9.

TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

B62755EN/01

TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

This chapter describes a troubleshooting of the serial interface spindle

amplifier.
9.1 LIST OF SERIAL INTERFACE SPINDLE
AMPLIFIER ALARMS . . . . . . . . . . . . . . . . . . . . . . . . 389
9.2 TROUBLESHOOTING FOR EACH ALARM . . . . . . 392

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9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

B62755EN/01

9.1
LIST OF SERIAL
INTERFACE SPINDLE
AMPLIFIER ALARMS
For troubleshooting the listed alarms, refer to 9.2 TROUBLE
SHOOTING FOR EACH ALARM.
Alarm No.

Meanings

Description

Remedy

Motor overheat

Detects internal motor temperature :

exceeding specified temperature.

Check load status.

Cool motor, then reset alarm.

AL02

Excessive speed deviation

Detects motor speed exceeding specified

speed excessively.

Check load status.

Reset alarm.

AL03

DC link section fuse

blown

Detects that fuse F4 in DC link section is

blown (models 30S and 40S).

Check power transistors, and so forth.

Replace fuse.

Input fuse blown.

Input power open phase.

Detects blown fuse (F1 to F3), open phase

or momentary failure of power (models 30S
and 40S).

Replace fuse. Check open phase and power

supply regenerative circuit operation.

Control power supply

fuse blown

Detects that control power supply fuse AF2

or AF3 is blown (models 30S and 40S).

Check for control power supply short circuit.

Replace fuse.

Excessive speed

Detects that motor rotation has exceeded

115% of its rated speed.

Reset alarm.

High input voltage

Detects that switch is set to 200 VAC when

input voltage is 230 VAC or higher (models
30S and 40S).

Set switch to 230 VAC.

Excessive load on main

circuit section

Detects abnormal temperature rise of power Cool radiator, then reset alarm.
transistor radiator.

Low input voltage

Detects drop in input power supply voltage.

Correct cause, then reset alarm.

Overvoltage in DC link
section

Detects abnormally high direct current

power supply voltage in power circuit section.

Correct cause, then reset alarm.

Overcurrent in DC link
section

Detects flow of abnormally large current in

direct current section of power circuit.

Correct cause, then reset alarm.

CPU internal data

memory abnormality

Detects abnormality in CPU internal data

memory. This check is made only when
power is turned on.

Correct cause, then reset alarm.

Spindle switch/output
switch alarm

Detects incorrect switch sequence in

spindle switch/output switch operation.

Check sequence.

RAM abnormality

Detects abnormality in RAM for external

data. This check is made only when power
is turned on.

Correct cause, then reset alarm.

Program ROM sum

check error

Detects program ROM data error. This

check is made only when power is turned
on.

Correct cause, then reset alarm.

Excessive U phase
current detection circuit
offset

Detects excessive U phase current detection circuit offset. This check is made only
when power is turned on.

Correct cause, then reset alarm.

AL19

Excessive V phase
current detection circuit
offset

Detects excessive V phase current detection circuit offset. This check is made only
when power is turned on.

Correct cause, then reset alarm.

AL20

AL24

Serial transfer data

error

Detects serial transfer data error (such as

NC power supply turned off, etc.)

Correct cause, then reset alarm.

AL25

Serial data transfer

stopped

Detects that serial data transfer has

stopped.

Correct cause, then reset alarm.

Disconnection of speed
detection signal for Cs
contouring control

Detects abnormality in speed detection signal for Cs contouring control (such as unconnected cable and adjustment error).

Correct cause, then reset alarm.

AL26

AL01

AL04

AL05
AL07

AL08

AL09
AL10

AL11

AL12

AL13

AL15

AL16

AL18

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9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

Alarm No.

Meanings

B62755EN/01

Description

Remedy

Position coder signal

disconnection

Detects abnormality in position coder signal

(such as unconnected cable and parameter
setting error).

Correct cause, then reset alarm.

Disconnection of
position detection signal
for Cs contouring control

Detects abnormality in position detection

signal for Cs contouring control (such as
unconnected cable and adjustment error).

Correct cause, then reset alarm.

Short-time overload

Detects that overload has been continuously applied for some period of time (such as
restraining motor shaft in positioning).

Correct cause, then reset alarm.

Input circuit overcurrent

Detects overcurrent flowing in input circuit.

Correct cause, then reset alarm.

Speed detection signal

disconnection motor
restraint alarm

Detects that motor cannot rotate at specified Correct cause, then reset alarm.
speed (but rotates at very slow speed or
has stopped). (This includes checking of
speed detection signal cable.)

Abnormality in RAM
internal to LSI for serial
data transfer

Detects abnormality in RAM internal to LSI

for serial data transfer. This check is made
only when power is turned on.

Correct cause, then reset alarm.

Insufficient DC link
section charging

Detects insufficient charging of direct current power supply voltage in power circuit
section when magnetic contactor in amplifier is turned on (such as open phase and
defective charging resistor).

Correct cause, then reset alarm.

Parameter data setting

beyond allowable range
of values

Detects parameter data set beyond allowable range of values.

Set correct data.

AL34

AL35

Excessive gear ratio data

setting

Detects gear ratio data set beyond allowable range of values.

Set correct data.

AL36

Error counter over flow

Detects error counter overflow.

Correct cause, then reset alarm.

AL37

Speed detector parameter setting error

Detects incorrect setting of parameter for

number of speed detection pulses.

Set correct data.

AL39

Alarm for indicating failure in detecting 1-rotation

signal for Cs contouring
control

Detects 1-rotation signal detection failure in

Cs contouring control.

Make signal adjustment.

Check cable shield status.

Alarm for indicating

1-rotation signal for Cs
contouring control not
detected

Detects that 1-rotation signal has not

occurred in Cs contouring control.

Make 1-rotation signal adjustment.

AL40

AL41

Alarm for indicating failure in detecting position

coder 1-rotation signal.

Detects failure in detecting position coder

1-rotation signal.

Make signal adjustment for signal conversion

circuit.
Check cable shield status.

AL42

Alarm for indicating position coder 1-rotation signal not detected

Detects that position coder 1-rotation signal

has not occurred.

Make 1-rotation signal adjustment for signal

conversion circuit.

AL43

Alarm for indicating

disconnection of position
coder signal for
differential speed mode

Detects that main spindle position coder

signal used for differential speed mode is
not connected yet (or is disconnected).

Check that main spindle position coder signal is

connected to connector CN12.

AL46

Alarm for indicating failure in detecting

position coder 1-rotation
signal in thread cutting
operation.

Detects failure in detecting position coder

1-rotation signal in thread cutting
operation.

Make 1-rotation signal adjustment for signal conversion circuit.

Check cable shield status.

Position coder signal

abnormality

Detects incorrect position coder signal

count operation.

Make signal adjustment for signal conversion

circuit.
Check cable shield status.

Position coder 1-rotation

signal abnormality

Detects that occurrence of position coder

1-rotation signal has stopped.

Make 1-rotation signal adjustment for signal

conversion circuit.

AL27

AL28

AL29
AL30

AL31

AL32

AL33

AL47

AL48

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9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

B62755EN/01

Alarm No.

Meanings

Description

Remedy

AL49

The converted differential Detects that difference between a spindle

speed is too high.
speed and another spindle speed has
exceeded allowable limit in differential
speed mode.

Calculate differential speed by multiplying speed

of other spindle by gear ratio. Check if
calculated value is not greater than maximum
speed of motor.

AL50

Excessive speed
command calculation
value in spindle
synchronization control

Detects that speed command calculation

value exceeded allowable range in spindle
synchronization control.

Calculate motor speed by multiplying specified

spindle speed by gear ratio. Check if calculated
value is not greater than maximum speed of motor.

Undervoltage at DC link
section

Detects that DC power supply voltage of

power circuit has dropped (due to momentary power failure or loose contact of magnetic contactor).

Correct cause, then reset alarm.

ITP signal abnormality I

Detects abnormality in synchronization signal (ITP signal) with CNC (such as loss of
ITP signal).

Correct cause, then reset alarm.

ITP signal abnormality II

Detects abnormality in synchronization signal (ITP signal) with CNC (such as loss of
ITP signal).

Correct cause, then reset alarm.

Overload current alarm

Detects that excessive current flowed in

motor for long time.

Check if overload operation or frequent

acceleration/deceleration is performed.

Power line abnormality in

spindle switching/output
switching

Detects that switch request signal does not

match power line status check signal.

Check operation of magnetic contractor for

power line switching.
Check if power line status check signal is
processed normally.

AL51

AL52

AL53

AL54

AL55

391

9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

B62755EN/01

9.2
TROUBLESHOOTING
FOR EACH ALARM
AL01

Motor overheat
Item

Cause of trouble

Defective fan motor

of motor

Check if fan motor is

rotating.

Replace fan motor.

Overload operation

Check cutting conditions

and how tools are worn.
Check load meter for
cutting.

Review cutting conditions

and tools.

Dirty motor cooling

system

Check motor cooling system for dirt.

Clean motor cooling

system with an air gun or
vacuum cleaner.

Disconnection or
loose contact of
motor overheat
signal line

Check signal line connection status.

Connect signal line

correctly.

AL02

Excessive speed
deviation

Check procedure

Item

Cause of trouble

Overload operation
(overload)

Check with load meter.

Review cutting conditions

and tools.

Defective transistor
module

Check if transistor collector-emitter is open.

Replace transistor module.

Check if fuses F3A to F3M

(models 1S to 26S) or FA
to FG (models 30S and
40S) are blown or removed.

Insert fuses firmly.

Replace any blown fuse.

Fuse for protecting

driver on PCB
blown or not inserted correctly
(disconnection,
loose contact, etc.)
Speed feedback
signal abnormality

Check level of speed feedback signal.

Check motor speed detector and signal cable connection.

Wiring failure
(disconnection,
loose contact, etc.)

Check that cables are

connected correctly.

Check procedure

Remedy

Remedy

NOTE
How to check the speed feedback signal
Observe the speed feedback signal with an osciloscope
after turning on power and setting the rotation command off
(motor stopped and drive power set off).
Observe the test points indicated below, while turning the
motor slowly by hand.

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9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

B62755EN/01

Test point

Normal wave form

PA0V

Vpp=0.360.5V
About 2.5V

0V
PB0V

Same as above

RA0V

DC2.5V0.2V

RB0V

Same as above

PAA0V
PBA0V
(CW rotation)

PAP

ON OFF

0V
PBP

ON

OFF
4.5V

0V
0.4V
Check that the ON/OFF duty cycle is 50%.
(The PAP and PBP signals are inverted in CCW direction.)

AL03

Blown fuse in DC
link section

AL04

Input fuse blown

Input power open
phase

This alarm indicates that the fuse (F4) in the DC link section is blown.
In this case, the transistor module may have failed.

Item

Cause of trouble

Check procedure

High impedance on
AC power supply
side.
Example:
Two transformers
are connected in
series, or variable
autotransformer is
connected.

Alarm No. 04 is on only at

time of deceleration from
high speed operation.
Alarm No. 04 can be on
when F1 to F3 are not
blown.

Defective transistor
module

Replace transistor module

and fuse.

Defective diode module or thyristor module

Disconnect diode modReplace defective part.

ules DM1 to DM3 and thy- Replace blown fuse.
ristor modules SM1 to
SM3, then check A-K
connection with multimeter. (Defective modules
are usually short-circuited.)

Defective surge absorber or capacitor

Check surge absorbers

Z1 to Z3 and capacitors
C4 to C6.

Replace defective part.

Replace blown fuse.

When input fuse is

not blown

Check if Item 1 is applicable.

When Item 1 is not applicable, replace PCB.

Remedy
Change power supply to
one with low impedance.
There may be loose connection of input power
cable
Example:
Open phase due to
screws not tightened
firmly

393

9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

AL05

Control power
supply fuse blown

Item
1

AL07

Cause of trouble

B62755EN/01

Check procedure

Defective PCB

Remedy
Replace PCB.

Check AC in
input
ut voltage
voltage.
See (5) above.

Abnormal power supply voltage

Item

Cause of trouble

Check procedure

Incorrect setting of
parameter for number
of speed feedback
pulses (No. 6511)

Check if number of speed

feedback pulses matches
parameter setting.

Excessive speed

(Detection by
digital value)

Remedy
Set correct value in
parameter.

NOTE
See Chapter 6.

AL08

AL09

High input voltage

Heat sink is
overheated

Item

Cause of trouble

AC power supply voltage 10% higher than

rated voltage.

Check power supply

voltage.

Incorrect setting of
toggle switch for voltage switching.

Check power supply

voltage.

Item

Cause of trouble

Check procedure

Cooling fan is defective.

Check if fan is rotating.

Replace fan.

Overload operation.

Check load by using a

load meter.

Re-examine the cutting

condition.

2
3

AL10

Input power
voltage drops

AL11

Overvoltage of DC
link circuit
(Regenerative
circuit is
faultyRegenerati
on failure)

AL12

Overcurrent flows
to DC link circuit

Check procedure

Dusty and dirty.

Remedy

Change setting from 200V

to 230V.

Remedy

Clean using compressed

air or vacuum cleaner.

This alarm indicates abnormally low AC power voltage (15% or less).

This alarm may be generated even during momentary power failures.

Item

Cause of trouble

Check procedure

Remedy

High power impedance.

Examine AC power specification.

PCB is defective.

Replace PCB.

Defective transistor
module (TM1).

Replace transistor module.

Item

Cause of trouble
Output terminals or
internal circuit of motor is shorted.

Check connections.

Transistor module is
defective.

Check the transistor

module.

PCB is defective.

394

Check procedure

Remedy

Replace transistor module.

Replace PCB.

9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

B62755EN/01

AL13

CPU internal data

memory alarm

AL16

RAM abnormality

AL18

AL19

Program ROM
sum check error

Excessive U
phase current
detection circuit
offset

Replace PCB .

Item

Cause of trouble

External data memory

(RAM) defective

Replace memory (RAM).

PCB defective

Replace PCB.

Cause of trouble

Check procedure

Remedy

Program memory
data (ROM) defective

Compare data displayed

when power is turned ON
with ROM labels.

Replace program memory

(ROM).

Item

Cause of trouble

Check procedure

Remedy

A/D converter defective

AL24
AL25

Excessive V
phase current
detection circuit
offset

Serial transfer
data error
Serial data
transfer stopped

Remedy

Item

Item

Replace A/D converter.

U-phase current detector circuit defective

After power is turned on,

check if offset voltage on
check terminal IU is beyond range of about
"100 mV.

Replace PCB.

Loose contact of connectors between PCB

and power circuit

Check connector connection between PCB and

power circuit.

Ensure that PCB and power circuit are securely connected with each other.

AL20

Check procedure

Cause of trouble

Check procedure

V-phase current detector circuit defective

After power is turned on,

check if offset voltage on
check terminal IV is beyond range of about
"100 mV.

Replace PCB.

Loose contact of connectors between PCB

and power circuit

Check connector connection between PCB and

power circuit.

Ensure that PCB and power circuit are securely connected with each other.

Item

Cause of trouble

Check procedure

Remedy

CNC power supply is

OFF

Check that CNC power is

ON.

Turn CNC power ON.

Defective optical
cable for serial data
transmission

Check that optical cable is

fitted securely to the connector. Check that the
cable is not broken.
Check that transmission/
reception surfaces of the
cable are clean.

Connect securely.
Replace optical cable.
Clean optical cable transmission/reception surfaces.

Defective data transmission/reception elements in LSI used in

serial data transmission

395

Remedy

Replace LSI.
Replace PCB.

9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

AL26

Disconnection of
speed detection
signal for Cs
contouring
control

Item

Cause of trouble

Signal level of spindle

motor for Cs
contouring control is
invalid.

Check the signal, and if necessary adjust to the normal

level using the variable resistor for signal level adjustment in the preamp.

Signal line of spindle

motor for Cs contour
control is
defective

Check that signal cable is

connected securely to
connector.
Check that signal cable is
not broken.

Position coder
signal
disconnection

Item

Shorttime
overload

Replace detector circuit.

Check that the parameter

setting does not indicate
that the Cs contour
control detector is used
when actually it is not.

Parameter CAXIS1 = 0
No. 4001#5

Check procedure
Check that signal cable is
connected securely to
connector.
Check that signal cable is
not broken.

Connect signal cable securely.

Replace signal cable.

Incorrect parameter
setting

Check that the parameter

setting does not indicate
that the position coder
signal is used when actually it is not.

Parameter MRDY2 = 0
No. 4001#2

Check procedure

Remedy

Item

Cause of trouble

Signal level of spindle

detector for Cs axis
control is defective

Check the signal level, and if necessary adjust to the

normal level using the variable resistor for signal level
adjustment in the preamp.

Signal line of spindle

detector for Cs axis
control is defective

Check that signal cable is

connected securely to
connector.
Check that signal cable is
not broken.

AL29

Connect signal cable securely.

Replace signal cable.

Cause of trouble

Disconnection of
position detection
signal for Cs
contouring
control

Remedy

Position coder signal

line defective
1

AL28

Check procedure

Defective detector circuit for Cs contour

control
Incorrect parameter
setting

AL27

B62755EN/01

Defective detector circuit for Cs axis

control

Item

Cause of trouble

Check procedure

Overloaded operation (Overload)

Use loadmeter to check

that a load close to the
load resistance limit is not
imposed continuously for
30 seconds or more.

396

Remedy

Connect signal cable securely.

Replace signal cable.

Replace detector circuit.

Remedy
Re-examine cutting
conditions and tools.

9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

B62755EN/01

AL30

AL31

Input circuit
overcurrent

Speed detection
signal
disconnection
motor restraint
alarm

Item
1

Defective of power
regeneration circuit

Item

AL33

AL34

Cause of trouble

Replace PCB.

Check procedure

Remedy
Remove cause.

Defective motor
speed feedback
signal

Check signal waveform.

(Alarm No. 2)

Remove cause.

Defective motor
speed feedback
signal cable

Check that cable is connected securely to connector.

Check that cable is not
broken.

Connect cable securely.

Replace cable.

Item

Cause of trouble

Defective LSI used in

serial data transmission

Insufficient DC
link section
charging

Item

Cause of trouble

Defective relay used

in DC link recharging.Disconnection of
resistor used in limiting re-charge current

Item

Cause of trouble

Remedy
Replace power transistor.

Check that nothing is

preventing the motor from
accelerating.

Abnormality in
RAM internal to
LSI for serial data
transfer

Parameter data
setting beyond
allowable range
of values

Check procedure
Check power transistor.

Motor constrained
1

AL32

Cause of trouble
Defective of power
transistor used for
power

Incorrect parameter
setting

Check procedure

Remedy
Replace LSI.
Replace PCB.

Check procedure
Check relevant parts.

Remedy
Replace amp.

Check procedure

Remedy

Check if specified parameter value is beyond allowable range of values.

Specify value within allowable range.

AL34 and FXXX are alternately displayed in the spindle amplifier

indicator section if an AL34 alarm is raised.
XXX indicates the data number internal to the spindle for a parameter
where a value beyond the allowable range is specified.

AL35

Excessive gear
ratio data setting

Item
1

Cause of trouble
Parameter data of
gear ratio and position gain are too
large.

397

Check procedure
Check gear ratio and
position gain data.

Remedy
Change to suitable values.

9. TROUBLESHOOTING (SERIAL INTERFACE SPINDLE)

AL37

AL39

AL40

AL41

AL47

Speed detector
parameter setting
error

Alarm for
indicating failure
in detecting
1rotation signal
for Cs contouring
control

Alarm for
indicating
1rotation signal
for Cs contouring
control not
detected

Alarm for
indicating failure
in detecting
position coder
1rotation signal

Position coder
signal
abnormality

B62755EN/01

Item

Cause of trouble

Check procedure

Incorrect setting of
parameter for number
of speed feedback
pulses (No. 6511)

Check if number of speed

feedback pulses matches
parameter setting.

Remedy
Set correct value in
parameter.

Item

Cause of trouble

Check procedure

Incorrect data ROM

type for Cs contouring
control detector
circuit, or incorrect
setting

Check data ROM type for

Cs contouring control
detector circuit and
setting.

Remedy

Low level of Cs contouring control feedback signal, or noise

on same feedback
signal

Check feedback signal

Adjust feedback signal.
level and also check if
Check shielding status.
feedback signal waveform
includes noise.

Item

Cause of trouble

Check procedure
Check 1-rotation signal
among Cs contouring
control feedback signals.

No occurrence of
1-rotation signal
among Cs contouring
control feedback
signals, or 1-rotation
signal offset adjustment error

Install correct type of

ROM.
Perform setting correctly.

Remedy
Make 1-rotation signal
offset adjustment.
Check cables.

Item

Cause of trouble

Check procedure

Remedy

Check number of position

coder signal pulses and
parameter setting.

Set correct value in parameter.

Incorrect setting of
parameter for number
of position coder signal pulses (No.
4003#4,6,7).

Incorrect amplitude
and offset of position
coder feedback signal, or noise on same
feedback signal.

Check feedback signal

Adjust feedback signal.
level and also check if
Check shielding status.
feedback signal waveform
includes noise.

Item

Cause of trouble

Check procedure

Remedy

Check number of position

coder signal pulses and
parameter setting.

Set correct value in parameter.

Incorrect setting of
parameter for number
of position coder signal pulses
(No. 4003#4,6,7).

Incorrect amplitude
and offset of position
coder feedback signal, or noise on same
feedback signal.

Check feedback signal

Adjust feedback signal.
level and also check if
Check shielding status.
feedback signal waveform
includes noise.

398