BNP-A282 l-02-A-E

r‘

t. .*.’.,.. .
LiC SPINDLE DRl.i/E

P
-SFJ L
MAINTENANCE -MANUAL

ADVANCED AND EVER ADVANCING

n/lmJBlsHl ELEcTmc
 -CO.NTENTS-

1. GENERAL . . . . . 1

1.1 Introduction . . . . . 1

1.2 Safety during maitenance and troubleshooting . . . . . 1

1.3 Storage . . . . . 2

2. WIRING . . . . . 3
2.1 External wiring . . . . . 3
2 . 2 Parts arrangement . . . . . 10

3. ADJUSTMENT . . . . . 12
3.i Preliminary check . . . . . 12
3.2 Power feeding . . . . .13
3.3 FR-SFJ status display and parameter settings . . . . . 15
3.3.1 (A) Status display and parameter setting
for ROM version A . . . . . 17
3.3.2 (B) Status display and parameter setting
for ROM versions after BO . . . . . 2C
3.4 Spindle control monitor on NC CRT dispaly
. . . . when FR-SFJ is connected to M300 CNC
through bus line . . . . . 26
3.5 Spindle control monitor on NC CRT display
. . . . when FR-SFJ is not connected to M300
CNC through bus line . . . . . 29
3.6 Test operation . . . . . 32
3.7 Adjustment of motor speed . . . . . 32
3.8 Adjustment of oriented spindle stop function . . . . . 34
3.9 Parameter list . . . . . 42

4. CARD SETTINGS AND CHECK TERMINALS . . . . . 50

4.1 Card SFJ-CA1 . . . . . 50
4.2 Card SF-ORJ . . . . . 55
4.3 Card SF-TLJ . . . . . 56
4.4 Card SF-DAJ . . . . . 57

5. ADDITION AND REPLACEMENT OF COMPONENT . . . . . 58

5.1 Addition of option card (SF-ORJ, SF-DAJ and
SF-TLJ) . . . . . 58
5.2 Replacement of card . . . . . 59
5.3 Replacement of ROM . . . . . 60
5.4 Replacement of diode moduie and transistor
module . . . . . 61
5.5 Disassembly and assembly of SJ-J type AC spin-
dle motor . . . . . 63

- 1/2-
6. INSTALLATICN OF ORIENTED SPINDLE STOP POSITION
DETECTOR . . . . . 72
6.1 Magnesensor l-point oriented spindle stop . . . . . 72

7. DISCHARGE RESISTOR UNIT . . . . . a2

a. TROUBLESHOOTING . . . . . a3
a.1 General information . . . . . a3
,a.2 First step of troubleshooting . . . . . a4
a.3 Second step of troubleshooting . . . . . 86
8.4 Alarm and warning table . . . . . a9
a.5 "Alarm/warning" display by LED readout . . . . . 94

9. PERIODIC INSPECTION . . . . 115

9.1 Inspection of control equipment . . . . 115
9.2 Inspection of motor . . . . 116
9.3 Inspection of discharge resistor unit . . . . ii8

10. PARTS LIST . . . . 119

-2/2-
 $1. GENERAL
1.1 Introduction
AC spindle drive unit, FR-SFJ series, is the inverter use,?
to control a machine tool spindle drive AC motor.
It is capable of contro.lling widely ranged motor speeds ac-
curately and quietly. Discharge resistors are connectec t-:
the drive unit to disperse regenerative energy for regenera-
tive braking of motor.

This manual mainly describes periodic maintenance and trou-

bleshooting which are very important to assure successful
use of your AC spindle drive.unit.

1.2 Safety during maitenance and troubleshooting

The maintenance and troubleshooting should be done with the
following safety consideration:
o The control system should be maintained and remedied by
qualified electrician.

,- o When a person who maintains or remedy the control system

must touch a part of control system under live condition,
he should take off finger ring, wristwatch, necktie pin,
and other metallic goods before starting the work.
o Electric shock may cause fatal accident.
When a circuit at high voltage must be checked, due care
should be taken to select appropriate test/inspection
equipment, tools, etc. and to use them safetly (no matter
whether or not the circuit is grounded).
When a test equipment is applied to a part, component, or
circuit of the unit, operator should pay attention not to
touch a grounded part.
In general, test equipment should not be grounded.
During test or measurement, it is likely that high voltage
is present across the test equipment and the ground.
When motor is run during adjustment or remedy, due care
should be taken in this respect.
o Person who carries out maintenance or remedy of rotative
machinery should not wear loosely (otherwise loose wear

- l-
 might be involved into the running machine.
o DO NOT TURN OFF THE POWER IMMEDIATELY AFTER OPERATION IS
TERMINATED. THE UNIT SHOULD BE HELD TURNED ON FOR AT
LEAST 10 MIN. FOR COOLING THE DISCHARGE RESISTOR UNIT
(BY COOLING FAN), AFTER THE OPERATION.
IF THE DRIVE UNIT IS TURNED OFF IMMEDIATELY AFTER THE
TERMINATION OF OPERATION, THE RESISTOR UNIT COOLING FAN
STOPS AND RESIDUAL HEAT, OF RESISTOR UNIT MIGHT CAUSE BURN-
ING OR DAMAGE TO OTHER COMPONENTS OF DRIVE UNIT.
o Do not touch the drive unit immediately after the opera-
tion is terminated (maintenance or remedy should be start-
ed in about 5 min. after the operation is terminated).

1.3 Storage
When your AC spindle drive unit is not used, store it in
clean and dry environment.
Note that humidity and dust entering into the control unit
may adversely affect insulation resistance of the drive unit.

When your, AC spindle drive unit is left out of operation for

any length of time, the same cautions should be taken.
It is recommended, if the storage is humid, to use a heater
to keep the environment dry.

- 2 -
 92. WIRING
2.1 External wiring
2.1.1 Control system.where FR-SFJ is not connected to M300
through bus line
a. Analog speed reference
signal
Nischarne r-es

“““chins rc*dy” Input

FWd r”” command
R.3” run command
orlsnttd eplndl* atoP
commmd
I.“*-spewi qsllr select
“rdlum-specrl genr select

f-
AUI .
AUX.
Input I
input 2 EYir:
A C4I

I
“Up-to-speed” st.m.1
O”tpUt

-
Zero speed output
5111”“1
“rlcntation complete
( In-po~ltIorl) output

Is=_ .I 36
AUX. output 1

*“I. output 2 I
R e 21

- 3 -
b. Digital speed reference signal (option card SF-DAJ is used)

Basic system composition F R - S F J - 2 -;;I; K - D

“VP-to-epee.9, OUrpUt aima,

“Zero speed” output signal
tJr,entstion ccmplett
(in-porrItIon~ signal
A”X. O”Ip”t I
A”X. output 2

speed meter
Lord rnCtCr

‘SF-DAJ”

Note 1:
This input port is used for speed
reference signal selection
between “analog” and “digital”.
F o r d e t a i l s , refer to paragraph
3.1.2 “ A u x i l i a r y i n p u t s i g n a l s ”
in the Standard Specifications.

- 4 -
 c. Control system equipped with oriented spindle stop func-
tion
A circuit illustrated below is added to the basic system.

(1) Magnesensor type oriented spindle stop (1 point) see-

cification (+ motor speed feedback signal output)
(For spindle speed display/sync. feed
signal) .

_--- --- --
display/sync. feed signal
f I
Option card
‘ S F - D A 1’
OI- _____h To NC
'SF-OHJ' (A.B,Z phases)
Pulse nu Number of pulses is
128/(reduction ratio).
.!.
_^ Maqnesensor detect

Magnesensor
f---

(2) Encoder type oriented spindle stop (4096 points) spe-

cification, equipped with index function
c
+_----_--_T_~
Speed display/sync. feed signal
Option card
'SF-D41'
Oriented stop
position command e To NC
(1024P/rev
c A.B.2 phases)

er detect signal

- 5 -
 (3) Z-phase controlled motor built-in encoder type ori-
ented spindle stop (4096 points) specification, equip-
ped with index function

Motor detector signal

_______----------
Option card
'iented spindle '5 F - D A 1’
top position ed display/sync. feed signal
Tmmand S F - O K J '

-----hTo NC
(128P/rev
A,B,Z phases)

-.

- 6 -
 2.1.2 Control system where FR-SFJ is connected to M300 ,through
bus line (option card SF-TLJ is used) FR-SF J - 2 $K-T
a. Basic system composition
I QR I I

Poker supply
I J

Connection is not
c required for CON1
signal in usual
operation.

c
I/O signal assignment
CM300 series interface)

c SRI jY251~Y2DI
CNI A
____ ‘< 1

,I
'SF-TL.J'
To CNlB of
‘< 2 Ot-

final axis 'SF-RSJ' Rev run I n d e x /Y255;Y2D5

MR-S servo IVEIl BLS
c amplifier ORC lY256!Y2D6

so
CNll7 I ,
‘<2
!
*,.rm “on” jXIC3 X243
ZS IXIC4/X244
us lxlc5ix2451

le : ORA /XlC61X246
7 J
- 7 -
b. Control system equipped with oriented spindle stop func-
tion
A circuit illustrated below is added to the basic system.

(1) Motor built-in encoder high-speed sync. TAP and magne-

sensor type oriented spindle stop (1 point) specifica-
tion

Opt ion card

'S Speed display/sync. feed signal

- To NC
(A.El.2 phases)
Number of pulses is 128/(reduction ratio).

Magnet

Detector
Magnesensor

(2) Encoder high-speed sync. TAP and multi-point (4096

points) oriented spindle stop specification, equipped
with 'index function

Option card Encoder detect signal

1024P/rev

Speed display/sync. feed signal

-To NC
(128P/rev
A,B.Z phases)

- 8 -
(3) Z-phase controlled motor built-in encoder high-speed
sync. TAP and multi-point oriented spindle stop spe-
cification, equipped with index function

Option c a r d A
‘SF-71 feed signal

- To NC
(128P ‘/rev
A,B,,Z p h a s e s )

- 9 -
 2.2 Parts arrangement 1
‘,’ ,,,&
(1) SFJ-CA card and option (2) Main board L \ -1
f I’
card

r
FR-SFJ-2- ::: K FR-SFJ-2- :::K-R

fit 1 1 II1lA
SFI-CA card SFJ-CA card

b
Option
OP
II!

RI 0

CON1 CON2 CON1 CON2

Et
04

01

0
MC2
6
O0

Cfl.
?

n n In n,r
%f

-2 I-
FR-SFJ-2- Ll K-D FR-SFJ-2- i:IK-T -6 .3-
-10 12-

1
-” ,-

SFJ-CA card S F J - CA card 0

w-1
CTV

IQ?
Cl I R2.2

Option option t
0
0
@

F r o n t panel
(namerIlate)

Option card

CON1 CON2
n n C a r d SFJ-CA z
r
IP-PM power

- 10 -
 FR-SFJ-Z-3.7K FR-SFJ- -5.5K

0
“\ 0
3‘ !

:
0
KL’

l-l-
0

1 .c? J

-L 4-
-Ii n-
-111 ,z-

c I I ’ -n ,-

- 11 -
$3. ADJUSTMENT
3.1 Preliminary check
Before turning on FR-SFJ, perform the following check:
(1) Is the external wiring in conformity with the relevant
wiring diagram?
(2) Are the motor and the drive unit grounded properly?
(3) Are all shielding wires terminated properly?
o Is each shield armour connected to the corresponding
terminal'?
o Is each shield armour not looped?

(4) Is any component or part not loose?

(5) Is any foreign matter is not involved in the drive unit?
(6) Is there any damage or defect on each,P.C. board?
(7) Do ROM No. and jumper pin settings meet the order sheet?

- 12 -
3.2 Power feeding
3.2.1 Turning on the power
Immediately after the FR-SFJ is turned on, see the ?-seg-
.ment LED readout at the center of front panel to check
conditions:
(1) For FR-SFJ connected to M300 through bus 1 .ne

3 4-AC200/220 ON
1
Wait for turning on NC power
I

1 + NC power is turned on.

I 1

Initial data communica-

tion with NC (momentary
display) Alarm code is
displayed in
case of failure.

1
Initial data communication
complete
Wait for "ready ON".

1
Normal operation
1
NC power is turned off.

Wait for turning on NC

- 13 -
 (2) For FR-SFJ not connected to M300

I_ 3 # - A C200~220 0 N

Alarm code is
1 displayed in
case of failure.

1
Normal operation
1
Power is turned off.

- 14 -
 3.3 FR-SFJ status display and parameter settings

Operation status is displayed by the 7-segment LED readout

on card SFJ-CA1 and parameters can be set by DIP switches.

Status display and parameter settings depend on ROM version

of card SFJ-CA1 card.
For ROM version A@ . . . . . (A) 3. 3. 1
For ROM version BO and thereafter . . . . (B) 3. 3. 1

When FR-SFJ is connected to M300 CNC through bus line, sta-

tus can be displayed and parameter can be set on the NC CRT.
(For details, refer to 3.5.)

DIP switch settings and functions

Since DIP switch settings must be changed only when test op-
eration is required, they should not be changed during normal
operation.

DIP switch setting Function

Mode
/ (0: Set position)
1 I

1 j i Normal operation
; g@$ !
I ,
I
I_i_ _--_._ -.._- _-._._... .__!_-_-_-_- ._-_.._ -_ __.__-__ ___. ___ _. __ _
2 i [ Spindle parameters displayed by NC
1 2 3 / CRT are ignored.
,
ON !o/
I I ,- When FR-SFJ is connected to M300 CNC,
I ;j ‘A j c ] the spindle parameters set and dis-
I played on the CNC side are ignored
I
and the parameters set on the FR-SFJ
! side are used.
I ! -.--. .--__ _.. ._ _. . ._
1 2 3 I Setting prohibited (for manufacturer's
3 !
1 test operation)

c _._._ __ __- -~_--.-. -.- ._-_--_ .._ &_ _.... -.

1 2 3
4

c
Setting prohibited (for manufacturer's

c
- 15 -
 DIP switch setting Function
M ode
- ( 3: Set position)
1 2 3
6

-
1 2 3
7 I 1
ON; ,i3lC!
I’v!
I’JI j’ j
-

Initialization of parameters
The standard values (manufacturer's)
are set for all parameters.
User should not use this setting.
-
9 4 Meter test mode
931 Speed meter/load meter output
c
I
; (for ROM versions after BO)

- 16 -
 3.3.1 (A) Status display and parameter setting for ROM version 1

(1) Readout and switches

"Motor speed", "alar::"

and "parameter seLting"
are displayed.
I-

1
Display MODE: Display mode can c?
selected between
I I I I I I I ADDRESS and DATA.
L ADRESSJ - D A T .A-
UP : Value displayed in

clr13~ !dODE Ii P DOWN

4n
SET
ADDRESS and DATA
can be incremented.
DOWN: Value displayed in
ADDRESS and DATA
can be decremented.
SET : Data set for para-
meter can be stcred.

1) The display modes include "motor speed" display, "alarm"

display, and "parameter setting", as described in Table

2) After turning on the power, "motor speed" is displayed

unless alarm occurs.
3) In case of alarm, alarm code is displayed.

Table 1 Display modes and information for ROM version I'.\ I'

Display mode Display example and information

Motor speed o Motor speed (rpm) is dispiay-

display ed in DATA section with 4-
digit numerals.
mi o Display in ADD section is in-
ADD DAT.A' significant.
o In this example, motor speed
is 5,OOOrpm.
c
Alarm dis- o In case of alarm, alarm No.
play \ / \ / and alarm code are displayed
in DATA section with 2-digit
'RI;-! ~ ‘,:I 31 . numerals (for details, refer
1,- J/L ~
L to APPENDIX 1).
c / \ / \
o Display in ADD section is in-
They flicker. significant.
o This example shows occurrence
of "excess error".
c
- 17 -
Display mode Display example and information

0 Parameter address (parameter

1
Parameter
display No.) and data value are dis-
played in ADD and DATA re-
spectively.
0 For methods of setting para-
meter, and checking set para-
meter, refer to the next page.
0 For details of each parameter,
refer to 3.9.

- 18 -
 (2) Parameter setting
Set parameters with READY signal (SET) turned off.

o Motor speed is displayed

(Fig. 1) when alarm does
not occur.

ADD DATA

Fig. 1 Motor speed

display

0 Each time @ switch is pressed, ADDRESS and

DATA alternate.
'0 Desired address can be selected in ADD section
Selecting the by pressing morH switch. Data at the
selected address is displayed in DATA section.

I1*
Note: If display in ADD
section does not
change, but DATA

f;;=$$;~~:,
press w switch t; Fig. 2
changemode from (Data at address
DATA to ADDRESS. "02 II is displayed
in **.)
Ex.: In example shown
in Fig. 1, ADD dis-
play changes to S I when cUPl switch is
pressed, and to SZ when the switch is
pressed again (Fig. 2).

o Display in DATA section can be incremented

or decremented by pressing @*or @ switch.
to set desired value for DA
o E;tB;zzsing a switch, the set data can be
.

o After the desired data has been set, press

f mlfll switch on card SFJ-CA1 or turn off and
Een on the power to reset FR-SFJ.
Now data setting (parameter setting) has been
completed.
(G&p->
f

- 19 -
 3.3.1 (B) Status display and parameter setting for ROM versions
after "BO"
(1) Readout and switches
"Operation status", "dia-
gnosis", "error alarm",
"parameter setting (1) -
(8)" and "debug" can be
displayed.
..
Function of each switch is
as follows:
MODE: Display mode can be
changed.
UP : Value displayed in
ADDRESS and DATA can
I MODE If P DOWN S E T I ’ be incremented.
DOWN: Value displayed in
Located on card SFJ-CA1 ADDRESS and DATA can
be decremented.
SET : Data set for paramet-
er is stored when
this switch is pres-
sed.

a) 12 display modes, namely, "operation status", "diagno-

sis", "error alarm", "parameter setting (1) - (8)" and
"debug", are selectable.

b) After turning on the power, "motor speed" is displayed

automatically unless alarm occurs.

c) In case of alarm, alarm code is displayed.

d) Display mode can be changed by pressing kdswitch.
e) For display mode sequence and display content, refer
to the chart on the next page.

- 20 -
 (2) Readout display mode sequence

, , ] t_______-________________~~~_~~~
L 2

o Display mode can be selected in the sequence shown above

by pressing D
EEI switch.

o Display content can be changed within the same'display

mode by 0 UP or o
pressing
El
switch.

- 21 -
 (3) Operation status display mode
In operation status display mode, codes listed below are
displayed.

Item Code Unit Description

Motor speed I- rpm Motor speed is displayed.
Reference - rpm Commanded reference motor speed is
speed I_ displayed.

Position Pulses Number of 'remaining pulses (delay

control pulses) on deviation counter is
droop % displayed.
For pulses (minus) in reverse rota-
- - tion, decimal point lights.
Load % Load condition is displayed (100%
I_ for 30min. rated output).

(4) Diagnosis display mode

In diagnosis display mode, "control sequence", "external
signal", "warning NO.", "parameter error No." and "alarm
No." can be displayed.
Item Display Description

Control ,- c_I - 0 1-l - Indicates that the controller

sequence -ID" DATA is ready for operation.

I- ,=: - I:1 I- Indicates that the'controller

ADD nlfl is not ready for operation.

(5) External I/O signals . . . . . I/O signal can be monitored.

 Warning No.

Name Display Description

Warning
N o . e

'Parameter error No.

I Name
Parameter
Display Description
Parameter error
error No. IDD. MT* No. is displayed.

(5) Alarm display mode

c Alarm No.

1 Name
i Display
I
Description
I
Alarm No. is
Alarm No. displayed. I

Alarm display

c I- Al.arm No. is displayed.

For details, refer to a.4
t'Alarm/warning table".

c Concurrent alarms are display-

ed in the order of AL0 - AL9.

- 23 -
 (6) Parameter setting

To specify parameter, set "SETl" and "SET2" (machine ready

for operation) to "OFF".

p+xj
BIIIII

A
0 Unless alarm occurs, speed
is displayed in operation
status mode by the readout ADD DATA
(Fig. 1).
Fig. 1 SPEED display

I Select mode. 1

o Mode changes step by step

when
k-3
00 switch is pressed.
Ex.: When EODEl switch is
pressed 3 times suc-
cessively, display
mode changes from op- ADD DATA
eration status mode
(Fig. 1) to parameter (1)
mode' (Fig. 2). Fig. 2

Select address.
J
o Address can be selected by
0
pressing UP and/or 0"~
switches.
When address is selected,
Q
the data at that address is
displayed.

0
Ex.: When up switch is pres-
sed while display is as
Fig. 3
shown in Fig. 2, CZ ap-
pears.
Another one touch of
switch causes display of,
c3 (Fig. 3).
When 0 OnH switch is pres-
sed while display is as
shown in Fig. 3, CZ ap-
pears.
Another one touch of
switch causes display of
CI (Fig. 2).

- 24 -
 I Data rewrite~~ I

To rewrite previously set

0
data, press SET switch.
When the switch is pressed,
LEDs ADD flickers indicat-
ing that data can be rewrit-
ten.
Set desired data by pressing
0
UP oawt switches.
and/or Cl
Value can e incremented by
pressing UP switch, and de-
cremented 0y pressing @j
switch.
Value changes continuously
while switch is held down.

0
When SEf switch i's pressed
again, newly set data is
stored.
After the switch is pressed,
LEDs ADD light continuously.

1 Data set.completed 1

0
o Press ~ESU switch and reset the FR-SFJ(or turn off and
then on the power).
Now data setting has been completed.

f-

- 25'-
3.4 Spindle control monitor on NC CRT display . . . when FR-SFJ is
connected to M300 CNC through bus line

Since display (format, content, etc.) and setting method dif-

fer from NC to NC, refer to the instruction manual for your
NC system.
Typical examples of NC CRT display are described here.

3.4.1 Status display

For status display, "SPINDLE
MONITOR" is selected from
the menu. f
-(SPINDLE MONlTOn] DIAGN 2. 21

For use of this display GAIN 10.0

DROOP 123456
function, FR-SFJ should be
I nPM 6000
connected to NC through bus L O A D nATE 80
ALARM NO. 46 23
line. I
DATA BIT MONlTOn
76543210
o/I IL oooooool
H ollooooo
0'0 Looololoo
~Hoooooool

Display Description
GAIN Position control loop gain is displayed.
When position control loop is not used, "0" is
displayed.
The standard position control loop gain is,
Motor speed (rad/s)
Response delay (rad/s) = 10
DROOP Error in true spindle angle from referenced
spindle angle is called "droop".
Droop is expressed in number of pulses.
When position control loop is not used, "0" is
displayed.

- 26 -
Display Description

MOTOR SPEED True motor speed is displayed in rpm.

MOTOR LOAD Load is displayed in ratio(%) to motor rated out-

put (capacity).
The output rated for 30 min. is 100%.
Range of display is from 0 to 120%.

SPINDLE ALARM If fault occurs with spindle amplifier, alarm

is displayed with code No. (current alarm and
previous alarm are displayed).
For alarm contents, refer to Appendix 2.

CONTROL I!IPiJT Signal input to spindle amplifier is displayed

by bit.
CI)IITROL IIII’IJ’P II CONTROL IWUT L

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

-3 2 :
,”
II L SRISRN
0 I :c;EAnO 1 5
z
1 0 :-An 1 0 0

1 1 1 :GEARI I I

CONTROL OUTl'lJT Signal output from spindle amplifier is display-

ed by bit.

- 27 -
APPENDIX 2 Spindle control alarm list

Description LO. Description (Note 1)

10 UNDER VOLTAGE PR 40 FR-TK SELECT ERROR PR NR
- -
11 41 FR-TK TRANSFER ERROR PR NR
_ _ _
12 MEMORY ERROR 1-____ AR 42
13 43
--14 44
15 MEMORY ERROR 2 PR, 4 5 , OVER HEAT (AMP.) PR NR
-
16 I 4 6 0vERtiEAT (MOTOR OR RESISTOR) PR, NR
17 BOARD ERROR ~P R 47 ~
20 NO SIGNAL 1 (PLG) IPR’ 50,
~_~~_
21 NO SIGNAL 2 (SPINDLE ENC.) PR’ 5 1 1
22 PR 52 ERROR EXCESS PR NR
23 ERROR EXCESS (SPEED) PRi 5 3 ,
24 MAIN CIRCUIT FAULT :PRi 54 I
25 BRAKING CIRCUIT FAULT ‘PRi 5 5 EMERGENCY ~ NR
26 ~P R : 56 i OTHER AXIS ALARM ~ * ~NR
27 1 AR; 57 j OPTION CARD ERROR j NR
30 / E 0 / IPF (INSTAN. POWER F A I L U R E) ! * ;
/
31 OVER SPEED ;PRiEl~ j * ~
1 I
32 OVER CURRENT IPRiE2; 1 I
33 OVER VOLTAGE ‘PRiE3,
34 DATA PARITY i PR! E 4 i WARNING PARAMETER ERROR / *
I I
35 DATA ERROR IPRlES~
36 TRANSFER ERROR iPR~E6;
I
37 PARAMETER ERROR ; P R ~ E 7 NCE (NC EMERGENCY)

PR: Reset by turning off power supply of NC.

AR: Reset by turning off power supply of controller FR-SFJ.
NR: NC reset
*.. "SERVO OFF" does not occur.

(Note 1: Modification is applied to software version BO and

thereafter.)

- 28 -
 3.5 Spindle control parameter setting on NC CRT display . . . when
FR-SFJ is connected to M300 series CNC through bus line
To set spindle control parameters, "SPINDLE SPEC." display
is used.
’ l-SPINDLE SPEc.J M-PARAM 7. 1 /
#
There are two types of 1 slimtl 1000 13 stap 1 527
2 : 790 14 2 264C
spindle parameters; one 3 4000 15 3
is those used on the NC : slnaxf 1000 1000 17 16 smmi 4
1
side, and the other is 6 s 790 18
those sent to FR-SFJ ; 4000 1000 20 19
when FR-SFJ is conencted 9 ssiftf 0 21 sori 0
to NC through bus line. 10 022 sgear 0
'1 1 32 0 23
'12 4 0 24
(1) Parameters used on
NC side
PLC MENU

Spindle parameter list (l/2)

Parameter Setting range

# Description
(unit)
1 slimt 1 Speed For GEAR 00‘ spindle speed
2 2 limit
GEAR 01 with motor at
3 - 3 GEAR 10 maximum speed
4 4 GEAR 11, is s e t . 0 - 9 9 9 9 9 ( rpm)

5 smax 1 Max. For GEAR 00 maximum spindle

6 2 speed GEAR 01 speed is set.
7 3 GEAR 10 Slimtk t Smax
a 4 GEAR 11,
9 ssift 1 Shift For GEAR GO‘ spindle speed
10 2 speed GEAR 01 for gear shift 0 - 32767(rpm)
11 3 GEAR 10 is set.
12 4 GEAR 11,
13 stap 1 TAP For GEAR 00‘ maximum spindle
14 2 speed GEAR 01 speed during 0 - 99999(rpm)
15 3 GEAR 10 TAP cycle is
16 4 GEAR 11, set.

- 29 -
 Description Setting range
# Parameter (unit)

17 / smini I:;:,, 1 Minimum spindle speed is set.

Spindle runs at this speed o- 32767(rpm)
even wlien speed specified by
S command is lower than this
speed.

21 sori
22 sgear Encoder Gear ratio between spindle gear 0:1/l
gear and encoder gear is set 1:1/2
ratio
2:1/4
3:1/8

- 30 -
(2) Parameters sent to FR-SFJ from NC

These parameters are For 9" CRT

sent from FR-SFJ to
NC when FR-SFJ is lsplND~E SPEC.] M-#'ARAM 7.2/ 2
# I
connected to NC
1 PGI 100 25 GRAl IOC
through bus line. 2 PC2 100 26 2 100
3 PGC 10.00 OnSl 4400 27 3 1oc
4 ZRZ 1.00 ORS2 0 28 4 100
Although FR-SFJ it- 5 OSP 0 TSP 4500 29 GRBl 100
ZSP 50 30 2 100
self has the same 67 CSP
PST 20:: CSN- 300 31 3 100
El BRC 0 SDT IO 32 4 100
parameters, the para- 9 TIM IO 33
meters appearing on VKP 63 34
VKI 60 35
the NC display are 12 TYP 0 36

valid when FR-SFJ is

connected to NC.
#( I> DATA(
MC-ERR 1 MACRO 1
>
SPINDLE 1 PLC 1 MENU
I
I

Note: Parameters on the

NC display can be
made invalid by setting DSW-1 switch of card SFJ-
CA1 to "ON".
In this case, the parameters stored in FR-SFJ are
all valid.

For details of parameters, refer to "Parameter

Table"..
For 14" CRT

~PrnoLr SPCC.1 W-PARA 9

1 sillt 1 17 SII"! 1 33 PGl 1W 49 TSP 4500

2 2 16 34 PG2 100 50 ZSP 50
3 3 19 35 PGC 10 00 51 CSN 300
4 4 M 36 ZRL 1.00 52 SOT IO
5 sux 1 21 SW, 0 37 OSP 0 53 TLY 10
6 2 22 spear 0 30 CSP 20 54 VKP 63
7 3 23 39 PST 2046 55 VKI 60
6 4 24 40 BRC 0 56 TYP 0

9 ssitt 1 25 41 57 GM1 100

IO 2 26 42 56 2 100
11 3 27 43 59 3 100
12 4 26 44 60 4 100
13 stap 1 29 45 61 GR61 100
14 2 30 46 62 2 100
15 3 31 47 ORSl 4400 63 3 100
16 4 32 48 ORSZ 0 64 4 100

- 31 -
3.6 Test operation
Connect the motor shaft to the machine shaft directly._
Run the machine and perform the following check:
(1) Does the true motor speed meet the given reference speed?
If no, make adjustment in accordance with the instruction
in 3.7.

(2) Is motor rotation smooth?

(3) Does any usual sound occur?
(4) Does any foreign smell arise?

(5) Is temperature of each bearing normal?

When it is verified that the motor and machine are in good
condition, operate the motor and machine under load condition
to check.

3.7 Adjustment of motor speed

All FR-SFJ controllers are adjusted, before shipment, in ac-
cordance with the order specifications. When analog voltage
speed reference signal is used, however, voltage drop caused
by signal line may cause deviation, and requires fine adjust-
ment.

When FR_SFJ uses option card SF-TLJ and is connected to M300

series CNC through bus line, or uses option card SF-DAJ for
digital speed reference signal, no deviation occurs and there-
fore readjustment is not required.
In this case, OD El is to be set to 1000.

Adjustment procedure:
(1) Set speed reference signal to the forward run minimum
speed and record the motor speed displayed by the 7-seg-
ment LED readout of controller (record the speed as NIP
(rpm)). When the desired motor speed is N,, (rpm), set
k, , determined from the following formula, for parameter
No. OB El.
N lr - N 1~
kl= x 2048
Max. motor speed with command
signal voltage at 1OV (rpm)

- 32 -
 Note: k, is either negative value or positive value, buz
not displayed with sign (+ or -).
When value can be incremented by pressing w bu:t:r.,
the value is negative (for ROM version AO).

(2) Set speed reference signal to the forward run maximum

speed and record the motor speed displayed by the 7-seg-
ment LED readout of controller (record the speed as N:r
(rpm)>.
If this NZK is not equal to the desired speed Nzr , set
kz , determined from the following formula, for parameter
No. OD I=].

kz = (Current setting) x K

(3) When the adjustment has been completed for forward run,
speed in reverse run should have been adjusted automati-
cally. It is, however, recommended to verify that
specified reference speeds are always equal to true motor
speeds.

Ex.: Let the rated motor speed be 8000rpm with 1OV speed re-
ference signal, and the reduction ratio be 2 : 1 (motor
speed : spindle speed) . . . . . .
N *r = 200 . . . . Motor speed should be 200rpm with spindle
speed command of SlOO
N lr = 188 . . . . Reading of 7-segment LED readout w ,ith
spindle speed command of SlOO.
188-200
.*. k,= X 2048 + - 3
8000

Set -3 for parameter

- 33 -
3.8 Adjustment of oriented spindle stop function
3.8.1 Oriented spindle stop motions
There are three types of oriented spindle stop and one of
them can be selected by setting parameter jORS2j.
1. PRE . . . . (a) Spindle approaches the stop position ’
in the direction of ratation which is
same as that of on-going rotation.
2. Forward spindle stop orientation .....
(b) Spindle always approaches the stop po-
sition in the direction of forward ro-
tation.
3. Reverse spindle stop orientation
(c) Spindle always approaches the stop po-
sition in the direction of reverse
rotation.

(1) When oriented spindle stop command signal ORC turns on,
motor speed changes from steady run s;;eed to positioning
control speed and at the same time "stop position command"
(multi-point spindle orientation) is read.

(2) When motor speed reaches the positioning control speed,

control mode changes from "speed control" mode to "posi-
tion control" mode (position control loop galn'parameter
(Note 1)).
(Speed at which control mode changes to position control
mode is automatically set in accordance with position
control loop gain setting.)

- 34 -
(3) When control mode changes to position contrcl mode, dis-
tance to the stop position is calculated and spindle
speed is decelerated in accordance with the deceleration
pattern set by parameter ICSP to stop.
(4) When the spindle enters the "in-position" range set by_
parameter IZRZ , oriented spindle stop complete (ir.- posi-
tion) signal ORA turns on.
(5) Spindle stop position can be shifted by setting parameter
IPsTl.
(6) When oriented spindle stop command signal ORC is turned
off, motor speed returns to the previously set reference
speed.

Motor speed

CTL. CTM

ORA

Note: Position control loop gain parameter

1 PGl 1 is used for magnesensor/motor built-in encoder
type oriented spindle stop, and El PG2 for encoder
type oriented spindle stop.

- 35 -
 0: Pat-ame ter name

Pnsiton control b l o c k Speed control block

I II I

From CONC
%elay/ +
advance . Power
$iiig, I amp1 ifier

I
s

I I2os1 t i o n f e e d b a c k
Speed feedback signal c
I L-3 Spindle motor.

sol -I
I
 3.8.4 Preparation for adjustment of magnesensor type oriented
spindle stop
Parameters

I For FR-SFJ connected to M300 CNC !For FR-SFJ not connected to M3r?C
I (NC display "spindle parameter", i CNC
I page 2) (7-segment LED readout;
Parameter I No. i Initial value ~ No. Initial T/alue
name
1 ’ Refer to appendix Refer ‘0 appenaix
PGl I 1 j table I. I 21 taDLe I

ORS2 16 30
GRAl / 25 1100-327671 39 1 64- 7 F F F
CRA2 / 26 /lOO-32767’ 3A ~ 64-7FFF
GRA3 j 27 / 100 -32767 / 38 ~ 6 I- 7FFF
GRA4 / 28 1100-327671 3C 64-7FFF 1
GRBl / 29 jlOO-327671 3D ~ 64-7FFF
GRB2 / 3 0 i 100-32767: 3 E 64 - 7 F F F 1
GRB3 31 10’0-32767 I 3F ; 64-7FFF
GRB4 32 jlOO-327671 40 , 64 - 7 F F F
I

OSL I 4 1 I 2 I

Preparation:

a) The entire reduction B

0. ratio (gear ratio or C
++-!!l!!!lLI
pulley ratio) should
be known. (A - F: Number of teeth)

Check gear tooth (ratio) parameter settings (GRAl -

GRB4).
icRAl, =AxCxE

‘ G R B ‘=BXDXF

Note: User may be requested to set gear tooth parameters

1x1 - w] for machine used.

b) Check parameters IPGL] , IF] and I] are set as list-

ed above.
No setting is required for [PG21 and IF].

c) After parameter setting is changed, be sure to turn off

and on the power, or press RESET button to reset.

- 37 -
3.8.5 Preparation for adjustment of encoder type ormiented spindle
stop
Parameters

For FR-SFJ connected to M300 CNC For FR-SFJ not connected to M300
(NC display "spindle parameter", CNC
2) ’ (7-segment LED readout)
- page -
Parameter No. Initial value No. Initial value
name ~____
Refer to woendix ileier t* aDDeo*,x
PC2 2 t.ble 1. 2 2 t&l. I
ZRZ 4 2 4
CSP 6 R*l*r eo .pLandir 2 6 RCICr ro appendix -
- - . t&k 1. r.bl* I
P S T 7 2 0 4 8 - 2 7 2 0 4 8
- - - ---. ..-___.__
R.fcr to .pp.n*ix RcIer to .pp*n*ix
ORSI 15 t&l.~--
I. 2F
-_ i.-__ ._ _---_ e.D1* I.
ORS2 1 6 30
_-.- -_.---_- --_ -___-- - - - -
GRA.1 2s l o o - 3 2 7 6 7t 3 9 64 -7FFF
GRAP 2 6 1 0 0 - 3 2 7 6 7
GRA3 2 7 1 0 0 - 3 2 7 6 7
G R A 4 1 2 8 1 l o o - 3 2 7 6 7 t 3C 1 64-7FFF 1
GRBI 2 9 100-32767 3 D 6 4 - 7 F F F
GRB2 3 0 IO&-32767 3 E 6 4 - 7 F F F
GRB3 1 3 1 1100-327671 1 64 - 7 F F F I
GRB4 1 3 2 1100-327671 4 0 1 64- 7FFF I
OSL I -- I 4 1 I 1 I

Preparation:
D
a) The entire reduction c
@-I!5
ratio (gear ratio or
pulley ratio) should (A - F: Number of teeth)
be known.

Check gear tooth (ratio) parameter settings (F] -

GRB4/ ).
[GRA] =AXCXE

. A

b) Check parameters E/ , pl and (PST) are set as

listed above.
No setting is required for IPGl and I OSP .
cj After parameter setting is changed, be sure to turn off
and on the power, or press RESET button to reset.

- 38 -
3.8.6 ,Adjustment of oriented spindle stop function

Adjustment procedure (( ) for encoder type oriented spin-

dle stop function)

(1) Spindle stop position

Since there is no control means (potentiometer or ro-
tary switch) for stop position adjustment, stop posi-
tion should be adjusted by changing parameter setting
as described below.
(a) With READY signal turned on, set "3" for parameter
0
"00" and press SET switch.

(b) After the spindle rotates two revolutions and stops,

"27" will be displayed by the 7-segment LED readout.
Press @ or @ switch to adjust stop position.
The spindle remains rotating while switch is held
down. The spindle rotates about 1 deg. for each
100 of data value (one revolution for 4096 of data
value).

(c) After the stop position has been determined, remove

dial gauge or other measuring device and press m
switch.
After the completion of stop position adjustment,
turn off and on the power or press RESET switch to
reset.

(d) When FR-SFJ is connected to M300 series CNC through

bus line, the values set for parameters "27" and
"30" should be also set for parameters IPST] and
0RS2 appearing on the NC display screen ("Spindle
parameter", page 2).

- 39 -
 (2) Adjustment of time for oriented spindle stop

Speed
Normal speed
Point at which speed changes to
"oriented spindle stop" speed

Set the corresponding parameters properly, referring

to the following table:

I Adjustment
Ip(;
; [;p(;:i] !csp;

Overrun at stop Note 1 f: Increase parameter

setting.
I -1 Do not change parameter
Long orientation setting.
\: Decrease parameter
setting.
Hunting at stop

Adjust 1x1
f [[%??I) irst and then adjust w].

If large hunting occurs at oriented spindle stop, it

is likely that position detector (magnesensor, encoder,
etc.) is installed improperly.
Install position detector correctly and then perform
the adjustment described above again.

3.8.7 Adjustment of servo rigidity

"Servo rigidity" at oriented spindle stop can be increased
as follows:

1) Increase IPGl setting (magnesensor type) or ElPG2 set-

ting (encoder type) to an extent where overrun does not
occur.

2) By setting bit of parameter I=], increase two magni-

fications Kp and Ki proportionally (if Kp is set to
"I . 2" , for example, Ki should be set to "'1.2").
If intense vibration occurs at oriented spindle stop,
the magnifications should not be increased further.

3) "T of parameter [El is "gain" for "advance/delay"

- 40 -
 compensation. Momentary servo rigidity can be in-
creased by increasing this value. With increase of
WT, however, torque for positioning motion decreases.
This adjustment is valid when bit 4 of parameter ['1RS1
is 1,(-J" .

3.8.8 "Advance/delay ContrOl” and "PI control" application

Usually, "advance/delay control" is employed.

In the case described below, use "PI control" function.

o Frictional torque of spindle is large and particularly
accurate stop is required.
When "PI control" is used, servo rigidiy is somewhat in-
ferior than that in "advance/delay" control.

- 41 -
 3.9 Parameter list

Set;A;&)range
c Parameter Description

01 NOX Motor type Set "0". Decimal nota-

tion
02 MSL Motor sel- SJ-J2.2A . . . . . 0 Decimal nota-
ection tion
SJ-J3.7A . . . . . 1
SJ-J5.5A . . . . . 2
SJ-J7.5A . . . . . 3
03 PLG Position Setting is made for number of Decimal nota-
control encoder pulses. tion
loop 0: 1024 pulses (encoder oriented
encoder spindle stop, sync. TAP)
type
04 MOD External Setting depends on interface with Decimal nota-
interface NC. tion
mode sel- 0: Decimal IO (CON1 signal is
ection used for operation)
2: Bus-line connection to M300
series CNC
05 DSR Digital Type of digital speed reference Decimal nota-
speed re- signal is selected. tion
ference This parameter is valid when MOD
signal type (#04) is set llo,,.
0: 12-bit binary
1: Signed 12-bit binary
2: BCD (2-digit)
3: BCD (3-digit)
06 MON Output Type of meter for monitor (MO2 Decimal nota-
monitor output of CONl) is set. tion
selection 0: Load meter
1: Torque meter
Standard setting: 0
07 OlSL Auxiliary 0: Speed detection ON 0 -- 4
output 1 1: Torque limit ON
selection
2: Spindle control ready
3: Emergency stop ON
4: Alarm ON
08 02SL Auxiliary 0: Speed detection ON 0 - 4
output 2 1: Torque *limit ON
selection
2: Spindle control ready
3: Emergency stop ON
4: Alarm ON

- 42 -
1
-
r Parameter Description
:7: jettin range
(unif )
,
I
1
19 :lsL 4uxiliary 0: Torque limit H/L, 2 stages 3ecirnal ncta-
input 1 tion
1: Index input
o - 7
2: Not used
3: Emergency stop input
4: Torque limit, single stage
- etc.
)A :2sL 2uxiliary 0: Torque limit H/L, 2 stages o-7
input 2
1: Index input
2: Not used
3: Emergency stop input
4: Torque limit, 1 stage, etc.
These settings (except for 0 and
1) should not be duplicated with
- parameter 1'09't settings.
)B 'OP ;peed re- dhen analog speed reference sig- Signed decimal
ference la1 is used, offset value is set. iotation
signal -999 to +999
offset Standard setting: 0
-
)C
- 'ON \Jot used. Set "0" .
)D 'GP speed re- ;ain for speed reference signal 1ecimal nota-
ference is set. tion
signal o- 1,150
3ain ad- 2ctual speed reference is product
justment Ibtained by multiplying speed re-
ference signal input from external
signal source by this setting
(1 multiplier = 1000).
- Standard setting: 1000
1E
- IGN Not used. Set "0" .
1F :SN2 2nd Set "1,000". Decimal nota-
cushion tion
(slow-
start)
time con-
- stant
LO 1TYP Data type Whether data of parameters #ll - Decimal nota-
#20 are valid or invalid depends tion
on this setting.
0: Invalid
1: Valid
When "1" is selected, data set fol
parameters #ll - #20 become valid
for input signal from connector
CONC of card SF-ORJ.

- 43 -
 Parameter Description Settin range
# (uni! )
For details, refer to the Specifi-
cation "BNP-A0801-22".
11 DTOl Data 1 These data are valid when "1" is Decimal nota-
12 DT02 Data 2 set for #10 parameter VI. tion
13 DT03 Data 3 Speed reference signal selected
14 DT04 Data 4 by speed reference signal select
15 DT05 Data 5 signal is set for each data.
16 DT06 Data 6
17 DT07 Data 7 Data is set in terms of motor
18 DT08 Data 8 speed within the range up to the
19 DT09 Data 9 motor maximum speed set by #31
1A DTlO Data 10 parameter ITspI.
1B DTll Data 11
1C DT12 Data 12
1D DT13 Not used. Set "0".
1E DT14 Not used. Set "0".
1F DT15 Not used. Set "0".
20 Not used. Set "0".
21 PGl Magnesens- The larger the setting, the short- 0 - 360
or orient- er is the time taken for oriented (l/10 rad/s)
ed stop spindle stop, and the higher is
position the servo stiffness.
control If setting is excessively large,
loop gain however, intense vibration may
occur, resulting in overrun.
Standard setting: See Table 1.
22 PG2 Encoder Same as above o- 360
oriented (l/10 rad/s)
spindle
stop po-
sition
control
loop gain Standard setting: See Table 1.
23 PGC Sync. TAP Spindle position control loop l- 512
gain in sync. TAP is set. (l/4 rad/s)
Standard setting: See Table 1. For NC display
parameter,
(NC display standard se;ti;T: o/o1 - 999.99
.
(-Us)
24 ZRZ Oriented In-position range within which Encoder Magne-
spindle "oriented spindle stop complete sensor
stop in- (in-position)" signal is output l- 5760 l- 512
position is set. (l/16
(l/16
range deg.) deg.
Standard setting: 16 For parameter
(NC display standard setting: on NC display
1.00) O -de3g5910
. - 3g
deg.

- 44 -
 Set;;;&)range
# Parameter Description
+ 25 OSP Not used. Set "0".
26 CSP Creep Time taken for oriented spindle o- 1000
speed stop is reduced by increasing
this setting.
Standard setting: See .Table 1.
* 27 PST Position Oriented spindle stop posi.tion is Encoder Magne-
shift set. sensor
O-4096 1536 -
Encoder: Stop position is set 2560
within 360 deg. with (pu1ses) ( a b o u t
increment of 360/4096. l/100
Magnesensor: Stop position is deg.
set within range from
-5 deg. to +5 deg.
with increment of
l/1024 (2048 for 0
deg.)
Standard setting: 2048
28 BRC Not used. Set tlOt' .
29 Not used. Set "0" .
2A Not used. Set "0".
2B Not used. Set t'O" .
2c Not used. Set 1'0" l

2D Not used. Set v'O'v .

2E Not used. Set llOtl .
2F ORSl Oriented Refer to "ORSlt . Hexadecimal
spindle notation
stop con-
trol 1
30 0RS2 Oriented efer to "ORS2". Hexadecimal
stop con- notation
f trol 2

Parameters marked with + are set on the CNC side when the control-
ler is connected to M300 series CNC through bus line.

c Table 1 Oriented spindle stop parameter standard settings

F o r smnll load CD’
(Machining center.
etc. 1
1 0 0
c 1 0 0

20
1400 A&--l
- 45 -
# Parameter Description Settin range
(unif >
31 TSP Motor max- The maximum speed of motor is set. 1 - 3276
imum speed (10rpm)
For parameter
setting on NC
display
10 - 32760(rpm
32 ZSP Zero speed Speed at which "zero speed" signal 1 - lOOO(rpmj
is output is set.
Standard setting: 50
33 CSN Accelera- Time for acceleration to reference 2 - 3276
tion time speed is set (invalid for position (10msecj
constant loop control).
For parameter
Standard setting: 30 setting on NC
display
(300 for parameter setting on 20 - 32760msec
NC display)
34 SDT Speed Speed at which "speed detect" o- lOO(%j
detection signal is output is set in terms
ratio of percentage to motor maximum
speed.
Standard setting: 10
35 TLM Torque Torque limit ratio is set in o- 120(%)
limit terms of percentage to input
torque limit.
Standard setting: 10
36 VKP Speed ioop Proportional gain is set for o- lOOO(rad/s
propor- speed control loop.
tional The larger the setting (about 100
gain - 150), the faster is the re-
sponse, but the larger is the
noise/vibration.
Standard setting: 63
37 VKI Speed loop Integral gain is set for speed o- 1000
control control loop. (l/lOrad/sj
integral It should be set so that its
gain
ratio to proportional gain VK? is
almost constant.
Standard setting: 60
3s TYP Position Setting is made for transition Decimal nota-
loop con- from "speed control loop" to tion
trol II IPJ'! "position control loop".
type 0: Position control loop "IN"
after spindle orientation
1: Position control loop ,l;N1l
at the time control loop mode

- 46 -
 # Parameter Description Setting range
(unit)
is switched.
Set "0" when initialization (home
-return) is required.
Otherwise, set "1".
Standard setting: 0
i- 3
39 GRAl Number of Number of gear teeth for gear 00' These para-
gear teeth is converted into hexadecimal mete.rs must be
(reduction value, and set. set for orient
3A GRA2 ratio) on Number of gear teeth for gear 01 eti spindle
spindle is converted into hexadecimal stop.
side value, and set.
(driven 64-- 7FFF
3B GRA3 side) Number of gear teeth for gear 10 (Iiex.)
is converted into hexadecimal For NC display
value, and set. its range is
3C GRA4 Number of gear teeth for gear 11 1co - 32767
is converted into hexadecimal (decimal) and
value, and set. conversion is
not required.
3D GRBl Number of Number of gear teeth for gear 00
gear teeth (on motor side) is converted into When motor
(reduction hexadecimal value, and set. speed is de-
* ratio) on Number of gear teeth for gear 01 termined from
3E GRB2 the following
c motor side
(drive (on motor side) is converted into formula,
side) hexadecimal value, and set. (GRAl-GRA4) ant
4
3F GRB3 Number of gear teeth for gear 10 (GRBl-GRB4)
(on motor side) is converted into should be set
hexadecimal value, and set. with the mini-
* mum integer
c 40 GRB4 Number of gear teeth for gear 11 ratio. (Note 1
(on motor side) is converted into
hexadecimal value, and set. Splndlc speed X
N u m b e r o f Spindle-side g e a r teeth (~17.4
ihnber of m o t o r - s i d e gear tech (CABI-
I Motor speed

Parameters with mark + are set on the NC side when FR-SFJ

is connected to M300 series CNC through bus line.
Note 1: If value GRA or GRB is smaller than 64~ (lOODin decimal
notation), the same multiplier should be applied to GRA
and GRB to make the values larger than 64~.
Ex .: When GRAl and GRB are 31 and 29 respectively, mul-
tiply these values by 4.
GRAl = 124,= 7CH GRBl = 116~3 74~

- 47 -
# Parameter Description

11 OSL Position Type of position detector used in Hexadecimal

detector oriented spindle stop function notation
type' is specified.
0: Motor built-in encoder
1: Encoder
2: Magnesensor

12 BSL Bit Hexadecimal

assignment notation

FEDCBA9876543210

z 7; ;
:I 55 F
:
25 H ;
z: : ;j
:- f i H 6
*a : : Y
00
Y : i E 3
; E
: 9 E 5
nL I s P 7
L.J L_.A u u -

.-

- 48 -
 Parameter Description Setting
range
(unit:
3RSl Oriented ’ FEDCBA9 8 7 6 5 4 3 2 10 Hexadeci-
spindle : ma1 ncta-
Sprndlc
stop con- orrent, Spindle z-0 (UT selxt
tion
orlent.
trol 1 i(l magnif. K, magnif.
I I I I I I

combination combinatzon
0: 0.6 (Fold*) 0: Il.6 (TOld”J 11: Irelnyllrdv~nce 0: 0.55 Irad/sJ
I: n.7 I : II. i I: PI I: I.1
2: II.8 2: 0.8 2 : I.65
1: 0.9 3: 0.9 3: 2.2
,f: I I: I I: 2 . 7 5
5: 1.2 5: 1.2 5: 3.3
6: 1.1 fi: 1.1 fi: :xRTr
7: I.ti 7: I.6 7: 1.1
A: I.11 8: I.8 8: 1.95
8: 2 9: 2 9: 5. i
A: 2.2 A: 2.2 *\: Ii. 05
II: 2.1 B: 2.4 R: 6.6
c: 2.6 c: 2.6 C : i.IS
D: 2.8 D: 2.8 0: i.i
E: 3 II: 3 1:: 8. ‘25
F: 3.2 I:: 3.2 1:: R.R

ORS2 Oriented Hexadeci-

spindle ma1 nota-
stop
control g

.-

0 : (II d,r.cti”,,
I : (-1 dlrectlan

0 : (*) dIvrrtLoel
I : C-1 dIrectlo”

0 : Closed

t : Jcmi-closed

0 : (*J dIrectI””
I : (-, dlwctio”

Parameter marked with * is that set on the NC side

wtlen the controller is connected to NC through bus line.

- 49 -
 94. CARD SETTINGS AND CHECK TERMINALS
4.1 SFJ-CA1 card
Card group No. G52

0 CHI
1 R3 0
. (111:
Hh 0

0 CH3
K9 0

l CH4
COh RI? 0 COh
101 IO?
0 Cll’i
Hli 0

I HI8 0 0 CH6
r __________________ --______:
p--w-.

‘7x-d group No.

/I
G53 card
CONlO?

1
CON104

CON CON
II 104

_-J
G51 card
Illustration below shows the
part which differs from that
of card G52.j
7

34 6
35 a
.sfi l
 (1) DIP switch setting table
c: Set to "ON"
x: Set to "OFF"
Switch No. Name Description
DSWl-1 Test mode Test mode is selected.
t
-3

Normal s e t t i n g
N C parameters ignored (internally set
F larameters a r e Galid)
- Test aging

- Parameter transfer
Test mode

* E2 ROM i n i t i a l i z a t i o n

DSWl-4 Meter (For ROM versions after "BO")

calibra-
tion
**.*** Meter full-scale output
. . . . . . Meter normal mode

Speed meter and load meter can be calibrat-

ed.

(2) Pushbutton table

1
C

c 1Yame -I

I;IODE Refer to the description about the readout of

FR-SFJ

IJP

1DOWN
c
<SET

c RESET This pushbutton is for master reset of CPU.

Press it after parameter setting.
I

- 51 -
 (3) Jumper pin setting table
Card group No.: G51 m.,...m . . .N. Set
o t s e t
No. Name Setting
T Description
L
Standard
settine
Sl Watchdog Watchdog alarm is valid.
alarm m
l o Watchdog alarm is invalid.
S2 Power control m "High-current" loop gain
loop gain m
setting l o "Low-current" loop gain
s3 I Bus interface FR-SFJ is not connected Shown to
s3 m to M300 series CNC the left
through bus line.
(Parameter #04 is set to
"0" . )
FR-SFJ is connected to
M300 series CNC through
bus line.
(Parameter #04 is set to
"2" . )
I
s4 Test pin lo
Pin should be removed for lo
I test.
S5 RAM storage 64Kbit RAM is used.
capacity
1 setting 16Kbit RAM is used.

Card group No.: G52

I
No. / Name Setting Description Standard
, setting
PINliCurrent con- m "High-current" loop gain
trol loop
gain setting lo "Low-current" loop gain
PIN2 Bus interface FR-SFJ is not connected Shown to
PIN? m to M300 series CNC the left
121 through bus line.
PIN3 PIN3 m
(Parameter #04 is set to
"0" . )

- 52 -
 Card group No .: G53 (for additional switches to card 2-5:
No. Name Setting Description I Standard
s e +-;,v
b,LL.LG

PIN4 Load meter Time constant is set to ;

filter .@zzl - about 400ms (same as that ’
time con- for card G52). Em
1
stant set- Time constant is set to :
ting l o about looms. ----_~
SPARE Spare For spare / .m
/

_ (4) LED table

No. Description I
I1
LED1 Status display and alarm display
1 I
LED6 . -~ -- __ _.__ _ i
LED7 Lights in case of watchdog alarm.

- 53 -
 (5 Check terminal table
No. Common Description
CHl R3, left U-phase base amplifier drive signal
CH2 R6, left V-phase base amplifier drive signal
CH3 1R9, left 1 W-phase base amplifier drive signal I
4 CH4 Ri2, left c-phase base amplifier drive signal
4 CH5 R15, left v-phase base amplifier drive signal
4 CH6 R18, left F-phase base amplifier drive signal
CH7 Not used

HCH8
CH9
q-phase PWM waveform
c-phase PWM waveform
c-phase PWM waveform
W-phase PWM waveform
V-chase PWM waveform
U-chase PWM waveform
Brake. transistor PWM waveform
U-phase PWM waveform
V-phase PWM waveform
W-phase PWM waveform
V-phase current waveform
A/D converter input waveform
U, V, W phase full-wave rectification waveform
Converter current waveform
U-DhaSe current waveform

CH23 - OV, AG (analog ground)

4 CH24 R29, left Brake transistor, base amplifier drive signal
CH25 - RG (relay ground)
CH26 RG +24V power supply
CH27 - OV DG (digital signal ground)
CH28 DG +5V power supply
CH29 OV AG (analog signal ground)
CH30 Analog speed reference signal input
CH31 AG Speed feedback, A phase
CH32 Speed feedback, B phase
CH33
---_ Speed feedback, Z phase
CH34 +15V power supp1.y
CH35 OV, AG (Analog signal ground)
CH36
_--. .--. -15V power supply
CH37 AG Speed meter out,put .--
CH38 Load meter output
% Is at high voltage. Pay attention to electric shock.
- 54 -
 4.2 Card SF-ORJ

0 0

I
CON4

CHl
2
3
5"

CON8

v Not u s e d

iUP P I N4
Application /DOWrJ,.P I

PIN4
OE oc
I
1I
5
PLC type/encoder
type orlcntsd
etop poeltlon
commmd Interface

CONC
c

Check terminal table

c
No. j Common i Description
CHI / CH6 I Position control feedback, A phase
CH2 1 CH6 / Position control feedback, B phase
C H 3 1 CH 6 / Position control feedback, 2 phase
d- CH4 1 CH6 ! Magnesensor output
CH !j 1 CH 6 1 Magnesensor linear zone output
CH6 / - j Common (DC)

c
- 55 -
4.3 Card SF-TLJ

-Card group No. COO

-Not used

COI

r_l
\a CHS

Not used

J
CON

Check terminal table

No. Common Description
Card name

CHI DG Position control feedback, A phase

CHI? DG Position control feedback, B phase
CH3 DC Position control feedback, Z phase
CH4 DG Magnesensor output
CH5 DG Magnesensor linear zone output

- 56 -
 4.4 Card SF-DAJ

0 0
1

CONS

-
-
PLC type/encoder
contact input, i)E
t y p e oriented
“E

“pen collertor s,E

c-Card group NO. COO

1
NCSF-DA
mool

CONCA

+ Card name

Check terminal table

No. C o m m o n Description
CHl ’ CH6 I Position control feedback, A phase
CH2 CH6 ~Position control feedback, B phase
C H 3 CH6 / Position control feedback, 2 phase
CH-I CH6 Magnesensor output
CH5 I C H 6 / Magnesensor linear zone output
CH6 I - ; Common (DC)
CHIO 1 - Common (RC) )

- 57 -
95. ADDITION AND REPLACEMENT OF COMPONENT

Before a component is added or replaced, be sure to turn off

the main power supply.
5.1 Addition of option card (SF-ORJ; SF-DAJ and SF-TLJ)
When an option card is newly added to FR-SFJ unit having no
option card, follow the procedure and cautions described
below.
Procedure:
(1) Remove the front panel of FR-SFJ unit (4 panel mounting
screws should be removed).
(2) Place the option card on the card SFJ-CAI, where the
space is provided for installation of option card, and
secure the option card with five mounting screws.
(3) Perform the required settings.
(For parameter settings, refer to 3.3 and 3.9 (parameter
table).)

Due care should be taken when parameter(s) must be set.

Option'card is shipped with the standard settings.
Upon reception of option card, check it against the
specifications.

(4) When setting is changed, the setting table in the order

sheet attached to your FR-SFJ should be revised in ac-
cordance with the change.
(5) Install the front panel.
(6) Affix the "option card nameplate" attached to the option
card to the FR-SFJ front panel, as shown below.

- 58 -
 Front panel
mounting screws

/ Rating plate Card

/ SFJ-CA1

Front view Location of option card

(View with front panel
removed)

5.2 Replacement of card

For replacement of card, the front panel should be removed

(remove 4 mounting screws>.

(1) Card SFJ-CA1

Disengage 6 card locks (0)
Card
to remove card SFJ-CAl. SFJ-CA1

- CAUTION
Before replacement, check ROM No., switch settings and
jumper pin settings.
When it is desirous to use the previous parameter settings,
remove the parameter ROM (E2 ROM) from the old card and
load it to the new card.

(2) Cards SF-ORJ, SF-DAJ and SF-TLJ

To remove these cards, remove 5 mounting screws (for loca-
tion of mounting screws, refer to 4.4).

-CAUTION
Before replacement, check switch setting and jumper pin
settings of new card.

c
(3) Card IM-PW2
To remove the card, follow the steps described below.
1. Remove card SFJ-CA1
c
- 59 -
 2. Disengage connectors 1 0 , @ and 0.
3. Disengage all card locks to let
float the card.
4. Disengage connectors 4 0 , @ and @
in this order.

To install a new card, perfo rm the re-

verse steps.

5 .3 Replacement of ROM
ROMs should be handled in pair; ROM1 (16G) and ROM2 (17G).
Replace a pair of ROMs.

Procedure:
(1) Remove the FR-SFJ front panel (remove 4 panel mounting
screws).

(2) Remove Llle ROMs.

To remove the ROMs, be sure to use a ROM remover and

carefulLy disengage each ROM from socket.
USC care not to bend ROM pins.

(3) 1,oad new ROMs.

To load, identify each ROM (see ROM No.) and check ori-
eritati on.
AfLer it is loaded, visually check for condition.

Example of ROM loading failure

I
@ F:xnmI)Ie of loading failure
ROM tilts and its pins are not put into the socket
securely.

\P.C.
b o a r d

- 60 -
 0
2 Rxnrriple of loading failure
ROM pin(s) is not put into the socket.

Pin bent o u t s i d e
ROM socket

Pin bent inside /

(4) After ttle replacement of ROMs, the corresponding descrip-

tion i.n the “ o r d e r s h e e t s ” a t t a c h e d t o t h e c o n t r o l l e r
stloul cl be changed accordingly.

5.4 Replacement of diode module and transistor module

(1) Removal of defective module
Disconnect wires from the module and remove the module
from the heatsink.
When the module is removed, note that base terminal B
and emitter terminal E of transistor module are of plug-
in type.

(2) Applying silicone grease

Uniformly spread silicone grease over the back surface
of the new module.

(3) Tightening
Secure the new module in place with the specified torque
I'
(see Table 5.1). After the installation, base terminal
(pin) and emitter terminal (pin) of transistor module
should be protected with insulating tube.

r CAUTION
Only diodes and transistors specified by us are applica-
ble. For replacement and spare, please place an order
with us.

- 61 -
Table 5.1 Clamping torque table

I Max. clamping Recommended

, torque clamping torque
Model Screw size
(kp-cm) (kq-cm)

?T768 M5 x 0. 8 '70

j
I
I
QM50DY-H
I
k
u
," QM75DY-H ; M5X0.8 20 17f2
2 I;
2 / QMlOODY-H /
b,

2 ,1 I
I

4J. QM15HA-H
-402, ! M 5 X 0 . 8 20 17+2
u1
::ii j / QM30HA-H

- 62 -
5.5 Disassembly and assembly of SJ-J type AC spindle motor
1 Cables and P.C. board
cl Terminal box cover

(1) Remove the cover

of terminal box
on the top of the
fan case.
(2) Disconnect the
cables and leads
coming from the
electric enclosure.
a) 3 motor main leads
(U, V and W).
b) 2 cooling fan
leads (BU and
Fin case
BV).
c) 2 thermal protector leads (OHS1 and OHS2).
d) Cable connected to external connector of P.C. board.

(3) Remove the ex-

Card mounting pan head screw
C,ard
ternal connector \

from the con-

nector bracket.
Disengage the
internal con-
nector.
(4) Remove the P.C.
board mounting
pan head screws
to remove the
P.C. board.
(5) To assemble, / I
External connector Internal connector
perform the External connector \
bracket Lead protection
reverse steps. packing

- 63 -
(2) To assemble, per-
form step (1) in
reverse order.

- 64 -
4
(4) To assemble, per-
form steps (1) -
(3) in the reverse
order.

Fan mote

lard

Fan

For frame No. 160

(1) Remove 3 fan case
mounting hexagon
socket head screws.
Pull back the fan
case to remove the
fan case together
with the fan.

(2) Remove the hexagon

socket head bolts
used to install the
finger guard.

- 66 -
(3) Remove two pan-
head screws used to Sensor bracket

install the sensor

bracket to remove
Bracket .mount.ing screw
the sensor bracket Sensor
\ \ /
together with sens-
or (take care to
prevent hitting of
the sensor against
the sensor gear).

(4) To adjust sensor

position, loosen
the sensor mounting
screw with the
sensor bracket held
in position and in-
sert a thickness
gauge into the gap I DQtector gear
Sensor mounting screw
between the sensor
and the sensor gear . Thickness gauge
Adjust the gap to
0.15-+0.01.
After making sure the sensor marking lines are aligned
with each other, tighten the sensor mounting screw to
secure the sensor in position.

(5) Apply lock p'aint to the

sensor mounting screw and
the sensor bracket mount-
ing screws.

(6) When the sensor is put into

the fan case, arrange the
sensor leads properly to Align these mark lines.
prevent sensor lead from being
wedged.

- 68 -
 (7) To remove the sens-
or gear, screw eye
bolts (M8) into the
tapped holes and ap
ply a tool shown to
the right to the
bolts.
After the removal
of the sensor gear,
rem_ove the two eye
bolts.
(8) To install the sensor
gear again, it must be shrinkage-fit at temperature with-
in 100°C - 15OOC.
Note that excessively high temperature may cause distor-
tion to the gear.

cl4 Bearings

(1) Remove the shaft

Apply sealant.
case cover mount-
Bracket mounting bolt
ing screws and the /l I
bracket mounting
hexagon socket head
bolts and remove
the bracket on the
counter-load side.

(2) When the bracket

on the counter-load
side is installed
again, apply seal-
ing compound to
the fitting sur-
faces.

- 69 -
(3) To remove the bear-
ing on the counter-
load side, remove
the shaft stop ring
and apply a bearing
remover.
The bearing can be
removed together
with the shaft case
cover.

Stop'ring for shaft

(4) To remove the bear-

ing on the load side,
apply a bearing re-
mover to the inner
ring of bearing and
turn the handle of
bearing remover.

(5) To install bearing to

shaft, all fitting sur-
faces should be thorough- press here.
ly cleaned and smoothed. Pipe
,Bearing

(6) Apply grease to bearing

bore surface and shaft.
Put a pipe on the bear-
ing inner ring and care-
fully depress the bearing
by a press machine.
Press machine is used to
install bearing.

- 70 -
(7) If press machine is not
available, lightly ham-
mer the pipe to drive
the bearing.

Use care not to hammer

. the outer ring of bear-
ing. I \
I
/ \
Pipe Bearing

Hammer is used to install

bearing.

- 71 -
56. INSTALLATION OF ORIENTED SPINDLE STOP POSITION DETECTOR
6.1 Magnesensor l-point oriented spindle stop
6.1.1 Magnet and sensor

The sensor generates two types of voltage signal as shown

in Fig. 6.1.

Direction of

Rotating d i s k

Output voltage
Amplifier

Output vol tagc

Fig. 6.1 Sensor signals

MS signal . . . . Signal.voltage is zero volt when the center

of magnet comes to the sensor head, and
maximum at both the extremities of magnet.

- 72 -
 Spindle is stopped with this signal at OV.

LS signal ,.... Signal voltage is constant within the zone

(width) of magnet.
This signal is used to verify that spindle
remains stopped within the zone of magnet.

- 73 -
6.1.2 Orientation of magnet and sensor head

The magnet and sensor head should be installed in the

specified orientation.

Standard type . . . . The center reference hole of magnet

IIigh-speed and the reference notch of sensor
standard type
head should come on the same side.
Refer to -1, -2/, -31
and [U N A C C E P T A B L E EXAMPLE 11.

High-speed . . . . The reference notch of sensor-head

miniature type should be located in reference with
polarity (N, S) of magnet.
Refer to -1, iCAsE and
/UNACCEPTABLE EXAMPLE 21.

High-speed . . . . The reference notch of sensor head

ring type
should be located in reference Gith
polarity (N, S) of magnet.
Refer to 1-1, 1-1 and
UNACCEPTABLE EXAMPLE 31.

IC/\SEl
. . . . Magnet is installed on the circumferential
surface of rotating disk.
The center reference hole of magnet and the
reference notch of sensor head should come
on the counter-load side, as shown in Fig.
6.3.

Counter-lo
side Load side
Counter-load side
View from A
Reference hole
Reference notch

Magnet is installed on circumferential surface of

rotating disk.

- 74 -
 flat surface of ratating disk.

(1) When the magnet is instal-
led on the counter-load
side of spindle, the ref-
erence hole of magnet and
reference notch of sensor
head should face inward,
as shown in Fig. 6.4.
(2) When the magnet is instal-
led on the load side of
spindle, the reference hole
of magnet and reference
notch of sensor head should
face outward, as shown in
Fig. 6.5.

View from "Olr hole Reference notch View from “C”

Magnet is installed on the Magnet is installed on the

counter-load side. load side.

=I . . . . In [=1), the magnet and sensor head can

be located, as shown below, so far as the
magnet is aligned with the sensor head cor-
rectly.
When the magnet and sensor head are instal-
led, as shown below, however, bit for para-
meter (orientation of oriented spindle stop
detector) must be changed correspondingly
(parameter 0RS2). I'

Reference hole

Reference notch

- 75 -
UNACCEPTABLE EXAMPLE 1 . . . . If the reference hole of
magnet and the reference notch of sensor head
are not on the same side, intense vibration
occurs when the' sensor head is at extremity
of the magnet (oriented spindle stop is im-
possible ).

Reference
hole - -

+
Reference hole
6
Reference notch

X
notch

X
[C/\SE]
. . . . Magnet is installed on the circumferential
surface of rotating disk.

The reference notch of sensor head should be

on the counter-load side and the magnet
should be installed in the polarity shown
below.

Counter-lo
side Load
side
Counter-load side Load side
+Reference not
View from A

Reference notch-
T
1
A

Magnet is installed on the circumferential

surface of rotating disk.

ICASE
. . 51 . . So far as the relationship between location
of the reference notch of sensor head and the
polarity of the magnet is in accordance with
F], the sensor head and the magnet can
be installed as shown below.
(Bit for parameter (orientation of oriented
spindle stop detector) must be changed cor-

- 76 -
 respondingly . . . . parameter ORS2)

Counter-load
side -- Load side

rence notch

Reference ho View from "A"

rence notch

UNACCEPTABLE EXAMPLE 2 . . . . If the reference notch of

sensor head is not located properly in re-
ference to polarity of the magnet, intense
vibration occurs when the, sensor head is
at extremity of the magnet, and oriented
spindle stop is impossible.

+I-@
Counter-load side Load side
Counter-lo

notch
View from A
Load side

In this example, polarity (N, S) of magnet

is inverse to that in [FAnI.

ICASE
. . 61 . . The reference notch of sensor head is on
the counter-load side of spindle and the po-
larity of the magnet is as shown below.

Load side

Counter-Load siw ide ‘O”

notch View from A

Reference notchT
t
A
Magnet is installed on the circumferential
surface of rotating disk.

- 77 -
 [Exq
. . . . So far as the relationship between location
of reference notch of sensor head and the
polarity of the magnet is in accordance with
ICASE 41 , the sensor head and the magnet can
be installed as shown below.
(BJ.t for parameter ORS2 (orientation of ori-
ented spindle stop detecl;or) must be changed
correspondingly.)

- Load side
Countcr-

Reference notch
View from “A”

Reference notch

IJNACCEP'I'ADLE EXAMPLE 3 . . . . If the reference notch of

sensor tread is not located properly in
reference to polarity of the magnet, in-
tense vibration occurs when the sensor head
is at extremity of the magnet, and oriented
spindle stop is impossible.

Load side

side

Reference hole View from “A”

Key groove

A
In this example, polarity (N, S) of magnet
is inverse to that in VI.

6.1.3 Caul;ion on installation of magnet

When the magnet is inskalled to the spindle, pay attetion
to ttle following:

(1) I)o riot locate an intense magnetic source near the mag-
11e 1;.

- 78 -
 (2) Carefully handle tile mag~let;, avoi (1 i rig rllectlanj cal. stlock
to the magnet.

(3) Secure the magnet to t;lle spi IIdle wil,ll appropriate

screws.
For applicable screws, r e f e r Lo t.tle cIr*awing stiow itIf:
the outside view of magrIe t;.

(4) A f t e r t h e maj;ne t i s irlst;aI. led, ba 1 ante Lhe eri t ire

spindle.

(5) A l i g n t h e center of I;tle magIlet; (beLwcen N a n d S) witch

t;he center I ine of t;he rotaLl r~[: cl-isk a n d m a k e s u r e
t;he orientatiorl o f I;tle magrle I; ;III~ sensor head i s as
indicatioti i n [EEq - [j?ET-T-1.

(6) K e e p c l e a n tile magtlet; and i l;s [)eripheral to be free

from iron particles (iron parl;icles may cause mal-
function).

(7) Apply lock pairIt, or 0 tiler sui Lab I e means, to prevent

mounting screw from becoming loose.

(8) Jf the magnet is inta1.led on a ground rotating disk,

tlemagne t i ze t:he d i. sk .

(9) D i a m e t e r o f rotating disk on wtlicll Llle m a g n e t ( o t h e r

Lhan r i n g type) i s iril;al l e d slloIllt1 be wi t;tliri ttle range
f r o m tUnra to 12Omm.
W h e n s p i n d l e s p e e d i s low, Ilowcver, use a rotating
disk of larger diameter.

(10) I f s p e e d o f tile s p i n d l e exceed:; G,OOOrpm, use a high-

speed type, h i g h - s p e e d mi.nialure t.ype or tligh-speed
ring type magnet .
c
(11) For details of high-speed ring type magnet, refer to
the relevant description in the standard specifica-
tions.

- 79 -
6 . 1 . 4 C a u t i o n o n instal1ati.n of serlsor h e a d

( 1) I.ns tall tzhe sensor tlead i n a c c o r d a n c e w i t h ICASE 1 J -

pii?Sl.

( 2 ) Ali.gn t h e c e n t e r l i n e of set~sor h e a d wi ttl the cerlter

0 f magne t .

(3) Gap belween t;he magnet. and the sensor head is listed
i.11 Table 1 - Table 3.

Wtlen a standard type magnet is installed in accor-

dance w i t h IC/\SE] or IC/\SE[ , refer to Table 1.

When a hip,tl- s p e e d sLnndard magnet is installed in

a c c o r d a n c e w i t h IC/\SE] or -1, r e f e r t o T a b l e
1.

Wtlerl a starl’dnrd magnet is installed in accordance

with IC/\SEl , refer to Table 2.

When a high-speed standard magnet is installed in

accordance w i t h [ml, refer to Table 2.

Wtletl a hi.p,tl-speed miniature magnet is installed in

nccordance w i t h (C/\SEl o r (CASEI, r e f e r to
Table 3.

“When magrle!ts are mass-produced, it is recommended

to prepare jigs for production.

( 4 ) For conrlec t o r used in the amplifier, oil-proof type

is used. ttowever, it is recommended to locate the
corirlect;or w h e r e i s f r e e f r o m o i l .

( 5 ) Ttle cable between t;he a m p l i f i e r a n d t h e c o n t r o l l e r

stiould be 1 aid down apart; from high-voltage cables.

(6) Ctlcc:k t.tle cnririectnr w i r i n g , securely engage the con-

IIC(: t.or* and Lip,tl tell corlrlec tar l o c k s c r e w s .

- 80 -
 Sptndle
_ .-_- _ = ___
-_:
Ii=

Magnet =
i-._ Max. gap
Min. g a p
PetmfssLbla error
f2mm

A d j u s t a b l e range
Mohting plate
f2nn
\ \ Center
Flange
Ceil r
P

Table 1
‘, BKO-CISlOHO3 RKO-Cl730H06

Radius (R) mm Max. gElp m Min. gap m Max. gap men M i n . gap mm

40 Il.Sf0.5 2.7f0.5 lOf0.5 l.22f0.5

50 9.5.to.5 2.8i:O.S 8f0.5 1.3lf0.5

60 R.5lO.S 3.of-0.5 7 f0.5 1.5 f0.5
70 8.01.0.5 3.110.5 7 i-O.5 2.38f0.5

Tnhle ‘2
BKO-Cl8lOH03 BKO-Cl730H06

Radius (n) mm gap M gap m

40 6 f0.5 5f0.5

50 * +

60 e *

Tat)lc 3
BKO-Cl730H09
Radius (R) m m M a x . gap M Min. gap mill

40 6.25f0.5. 3.3 f0.5

50 6.0 10.5 3.7 f0.5
60 5.75io.5 3.851:O.S
70 5.5 kO.5 3.87f0.5

- 81 -
97. DISCHARGE RESISTOR UNIT
FR-SF unit can be combined with discharge resistor unit as
listed below.

R-UNIT-1(30fl, R-UNIT-Z(15R) R-UNIT-3(15fl)

FR-SFJ-2-2.2K X X
0 (Controller may be (Controller may be 0.. Applicable
3.iK damaged.) damaged.)
5.58 X
-( OV alarm may 0 0 x... Not applicable
7.4 occur.)

R-UNIT-l and 2 are the standard resistor unit, and R-UNIT-3

is for heavy duty application.

CAUTION:
Hot air will flow out from the top of unit.
Resistor unit should be installed so that the hot air is led
outside the enclosure.

- 82 -
$8. TROUBLESHOOTING
8.1 General information

If any trouble occurs with the control system, perform the

preliminary check described below and then proceed to the
troubleshooting described later.

The following preliminary check is very important when you

consult with service engineer.

Preliminary check:
1. Was any alarm displayed on the controller?
If yes, identify the cause of alarm.
Also examine previous alarms through the LED readout in
"alarm" mode (refer to "Alarm/warning table").

2. If fuse was blown out, identify the phase in which the

blown out fuse was used (control circuit power supply
fuse).

3. Is the trouble or failure reproducible?

4. Are ambient temperature and panel inside temperature nor-

mal?

5. When the trouble occurred (during accelerat ion, or dece le-

ration, or steady-speed operation)?
What was the speed?

6. Is direction of rotation correct?

7. Did instantaneous power failure not occur?

a. Does the same trouble occur in a specific operation, or

when a specific command is given?
9. How frequently occurs the trouble?

10. Does the trouble occur when load is applied, or when load
is removed?

11. Was any part replaced or any provisional remedy done?

12. How many years have been used the control system?

- 83 -
 13. Is supply voltage normal?
Does it change from time to time?

8.2 First step of troubleshooting

Perform the following check:

(1) Power supply voltage should be 2OOV+:$, 50/60Hz, or

21OV, 210V or 23OV+:gg. .

In any case, it should not go down below -15% of 200V.

o Check if the supply-voltage drops at a specific time

everyday.

o Check if the supply voltage drops at start of a speci-

fic machine in the factory.

(2) Are the peripheral control devices or functions in good

condition?
o Are the NC and programmable controller wired proper-
ly?
o Visually check cables and other components for condi-
tion.

(3) Is temperature inside and outside the control equpment

below 55OC?

(4) Visually check the control equipment.

o Cards, circuit patterns, etc.
o Looseness of wire, damage, foreign matter, etc.

(5) All control power supplies of IM-PW2 card meet the

specified voltages?

Output voltage, p 5 P15 Nl 5 P24

nominal
Check pin C H 28 c H 3 4 CH36 CH26
Common CH27 c H 3 5 CH35 CH25
Normal voltage
(V)
5f5% 15st5% -15f5% 24flOX

- a4 -
The most likely troubles or failures with FR-SFJ can be large-
ly divided into the following two groups:

r Control equipment does not work satisfactori-

ly when it is turned on for the first time (Ij.
Control equipment comes into a standstill
Trouble A abruptly (II).
I-
I Control equipment fails from time to time,
or error occurs in oriented spindle stop po-
sition, or "alarm" lamp lights (II).

*Trouble with Failure in main circuit

control equip- -7 Failure in control circuit
ment
.Trouble with Failure in speed detect
detector encoder
Trouble B Failure in multi-point
oriented spindle stop en-
coder
Failure in l-point oriented
spindle stop magnesensor

Failure in parameter data transfer from NC

'Trouble with power supply
,Trouble with motor
Other troubles (mismatching input signal con-
ditions, cable disconnection, etc.)

- 85 -
8.3 Second step of troubleshooting
Trouble I Checkup Remedy

Control equip- As far as the control

ment does not equipment is handled
work satisfac- carefully, this type of
torily when it trouble is quite unl ikely
is turned on to occur. The most
for the first possible cause is,
time. (1) Mechanical shock or (2) Visually,check if
impact was given to any part of the
the equipment dur- equipment is dam-
ing shipment, in- maged.
stallation or hand-
ling.

(2) Wiring is incorrect, (3) Check that the power

or disconnected. indicator LED in
SF-PW is on.
Check grounding wire. (Note 1)
(It is not required Check the wiring.
to consider power
phase sequence.)
(3) Check ROM No. and (3) If discrepancy is
parameters against the found, replace ROM
order sheets. or change parameter
setting.

(4) Motor speed cannot be (4) Interchange motor

increased. connection between
any two phases (U,
V and W).
(5) No-load operation is (5) Check load condition.
in good condition. ’

(6) Only oriented spindle (6) Readjust.

stop function is notir
good condition (over-
run, etc.)
(7) "Alarm" lamp lights. Refer to 7.4.

Note 1: "Start signal CW (CCW)" should be turned on after

- 86 -
 "READY" signal and "speed reference" signal have
been input.
Trouble II Checkup Remedy

Control equip- (1) Check if fuse was (1) Replace blown out
ment comes into blown out or main fuse. If fuse is
a standstill circuit no-fuse break- blown out again,
abruptly er was tripped. proceed to "Step
rn).
(2) Check the input power (2) Input correct power
suPPlY* supply.
AC200V':$, 5OHz Provide power sup-
+lO% ply with sufficient
AC200 - 23OV_l5%,
60Hz margin in capacity.

(3) "Alarm" is displayed. Refer to 7.4.

(4) Are signals from NC

and-programmable con-
troller proper?
Check the input sig-
nals (machine "READY",
"FWD run", "REV run",
etc.), using "diagno-
sis" function (read-
out).

(5) In open-loop control (5) If operation be-

mode, comes possible,
0 set control paramet- it is likely that
ter to 00 0001 , speed feedback
ADD DATA system is in fail-
0 input "speed refer- ure..... replace
ence" signal and the encoder.
"start" command to
If operation is
try operation.
I impossible, it is
(Control mode returns 1 likely that the
to closed-loop mode, I
I
I
main circuit is in
0
when *p' button is 1 failure ("alarm"
pressed, or the power! lamp will light).
is turned off after ,
parameter setting.)
- a7 -
 Trouble III I Checkup 1 Remedy
Control equip- In this case, the compre-
ment fails from hensive analysis must be
time to time, or accomplished to deter-
error occurs in mine the cause (load con-
oriented spindle dition, operation mode,
stop position. etc.).
(Condition is (1) Check if instantaneous (1) Check the power
restored when power failure occurred suPPlY*
the power is or "UNDER VOLTAGE"
turned off and was displayed.
then on to re-
(2) Check if malfunction (2) Determine the
set.)
occurred in contol noise source and
circuit, due to large - install a surge
noise. killer, etc.
The control equipment Check and improve
is capable of with- grounding method
standing noise (in (particularly,
power supply) of 16OOV/ grounding of de-
1u.s. tector).
(3) Check if overload oc- (3) Check mechanisms
curred due to momentary carefully.
change of load. Check backlash
Check with particular between spindle
care if error occurred and spindle en-
in oriented spindle coder.
stop. /’

- 88 -
8.4 Alarm and warning table

ilarm Motion
Abbr. Name Description (Note)
io.
10 uv UNDER VOL- This alarm occurs if input sup- A
TAGE ply voltage goes down below the
specified level, or if instan-
taneous power failure lasting
for over 15ms occurs.

12 ME1 MEMORY ER- This alarm occurs if read from, A

ROR 1 or write to internal memory for
controller system control does
not go normally (memory is
checked when the control system
is turned on).

13 CE EXT. CLOCK This alarm occurs if error oc-

ERROR curs in access time (2-ports me-
mory), due to failure in exter-
nal clock, during NC mode opera-
tion with FR-SFJ connected to
M300 CNC through bus line.

15 ME2 MEMORY ER- This alarm occurs if 2-port me- A

ROR 2 mory for data communication
(when FR-SFJ is connected to‘
M300 series CNC) does not func-
tion properly.

17 BE BOARD ERROR This alarm occurs if any part of A

control card is not in good con-
dition.

20 NS1 NO SIGNAL This alarm occurs if signal from A

(PLG) motor built-in encoder is not at
normal level.

21 NS2 NO SIGNAL This alarm occurs if signal from A

(SPINDLE encoder for oriented spindle
ENC.) stop is not input, or not at
normal level.

22

- 89 -
;iarrn Abbr. Name Description Motion
. (Note)
23 OSE ERROR This alarm occurs if deviation A
EXCESS
(SPEED) of true motor speed is excessi-
vely large from reference speed.
24 MCF MAIN CIR- This alarm occurs if main cir- A
CUIT FAULT
cuit does not work properly.
25 BCF BRAKING This alarm occurs in case of A
CIRCUIT trouble with braking circuit.
FAULT
26
27 CPUE CPU ERROR This alarm occurs if error oc- A
curs in arithmetic operation
(division) by CPU, due to impro-
perly set parameter.
31 OS OVER SPEED This alarm occurs if motor speed A
exceeds 115% of the maximum mo-
tor speed.
32 oc OVER This alarm occurs if current A
CURRENT
larger than the specified maxi-
mum current flows into FR-SFJ.
33 ov OVER VOL- If voltage on main circuit capa- A
TAGE
citor exceeds the specified max-
imum level, due to regenerative
energy, during acceleration of
motor.
34 DP DATA PARITY This alarm occurs if parity A
I’
check error occurs in data
transmission between M300 series
CNC and FR-SFJ (when FR-SFJ is
connected to CNC through bus
line).
35 DE DATA ERROR This'alarm occurs if data trans- A
fer does not go satisfactorily
(when FR-SFJ is connected to CNC
through bus line).

- 90 -
Alarm Abbr Motion
No. . Name Description (Note)
36 TE TRANSFER This alarm occurs if data trans- A
ERROR
fer does not go satisfactorily
(when FR-SFJ is connected to
CNC through bus line).
37 PE PARAMETER This alarm occurs if set para- A
ERROR meter value is out of the per-
missible range (this check is
made when the control system is
turned on).
40 TKCE FR-TK SEL- This alarm occurs if signal for ,A
ECT ERROR
selection of FR-TK unit (when
FR-TK unit is used) is not input
properly.
41 TKTE FR-TK This alarm occurs if data com- A
TRANSFER munication with FR-TK unit
ERROR
(when FR-TK unit is used) does
not go properly.
45 OHP OVER HEAT This alarm occurs if ambient A
(AMP.)
temperature is excessively high,
or main (power) circuit semi-
conductor overheats, due to
overload or stop of cooling fan.
46 OHM OVERHEAT This aiarm occurs if motor over- A
(MOTOR OR
RESISTOR) heats due to overload or stop of
'1
motor cooling fan.
52 OD ERROR This alarm occurs if difference A
EXCESS
(error) between referenced stop
position and true stop position
is excessively large (in posi-
tion control loop).
56 OA OTHER AXIS This alarm occurs if trouble oc- A
ALARM
curs with other servo control
axis (when FR-SFJ is connected
to CNC through bus line).

- 91 -
Alarm Motion
Abbr. Name Description (Note)
No.
57 OPE OPTION CARD This alarm occurs if "sync. TAP", A
ERROR "C-axis control" or "index" sig-
nal is input though FR-SFJ is
not equipped with the correspon-
ding option card.

EO IPF INSTAN. This warning arises in case of C

POWER FAIL- instantaneous supply voltage
URE
drop.

'E4 WPE WARNING This warning arises if parameter C

PARAMETER setting is beyond the specified
ERROR
limit.

E7 NCE NC EMERGEN- 0 If emergency stop signal is in-

CY -put to FR-SFJ from CNC (when
FR-SFJ is connected to CNC
through'bus line), this warn-
ing is given.
0 If emergency stop signal is in-
put from external signal source
(when parameter kc42 (BSL) is
set so that external emergency
signal is acceptable), this
warning is given.

Note: If protective function listed above is activated,

Alarm No. is displayed by 'I-segment readout and the
following occurs.

Motion A . . . . . Controller base current is shut off, main

(power) circuit contactor opens and the motor
stops after coasting.
Fault signal contact FA-FC opens.
Motion B . . . . . Motor is decelerated by regenerative brake and
stops. After motor stops, base current is'
interrupted.
In this case, whether fault signal contact
FA-FC opens or not depends on parameter set-

- 92 -
 ting.

Motion C . . . . Only warning is displayed (operation can be

continued).

I-

i-

.
- 93 -
 8.5 "Alarm/warning" display by LED readout
(1) UNDER VOLTAGE

This alarm appears if voltage under 170V lasts for longer

than 15ms.
Cause Checkup Remedy
Tower supply This alarm appears when speed Increase capacity of
capacity is changed or load is exces- input power supply.
insufficient sive.
Interval bet- AC power supply should be Prolong AC power sup-
ween turning turned on in minimum 1 sec. ply off time.
off and on after turned off.
AC power sup-
ply short
Card SFJ-CA1 It should be checked if this Replace the card SFJ-
not in good alarm is reproducible. CAl.
condition Replace the card SFJ-CA1 in
use with a new card SFJ-CA1
to check if the same alarm
occurs again.
Use the previous card SFJ-
CA1 again to check if the
same alarm occurs again.

IM-PW power After making sure this alarm /Replace the IM-PW
unit not in is reproducible, replace the /power unit.
good condi- card SFJ-CA1 in use with
tion a new card SFJ-CA1 to.check.

- 94 -
 (2) MEMORY ERROR 1

This display appears if read from, or write to the memory in-

corporated in the controller cannot be done successfully.

Cause Checkup Remedy

ROM load&d im- Visually check that all Load ROM Properly.
properly pins of ROM are put into
the socket properly.
Card SFJ-CA1 Check card SFJ-CAl. Replace the card
trouble SFJ-CA1.

(3) MEMORY ERROR 2

This display appears if the buffer for bus-linkage with

CNC, M300 series, does not function properly.

Cause Checkup Remedy

1
Bus linkage ca- Replace the cable in use Replace the cable.
ble defective with a new cable ta
check.
-- _________._~.
Card SF-TLJ After making sure this Replace the card SF-
trouble alarm is reproducible, TLJ.
replace the card SF-TLJ
in use with a new SF-TLJ
card to check.

(4) NO SIGNAL SPINDLE ENC.

This alarm appears if signal from the encoder is not input

correctly.

- 95 -
 Cause Checkup [ Remedy
Trouble with Check waveform of signal Replace the defecti-
encoder. or encoder fed back from encoder, ve encoder or cable.
cable using a synchroscope
Card SF-ORJ
Card SF-DAJ CHl - CH3
Card SF-TLJ
Error in parameter Although the control sys- Set parameter I
OSL
setting tern has no encoder type (#41) to “0”.
oriented spindle stop
function, parameter
IOSL (#41) is set to "1". /
I
Card trouble After making sure this Replace the card
alarm is reproducible, re- SF-ORJ, DAJ and/or
place the cards SF-ORJ, TLJ.
DAJ and TLJ to check.

(5) ERROR EXCESS SPEED

This alarm occurs if deviation of true motor speed from

the specified speed is larger than 500rpm, lasting for
12' sec. or longer.

Cause Checkuo Remedv

Motor wiring im- Motor cable connection Connect the motor
proper (phase (U, V and W) is not cor- cable in correct
sequence failure rect. phase sequence.
Error in parameter "Motor constant" parameter Change parameter
setting IMSL (#2) setting does not setting.
meet the motor used.
GD2 excessively It takes more than 6 sec. Increase setting of
large for acceleration to the parameter /?ZZK]
maximum motor speed from ; (ff52).
zero speed.
I I

- 96 -
 Cause Checkup Remedy
I --/
Overload Load (read on load meter) iDecrease the load. 1
I
is larger than 120%. ILighten the duty. ’
Trouble with CON2 Rotate the motor shaft with /Replace the CON2
I
cable or motor "READY" signal turned off jcable or motor
built-in encoder with hand and check speed ibuilt-in encoder.
indication by the LED read- 1
/
out. /

Trouble with card After making sure this alarm Replace the card
SFJ-CA1 is reproducible, replace the SFJ-CAl.
card SFJ-CA1 in use with
a new card SFJ-CA1 to check.
Trouble with con- Check that speed can be in- Replace the con- 1
I
trol unit creased to desired speed in trol unit.
open loop control mode.
Check speed indication by
the LED readout.
._I

(6) MAIN CIRCUIT FAULT

This alarm occurs if the main circuit is not in good con-

dition.
-__--.-. -
Cause Checkup Remedy
.i
j Trouble with card j Replace the card SFJ-CA1 with Replace the card 1
; a new card SFJ-DA1 to check. with a new one. 1
PP. --.- _--.. - . -. _.__._
1
t-Trouble with con- j If the same alarm occurs Replace the con- i
I
trol unit again with a new card SFJ- ,trol unit.
c CAL, the control unit is
/
likely to be defective.
1 1

- 97 -
 (7) BRAKING CIRCUIT FAULT

This alarm occurs if the braking circuit does not func-

tion properly.'
* ?
Cause Checkup Remedy
* Trouble with card Replace the card SFJ-CA1 Replace the card
SFJ-CA1 with a new one to check. SFJ-CAL.
I
Trouble with con- 'If the same alarm occurs Replace the con-
trol unit. 1 again with a new card SFJ- 1 trol unit.

. ; CA1, the control unit is

j likely to be defective.
- I I

(8) OVER SPEED

This alarm appears if motor speed exceeds 115% of the

rated speed.
I
Cause Checkup Remedy
r
1 Parameter setting / The motor maximum speed set- If the setting is
improper iting is under 1000rpm. too low, speed de-
, tection range is
narrow (15%) and
therefore this
alarm is likely to
occur.
Increase setting
of maximum speed
parameter ITSPI
(#31).
Speed detection Observe the signal from CH31 Use a continuous
: signal distorted : and 32 (common CH23) of SFJ- cable to assure
by noise CA1, using an oscilloscope, continuous shield-
/
.to check for signal. ing.
Check if shielding of cable
'between motor and CON2 is

- 98 -
 Cause Checkuo Remedy
between motor and CON2 is
disconnected.
1
Trouble with motor Observe the signal from Replace the motor /
built- in encoder CH31 and 32 (common CH) of built-in encoder. j
SFJ-CAl, using an oscillo-
scope.
When motor runs at 1500rpm,
the signal should be sinu-
soidal-wave signal at the
following frequency:
1500 x 128 = 3.2kHz
-
60
Trouble with posi- This alarm occurs due to Set parameter
tion control loop out of control in sync. TAP, (ORS2] (orienta-
function sync. control, or other po- tion of position
sition control loop opera- detector) proper-
tion. ly*
Gear ratio parameter GRAl - Set gear ratio
GRA4, GRBl - GRB4, is not parameter proper-
set properly (parameter set- ly (refer to
ting is smaller than 100). "Parameter Table").

(9) OVER VOLRRAGE

This alarm appears.if voltage across recitifier capacitor

is excessive (due to excessively large regenerative energy).
I
Cause I Checkup Remedy
Wrong wiring iDischarge resistor unit is Connect discharge
inot connected to FR-SFJ. resistor unit.
I
.-
Motor constant paraiparameter 0 MSL (#2) setting Set parameter=/
1
meter set improperly'does not meet motor in use. (#2) properly.
r

Trouble with dis- Resistance measured across Replace the dis-

charge.resistor 1 Rl and R2 of discharge resis- charge resistor
unit tor unit is improper, or zero unit.

- 99 -
 Cause Checkup Remedy - -
(open circuit). ?-

30n for 2.2K and 3.7K FR-

SFJ

Trouble with card

t
I
150 for 5.5K and 7.5K FR-
SFJ
Replace the card SFJ-CA1 card
I I
Replace the card
I
SFJ-CA1 with a new one to check. SFJ-CAl.
Trouble with power iReplace the power unit IM-PW Replace the power
unit IX-PW iwith a new one to check. iunit IM-PW.
I
Trouble with con- iThe control unit will be de- 1 Replace the con-
trol unit fective if the same alarm oc- 'trol unit.
curs again even after the I

remedy described above.

--
(10) OVER CURRENT

Overcurrent
I
Cause Checkup Remedy
1
/ Motor constant para- Parameter ;MSLi (#2) setting Set parameter
: meter set improperly does not meet motor in use. IMSL i (#2) pro-
; perly.

; Overload ,Load (read on load meter) is 'Reduce the load.

llarger than 120% of rated
load.
t
Motor wiring impro- Motor wiring is incorrect. 1 Correct motor
2 I
; per 0 Loose terminal screw wiring.
o U, V or W lead grounded
o Short-circuit of motor leads
,
(U, V or W).

Motor coil layer- Measure insulation resistance.! Replace the motor

: short, or grounding Insulation resistance should
be less than 1MR.

- loo-
 Cause
Power supply capa-
Checkup
Check if AC input supply F Remedy
Use power supply
of larger capa-
city insufficient (R, S, T) goes down below
17OV. city (refer to
the Specifics-
tion).
Operate FR-SFJ
with limited
torque and reduc-
ed output.
_ --- -_.~-- - .-j- ___ _ ._. ..__ __---- .-..-
Trouble with card Make sure the same alarm is {Replace the card
SFJ-CA1 reproducible and then replacei SFJ-CAl.
the card SFJ-CA1 in use with ~
I a new one to check.

Trouble with control If the same alarm occurs Replace the con-
unit again even when a new card trol unit.
SFJ-CA1 is used, the control :
I
unit is likely to be defec-
tive.
i

(11) DATA PARITY and TRANSFER ERROR

DATA PARITY

TRANSFER ERROR

These alarms appear if parity error occurs, or data are

not transferred correctly in data communcation between
M300 series CNC and FR-SFJ.
1

I Connector
Cause
engaged
I Checkup
1 Cable connector is not en-
! Remedy
i%gage connector
,I
loosely 1 gaged securely or connector 1 securely and
/ mounting screw is loose. 1 tighten all
I
I i screws. __
-_-.__ .- ---- .~_ _.-+__ --. _---_-.-_-_--.___&____ ._ ___.
Trouble with term- i Check if this alarm occurs :Replace the term-
inal resistor on the servo axis when spin- inal resistor.

- 101 -
 Cause Checkup Remedy
dle amplifier is discon-
nected and the terminal re-
sistor is connected to
servo axis.
Trouble with bus-line Exchange cable for servo Replace the
cable axis control with cable for bus-line cable.
spindle amplifier to check.
Trouble with card Check if alarm disappears if Replace the
SF-TLJ the card SF-TLJ is replaced card SF-TLJ.
with a new one.

(12) DATA ERROR and PARAMETER ERROR

DATA ERROR
waannm

PARAMETER ERROR
~U~n~~~.

The upper display appears when commanded movement is

larger than the specified 15mit in operation of FR-SFJ
connected to M300 series CNC.
The lower display appears when parameter setting is
larger than the specified limit in operation of FR-SFJ
connected to M300 series CNC.

Cause Checkup Remedy

Parameter setting 1. Check that parameter 1. Correct
improper settings meet the order parameter
Programming error specifications. setting.

, 2. Check the program. 2. Correct

I/ program.
Parameter setting 1 Gear ratio parameter CRAl - Set gear ratio
improper CRA4, CRBl - CRB4, is not parameter pro-
set properly (parameter perly (refer tc
1 setting is smaller than 100). "Parameter
! Table").

-102-
 (13) OVER HEAT AM?.

This alarm appears if thermal protector of FR-SFj

trips (installed on cooling fan).

Cause Checkup Remedy

Overload 1. Check motor for load condi- 1. Lighten load.

tion.
2. Check motor start/stop fre- 2. Decrease
quency. start/stop
frequency.
High ambient temp- Measure the ambient tempera- If the ambient
erature ture. temperature is
C‘
higher than 55'C,
appropriate pro-
vision shouid be
made to cool.
c
Trouble with cool- Check if the FR-SFJ cooling Replace the cool-
ing fan fan does not work properly. ing fan.
Heat radiating fins Check if heat radiating fins Clean the fins.
c fouled on the back of FR-SFJ are
fouled heavily.
Fuse blown out Check if fuse is blown out. Replace the fuse.

If new fuse is blown out Refer to "Alarm

again . . . . 46".

-103-
 (14) OVER HEAT MOTOR OR RESISTOR UNIT
OHSl/OS2 discontinuous
Cause Checkup
24V power supply Check if the alarm disappears Remedy the 24V
when the power is turned on
with CONl, CON5, CONC and
CONCA disengaged.
Wrong wiring Voltage is not output across
terminals A and B (at top of
FR-SFJ).
7
1 Overload 1. Check motor for load con-
dition.
2. Check frequency of start/
stop.
,Trouble with Fan does not run satisfac-
j controller cooling torily, or remains stopped.
j fan
1 Motor air inlet Check cooling air flow.
i clogged
fI Trouble with motor Check if the thermosensor
1 thermosensor does not reset when the mo-
j (thermoswitch) tor fan is operated for
15 - 16 min. with the motor
L. _____ . . ._ -_ .-_.
-104-
Remedy
power supply wir-
ing.
Jumper pin (Pin 4,
5) settings should,
meet input inter-
face for speed re-
ference and posi-
tion reference 12-
bit signals.
(Refer to the
standard specifi-
cation)
Remedy the wiring.
1. Lighten load.
2. Reduce start/
stop frequency.
Replace the fan.
-;
I
Clean the air in-
let.'
1. Shortcircuit i
OHSl-OHS2 to I/
continue opera- !
tion (provi-
i
 ._--_._-_--_ - _ _ _
Cause Checkup Remedy .- - --_ /
'stopped tional rernedy~./
2. Replace the :
I motor.
__-___-_ .- _
Fuse biown out Check 'if the fan remains Replace the fuse.
stopped due to blown out
fuse.
If new fuse is blown out I
again,
1. Check wiring of motor Remedy the wiring./
I
cooling fan and discharge I
resistor unit cooling
I
fan (short-circuit,
grounding fault, etc.).
- --.-
Trouble with dis- Check if resistor unit cool-iReplace the cool-
charge resistor unit ing fan is in standstill or ing fan.
cooling fan does not run satisfactorily.i
~ -.._.--.._.
Trouble with dis- Check if thermosensor does Replace the dis-
charge resistor unit not reset when the cooling charge resistor
thermosensor fan is operated for 15 - unit.
(thermoswitch) 16 min. with the motor
stopped.
.

(15) ERROR EXCESS POSITION

This alarm appears if deviation of true stop position

from commanded stop position is excessive in oriented
spindle stop operation or position control loop opera-
c tion.
--- -_-____ ___ -_-. .__ -.- -.- - . _. _ _..__ _
I--’ .- !
I
I Cause
Parameter (orien-
Checkup
----.-- -.-- -. _.__. _ __.
Check if alarm is removed
Remedy
_ _. 1I
Set parameter I
tation of encoder) when bit 8 of par,ameter 0RS2 properiy. /
c I
setting improper ORS2,is inversed in encoder /
type oriented spindle stop
I
operation.
-.- _ _--.._______ .__ .___

-105-
 Cause Checkup Remedy
Encoder type oriented Check if alarm is removed Set parameter
spindle stop function when value of parameter OSP properly.
1
adjusted improperly CSP setting is halved.
lx
Sync. TAP adjusted Check if alarm is removed Set time constant
improperly when sync. TAP command TAP-T1 properly.
time constant is increas-
ed.'
Trouble with encoder Stop position is valiable Replace the en-
in each oriented spindle coder.
stop (encoder type).
(Check the encoder shaft.)
Trouble with card Check if alarm is removed Replace card SF-
SF-ORJ, TLJ or DAJ when card SF-ORJ, TLJ, or ORJ, TLJ or DAJ.
DAJ is replaced with a new
one.

- TO6 -
 8.5.1 Troubles that are not displayed by LED readout
(1) No alarm display appears, but motor does not start . . . .
Cause Checkup
Miswiring or Check the wiring.
wire disconnec-
tion
Input power Check the input power sup-
supply (volt- ply (2OOV 50Hz or 200 -
age) improper 230V 60Hz in all 3 phases).
Control power Measure the control power
supply improper supply voltage, using a
multimeter and check pins.
Required signal Check if contactor closes
not input [click arises when con-
tactor is closed).
Check that start signal
(SRN, SRI or ORC) is in-
put within 1 sec. after
"ready" signal is input.
Speed reference Rotate motor shaft to make
signal remains sure motor is under "servo
zero. lock" condition.
1. Signals SRN and SRI turn
on at the same time.
2. "slimit" or "smax" (NC
display parameter) is
set at "0".
3. "Analog/digital select"
signal is on.
4. Signal input interface
(open collector, emitter)
does not meet parameter
-107-
Remedv I
Correct or remedy - 1
the wiring.
Use the specified
power supply.
Replace card IM-PW2.
__ _ ..--- --
1
Input "ready" signal.
Signal input sequence
should be changed so
that start signal is
input in 2 - 3 sec.
after "ready" signal
turns on.
_.__-__ --.-
1. Change the program
so that SRN and
SRI do not turn on
at the same time.
2. Set "siimit" and
I'smax" properly.
3. Turn off "analog/
digital select"
signal.
4. Set parameter
lBSL/
i (#42) that
meets signal input ;
 -~-._----__ . 3I Checkup Remedy
BSL setting. I interface.
I El _
-.____. .-__-__ .__ .__--- -.__. _. .- ___. --_.__-- .- ___ __ _ ~. . .._
I
Oriented spin- Oriented spindle stop sig- t (Turn off oriented
stop signal 'nal (ORA) is on. f spindle stop signal.

I_-. . __ - I

(2) No alarm disply appears, but motor rotates slowly (accele-

ration is impossible), or large sound arises in motor
. . ..-. ~______~_. . _-.
Cause Checkup
-__-~-----_ Remedy-_.---.._ _
Miswiring o!" Check wire connection to Correct or remedy
rr!f , : I, :‘ output terminals U, V and the wiring.
W of FR-SFJ (phase sequen-
ce).
-_- _ _._-_ ---.-__ ._-_-. _-___
Input power j Check the input power sup- Use the correct spe-
/ Supply (VOlt- ply in all 3 phases. cified power supply.
1 age) improper I
i ~____. -.-_-._-_ --j- .-__.---.-..-._- ._.. ._.-- -
1 Speed reference Check if motor speed does Remedy the external
1 signal input ! not increase in accordance speed reference sig-
j from externai with speed reference signal. nal circuit.
1 signal source :
-_______-~_- -- _---_.-. _-_
1 -- ~- --‘-t
~ Trouble with ’ When motor shaft is turned Check the motor
/ motor built-in
,
by hand with "ready;' signal built-in encoder/
/ encoder/CON2 turned off, speed display CON2 cable.
/ cable or motor by the LED readout is not Replace the motor
built-in en- in accordance with motor buiit-in encoder.
/ coder ! shaft rotation.
'__-- 1
! Pin 2 and 3 of j Check Pin 2 and 3 settings
j card SFJ-CA1
-wtiai~r-FR~SFJ is con-
1 not‘set proper- nected--.
to _--
M30Q or -.-
_..- not.
- .-. t
Connected Not
connected
_ _ _ ~___.__. _ -.-
; 1Y
4 _.. ---..-

ggj?j: Shows that pin

is set.
L -. __ --__ -._._ .._ ---.- .---.-- _.___. ---___--_-L --

-108-
 (3) True speed does not meet referenced speed . . . .

Cause Checkup Remedy

Adjustment Adjustment is not made for Correct spindle para-
improper S-analog speed reference. meter setting {PIG
1 display).
II
External speed Voltage of speed reference / Remedy the external
reference signal signal from external signal 1 speed reference signal I
improper source does not change lin- circuit.
eally from OV to 1OV.
(Analog speed reference
signal input: CH30 - AGA)
S command code BCD code is output instead ,Binary code should be
improper of binary code for S com- used for S command.
mand (machine parameter (Set "Shin" to "1")
"Shin" is set at "0").

(4) Required torque cannot be obtained . . . . .

Perform check in accordance with (l), (2) and (5).

(5) It takes ionger time to start the motor . . . . .

I Load
Cause I Checkup Remedy
I
II increased
I
Check the load condition. ) Lighten the load.
I I
I

(6) "Up-to-speed" signal is not output (for DIO interface with

NC) . . . . .
I

Cause Checkup Remedy

I
Trouble with Check that "up-to-speed" / Replace the card SFJ-
c
output circuit flag (external output in j CAl.
of card SFJ- DIAGNOSIS mode) turns on i
CA1 when motor speed reaches
! the preset speed.
c
If the flag does not turn
on, the output circuit is
; defective.

(7) Data sent from the NC is not accepted . . . . . .

Interlock turns on because "up-to-speed" signal is not
output properly. Check the control sequence and perform

-109-
 check in accordance with (6).

(8) "Speed detection" signal is not output (for DIO interface

with NC) . . . .
Cause Checkup Remedv
Trouble with Check that "speed detection" Replace the card
card SFJ-CA1 flag. (external output in SFJ-CAl.
DIAGNOSIS mode) turns on
when motor speed reaches the
preset speed.
If the flag does not turn on,
the output circuit is defec-
tive.

(9) "Zero speed" signal is not output (for DIO interface with
NC) . . . . . .

Cause Checkup Remedy

Trouble with Check that "zero speed" flag Replace the card
card SFJ-CA1 (external output in DIAGNO- SFJ-CAl.
SIS mode) turns on when mo-
tor speed is below 25rpm or
50rpm.
If the flag turns on, the
output circuit is defective.

(10) Speed range cannot be changed (for DIO interface with NC)
. . . .

"Speed detection" and/or "zero speed" signal is not out-

put properly.
Perform check in accordance with (8) an (9).

(11) Speed cannot be increased over a certain speed . . . . .

Check the maximum speed setting.
Check if "override" (speed clamp) signal is input.
Check if leading of the load meter is excessively large
(check the load conditions).

-llO-
 Cause Checkup Remedy
Dynamic unbal- Large vibration and noise Balance the control
ante occur during coasting of system and motor
motor. dynamically.
Insulation Disconnect the power cable if insulation resis-
resistance de- (R, S, T) and measure in- tance is found de-
creased sulation resistance, using creased, identify the
500V megger (each ground- part where insulation
ing wire should have been is deteriorated and
disconnected. remedy.
(a) Between entire main
circuit and ground
At least 20Megohm 1
. . .
(Terminals R, S, T, U,
V, W, MS1 and MS2,
c
and E)
(b) Between control cir-
cuit COM and ground
c . . . At least 20Megohm
(Terminal CH23 of
card SFJ-CA1 and.
ground)

c Cc> Between entire main

circuit and control
circuit COM
. . . At least 20Megohm

Trouble with Turn the motor shaft by If the motor shaft

motor bearing hand to check. cannot be rotated
smoothly, replace
bearing.
Motor mounting Check motor mounting screws Retighten bolts.
screws loose for looseness.
Motor shaft run- Check if any trace of phy- Remedy or replace
out sical damage is found on the motor.
motor shaft.
Pin -2 and 3 of Refer to (2). Refer to (2).
card SFJ-CA1
set improperly.
._.
- 111 -
 Cause Checkup Remedy
"Speed detection" Signal on CH31 and 32 (CH23 Shield the cable
signal distorted for common) of card SFJ-CA1 between CON2 and
by noise is distorted by noise. motor built-in
encoder (without
discontinuity).
Use a cable of
larger size for mo-
tor.

S-analog speed Signal on CH30 (CH23 for com- Shield the signal
reference signal man) of card SFJ-CA1 is dis- line properly.
distorted by torted by noise.
noise.
Trouble with Signals on CH31 and 32(CH23 Replace the motor
motor built-in for common) of card SFJ-CA1 built-in encoder.
encoder do not offset accurately.
Normal waveform

’ ,+z&,JJ fl.5”

Peak voltage of signal is not

within t1.5V.

-112-
 (13) Speed can be controlled normally, but spindle cannot be
stopped in position (oriented sindle stop) . . . . .
Cause Checkup Remedy
Speed can be de- Check if position feedback Replace the posi-
creased to "ori- encoder or magnesensor tion detector or
ented spindle is in good condition. replace card SF-CR;
stop" speed, but Run the motor under speed DAJ or TLJ.
motor does not control to check position
stop. feedback signal.
Check the signals on the
'following check pins of
i -

cards SF-ORJ, DAJ and TLl

while the motor is running
forward.
CHl-CH6 (DG) :
CH2-CH6 (DG)
CH3-CH6 (DG) &
(Mark pulse)

Check on the following pins

of card SF-ORJ, DA1 and TLJ
while the motor is running
forward.
3-sv
CH4-CH6 (DG)
%-
CON4(16)
or CONB(10) -a-r6 (DG)--~
t-
Oriented spindle Backlash in encoder is Reduce the back-
stop position in large. lash.
forward rotation
deviates from
c oriented stop po-
sition in reverse
rotation (during
multipoint ori-
c ented spindle
stop).

-113-
 Cause Checkup Remedy
Hunting occurs at Decrease parameter 1x1 and Parameter #22
stop. 0PG2 settings to check. EPG2l
Parameter #21
IPGl
Set these para-
meters properly.
Servo stiffiness Check gear ratio settings. Increase speed
(stability) poor control loop con-
stant.
o
(lVKpj,IVKIJ r
IORSII >

Overshoot in Decrease speed

speed control _ control loop con-
stant.
( (VKI] 1

- 114
 $9. PERIODIC INSPECTION

In order to ensure high-performance operation of equipment,

and trouble-free long use of equipment, the periodic inspec-
tion is particularly important.

CAUTION: To prevent accident, make sure the power is inter-

rupted completely before starting the inspection.

9.1 Inspection of control equipment

Frequency Check Remedy

1. Cooling fan Monthly 1. Rotate the fan shaft Replace the

by hand to check. fan.

2. Turn on the fan to

check that the fan
runs powerfully.
3. Check if foreign
sound occurs in bear-
c- ing.

2. Soiling, de- Appropri- Check the components

ate in- for cleanliness, and
formation, terval
and terminal terminal screws for
c screw loose- _ looseness.
ness
3. Miniature Every 3 1. Check contact points Replace de-
months for wear. fective re-
relays
c lay(s).
2. Check that main cir-
cuit contactor opens
and closes in accor-
dance with relay op-
c eration.

4. Wiring Appropri- Check if any wire or

ate in-
terval conductor is short-
circuited.
c

-115-
9.2 Inspection of motor

Frequency Check Remedy

1. Sound (noise) Monthly o Check if foreign
and vibratioon sound or intense' vib-
ration occurs.
If foreign sound or in-
tense vibration occurs,
perform the following
check:
1. Check foundation and
installation.
2. Check shaft alignment.
3. Check if vibration is
transmitted through
shaft coupling.

4. Check if bearing is
damaged.
5. Check if noise or vib-
ration is caused by
reduction gear or
belt.
6. Check control equip-
ment for condition.
7. Check cooling' fan for
condition.
8. Check belt tension.

2. Temperature Monthly o Check bearing tempera- Clean.

rise ture.
(Amb. temp. + lot0 4oocj

o Check motor frame temp-

erature.
If temperature is high ex-
cessively, perform the
following check:

-116- _
 Frequency Checkup Remarks
1. Check cooling fan op-
eration.

2. Check cooling air

passage (between
frame and cover).
3. Check load condition.
-----_-----__-----_-_--__--___----_
4. Check control equip- See "Trou-
ble shoot-
ment. ing".
3. Insulation Every 6 o Check if insulation
months resistance is exces-
resistance
sively low.
To check, measure in-
sulation resistance
between the entire
circuit and ground
(control panel discon-
nected).
Insulation resistance
should be larger
than lMegohm, measur-
ed by 5OOV megger.
If insulation resis-
tance is less than 1
Megohm, clean and dry
motor interior.
To dry, disassemble
and heat motor at
temperature less than
9o"c.
4. Cooling fan Weekly o Check cooling fan
Monthly for operation, noise
and vibration.

-117-
9.3 Inspection of discharge resistor unit
Freauencv Check Remedv
1. Cooling fan Weekly 1. Check if fan shaft Replace the
Monthly can be rotated fan.
smoothly by hand.
2. Check if fan motor
runs powerfully.
3. Check if foreign
sound arises in
bearing.

-118-
 610. PARTS LIST

AC spindle controller and motor

1. Spare . . . . Spare parts recommended to be replaced every
2 years.
2. Spare . . . . Spare parts recommended to be replaced every
5 years.
3. Spare . . . . Spare parts recommended to be stored by ma-
chine manufacturer.
/
PI Spare
I
,Capa-1 ; Manufac- S y m b o l I -~\~~~d S e l e c t i o n Remarks
O., Name Model I turer
;city ;
I XL!acces
i?
IKW: 10 1 sory ,A’B C
I I I /
1 BKO-Cl869 ;
/ / 2.2 I QM50DY-H i I
i---i HO3 ;
/
j BKO-Cl984 /
/ 3.7 / QM75DY-H I
HO1 ~
~TRU
5.5i ~BKO-Cl869 ~MITSUBISHI
1 ~TRANSISTOR +7 5 ~QMlOODY-H ~ 'TRV 3 0 0 10 3
HO5 ELECTRIC I
I . I /TRW ; ~ ~
~ I
/ ,
! I I

1 I
7-7 L. Cl 1 0 lo11 li
1
~ 3.7: BKO-X1043, : .; i
! 2,100 UFX350V ~ ~Cl-l
~ 5.5' H17 2 0 'Oi2 2'
~Cl.2
7.5 -
4 / CAPACITOR I
I
/ i
I / I
I I /
I /
j : I !
I I 1
-119:
 /
I I 1 PI Spare
Manufac- /~ Symbol /
To. / Name apa- Model / EStfm- /,Selection IR emarks
I F /turer L dard
,city / i,X
‘_ acces-t I
I IKW/
r lo sol-y lA~B!C
I 2.2; I
I
12~RELAY i3.7 1 JHlAS-DC24V
~ 5.51 I
I /
: PC-5-4A DC24V
13 CONT.tCTOR i 7.5 /
I BMP650504
I
I 2.2; I
14 ; THERMAL ~I i OHD-1OOB
/
~ 7.51
-4 I ,,
I 1 I
/ 2.2 / 15A 50MV BKO-NC6131-H53 j I
1 I j
/ ~
’ 3.7 ~ 25A 50MV BKO-NC6131-H54
y-u I I
j 5.5 / 32A 5OMV BKO-NC6131-H55 ~KOOSHIN I ~
15 CT I ! CT-V i3; o
j 7.5 / 38A 50MV BKO-NC6131-H56 i DENKI ;
,CT-L ! I
I I
/ !
~ I
; 2.21 / I
/ /I
+y I
I /
16 i TERMINAL i TEl
/ I I
/ 1
I I
/ ,
2.2 1 I i
~MITSUBISHI i
17 TERMIN.4L / I ~ TE-K5.5.3S 1 TE2-1 il/ o
i ELECTRIC / I I
- i 7.5~ I
1 2.21 I
; MITSUBISHI !
18 'TERMINAL ~I I TE-K2-3s ~TE2-2
ELECTRIC
I 7.5:
/ 2.2;
I SHIZUKI /
19, FILTER j I 1 BKO-NC6143-HO1 I FIL
DENKI /
/ 7.51
~ 2.2: Fl
20 FUSE ~ I I MFGONR.jA-S ~TOY0 1 F2 i3~ 3
7.5! ,F3 ,;
2.2
21 DIODE I UO5C DB 1 0 ,O'O 1
7.5 ',
2.2 I : ~ ~
3. 7 ~MC1 I1 I i ,11
22 REL.AY ; 5.5 C4J3342TDC211 OMRON :
' O ~O:Oi
MC1.l ~ I I ~
7.5 ,2 ~
:MCl-2 I), ,2'

-120-
 -
Spare

1
Zapa- Manufac --
JO Name
city Model turer iard 1
jtan- S e l e c t i o n
Remark
scces.
A- T c-
2: FAN p-p- F.4N '1
sory

0 1
-
0
T 1
- - - -
PRINTED 2. 2
IM-PW POWER
24 CIRCUlT I YAMABlSIll 0 0 1
BKO-NC6293 SUPPl.Y
BOAHD 7. 5
- - - -
I'RINTED
25 CIHCUII SFJ-CA1 1 0 0 1
BOARD
- - - -
SF-OHJ
OPTION I
I’K I NTED - SF.TI,I
26 0 0 1
CIHCUIT
BOARD

- - - -
SONY
BKO-C18101103 1 0 0 0 1
MACNESCA1.E
- -
BKO-Cl7301106
BKO. c17301109
AGNET BKO-Cl7301111
MACOME
‘Ir
0 0 1
OPTION BKO-C17301112
MACNhI'IC BKO-Cl7301113
r SENSOK BKo-c173oll14
!7 - - -
SONY
BKO~C1810ll02
ENSOR MACNESCALE 0 0 1
1 BKO-Cl7301102 MACOME
- - -
SONY
WI.I- BK0~C18101101
c MAGNESCA1.E 0 0 1
IRE .
BKO-C17301101 MACOME
- - -
OPTION
TAMACAWA
ROTARY - RFll1024~22~1M~68 0 0 0 1
SEIKI
MCODER
c - - -

- 121 -
 0 Spare

Name Capa- Model Manufac- -iStan-

VO.
turer Symbol 3: dtird Selection Remarks
city
K W acces-
b sory A B C
8550MvL
28 FAN - BKO-Cl932- 1101 TOHISlll FANI . 1 0 1 0 1

MITSUUISIII
29 TfiRMINAL - I'E. KS. 5-6s TEI 1 0 0 0 1
ELF.CTHlC
2. 2 9oow 30 OIIM
3. 7 BYO~NC1115 1101
Kl I O 0 0 1
5. 5 9oow 15 OllM
30 RESISTOR
7.5 MO-NC1115 II02
5. 5 9OOW 45 OIIM
R1,2,3 3 0 0 0 3
I , 7.5, MO-NCIIIS 1103 I I I I I
PULSE
'I‘AMACAW.4 FOH
31 SIGNAL - TSl860N55 I O 0 0 1 .
SEItil MoT0H
GENERATOR
A 90
R6550.7 TOHlsIII
I1 90
All2 ' ' UNION
IA-15101
Hll2 SEIEO FOR
32 FAN 1 0 0 1 1
MOTOR

1 A 90 I
6206ZZC3
B 90
All2
RERlNC 6307M2ZZCS19
8112 TOY0 FOR
33 LOAD 1 0 0 1 1
BEARING MOTOR
SIDE

A 90
6006ZZC3
B 90
Al12
BERING 6306M2ZZCSl6
Ul12 'fO1'O FOR
34 OI'I'OSI'I‘E IO 011
KAKING MOTOR
s I Dli

- 122-