DRIVE UNITS BLI-D/VACIL/VACII MAINTENANCE MANUAL (4th Edition) Pub.No.3727-E-R3 (SE34-001-R4) June 1995. OKUMASE00-002-R1 P-(i) ‘SAFETY PRECAUTIONS SAFETY PRECAUTIONS 1. ‘The machine is equipped with safely devices which serve to protect personnel and the machine itself from hazards arising from unforeseen acoldents. However, operators must not rely exclusively on these safety devices: they must also become fully familiar with the safety guidelines presented below to ensure accident-tree operation. This instruction manual and the waming signs attached to the machine cover only those hazards which (Okuma can predict. Be aware that they do not cover all possible hazards. PRECAUTIONS RELATING TO MACHINE INSTALLATION (1) Prepare a primary power supply that complies with the following requirements. = Voltage: 200 = Voltage fluctuation: 10% max. ~ Power supply frequency: 50/60 Hz ~ Donot draw the primary power supply from a distribution panel that also supplies a major noise source (for example an electric welder or electric discharge machine) since this could cause malfunction of the NC unit. - If possible connect the machine to @ ground not used by any other equipment. Ifthere is no choice but tose a common ground, the other equipment must not generate a large amount of noise (such as an electric welder or electric discharge machine). (2) Installation Environment ‘Observe the following points when installing the electrical control cabinet. ~ Make sure that the NC unit will not be subject to direct sunlight. ~ Make sure that the electrical control cabinet will not be splashed with chips, water, or ol. - Make sure that the electrical control cabinet and operation panel are not subject to excessive vibrations or shock. - The permissible ambient temperature range for the electrical control cabinet is 0 to 40°C. = The permissible ambient humidity range for the electrical control cabinet is 30 to 95% (no condensation). = The maximum altitude at which the electrical control cabinet can be used is 1000 m (3281 ft.). POINTS TO CHECK BEFORE TURNING ON THE POWER (1) Close all the doors of the electrical control cabinet and operation panel to prevent the entry of water, chips, and dust. (2) Make absolutely sure that there is nobody near the moving parts of the machine, and that there are ‘no obstacles around the machine, before starting machine operation. (8) When tuming on the power, tun on the main power disconnect switch first, then the CONTROL ON switch on the operation panel.SE00-002-R1 P-(i) ‘SAFETY PRECAUTIONS PRECAUTIONS DURING MAINTENANCE INSPECTION AND WHEN TROUBLE OCCURS In order to prevent unforeseen accidents, damage to the machine, etc, It is essential to observe the {following points when performing maintenance inspections or during checking when trouble has occurred. (1) When trouble occurs, press the emergency stop button on the operation panel to stop the machine. (2) Consult the person responsible for maintenance to determine what corrective measures need to be taken, (8) If two or more persons must work together, establish signals so that they can communicate to ‘confirm safety before proceeding to each new step. (4) Use only the specified replacement parts and fuses. (6) Always tum the power off before starting inspection or changing parts. (6) When parts are removed during inspection or repair work, always replace them as they were and ‘secure them property with their screws, etc. (7) When carrying out inspections in which measuring instruments are used — for example voltage checks - make sure the instrument is properly calibrated. (8) Do not keep combustible materials or metals inside the electrical control cabinet or terminal box. (8) Check that cables and wires are free of damage: damaged cables and wires will cause current leakage and electric shocks. (10) Maintenance inside the Electrical Control Cabinet 8) Switch the main power disconnect switch OFF before opening the electrical control cabinet door, b) Even when the main power disconnect switch is OFF, there may some residual charge in the servo amplifier and spindle drive unit, and for this reason only service personnel are permitted to perform any work on these units, Even then, they must observe the following precautions. ~ Servo amplifier Discharge the residual voltage one minute after turning off the breaker inside the unit. = Spindle drive unit Discharge the residual voltage one minute after turing off the main power disconnect switch, ©) The electrical control cabinet contains the NC unit, and the NC unit has a printed circuit board ‘whose memory stores the machining programs, parameters, etc. In order to ensure that the contents of this memory willbe retained even when the power is switched of, the memory is ‘supplied with power by a battery. Depending on how the printed circuit boards are handled, the contents of the memory may be destroyed and for this reason only service personnel should handle these boards.‘$E00-002-R1 P-(il) ‘SAFETY PRECAUTIONS 4. (11) Periodic inspection of the Electrical Control Cabinet '8) Cleaning the cooling unit ‘The cooling unit in the door of the electrical contro! cabinet serves to prevent excessive ‘temperatura rise inside the electrical control cabinet and increase the reliability of the NC unit. Inspect the following points every three months. = Is the fan motor inside the cooling unit working? ‘The motor is normal if there is @ strong draft from the unit. ~ Is the extemal air inlet blocked? ItitIs blocked, clean it with compressed alr. GENERAL PRECAUTIONS (1) Keep the vicinity of the machine clean and tidy. (2) Wear appropriate clothing while working, and follow the Instructions of someone with sufficient training. (8) Make sure that your clothes and hair cannot become entangled in the machine. Machine operators ‘must wear safety equipment such as safety shoes and safety goggles. (4) Machine operators must read the instruction manual carefully and make sure of the correct procedure before operating the machine. (6) Memorize the position of the emergency stop button so that you can press it immediately at any time and from any position. (6) Do not access the inside of the control panel, transformer, motor, etc, since they contain high-voltage terminals and other components which are extremely dangerous. (7) |ftwo or more persons must work together, establish signals so that they can communicate to cconfirm safety before proceeding to each new step. SYMBOLS USED IN THIS MANUAL ‘The following waming indications are used in this manual to draw attention to information of particular importance. Read the instructions marked with these symbols carefully and follow them. (Acid: : Indicates an imminent hazard which, if not avoided, will result in death or serious injury. aa Indicates hazards which, if not avoided, could resutt in death or serious injury. Indicates hazards which, if not avoided, could result in minor injuries or damage to devices or ‘equipment. NOTICE | : Indicates precautions relating to operation or use.S727-E Pw) CONTENTS BLII-D TYPE VACIIL SPINDLE DRIVE UNIT FOR VACII MOTOR (OKUMA MAKE) This book contains several instruction manuals. Some instruction ‘manuals might be for those specifications which are not selected by the user. Refer to the Final Spectfications of your machine for details.8727-E P-(v) TABLE OF CONTENTS PAGE A; BLI-D TYPE A SECTION1 OUTLINE... A SECTION2 CONFIGURATION AND CONNECTION ... a2 1. a2 141. 22 12. 3 18. a3 2. M 3. AS at. AS 32, As 33. As a4, AT SECTION 3 OPERATION STATUS INDICATION ... AB 1. ‘Status Indicating Lamps AB 2. Monitoring Function .. 8 3a 9 4 Layout Drawing of Status Indicating Lamps, Check Pins, Reset Switch . Ato 5. ‘Abnormality Detecting Function ... Att ‘SECTION 4 TROUBLESHOOTING + AN 1 12. 18. 1-4, 15. 16. 17. ‘Trouble and Troubleshooting . .. ‘The Indicating Lamp PON Does Not Light Up . ‘The Indicating Lamp LOSS Lights Up ‘The Indicating Lamp OCM Lights Up . ‘The Indicating Lamp OCS Lights Up . ‘The Indicating Lamp OV Lights Up ‘The Indicating Lamp UV Lights Up . ‘The Indicating Lamp BOH Lights Up . ‘The Indicating Lamp ROH Lights Up .... - ANT3727-E P-(vi) 1-8. The Circuit Protector Trips 1-8. The WARNING CHARGE Lamp Does Not Go OFF with the Circuit Protector OFF 1-10. The Motor Hunts SECTION 5 MAINTENANCE AND INSPECTION 1 Maintenance Instruments and Parts .. 2 ‘Semiconductor Elements Inspection and Replacement Method . 2-1. IGBT Module Inspection Procedure . 2:2, Diode Module Inspection Procedure 2:3, Procedure for Replacing Semiconductor Elements in Main Circuit B; VACII SECTION 1 OUTLINE ... SECTION 2 CONFIGURATION AND CONNECTION ... 1. Configuration .... 1-1, Total Unit Configuration 1-2. Major Component Parts Arrangement 2 Connections 2-1. Connection Diagrams . 2:2, Terminal Block Size on the VACIII Drive Unit SECTION 3 OPERATION STATUS INDICATION .... 1 Control PCB Operation Status Indicating Lamps 2 Operation Status Indicating Lamps .... 2-1. Normal Operation Status Indication . 2-1. Failure Operation Status Indication . SECTION 4 TROUBLESHOOTING .... 1. Confirmation of Power Supply and Connectors . 2. ‘Trouble and Troubleshooting .. ~ Bat + B223. SECTION 5 MAINTENANCE AND INSPECTION .. SECTION 6 APPENDIX . 1 2. Res ee 24. 22, 24. 1 12, 3727-E P-(vi) POWER LED Does Not Light Up LOSS LED Light Up . LED's Show Failure Occurrence Condition Motor Hunts. ‘Commanded Motor Speed Cannot be Obtained Motor Does Not Rotate. . Low Cutting Performance .... Long Acceleration and Deceleration Time Excessive Vibration and Noise While the Motor is Rotating . Recovery from Failure Status .. Instruments and Parts Used for Maintenance .. ‘Semiconductor Elements Inspection and Replacement Method IGBT Module Inspection Procedure Gate Circuit Inspection Procedure Diode Module Inspection Procedure ... Procedure for Replacing Semiconductor Elements in Main Circult . Replacing Control PCB and Power Supply Unit .. Control PCB Replacement Procedure Power Supply Unit Replacement Procedure \VACIII Drive Unit Assembly Replacement Procedure . Trial Operation Procedure .... ROM and File Name for VACIII Drive Unit... ROM for VACIII Drive Unit File in the Control Floppy Disk Check Terminals .. Mathod of inspecting Optical Fiber Cable . BRRRR &3727-E P-(vill) C; SPINDLE DRIVE UNIT FOR VAC II MOTOR (OKUMA MAKE) SECTION 1 OUTLINE ... C1 SECTION 2 CONSTRUCTION AND CONNECTION .. A Construction ... 1-1. Major Component Parts Arrangement . 2. Connections 2-4. Standard Specification .. 2-2. Winding Changeover Specification VAC Motor + C14 SECTION 3. OPERATION STATUS INDICATION ... . C17 1 Control PCB Operation Status Indicating Lamps . - C17 2 ‘Operation Status Indicating Lamps ... - C18 2-1. Normal Operation Status Indication . . C18 2:2. Failure Operation Status indication . + C19 SECTION 4 INSPECTION AND MAINTENANCE ... c28 1. Instruments and Parts Used for Maintenance .... . C28 2. Inspection and Replacement Procedure for Semi-conductor Devices . 630 2-1, Transistor Module inspection Procedure - ©30 2:2, Base Circuit Transistor Inspection Procedure - C32 2:3, Diode Module Inspection Procedure . C32 2-4, Procedure to Replace Main Circult Semi-conductor Devices - 034 3. Fuse Replacement . + C35 3-1. Fuse Blown Condition . + 035 3-2. Inspection and Replacement Procedure for Fuses + 035 39, Fuse Rating .. + 036 4 Replacing Control PCB and Power Supply Unit . . C37 4-1. Control PCB Replacement Procedure .... . 037 4-2. Power Supply Unit Replacement Procedure... . 638 4-3, VAC Drive Unit Assembly Replacement Procedure . C39 4-4, Trial Operation Procedure .. + C403727-E P-(ix) PAGE SECTION 5 TROUBLESHOOTING .. . CH 1 Confirmation of Power Supply and Connectors cat 2 ‘Trouble and Troubleshooting can 3. Recovery from Failure Status 59 APPENDIX1 ROM AND FILE NAME FOR HIGH-PRECISION VAC DRIVE UNIT FIOM for High-Precision VAC Drive Unit . 88888 8 APPENDIX2 CHECK TERMINALS ...A; BLi-D TYPE A8727-E P-A1-R3 SECTION 1 OUTLINE SECTION1 OUTLINE ‘This manual describes maintenance methods of BLII-D type A unit. Before you change parts such as boards or units, TURN OFF THE CIRCUIT PROTECTOR, AND ENSURE THAT WARNING CHARGE (RED) LAMP IS OFF. ( Maintenance work with the WARNING CHARGE lamp ON may cause injury from electric shock or breakage of the unit.)3727-E P-A2 SECTION 2 CONFIGURATION AND CONNECTION SECTION 2 CONFIGURATION AND CONNECTION 1. Configuration 1-1. Total System Configuration ‘The BL-ACT type A is composed of the parts shown in Fig. 2-1. oes the BLI-D type A unit varies in type depending on the applications: 1-axis unit and 2-axis unt (1) 1-axis Unit Configuration ‘S-phase 180 to 240 V, 50/60 Hz BLI-D es A SvPI-D Current command t— 2a servo Signal from detector [sero ampiiier | toad T= Bea et L@e=® ‘Servo amplifier (2) 2-axis Unit Configuration ‘S-phase 180 to 240 V, 50/60 Hz SVPI.-D Current command BLI-DesA (a )=(re) servo a first and second board axes servo OAC) ‘Signal from detector Fig. 2-49727-E P-AS SECTION 2 CONFIGURATION AND CONNECTION 1-2. Unit Type ‘The BLII-D type A show their power unit capacity in their unit name. t-axis unit ..... BLI-DesAs LL special function ‘—Power unit capacity (16 to 160) As L speci function Power unit capacity for the second axis (15 to 75) '—Power unit capacity for the first axis (15 to 75) 1-3. Unit Configuration ‘The BLI-D is composed of combination of control boards (SVCII) and power units (BLII-D P.U). ‘SVC BOARD 2-acie BLI-DISAPU ‘BLI-D90A PU ‘BLI-DsOA PU BLU-D75A PU BLU-DIO0A PU BLI-DISOA PU BLU-DISI6A PU BLU-D3016A PLU BLU-DS016A PU BLU-D7515A PU BL-D3090A P.U BL-D5090A PU BL -D7590A P.U BL-DS050 P.U BLII-D7550A PU BLU-D7575A PU (A)BLI-D100A5 PU (BL I-DISOAS PU (#1) Used for the BLII-D with pick-off function3727-E P-A4 SECTION 2 CONFIGURATION AND CONNECTION 2. Unit Structure BLIL-D unit is composed of the following parts: Radiator plate Power board |__| Bower unit SVCI board —§ $A _$__________________________ Control board SVCI board Power board Radiator plate Fig. 2-23727-E P-AS SECTION 2 CONFIGURATION AND CONNECTION Connection ‘The following diagram shows wiring connections of BLII-D type.A with extemal units and signal names. 3-1. Connection Diagram 3 7 (23,200 VAC 3 w T E 10 vac cs nc Mato bake FE 2-1) Mer sora LT 2-2) MEN Motor ove’ [T 2-3) 17 fe ‘etecton sna | T 2-3) PN Fig. 2-3,3727-E P-AB SECTION 2 CONFIGURATION AND CONNECTION 3-2. Screw Size Used on BLII-D Type A Terminal Base In BLIL-D type A, all the screws used on the terminal base are M4. 3-3. Connectors The following connectors are used for the input signal wires of BLII-D type A. Signal Name Current command input signal for first axis Current command input signal for second axis Input signal to motor thermal brake Input signal to motor thermal brake for first axis Input signal to motor thermal brake for second axis Optional: First axis load output “| The connectors for XB1-1 and XB1-2 are fixed by the metal fixtures (MR20-OKT E3708- 578-001 made by Nisshin Seigyo). "2 The connectors for XB2 and XBS are used together with key-in plugs (175855-1 made by Nippon AMP).3727-E P-AT SECTION 2 CONFIGURATION AND CONNECTION 3-4. Connector Pin Layout XB1-+ Pin Layout Pin | Abbrev. Signal No. Name a 1 [ake @ [ALARM AST on [2 | CK *N. eae ea 11 |PXD* ese] 72 [CURRENT OFF +| © | STROBE* | FXSTB aa ISAOP EN 6_| STROBE «NV AXSTS oN 7_[ com ‘The mark * is a substitute for the axis No. ee4 o=2 XB2 Pin Layout 1 2 3 4 5 ‘MBP ‘MBN TPP TPN * ‘The star mark indicates the pin to be fitted by the key-in plug. XB3-1 Pin Layout 1 2 3 4 6 MB11 MB2i TPit * TP2t ‘The star mark indicates the pin to be fitted by the key-in plug. XB3-2 Pin Layout (only for 2-axls unit) MB12 ‘The star mark indicates the pin to be fitted by the key-in plug. XBT-+ Pin Layout TOX*8727-E P-AB SECTION 3 OPERATION STATUS INDICATION SECTION 3 OPERATION STATUS INDICATION The BLIL-D type A indicates operating status on SVCII BOARD and POWER BOARD. Indication methods are as follows: Operation indicating lamp (Green) Operation indicating lamp (Yellow) Operation indicating lamp (Red) .. Normal operation Reset condition Malfunction (SVC BOARD) On charge (POWER BOARD) 1. Status Indicating Lamps ‘The BL II -D type A is provided with the following status indicating lamps. Table 3-1 Description Power is being supplied to the control board. ‘The control circuit is reset by an external command or alarm occurrence. ‘Overcurrent is supplied to the motor. ‘Overcurrent is supplied to the inverter circuit. ‘The inverter DC voltage is abnormally high. ‘The inverter DC voltage is abnormally tow. regenerative energy discharge circuit is overheated. ‘The power board is overheated. ‘The control circuit voltage exceeds the ‘safety operation range. Power is being supplied to the main circuit. @) Green lamp Yellow lamp (R) .... Red lamp3727-E P-AS SECTION 3 OPERATION STATUS INDICATION 2. Monitoring Function ‘The BLIL-D type A allows to check the motor speed and torque using check pins shown below. Table 3-2 Description Rated Output ‘Analog signal indicating BL motor (frst £10 W760 rpm axis) speed ‘Analog signal indicating torque commands | 10 Vi{torque limit) given to BL motor (frst axis) ‘Analog signal indicating BL motor (second | 10 W750 rpm axis) speed * Only the board for 2-axis unit ‘Analog signal indicating torque commands | 10 Vi(torque limit) given to BL motor (second axis) * Only the board for 2-axis unit Power source of 5 V for control circuit * Only the board for 1-axis unit Ground for control circuit 3. Servo Reset Function ‘The BLIT-D drive unit can be reset using SW1. On resetting, the OP lamp lights up. Table 3-33727-E P-AI0 SECTION 3 OPERATION STATUS INDICATION Layout Drawing of Status Indicating Lamps, Check Pins, Reset Switch (1) SVCI for 1-axis Unit Board a) od 0000000860e000 ®0' ELI TO! VEL2 Toe COM PON OP COM OCS OY _UV _AQH_BOH LOSS OCs OcM OP Fig. 3-23727-E P-AN SECTION 3 OPERATION STATUS INDICATION 5. Abnormality Detecting Function The BLIL-D type A is provided with the following protective and abnormality monitoring functions. Table 3-4 Purpose/Description ‘The circuit protector shuts off the power the moment ground fault ‘occurs inside the servo amplifier or the motor. ‘The 3.2 A fuse is blown by the overcurrent from the power circuit ‘caused by control circuit failure. Power is thus shut off immediately. ‘When a large current exceeding 160 % of the limit value flows into the motor, an alarm occurs to prevent breakage of main circuit elements and motor demagnetization. When the inverter DC power is shorted because of the trouble in ‘main circuit elements or control circuit, or when an overcurrent flows because of ground fauit inside the motor, an alarm occurs to prevent secondary breakage of main circuit elements. If the inverter DC power voltage increases to an abnormally high level, an alarm occurs to prevent breakage of main circuit elements. If the inverter DC power voltage decreases to an abnormally low level, an alarm occurs to prevent unstable operation of the motor. If the regenerative energy discharge resistances pass the current Continuously because of the trouble in the control circuit or is overheated by excessive regenerative energy, an alarm occurs to prevent burning of the resistances. If the power board is overheated by the trouble in main circuit ‘elements or control circuit, an alarm occurs to prevent buming of the board. If the control circuit voltage exceeds the safety operation range because of circuit failure, an alarm occurs to prevent malfunction of the circuit,8727-E P-A12-R3 SECTION 4 TROUBLESHOOTING SECTION4 TROUBLESHOOTING ‘One occurence of troubles, take actions according to the following tables. Before you change parts such as boards or units, TURN OFF THE CIRCUIT PROTECTOR, AND ENSURE THAT WARNING CHARGE (RED) LAMP IS OFF. ( Maintenance work with the WARNING CHARGE lamp ON may cause injury from electric shock or breakage of the unit.) 1. Troble and Troubleshooting Ifa problem is found, take necessary procedures as indicated In Table 4-1. Table 4-1. Classification of Failures Failure Will Lie In Failure Indicating lamp PON does not light up Indicating lamp LOSS lights up Indicating lamp OCM lights up Indicating lamp OCS lights up Indicating lamp OV lights up Indicating lamp UV lights up Indicating lamp BOH lights up indicating lamp ROH lights up WARNING CHARGE lamp does not light out [Motor hunts3727-E P-A13 SECTION 4 TROUBLESHOOTING 1-1. The Indicating Lamp The Indicating Lamp Failure Factor PON Does Not Light U LOSS Lights op : Check Measures ‘Abnormally high or low source voltage Check if the voltages applied to the input terminals R, S, and T of BLII-D unit are within the allowable range: 170 to 242 VAC. ‘Adjust the input voltages to values within the allowable range. Fuse (HM3.2A) is Check if the fuse mounted on SVC board is blown. Check if the interboard connectors are securely inserted into the connectors on the control PC board. Replace the fuse. Insert properly. Power is not supplied from the power unit to the control PC. Remove the blue connector cover. With the power ON, check if the voltage ‘across the 6th and 10th pins of the ‘connector XBE on the control PC board is 200 VAC using a voltmeter. Use utmost care because high voltage Is applied. Check if all the above checking items are normal. OCM Lights Up Check Replace the power unit. Check if the terminal screws are securely tightened. circuit, ground fault of the motor cables Remove the motor cables from BL -D rive unit to check them for continuity. Failure of the BL motor Imperfect connection of the connector XB1 ‘Measure the insulation between the BL ‘motor terminals and the frame using a megger. ‘Check the connector. Replace the BL motor. Property connect. Defective SVP board in the CPU unit Failure of the control PC board Check if all the above checking items are normal. ‘Check if all the above checking items are normal. Replace the SVP board. Replace the control PC board. Failure of the power unit Check if the OGM lamp lights up even’ after the control PC board is replaced. Replace the power unit.3727-E P-A14 SECTION 4 TROUBLESHOOTING 1-8. The Indicating Lamp OCS Lights Up Failure Factor Measures: Failure of the control | See Table 4-2. ‘See Table 4-2. PC board or the power unit Interphase shor- | Remove the motor cables from BLI'-D | Replace the motor cables. circuit of the motor _| drive unit to check them for continuity. cables Failure of the BL Check the insulation between the BL Replace the BL motor. motor motor terminals and the frame using @ megger. Table 4-2 Method of Checking Control PC Board and Power Unit on Occurrence of OCS Contents, ‘Turn OFF the power. (Tum OFF the circuit protector and make sure that the WARNING CHARGE red lamp is OFF.) Remove the contro! PC board (SVC BOARD) and check if the interboard ‘connectors are securely engaged with the XB connectors 4 to 6 on the power unit. Ensure that they are fixed together. Prees igh. ‘Connector on power unit | Check the 1@BT module. (See Section 5, 2-1. “IGBT Module Inspection Procedure”.) | install the control PC board. Make a trial run to check if the OCS lamp lights up If the lamp lights up again, replace the control PC board and make a trial run. if the lamp still lights up, replace the power unit.3727-E P-AIS ‘SECTION 4 TROUBLESHOOTING 1-4, The Indicating Lamp OV Lights Up Check Measures Check if the voltages applied to the input | Adjust the input voltages to terminals R, 8, and T of BLIL-D unit are | values within the allowable within the allowable range: 170 to 242 | range. VAC. ‘@ Turn OFF the power. Tighten the screws Check if the power cable terminals | Surely. are securely fixed with the screws. ‘After taking actions according to the See Table 4-3. steps in Table 4-3, check if the OV lamp still ights up. Contents ‘Tum OFF the power. (Turn OFF the circuit protector and make sure that the WARNING CHARGE red lamp is OFF.) Remove the control PC board (SVC II BOARD) and check if the interboard connectors are securely engaged with the XB connectors 4 to 6 on the power unit. ‘Check if the terminals VH and TRC for connecting the regenerative resistance are securely tightened. ‘Check the IGBT module for regenerative circuit. (See Section 5, 2-1. “IGBT Module Inspection Procedure”.) Install the control PC board. Make @ tral run to check if the OV lamp lights up. If the lamp lights up again, replace the control PC board and make a tral run, If the lamp still lights up, replace the power unit.3727-E P-AI6 SECTION 4 TROUBLESHOOTING 1-5. The Indicating Lamp UV Lights Up Failure Factor Check Measures. ‘Abnormally low (Check if the voltages applied to the input | Adjust the input voltages to source voltage terminals R, S, and T of BLIL-D unit are | values within the allowablo within the allowable range: 170 to 242 | range. VAC. 'No input voltage to | Check the input voltages. ‘Check the power cables. one of the three phases. Circuit protector is | Check the circuit protector. Turn ON the circuit turned OFF. protector. Loose screws on Check the screws. Tighten them securely. IGBT module Failure of GBT Check the module. (See Section 5, 2-1. | Replace the IGBT module. “IGBT Module Inspection Procedure”.) _| See Section 6, 2-3. “Procedure for Replacing ‘Semiconductor Elements in Main Circuit”. (Check if the interboard connectors are securely inserted into the connectors on the control PC board. Failure of power unit | Check if all the above checking items are normal. Failure of control PC | Check if the UV lamp lights up even after board replacement of power unit. 1-6. The Indicating Lamp BOH Lights Up Check Measures Check the overload rate with the load | Review the operation display. Program. Check if the interboard connectors are _| insert properly. ‘securely inserted into the connectors on the control PC board. Failure of control PC | Check if all the above checking items are | Replace the control PC board normal. board. Failure of power unit | Check if the BOH lamp lights up even | Replace the power unit. after replacing the control PC board.3727-E P-AIT SECTION 4 TROUBLESHOOTING 1-7. The Indicating Lamp ROH Lights Up Check Measures ‘Check the IGBT. (See Section 5, 2-1 “IGBT Module Inspection Procedure.) ‘Check if the interboard connectors are _| insert properly. securely inserted into the connectors on the control PC board. ‘Check the overload rate with the load | Review the operation display. program. ‘Check the screws on the terminals THR | Tighten them securely. and COM. Replace the power unit, Failure of control PC | Check if all the above checking items are | Replace the control PC board Rormal. board. Failure of power unit | Check if the ROH lamp lights up even | Replace the power unit. after replacing the control PC board. 1-8. The Circuit Protector Trips Check Measures. Check them for wiring. Correct the wiring. Remove the motor cables from BLI-D | Replace the motor cables. rive unit to check them for continuity. ‘Check the IGBT. (See Section 5, 2-1. | Replace the IGBT or the “IGBT Module Inspection Procedure”.) | power unit. ‘Check the module. (See Section 5, 2-2. | Replace the diode module. “Diode Module inspection Procedure”.) ‘Check all the above checking item are | Replace the power unit. normal. ‘Check if the circuit protector trips even _| Replace the control PC after replacing the power unit. board. 1-9, oe WARNING CHARGE Lamp Does Not Go OFF with the Circuit Protector Failure Factor Measures Failure of power unit ‘After leaving the unit for about 30 minutes, make sure that the lamp is OFF. Then, replace the power unit.3727-E P-AIB SECTION 4 TROUBLESHOOTING 1-10. The Motor Hunts Failure Factor Check Measures Failure of IGBT (Other defective units (such as motor, detector, SVP) ‘Check the IGBT. (See Section 5, 2-1. “IGBT Module Inspection Procedure”. ‘Check all the above items are normal. Check if the motor still hunts after replacing the control PC board. Refer to the maintenance manuals for the other units. Replace the IGBT or the Power unit. Replace the control PC board. Replace the power unit. Replace the defective unit.3727-E P-AI9 SECTION 5 MAINTENANCE AND INSPECTION SECTION 5 MAINTENANCE AND INSPECTION 1. Maintenance Instruments and Parts Table 5-1 shows the instruments used for maintenance or inspection. Table 5-1 Application ‘Measurement of source voltage Resistance check @Phillips screwdriver | Middle and small size Table 5-2 shows the parts used in BLII-D drive unit and required for maintenance. Table 5-2 Type Product No. @MBISOFA-060 | £4443-722-037 30A:600V (Fuji) @MBIS0FA-060 | £4443-722-038 ‘50A-600V (Fuji) 6MBI76FA-060 | £4443-722-039 ‘75A-600V (Ful) ‘@MBIT0OFA-060 | £4449-722-043 100A:600V (Fuji) ‘6MBI1S0FB-060 | £4443-722-040 150A:600V (Fuji) ‘GRIS0E-080 2714-72-01, 50A:800V (Fuji)9727-E P-A20-R3 SECTION 5 MAINTENANCE AND INSPECTION 2. Semiconductor Elements Inspection and Replacement Method This subsection describes the methods of inspecting and replacing semiconductor elements. (Aacaon] When inspecting and/or replacing the elements, ensure that: WARNING CHARGE lamp is OFF with the circuit protector OFF. ‘The screws removed in Inspection or replacement are tightened securely in correct positions. No screws are dropped. 2-1. IGBT Module Inspection Procedure: 1) 2) 3) 4) 5) 8) Remove the power and the motor cables. Remove the control PC board. Remove the power board. Measure the resistance between the terminals using a multimeter. The terminal layout and intemal equivalent circuits in the IGBT module are shown in Fig. 5-1 and§-2. The terminal names of one element in the module is shown in Fig. 6-3. Check the equivalent circuit to see if its resistances conform to the criteria in Table 5-3. It measured resistance Is abnormal, replace the IGBT module. f normal, install the power board. Be sure to tighten the screws. After inspection or replacement, install the control PC board and fix it with screws. Then, ‘mount the motor cables and the power cables. 1-In-1 type. G-in-1 type. Fig. 5-1 IGBT Module Terminal Layout9727-E P-A21-R3 ‘SECTION 5 MAINTENANCE AND INSPECTION c E 6-in-1 type Fig. 5-2 Equivalent Circuit of IGBT Module © ® 4 «) Fig. 5-3 Terminal Names of One Element on IGBT Module Table 5-3 Criteria 1QBT Terminal Normal Range ‘Abnormal Range Mutimetor Terminal | Mutimetor Terminal | tint 6int tint eint () side Ose ‘Several tens to ‘Several tens to ‘several hundreds | several hundreds ofidoohms [of ohme © © ‘Soo REMARKS 1. ohm, co © © @ _SeeREMARKS2, | Several hundreds of ohme or less © @ © ‘Several thousands of ohms or lass @ © © ‘Several thousands of ohms or loss @ © © ‘Several thousands of ohms or loss © @ hed ‘Several thousands of ohms or less NOTICE]: (1) Measure the resistance with the muitimeter measuring range set to “x 1". (2) In order to obtain correct measurements, short the circuit between @ and E.3727-E P-A22 SECTION 5 MAINTENANCE AND INSPECTION 2-2. Diode Module Inspection Procedure 1) Remove the contro! PC board and the power board. 2) Measure the resistance between the terminals on the diode module using a multimeter. +0 «®) a) Fig. 5-8 Terminal Names of One Element on Diode Module Table 5-4 Criteria Diode Module Terminal Multimeter Terminal | Multimeter Terminal ‘Abnormal Range (+) side (-) side @ © 0 “ ‘Several hundreds ohms or less 3) If the measured resistance is abnormal, replace the diode module. 4) When the measured resistance is normal, reinstall the power board and the control PC board. Be sure to tighten the screws.3727-E AQQE SECTION 5 MAINTENANCE AND INSPECTION 2-3. Procedure for Replacing Semiconductor Elements in Main Circuit If any of the semiconductor elements in the main circuit are judged to be defective by the inspection method described in the previous and this sections, replace the elements according to the procedure in Table 5-5. Table 5-5 Contents Remove all the screws from the power board to dismount the board from the main unit. Remove the module fixing screws to dismount the module. ‘Apply silicone compound to the back of anew | The compound will increase module. adherence of the module to the mounting face, and so the module will be cooled better. Install the new module and fix it with the Make sure that the module is placed screws. in the correct direction. Be careful that the IGBT, element made of MOS compound, tend to generate static electricity. Install the power board and securely tighten | Do not forget to tighten the screws. the screws which were removed in Process 1.B; VAC3727-E P-B1 SECTION 1 OUTLINE SECTION 1 OUTLINE This section covers the maintenance procedures and necessary information related with the VACII drive unit.3727-E P-B2 SECTION 2 CONFIGURATION AND CONNECTION SECTION 2 CONFIGURATION AND CONNECTION 1. Configuration 1-4. Total Unit Configuration ‘The VACII drive unit configuration is illustrated in Fig. 2-1. 2-010 Power POR ps L SS VAC I DRIVE UNIT \VAGH GD BOARD be ACI CPU BOARD j<—_Cover_ |< Soe VAC II (D6) VAG I (011~D22) Fig. 2-1 VACIII Drive Unit Configuration3727-E P-B3 ‘SECTION 2 CONFIGURATION AND CONNECTION 1-2. Major Component Parts Arrangement ‘Arrangement of major component parts on the control PCB and the power supply unit are shown in Figs. 2-2 to 2-7. ‘Major Component Parts Arrangement on CPU Board for Dé Major Component Parts Arrangement on GD Board for D6 ‘Major Component Parts Arrangement on VAC Board II for D11- D22 ‘Major Component Parts Arrangement on Power Supply Unit for D6 ‘Major Component Parts Arrangement on Power Supply Unit for D11 Major Component Parts Arrangement on Power Supply Unit for D23727-E P-B4 SECTION 2 CONFIGURATION AND CONNECTION om MM i123 466 oS Ltt 23 eo IIT M37 8 8 10 1112 13 ALMRST| sw sw2 vat [0] R vre [O] ° a vrs [0] VoMP @ Ta @ MON @ VEL @ @ND © ™ ® q Euc © 4 WUC ® ue EC @ v @ c ® N NC ® ipv 5 fl ee a 2® 2 ae GND® IDcs004 Nt ® = Check terminal [D]: Variable resistor Fig. 2-2 Major Component Parts Arrangement on CPU Board for D63727-E P-B5 SECTION 2 CONFIGURATION AND CONNECTION Gate circuit for convertor c N 16 HM fuse c ees N {Gate circuit for invertor 15 |__| et Warning fuse (5A) c Ear N | swii swi2 a 4 Rise ® & 3 av Is ir ©e000 ee Nit conte GND +15V +8V ® : Check terminal Fig. 23 Major Component Parts Arrangement on GD Board for D63727-E P-B6 SECTION 2 CONFIGURATION AND CONNECTION HM fuse Warning fuse (5A) ‘i eo N 6V COM 8 swt sw2 M1 M2 42.3 4 5 6 o 48222454 5 N 20 oo e———— 7 M3 7 8 9 10 11 12 13 @®GND ROM c N 6 Aumast| DC CNT 9004 ons] Fig. 2-4 Major Component Parts Arrangement on VAC Board I for D11-D223727-E P-B7 ‘SECTION 2 CONFIGURATION AND CONNECTION ‘Terminal block for power cables\ fe Tan anotor tables Fig. 2-5 Major Component Parts Arrangement on Power Supply Unit for D63727-E P-BB ‘SECTION 2 CONFIGURATION AND CONNECTION Terminal block Terminal block for power cables for motor cables Fuses Terminal block for fan motor cables Fig. 2-6 Major Component Parts Arrangement on Power Supply Unit for D113727-E P-B9 ‘SECTION 2 CONFIGURATION AND CONNECTION Fuses Heat sink cooling fan ‘Choke coil ACLS Heat sink ‘cooling fan Fig. 2-7 Major Component Parts Arrengement on Power Supply Unit for D2224. 22. Connections 3727-E P-B10 SECTION 2 CONFIGURATION AND CONNECTION, The connection between the VACII drive unit and the VAC motor, and between the VACII drive unit and the NC unit are explained in what follows. Connection Diagrams (@) (b) © @ () General view of VACII drive unit Interconnections ‘Connection diagram of winding changeover specification Connector pin assignment \VACII drive unit and VAC motor connection diagrams: Motor with 16-pin commercial MATE-N-LOCK connector Motor with 10-pin commercial MATE-N-LOCK connector Motor with 9-pin commercial MATE-N-LOCK connector Connectors Fig. 2-8 Fig. 2-9 Fig. 2-10 Fig. 2-11 Fig. 2-12 Fig. 2-13 Fig. 2-14 ‘Signal wires on the motor side are inserted into the connectors shown in Table 2-1. Connector Name Table 2-1 ‘Commercial MATE-N-LOCK Commercial MATE-N-LOCK Universal MATE-N-LOCK Terminal Block Size on the VACII Drive Unit ‘The terminal block size on the VACII drive unit is indicated in Table 2-2. Table 2-2 Power Supply Unit Model be | p11 Ma M63727-E P-B11 SECTION 2 CONFIGURATION AND CONNECTION VACII drive unit VAGIT control PCB Magnetic pulse generator {or photoelectric pulse generator) ‘SVP board [oc ENT] [9004 [GNA] [ONS ‘SPCS card t “Terminal block for power cables | [Terminal block for Resolver motor cables EC board (or ECP board) on ‘VAC motor Relay circuit © ‘AC180 V - 242 V (50/60 Hz) Note: Resolver is not used for builtin motor. Fig. 2-8 General View of VACIII Drive Unit,svariereseaind ‘SECTION 2 CONFIGURATION AND CONNECTION [Mant encoder ARAT (19 A 8 ABATE a) Az T oo Ht Bae °2;10 ch) Go 2S Ip T $004 +rvisy JT i Any one is selected GND a according to MRDY (1 Machine ready MRDY-COM (8) “(s] AC180 V - 242 V (6060 Hz) Breaker R 8 T E es ‘OL (28) sealed cable | 1SO-SG (13), es) Q: Connector (Honda MR series) + Dé: CNT + CNIZ cN2 = ONt ©: Screw type terminal block Ges oni Fig. 2-9 Interconnections3727-E P-B13, ‘SECTION 2 CONFIGURATION AND CONNECTION | Inpatxtput signals ctring kom the standard specication we inated. Screw type terminal block. Fig. 2-10 Connection Diagram of Winding Changeover SpecificationSiena ‘SECTION 2 CONFIGURATION AND CONNECTION Assignment of Pins of Connector CN2* * De: CNT + CNIZ CN2 = CNt Fig. 2-11 Connector Pin Assignment___—«8727-E PA ‘SECTION 2 CONFIGURATION AND CONNECTION 14 st 15 $2 : 16 = 17 Ri 7 : 1 12 19 is 20 ‘OL -- Assignment of Pins of Connector CN3* * DB: CNS ONIT Fig. 2-11, Connector Pin AssignmentSTepErBeERS SECTION 2 CONFIGURATION AND CONNECTION VACII drive unit VAC motor * D6: CNS = CNIT Fig. 212 VACIII Drive Unit and VAC Motor Connection Diagram (Motor with 16-pin Commercial MATE-N-LOCK Connector)‘ST2TAE/REBPRRZ SECTION 2 CONFIGURATION AND CONNECTION * D6: CNS + CNT Fig. 213. VACIII Drive Unit and VAC Motor Connection Diagram (Motor with 10-pin Commercial MATE-N-LOCK Connector)STETE PRIOR © pag SECTION 2 CONFIGURATION AND CONNECTION VACII drive unit VAC motor * D6: ONS — CNIT Fig. 2-14 VACII Drive Unit and VAC Motor Connection Diagram (Motor with 8-pin Universal MATE-N-LOCK Connector)3727-E P-B19 SECTION 3 OPERATION STATUS INDICATION SECTION 3 OPERATION STATUS INDICATION ‘The VACII drive unit has LED's on the control printed circuit board to indicate the operation status. Lighting conditions of the LED's can be checked through the opening in the cover. Fig. 3-1 shows the LED names. POWER Sap MIN os eG == ss H GCOC FI Titel oo M3 7 8 9 10 11 12 13 CPUALM EE Control PCB operation Operation status indicating status indicating lamps lamps Fig. 3-1 LED Names 1. Control PCB Operation Status Indicating Lamps The following three LED's indicate the operation status of the VACII drive unit. The relationship between the lamp illumination and PCB operation status is indicated in Table 3-1. Table 3-1 Relationship between LED Illumination and PCB Operation Status Operation Remarks Power supply for VACII drive unit | i this is not illuminating while pow- control circuit is being supplied. ‘er supply to the VACIII drive unit is n, it indicates an occurrence of a trouble. Voltage in the calculation circuit of | f this LED is turned on, the calcu- the VACII drive unit is outside the | lation circuit is not functioning nor- specification. mally. ‘The lamp indicates an occurrence of | Contents of the problem are {problem in the calculation circuit in| cated by the operation status indi- the VACII drive unit. cating lamps.3727-E P-B20 SECTION 3 OPERATION STATUS INDICATION 2. Operation Status Indicating Lamps ‘The LED's M1, M2 and M3 indicate the operation status of the VACIII drive unit and the VAC motor. ‘There are two different operations status as “normal operation” and “faulty operation”. They are indicated by the following LED illumination conditions. Normal operation .... M1, M2 and M3 are all OFF Faulty operation ..... M1, M2 and/or M3 is ON or flickering.3727-E P-B21 SECTION 3 OPERATION STATUS INDICATION 2-1. Normal Operation Status Indication ‘While the VACII drive unit is operating normally, the LED's indicate the input/output status of the inpuvoutput signals. These input/output signals are shown in Fig. 3-2 (for the standard ‘and winding changeover specifications). MS ON ‘SFR No dapay WCHG TUMC. MRDY Mi Mat bv 3h v5 /6y oto cor ee ee ee I elt Wa MONTRERSHQTIZNGA EMR AWCHG “HMSCHG, LMSCHG ZERO "AGRE ‘SROY ‘nt signals Main ckcuit charging stan i i i ; Motor col power supply Winding changeover signal | J Note 1 ‘Torque nit command signat |] ON when signals are Machine ready signal rout Note 1: WCHG Winding changeover signal ON when the high-speed range winding selection command is input OFF — when the low-speed range winding selection command is input Note 2: AWCHG Winding changeover completion signal ON when the high-speed range winding selection is completed OFF when the low-speed range winding selection is completed Note 3: When the power to the machine is tured on, it indicates “01”. When the contro! power is tured on and the NC is ready, the indication changes to “02". Fig. 3-2 Signal Assignment at LED's for Normal Operation9727-E P-B22 ‘SECTION 3 OPERATION STATUS INDICATION 2-2. Failure Operation Status Indication ‘A faulty operation status is indicated by the LED's M1 and M2 in the following conditions. (@) M1 and M2 flicker simultaneously. (b) M1 lights up. (©) M2 lights up. LED's other than M1 and M2 light up corresponding to the failure conditions occurred to ‘On the VACIII control PCB, the 7-segment LED displays the failure operation status by the 2- digit number. ‘The alarm information is transferred to the NC unit, and alarm name and alarm data are displayed on the CRT screen of the NC operation panel. (1) Alarm Type ‘There are two types of alarm with the VACII drive unit. One is detected in the VACII drive unit, and the other is detected in the NC. [— (@) Alarms detected in the VACII drive unit Power circuit alarms (IOCM, IOCS, OV, UV, etc.) VACII Alarms ————} Arithmetic circuit alarms (AD, PAR, LOOP, etc.) Others “— (b) Alarms detected in the NC unit ‘VAC PBU file read alarm VAC start alarm ‘VAC communication alarm Others (2) Alarm Indication ‘The VACII alarm is indicated in the following three places. (a) CRT screen of the NC operation panel ‘Alarm name and alarm data are displayed. (b) 7-segment LED on the control PCB VACII ‘Alarm number is displayed. (©) Single LED (green) on the control PCB VACII The LED corresponding to the alarm contents lights up.9727-E P-B23-R3 SECTION 3 OPERATION STATUS INDICATION Note: “O" indicates “displayed, and “X" indicates “not displayed”. NOTICE | : (1) When more than one alarm occurred, the alarm of the highest level is displayed. When the alarms of the same level occurred, the alarms detected first will be displayed. Note the signal LEDs corresponding to the alarms occurred will alight up. (2) For the alarm winich occurred after the power to the NC is truned on but before the NC gets ready, “VAC start” is displayed on the CRT. (8) Alarm Contents: (e) Alarm indication on the CRT screen of the NC operation panel ‘Alarm No. and contents vary depeing on the NC unit type (sure as OSPSO20L, M. G, ete.). Refer to the alarm list of the relevant NC unit. (b) Alarm indication of the 7-segment LED on the VAC BOARD I Refer to Table 3-3., “VACII Alarm List (1/3 - 3/3)". {c) Alarm indication of the signal LED on the VAC BOARD II Refer to Table 3-5., *Failure Operation Status Indication Mode". Failure contents are detailed in Figs. 3-3 through 3-5.3727-E P-B24 SECTION 3 OPERATION STATUS INDICATION Table 3-3 VACII ‘Alarm List (1/3) Contents ‘The number of the detected PG counts ‘exceeds the PBU data. The actual VAG motor speed is too high. ‘The actual spindle speed is too high. Excessive velocity command value in the spindle control mode or excessive feedrate unit amount in the C-axis control mode Excessive feedrate unit amount per ‘communication, or calculation of the CON is delayed from the timing of ‘communication. DIFF over occurred in the C-axis control mode. ‘The VAC resolver signal is not output. ‘Read/rite fromvto the RAM cannot be carried out correctly. 2 ‘Communication data between the VAC and the NC is stopped, or communication data is faulty. ‘The command communicated is ‘undefined or not executable. Instantaneous overcurrent in the VAC. motor cable ‘Short circuit in the inverter bridge arm (Overcurrent in the regenerative main circuit Excessive DC voltage in the main circuit ‘The three-phase input power supply ‘voltage is lower than the specified value, + 7-segment LED For the alarm level, refer to Section 4, 3. “Recovery from Failure Status”. The processing level show the priority of releasing alarms. For VAC operation ‘corresponding to the processing level, see Table 3-4. Note1: Note2: [Any of the three-phase input is open.3727-E P-B25 SECTION 3 OPERATION STATUS INDICATION Table 3-3 VACII Alarm List (2/3) ‘Alarm Name Contents Loss of arithmetic. circuit power Control power supply voltage on control PCB is low. Power circuit low voltage DC voltage in the main circuit does not rise. INT loop error Interruption cannot be performed correctly. ‘Motor overload The temperature inside the VAC motor is higher than the permissible value. Heat sink overheat The temperature of the heat sink in the drive unit is higher than the permissible value. Data setting abnormal ‘The PBU data of the VAC or the on-line change parameter setting is abnormal. (The data outside the data setting range ‘set or sent.) Internal velocity ‘command too fast Excessive velocity command value during velocity control or position control in the VAC P.G. error ‘The magnetic pulse generator signal is not output. P.G. marker latch data ‘error ‘The number of counts until the first marker is passed after the power has been turned on exceeds the PBU data. Cycle over error ‘A cycle over error occurred with the vac. Watchdog error ‘The watch dog timer is not cleared. ‘AD access alarm ‘AD access is attempted during AD conversion. ‘Master CPU error + 7-segment LED ‘The master CPU can detect: Bus error, prohibiting instruction error, division by zero error, CHK instruction ‘error, TRAPV instruction error, privilege violation error, trace error, 1010 emulator error, 1111 emulator error, unused area error, address error, interruption error, TRAP error, user interruption error, spurious interruption error.9727-E P-B26 SECTION 3 OPERATION STATUS INDICATION Table 3-3 (3/3) Contents ‘The slave CPU can detect: bus error, address error, prohibiting instruction error, division by zero error, CHK instruction error, TRAPV instruction error, privilege violation error, trace error, 1010 emulator error, 1111 ‘emulator error, unused area error, INT 7 interruption error, spurious interruption ‘error, interruption error, TRAP error, user interruption error. Excessive VAC motor velocity deviation ‘The winding changeover MS is not tured on. ‘The contents of the RAM cannot be cleared when the power is tured on. VAC Operation ‘Shut off current to set the motor running free. ‘Shut off current after reducing speed and stopping the motor. ‘Shut off current after reducing speed and stopping the motor. ‘See Note. ‘The alarm shifts to level 3 after elapse of 30 seconds. Note: The VACII drive unit performs the same operation in alarm levels 2 and 3 though there is difference in internal processing.9727-£ P-B27 SECTION 3 OPERATION STATUS INDICATION Table 3-5 Failure Operation Status Indication Mode ‘AD. PAR acc | Cycle over error LooP [INTE loop error wo0G _| Watchdog error 100M __| Motor cable overcurrent tocs inverter bridge short 1OCR__ | Regeneration circuit IGBT short ov Power circuit overvotage Uv input voltage drop PH Phase defect Loss [Arithmetic circuit voltage drop os (Over speed UvP_| Power circuit low voltage RAER [RAM abnormal DSC [Excessive velocity deviation error INT4 loop error INT1 loop error Winding changeover error Hoat sink overheat Motor overload, Note: 'M3 lights when an alarm occurs with the power circuit (IOCM, IOCS, OCR, OV, UV, PH, LOSS).3727-E P-B28 SECTION 3 OPERATION STATUS INDICATION RES Resolve alarm PAR RAM parity error acc Cycle over error (tw INTE loop error 7—{ W00G_ | Watch dog error mime’ 1% 24 3¥ 4% 54 6 DOoOoOoOOOo oO dG fe) Pea) es) fe) Fd Ge] M37, 8, 9,10, 11,12, 13 Arithmetic circuit voltage drop Phase defect Input voltage drop Power circuit overvoltage Regeneration circuit IGBT short Inverter bridge short Motor cable overcurrent ‘Alarm at power circuit Fig. 3:3 Failure indication by LED's (with M1 and M2 LED's flashing)3727-E P-B29 SECTION 3 OPERATION STATUS INDICATION oN OFF UvP —_| Power circuit low voltage RAER | RAM abnormal i. DSc —_| Excessive velocity deviation error 6 WCHER | Winding changeover error LOOP1 —_| INT1 loop error LOOP4 . | INT4 loop error Fig. 3-4 Failure Indication by LED's (with M1 ON)3727-E P-B30 SECTION 3 OPERATION STATUS INDICATION OFF oN OH Heat sink overheat OL Motor overload 4 mivMa¥ 1¥ 2¥ 3¥ 4¥ BY 6 oOoo0o0ooo oO (ee) ee ee ed fe) Ne) MBq 74 8% Dy 10K My 124 13: Z Fig. 3-5 Failure Indication by LED's (with M2 ON)9727-E P-B31-R3 SECTION 4 TROUBLESHOOTING SECTION4 TROUBLESHOOTING Measures to be taken when a problem has occurred are explained in 4-1. and 4-2., and ‘measures to recover from the failure status are explained in 4-3. Locations of the component arts are shown in 2. “Configuration and Connection”. ne 1 Since high voltage is applied to the VACIII drive unit, first record the illuminating LED oz number(s) and tun off power supply to the VAC drive unit. 1. Confirmation of Power Supply and Connecters Before carrying out the steps explained in 4-2., check the items according to Table 4-1. ‘Table 4-1. Confirmation of Power Supply and Connecters Monaur volage acre Fpl tomas R67 ‘Correct input power of VACIII drive unit and power supply grounding | supply so that it is within terminal to check if it is within the allowable range. ‘Allowable range: AC 170 V to 242 V (+ 10%), 50/60 Hz ‘Make sure that the MR connectors (CN1, 2, 3) are all secured by screws. ‘The between-PCB connectors (CN 6, 7, 8) must tbe securely inserted into the upper part of the ‘connectors on the control PCB.3727-E P-B92 SECTION 4 TROBLESHOOTING 2. Trouble and Troubleshooting If a problem is found, take necessary procedures as indicated in Table 4-2. For the methods of inspecting or replacing each part, refer to the Section 5, “Maintenance and inspection”. Table 4-2 Classification of Failures Failure POWER LED does not light up. LOSS LED fights up. LED's show failure occurrence condition. Motor hunts. [Commanded motor speed cannot be obtained. OJOLOJO/OJO/OJOJO OJOJOJO/O}]O/O}O}O3727-E P-B33 SECTION 4 TROBLESHOOTING 2-1, POWER LED Does Not Light Up LOSS LED Lights Up Table 4-3 Check Measures ‘See Table 4-1. ‘See Table 4-1. Fuse (Fes) or warning fuse |(MP 50) is blown. ‘Check whether the fuses have been blown or not. (Refer to Section 6, 3-2. “Inspection and Replacement Procedure for Fuses”.) Replace blown fuse. Check to be sure that the between-board connector can be seen at the surface of the connector on the control PCB. 1) Detach the cover. 2) Check voltage across 3 and 4 of connector CNS with a voltmeter voltage must be 300V DC. Caution: High voltage is applied to the gate circuit and the Tegeneration circuit. Make sure that all the items. above are correct. Replace the control PCB. (Refer to Section 5, 4-1. “Control PCB Replacement Procedure”.)3727-E P-B34 SECTION 4 TROBLESHOOTING 2-2. LED’s Show Failure Occurrence Condition When LED's show failure occurrence condition, take necessary measures in accordance with the alarm number displayed on the VACII control PCB. For the alarm name and the alarm contents, refer to Table 3-3, “VACIII Alarm List". (1) Alarm No. 1 *P.G. count error” is displayed. Failure Factor Table 4-4 Check [The magnetic encoder sensor lor the gear is faulty. (2) Alarm No. 2 “Excessive motor speed” is displayed. Rotate the spindle by hand and | Replace the sensor or the check the output signals of the | gear. ‘encoder. (Refer to Section 6, 2.*Check Terminals” when checking the output signals.) Make sure that all the iterns above are correct. Table 4-5 Check Rotate the resolver by hand and check the output signals. (Refer to Section 6, 2. *Check Terminals” when checking the output signals.) Rotate the spindle by hand and check the output signals of the encoder. (Refer to Section 6, 2."Check Terminals” when checking the output signals.) ‘Check whether connector CNS and the connector in the VAC ‘motor terminal box are inserted Properly. Remove the motor signal ca- bles or the magnetic encoder signal cables and conduct the continuity test. Make sure that all the items above are correct.3727-E P-B35 SECTION 4 TROBLESHOOTING (8) Alarm No. 3 “APA speed” is displayed. Table 4-6 Check Measures Rotate the spindle by hand and | Replace the sensor or the check the output signals of the | gear. encoder. (Refer to Section 6, 2. “Check Terminals” when checking the output signals.) ‘Check whether connector CN3__ | Insert the connector property. is inserted properly. ‘Remove the magnetic encoder | Check the magnetic encoder signal cables and conduct the _| signal cables. continuity test. (4) Alarm No. 4 “CON speed” is displayed. Make sure that all the items | Replace the control PCB. above are correct. Table 4-7, (6) Alarm No. 5 “DIFF over" is displayed. Failure Factor Table 4-8 Check lOperation in overioaded condi- tion ‘Check the cutting conditions. ‘Check the machine for mechani- cal troubles: lubricating oil, etc. Make sure that all the items above are correct.3727-E P-B36 SECTION 4 TROBLESHOOTING (6) Alarm No. 6 “Resolver error" is displayed. Table 4-9 Check Measures. ‘Check whether or not connector | insert them properly. CN2 and the connector in the |VAC motor terminal box are in- serted property. Remove the motor signal cables | Replace the motor signal ca- and conduct the continuity test. | bles. ‘Make sure that all the items Replace the control PCB. above are correct. ‘Make sure that the alarm No. 6 | Replace the resolver in the is indicated even after the re- | VAC motor. placement of the control PCB. (7) Alarm No. 7 “RAM parity error” is displayed. Replace the control PCB. (8) Alarm No. 8 “Communication error” is displayed. Table 4-10 Check ‘Check whether or not connec- tors of optical fiber cables of ‘control PCB are inserted proper- y. ‘Check whether or not optical fi- ‘ber cables are broken. (Refer to Section 6, 3. “Method of In- ‘specting Optical Fiber Cable” when checking the optical fiber cables.) [SPOS (card on the SVP Make sure that all the items board) on the NC is faulty. _| above are correct. [The contro! PCB is faulty. Make sure that all the items above are correct.3727-E P-BS7 SECTION 4 TROBLESHOOTING (8) Alarm No. 9 “Command error” is displayed. Table 4-11 Failure Factor Check Measures [Fauity NC software (Undefined | Check the communication in instruction or non-executable | which an alarm occurs. instruction is communicated.) (10) Alarm No. 10 “Motor cable overcurrent” is displayed. Table 4-12 Check Correct the NC software. Check motor power cable con- lpower cables at terminal block | nection at the terminal block of {the motor and the VACIII drive unit. [Motor power cables are Disconnect the motor power ca- broken, short-circuited, or _| bles from the VACII drive unit lgrounded. and the motor, and check con- ‘Check the connectors at the VAI drive unit (CN3) and in the VAC motor terminal box. - Are they inserted property? ‘Measure resistance between the ‘VAC motor power cable terminal and the frame using a Megger ingulation tester. Make sure that all the items. above are correct. Make sure that the alarm No. 10 is indicated even after the re- placement of the contro! PCB.3727-E P-B38 SECTION 4 TROUBLESHOOTING (11) Alarm No. 11 “Inverter bridge short” is displayed. Table 4-13 Check Measures: [The control PCB or the power | Refer to Table 4-14. Refer to Table 4-14, Disconnect the motor power | Replace the cables. cables from the VACII drive unit and the motor, and check continuity. The VAC motor is faulty. Measure resistance between | Replace the VAC motor. the VAC motor power cable terminal and the frame using Meager insulation tester. For the VAC motor of the Refer to the maintenance man- | Replace the magnet switch or winding changsover val for the machine. ‘magnet switch drive relay. specification, the magnet switch for changing winding or magnet switch drive relay is faulty. Table 4-14 Contents ‘Tum off the power supply. ‘Check the fuses in the G1 - G12 base circuits. Refer to Section 5, 3-2. “Inspection and Replacement Procedure for Fuses. ‘Remove the control PCB and check to be sure that the between-board connectors are ‘securely connected to the ‘connectors CN6 to 8 on the power PCB, Hf not, firmly fix the between- board connectors. Connector on power unit Check the IGBT modules IGBTM1 - IGBTM3. Refer to Section 5, 2-1. “IGBT Module Inspection Procedure”. Install the control PCB. Refer to Table 5-10. Run the VACII drive unit. Check whether the alarm No. 11 is displayed. Refer to Section 5, 4-4. “Trial Operation Procedure”. If the alarm No. 11 is displayed again, replace the control PCB and then run the VACIII drive unit. Refer to Section 5, 4-1. “Control PCB Replacement Procedure”. if the alarm No.11 is stil displayed, replace the power supply unit. Refer to Section 5, 4-2. “Power Supply Unit Replacement Procedure”.3727-E P-B39 SECTION 4 TROUBLESHOOTING (12) Alarm No. 12 “Regenerator IGBT short” is displayed. Table 4-15 Check Check the power supply. Refer to Table 4-16. Table 4-16 Contents ‘Tum off the power supply. ‘Check the fuses in the G7 - G12 base circuits. Refer to Section 5, 3-2. “Inspection and Replacement Procedure for Fuses”. ‘Remove the control PCB and check to be sure that the connector pins at the supply Unit side of the connector CNE to CNB are fixed to the connector. ‘Check the IGBT module IGBTM4-- IGBTM6. Refer to Section 6, 2-1. “IGBT Module Inspection Procedure. Install the control PCB. Refer to Table 6-10. Run the VACII drive unit. Check whether the alarm No. 12 is displayed. Refer to Section 5, 4-4. “Trial Operation Procedure” If the alarm No. 12 is displayed again, replace the control PCB and then run the \VAGII drive unit. Refer to Section 5, 4-1. “Control PCB Replacement Procedure”. {f the alarm No. 12s stil displayed, replace the power supply unit. Refer to Section 5,42. “Power Supply Unit Replacement Procedure”. (13) Alarm No. 13 “Power circuit overvoltage” is displayed. Table 4-17 Check Measures ‘See Table 4-1. ‘See Table 4-1. Power supply cable terminal |1) Tum power supply off. | Secure the screws tightly. [screws are loose. 2) Check the screws if they are loose. faulty. Follow the steps in Table 4-16. | See Table 4-16. Power supply impedance is | The alarm No. 13s displayed | Use a power supply unit with high. ‘only while decelerating. a low impedance.3727-E P-B40 SECTION 4 TROUBLESHOOTING (14) Alarm No. 14 “Input voltage drop” or Alarm No. 15 “Open phase"is displayed. Table 4-18 Failure Factor ‘Check Measures. Power supply voltage is low, | See Table 4-1. ‘See Table 4-1. or one of three phases is ‘open. Fuso FIR to F3T is blown. | Check whether the fuses have | Replace blown fuse. been blown or not. [The screws in the IGBT mod- | Check the screws in the IGBT | Secure the screws tightly. ule 4 to 6 is loose. module. Check the IGBT module. Replace the IGBT module. Refer to Section 5, 2-4. “Procedure to Replace Main Circuit Semiconductor Devices’ Insert the connector property. The control PCB is faulty. ‘Make sure that all the items | Replace the control PCB. above are correct. The power supply unit is ‘Check to be sure that the Replace the power supply auitty. alarm No. 14 or No. 15 is dis- | unit. played even after the replace- ‘ment of the contro! PCB. ‘The alarm No. 14 or No. 15s [Use a power supply unit with displayed only during accelera- | a low impedance. tion and deceleration of the motor.9727-E P-B41 SECTION 4 TROUBLESHOOTING (18) Alarm No. 16 “Loss of arithmetic circuit power” is displayed. Refer to Table 4-3. (16) Alarm No. 17 “Power circuit low voltage” is displayed. Table 4-19 Check Measures ‘See Table 4-1. ‘See Table 4-1. [The screws in the IGBT mod- ule 4 to 6 is loose. ‘Check the screws in the IGBT module. ‘Secure the screw tightly. Check the IGBT module. Replace the IGBT module. Refer to Section 5, 2-4. “Procedure to Replace Main Circuit Semiconductor Devices”. [The connector is not plugged in property. ‘See Table 4-1. ‘See Table 4-1. [The power supply unit is faulty. ‘Make sure that all the items above are correct. Replace the power supply unit. The contro! PCB is faulty. The alarm No. 17 is displayed after the replacement of the power supply unit. (17) Alarm No. 18 “INT loop error” is displayed. Replace the control PCB. Replace the contro! PCB.3727-E P-Ba2 SECTION 4 TROUBLESHOOTING (18) Alarm No. 19 “Motor overioad” is displayed. Table 4-20 Alarm No. 19 is Displayed during Motor Rotation Failure Factor Check Measures [Operation in overloaded condi- tion ‘Check the motor temperature. [Loose connection of the fan | The motor cooling fan does not block ‘operate when power is turned on, Check fan motor cable con- nection at the terminal block of the motor and the VACII drive unit. ‘The motor cooling fan does not ‘operate when power is turned on. Check continuity. Review the operation pro- gram. ‘Connect the cables correctiy. Replace the fan motor cables. [Motor cooling fan is faulty. The motor cooling fan does not ‘operate when power is turned on. Replace the motor cooling fan. ‘Check contamination degree. Clean with compressed air or using vacuum cleaner. ‘Make eure that all the items above are correct. Replace the control PCB. ‘Check the connectors at the \VACII drive unit (CN2) and in the VAC motor terminal box. - Are they inserted properly? Insert the connector properly. Remove the signal cables and ‘conduct the continuity test. Measure the resistance be- ‘tween thermostat terminals of ‘the connector in the VAC mo- tor terminal box. If itis an infi- nite value (©), it indicates that the thermostat is faulty. ‘Make sure that all the items. above are correct.9727- P-B43 SECTION 4 TROUBLESHOOTING (19) Alarm No. 20 “Heat sink overheat" is displayed. Failure Factor Table 4-21 Measures PCB connector CN7 is not in- ‘serted properly. Heat sink cooling fan is faulty. Check if the heat sink cooling fan is operating when power is tumed on. Insert the connector properly. Replace the power supply unit. Heat sink cooling fan and heat ‘Check contaminated condition at the back of the power sup- ply unit. ‘Clean with compressed air or using vacuum cleaner. ‘Check the cutting conditions and cutting tools. Make sure that all the items above are correct. Replace the control PCB. The power supply unit is faulty. Make sure that the alarm No. 20 is displayed after the re- placement of the control PCB. (20) Alarm No. 21 *Data setting abnormal” is displayed. Table 4-22 Check Replace the power supply unit. ‘Check the VAC PBU data or (21) Alarm No. 22 “intemal velocity command too fast" is displayed. cone-ine change parameter. Table 4-23 Check Measures. ‘Check the machine for the me- chanical trouble factor. Remove the mechanical trouble factor.3727-E P-B44 SECTION 4 TROUBLESHOOTING (22) Alarm No. 23 “P.G. error” is displayed. Table 4-24 Check Measures Rotate the spindle by hand and | Replace the sensor. ‘check the output signal of the ‘encoder. (Refer to Section 6, 2 “Check Terminals” when checking the output signals.) ‘Check whether connector CN2 is inserted properly. Remove the magnetic encoder ‘cables and conduct the con- tinuity test. (28) Alarm No. 24 “P.G. marker latch data error” is displayed. Table 4-25 Check Rotate the spindle by hand and check the output signal of the ‘encoder. (Refer to Section 6, 2 “Check (24) Alarm No. 25 "Cycle over error" is displayed. Table 4-26 (25) Alarm No. 26 "Watchdog error” is displayed. ‘Alarm No. 27 “A/D access alarm” is displayed. ‘Alarm No. 28 “Master CPU error” is displayed. ‘Alarm No. 29 “Slave CPU error” is displayed. Table 4-27 Failure Factor ‘Check Measures [The contro! PCB is faul Replace the contro! PCB.3727-E P-B45 SECTION 4 TROUBLESHOOTING (26) Alarm No. 30 “Excessive velocity deviation error” is displayed. Table 4-28 Failure Factor Measures ‘Operation in overloaded condi- ‘Check the cutting conditions: tion and cutting tools. ‘Open or loose contact of mo- | Check the motor power cables. | Connect the motor power ca- tor power cables bles correctly. ‘Motor signal cables are faulty. | Check the motor signal cables. | Connect the motor signal ca- (loose connection, miswiring, bles correctly. etc.) ‘The power supply unit is faul- Replace the power supply ty. unit. ‘The control PCB is faulty. Replace the control PCB. For the VAC motor of the Replace the magnet switch ‘winding change specification, for changing winding or the magnet switch for ‘magnet switch drive relay. ‘changing winding or magnet switch drive relay is faulty. (27) Alarm No. 31 “Winding changeover error” is displayed. Table 4-29 Failure Factor Magnet switch and/or magnet switch drive relay for winding [changeover is faulty. The control signal cable is Haulty. (broken or loose con- tact) [The control PCB is faulty. Make sure that all the items | Replace the contro! PCB. above are correct. (28) Alarm No, 32 “RAM error” is displayed. Table 4-30 Failure Factor3727-E P-B46 SECTION 4 TROUBLESHOOTING 2-3. Motor Hunts Failure Factor Table 4-31 Measures Faulty motor power cables and motor signal cables (loose [contact, miswiring, etc.) ‘Check the cables. Connect the cables correctly. Fuses in G1 - G6 gate circuits are blown. IGBT modules IGBTM1 - IGBTM6 are faulty. ‘Check the fuses in the G1 - G6 gate base circuits. (Refer to Section 5, 3-2. “in- spection and Replacement Procedure for Fuses”.) ‘Check the IGBT module IGBT1 = IGBTS. (Refer to Section 5, 2-1. “Transistor Module Inspection Procedure".) Replace blown fuse. Replace the IGBT module. Make sure that all the items above are correct. Note: With the VAC motor winding change specification, the motor power cables are wired through the winding change magnet switch. Therefore, the possibilty of loose contact, wiring error, etc. related with the magnet switch for changing winding must also be checked.3727-E P-B47 SECTION 4 TROUBLESHOOTING 2-4. Commanded Motor Speed Cannot be Obtained Motor Does Not Rotate Table 4-32 Check Measures: The VACII drive unit is faulty. | When a rotation command is | See 2-2. “LED's Show Failure ven, the LED’s light up indi-_ | Occurrence Condition”. cating the faulty operation con- dition. [Broken or loose contact of the | Check the motor signal and | Connect the cables correctly. motor power cables power cables. The resolver is faulty. Chuck the resolver signal. | Replace the motor. (Refer to Section 6, 2. “Check “Terminals” when checking the output signals.) |The magnetic encoder is faul- | Check the output signal of the . ‘encoder. (Refer to Section 6, 2. “Check Terminals” when checking the output signals.) ‘Make sure that all the items above are correct. ‘Make sure that all the items. above are correct. Refer to the maintenance ‘manual for the machine. Note: With the winding changeover specification, motor speed range varies according to the selected winding. High-speed winding: 0 - max. motor rpm Low-speed winding: 0 - max. motor rpm in low-speed range 1 a motor speed exceeding max. rpm in the low-speed range is specified while the low-speed winding is selected, the motor rotates at the max. speed in the low-speed range.3727-E P-B48 SECTION 4 TROUBLESHOOTING 2-5. Low Cutting Performance Table 4-33 ‘Check Measures ‘Check the signal existing. ‘See TLMC in Fig. 3-2. Clear the torque limit /command. Refer to the maintenance man- ual for the machine. Refer to the maintenance manual for the machine. The control PCB is faulty. Make sure that all the items above are correct. 2-6. Long Acceleration and Deceleration Time Table 4-34 Replace the control PCB. Check the signal existing. See TLMC in Fig. 3-2. ‘See Table 4-1. ‘Check the motor power cables. (Check the fuses in gate cir- cuits. (Refer to Section 5, 3-2 “In- spection and Replacement Procedure for Fuses”) IGBT module is faulty. Check the IGBT module. (Refer to Section 6, 2-1. “IGBT Module Inspection Proce- dure”.) Replace the IGBT module. ‘Make sure that all the items above are correct. ‘Only deceleration period is elongated.3727-E P-B49 SECTION 4 TROUBLESHOOTING 2-7. Excessive Vibration and Noise While the Motor is Rotating Table 4-95 [VAC motor is faulty. it Replace the VAC motor. To determine the cause of the problem, run the VAC motor freely. For this, follow the procedure below. 1) Start the VAC motor. 2) Remove the optical ber connector from the VACII drive unit. 3) The “communication abnormal” occurs and the VAC motor runs freely.3727-E P-B50 SECTION 4 TROUBLESHOOTING 3. Recovery from Failure Status ‘When LED's indicate the faulty operation status, it is necessary to remove the cause of failure first and then reset the alarm state to recover the operations of the VACII drive unit. VAC alarms are classified into the following four levels according to the operation at their ‘occurrence and the way to reset them. Refer to Table 3-3, “VACII Alarm List”. Table 4-36 Operation at Occurrence How to Reset Transited to alarm level 1 | Set the three-phase VAC hardware must be {immediate power shutoff) | breaker to the “OFF” | initialized. (for example position and then set it | exception alarm) to the “ON” position again. ‘Transited to alarm level 1 | Tum off the power to (power shutoff after the | the NC once and then motor is stopped.) tum it on again. Transited to the alarm Reset the NC from the state in the mode in which | operation panel. the alarm occurred. “1 (The reset command is (Operation varies generated in each depending on the main | mode.) ‘mode in which the alarm occurred.) ‘The VAC sends Reset the NC from the information to the NC that | operation panel. an alarm of level 3 has | (The reset command is, ‘occurred. The VAC generated in each operates for 30 seconds | mode.) after the alarm occurred, then the alarm level is transited to "2". ‘1 The main mode means the speed control mode (usually commanded by $ codes) and the position control mode (for C-axis control).3727-E P-B51 SECTION 5 MAINTENANCE AND INSPECTION SECTION 5 MAINTENANCE AND INSPECTION 1. Instruments and Parts Used for Maintenance Instruments used for maintenance are indicated in Table 5-1. Table 5-1 Maintenance Instruments For measuring power supply voltage For checking resistance 13 mm (0.51 in.) For replacing semiconductor elements used in the main circuits Components parts used in the VACII drive unit and those necessary for maintenance are indiceted in Table 5-2.3727-E P-B52 SECTION 5 MAINTENANCE AND INSPECTION Table 5-2 Maintenance Parts for VAC Drive Unit Type ‘6MBI100-080 100 A 600 V (Fuji) 100 A 600 V (Mitsubishi) (CMI50DY-12E 150 A 600 V (Mitsubishi) ‘2MBI150-060L_ 150 A 600 V (Fuji) ‘CM200DY-12E 200 A 600 V (Mitsubishi) 200 A 600 V (Fuji) (CMS00DY-12E '300 A 600 V (Mitsubishi) '2MBI300-060L 300 A 600 V (Fuji) ‘CM400DY-12E 400 A 600 V (Mitsubishi) 400 A 600 V (Fuji) Diode module. [RMS0HA-12F £2714-820-006 50 A 600 V (Mitsubishi) RM100C22-H 100 A 800 V (Mitsubishi) RM100022-H 100 A 800 V (Mitsubishi) F.GBO 5 A250 V (Fuii) FGBO 0.5 A 250 V (Fu) MP50 5A (Daito Tsushin) M03 0.3 A (Daito Tsushin) £2714-820-005 E2714-820-005 2442-727-004 E2442-727-00 £2442-392-215 £2442-992.213 Note: The elements of which quantity is shown in ( ) are compatible with the ‘elements immediately above.9727-E P-B53-R3 SECTION 5 MAINTENANCE AND INSPECTION 2. Semiconductor Elements Inspection and Replacement Method (acai): When inspection and/or replacing semiconductor elements used in the main circuits, pay attention to the following points. After the completion of inspection or replacement, set the leads and bus bars to the riginal Position correctly and tighten the screws firmly. If all screws are not tightened, the unit might fail to function correctly. ‘Take care so that you do not lose screw. 2-1. IGBT Module Inspection Procedure » 2) 3) 4) 5) Remove the power and the motor cables. Remove the control PCB. Remove the power PCB. Measure resistance between terminals using a muitmeter. “Terminal locations and intemal equivalent circuit on the IGBT module are shown in Fig. 6-1 and Fig. 5-2. For the judgment criteria, see Table 5-3. Follow the procedure below depending on transistor conditions. Always make sure that the power PCB is secured with screws correctly. ‘After completion of inspection and maintenance, install the control PCB, clamp it in place with screws and connect it with the motor and the power cables. ° = . 8} lo. ® ] ( el] ° FI [ol |* aie oO} (a) 2in 1 Type. (b) 6 in 1 Type Fig. 6-1 IGBT Module Terminal Arrangement9727-E P-B54-R3 ‘SECTION 5 MAINTENANCE AND INSPECTION C2E1 ae || a : e2 J et G2 2 (2 in 1 Type) (6 in 1 Type) Fig. &-2 Equivalent Circuit of IGBT Module Table 5-3 Judgment Criteria (Multimeter Range Setting: x 10) NOTICE | : To obtain correct measurements, make short-curcuit between terminals G and E.3727-£ P-B55 SECTION 5 MAINTENANCE AND INSPECTION 2-2. Gate Circuit Inspection Procedure Check the gate circuits No. 1 to 12 and replace fuses according to 3-2 “Inspection and Replacement Procedure for Fuses”. 2-3. Diode Module Inspection Procedure a) 2) a Remove the control PCB and power PCB. Measure the resistance between the terminals of diode module using a multimeter. 5 Fig. 5-3 Terminal Arrangement Fig. 6-4 Equivalent Circuit of Diode Module of Diode Module Table 5-4 Judgment Criteria (Multimeter Range Setting: x 10) Diode Module Terminals Multimeter Terminal | Mutimeter Terminal (+) Side (—) Side a @ a ‘Several tens to O) @ several hundreds of ohms ‘Several tens to a) several hundreds of ohms Follow the procedure below depending on the diode module conditions. ‘When abnormal: Replace the diode module. For the procedure to replace the diode module, refer to Section 5, 2-4, “Procedure for Replacing Semiconductor Elements in Main Circuit”. ‘When normal: Install the power PCB and control PCB while making sure that all the screws are secured.3727-E P-B56-R3 SECTION 5 MAINTENANCE AND INSPECTION 2-4, Procedure for Replacing Semiconductor Elements in Main Curcuit Table 5-5 Contents ‘Remove all the screws and gate connectors from the power PCB to dismount the PCB from the main body. Remove the module clamping screws and gate wires to detach the module. Coat silicone grease to a new module. Install a new module and securely tighten the screws. ‘Connect the gate wires to the new module. Install the power PCB by securely attaching screws and connectors without omission. This is to improve contacting conditions between the module and the installation surface thus to provide better cooling effect. Pay attention to module installation orientation, The IGBT uses metal oxide semiconductor (MOS) elements. Be Careful not to get electrostatic shook. Ensure that all the screws are tightened. + Donot remove the static electricity preventive mat before connecting gate wires.3727-E P-B57 SECTION 5 MAINTENANCE AND INSPECTION 3. Fuse Replacement 3-1. Fuse Blown Condition Blown conditions of fuses used in the VACII drive unit are shown in Table 5-6. Table 5-6 Fuse Blown Conditions Blown fuse element ‘The fuse element is blown as illustrated to the left when viewed from the front. White ‘The white fuse blown indication appears at upper portion of the fuse cartridge when viewed from the front. Blown fuse element ‘The fuse element is blown as illustrated at the left when viewed from the front. ‘There might be cases where the blown fuse ele- ‘ment cannot be found visually.3727-E P-B58 SECTION 5 MAINTENANCE AND INSPECTION 3-2. Inspection and Replacement Procedure for Fuses 1) Take the fuse out of the fuse holder. 2) Measure resistance across the glass-tubs filled fuse element using a multimeter. Reading must be On. When it is “=>” it indicates that the fuse has been blown. 3) If the fuse is blown, replace the fuse. 4) Set the fuse in the fuse holder. If the fuse is provided with a cover, do not forget to set the cover. 3-3. Fuse Rating For fuses F1 - F3, MP50 and HM03, use § A, 0.5 A and 0.3 A rating fuses as indicated in Table 5-7. Table 5-7 Fuse Current Rating Fuse Rating [A] FaR | Fas. os | 05 05 | 053727-E P-B59 SECTION § MAINTENANCE AND INSPECTION 4. Replacing Control PCB and Power Supply Unit 4-1. Control PCB Replacement Procedure Table 6-8 Procedure to Replace the Control PCB Contents ‘Tum off the power supply. Loosen screws and detach the cover. Remove the control PCB. Install the new control PCB. Run the VACII drive unit. install the cover and secure it with screws. Table 6-9 Table 6-10 4-4, ‘The procedure to remove an mount the control PCB is indicated in Tables 5-8 and 6-9. For the arrangements of the connectors, refer to Fig. 2-2. Table 6-9 Procedure to Remove the Control PCB ‘Loosen connector fixing screws and remove connectors CN1 - CN3. Remove the connector for the optical fiber. Remove the M4 screws which fix the control PCB. ower supply unit rack. Pull the control PCB while holding its upper and lower parts and remove it from the3727-E P-B60 SECTION 5 MAINTENANCE AND INSPECTION Table 5-10 Procedure to install the Control PCB: Contents Insert the connector between the control PCB's in the connectors on the control Pos. Fix the control PCB with the M4 screws. Connect the connectors CN1 - CN3 and clamp them firmly with connector fixing screws. ‘Check the ROM, switch settings and potentiometer settings in reference to the VAC Series Characteristics Table. 4-2. Power Supply Unit Replacement Procedure Table 6-11 Procedure to Replace the Power Supply Unit Contents. Tum off the power supply. Remove the power cables and motor power cables. ‘Loosen the connector fixing screws and remove connectors CN1 = CN3. Remove the connector for the optical fiber. Loosen screws and detach the cover. Remove the control PCB. Install a new power supply unit. ‘Connect the connectors CN1-CN3 and clamp them firmly with ‘connector fixing screws. Install the connector for the optical fiber. Run the VACII drive unit. Install the cover and clamp it with screws.3727-E P-B61 SECTION 5 MAINTENANCE AND INSPECTION 4-3. VACII Drive Unit Assembly Replacement Procedure Table 5-12 Procedure to Replace the VACII Drive Unit Assembly ‘Tum off the power supply. Remove the power cables and motor power cables. Loosen the connector fixing screws and remove connectors CN1- CN3. Remove the connector for the optical fiber. Install a new VACII drive unit. ‘Connect the connectors CN1-CN3 and clamp them firmly with connector fixing screws. Install the connector for the optical fiber. Detach the cover and check the ROM, switch settings and potentiometer settings in reference to the VAC Series Characteristics Table. ‘Connect the power cables and motor power cables and then run the VACIII drive unit. Install the cover and secure it with screws. 4-4, Trial Operation Procedure After replacing parts or units, make a test run according to the procedure in Table 5-13. ‘Table 6-13 Trial Operation Procedure Confirm that the ROM, switch settings, potentiometer settings, and unit type are all correct, referring to the VAC Series Characteristic Table. ‘Tum on the power and confirm that the green LED “POWER? lights. Confirm that the cooling fan of the VACIII drive unit and the VAC motor rotate. Check if the 7-segment LED's indicate 01 immediately after tuming on the main breaker, and the indication turns to 02 when the NC starts up by operation power supply. Input the rotation command to check the motor rotation both in the forward and reverse directions. Check the operations over the entire speed range and in the position control mode.9727-E P-B62 SECTION 6 APPENDIX SECTION 6 APPENDIX 1. ROM and File Name for VACII Drive Unit ‘The control software for the VACIII drive unit is supplied as below: 1) ROM to be mounted on control PCB (1 unit) 2) File in the control floppy disk (PBU file x 1) 1-1, ROM for VACII Drive Unit (1) Mounting Place ‘One ROM is mounted on the control PCB. Refer to Fig. 2-2. @) ROM Namo VAC A121¢ Patch code Revision No. ‘Version No. High-precision position control specification 1-2, File in the Control Floppy Disk (1) Type of File The following file are developed to store the control data for the VAC. drive unit. (@) LM, @ common filo L Me vuse — ak PBU w Contents: Indexing parameter, motor type, gear ratio, etc. Remark: This file includes parameters that may be set by the user such as parameter for indexing, make a backup file in the floppy B. (b) File for synchronized tapping MVTO#— #3 — POL Contents: No. of gear stops for synchronized tapping, motor speed range for synchronized tapping in each step, otc.9727-E P-B63 SECTION 6 APPENDIX (2) File Name ‘The VAC PBU file name contains the following codes and symbols. 1 VU 4p g— Hy 5 Ho— 7. PBU [ ‘Spindle No. (1: First, ‘Version Machine type/specifications Numerically controlled position code (LM, oF G code) ‘VAC type 0: General-purpose, 1: High-precision Kind of Machine LL lathe, M: machining center, @: grinder, 'W: OH-make lathe ‘Second, 3: Third, 4: Fourth)9727-E P-B64 SECTION 6 APPENDIX Check Terminals For the layout of the check terminals, refer to Fig. 2-2. Contents Control circuit ground ‘Separated from the regenerative contro! Circuit, the inpuvvoutput signal circuit, and the base circuit. Resolver excitation signal Sine wave Resolver feedback signal When motor > 3 stops glo T= 128 (0) 2 Phase difference to the excitation signal changes as the motor rotates. Frequency f (Hz) varies as indicated below ‘according to the motor speed N (rpm). 1 8N te Ute enoaix aces (00) (+ in the forward rotation and — in the reverse rotation) Velocity monitor ‘The motor speed (rpm) is indicated. £10 [V] at the maximum motor speed ‘Torque monitor ‘The motor output torque is indicated. £10 [V] at the maximum motor output3727-E P-BE5 SECTION 6 APPENDIX Remarks. Inverter circuit current detection ‘The 1OCS alarm cours at higher than approx. 2.75 V (1.4 V for D3) Regeneration circuit current detection The IOCR alarm occurs at higher than approx. 1.7 V (0.85 V for D3) U-phase current feedback signal \V-phase current feedback signal Current feedback three- phase full wave rectifying signal 0 (V) Cycle and amplitude Changes depending on a yme™veyeting operation state. With the VACIIL control PCB, the current feedback signal is rectified to negative voltage. U-phase current ‘command signal oM= \V-phase current ‘command signal Cycle and amplitude changes depending on operation state. U-phase current amplifier signal om \V-phase current amplifier signal Cycle and amplitude changes depending on operation state.3727-E P-B66 SECTION 6 APPENDIX Usphase induced voltage command signal \V-phase induced voltage command signal Cycle changes depending on the motor speed. Control circuit power voltage Control circuit power voltage Control circuit power voltage Grounding in regeneration control circuit When checking the waveform in the regeneration circuit, use an insulated oscilloscope. Be careful that the COM terminal is not short- circuited with other circuit, for example with the GND terminal, in the oscilloscope. Regeneration control circuit power voltage:3727-E P-BE7 SECTION 6 APPENDIX Remarks. T is determined on the basis of the number of gear tooth and the speed. 2: Number of gear teeth N: Speed (rpm) Nx 1/60xZ, (sec) ‘Amplitude at Aand B: Voc = 2.5V Vpp = 3V ‘Amplitude at Z: Voc = 2.5V Vep = 3V3727-E P-B6BE SECTION 6 APPENDIX 3. Method of Inspecting Optical Fiber Cable ‘Throw light on one of the optical fiber connectors and check if the other connector lights up. Seo Fig. 6-1. Fig. 6-1C; SPINDLE DRIVE UNIT FOR VAC II MOTOR (OKUMA MAKE)9727-E P-C1-R2 SECTION 1 OUTLINE SECTION1 OUTLINE ‘This section covers the maintenance procedures and necessary information related with the high-precision VAC II drive unit. ‘The VAC II drive unit consists 0 the following units and component parts. 1) Control printed circuit board (PCB) :_ VAC II 2) Control printed circuit board (PCB): VAC card 1 8) Power supply unit : poo 4) Spare parts ‘Table 1-1. VAC II Drive Unit Configuration Model Power Supply Unit Control PCB Spare Parts ‘VAC 1-030 | Power supply unitD30A_| VAC board II + VAC card 1 ‘Spare parts of VAC ‘VAC TI-D45 [Power supply unit D45A_[VAC board I-HPW + VAC card 1 | drive unit Note 1: The power supply unit and spare parts are common to the VACII drive unit and VAC drive unit type A. Note 2: The contra! PCB cannot be installed on any power supply unit other than the type A unit. Combinations between the contro! PCB and the older type power supply unit than the type A unit will lead to malfunctioning of the VAC IT drive unit. ‘Setting switches and potentiometers to be adjusted on the control PCB according to the motor specification are summarized in Table 1-2. No other settings and adjustments are necessary on the control PCB. ‘Table 1-2 Setting and Adjusting Switches and Potentiometers Name Use DIP switch SW1 and SW2_| Setting of control software according to specifications DIP switch SW3 and SW4_| Setting of control software according to the motor ROM Device to store control software; common to all ypes of motors except special specifications VAI |VR2 Invalid for the high-precision VAC, VAs SM Fine adjustment of full-scale output current for speed meter LM Fine adjustment of full-scale output current for load meter3727-E P-C2-R2 SECTION 2 CONSTRUCTION AND CONNECTION SECTION 2 CONSTRUCTION AND CONNECTION 1. Construction ‘The VAC drive unit construction Is illustrated in Fig. 2-1. Mounting holes (Upper: slot x 2 Cover Power supply unit Lower: round end slot x 2) Control PCB (VAC boardIl_ VAC card 1) Fig. 2-1 VAC Drive Unit Construction ‘The control PCB and the cover are fixed to the power supply unit door with the screws. The power supply unit door can be opened by removing the screws at the upper and lower right sides. ‘Arrangement of major component parts on the control PCB and the power supply unit are shown in Figs. 2-2 to 2-5. 1-1. Major Component Parts Arrangement [Major component parts arrangement on control PCB VAC board I Fig. 22 [Major component paris arrangement of control PCB VAC card 1 Fig. 2-3 [Major component parts arrangement for DOA Fig. 2-4 [Major component parts arrangement for D45A. Fig. 2-5,9727-€ P-C3-R2 ‘SECTION 2 CONSTRUCTION AND CONNECTION aad Manulactunog No Sues ua pa No 0% cn 7 £4809-045-140 —4 a | or — 1. fl ceases : = ‘| jo ea a =o iad i ‘Teanstormer rr eee Warring fuse PCO rae so e590 ae ‘tome! s sv. GNo =e 2 eee ¢ av tev *| 2 cea E2445-392-228 - (Balto Teushin) —— 2 MPEO E2M46 302-216 {Dato Teushin) a Base croak |iayio E2M45-962257 yt (Datto Teushin) ‘1 Transistor modules EVM31-050A ana QM150DX-H are interchangeable each other, and thus either of them can be used for D8 and Dit. For D22, both employing parallel transistor drive, only EVM31-050A can be used. 3. These fuses are supplied with the VAC drive unit as spare parts.9727-E P-C29-R2 ‘SECTION 4 INSPECTION AND MAINTENANCE 2. Inspection and Replacement Procedure for Semi-conductor Devices When checking or replacing semi-conductor devices used in the main circuits, pay attention to the following points. 1) After the completion of checkup or replacement, set the leads and bus bars to the original position correctly and tighten the screws firmly. If all screws are not tightened, the unit might fail to function correctly. 2) Take care s0 that you do not lose a screw. (AcAmion] = ‘After the completion of inspection or replacement of semi-conductor devices, connect the leads and bus bars which have been disconnected to the previously connected positions and tighten all the screws securely. tf even one screw is not tightened or left loose, it will preclude operation. Pay sufficient care not to drop a screw. 2-1. Transistor Module Inspection Procedure 1) Remove screws fixing the power supply unit door in place and open it. 2) Disconnect all leads of transistors to be checked. ‘With D2, parallel drive using two transistor devices is implemented; remove the bus bar between the two devices and check the individual transistors. 3) Measure resistance between transistor terminals. For this measurement use a multimeter. a ciel Ef C2 82 2 cr Ble! C262 €2 (e) OM75D1X-H (b) EVM31-050A, OM1500X-H Fig. 4-1 Transistor Module Terminal Arrangement BI B2 Fig. 4-2 Equivalent Circult of Transistor Module3727-E P-C30-R2 SECTION 4 INSPECTION AND MAINTENANCE Table 4-3 Judgement Criteria (Multimeter Range Setting: x 10) Transistor Terminals Multimeter Terminal | Multimeter Terminal Nome ‘Abnormal (#) Side ©)Side ‘Several tens to several c E hundreds of ohms one ‘Several hundreds of E . 2 ohms or less ‘Several tens to several 8 hundreds of ohms ean ; c S ‘Several hundreds of ohms or less ‘Several hundreds of B E beak 09, © ‘Several hundreds of E 8 cme 09,0 NOTICE | :_ !ta transistor is damaged, terminals C and E, and terminals C and B are shorted. 4) Follow the procedure below depending on transistor conditions. (2), When abnormal Replace the transistor module. For the procedure to replace transistor modules, refer to 2-4. “Procedure to Replace Main Circuit Semi-conductor Devices". (b) When normal Connect the leads which have been disconnected, installing the bus bar. ‘Always make sure that the leads are connected in correct locations and secured with screws: correctly. With D22, connect the leads after 5) After the completion of inspection and maintenance, close the door and clamp it in place with screws.3727-€ P-C31-R2 ‘SECTION 4 INSPECTION AND MAINTENANCE 2-2. Base Circuit Transistor Inspection Procedure 1) Loosen screws and remove the cover. 2) Detach the contro! PCB. For the procedure to detach the control PCB, refer to Table 4-10. '3) Measure resistance between transistor terminals using a multimeter. C_(radiation plate) C_(radiation plate) a f : 8 E 8 E (a) ET191 (b) ©3346 Fig. 4-3 Base Circuit Transistor Terminal Arrangement ‘To determine whether the transistor checked in normal or not, refer to Table 4-3. 4) Follow the procedure below depending on transistor conditions. (@) When abnormal Install the detached control PCB. (b) When normal Install the detached control PCB. For the procedure to install a contro! PCB, refer to Table 4-11. 5) Fix the cover with screws. 2-3. Diode Module Inspection Procedure 1) Remove screws fixing the power unit door in place and open it. 2) Disconnect the leads. (a) D3, D6 and D8 Disconnect the diode module lead. (b) D1 and D22 Disconnect the bus bar and the leads connecting the diode modules.9727-E P-C32-R2 SECTION 4 INSPECTION AND MAINTENANCE 3) Carry out measurements. (a) D3, D6 and D8 Measure the resistance between the terminals of diode module PT768 using a multimeter. ‘Table 4-4 Judgement Criteria (Multimeter Range Setting: x 10) P1768 Terminals ‘Multimeter Terminal | Multimeter Terminal Normal ‘Abnormal (+) Side. © Side © ® ‘Several hundreds of @ 2) a on, (+) (3) (1) (+) ‘Several hundreds of @) © © ‘ohms or less (3) (+) © () ‘Several hundreds of © @) . ohms or less. o (3) ao oO ‘Several hundreds of @ @ a 02% (3) isi (1k (2) (3) (1) (2) (3) c) ) (+) (-) Fig. 4-4 PT768 Terminal Arrangement Fig. 4-5 Equivalent Circuit of PT768 (®) D11 and p22 Measure the resistance between the terminals of a diode module. (1 (2) (3) a) (2) (3) Fig. 4-6 PT768 Terminal Arrangement Fig. 4-7 Equivalent Circult of Diode Module of Diode Module9727-E P-C33-R2 SECTION 4 INSPECTION AND MAINTENANCE Table 4-5 Judgement Criteria (Multimeter Range Setting: x 10) Diode Module Terminals i] Multimeter Terminal | Multimeter Terminal Normal ‘Abnormal (Side OSide ‘Several hundreds of 2 = 2 ohms or less ” ® enue 09, © @ o aareeees [cae a 0 ~ 4) Follow the procedure below depending on the diode module conditions. (@) When abnormal Replace the diode module. For the procedure to replace the diode module, refer to 2-4. “Procedure to Replace Main Circuit Semi-conductor Device: (&) When normal ‘Connect the bus bar andthe leads which have been disconnected. Always make sure that the leads are connected in correct locations and secured with screws correctly. 5) After the completion of inspection and maintenance, close the door and fix in place with screws, 2-4, Procedure to Replace Main Circuit Semi-conductor Devices Table 4-6 Process Contents Remarks 1 Disconnect all bus bars and|leads con- | Before disconnecting bus bare and leads, ected to the module to be replaced. mark ID's for reconnection. 2 ‘Remove the module clamping screws and detach the module. 3 Coat silicone grease to anew module. | This is to improve contacting conditions between the module and the installation surface thus to provide better cooling ef- fect. 4 Install a new module and securely tighten | Pay attention to module installation the screws. orientation. 5 ‘Connect the bus bar and leads which have | Always make sure that the leads are oon- been disconnected. ected in correct locations and secured with screws correctly.3727-E P-C34-R2 ‘SECTION 4 INSPECTION AND MAINTENANCE 3. Fuse Replacement 3-1, Fuse Blown Condition Blown conditions of fuses used in the VAC dive unit are shown in Table 4-7. Table 4-7 Fuse Blown Conditions Fuse Name : Blown Condition fi ae Neon tube lighting up (excluding 0224) A ‘Theneon lamp light up asillustratedto the left when viewed from the front. (only when power is ON.) Fuses Free Blown fuse element (0224) ‘The fuse element is blown as illustrated to the left when Viewed from the front. Warming fuse mite SMP32 Be MPs ‘The white fuse blown indication appears at upper portion of the fuse cartridge when viewed from the front. Base circuit fuse oe Blown fuse element < ‘The fuse element is blown as ilustrated at the left when viewed from the front. “There mightbe cases where the blown fuse element cannot be found visually. 3-2. Inspection and Replacement Procedure for Fuses 1) Fuse Fi to F7 (For D22A only) (@) Tum off power supply. (0) Remove the fuse cover using a screwdriver. (©) Remove the glass-tube filled fuse element using a screwdriver,9727-€ P-C35-R2 SECTION 4 INSPECTION AND MAINTENANCE. (0) Measure resistance across the glass-tube filed fuse element using a multimeter. Reading must be 0. When itis “~", it indicates that the fuse has been blown. (©) the fuse Is blown, replace the fuse. ( Sotthe fuse holder. Refer to 3-3. “Fuse Rating”, (9) Place the fuse cover. Fuse cover TX Gis tube filed fuse Fuse holder Fig. 4-8 Fuse for D22 2) Waming Fuse SMP32, MP5O, and Base Circuit Fuse KM10 (@) Loosen the screws and remove the cover. (b) Check the fuse. ‘Waming fuse: Visually check the blown indication. Base circuit fuse: After removing the fuse, measure resistance between the terminals using a muttimeter Leal tide) Terminal In elther case, reading must be 0.9. When itis “co, it indicates that the fuse has been blown. (©) Remove the blown fuse and set a new fuse in the holder. Fig. 4-9 KM10 (@) Place the cover and secure the screws. 3-8. Fuse Rating For fuses F1 to F7, use 5 A and 0.5 A rating fuses as indicated in Table 4-8. When replacing a fuse, always use the one with the same current rating. ‘Table 4-8 Fuse Current Rating Fuse Rating (A) UotType erro] ro] ra | ro] FO] Dao, | 5 | 5 | 5 | 5 | & | 05 | 05 |Onlyforpowerunits of Ver. 1.0, D45A’ all fuses were 5 A rating. Remark3727-£ P-C36-R2 SECTION 4 INSPECTION AND MAINTENANCE 4. Replacing Control PCB and Power Supply Unit Control PCB Replacement Procedure Table 4-9 Procedure to Replace the Control PCB Process Contents Reference Item 1___ | Tum off the power supply. 2 [Loosen screws and detach the cover. '3___ [Remove the control PCB. Table 4-10 4 [install the new control PCB. Table 4-11 5 [Run the VAC drive unit. 4-4 6 Install the cover and secure it with screws. ‘The procedure to remove and mount the control PCB Is indicated in Tables 4-10 and 4-11. For the arrangements of the connectors, refer to Fig. 2-2. ‘Table 4-10 Procedure to Remove the Control PCB Process Contents 1 [Loosen connector fixing ecrews and breasts CN1, CN3 and MR connector 13. Remove the connector for the optical fiber. Connector ing screw| -O=— Fig. 4-10 Connectors CN1, CN3 and CN13 2 | Remove the six M4 screws which fix the control PCB. ‘3 [Pull the control PCB while holding its upper and lower parts and remove it from the power ‘supply unit rack,3727-E P-C37-R2 SECTION 4 INSPECTION AND MAINTENANCE 4-2. Table 4-11 Procedure to install the Control PCB. Process Contents 1 [Align the guide holes of connectors CCNA through CN7 of a new control PCB with the guide pins atthe power supply unit and insert the control PCB. Inert the control PCB until the red mark on the guide pin is visible from Connector Cen tee the connector surface. Guide hole Guide pin Ried mark Fig. 4-11. Connectors CN4 - CN7 2___|Fix the control PCB with the six Mi screws. 3 | Connect the connectors CN1, CN and CNT and clamp them firmly with connector fixing screws. 4 | Check the ROM, switch settings and potentiometer settings in reference to the VAC Se- fies Characteristics Table. Power Supply Unit Replacement Procedure Table 4-12 Procedure to Replace the Power Supply Unit Process: Contents, Reference item 1__ [Tum off the power supply. 2 [Loosen screws and detach the cover. 3 [Remove the control PCB. Table 4-10 4 __ [Remove the power supply unit. Table 4-13 5___| Install a new power supply unit. Table 4-14 ‘6 __| Install the control PCB. Table 4-11 7__|Run the VAC drive unit +4 8 [Install the cover and clamp it with screws. ‘The procedure to remove and mount the power supply uni indicated in Table 4-13 and 4-14. For the arrangements of the cable terminals, refer to Figs. 2-4 through 2-7. ACAUTION : When replacing the power supply unit, always confirm that all cables are connected correctly and all screws are tightened firmly.3727-E P-C38-R2 SECTION 4 INSPECTION AND MAINTENANCE ‘Table 4-13, Procedure to Remove the Power Supply Unit Process Contents 1 Remove the power cables, motor power cables, and the fan motor cables from the power supply unit | 2 [Loosen the two power supply unit clamping screws at lower sides, 3 Remove the two power supply unit clamping screws at upper side. 4 Hold and remove the power supply unit. ‘Table 4-14 Procedure to Remove the Power Supply Unit Process Conteris Place the power supply unit so that the two mounting holes under the power supply unit are correctly aligned with the two power supply unit clamping screws which are set in ad- vance, Install the two upper power supply unit clamping screws. ‘Secure the total of four power supply unit clamping screw evenly. ‘Connect the power cables, motor power cables and the fan motor cables. Always ensure the correct cable connection referring to the cable identification given on the sleeve. VAC Drive Unit Assembly Replacement Procedure Table 4-15 Procedure to Replace the VAC Drive Unit Assembly Contents: ‘Tum off the power supply. Loosen the connector fixing screws and remove connectors CN1, CNS and CN13. Remove the connector for the optical fiber. Remove the VAC drive unit in the same manner as indicated in Table 4-13 Install a new VAC drive unit in the same manner as indicated in Table 4-14. ‘Connect the connectors CN1, CN3 and CN13 and clamp them firmly with connector fixing ‘screws. Install the connector for the optical fiber. ‘Loosen screws and detach the cover. ‘Check the ROM, switch settings and potentiometer settings in reference to the VAC Se- ies Characteristics Table Run the VAC drive unit in the same manner as indicated in 4-4, Install the cover and secure it with screws.9727-E P-C39-R2 SECTION 4 INSPECTION AND MAINTENANCE Trial Operation Procedure Table 4-16 Trial Operation Procedure Process Contents Confirm that the ROM, switch settings, potentiometer settings, and unit type are all cor- rect, referring to the VAC Series Characteristic Table. ‘Open the power supply unit door and check the VAC drive unit on the following points. Check Pay attention to ‘Are all cables connected correctly? Sleeves ‘Are cables connected securely at terminal? Terminals of cables and major component parts in the circuits Are all fuses set correctly? Base circuit fuses, waming fuses, fuses F1 10 F7 ‘Aro all connector inserted at the specified locations securely? CNt to CN3: Connector clamp screws CN4toCN7: Red mark ‘Are all clamp screws tightened securely? ‘Control PCB clamping screws, power sup- ply unit clamping screws ‘Are wire fragments left causing short cir- cults? ‘Ara the VAC motor, spindle and the ma- ‘chine ready for operation without possibility of interference or other problems? ‘Close the power supply unit door and fix it with the screws. ‘Tum on the power and confirm that the green LED “POWER lights. Confirm that the cooling fan of the VAC drive unit and the VAC motor rotate. Input the rotation command to check the motor rotation both in the forward and reverse directions. Check the operations over the entire speed range.8727-E P-C40-R2 SECTION 5 TROUBLESHOOTING SECTION 5 TROUBLESHOOTING ‘Measure to be taken when a problem has occurred are explained in 1. and2., and measures to recover {rom the fallure status are explained in 3. Locations of the component parts are shown in Section 2. “CONSTRUCTION AND CONNECTION", Since high voltage is applied to the VAC drive unit, first record the illuminating LED number(s) and turn ‘ff power supply to the VAC drive unit before attempting to touch inside the unit, 1. Confirmation of Power Supply and Connectors Before carying out the steps explained in 2., check the items according to Table 5-1. Table 5-1 Confirmation of Power Supply and Connectors Items to Check How to Check Measures to Take DIP switches Settings must be as indicated on the Set as indicated. [SW1 to SW4 VAC Series Characteristics Table. ROM Make sure that the ROM currently used | Change with the PGB on which the spe- is the version as indicated on the VAC _| cified ROM is set. Series Characteristice Table, Refer to Section 4, 4-1. “Control PCB Replacement Procedure”. Potentiometers _ | Make sure that the settings of the poten- | Correct settings as indicated. \VR1 to 3, SM LM | tiometers are as indicated on the VAC Series Characteristics Table, Power supply Measure voltage across input terminals | Correct input power supply so that it is R, S, T of no-fuse breaker and power within the allowable range. supply grounding terminal to check if It is within the allowable range. Allowable range: ‘AC S-phase, 200 V (-15%) to 220 V (+10%), 50/60 Hz [Connectors - Make sure that the MR connectors ‘Connect correctly. {CN1, 2, 8) are all secured by screws. + For the PCB connectors (CN4 to beans healiee CN7), make sure that the read mark. taeeg CNA 7 ‘on the connector guide can be seen at the surface of the connector on the ‘control PCB,8727-E P-C41-R2 SECTION 5 TROUBLESHOOTING 2. ‘Trouble and Troubleshooting {ta problem is found, take necessary procedures as indicated in Table 5-2. Table 5-2 Classification of Failures Failure willie in Failure Reference /———arpca | Power Uni POWER LED does not ight up. © oO o LOSS LED lights up. @ ° o LED's show failure occurrence condition. @) o ° Motor hunts. @) ° o ‘Commanded motor speed cannot be obtained. «) oO oO Motor does not rotate. o ° [Low cutting performance © } Long aaceleration and deceleration time ) °o ° [Excessive vibration and nolse while the motor is rotating. @ ° o9727-E P-C42-R2 SECTION 5 TROUBLESHOOTING 1) POWER LED does not light up. LOSS LED lights up. Table 5-3 Failure Factor Check Measures Input power supply is abnormal. _| See Table 5-1. ‘See Table 5-1. Fuse F2, F3, F4 or F5 is blown. Check whether the fuses have Replace blown fuse. been blown or not. ‘Warning fuse SMP32 or MP50 is _| (Refer to Section 4, 3-2. “Inspec- blown. tion and Replacement Procedure for Fuses") PCB connector CN7 is not inserted | Check to be sure that the red mark | Insert the connector properly. properly. ‘on the connector guide can be ‘seen at the surface of the connec- ‘tor on the control PCB. Power is not supplied to the control |(1) Detach the cover. Replace the power supply unit. PCB from the power supply unit. or | (2) Check voltage across 1 and 3, | (Refer to Section 4, 4-2. "Power supply voltage is other than 19V and 2 and 3 of connector CN7 | Supply Unit Replacement Proce- with @ voltmeter voltage must be 19V AC. aciav] [2]°N7 [repenerawve eanvolcreut [eee High voltage is applied to the base circuit and the regeneration circuit. ACALTION] dure”) [Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. (Refer to Section 4, 4-1. ‘Control! PCB Replacement Procedure”)8727-E P-C43-R2 SECTION 5 TROUBLESHOOTING 2) LED's show failure occurrence connection. ‘When LED's show failure occurrence condition, take necessary measures in accordance with the ‘alarm number displayed on the VAC BOARD IL For the alarm name and the alarm contents, refer to Table 3-3, *VAC II Alarm List". (@) Alarm No. 1 “VAC P.G count abnormal" is displayed. Table 5-4 Failure Factor Check Measures: [The magnetic encoder sensor or | Rotate the spindle by hand and __| Replace the sensor or the gear. the gear is faulty. check the output signals ofthe en- r. (Reter to Appendix 2, “CHECK TERMINALS" when checking the output signals.) The contol PCB (VAC card 1) is ‘Make sure that all the items above are correct. Replace VAC card 1. (®) Alam No. 2 “VAC motor acceleration rate” is displayed. Table 5-5 Fallure Factor Check Measures [The resolver is faulty. Rotate the resolver by hand and | Replace the VAC motor. check the output signals. (Retr to Appendix 2, “CHECK TERMINALS" when checking the output signals.) [The magnetic encoder sensor or | Rotate the spindle by hand and __| Replace the sensor or the gear. the gears faulty. ‘check the output signals of the en- coder. Loose connection of the connectors | Check whether connector CN3, __| Insert them properly. Jof motor signal cables or magnetic _|CN13, and the connector in the Jencoder signal cables VAC motor terminal box are in- serted properly. [Broken motor signal cables or mag- | Remove the motor signal cables or | Replace the motor signal cables or netic encoder signal cables ‘the magnetic encoder signal cables | the magnetic encoder signal and conduct the continuity test.__| cables. [The control PCB is faulty. Make sure that all the items above | Replace the control PCB. are correct.8727-E P-C44-R2 SECTION 5 TROUBLESHOOTING (©) Alarm No. 3 “VAC APA speed” is displayed. Table 5-6 Failure Factor Check Measures [The magnetic encoder sensor or | Rotate the spindle by hand and __| Replace the sensor or the gear. the gear is faulty. check the output signals of the en- ‘coder. Loose connection of the connector | Check whether connector CNi3 is _| Insert them property. ‘of magnetic encoder signal cables _| inserted properly. Broken magnetic encoder signal [cables Remove the magnetic encoder sig- nal cables and conduct the continu- ty test. Replace the magnetic encoder sig- nal cables. The control PCB is faulty. ‘Make sure that all the items above are correct. Replace the control PCB. (@) Alarm No. 4 "VAC CON speed" is displayed, ‘Table 5-7 Failure Factor Check Measures Faulty NC software ‘Check the setting value. | ‘Change the setting value. (setting error for feed unit amount) (e) Alarm No. 5 “VAC DIFF overflow” is displayed. Table 5-8 Failure Factor Check Measures: | Operation in overloaded condition | Check the cutting conditions. ‘Change the cutting conditions. |Check the machine for mechanical | Remove the mechanical trouble ‘troubles: lubricating oil, etc, factor. The control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB.8727-E P-C45-R2 SECTION 5 TROUBLESHOOTING (f) Alarm No. 6 "VAC resolver abnormar” is displayed. Table 5-8 Failure Factor Check ‘Measures Loose connection of the connectors | Check whether or not connector _| Insert them properly. ‘of motor signal cable ‘CNS and the connector in the VAC ‘motor terminal box are inserted properly. [Broken motor signal cables Remove the motor signal cables | Replace the motor signal cables. (Resolver signal) and conduct the contimuity test. |The contro! PCB is faulty. Make sure that all the items above [are correct. Replace the control PCB. The resolver is faulty. Make sure that the RES is indi- ‘cated even after the replacement of the control PCB. Replace the resolver in the VAC motor. (g) Alarm No. 7 VAC RAM parity erro” is displayed. faut. Table 5-10 Fallure Factor Cheek Measures [The control PCB is faulty. = Replace the control PCB. (h)_ Alarm No. 8 "VAC communication abnormal is displayed. Table 5-11 Failure Factor (Check Measures Loose connection of the connectors | Check whether or not connectors of | Insert them property. of optical fiber cables ‘optical fiber cables of VAC card 1 are inserted property. Broken optical fiber cables ‘Check whether or not optical fiber | Replace the optical fiber cables. cables are broken. [SPCé (card on the SVP board) on |Make sure that all the items above | Replace SPCS card. the NC is faulty. are correct. ‘The control PCB (VAC card 1)is | Make sure that all the items above | Replace VAC card 1. are correct.3727-E P-C46-R2 SECTION 5 TROUBLESHOOTING (Alarm No. 9 *VAC instruction command NG.”is displayed. ‘Table 5-12 C Failure Factor ‘Check ‘Measures Faulty NC software (Undefined Check the communication in which | Correct the NC software. instruction or non-executable an alarm occurs. instruction is communicated.) Alarm No. 10 *VAC motor cable overcurrent” is displayed, ‘Table 5-13 Failure Factor Check Measures Loose connection of motor power | Check motor power cable connec- | Connect the cables securely. ‘cables at terminal block tion at the terminal block of the mo- tor and the VAC drive unit. Motor power cables are broken, Disconnect the motor power cables | Replace the cables. ‘short-circulted, or grounded. ‘from the VAC drive unit and the motor, and check continuity. Loose connection of the motor sig- | Check the connecters at the VAC _| insert the connector property. inal cables ‘drive unit (CN3) and in the VAC ‘motor terminal box — are they in- ‘serted property? The VAC motor is faulty. ‘Measure resistance between the | Replace the VAC motor. \VAC motor power cable terminal ‘and the frame using a Megger in- ulation tester. ‘The control PCB is faulty. ‘Make sure that all the items above are correct. (Check the settings at DIP switches SWS and SW4,) Replace the control PCB. [The power supply unit is faulty. ‘Make sure that the IOCM is indl- cated even after the replacement of the control PCB. Replace the power supply unit. (k) Alarm No. 11 *VAC inverter bridge short circuit” is displayed. ply unit is faulty. Table 5-14 Failure Factor ‘Check’ Measures: The control PCB or the power sup- | Refer to Table 5-15. Refer to Table 5-15. VAC motor power cable terminal and the frame using Megger insula- tion tester. Motor power cables are broken, __| Disconnect the motor power cables | Replace the cables. short-circuited, or grounded. from the VAC drive unit and the ‘motor, and check continuity. "The VAC motor is faulty. Measure resistance between the | Replace the VAC motor. For the VAC motor of the winding [changeover specification, the mag- Net switch for changing winding or magnet switch drive relay is faulty. Refer to the maintenance manual {for the machine. Replace the magnet ewitch or mag- net switch drive relay.8727-E P-CA7-R2 SECTION 5 TROUBLESHOOTING Table 5-15 Procedure at an Occurrence of ICOS Alarm Process Contents a Tum off the power supply. 2 | Check the fuses in the TR1 to TRS base circuits. Refer to Section 4,3-2. ‘3 | Check the transistors in the TR1 to TR6 base circuits. Refer to Section 4, 2-2. 4 | Remove the control PCB and check to be sure ‘that the connector pins at the supply unit side Pana yp gy of the connector CNS or CN6 are fixed to the connector. Suite se {f not pull, the connectors pin up to fix them. onnector Refer to Table 4-10. cen comectr ‘5 | Check the transistor modules TRM1 to TRMS. Refer to Section 4, 2-1. @ | Install the control PCB. Refer to Table 4-11. 7 | Run the VAC drive unit. Check whether the IOCS lamp lights up. Refer to Section 4, 4-4. ‘8 __| ifthe IOCS lamp lights up again, replace the control PCB and then run the VAC drive unit. Reefer to Section 4, 4-1. ‘9 | Ifthe IOCS lamp stil lights up, replace the power supply unit. Refer to Section 4, 4-2. (Alarm No. 12 "VAC power trans short circuit” is displayed. Table 5-16 Failure Factor Check Measures [An instantaneous power failure | Check the power supply. Reset and restart. occurs while the motor is stopped. FThe control PCB or the power _| Refer to Table 6-17. Refer to Table 5-17. supply units faulty. ‘Table 5-17 Procedure at an Occurrence of ICOS Alarm Process Contents: 1 [Tum off the power supply. 2 __ | Check the fuses in the TR7 to TA12 base circuits. Refer to Section 4, 49-2. ‘3 | Check the transistors in the TR7 to TA12 base circuits. Reefer to Section 4, 2-2, “4 | Remove the control PCB and check to be sure that the connector pins at the supply unit side of the connector CN6 and CN7 are fixed to the connector. Refer to Table 5-15. (Check the transistor modules TRM4 to TRM6. Refer to Section 4, 2-1. Install the control PCB. Refer to Table 4-11. lun the VAC drive unit. Check whether the IOCR lamp lights up. Refer to Section 4, 4-4. Ifthe IOCR lamp lights up again, replace the control PCB and then run the VAC drive unit. Refer to Section 4, 4-1. ‘9 [ifthe IOCR lamp stil lights up, replace the power supply unit. Refer to Section 4, 4-2. elvlola8727-E P-C48-R2 SECTION 5 TROUBLESHOOTING (m) Alarm No. 13 “VAC power circuit overvoltage" is displayed. ‘check if the OV lamp light up. Table 5-18 E Failure Factor ‘Check Measures ‘Source voltage Is abnormally high. | See Table 6-1. See Table 5-1. Power supply cable terminal 1) Tum power supply oft. ‘Secure the screws tightly. screws are loose. 2) Check the screws if they are loose. ‘The regeneration circuit is faulty. | Follow the steps in Table 6-17 to | See Table 6-17. Power supply impedance is high. ‘The OV lamp lights up only while decelerating. ‘Use @ power supply unit with a low impedance. (f) Alarm No. 14 “VAC input voltage drop” or Alarm No. 15 “VAC phase defect" is displayed. Refer to Section 4,3-2. “t and Replacement Procedure for Fuses". Table 5-19 Failure Factor Check Measures Power supply voltage is low, or one | See Table 5-1. ‘See Table 5-1. of three phases is open, The no-fuse breakers in the OFF | Check the no-fuse breaker setting _| Set the no-fuse breaker in the ON position. visually. position, The no-fuse breaker is tipped. a ae ‘Check the power supply unit. p Tel k OFF «OFF OFF ONstaus Tipped OFF status No-fuse Breaker Handle Positions Fuses F5, F6 or F71s blown. ‘Check the fuses whether they have | Replace blown fuse. been blown or not. eration of the motor. "The screws in the diode module is | Check the screws in the diode | Secure the screws tightly. loose. module. (Peter to Figs. 2-4 and 2-5.) [The diode module is fauly. (Check the diode module. Replace the diode modul Refer to Section 4, 2-3. "Diode _| Refer to Section 4, 2-4. “Procedure Module Inspection Procedure". _| to Replace Main Circuit Semi-con- ductor Devices". PGB connactor CN6 Is not plugged | See Table 5-1. See Table 5-1. in property Control PCB is faulty. Make sure that all the tems above | Replace the control PCB. ‘are correct. [The power supply units faulty. | Check to be sure that the UV and’ | Replace the power supply unit. (or PH lamp lights up even after the replacement of the control PCB. Power supply Impedance Is high. _ | The UV and/or PH lamp lights up| Use a power supply unit with a low only during acceleration and decel- | impedance.8727-E P-C49-R2 SECTION 5 TROUBLESHOOTING (0) Alarm No. 16 “VAC arithmetic unit volt drop” is displayed. Refer to Table 5-3, (p) Alarm No. 17 “VAC power circuit low voltage” Is displayed. Table 5-20 Failure Factor ‘Check Measures [Source voltage is low. ‘See Table 5-1. ‘See Table 5-1. "The screws in the diode module is_| Check the screws in the diode ‘Secure the screw tightly. loose. module. (Peter to Figs. 2-4 and 2-5.) [The diode module is faulty. (Check the diode module. Replace the diode module. Refer to Section 4, 2-3. “Diode Module Inspection Procedure”. Refer to Section 4, 2-4. “Procedure to Replace Main Circuit Semi-con- ductor Devic ‘See Table 5-1, PCB connector is not plugged in | See Table 5-1. properly. ‘The power supply unit is faulty. | Make sure that allthe items above | Replace the power supply unit. me cote Refer to Section 4, 4-2. "Power Supply Unit Replacement Proce- dure”. "The control PCB is faulty. ‘The UVP lamp lights up afterthe | Replace the control PCB. replacement of the power supply | Refer to Section 4, 4-1. "Control a PCB Replacement Procedure”. (q) Alarm No. 18 “VAC interval loop error” is displayed. Table 5-21 Fallure Factor ‘Check Measures [The control PCB is faulty. = Replace the control PCB.9727-E P-C50-R2 SECTION 5 TROUBLESHOOTING (9) Alarm No. 19 "VAC motor overload’ is displayed. Table 5-22 OL Lamp Lighting Up during Motor Rotation Failure Factor (Check Measures (Operation in overloaded condition | Check the loaded conditions with | Check the cutting conditions and the load meter. Cutting tos. Fuse F1, F2 or Fis blown. ‘Check whether the fuses have | Replace the fuses. been blown or not, (Refer to Section 4, 3-2. “Inspec- tion and Replacement Procedure {tor Fuses”,) Loose connection of the fan motor | The motor cooling fan does not op- | Connect the cables correctly. ‘cables at terminal block erate when power is turned on. Check fan motor cable connection at the terminal block of the motor land the VAC drive unit, Fan motor cables are broken. ‘The motor cooling fan does not op- | Replace the fan motor cable ‘erate when power is turned on. ‘Check continuity Motor cooling fan is faulty. ‘The motor cooling fan does not op- | Replace the motor cooling fan. ‘erate when power is tumed on. ‘Motor cooling fan, fan guard, ‘Check contamination degree. Clean with compressed air or using ventilation ports, etc. are vacuum cleaner. contaminated, Control PCB is faulty. ‘Make sure that allthe items above | Replace the control PCB. are correct. ‘Table 5-23 OL Lamp Lighting Always Failure Factor ‘Check Measures [Loose connection ofthe motor | Check the connectors at the VAC _| insert the connector properly. signal cables drive unit (CN3) and in the VAC motor terminal box — are they in- /serted properly? [Broken motor signal cables Fiemove the signal cables and con- | Replace the signal cables. (Overtoad signal) ‘duct the continuity test. (Refer to Figs. 2-9 through 2-11.) [The thermostat inside the VAC___| Measure the resistance between _| Replace the VAC motor. motor is faulty. thermostat terminals of the connec- tor in the VAC motor terminal box. Itt an infinite value (<), It indl- cated that the thermostat is faulty. Control PCB Is faulty. Make sure that al the lems above | Replace the control PCB. are correct.9727-E P-C51-R2 SECTION 5 TROUBLESHOOTING (6) Alarm No. 20 “VAC heat sink overtoad is displayed. Table 5-24 Failure Factor ‘Check Measures Fuse Fi, F2 or FSis blown. ‘Check whether the fuses have _| Replace the blown fuse. been blown or not, (Refer to Section 4, 3-2. “inspec- tion and Replacement Procedure {for Fuses") PCB connector GNS is not inserted | See Table 5-1. Insert the connector property. roperty. Heat sink cooling fan is fauly. ‘Check ifthe heat sink cooling fan is | Replace the power supply unit. ‘operating when power is tured on. Heat sink cooling fan and heat sink | Check contaminated condition at _ | Clean with compressed air or using are contaminated. the back of the power supply unit. | vacuum cleaner. ‘Operation in overloaded condition | Check the loaded conditions with | Check the cutting conditions and the load meter. eutting tools. Control PCB is faulty. ‘Make sure that all the items above | Replace the control PCB. are correct, [The power supply unitis faulty. | Make sure that the OH Is indicated | Replace the power supply unit. after the replacement of the control PCB. (Alarm No. 21 “VAC data setting” Is displayed. Table 5-25 Fallure Factor ‘Check Measures Faulty NC software ‘Check the VAC PBU data or one- | Correct the faulty data. line change parameter. (u) Alarm No. 22 “VAC data setting” is displayed. Table 5-26 Failure Factor ‘Check Measures ‘Mechanical rouble around the Check the machine for theme- | Remove the mechanical trouble spindle (colision, overload, etc.) | chanical trouble tactor. factor.3727-€ P-C52-R2 SECTION 5 TROUBLESHOOTING (¥) Alarm No. 23 “VAC magnetic P.G. abnormal” is displayed. ‘Table 5-27 Failure Factor Check Measures Rotate the spindle by hand and | Replace the sensor. The magnetic encoder sensor is faulty. ‘check the output signal of th coder. (Refer to Appendix 2, “CHECK TERMINALS" when checking the ‘output signals.) Loose connection of the connectors: lof magnetic encoder signal cables ‘Check whether connector CN13 is. inserted properly. Insert the connector properly. ‘Broken magnetic encoder signal cables (w) Alarm No. 24 “VAC P.G. marker data NG." is displayed. Remove the magnetic encoder cables and conduct the continuity test. Replace the magnetic encoder sig- nal cables. Table 5-28 Failure Factor Check ‘Measures The magnetic encoder sensor or | Rotate the spindle by hand and __| Replace the sensor or the gear. the gear is faulty. check the output signal of the en- coder. (Refer to Appendix 2, “CHECK TERMINALS" when checking the output signals.) (%)_ Alarm No. 25 "VAC cycle overflow error’ is displayed. Table 5-29 Failure Factor (Check Measures Loose connection of the connector | Check whether or not the connec- _| Insert them property. between the control PCB's, ‘tor between the control PCB's is in- sorted properly. [The control PCB is faulty. ‘Make sure that allthe items above | Replace the control PCB. are correct. (¥) Alarm No. 26 "VAC watchdog error” is displayed. ‘Alarm No. 27 “VAC analog-to-digital access alarm is displayed. ‘Alarm No. 28 “VAC board; CPU error" is displayed. ‘Alarm No, 29 “VAC card; CPU error’ Is displayed. Replace the control PCB.3727-£ P-C53-R2 SECTION 5 TROUBLESHOOTING (2) Alarm No. 30 “VAC speed deviation to large” is displayed. Table 5-30 Failure Factor ‘Check Measures [Operation in overloaded condition | Check the loaded conditions with | Check the cutting conditions and the load meter. cutting tools. [Open or loose contact of motor power cables Check the motor power cables. ‘Connect the motor power cables correct. ‘Motor signal cables are faulty. (loose connection, miswiring, etc.) ‘Check the motor signal cabl ‘Connect the motor signal cables correctly. The regeneration circuit is faulty. ‘Check whether DSC lamp lights up during the procedure as explained in Table 5-17. ‘Check the operation conditions. ‘Are acceleration and deceleration "The inverter circuit is faulty. ‘Check whether DSC lamp lights up during the procedure as explained in Table 5-15. Refer to Table 5-15. The control PCB is faulty. ‘Make sure that all the items above are correct. Replace the control PCB. For the VAC motor of the winding [change specification, the magnet /switch for changing winding or magnet switch drive relay is faulty. Refer to the maintenance manual {or the machine. (aa) Alarm No. 31 “VAC coll switch’ is displayed, Table 5-31 WCHER Lamp Lighting with Winding Changeover Specification Failure Factor ‘Check Replace the magnet switch for changing winding or magnet switch drive relay. Measures (Magnet ewitch and/or magnet switch drive relay for winding changeover is faulty. Refer to the maintenance manual for the machine. Replace magnet switch and/or magnet switch drive relay. The control signal cable is faulty. (broken or loose contact) (magnet switch operation signal, confirmation signal) ‘Check the cables. Connect the cables property. The control PCB is faulty. ‘Make sure that all the items above are correct. Replace the control PCB. (ab) Alarm No, 32 “RAM abnormat” is displayed. Table 5-32 Failure Factor Check’ ‘Measures [The control PCB is faulty. Replace the control PCB.8727-€ P-C54-R2 SECTION 5 TROUBLESHOOTING 3) Motor hunts. Table 5-33 Failure Factor ‘Check ‘Measures Faulty motor power cables and mo- | Check the cables. Connect the cables correctly. {tor signal cables (loose contact, miswring, etc.) Refer to Fig. 2-9 through 2-12. Fuses in TR1 to TR6 base circuits are blown. ‘Check the fuses in the TRI to TRE base circuits. (Refer to Section 4, 3-2. “Inspec- tion and Replacement Procedure for Fuses”) Replace blown fuse. Transistors in TR1 to TR6 base cuit are faulty. Check the transistors on the TRI to ‘TR6 base circuits. Refer to Section 4, 2-2. “Base Cir- cuit Transistor Inspection Proce- dure” Replace the control PCB. Transistor modules TRMi to TRM3 are faulty. Check the transistor module TRM1 10 TRM3. Refer to Section 4, 2-1. “Transistor Module Inspection Procedure”. Replace the transistor module. Reter to Section 4, 2-4. “Procedure to Replace Main Circuit Semi-con- ductor Devices”. Control PCB is faulty. ‘Make sure that all the items above are correct. Replace the control PCB. NOTICE With the VAC motor winding change specification, the motor power cables are wired through the winding change magnet switch. Therefore, the possibilty of loose contact, wiring error, etc. related with the magnet switch for changing winding must also be checked. 4) Commanded motor speed cannot be obtained. Motor does not rotate. Table 5-34 Failure Factor ‘Check Measures [The VAC drive units faulty. ‘When a rotation command is given, | See item (2). the LED's light up indicating the faulty operation condition. Broken or loose contact of the mo- | Check the motor signal and power | Connect the cables correctly. {tor signal cables and power cables | cables. Refer to Figs. 2-9 through 2-12. [The resolver is faulty. Check the resoiver signal. Replace the VAC motor. ‘The magnetic encoder is faulty. | Check the output signal of the en- | Replace the sensor of the encoder. coder. Control PCB is fauity. Make sure that all the items above are correct. Replace the control PCB. ‘The power supply unit is faulty. Make sure that all the items above are correct. Replace the power supply unit.9727-E P-C55-R2 SECTION 5 TROUBLESHOOTING Table 5-35 Fallure Factor ‘Check Measures Winding changeover signal WCHG | Check if the winding changeover | Input the signal correctly. 'does not correctly input. ‘signal WCHG input correctly or not bby LED's indication. (Note) (Refer to Fig. 3-2.) (Winding changeover magnet switch \d/or magnet switch drive relay is. Refer to the maintenance manual for the machine. selected winding. High-speed winding: 0 max. motor mm Low-speed winding: — max. motor rpm in low-speed range 1f a motor speed exceeding max. rpm in the low-speed range is specitied while the low-speed winding is selected, the motor rotates at the max. speed in the low-speed Refer to the maintenance manual for the machine. With the winding changeover specification, motor speed range varies according to the range, 5) Lowcutting performance Table 5-36 Failure Factor Check ‘Measures [Torque limit command is provided. | Check the signal existing. Clear the torque limit command. See TLM in Fig. 3-2. Problem lies with the machine spindle. Refer to the maintenance manual {for the machine. Refer to the maintenance manual {for the machine. (Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB.3727-E P-C56-R2 SECTION 5 TROUBLESHOOTING 6) Long acceleration and deceleration time the load meter. Table 5-37 Failure Factor ‘Check Measures ‘Operation in overloaded condition | Check the loaded conditions with | Reduce load. power cables ‘Torque limit command is provided. | Check the signal existing. Clear the torque limit command. See TLM in Fig. 3-2. ‘Source voltage is high. ‘See Table 5-1. ‘See Table 5-1. Broken or loose contact of motor | Check the motor power cables. | Connect the motor power cables correctly. Fuses in base circuits are blown. ‘Check the fuses in base circuits. (Refer to Section 4, 3-2. “inspec- tion and Replacement Procedure for Fuses") Replace blown fuse. Transistors in the base circuits are faulty. Check the transistors in he base circuits. Refer to Section 4, 2-2. “Base Cir- cuit Transistor Inspection Proce- dure”. Replace the control PCB. Transistor module is faulty. ‘Check the transistor module. Refer to Section 4, 2-1. “Transistor Module Inspection Procedure”. Replace the transistor module. Refer to Section 4, 2-4. “Procedure to Replace Main Circuit Semi-con- ductor Devices”, Control PCB is faulty. Make sure that all the items above are correct. Replace the control PCB. Power supply impedance is high. Only deceleration period is elon- gated. Use a power supply unit with a low impedance. 7) Excessive vibration and noise while the motor is rotating. are correct. Table 5-38 Failure Factor ‘Check ‘Measures Motor installation is loose; coupling | Check motor installation or motor _| Install the motor correctly. with the spindle is loose. coupling to spindle. [VAC drive unit or connection of | Refer to Table 5-33. Refer to Table 5-33. cables is faulty. [VAC motor is faulty. Make sure that all the items above | Replace the VAC motor. NOTICE | : procedure below. (1) Start the VAC motor. To determine the cause of the problem, run the VAC motor freely. For this, following the (2) Trip the no-fuse breaker in the VAC drive unit to OFF. (8) The PH (phase-loss) alarm occurs and the VAC motor runs freely.‘3727-E P-C57-R2 SECTION 5 TROUBLESHOOTING Recovery from Fallure Status ‘When LED's indicate the faulty operation status, it is necessary to remove the cause of failure first and then reset the alarm state to recover the operations of the VAC drive unit. VAC alarms are classified into the following four levels according to the operation at their occurrence land the way to reset them. Refer to Table 3-3, “VAC II Alarm List” Table 5-39 ‘Alarm Level_| Operation at Occurrence How to Reset Nature of Alarm Level 1a | Transited to alarm level 1 | Set the three-phase break- | VAC hardware must be ini (immediate power shutoff) | er to the “OFF” position | tialized, (for example ex- and then setit to the “ON* | ception alarm) position again. Level 1b | Transited to alarm level 1 | Tum off the power tothe __| Parameters must be intial- (power shutoff after the NC once and then tum it ized. Totor is stopped.) on again, Level2 | Transited to the alarm state | Reset the NC from the op- | Alarm which might be in the mode in which the | eration panel. caused by cutting condi- alarm occurred. (The reset command is | tions. (Operation varies depend- | generated in each mode.) | (for example DIFF OVER ing on the mode in which alarm) the alarm occurred.) Level 3 | The VAC sends information | Reset the NC from the op- | Overload-related alarms to the NC that an alarm of | eration panel. level 3 has occurred. The | (The reset command is ‘VAC unit operates for 30 ‘seconds after the alarm oc- ‘curred, then the alarm level is transited to *2". generated in each mode.)8727-E P-C58-R2 APPENDIX 1 ROM AND FILE NAME FOR HIGH-PRECISION VAC DRIVE UNIT es APPENDIX 1 ROM AND FILE NAME FOR HIGH-PRECISION VAC DRIVE UNIT ‘The control software for the high-precision VAC drive unit is supplied as below: + ROM to be mounted on VAC board II (1 unit) ~ File in the control floppy disk (PBU file x 1) 1. ROM for High-Precision VAC Drive Unit 1-1. Mounting Place One ROM is mounted on the VAC board II (E409-045-140A) for the high-precision VAC drive unit. (Since mounting place is in the shade of the card, ROM name is written on the cover.) 1-2. ROM Name VACA 1 21 & Lee Revision No. Version No. High-precision position control specification by VAC board II: A (Changes according to a thorough revision of hardware) 2. File in the Control Floppy Disk 2-1. Type of File ‘The following file are developed to store the control data for the high-precision VAC drive unit. File Name: LWUsek_ok_t_.PBU Contents: Indexing parameter, motor type, gear ratio, etc. This file is provided for each VAC drive unit. With sub spindle specification models, two files are provided.3727-E P-C59-R2 APPENDIX2 CHECK TERMINALS APPENDIX 2 CHECK TERMINALS For the layout of the check terminals, refer to Fig. 2-2. Check Terminal Probe Common’ Terminal Contents Remarks GND ‘Separated from the regenerative control circuit, the input/output signal circuit, and the base circuit, ‘St ‘GND Resolver excitation signal Sine wave ow. Poll GND ae ar Cosine wave RI ‘GND Resolver feedback signal > 3 ‘When motor {jm X0SEE, x ——_- ~ Phase difference to the excitation signal changes as the motor rotates. + Frequency f (Hz) varies as indicated below ‘according to the motor speed N (rpm). eg One feT= —1__ 128 x 10 60 (+ in the forward rotation and — in the reverse rotation) VEL ‘GND Velocity monitor |The motor speed {rpm} is indicated, £10 [V] at the maximum motor speed GND. ‘Torque monitor ‘The motor output torque is indicated. £10 (VJat the maximum motor output @ND Inverter circuit current detection The IOCS alarm occurs at higher than 250 [mV]. GND Regenerative circuit current detection ‘The OCS alarm occurs at higher than 250 [ml3727-E P-C60-R2 APPENDIX 2 CHECK TERMINALS [creck Trnns [7B Comnon Contents Remarks Ww GND | U-phase current feedback signal ow wv @ND | V-phase current feedback signal Cycle and amplitude changes depending on operation state, ™ GND | Current feedback three-phase full wave rectify- | The IOCR alarm occurs ing signal at lower than -6.6 V. + Cycle and ampli- 91! tude changes depending on Rar ein operation state. + With the type A control PCB, the current feedback signal is reciied to negative volt- age. ~ With the previous contro! PCB, the current feedback signal is rectified to positive vott- age. Tue GND | Uphase current {eedback signal Wve GND | V-phase current feedback signal du GND | U-phase current ‘amplifier signal Idv GND \V-phase current 1 ‘amplifier signal Cycle and amplitude changes depending on operation state.3727-E P-C61-R2/E APPENDIX 2 CHECK TERMINALS —— _ Probe Common ‘Check Terminal | Probe Come Contents Remarks Euc GND | U-phase induced ‘voltage command signal Eve GND _| V-phase induced voltage command signal ‘Cycle changes depend- Ing on the motor speed. MON GND +5V GND | Control circult power voltage +15V GND __| Control circuit power voltage =15V GND __| Control circult power voltage ‘COM = Grounding in regenerative control circuit When checking the waveform in the regenera tive circuit, use an insulated oscilloscope. Be careful that the COM terminal is not short- ‘crculted with other circuit, for example with the GND terminal, in the oscilloscope. BV COM | Regenerative control circuit power voltage A GND T is determined on the basis of the number of gear teeth and the speed. /Z: Number of gear teeth fa N: Speed {rpm} —___ | N x 1/60 xz B GND ‘Amplitude at A and B: Voc = 2.5V Vep=3V ‘Amplitude at Z: Voc =2.5V Vpp=3V iz @ND £2 Tre sto wonton oe ‘Diana tien Bs encode is OW aated as Rusbated to De {ah aed th gear eat {ha GW dracon viewing Irom the 2-phace gear wath phase goerLIST OF PUBLICATIONS Publication No. Date Edition 3727-E March 1993 1st (3727-E-R1 December 1993 2nd 3727-E-R2 April 1994 3rd ‘Thia manual may be at variance withthe actual product dus to specification (r design changes. Pease also note that specications are subject to change without notice, Mtyourequire clarfication or further explanation of any point thle manual, please contact your OKUMA representative.OKUMA OFFICES DOMESTIC OFFICES REGISTERED OFFICES 1-32 Tsujimachi, Kita-ku Nagoya 462-91, Japan WORLD HEADQUARTERS-OGUCHI PLANT Okuma Corporation Oguchi-cho, Niwa-gun Aichi, 480-01, Japan Phone (0587) 95-7825 Fax (0587) 95-6074 Telex 4573310 OKUMA J KANI PLANT Okuma Corporation 2 Banchi, Shimogiri, Himegaoka, Kani-shi, Gifu-ken, 509-02, Japan Phone (0574) 63-5611 Fax (0574) 63-5678 OVERSEAS OFFICES Okuma Corporation Melbourne Liaison Office c/o Atlas CNC Machines Ltd. 20 Stamford Road Oakleigh East, Victoria 3166 Australia Phone (03) 567-8105 Fax (03) 569-4024 Okuma Corporation Singapore Branch 422 Tagore Avenue Singapore 2678 Phone 4590819 Fax 4598276 OVERSEAS AFFILIATE Okuma Machinery, Inc. 12200 Steele Creek Road, Charlotte, NC 28273, U.S.A. Phone (704) 588-7000 Fax (704) 588-6503 OVERSEAS SUBSIDIARIES Okuma Machine Tools Inc. 12200 Steele Creek Road, Charlotte, NC 28273, U.S.A. Phone (704) 588-7000 Fax (704) 588-6503 Okuma Europe GmbH Europark, Fichtenhain A20 47807 Krefeld , F.R. of Phone (49) 2151-374-0 Fax (49) 2151-374100 Okuma Service Center TPE ‘Tatung Co., 22 Chungshan N. Rd.,3rd Sec.Taipei, Taiwan, 10451 R.0.C Phone (02) 673-6901 Fax (02) 673-6900