.Transistor collector-emitter is open.

Replace transistor

module. (Note 1)

Blow out or poorconnection of thedriver protectivefuse on PCB.

Check fuses F4A - F4Mfor blown out ormissing.

3 Connect fuses securely,and replace blown outfuses, if any.

4 Speed feedback signalis defective.

Check the speed feed¬back signal level.(Note 2)

Check the motor speeddetector or signalcable.

Check if connectioncables are normallyconnected.

Wiring failure(disconnection, poorcontact, etc.)

5

Note 1) Refer to section 6.4.Note 2) Speed feedback signal check

Observe the speed feedback signal using an oscilloscope under the rota¬tion command off (motor stop, drive power off) condition after turningon the power supply. Observe it at the following check terminals, whileslowly turning the motor by hand.

Test points Normal waveforms

PA-OV Vp-p = 0.36 — 0.5 V

About 2.5V0 V.

Same as shown abovePB-OV

RA-OV 2.5 +0.2 VDC

RB-OV Same as shown above

PAP-OVPBP-OV

(CW rotation)

( Adjust KVI8IPAP0V

4.5 V(Adjust (tV 19)

PBP t -=t=- 0 V

0.4 V

Check within ON/OFF duty is 50%.

(PAP and PBP signals are inverted in CCWdirection. )

13

3) Alarm No. 03 (AL-03)

- Models IS 3S: Defective regenerative circuit

RemedyCheckCausesI tern

Check collector (C) ,emitter (E) and base(B) of transistor.

Refer to section 6.4.

Replace transistor TR1.Transistor TR1 on the

regenerative circuit

is defective.

1

+24 fuse is blown.- Models 6S - 22S:

RemedyCheckCausesItem

Replace fuse FI.Fuse FI on PCB is

blown.1

4) Alarm No. 04 (AL-04) Open phase of input power (models 6S - 22S)

RemedyCheckCausesItem

- Replace the powersupply having lowpower impedance.(Note 1)

- Looseness of input

cable connector.Example:

Open phase due toloosened screws.

Alarm AL-04 lightsonly when the motor

speed is reducedfrom high speed.

High impedance on ACpower supply side.(Example)Two transformers areconnected in series orwhen a variable auto¬

transformer is

connected .

1

Replace transistormodule. (Note 2)

Transistor module is

defective.2

Replace the defectivepart .

3 MCC or AC reactor is

defective. Detection

resistor R5 or R6 isopen.

Note 1) Power impedance checking method.

IKAC spindlemotorS AC spindle

servo unitlo AC powersupply

1’ \V<c;K;

!•:AC voltmeter

14

Calculation formula

EO - Elx 100 (%) < 7 (%)

EO

Voltage when the motor stops operating.Voltage during acceleration of motor or voltage just beforethe motor speed begins lowering with a load applied.

where EO:El:

Input power specifications

SpecificationsName

200/220/230 VACNominal rated voltage

Allowable voltagefluctuation width

-15% - +10%

50/60 HzPower frequency

Voltage fluctuation due to load (120% load at

30 minute rating) : Less than 7%Power impedance

Note 2) Refer to section 6.

5) Alarm No. 06 (AL-06) Overspeed (analog detection)


PCB setting failure oradjusting failure

1 Check PCB for normalsetting and adjustment.

Change setting of PCB.Confirm parameter F-5.

Wrong specification ofROM (memory IC)

2 Check specificationreferring to Table1.2 (a).

Replace ROM.

PCB is defective.3 Replace PCB.section 6.

Refer to

6) Alarm No. 07 (AL-07) Overspeed (digital detection)

Same as in alarm No. 06 (AL-06).

7) Alarm No. 08 (AL-08) Overvoltage


AC power voltageexceeds the ratedvalue.

Check power voltage.1 Stabilize the inputvoltage.

15

8) Alarm No. 09 (AL-09) Radiator is overheated. (models 6S - 22S)


Cooling fan is

defective.1 Check if fan is

stopping.Replace fan.

Overload operation.2 Check load by using aload meter.

Re-examine the cuttingcondition.

Dusty and dirty.3 Clean using compressedair or vacuum cleaner.

9) Alarm No. 10 (AL-10) Input power voltage drops.This alarm indicates abnormally low AC power voltage (-15% or less).

10) Alarm No. 11 (AL-11) Overvoltage of DC link circuit.(Regenerative circuit is faulty ... Regeneration failure)


High power impedance.1 Examine AC powerspecification.Refer to section 4.2.

PCB is defective. Replace PCB. (Note)2

3 Defective transistormodule (TM1) .

Replace transistor

module. (Note)

4 Resistor RIO is open. Repair resistor RIO.

Note) Refer to section 6.

11) Alarm No. 12 (AL-12) Overcurrent flows to DC link circuit.

Causes CheckItem Remedy

Output terminals orinternal circuit ofmotor is shorted.

Check connections.1

Transistor module isdefective.

Check the transistor

module.Replace transistormodule. (Note)

2

Replace PCB. (Note)PCB is defective.3

Note) Refer to sections 6.2 - 6.4.

12) Alarm No. 13 (AL-13) CPU alarm. (models 6S - 22S)

Replace PCB. Refer to section 6.

16 -

13) Alarm No. 14 (AL-14) (models 6S - 22S)ROM is defective.

Item Check RemedyCauses

Check if ROM isunplugged from thesocket or if its leadsare broken.

1 ROM is not mounted at

all or not properlymounted.

Mount ROM properly.

Replace ROM havingcorrect specification.See Table 1.2 (a).

2 ROM is defective. Check series No. ofROM.

14) Alarm No. 15 (AL-15) Defective optional circuit (models 6S - 22S)


Defective optional PCB Replace PCB. (Note)

Refer to section 6.3.1

Check and correct theconnection.Refer to Appendix 1.

2 Optional PCB con¬nection is improper.

3.4 Motor does not Rotate or its Rotation is Abnormal

Check procedureItem Causes Remedy

Defective phases ofmotor power line

Alarm lamp lights onspindle servo unit whenrotation command isgiven.

1 Repair phases.Refer to Appendix 2.

Alarm lamp does notlight.

Apply higher voltageof speed command.

Command signal

connection failure2 Check signal cable

Connection.

3 Parameter is notproper.

Set parameters F-01 andF-02 correctly.Refer to section 5.4.

4 Check series No. ofROM.See Table 1.2 (a).

ROM is not proper. Set ROM correctly.

17

3.5 Vibration or Noise is too Large during Rotation

RemedyCheck procedureCausesItem

Replace motor.Motor is defective.1

Replace PCB.Refer to section 6.

PCB is defective. Run the motor idly.When the connector CN2from AC spindle servounit while rotating themotor, overheat alarm(AL-01) occurs, andthe motor runs idly.(Note)

If vibrations andnoises are reducedduring idle run ascompared with normalrotation time, thecontrol circuit is

defective.

2

Note) To perform idle run contact with the MTB whether idle run is considered.Some of sequences makes brake enable.

3.6 Noise is Produced from Motor during DecelerationDuring deceleration of the motor, energy is regenerated to the power supplythrough the regenerative control circuit.excessive, the regenerative current limit circuit operates to change the motorcurrent waveform, causing an abnormal noise to be produced from the motor. Insuch a case, lessen parameter F-20 until no abnormal noise is produced.Lessening F-20 makes the deceleration period long.

If the regenerative energy is

3.7 Speed Overshooting or Hunting Occurs

Causes Check procedureItem Remedy

Overshooting1 Enlarge F-21 or F-22.(Note)

Readjust. Refer tosection 5.4.

Spindle hunting2 Lessen F-21 or F-22.(Note)

Readjust. Refer tosection 5.4.

Note) Adjust F-21 for "HIGH" clutch, and F-22 for "LOW" clutch.

3.8 Cutting Force is Low

CausesItem Check procedure Remedy

ROM is not proper. Check it referring to

Table 1.2 (a).1 Replace ROM.

Torque limit commandis applied.

Check signal.2

Loosened belt Check belt tension.3

18

3.9 Orientation is not Correct

Check procedure RemedyI tern Causes

Check if circuit is set

and adjusted asspecified in datasheet .

Refer to section 7.1 Setting or adjustingfailure of orientationcontrol circuit.

Orientation controlcircuit PCB is

defective.

Replace PCB. Refer tosection 6.

2

Spindle control PCB isnot adjusted properly.

Adjust decelerationtime of spindle controlcircuit. Adjustparameter F-20 toshorten the decelera¬tion period.

Adjust PCB.section 7.

3 Refer to

4 Position detection(position coder ormagnetic sensor) isdefective.

Check the output signalwaveform of theposition detector.

Replace the positioncoder or magneticsensor.

3.10 Acceleration/Deceleration Time is Long

Check procedureItem Causes Remedy

1 Torque limit commandis applied.

Check signal.

Defective receiverpart activates thetorque limit.

2 Change torque limitparameter F18 toadjust accelerationperiod.

Replace receiver part(HY2) or PCB.

PCB is not adjustedcorrectly.

3 If parameter F-20 is

set too low, thedeceleration periodbecomes long.Refer to section 3.6.

Readjust F-20. Referto section 5.4.

19 -

4. INSTALLATION

4.1 Installation ProcedureObserve the checking procedure shown in Table 4.1 at the installation.

Table 4.1 Installation procedures

Description RemarksItem

Check if specifications of motor,

servo unit, options, etc. arecorrect.

1 Check if motor corresponds tounits, PCB, and ROM correctlyaccording to Table 1.2.

Check appearance for damage2 Check resistors, and parts on thePCB.

3 Check the working AC power supplyfor voltage, voltage fluctuation,power capacity (kVA) andfrequency.

See Table 4.2.1.

4 Connect the earth wire, powercable and drive power cable.

Refer to sections 4.2, 4.3, 4.4and Appendix 1.

Check setting and adjustmentresults.

Refer to section 5.1.5

6 Turn on AC power supply, and makesure that green lamp PIL lights onPCB.

Refer to Appendix 6.

Give rotation command to check thenormal rotation and reverserotation movement.

7

8 Check the operation over theentire velocity range.

9 Adjust spindle orientationcircuit.

Refer to section 7.

20 -

4.2 Power Connection

4.2.1 Power voltage and capacity check

Measure the AC power voltage before connecting the power supply, and take thefollowing measure according to power voltage.

Table 4.2.1 (a) Checking AC power voltage

Nominal voltageAC power voltage Measures

170 - 253 VAC Connect directly.

Higher than 254 VAC 380 V to 550 V Set input voltage to 200 VAC usinginsulation transformer.

The input power specification of the AC spindle servo unit is as specified inTable 4.2.1 (b).sufficient allowance so that no trouble due to voltage drop occurs with themaximum load.

Use a power source having the power capacity having a

Table 4.2.1 (b) Input power specification of AC spindle servo unit

200/220/230 VAC, 3 phasesNominal rated voltage

Allowable voltage fluctua¬tion

-15% to +10%

50 Hz/60Hz +1 HzFrequency

6S/ 12S /Motor model IS 1.5S 2S 8S 12S 15SPower

capacity3S 6S 18S 22S

A3 A8Capacity with30-rainuterating (kVA)

4 7 7 9 12 17 17 22 269 32 37

4.2.2 Protective earth connection

Connect the protective earth to connection terminal G before connecting thepower supply. Use the protective earth having sufficient capacity as comparedwith the feeder circuit breaker capacity.

4.2.3 Power connection

Connect the power cable after protective earth connection.The power phase rotation is not specified for AC spindle servo unit.The cooling fan motor employs three-phase power. When connect the input powerto the unit, check the proper phase connection.

4.3 AC Spindle Motor ConnectionConnect the AC spindle motor according to the connection diagram in Appendix 1.If the drive power cable connection sequence is in error, vibration are producedthe motor does not rotate or alarm (AL-02) occurs to stop the motor. Alwaysconnect protective earth "G".

4.4 Single Cable ConnectionConnect the signal cable according to the connection diagram in Appendix 1.

21

5. SETTING AND ADJUSTING

5.1 Jumper and Variable Resistor on Spindle Control PCB (models IS - 3S)

Refer to Appendices 5 and 6 for part locations of the unit and PCB.confirm the location of parts on PCB before power on.

Always

Table 5.1 (a) Jumpers (models 1S - 3S)

Setting atshipment

Contents StateJumper

Switches mode ofcontrol circuit

Test mode TEST DRIVESI

Operation mode DRIVE

Selects from righttable according tothe speed at ratedcommand (VCMD = 10 V)

Depends uponmodel.

S2 DetectorI (rpm)

Detector

II (rpm)S3

6000 D

4500Detector I:Gear of 256 teeth

Detector II:Gear of 128 teeth

8000 C

6000 10000 to

12000B

8000 to

10000A15000 to

20000

S4 Switches gain Normal operationmode

OFF OFFS5

Switches gain ON

Table 5.1 (b) Variable resistor (models IS •3S)

Variableresistor

Contents Setting at shipment

RV1 Maximum speed in CCWdirection

Depends upon model.

RV2 Maximum speed in CW direction

RV3 Offset of speed detectioncircuit

Adjust TS3 to 0 mV +0. 1 mV atrotation command OFF.

RV4 Voltage of +5 V +5 V -1-0.1 V

Adjusts gain at switching ofgain

RV5 50%

Gain of speed detectioncircuit for low speed

RV6 Value

(rpm)Max. speed(rpm)

Mode1

Adjusts speed at 25 mV +2 mVof VCMD for each model

3S 15 +3 6000

IS, 1.5S, 2S 20 +4 8000

22 -

5.2 Jumper on Spindle Control Circuit (models 6S - 22S)Refer to Appendices 5 and 6 for parts location of the unit and PCB.confirm the location of parts on PCB before power on.

Always

Table 5.2 Jumpers (models 6S - 22S)

Setting atshipment

PositionContentsJumper

SI Drive mode DRIVEDRIVE

Test mode TEST

Increases 10% of power voltage of+5 V

S2 +10 No setting

Decreases 10% of power voltage of+5 V

-10

M0FF1 (CN3 - 15) and MOFF2(CN3 - 16) signals are used.

S5 INTEXT

M0FF1 and M0FF2 signals are notused.

INT

S6 Option setting S6A: ON +24 V

S6B: ON +5 V

S6C: ON -15 V

OFF: Not apply

Optional

setting isnot set.OFF

5.3 Parameter Setting MethodThe setting switch and the display part are arranged on the PCB like the figurebelow.These switches enable to confirm and set parameters,

Refer to Appendix 6.

Display part

Me? M M Jy

Setting switch

0[&]DATA DOWN'

0SET

1) To confirm the current parametera) The speed is usually displayed at the display part (Five digits).

The current parameter number can be displayed when "MODE" is on.parameter number is displayed as two digits of "F-XX".

The

23

2) To confirm the setting data

a) Select the parameter number of data to be checked in the following manner.b) Continuously turn 4 switches "MODE", "+ UP", "+ DOWN" and "DATA SET" ON at

the same time for more than one second.c) The display part changes from the blank to "FFFFF".d) Off all switches.e) The current parameter is displayed when "MODE" is on.f) When "+ UP" is on with "MODE" on, the parameter number is incremented

by 1.g) When "+ UP" is continuously on with "MODE" on, the parameter number

increases continuously.h) When "4- DOW" is on with "MODE" on, the parameter number is decremented

by 1.i) When "+ DOWN" is continuously on with "MODE" on, the parameter number

decrements continuously.j) With "MODE" off, the data is displayed (4 digits) after approx. 0.5

second.k) After approx. 10 seconds the data display is selected, the speed display

is selected. When all switches are off in any mode, the speed is finallydisplayed .

3) To alter the dataa) Select the parameter to be changed according to the steps (2) — (b ) to (i) .b) Turn "MODE" off: The data of parameter is displayed after approx. 0.5

second.c) Turn "+ UP" on: The data is incremented by 1.d) Turn "t UP" on continuously: The data is incremented continuously.e) Turn "+ DOW" on: The data is decremented by 1.f) Turn "+ DOW" on continuously: The data is decremented continuously.g) The motor is controlled using the displayed data.h) When replacing the data with the modified data, keep turning "DATA SET" on

for one second or more.i) The display part changes from the blank to "88888" and modification of the

data completes.j) Wen changing the data once again, follow the steps from (3)-(a) above.k) The speed is indicated automatically after about 10 seconds. For para¬

meters F-13, F-14 and F30, speed is displayed after 2 seconds.

5.4 Number and Content of Parameter1) Motor speed indication

Display data(Five digits)

Contents of dataParameter No.

The speed of the motor is displayed.(rpm)

F-00

2) Use/no use of the machine ready signal (MRDY)

Display data(Five digits)


0, 1 (Standard setting: 0)F-01 0001

Explanation: Machine ready signal (MRDY) is usedMachine ready signal (MRDY) is not used: 0

1

- 24

3) Use/no use of speed override (models 6S - 22S)

Display data(Four digits)

Parameter No. Contents of data

0, 1 (Standard setting:F-02 0001 1)

Explanation: Use speed overrideNot use speed override: 0

1

4) Range of speed override (models 6S - 22S)




Explanation: Upper limit of speed override (up to 120%): 1Upper limit of speed override (up to 100%) : 0

Note) When F-02 is set to 0; speed override is not used, F-03 should be setto 0.

5) Maximum speed (models 6S - 22S)



0-3 (Depend upon motor)F-05

Explanation: 6S - 22S(rpm)

IS - 3S(rpm) Setting

Up to 5000 Up to 10000 0

Up to 6000 Up to 12000 1

Up to 15000 2

Up to 20000 3

6) Output limit pattern



0 to 6 (Standard setting: 0)F-06 0000

Explanation: This function is not available for a conventional type.In the following cases, select a pattern which is appropriaterespectively.A. When the output is limited only at acceleration and

deceleration, the motor accelerates and decelerates slowly,and operates at the rated output during steady rotation(Setting data: 1 or 4) (function similar to software startand stop)

B. When the motor accelerates and decelerates at the maximumrated output and the output is limited during stablerotation (Setting data: 2 or 5)

25

C. When the same motor and amplifier are used to operate themachine as a different output specification machine (Settingdata: 3 or 6)

Setting dataContent

Pattern 1 Pattern 2

The output is not limited. 0 0

Output is limited only at accelera¬tion and deceleration.

1 4

No output is limited at accelerationand deceleration but it is limitedduring steady rotation.

2 5

The output is limited over all move¬ments.

3 6

(Output limit pattern 1): The setting data =1, 2, 3

OutputCatalog descriptionvalue

Pm 100%

_ IF-071Pout x Pm100

0Nb Nm

Speed

(Output limit pattern 2): The setting data =4, 5, 6

OutputCatalog descriptionvalue

Pm 100%

_ 1 P-07 1Pout x Pm100

0NmNb

Speed

7) Limit value at output limited



0 to 100 (Standard setting: 100)F-07 0100

Explanation : With the maximum rated output (overload capacity) as 100%, setthe limit value to a value to be limited.available when the output is limited due to parameter F-Ob.

This value is

Output limit value = Maximum rated output x (setting data) %

2b -

8) Delay time to motor power interruption



0 to 255 (Standard setting: 5)0005F-08

Delay time from zero speed signal detection to the motor powerinterruption.

Explanation:

Delay time = (Setting data) x 40 msec

9) Use/no use of excitation interruption of motor power using machine readysignal (MRDY)

Display data(Four digits) Contents of dataParameter No.

0, 1 (Standard setting: 0)0000F-09

The function is used when it is presumed that the electro¬magnetic contactor is switched frequently.ready signal (MRDY) is off, only motor power is interrupted,and the electromagnetic contactor remains on.The function is used :The function is not used:

Explanation:When the machine

10

10) Adjustment of speed error offset at the time of the forwardrotation command (SFR)



0128 0 - 255 (Standard setting: 128)F-10

Explanation: The speed error offset is adjusted when stopping motor withthe forward rotation command (SFR) and speed command voltage0 V (zero rotation command) applied.stopping the motor rotating counterclockwise (CCW) , as viewedfrom the shaft.

Increase the data when

11) Adjustment of speed error offset at the time of the reverse rotation command(SRV)



F-ll 0128 0 - 255 (Standard setting: 128)

Explanation : The speed error offset is adjusted when stopping motor withthe reverse rotation command (SRV) and speed command voltage0 V (zero rotation command) applied.stopping the motor rotating CCW, as viewed from the shaft.

Increase the data when

27 -

12) Adjustment of speed error offset at the time of the orientation command(ORCM)



0 - 255 (Standard setting: 128)F-12 0128

Explanation: The parameter is used for adjustment when no adjustment ispossible so that the LED of IN-POSITION FINE is lit atorientation using the variable resistor on the orientationcircuit .

13) Speed at forward rotation command (SFR)



0 - 255 (Depends upon motor)F-13

Adjust the speed when inputting specific speed command atforward rotation command (SFR).speed.

Explanation:Increase data to increase

14) Speed at reverse rotation command (SRV)



0 - 255 (Depends upon motor)F-14

Explanation: Adjust the speed when inputting specific speed command atreverse rotation command (SRR) .speed.

Increase data to increase

15) Speed when speed command voltage is 10 V



0 - Rated speed (Depends upon motor)F-15

When making adjustments in sections (14) and (15), always setthis mode.voltage divided by 100.

Explanation :Set the value of speed at 10 V speed command

Speed at 10 V speed command voltage (rpm) = (Setting data)

x 100

28

16) Detection range of speed arrival signal (SAR)




Sets the detection range of the speed arrival signal (SAR).The speed arrival signal (SAR) is outputted when the motorspeed reaches the range within specific percentage of thecommand speed.

Explanation:

Detection range = (Command speed) x ( + (Setting data)) %

17) Detection range of speed detecting signal (SDT)



0 - 100 (Standard setting: 3)0003F-17

The detection range of the speed detecting signal (SDT) isset.The speed detecting signal (SDT) is outputted when the motorspeed becomes the specific percentage of a maximum speed orless.

Explanation:

Detection range = (Maximum speed) x (Setting data) %

18) Setting of torque limit value

Display data(Four digits)Parameter No. Contents of data


Explanation: When the torque limit signal (TLMH) is turned on, torque limitvalue is set .Torque limit value = (Maximum rated torque) x (Setting data) %

19) Acceleration/deceleration time



0010F-19 0 - 255 (Standard setting: 10)

Explanation: Set this parameter when the acceleration time from the stop tothe maximum speed is longer than 5 seconds.

Setting value = (Acceleration time, sec) x 2

29 -

20) Limit of regenerative power (Adjustment of deceleration time)




Explanation: Adjust the deceleration time to the same as the accelerationtime.The deceleration time shortens when the setting valueincreases.The deceleration time lengthens when the setting valuedecreases.However, when the regenerative power is excessive, theregenerative limit circuit is actuated and the motor current

waveform changes; therefore, abnormal noise may be producedfrom the motor. In this case, this abnormal noise issuppressed by decreasing the setting value.

21) Speed control phase compensation P: HIGH gear (CTH = 1)




22) Speed control phase compensation P: LOW gear (CTH = 0)



F-22 0050 0 - 255 (Standard setting: 50)

23) Speed control phase compensation P in orientation: HIGH gear (CTH = 1)




24) Speed control phase compensation P in orientation: LOW gear (CTH = 0)




25) Speed control phase compensation I: HIGH gear (CTH = 1)




- 30 -

26) Speed control phase compensation I: LOW gear (CTH = 0)



30)0 - 255 (Standard setting:0030F-26

HIGH gear (CTH = 1)27) Speed control phase compensation I in orientation:




LOW gear (CTH = 0)28) Speed control phase compensation I in orientation:




29) Speed detection offset (models 6S - 22S)

Note) Refer to paragraph of speed offset adjustment for models IS - 3S.



0 - 255 (Setting at shipment: approx.128)

F-29 0128

Explanation: Adjust this parameter so that the test pin TS3 will be 0 mV atmotor stopping.

30) Rigid tap mode



F-31 0000 0-1 (Standard setting: 0)

Explanation: The torque limit signal (TLML) is used to a conventionaltorque limit: 0The torque limit signal (TLML) is used for motor voltageswitching when improved transient response characteristics arerequired for rigid tapping operation: 1

31) Motor voltage at normal operation

Display data(Four digits )



31

32) Motor voltage in orientation




33) Motor voltage in rigid tap mode




This parameter is effective when data of F-31 is 1.Explanation:

34) Detection range of zero-speed detection signal



0 - 255 (Standard setting: 75)F-35

Explanation: The zero-speed signal is used as the completion signal forstop command.This signal is detected when the speed of the motor becomes(The setting data/100) % of a maximum speed or less.

The detection range = (maximum speed)x (The setting data/100)%

35) Detection range of load detection signal



0 - 100 (Standard setting: 90)F-36

Explanation : The load is detected when the load becomes greater than thespecific percentage of maximum detection level of the loadmeter.

Detection level = (maximum detection level of load meter, 10)

x (setting data)% or more

32 -

36) Time constant of torque deviation at deceleration start (models 6S - 22S)



0-3 (Standard setting: 0)0000F-37

Explanation: Use this parameter when the gear noises at deceleration in lowspeed rotation (base speed) due to the backlash of thespindle.

Data Time constant (msec)

0 01 502 1003 150

Set the data to 2 when the gear noises.

37) Characteristics of control in deceleration (models 6S - 22S)




Explanation: Use this parameter when the gear noises at deceleration inhigh speed rotation.deceleration rate.

Set the data to 1 to slow down the

38) Characteristics of control in stable rotation with no load (models 6S - 22S)



F-39 0, 1 (Standard setting: 0)0000

Explanation: The motor speed may undulate in the stable rotation whensetting the motor voltage (F-32) greater than the standardvalue (10). Set F-39 to 1 to reduce the motor undulation.

39) Characteristics of control in torque limitation (models 6S - 22S)



F-40 0, 1 (Standard setting: 0)0000

Explanation: The motor speed may overshoot due to the timing of the torquelimit signal when making the torque limit in mechanicalorientation.speed.

Set F-40 to 1 to reduce the overshoot of the

33 -

5.5 Setting Rank (models IS - 3S)

- Rank A (always setting)

Parameter No. Contents

Use/no-use of the machine ready signalF-01

- Rank B (special setting)


F-16 Range of detecting the speed arrival signal

F-l 7 Level of detecting the speed detection signal

F-35 Level of detecting the zero-speed signal

F-l8 Torque limit value

F-06 , 07 Output limit

Period of acceleration/decelerationF-l 9

Limit of regenerative power (deceleration time)F-20

Use /no-use of motor power off using the machine ready signalF-09

F-36 Level of detecting the load

5.6 Setting Rank (models 6S - 22S)Parameters in only rank A are checked and changed by the MTB.When changing the operating conditions (change of speed and special setting),the machine tool builder should divide the rank for use.Pay attention not to alter the setting value by mistake.

- Rank A (always setting)


Use/no-use of machine ready signalF-01

Use/no-use of speed overrideF-02

F-03 Range of speed override

34

- Rank B (changing the speed)

ContentsParameter No.

Speed in forward directionF-13

Speed in reverse directionF-l 4

Speed at maximum speed command voltage (10 V)F-15

- Rank C (special setting)

ContentsParameter No.

Range of detecting the speed arrival signalF-16

Level of detecting the speed detection signalF-l 7

Torque limit valueF-l8

Period of acceleration/decelerationF-l 9

Limit of regenerative power (deceleration time)F-20

Use/no-use of motor power off using the machine ready signalF-09

5.7 Setting and Adjusting Spindle Orientation Control Circuit (option)Refer to section "Spindle orientation control circuit."

35 -

6. REPLACING FUSE AND PCB

6.1 Replacing FuseRefer to Appendices 5 and 6 for the spindle control circuit PCB and fuses on thecontrol circuit.

6.2 Replacing Spindle Control Circuit and Control Circuit PCBRefer to Appendix 2.

Steps Contents

Turn off the breaker on the magnetics cabinet to off the AC inputpower, and then remove the motor power line.

1

Remove the spindle control circuit PCB by pushing ten PCB holdersoutward .

2Replace the PCB with new one.

Remove screws other than that mounting electronic parts from thecontrol PCB, and then remove the PCB. Refer to Appendix 2. Replacethe PCB and/or transistor modules if necessary. Refer to section 6. A.Confirm screws to be bolted.

3

Note) Always confirm the voltage between plus and minus terminals of capacitorCl is less than 60 VDC using a tester before handling the control circuit.

6.3 Replacing Spindle Orientation Control Circuit PCB

Steps Contents


1

Remove the spindle control unit PCB and then cables from PCBs.2

Remove four push rivets or M3 screws from the plates mounting the PCB.3

C-3/

<=51 Four push rivcts/M3 screws

Orientation PCD

Remount the PCB reversing the above procedures.

36 -

6.4 Replacing Transistor Module

Steps Contents


1

Check resistance of transistor modules on the lower control circuitPCB using a tester. Refer to Appendix 6.1. © (collector) - U, V, W (emitter)

2. U, V, W (collector) - © (emitter)

3. © (collector) - Bl, B3, B5 (base)

4. U, V, W (collector) - B2, B4, B6 (base)

5. Bl, B3, B5 (base) - U, V, W (emitter)

6. B2, B4, B6 (base) - © (emitter)

2

OP

13 1 B 3

MilBl

o-K sffl

B2 16 PN O v0 "—u—OvVoO u0

fflU. B2 B-l B 6

o-K A o-K A o—K 5

ON

Judgment (Range of tester: x 10 ohm)

Terminal NormalTester Abnormal

500 - 600 ohmsC - E C: + Short, infinity

InfinityC Short, 500 - 600 ohms

500 - 600 ohmsC - B C: + Short, infinity

InfinityC Short, 500 - 600 ohms

B - E 500 - 600 ohmsB: + Short, infinity

B 500 - 600 ohms Short, infinity

When a transistor is defective, terminals between collector andemitter, and between collector and base are short.

3 Remove the lower control circuit PCB and replace it with new one.Apply thin silicon grease.Silicon grease: A98L-0001-0653

4 Remount the lower PCB. Firmly bolt all screws.

37

ContentsSteps

Check the transistor drive circuit on the PCB.(T) Turn on AC input power. Be sure not to specify rotation commands

(SFR, SRV) .(2) 12 points of voltage between the base and the emitter on

transistors (U, V and W phases) using a tester. Take care of highvoltage around the drive circuit.

5

Judgement

Voltage between base and emitter (emitter standard)

Approx. -0.8 to -1.3 VNormal

Abnormal Approx. 0.0 to -0.8 V

The waveforms in normal /abnormal are shown below.

Note) Take care of high voltage (approx. 300 VDC) around the drivecircuit.

Specify the forward/reverse rotation command with 0 rpm of speedcommand.sistors (U, V and W phases) on the lower PCB using an oscilloscope.

Observe waveform between the base and the emitter of tran-

6

Normal Abnormal

Approx. -I- 1. 0 V

- —1.5VApprox. + 1.0 V

-1.5V

0V0VApprox. — 1.0

---1.5VApprox. 0.0 V— 0.8V —J 1 66 L_-I' U-1 66

V sec s e c

If the PCB is defective repair it using following steps.whether fuses F4A - F4M of the drive circuit are blown using a tester.When a fuse is blown, replace it and check the PCB following steps (T)and (2) in 5.

Check

Connect the motor power line to restart an operation.7

38 -

7. SPINDLE ORIENTATION CONTROL CIRCUITThis chapter describes maintenance, installation, and adjustment when the

electric orientation function is added to the spindle of CNC machine tool.

7.1 Configuration

r i Spindle orientation command

Ml 9

Spindleservo unit Orientation circuit A, K

(option) Gear or belt

CNC r ii—iCNI

Magneticcabinetsequencecircuit

I I Spindlemotorr-—Ci---1 /•

i ii 7ÿ-ÿ-CNA : SpindleL J Cutting tool

CNH I Positioncontrolloop

-st w

__/V.

Direct coupling gear orliming belt (1 to 1)

Position coder

Fig. 7.1 (a) Configuration of spindle orientation using position coder(Internal stop position setting type)

Spindle orientation control circuit B, FZ (option)

Spindleservo unit

Magnetic cabinetsequence circuitCNC Z Gear or beltCNI

/ z'I !~r z---1i i Spindle

motorCNH CNACNC

I11=1 t=3

__ÿ_J L_I__

iSpindlei Cutting tool: i 2

i + I.j

Positioncontrol loop

Direct coupling gear ortiming belt (1 to 1)

Position coder

External stop position command signal

12-bit binary(4096=360°)

Fig. 7.1 (b) Configuration of spindle orientation using position coder(External stop position command type)

Note 1) If a position coder has been mounted on a lathe, etc., it can be used.Note 2) Asterisked cable route is employed when the position coder for the lathe

or synchronous feed in machining center is combined.

39 -

---1 Spindle orientation command

l mi9 rlSpindleservo unitr 1

Gem or belt1

iCNC Magnetic

cabinetsequencecircuit

I CN1i

I Spindlemotor---1

II =v CNATi Spindle

_J LL J Cutting tool

3/Positioncontrolloop

r-KjeBa

' y1 Magnetic element[ (direct-coupled)

-j !\Spindle orientation controlcircuit C. D, G (option) Magnetic

sensor

N Amplifier

Magnetic sensor

Fig. 7.1 (c) Configuration of spindle orientation using magnetic sensor

7.2 Adjusting Spindle Orientation Control Circuit of Position Coder System

7.2.1 Setting and adjusting spindle orientation control circuit in 2-step spindle speed change or less

Following functions are required:Models IS - 3S : Orientation ARII, BRII (A06B-6059-J 1 10, Jill)

Models 6S - 22S: Orientation ASTI, BSII (A06B-6059-J130 , J131)Setting and adjustment of PCB (A20B-0008-0242, 0243, used for models IS - 3S and6S - 22S) are described below.1) Display contents

The following display is done using LED.

Lightingcolor

SymbolLED No. Description

LED 1 ORIENTATION Green Lights when orientation command(0RCM1, 2 ON) is input.

LED 2 LOW Green Lights when cluth switching signal *CTH

contact is closed.is selected.

It means that cluth LOW

LED 3 IN-POSITION Green Lights when orientation end signal 0RAR1-2is sent.OUT

LED 4 IN-POSITIONADJUST

Lights when spindle enters within 1 pulsewidth of orientation command position.Adjust OFFSET adjusting RV3/RV5 so thatthis LED4 lights at gear HIGH/LOW, and thestop positions at gear 1ITGH and LOW

coincide with each other.

Green

2) Settinga) Setting power supply of position coder

If the power supply -f-5 V of position coder is supplied from the spindleamplifier, short the circuit between +5V - 5H and 0Gcircuit between +5Vmachine tool.

Open the0V when +5 V is supplied from CNC

0V.5H and 0G

- 40 -

b) Setting jumpers T6 - T14

Position coder Jumpers T6 - T14

Balanced A side: ON

Unbalanced B side: ON

c) Setting jumpers SH01, SH02 and SH03Make setting using the table below.

41

Table 7.2.1 Setting SH01, SH02 and SH03

0: Open X: Short

SH01 SH02 SH03

1 2 3 5 6 7 8 64 1 2 3 7 8 24 5 1Setting contents RemarksNo

|16- 15 14 13 12 11 10 16 15 149 13 12 11 10 9 2 3

Setting of rotating directionin the first orientation afterturning on the power switch.

CCW O ( Standard)1

CW oCCW direction

Setting of rotating directionin the second and sub¬sequent orientation.

only O ( Standard)x2

CW directiononly y x

Same as rotat¬ing direction ( Standard)O x

1 X XSetting to clamp the orien¬tation speed determined byposition gain to 1, 2/3 and1/3.

2/3 O X3

1/3 OX

Same direction Depens upon machine tools. Hunting occurs.if this setting is inverted.

O XSetting by spindle rotationand rotating direction ofposition coder.

Oppositedirection

4I Ox

ro pulse O OO O O O

ISetting of the in-positionwidth when orientation endsignals (ORAR1, 1) areoutput .

+4 O O O O O(+16 pulse corresponds to +1.3°)

5+8 O O O o

+ 16 O O O

+ 32 O O

+64 O

No compensation (Standard)x X

Setting by hysteresis ofposition coder

6+ 1 pulse O x

- 1 pulse Ox

When DC spindle servo unit is used.DC O XSetting according to thetypes of spindle servo unit.

7When AC spindle servo unit is used.AC OX

(Note) Sending condition (C) of orientation end signal are as below:

* The angle position is located with the in-position setting pulse range.* Speed zero signal is turned on.* ORCM is turned on.

d) Setting position switches (SW1, 2, 3)

Angle per 1 divisionPulse number per 1 divisionSetting switch

Every 22.5°4096/16 = 256 pulsesSW1

256/16 = 16 pulses Every 1.4°SW2

Every 0.088°16/16 = 1 pulseSW3

SW1 to SW3 are digital switches with 16 scale.The spindle motor can be stopped at any position in one rotation in theunit of 1/4096 x 360° = 0.088° by setting these switches in the order ofSW1, SW2, SW3.

3) Adjustments

Name ofvariableresistor

Standardadjustment(Division)

Item DescriptionNo. Measuring point

Speed feedbackvoltage offset

1 RV1 Adjust RV1 untilTSA2 voltagebecomes 0 +1 mV.

5 TSA2CH14 (TSA2)

3-42 Gear HIGHposition gain

RV2 Spindle motion

or CHI 4Set the gain tothe maximum withina range where thespindle does notovershoot.

LED4 (ADJUST)3 RV3Gear HIGH

offsetAbout 5 Adjust RV3 until

LED4 lights orflickers.

4 RV4 3-6Gear LOWposition gain

Spindle motion

or CH 14Set the gain tothe maximum withina range where thespindle does notovershoot.

LED4 (ADJUST)5 Gear LOWoffset

RV5 About 5 Adjust RV5 untilLED4 lights orflickers.

6 Speed loopgain

RV6DC(DC motor)

0 Make sure thatmotor is nothunting.The rigidityincreases duringstop by turningthese RV clock¬wise.

CH 14

RV6AC(AC motor)

7 CHI 4

43 -

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Fig. 7.2.1 Location of test pins, variable resistors, jumpers, and light-emitting diodes (LED)

(PCB A20B-0008-0242, 0243, models 1S - 22S with position coder system)

- 44 -

7.3 Adjusting Spindle Orientation Control Circuit of Magnetic Sensor Type

7.3.1 Mounting magnetizing element and magnetic sensorDetermine the mounting directions of the magnetizing element and magnetic sensoraccording to the following procedure. If they are not mounted correctly, thespindle may repeat normal rotation and reverse -rotation without being stopped,the hunting occurs, or the spindle stops at the position where the magnetizingelement end is opposite to the sensor head.

Mounting procedure of magnetizing element and magnetic sensor

Item Procedure

Mount the magnetizing element is such a way as the reference hole facesas shown in Fig. 7.3.1 when the spindle is turned by the spindle motornormal rotation command (SFR, VCMD: Positive).

1

Mount the magnetic sensor head so that the pin hole of the flange isopposite to the reference hole.

2

Adjust the gap between the magnetizing element and the sensor head, sothat the minimum gap value AL becomes AL = 1.5 +0.5 mm.

3

Reference hole

Moving direction of mawhen thedirection

ignctizing elementr turns in normalspindle moto

(SFR).

Pin hole

1/

=r-r.l

Magnetizing element Sensor head

Fig. 7.3.1 (a) Mounting direction of magnetizing element (Reference drawing)

7.3.2 Setting and adjusting spindle orientation control circuit in 2-step speed spindle for standard type

Following functions are required:Models IS - 3S : Orientation CR (A06B-6059-J120)

PCB (A16B-1300-0110)

Models 6S - 22S: Orientation CSII (A06B-6059-J140)PCB (A20B-0008-0032)

Setting and adjustment of PCB are described below. See Fig. 7.3.2 (a), (b).1) Setting jumpers SH01 - SH05

Table 7.3.2 (a) shows the setting and functions of jumpers. Select thesejumpers by user.Terminal SH01 is provided for adjustment and testing at site. Set this SH01terminal after turning on the power supply, and disconnect it afteradjustment without fail. Make sure that LED7 goes out.

- 45 -

Table 7.3.2 (a) Setting jumpers (SH)

Jumpers(The double frame indicates standard setting)

Setting(Note 1)

RemarksFunction

1-2 2-3SH

(Note 2) Set for adjustment only.Sets the test mode.01 o

SH03 setting takesprecedence of SH02.This is effective onlywhen 1-2 pins of SH03 areshorted.

Rotates the motor shaftclockwise when the orientation

command is given beforeoperating the spindle afterturning on the power.

02 xo

Rotates the motor shaft counter¬clockwise when the orientationcommand is given before operatingthe spindle after turning on thepower.

x o

Orients in the direction of thespindle rotation just before theorientation command was given.

SH02 setting becomes

effective.03 o x

Always orients the spindlecounter-clockwise.

ox

Always orients the spindleclockwise.

xX

04 Sets the initial orientationspeed of the spindle:Approx. 60 x (spindle position

loop gain, sec rpm

Since the position loopgain of spindle is

5 secinitial speed is about300 rpm without limita¬tion.

x x

-1in general, the

Limits the initial orientationspeed to 1/3.

o x


ox

05 For DC spindle servo unit.xo

For AC spindle servo unit.x o

- 46 -

Note 1) o indicates short, while x indicates open.Note 2) Use of the TEST MODE

(1) Turn on the spindle orientation command.(2) Spindle orientation end signals (0RAR1, 2) are not sent.(3) The spindle turns at the initial orientation speed, while the SW1

(INITIALIZING BUTTON) is being pressed and the spindle stops at thespecific position when SW1 is released.)

(A) Red LED7 lights in this mode.2) LED

7 are mounted on spindle orientation controlThe following table shows their display

Seven indicator lamps LED1circuits CR, GR, CSII and GSII.contents.Neither LED1 nor LED2 is mounted on PCB of 01A version.

LED display contents

Lightingcolor

Display contentsLED Description

Lights when spindle orientationcommand is given (0RCM1 and 2 areshorted).

1 ORIENTATION(In orientation)

Green

Lights when LOW clutch (gear)signal is turned on (*CTH1 and 2are shorted).

2 LOW Green(LOW clutch (gear))

3 MS PEAK LEVEL(Magnetic flux detectionsignal peak value adjust¬ing indicator)

This adjusting indicator lightswhen the peak value of the magneticflux detection signal (MS) exceeds+10 V.

Green

A SLOWDOWN PERIOD(Low-speed rotation periodadjusting indicator)

Lights when the spindle approachesthe stop position and entersthe low speed rotation area duringspindle orientation motion.

Green

Lights when the magnetic fluxsignal (output) value is within thesetting range of 0.1° as aconverted spindle angle.This LED5 may also light when thesensor is not positioned on themagnetizing element.

5 IN POSITION FINE(In-position adjustingindicator)

Green

6 IN-POSITION(In-position)

Lights when the spindle is within+1° of the aimed adjusting positionafter completion of spindleorientation.orientation end signal (0RAR1 and 2are shorted) is sent when this LEDis lighting in a mode other thanTEST mode.

Green

The spindle

Red7 TEST MODE(In test mode)

Lights when setting terminal SH01pins are shorted. The orientationend signal is not sent in this modeeven if the orientation motion isexecuted.

A 7 -

3) Setting variable resistorsAdjust the variable resistor as shown in the following table before startingadjustments.Asterisked items are readjusted during adjustment procedure described later.Set these items also as the preliminary setting.

Adjusting variable resistor

Variable resistorOrientation

RV3RV1 RV4 RV5 RV6 RV7 RV8 RV9 RV10 RV11 RV12 RV1 2RV2

* * ** * * * DC AC

ARII , BRII,ASH, BSII ,CSII, GSII

5.0 6.0 See See See 2.0 5.0 2.0 5.0 5.0 0 7.0See(a) (a) (b) (c)

5.0CR

8.06.0 5.05.0GR

a) RV3, RV4Follow the distance H between the rotational center of magnetic elementand center of sensor head surface.

60To To ToTo To To To ToTo

H (mm) to9080 85 95 10570 75 100 110

65

6.0 4.0 3.0 2.5 2.0 1.5 1.07.0 5.0 0.5Division

b) RV5Follow the number of HIGH spindle rotation (Nhm) at rated speed.

2000ToTo To To ToTo To To To

Nhm (rpm) to4000 45002500 2700 3100 3500 5000 5500 6000

2200

7.5 6.5 4.5 2.5 2.0 1.5 1.05.5 3.5 0.5Division

c) RV8Follow the gear ratio Rh/1 of HIGH/LOW spindle.

ToTo To To ToTo ToTo ToToRh/1 3.7 4.4 5.3 6.0 7.02.8 3.22.52.0 2.2

10.07.0 8.0 9.06.0 9.54.0 5.02.0 3.0Division

54 6

73 o o8291

100

Division of variable resistor

48 -

4) Adjusting variable resistorsAdjust RV1 - 12, 12DC, and 12AC according to the following table. Adjust theoffset and gain of spindle control circuit PCB before adjusting the orienta¬tion circuit. When RV12 and RV13 of the spindle control circuit PCB arechanged, the stop position may be deviated.

Table 7.3.2 (b) Adjusting variable resistors

Set the test mode for the following adjustments by shorting SH01 pins.


Item to beadjusted

Adjusting method(specification)

Item Conditions

RV1 TS OFFSETTachogeneratoroffset.sation for thedifference of theslow down time innormal and reverserotating direc¬tion)

Compare the slowdown time during theorientation innormal and reversedirections aftercompletion of thisadjustments.

The standard settingvalue is 5 divisions.Adjust RV1 until thedifference of theslow down timebetween normal andreverse rotationbecomes shorter than0.1 sec.

1

(Compen-

2 RV2 MS PEAK LEVELMS signalamplitude value.

Keep pressing SW1(initializingbutton) .

Set VR2 to the posi¬tion where LED3 (MSPEAK LEVEL) startsflickering.

See 7.3.2 (3)-(a).RV3 SLOWDOWN REFERENCESlowdown speedreference.

3

See 7.3.2 (3)-(a).4 RV4 AMS PEAK LEVELAMS signalamplitude value.

LED4 (SLOWDOWN

PERIOD) shouldclearly light at amoment just beforethe spindle stops.

SLOWDOWN TIME INHIGH MODESlowdown time inclutch (gear) highmode.

5 RV5 Set the clutch(gear) HIGH mode.Stop the spindle atthe fixed positionby depressing SW1once.is OFF (option).

*CTH signal

GAIN (H)Position loopgain.

6 RV6 Turn RV6 clockwiseto such an extent asdoes not cause anyovershoot when thespindle stops.

Same as specifiedabove.

LED5 (IN-POS FINE)

should light duringlighting of LED6(IN-POSITION) .

IN-POSITION (H)

Spindle stopposition (H) .


7 RV7

- 49 -


Adjusting method(specification)

Item to be

adjustedConditionsItem

LED (SLOWDOWNPERIOD) shouldclearly light at amoment just beforethe spindle stops.(See item 5 in thistable. )

Set the clutch(gear) LOW mode.Stop the spindle atthe fixed positionby depressing SW1

*CTH signal

SLOWDOWN TIME INLOW MODESlowdown time inclutch (gear) lowmode.

RV88

once.is turned on(closed) .

GAIN (L)

Position loopgain.

Turn RV9 clockwiseto such an extent asdoes not cause anyovershoot when thespindle stops.


RV99

LED5 (IN-POS FINE)

should light duringlighting of LED6(IN-POSITION).

IN-POSITION (L)

Spindle stopposition (L) .


RV 1010

The spindle stopposition can befinely adjustedwithin a range +1°the spindle angle.

POSITION SHIFTSpindle stopposition shift.

RV 1111

Adjust RV12 when DC

spindle servo unit

is used.

Standard adjustingvalue: 0 divisions.

RV 12 HIGH GAIN DC

High gain.12

DC

RV12 Adjust RV12 when ACspindle servo unit

is used.


13 HIGH GAIN AC

High gain.AC

After adjustments, cancel the test mode, and make sure that the LED7 (red)goes out.

50 -

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- 52 -

7.3.3 Setting and adjusting spindle orientation control circuit in 2-step speed spindle for high speed type

Following functions are required:Models IS - 3S : Orientation GR (A06B-6059-J121)

PCB (A16B-1300-0111)

Models 6S - 22S: Orientation GSII (A06B-6059-J141)

PCB (A20B-0008-0033)

See Fig. 7.3.2 (a), (b).Setting and adjustment of PCB are described below.1) Setting jumpers SH01-SH05Table 7.3.3 (a) shows the setting and functions of jumpers.jumpers by the MTB.The jumper SH01 is provided for adjustment and test.turning on the power, and always open it after adjustment.Make sure that LED7 goes out.

Select these

Set this SH01 after

Table 7.3.3 (a) Setting jumpers (SH)

Jumpers(The double frame indicates standard setting)

Setting(Note 1)

Function RemarksSH 1-2 2-3

(Note 2)Sets the test mode.01 Set for adjustment only.o

02 Rotates the motor shaftclockwise when the orientationcommand is given beforeoperating the spindle afterturning on the power.

SH03 setting takesprecedence of SH02.This is effective onlywhen 1-2 pins of SH03 areshorted.

xo

Rotates the motor shaftclockwise when the orientationcommand is given beforeoperating the spindle afterturning on the power.

x o

03 Orients in the direction of thespindle rotation just beforethe orientation command wasgiven.

SH02 setting becomeseffective.

o x

Always orients the spindlecounter-clockwise.

x o

Always orients the spindleclockwise.

x x

- 53 -

Setting(Note 1)

RemarksFunction2-31-2SH

04 Sets the initial orientationspeed of the spindle:Approx. 60 x (spindle position

loop gain, sec rpm

Since the position loopgain of spindle is

5 secinitial speed is about300 rpm without limita¬tion.

x X

-1in general, the

Limits the initial orientation

speed to 1/3.o x


ox

05 For DC spindle servo unit.xo

For AC spindle servo unit.x o

Note 1) o indicates short, while x indicates open.Note 2) Use of the TEST MODE.

(1) Turn on the spindle orientation command.(2) Spindle orientation end signals (0RAR1, 2) are not sent.(3) The spindle turns at the initial orientation speed, while the SW1

(INITIALIZING BUTTON) is being pressed and the spindle stops at thespecific position when SW1 is released.)

(4) Red LED7 lights in this mode.2) LED

Seven indicator lamps LED1circuits GR and GSII.

7 are mounted on spindle orientation controlThe following table shows their display contents.


Lightingcolor

Display contentsLED Description

1 ORIENTATION(In orientation)

Green Lights when spindle orientationcommand is given (0RCM1 and 2 areshorted) .

2 LOW Green Lights when LOW clutch (gear)signal is turned on (*CTH1 and 2are shorted).

(LOW clutch (gear))

3 MS PEAK. LEVEL(Magnetic flux detectionsignal peak valueadjusting indicator)

Green This adjusting indicator lightswhen the peak value of the magneticflux detection signal (MS) exceeds+10 V.

- 54 -


Lightingcolor

DescriptionDisplay contentsLED

Lights when the spindle approachesthe stop position and entersthe low speed rotation area duringspindle orientation motion.

Green4 SLOWDOWN PERIOD(Low-speed rotation periodadjusting indicator)

Lights when the magnetic fluxsignal (output) value is within thesetting range of 0.1° as aconverted spindle angle.This LED5 may also light when thesensor is not positioned on themagnetizing element.

IN POSITION FINE(In-position adjustingindicator)

Green5

Lights when the spindle is within+1° of the aimed adjusting positionafter completion of spindle

The spindle

6 IN-POSITION(In-position)

Green

orientation.orientation end signal (ORARI and 2are shorted) is sent when this LEDis lighting in a mode other thanTEST mode.

7 TEST MODE(Test mode)

Red Lights when SH01 pins are shorted.The orientation end signal is notsent in this mode even if theorientation motion is executed.

3) Variable resistorsAdjust the variable resistor as shown in the following table before startingadjustments.Asterisked items are readjusted during adjustment procedure described later.Set these items also as the preliminary setting.

Setting and preparation of variable resistors

RVI RV2 RV3 RV4 RV6RV5 RV7 RV8 RV9 RV10 RVI1 RVI 2 RV 12A A A A A A A A DC AC

Variableresistor

scaleposition

5.0 5.0 See See See 2.0 5.0 See 5.0 5.0 5.0 0 8.0(a) (a) (b) (c)

a) RV3 , RV4Follow the distance H between the rotational center of magnetic elementand the center of sensor head surface.

40To To To To ToTo To To ToH (mm) to50 55 60 7065 80 90 100 11045

Division 9.5 7.0 4.05.0 3.0 2.5 2.0 1.5 1.0 1.0

- 55

b) RV5Follow the number of HIGH spindle rotation at rated speed.

6000To To To To To To To To ToNhm (rpm) to

7000 7500 8000 8500 9000 9500 10000 11000 120006500

Division 6.0 5.0 4.5 4.0 3.5 3.0 2.5 2.5 2.0 1.0

c) RV8Follow the gear ratio Rh/1 of HIG/LOW spindle.

To To To To To To To To ToRh/12.2 2.5 2.8 3.2 3.7 4.5 5.0 6.0 7.0

Division 2.0 3.0 4.0 5.0 6.0 7.0 8.0 8.0 9.0

54 6

73 o o a291

100

Division of variable resistor

4) Variable resistor

Adjust variable resistors RV1 - 12, 12DC, and 12AC following the table listedbelow.gain of the spindle control circuit PCB to adjust the variable resistors.Note that the position may deviate when RV12 and 13 on the spindle controlcircuit PCB are changed.

For adjusting the orientation circuit, first adjust the offset and

Table 7.3.3 (b) Adjusting variable resistors

Set the test mode for the following adjustments by shorting SH01 pins.

No. Name Item Conditions Procedure

RV1 TS OFFSETTachogeneratoroffset.sation for thedifference of theslow down time in

forward andreverse rotationaldirections)

1 Compare the slowdown time during theorientation inforward and reversedirections aftercompletion of thisadjustments.

The standard settingvalue is 5 divisions.Adjust RVl until thedifference of theslow down timebetween forward andreverse rotations

becomes shorter than0. 1 sec.

(Compen-

RV2 MS PEAK LEVELMS signalamplitude value.

2 Set VR2 to the

position where LED3(MS PEAK LEVEL)

starts flickering.

Keep pressing SW1(initializingbutton) .

See 7.3.3 (3)-(a).RV3 SLOWDOWN REFERENCESlowdown speedreference.

3

56 -

No. Name Item ProcedureConditions

See 7.3.3 (3)-(a).4 RV4 AMS PEAK LEVELAMS signalamplitude value.

LED4 (SLOWDOWNPERIOD) shouldclearly light at amoment just beforethe spindle stops.

5 RV5 SLOWDOWN TIME INHIGH MODESlowdown time inclutch (gear) highmode.

Set the clutch(gear) HIGH mode.Stop the spindle atthe fixed positionby pressing SW1once.is OFF (option).

*CTH signal

GAIN (H)

Position loopgain.

6 RV6 Same as specifiedabove.

Turn RV6 clockwiseup to the level notto make an overshootwhen the spindlestops.

IN-POSITION (H)Spindle stopposition (H) .

LED5 (IN-POS FINE)



LED (SLOWDOWNPERIOD) shouldclearly light at amoment just beforethe spindle stops.

RV88 SLOWDOWN TIME INLOW MODESlowdown time inlow clutch (gear)mode.

Set the clutch(gear) LOW mode.Stop the spindle atthe specificposition by pressing

SW1. *CTH signalis turned on.

GAIN (L)

Position loopgain.


Turn RV9 clockwiseup to the level notto make an overshootwhen the spindlestops.

IN-POSITION (L)Spindle stopposition (L) .

LED5 (IN-POS FINE)



11 RV11 The spindle stopposition can befinely adjustedwithin a range +1°of the spindleangle.

POSITION SHIFTSpindle stopposition shift.

12 RV12 DC HIGH GAIN DCHigh gain.

For DC spindle servounit.


RV12 AC For AC spindle servounit.


13 HIGH GAIN ACHigh gain.

- 57 -

After adjustments, cancel the test mode, and make sure that the LED7 (red)

goes out.

7.3.4 Checking method of spindle position loop gain

The spindle position loop gain can be checked according to the followingprocedure. Check it after adjusting the spindle orientation control circuit.

Checking procedure of spindle position loop gain

Set the mode to TEST mode (LED7 ON) after shorting SH01 pins.1

Release 1-2 and 2-3 pins of SH04 to release the limit of orientation

speed.2

Measure spindle rotation (Ns(H), Ns(L), rpm) when SW1 (initializingbutton) is pressed (on) and the spindle clutch (gear) is set to HIGH(*CTH1, 2: Open) and LOW (*CTH1, 2: Close), respectively.

3

The spindle position loop gain can be obtained by the followingformula.Kp (H or L) s Ns (H or L) / 55 (sec )

where Kp (H): Position loop gain when the spindle is set to HIGH gear(clutch) .

Kp (L): Position loop gain when the spindle is set to LOW gear(clutch) .

4

58 -

APPENDIX

>“0"UmAMP

connectorhousing

350720- 1Socket

350689 1

AC spindle servo unit Zo

cxi CN2 AC spindle motorconnector

CM X34 \ Li ia s AH 1 PA OVLDIi CN2VK 5 3 | 2 | 1 AMPhousing

350782-1

Signc]J_i Z 1 5 Z K 4D aMR - \ S AH 23

RA j-'LMagneticscabinet

PB I PA -*-5 VLUT2 . OH 2O50LFH 3.a 16 TIQ

6 5 4 OMR-20LFHARSTl SST 1 PB OH 1 PmKB RA OV zRB t

i'> 4 _iill T1 350690-1i i A zARST2 SST 2 —-—l 8 7G Ga 7 5 I B 521 mVPowerbT JL line

OH 2 i SS • OH 1TLM ou

3H 2? 6 Qj HK2 U . Z V , X W . YV Gl—Li—ORARl OT VO~5V r-7

SS Xi39 23 /

Ww l’ ZV w GORAR2 MRDY1“T1To T«• AT Crimp style

terminalScrewterminal M5 OMRDY2 T 1

—1 1_

Z1 9 Fan motor cableR >a ORQ11 TLM5 S m-n

o4 2 26 1 0 FMU FMV FMWT 73ACORCM2 TLM6O G >Spindle motorScrew

terminalM4Power

transformer(option)i ,

43 21 11o i 1 sALMlNo»fusebreaker

I 1

iD 4 4 ;

_2B 11 M49—1(0 VR ALM2a W4 5 2 9 1 3

O R J i <5”~b- i6 SFR.-15V OR4 6- 5 1)

IsDI 1

Fan motorof unit

] •;it5: S JL KJJS TSRV OS6— i iQ)

DO ±J 31 1AIi i3 ESP 1 DA2 SDT I-16 i I I3 o A TA TbG T2 ji ESP2 E SDT 2! I a Resistor unit

Standard (

4 ID i3 17

xir>_L2-l KB

b-JM4 T 3- 1Crimp style

terminalI5ni mo LMl CTH )I AC line filteria lkW5LQ

2. I SMI / \ OMm

Crimp styleterminal [A03Crimp style

1 terminalco i j

i Fuse (5A) of--JNo-fusc breaker

AC power3-phase 240 - 480 VAC

i

DiThermostat line

:K3

K9

To magnetic cabinet control panel

Note) The fan motor of unit and no-fuse breaker are prepared by the MTB.

AMPconnectorhousing350720- 1

Socket350689- 1

AC spindle servo unit

CNI CN2AC spindle motorConnector

T3 T 14 !CNI SAR 1 PA OV

03i Z 1 5 CN2 3 2 1 AMP

housing350782-1

K5 S AR2 9RA OH2 aD K 4 Signal PBMR- PA x5VTl 35 1 9 1 \ B 3 line50LFH TTTARST1 SST 1 PB OH1 6cp 5 4Magneticcabinet

Pm3 t) 20 1 n 4 MR-20LFH RB RA OV 350690-1CN3 SST2ARST2 RB9K6 B 7at 3 7 2 1 5 fiT 5) U PowerIJTLMH TLML 1 j OH 2 SS OH 1MP- lineTlV3d 2 2 tT VI 9 6.2 0LMHO i ORAR1 OTo w u , zK 2 V , X \V , VVV GOM + 5V3 9 23 7 20 7

ORAR2 NflDYl+24 V SS UG V w GK7a SMI G4 n 24 tis Crimp style

terminalCTM MRDY2TB LMlO' Crimp style

terminal(Tl*4)

•it 2s I OM1 TB3ORCMl TLM5+5 V

2 SMI42 2 B 1 5 T2D2 R0 K 33 LMl R0ORCM2 TLM6 TlCQ ACON R0 SO TO3 4 a 27 11ro R so Spindle motorSO3 OVR1 ALM1-IS V iSXNo-fuse

breaker20 7 II 28 124 4 13 TOT TO-3 OVR2 ALM2 COM I1 9 6 Go R 2 9 13AC power

3-phase

4 5 1 2 iQ- U-15V ORSFR I1 6 5Rro_ o v4 6 30 1 4 »1 1LPT2in SPower

s , transformer—Q(option) r>

iSRV OS II A L8 4 W8 I

K 1 LUTl 1031 T5 I7

r° °i_

j-cT"i J

1 6 . AL4 3T DA2 SDT 1ESP 1I

MOFFl 915 IAL2 2

"I (ro T212 If,48ro240 * .

T

480 VAC

1

ESP2 E SDT200 G MOFFl1 849 1 714 1 AL 1 l 1LMl CTH ICrimp style

terminalG

50 1 riCN3 ISMI OM

t I

Fan motorof unit

I

Note) Fan motor and no-fuse breaker are provided by the MTD.

Spindle servo unitCN1A 9 4 7 4 65 n 4 5 43 1 2 39 384 H 4 4 4 1 4 0 37 36 3 5 3 1 3 3MR-50RMA

TlCN1 SM 1 LM1 ESP 2 ESP 1 SRV SFR*P

CNC cabinet ormagnetic sequencecontrol

\K5 3 2 3 1 30 2 9 28 2 7 26 23 22 1 925 2 4 2 1 20

DA 2 H5V ORCM2 ORCM1 ORAR2 ARST2 ARST1r \ 71 8 1 6 1 5 1 1 1 3 1 2 1 0 091 1 08 07 06 05 03 02 0 1{/) 04

MR-50LFH*& OM CT1I SDT2 S DT 1 OS OR A LM 2 ALM2 TLM6 MRDYl OT TLMTLM5 MRDY2 SST2 SST1 SAR2 SARI3

&reO MR-20LMH2. CN 9re

To magneticsequencecontrol

re CNC rS& Orientation control circuitK8 ]o3 CNA.CNB CNC8 2 0 9 1 8 1 7 1 6 1 5 1 4 1 5 1 6 1 7 1 8 1 91 4 203

CNB3 OG *SC*FB PB *P A PA SC OL HI 2 HI 1 HI 0 HO 9 HO 8 HO 7To CNC cabinet J4re]

X X X08 09 1 0 1 1 1 2 1 31 3 1 2 09 08l 1 1 05'l3 NZZ NZX 1 IB HAMR-20LFHo> 9:

LO 06 1 0507 04 0203 0 1 0 1 0 2 0 3 0 5 0704 06reca

I + 1 2N 1 511 + 5H OH OH OH HO 6+ 5H HO 3 HO 2 H01HO 5 HO 4reCNA3

J3oQ.

2. MR - 20RMA (CNA, B)<-n

£cnMachine tool side

|J Gear or belta SpindlemotorTo manual pulse generator

To proximity switch Tornear zero point

£

zr iK21o

i Tool

21. Position coder Spindle

bio I

3

I Directly coupled or timing belt

re

Note 1) Signal cable K22 applies to spindle orientation BRII.

Spindle servo unitCN 1

5 0 I 9 4 8 7 4 5 1 3 3 9i 6 1 2 4 1 4 0I 4 38 3 7 36 3 5 3 1 3 3MR-50RMA(Wl\ SMI ESP2LM1 ESP 1 SR V SFR

CNC cabinetor magnetic-sequence

\ 3 2 303 1 2 9 28 26 2 427 2 5 23 22 2 1 20 1 9-n

E DA 2 + l 5 V OVR2 OYR 1 ORCM1 CTMORCM2 ORAR2 0RAR1 TLMH ARST2 ARST1f

ra 1 8 1 7 1 6 1 5 1 4 1 3 09 081 2 1 1 1 0 0 7 06 0 5 0 4 03 0 2 0 1MR-50LFH

OM CTM SDT2 S DT 1 OROS A LM 2 TLM6 MRDY2MRDY1 OTALMl TLM5 SST 2TLML S ST 1 S AR 2 SARIGO

aMR- 20LMHra

O CN 9S' To magnetics

sequence3 -ECNC r 1Orientation circuitK22 1o‘D CN A , CNB CNCo

20 1 81 9 1 7 1 6 l 5 1 4 1 71 4 1 5 1 6 1 8 1 9 205 CNBTo CNC

cabinetOG * PB *SCPB *PA PA SC OL HI 2 HI 1 HI 0 HO 9 H 0 7HO 8o

J4oI

08 09 1 0 1 1 1 31 21 3 1 2 091 1 081 0ON S: MR- 20LFH NZZ NZX HB HA0}

inI 3 07 06 0 5 04 03 02 0 1 0 2 0 30 1 0 4 0 5 06 073

i 1 2N + 5H + 5H + 5H OH OH OH HO 6 1105 H 0 4 HO 3 HO 2 HO 13 CN Ao& Jurnco

MR - 2 0RMA ( CNA , B )roK)

GO

1 Machine mGear or belt~o

Spindle motorgSome of lines are connectedto the manual pulse generatorand the near zero switch.

5 so3 f ToolK21o

'{][s- tC=>znPosition coder Spindle3

\1 E=]II

Note 1) Signal cable K22 is used for the spindleorientation BSII.

Direct coupling or timing belt

&

|CNA| Manual pulsegeneratorOrientation control

circuit A/B, AS/BS tOH)HA =6 5

O OLu>9> n<> HU I* o

T ooI 5 V 1 TP(ni )(n2)(0.i i

T i0 OH __r-_ 1 I 2N

Oi r.vI Open I.1

fill9 (0 11(05 '(OtiO +5H —i - -I -

+5V power is suppliedfrom CNC cabinet

Proximity switch for near zeropoint

(101

2:O NZXTo CNC cabinet via

connector CNB

Cfc-rMl) I

NZZ

07)+12N — (Note i) Wlien manual pulse generator

and proximity switch for near7.cro point are not used, HA

HU. NZX, NZZ and +12Nneed not be connected.

-4 —l

(20 • OG

i OG

9 OV

-==" Shield grounding

Open |(Note 2) AS/US type applies to

model l/2/small model 3.i

Position coder

~dJ K (OV)

i

-=& H (+5V)

(1 ti 1

I<S PA A (PA)4,000 rprn6,000 rpmposition codersign'd input

M7) N (*PA)-PA

iiiil—A PB C (PB)i

(19)O R CPU)*PB

(14)B (SC)sc

(16) pesoo *sc

Fig. 1 (e) Spindle orientation connection diagram using position coder(For lathe and synchronous feed of machining center)

65 -

Orientation control circuit

I CNA I+ 5 V Position coder

+ 5V ( 01 )( 02 U03+5V is supplied byspindle servo unit -O OH <1 K ( II V )

Lower than•lOO in A

Short

SH (04)(05)(06f5H OH ( *ÿ f> V )

( 2000

00

OV

4000 rptn, 6000 rpttiposition codersignal input

116)-7)PA A l PA )

117 1 •PA N(*PA)

( 1 II )PB Cl PB )

(19) -6 *PB —i- R ( PB I

L 11), SC Bi SC 1

(15) *SC P(s

Note) The cable length should be shorter than 20 m between the servo unit andthe position coder.

Fig. 1 (f) Spindle orientation connection diagram using position coder

(Only spindle orientation for machining center is used)

66 -

1Orientationcontrol circuit CNA

Position coder+ 5V

X+5Vy5H ( 01 UOSU 06 )

(0 1 )( Q2)( 03 ) -6 OH K (0V)

Lower than400 mAA H (4 5V )t 511

(20)00

i oo

40V4000 rpm, 6000 rprnposition codersignal input

(16)A ( P A )<> PA —f

(17)o * PA •6 N t t PA )

(18)A C( PH )A PU

(19)-6 R ( * pH )A *PB

(14)-6 IK SC)-6 SC

(15)A *sc O Pi 4SC )

CBN is relayed or +5V poweris supplied from CNC cabinet forsynchronous feed control.

Magnetic sequencecontrol circuit1 CNC|

(07) 110 1 12°

(06) HO 2 2 2 1

?(05) i 110 3 4

2JConverter circuit

4 0 9 G

=360°24 20 4 B

=180°10 2 4

=90°5 1 2

=45°2 4 I

=30°

(04) BA-11.0 4 23Stop positioncommand signal (03) HO 5 1 6

Q

(02) 2 2HOb 23i

(20) 1H07 2ttjk

(19) HOB 1 2 H 2 7

(18) 2 5 f>A_a°i 2"

(17) HI 0 5 1 22®

06), 102 4111 1i

2 io

(15) H I 2 2 04 80- 2 11

(14) OL

fStop position command * T"*

Fig. 1 (g) Spindle orientation connection diagram using position coder(External command of stop position)

67 -

rWaveform conversion circuit

A2OB—90 00 —0180

CNl

OH I O-OH2 O-

Thermostat0V01 VZ14

DH208Tl0 V02 1 5

0 9 DH103AMP 16 VAAMP

CNC10plugcap 5 V0 4 *VA17zr350783-1socket350689-6

350735-1 1 15 V05 VB18pinco 1 2CNl 350706-7 06 *VB19Built-in sensor KOI 13ffl 07 20 OG2:

CNlCD

K0 0 CNlo

IV2. 1 4 CNlconnectorMR-20 LFM

CD3 *VA VA2 5CJ CN2

CN2*VB VB3 6o K043SC14 OH01HONDA connector

CN1.CN2Z-374HONDA contactCNl , CN2HKP-F413

s 08I1 5 *SC OH023 AMP plug 09CN2ON 3

PA16 OH03CDOO a 105 V 5 V1 4 AC spindle servo unit*PA17 +5H0 45 V VZ1 7O' 1 13 VZ 52 PB18 05 +5HVA2 8

Ss 120 V 0 V3 6 *PB +5H1 9 06*VA3 9CD

13cnOG20 070 V DH104CD

CNB3VB SS5 1 1 CNB

connectorM R—20 LFH

cOrientationcontrolcircuit

52. *VB DH6 123ta

CNAcrE. CN3 K02[}ov01 PA14

CNAconnectorMR-2 0 LFH

3 08 CN2connectorMR-20 LMH

02 OH2 RA15£ 093 PB03 OH 1AC spindle motor 16tn

J 10o

[}04 RB {]17

K0305 1812 CN 3

connectorMR-20 LFH

CN2 -connectorMR-20 LFH

06 191 3 +5V

07 SS20

Spindle servo unitCN1MR-50RMA3 4 9 j 4 fi 4 7

I.M1 ESP 2 KSPl

334 6 45 39 38 37 36 3 5 345 0 4 3 4 2 4 l 4 04 4iCN1

\ SR\ SFRSMICNC cabinet ormagnetic sequence K5control

32 3 1 28 27 25 24 2330 29 26 2 122 20 1 9

E AHST2 AKST1HA 2 ORCM2 ORt Ml ORAR 15 \ 10RAK2I2 /1 7 07 061 8 1 6 1 5 1 4 1 2 1 1 1 0 0 9 08 0 5 04 03 02 0 11 3/S: MR-50LFH <T1I SPT2[S1)T 1 OSOM OR A LM 2 A LM 1 TLM6 T LM 5 MRP> 2 MHJiYl OT TLML SST2 SST I SAR2 SAR 1CD

o2.CD

CN9Hao 4r -1

8Orientation control circuit

3iCD 20 1 9 1 8 1 7 1 6 1 5 1 4 i

MR - 2 0HMACNA5* OY T 1 5 V LSB LSA MSB MSAOO\I 3

12' II1 3 09 081 0aONCDVO U3

/CDI 07 06 0 5 03 02 0 1043MR

3 20LFH

s. _l2.in

CO

8Machine tool side 3 Gear or belt

Spindlemotor

=r3 i£ ia Tooli

CD

o' Magnetizing element Spindles3 Metal plug socketin

K21O

O Magnetic sensor

Amplifier

Spindle servo unitCN1MR-50RMA

CN1'i 50 49 48 47 45 43 42 40 3946 44 41 38 37 36 35 34 33

IX LM1 ESP 2SMI ESP1 SRV SFR21 CNC cabinet

or magnetics K5sequence

2532 31 30 29 28 27 26 24 23 22 21 20 19

E DA2 4- 15V OVR2 OVRl JRCM2 ORCM I CTM ORARZ ORAR10 ARST2 AR5T1

/ 1 8 17 16 14 1315 10 0812 11 09 07 06 0304 0205 0100 MR-50LFHS, OM CTH SDT2 OR \LM2SDT 1 OS ALM1 TIM6TIM5 OT TLML SST2 SST1 SAR2 SARIMRDY2 M RDY 13— Irao5'

CN93t 1o’

3

s Orientation control circuit3 I20 15 1419 18 17 16g MR-20RMAa OG LSB LSA MSB MSAov 4-15VCNA\o’

13 12 080911 10I

*B:

>ÿ j £o a 07 05 03 02 0106 04 iMR2I2 0LFH

2o

18- _iSTCDC/3

IO

£an

Machine tool side3*

Gear or beltSpindle motorCJuc I 1g I

Toola Bn

is SpindleMagnetizing element5 fcJQ

Metal connectori

K 13 Magnetic sensor

Amplifier

Orientation control circuit

Metal connector Magnetic sensoramplifierCNA

04)I AA MSA

IISD1MSB

06)LS A F

iii07) A LS B i

E

OS A + 1 5 V c

13_A ov Bv

M <|) OQ

iOV

Note) The cable length should be shorter than 20 m between the servo unit andthe magnetic sensor amplifier.

Fig. 1 (k) Spindle orientation connection diagram using magnetic sensor

- 71

APPENDIX 2 CABLE ROUTING

To regenerative discharge resistor

a(o)

1 2T 2

1 2Spindle controlcircuit

A I II 00 0200

T 3

16TControl circuit

A16B 1100 02411To magnetic

circuit(PCB 1)

(PCB 2)

CN1 CN 2T 1

K S T GGUVW

Regenerative dischargeresistor unit

(o) (o) (o) to) (o) tot

From 3-phaseAC power

To magnetics To AC motorcabinet or CNCcabinet

To AC motorpower line

Fig. 2 (a) Cable routing (models 1S - 3S)

72 -

Spindle control circuit

A20B 1003-0010Control circuit

A2011 1003-0020

(PCB 1 )

(PCB2)

CN1 CN3 CN2 TBT2 T I

fcfefcfl R S T G II V W

To speed andload meters

It S T G G LI V VVI o) 1 ©

To AC motorTo magnetics cabinetor CNC cabinetTo fan motor

of unit

To fan motor From 3-pliase To AC motorof motor power power line

Fig. 2 (b) Cable routing (models 6S - 12S)

73 -


Control circuit A20B 1003-0010

A20B -1 003—0120

(PCB1)

(PCB2)

CN1 CN3 CN2 TB

To speed meter andload meter

T2 T1

felfefeJ R S T G U V W

MMMMmTo AC motor

To magneticscabinet or CNCcabinet

RSTGGU VW3} <f > © ©

To fan motorof unit

To fan motor From 3-phaseof motor AC power

To AC motorpower line

Fig. 2 (c) Cable routing (models 15S - 22S)

\

74 -

APPENDIX 3 CABLE SPECIFICATIONS

The cable specifications are as shown below.1) Power and drive lines

Cables are provided by the MTB.

FANUCspecification

No.SymbolModel Specifications

Cablyre cableJ IS C" 33124 conductors

K1 A06B-6052-K201IS(Lower than5 kVA)

K2 7 m

f1 2.0 037/0.26

(2.0mm1 )Crimp styleterminalsT2-4

Crimp styleterminalsT2-4

Cabtyre cableJ1S C 33124 conductors

K1 A06B-6052-K2021.5S, 2S(Lower than

7 kVA)K2 7 m

I

T45/0.32

(3.5nmi3)1 4.00

Crimp styleterminalsT5.5-1


Cabtyre cableJISC33124 conductors

3S K1 A02B-0008-K853(Lower than12 kVA)

K2 7 m

i

1 0.5070/0.32(5.5mm3)15.5 tp Crimp style

terminalsT5.5-6


Cabtyre cableJ IS C 33124 conductors

A02B-0008-K8546S K1(Lower than16 kVA)

K2 7 m

50/0.45(8nun3)

20 «Crimp styleterminals

Crimp styleterminals

8-6 8-6

Cabtyre cableJ IS C 33124 conductors

8S, 12S(Lower than25 kVA)

A06B-6044-K01 77 nt

K1 oQ.

O'

88/0.45(14mm3 )

24 <5OA06B-6044-K018K2 Crimp style

terminals14-6 (K.2: Drive line)

14-8 (K 1: Power line)

Crimp styleterminals14-6

7 m

75 -

FANUCspecification

No.Symb o1 SpecificationsModel

A06B-6044-K019K115SHeal resisting vinyl cable

(Lower than30 kVA)

K2 7 ml-oo—[

l—oO-t}—oo-C1-00-£

Crimp styleterminal14 - 8

Crimp styleterminalR14-6S

7/20/0.45(14 mm3)

Heat resisting vinyl cable18S K1(Lower than45 kVA)

K23—°o-t

j-oo-Cl-oo-C1-0o—[

7/27/0.45(20 mm3 )

Crimp styleterminal20-8(Note)


22S K1 Heat resisting vinyl cable(Lower than45 kVA)

K2l-oo-C1—0O—C1-0o—C

o-C

7/27/0.45(30 mm3)


Crimp styleterminal30-8

Note) Use the flame retardant poli-flex cable (MLFC)(Maximum temperature of conductor: 105°C)

76 -

APPENDIX 4 CONFIGURATION OF SPINDLE CIRCUIT

H

3 > -5 Oo o o U

-0--0-r n

XÿJ& ¥s f*-<J -o—o ---o—o- ---6-

N+ i

-6-<IY 10

Ty1+3

i J—6—6—< >-—( )—( >—6-—6-

1os!-o'<

nS Tro'u1

IIS'L_UXUXUX J fed

\KJ

1 1

r+-WV—I H- 'I I

•fSUShOS oBSqE-O£3 3/

JPS

' HI- Hh 1

CT"'6 6 6OS W El

6 6 6ocS W Ho

£-*

- 77 -

APPENDIX 5 LOCATION OF UNIT

1) Unit (models IS - 3S)

TR 1Transistor

C 1 DM1Capacitor

+Diode module

A50L-0001-0126 HE

A42 L- 0001-0142#A,

A50L-2001-0193#A

TH ThermostatA57L-0001-0071/'B95

TM 1

MC C TransistormoduleMagnetic contactor

A50L-0001-0125 #A

A58L-0001-0207 #A

A50L-6001-0347Heat sink

Spindle control circuit PCB (PCB1) :Control circuit PCB (PCB2) :

A16B-1100-0200A16B-1100-024Q

See Fig. 2 (a) in Appendix 2.

78 -

2) Unit (models 6S - 12S)

Thermostat

TH Display of charge

O(RED)LEDA57L-0001-0071/B95

ClDiode module

A50L-2001-0236Capacitor D1

+

A42L— 0001 — 020]

TM2

ACRTransistor module

AC reactor

A50L-0001 — 0175

A81L-0001 — 0096 TM2

MCC

FURTransistor module

FUSMagnetic contactor

FUT

FU(5A)A58L-0001-0264 A50L-0001-0175

T2

T1

Spindle control circuit PCB (PCB1): A20B-1003-0010Control circuit PCB (PCB2) : A20B-1003-0020

See Fig. 2 (b) in Appendix 2.

79 -

3) Unit (models 15S - 22S)

Thermostat

A 57L-0001-007 L/B95

LCDFUR(RCD)Til [ ZJFUS

IDCapacitor

A42L-0001-0201

D 1FUT

TM 1Diode module

ClA 50 L- 2001-0236\

TM 2C2

AC reactorACR

A 81L—0001-0098 moduleA50L- 0001-0175

TM3

/TM 4Magnetic contactor

A58L-0001-0264MCC1

MCC2 TM5

\

T2

T 1

Spindle control circuit PCB (PCB1): A20B-1003-0010Control circuit PCB (PCB2) : A20B-1003-0120

See Fig. 2 (c) in Appendix 2.

- 80 -

APPENDIX 6 LOCATION OF PCB

1) Models IS - 3S

ROM FI F3A(3.2A) (0.3A)001

SI

D PIL F3C(0.3A)O

ROM

002 F3EDisplay [ |RV 4 (0.3A)

Specification,version

F3GNOVRAMSwitch( 1.0A)

®ST nCN9RV1

| |RV 2

F2 (1. 0 A ) CN5

O ER

O VCMD o CLK1

O TSA O SLIPS 4 S 5

O0V O TS3

O -15V o TS 2

O DTDC0ss0 DDS2

1HIRV5 rLLM o O +5V

SM O O VDC0V o O IUIW o O IV

PAP o O +15V

+ 24V O O PBPO RB

O RA

o PB

- O PA

O DA2

RV 6

CN4

_I

CN1 CN2 n CN8 n

81

2) Models 6S - 22S

U CN8 UF3(1.0A)

CN10

]ROM002 F4 A( 0. 3A )

(1.0A)(3.2A) S 2FI F2 QROMOOl F4B ]C0.3A)1

]NOVRAM[F4C

CN6(0.3A)

Display

STPILO

F 4 FSwitch ]CN9 ( 1. 0 A )

F4GSI*RGHLD O

ADIN O

CLK1 O

SLP O

(0.3A)1CN5

F4H I I( 0. 3A )

[ + 24V O

SDC O O VDC+5V OOOV

+15V O O -15VTS3 6 O TSA

TSAF O O TSARTS2 O O 0V

VCMD O O 0VPBP O O PAP

0V O O IWDA 2 O O IV

ER O O IURB O O RAPB O O PA

F4 J [Specification,version ( 0.3A)

CN4

F4M(1. 0 A )I I

S 6A

B

C TBCN1 S 5 A, B CN3 CN2 1

- 82 -

APPENDIX 7 MAJOR PARTS

1) Models IS - 3S

Symbol Specifications RemarksName

Spindle control circuitPCB

PCB1 A16B-1100-0200

A60L-0001-0175/3. 2AFuse FI 3.2A

A60L-0001-0175/1. 0AF2, F3G 1.0A

A60L-0001-0175/0.3AF3A, C, E 0.3A

Control circuit PCB PCB2 A16B-1100-024

50A/600Vx6Transistor module A50L-0001-0125//ATM1

A50L-0001-0126//B 50A/600VxlTransistor TR1

A50L-2001-0193//ADiode module DM1

A58L-0001-0207//AMagnetic contactor MCC

A42L-0001-0142//ACapacitor Cl

A57L-0001-0071/B95Thermostat TH

A81L-0001-0083/3CAC line filter option

83 -

2) Models 6S - 22S

RemarksSymbol SpecificationsName


PCBA20B-1003-0010PCB1

A60L-0001-0046/1. 0Alarm fuse FI 1.0A

A60L-0001-0046/3. 2F2 3.2A

A60L-0001-0175/1. 0AF3, F4M,Fuse 1.0AF4F

A60L-0001-0175/0.3AF4A, B, C,G, H, J

0.3A

Control circuit PCB PCB2 A20B-1003-0020 Models6S - 12S

A20B-1003-0120 Models15S - 22S

A60L-0001-0031/5AFuse FUR, S, T 5.0A

120A/600Vx6Transistor module TM1 - 5 A50L-0001-0175

Diode module D1 A50L-2001-0236

Magnetic contactor A58L-0001-0264MCC

Capacitor Cl, 2 A42L-0001-0201

A50L-2001-0155/20D431

Surge absorber

A57L-0001-0071/B95Thermostat TH

AC reactor ACR A81L-0001-0096 Models6S - 12S

ACR A81L-0001-0098 Models15S - 22S

Terminal cover A300-0001-X088 Models6S - 22S(basic)

- 84

APPENDIX 8 MAGNETIC SENSOR SIGNALS CHECKING METHOD

8.1 ApplicationThis document applies to the following check procedure by observing outputsignals of the magnetic sensor (specification: A57L-0001-0037) employed formagnetic sensor system spindle orientation.

Item Check item

1 Whether magnetizer, magnetic sensor head, and magnetic sensor amplifierare defective or not.

Whether magnetizer and magnetic sensor head are properly mounted ornot ;

2

Whether magnetic sensor signal cables are properly connected withoutany connection failure and short-circuit.

3

8.2 Check Procedure1) Preparation

(T) Rotate the spindle at about 120rpm. Select the counterclockwise rotating

direction as viewed from the AC spindle motor shaft (in such a directionas the voltage at the test point (VCMD) of AC spindle control circuit PCBbecomes positive against 0 V.Models IS - 3S : A16B-1100-0200Models 6S - 22S: A20B-1003-0010

(2) Check the peak voltage and offset voltage levels of the following signalwaveforms at the test points of the orientation circuit (A20B-0008-0030

to 1 or A20B-0009-0520) using an oscilloscope. The names of test pointsand signal contents are common, irrespective of the kinds of orientationcircuit.

Prove commonterminal

Test points Signal name Symbol

CHI Magnetic sensor output singal A MSA0 V

CH2 Magnetic sensor output signal B LSA

- 85 -

APPENDIX 9 PARAMETER LIST

Note) Parameters made with * are used for models 6S - 22S.

Standardsetting

Mode Contents Data

F-00 Display of rotation number of motor

Use/non-use of machine ready signal (MRDY)F-01 1Use : 1

Non-use: 1

Use/non-use of override functionF-02 Use : 1 1k

Non-use: 1

F-03 Setting of override range 120% : 1 1

*100% : 0

Setting of maximum speed Dependsupon themotorspecifi¬cation

F-05

*High speedspecification

Standardspecification

Setting

- 5000 rpm - 10000 rpm 0

- 6000 rpm - 12000 rpm 1

- 15000 rpm 2

- 20000 rpm 3

Pattern setting of output limit 0F-06

SettingContents

Pattern 1 Pattern 2

No output limiting made 00

Output limit is made only atacceleration /deceleration

41

Output limit is made only atnormal rotation, not atacceleration /deceleration

52

6Output limit is made for alloperations

3

Rated maximum output is 100 100Setting of limit value at

output limitF-07

5Setting of delay time before shut-off of motor powerDelay time = (Set value) x 40 msec.

F-08

86 -

Standardsetting

Mode Contents Data

Use/non-use of shut-off of motor power bymachine ready signal (MRDY)

F-09 Use : 1 0

Non-use: 0

Velocity deviation offset adjustment at forward rotation

command (SFR)F-10 128

Velocity deviation offset adjustment at reverse rotationcommand (SRV)

F-ll 128

Velocity deviation offset adjustment at orientationcommand (OCR)

F-12 128

Rotation number adjustment at forward rotationF-13 DependsuponmodelsRotation number adjustment at reverse rotationF-14

Rotation number at velocity command voltage, 10 V

Rotation number = (Set value) x 100 rpmF-15

F-16 Detection range of velocity arrival signalDetection range = Within +(Set value) % of command

rotation number

15

Detection level of velocity detection signalDetection range = Less than (Set value) % of maximum

rotation number

F-17 3

F-18 Setting of torque limit valueTorque limit value = Less than (Set value) % of maximum

output

50

Setting of time needed for acceleration/decelerationSet value = (Acceleration time, sec) x 2

F-19 10

Limiting of regenerated power (Adjustment ofdeceleration time)

Setting range = 0 - 100

F-20 60

Setting of velocitycontrol phase compensation P:

F-21 50HIGH gear (CTH = 1)

F-22 Setting of velocitycontrol phase compensation P:

50LOW gear (CTH = 0)

F-23 Setting of velocity control phasecompensation P at orientation: HIGH gear

100

F-24 Setting of velocity control phasecompensation P at orientation: LOW gear

100

F-25 Setting of velocity controlphase compensation I: HIGH gear (CTH = 1)

30

87

Standardsetting

DataContentsMode

30Setting of velocity controlphase compensation I: LOW gear (CTH = 0)

F-26

30Setting of velocity control phasecompensation I at orientation: HIGH gear

F-27

30Setting of velocity control phasecompensation I at orientation: LOW gear

F-28

Adjustment of velocity detection offset (adjusted atshipping)

Approx.F-29128k

oSetting of rigid tap modeF-31

10Setting of normal motor voltageF-32

10Setting of motor voltage at orientationF-33

100Setting of motor voltage at rigid tap modeF-34

Setting of zero speed signal detection level 75F-35

Setting of load detection level 90F-36

Time constant of torque change at deceleration 0F-37

*

Setting of control characteristics at deceleration 0F-38*

Setting of control characteristics at stable rotationwith no load

0F-39

*

Setting of control characteristics at torque limit 0F-40k

88 -

Revision Record

AC SPINDLE SERVO UNIT S series MAINTENANCE MANUAL (B-65015E)

01 ‘87, 1 1

ContentsDate Edition DateEdition Contents

•No part of this manual may be

reproduced in any form.

•All specifications and designs

are subject to change without

notice.

Documents

AG Spindle Servo Unit S Series1.1.2 Models 6S-22S Models 6S-22S of S series AC spindle servo units consist of the following units. 1) Spindle control unit (basic) 2) Spare fuse (basic)