Need Help!- VF2 - Control overheat 122 alarm??

[DaOne]

I was doing a job yesterday and was doing some simple 3/8 16 tapped holes. As the tap was reversing it broke coming out. I pulled out the tool and replaced it. As I was replacing the tool (machine not running) the control alarmed out. I am now getting a "Control Overheat 122" message. I come up about 4 minutes after the machine is turned on even if I do nothing. Is this a sensor failure? Not even sure where to look. I believe this is a 1995 VF2 7500RPM 10HP.

[Donkey Hotey]

Have you checked all the fans? I'm not familiar with the older machines but many of the things should be the same:

• Are the air filters on the cabinet clear? If they're plugged up with coolant goo, they'll flow zero air.
• Are the cabinet fans running?
• What about the internal fans? There should be at least one on the spindle drive and there may be a few on things like the small DC power supply near the computer boards.
• Has anybody recently been poking around inside the cabinet? I think I remember that there were some shrouds that were designed to be 'in place' so the cooling air was directed across the right boards.

[DaOne]

Fans are running fine. There is airflow. Also it is very cold in the shop right now and if I power up the machine it will alarm out in approx 4 minutes. I have checked everything as far as running the machine and the spindle works, everything is fine till it shuts it down with that message. It doesn't mater if I don't touch the machine or attempt to run it. It shuts down in the same time. I have even put a box fan blowing into the control. Same issue.

[rlabonte18]

FROM THE SERVICE MANUAL:::::

The control internal temperature is above 150 degrees F. This can be caused by almost
anything in the control overheating. But is usually caused by overheat of the two regen resis
tors for servos and spindle drive. This alarm will also turn off the servos, spindle drive, coolant
pump, and tool changer. One common cause of this overheat condition is an input line voltage
too high. If this condition remains for 4.5 minutes, an automatic shutdown will begin.

[DaOne]

Originally Posted by rlabonte18 FROM THE SERVICE MANUAL::::: The control internal temperature is above 150 degrees F. This can be caused by almost anything in the control overheating. But is usually caused by overheat of the two regen resis tors for servos and spindle drive. This alarm will also turn off the servos, spindle drive, coolant pump, and tool changer. One common cause of this overheat condition is an input line voltage too high. If this condition remains for 4.5 minutes, an automatic shutdown will begin.

I read that in the manual as well. Basically it doesn't tell much more than its gonna be expensive and they arnt gonna provide any lube.


I Did check the line voltage and the legs very a bit but they are still within range of the tap I have it connected to. This machine is being run off a phase converter. I checked the DC Buss voltage on the diagnostics page and it reads anywhere from 156-160. Anyone else have any ideas?

[Donkey Hotey]

The newer machines have specific error codes for this but the older ones may have lumped them all together:

Have you checked the regen resistor to see if it's hot? I'm wondering if the spindle drive might have a dead or shorted regen IGBT.

[DaOne]

Originally Posted by Donkey Hotey The newer machines have specific error codes for this but the older ones may have lumped them all together: Have you checked the regen resistor to see if it's hot? I'm wondering if the spindle drive might have a dead or shorted regen IGBT.

Yes the regen resistor is getting warm but not anywhere near where I have felt it get. I am able to run the spindle until it shuts down. It doesnt matter what I do. Spindle can be running or stopped and it still shuts down. As soon as I power up and clear the alarms. I don't even have to do a power up reset. It will alarm out within 10 minutes after alams are cleared untouched.

[Donkey Hotey]

Does the regen resistor get warm even if you just reset everything but don't run the spindle? That's the symptom of a failed regen IGBT in the spindle drive.

[DaOne]

Originally Posted by Donkey Hotey Does the regen resistor get warm even if you just reset everything but don't run the spindle? That's the symptom of a failed regen IGBT in the spindle drive.

Ok, we tested the regen resistor and it was 25 ohms like it is labeled. We then bypassed the temp sensor and the machine never alarmed out but after about 15 minutes of running the spindle it was glowing hot. Not the next question I have. If this is the IGBT. Can we just replace it with the same model (Freqrol A200 FR-A220-5.5K) or does it need to be a Haas replacement? It also has a red/white sticker that says "special type" on it.

[Donkey Hotey]

IGBT: Integrated Gate Bipolar Transistor. It's a part inside the spindle drive, not the regen resistor. The fact that the regen resistor is getting really hot, suggests that the IGBT is leaking.

Electronically what's happening is that the spindle is running with both the throttle and the brakes at the same time. It's spending very little power making the spindle turn, but it's burning up the rest of the electricity heating up that regen resistor.

I might be wrong on this, but that's my guess based on what you've posted--especially the broken tap (indicating a loss of spindle control).

[DaOne]

I am great with electronics and even own hot air tools to do SMD devices. Can I replace the part that failed myself? If not, where can I get this unit cheaper than the $4000 Haas just quoted me? Is it possible to have this repaired? They told me no due to loss of programming. I am not sure where to go on this. I don't even have the $4000 required to fix this this thing.

Originally Posted by Donkey Hotey IGBT: Integrated Gate Bipolar Transistor. It's a part inside the spindle drive, not the regen resistor. The fact that the regen resistor is getting really hot, suggests that the IGBT is leaking. Electronically what's happening is that the spindle is running with both the throttle and the brakes at the same time. It's spending very little power making the spindle turn, but it's burning up the rest of the electricity heating up that regen resistor. I might be wrong on this, but that's my guess based on what you've posted--especially the broken tap (indicating a loss of spindle control).

[HuFlungDung]

I feel for ya

If you are the adventurous type, open up the drive and start looking around for major component failure. Find part numbers. Use Google to search for the parts, perhaps at a place like Digikey or Newark.