Y Servo Overheating

[Swykore]

Originally Posted by Chris53 C axis refers to the spindle drive and usually is related to the inverter having a fault or the orientation prox switch not switching during spindle rotation. I guess I would have to know what fault number is reported by the control to really have an idea what is happening for sure. fadals are not too terribly sophisticated and error reporting is not the most in depth or comprehensive part of these controls. The error usually - but not always point you in the direction of the actual failure. In the case of an axis fault the axis reported as having failed could just be where the jog selector switch was set when the failure occured rather than the actual axis at fault and the red light on the amplifier in question is sometimes momentary so you have to catch the actual moment of failure to know which axis went- or see a standing error on the position display to the right of the axis position in question. With no motion, error values would normally be "0" rolling +/- 1 or 2 counts if everything is normal and the drives up. if the axis is in a bind or "lost" the error value will go up +/- from 0 and will fault the machine when too large a value is seen by thhe control. the only way to recover when this happens is to power down and restart the control.

The spindle on our 6030 will not turn on- we get the "C axis faults" error # 8 message... This just started today- We were correcting the spindle which would run in reverse- this is a new used machine for us. The previous owner had switched the polarity of the 3 phase cables in the control box- We called Fadal and they told us this would be an easy fix- to simply put it the way it was originally. We did but then after prompting the spindle to turn (s300m3) it worked but then stopped working--

and now we get the error and the spindle will not rotate at all???
HELP PLEASE!!

[dango]

first the spindle problem
first try to operate the spindle from the inverter this will tell you from where
the problem came if you can run fro the inverter then your problem
in the axis controler if you can't it came from the inverter
then we can proceed also check on the inverter if it on remote or in local
if it in local this is your problem
and for the Y axis problem it look like the mecanical stop holding the motor
easy way to check it to go one turn backwards on the CS mark do a CS in
the new place and then go again to the limit only oposite way from the way you put the mark on
and check if there is no problem go back make CS in correct place and adjust
the mecanical stop

[Swykore]

Originally Posted by dango first the spindle problem first try to operate the spindle from the inverter this will tell you from where the problem came if you can run fro the inverter then your problem in the axis controler if you can't it came from the inverter then we can proceed also check on the inverter if it on remote or in local if it in local this is your problem and for the Y axis problem it look like the mecanical stop holding the motor easy way to check it to go one turn backwards on the CS mark do a CS in the new place and then go again to the limit only oposite way from the way you put the mark on and check if there is no problem go back make CS in correct place and adjust the mecanical stop

Thanks Dango... well, we had Fadal come out and they determined the encoder was good and the spindle motor, the BAD news is they said it needs a new Drive, the large circuit board that costs $5000 - I am now wondering if the previous shop had switched the polarity at the back of the Fadal going into the Drive for some reason and always ran it in reverse but just switch m3 and m4 commands when they programmed. I just cannot figure out why the drive failed immediately after we switched the polarity - WHICH the tech at FADAL instructed us to do.... or if something was fishy, why the previous operator at the previous shop did not give us a heads up on switching the m3/m4 commands and just running it.
I just feel like we got majorly screwed here, we just purchased this machine and already are having to spend $5000 before we have even cut our first mold on it!!

[dango]

Dear Swykore
First don't go too fast to invest 5000$
So what I assumed the guy from Fadal told you that the inverter is bad
First I can give you company in the state the name is practec they repair
I think for about 1000$
Second I had this kind of problem the change of polarity you mean is in the
Inverter I don't remember now the numbers
If it is correct I had the same problem twice in the same machine
Changing the inverter not going to solve it I was doing some measuring and it like I was making reset the machine start again
It was good for 5 years then it came again I was doing the same thing again
And it disappear
Try now if the machine runs now in M4 the direction of M3 and if in M3 it cause
Emergency then let me know and I will try to give you the way to do the measuring

[Swykore]

Originally Posted by dango Dear Swykore First don't go too fast to invest 5000$ So what I assumed the guy from Fadal told you that the inverter is bad First I can give you company in the state the name is practec they repair I think for about 1000$ Second I had this kind of problem the change of polarity you mean is in the Inverter I don't remember now the numbers If it is correct I had the same problem twice in the same machine Changing the inverter not going to solve it I was doing some measuring and it like I was making reset the machine start again It was good for 5 years then it came again I was doing the same thing again And it disappear Try now if the machine runs now in M4 the direction of M3 and if in M3 it cause Emergency then let me know and I will try to give you the way to do the measuring

Thanks for the heads up on Protec but I am in California- I will look for a good outfit in my area- I am a designer at my company and have been helping to set up the mold shop- my company will be shelling out the five grand but I feel badly how this has gone down. I will mention to my boss that we may want to look at a remanufactured drive but I think his thinking is that we just have to get this machine going quickly.

[dango]

o.k. but if you will need help there
the name of the man there is Kyle and the web sight is www.practecllc.com
they got some time Fadal inverter in stock

[Swykore]

Originally Posted by dango o.k. but if you will need help there the name of the man there is Kyle and the web sight is www.practecllc.com they got some time Fadal inverter in stock

Thanks Dango for your help. Turns out that we had the new vector driver put in and we are up and running. It was my boss's call, his money so that is that.

One thing that I did learn from the Fadal tech was that they sell remanufactured machines that are gone through, inspected, repaired and sell with a ONE year warranty which would of been NICE. In retrospect, I wish I would of looked into that... we kind of acquired the machine we have by recommendations from friends in the mold making industry etc. but there was no warranty whatsoever and I am thinking that might be a big mistake!!! At least we are good to go now and while it was an expensive fix, the cost will amortize itself out in all the added production we will get.

[wevz]

We have a Mori-Seki mill that is doing the exact same thing. I have looked at it and found that on top of the Y-axis ball screw there is a thick dense rubber stopper type bushing. It is either a stop or a type of wiper for the ball screw. Anyways I noticed that when the Y-axis is brought to it's upper most position and left there that the servo motor is fighting the brake and this piece of rubber, which makes it continuously be energized and try to stay at it's coordinates. Before I noticed this I already sent the servo motor out and had it rebuilt. (It made no difference!) Just an idea of what you might look at.