4th axis controller 1010-5D jumper socket

[timo2le]

I bought a '97 vmc 15 at an auction. Came from the factory with 4th axis wiring & amps. I bought a VH65 at the same auction. It was sitting on a 4020. We verified that it worked on the 4020. On my VMC 15, with the dummy plug installed the AMC -AMP-0014, shows a red LED. When I connect the VH65 to the VMC15 I get an error #3 axis overload. I have had the 4th running (continuous rotation/without control) by disconnecting some wires. So, based on testing the 4th at the auction, and getting it to run out of control, I feel like the motor is OK.

Last night I did an inventory of the cards as they are installed in the card cage. Slot 13 is designated as the A axis card. It has a 1010-5D card installed. (all axis cards are 1010-5D) and the EPROMs are labled for the A-axis. (all other cards have the EPROMs labled for the appropriate axis).

I compared jumper socket wiring to the manual for all cards. What I found on the A axis card is: the 12 - 5 jumper wire is cut. I found in the manual that this jumper should be cut for other brands of 4th axis, but not for the VH65.

I had to leave my shop, so I didn't get a chance to replace the jumper. I can't wait to get to the shop tonight to replace that jumper an see what happens. What specifically does that jumper do? Does it sound like the root of my problem or do I have deeper control issues?

[Neal]

Timo2le--
The pins 12 and 5 at address J4 are for the direction of the motor. If it rotates the wrong direction place a jumper across 12 to 5 or if one IS there already remove it. If this is an AC rotary servo motor, on the black connector at the contorller card, reverse the black and red wires.
If this a DC rotary, the reverse the motor and tach wires at the motor.

Neal

[timo2le]

Thanks Neal,


My system is a DC rotary (glentek). Sounds like my problems are deeper than the jumper (since it controls motor rotation). At this point, I can't get the motor to rotate since I get the axis overload alarm #3. I have read here and in the manual so I will do the voltage checks, but probably more importantly verify all the leads from the orange connecter to ground, and also continuity in each of the leads.


Tim

[Neal]

Don't over look the Tach in the motor as a source of the issue.

Neal

[timo2le]

My last update didn't go through, so here it is again.

Recently, there was a guy that bought and 4020 from 1 shop, and VH65 from another and couldn't get the 4th to work. Similar situation to mine except I bought them both at the same auction, but didn't see the VH65 run on my machine, but did see it run on a 4020

I couldn't find anything obvious in the control cabinet by checking voltages, checking for shorts, and resistance in cables. (Made simple comparisons between all axis at the orange connector, and the amplifier.) So I went to the servo. Neal said there were (4) combinations of motor/tach leads so I tried those.
WIth my original combination, I would press JOG and get an e-stop, #3 axis motor overload. The 4th would increment about 2°. I did this several times. (I did some research on resolvers, and now I question the significance of the display incrementing by 2°. There were a few times where the displayed number would be significantly different, and then it would increment by 2° after each e-stop reset.

I found a combination that allowed the control to stay on without an e-stop. I was able to jog the 4th forward and backward. Rotation of the 4th was "mushy" meaning the axis would lag the Pulse generator, and continue to rotate after I stopped turning the PG. I did a few revs. forward/back and then I got an e stop, and couldn't "revive" the system. I received #16, #17 & #18 alarms. (relates to the resolver.)

I have an old resolver with bad bearings from a parts motor, and this resolver. I brought them into work to have one of the Electronics Tech look at them with a scope and signal generator.

Is this a textbook case of "replace the resolver", or should I be looking for something else. ??? Try this resolver in a different axis ???

Thanks,

Tim

[timo2le]

Finally!!!! The Electronics Tech at worked tested the resolvers. He didn't know exactly how to test this model, but he did have consistent wave forms so they looked like they were functioning. I saw enough to think they are not the problem.

So, with an experienced operator at the control an me at the CNC panel and me at the elec. disconnect, we would individually components of the 4th axis (card, coax, amp, servo) The machine was to the point where the control would fault (e stop) when it tried to start the amps. We had mixed results, and I finally got to the point where I swapped the X & A axis cards (swapped eproms and jumpers also). The control did not alarm-out. The 4th operated as it should (although +A was CW rotation). We tested and it seemed to be working ok. Now for the real test - swap the boards back to original. Everything still worked?!?!?!?! All I can think is that reseating the eproms did the trick. I had reseated the boards several times. The cabinet is clean (no oil or dust) but there must have been some oxidation.

I hope this helps somebody else.

Tim