KM3-P Spindle Servo Fault

[jbmozer]

My KM3-P has a new problem after a cross-country move. When I turn the spindle on, it stops after about one revolution with a servo error. I've reseated all of the cards and connectors, checked the microswitches in the speed dial and generally "thunked" everything that might have come loose during shipment.

The spindle does run normally when I manually depress the magnetic switch in the power cabinet. Someone added a manual speed increase/decrease switch to the front of the head that allows me to run the speed up and down so the speed control motor is working. But any time I try to run it through the MAX-2 controls, I get the servo fault.

Any advice?

-joel

[jbmozer]

This is an old question from a post that I made many months ago, but I still have the problem. I'm hoping that by posting some additional information, I can get some help getting me off of top-dead-center with respect to troubleshooting the issue.

This is a KM3-P, runing Ultimax 2, version 7.24.

The basic problem is that I cannot run the spindle through software control. Whenever I command the spindle on, I get a "SERVO ERROR" either instantly, or withing a second or two. The spindle will start to rotate, but never gets up to speed before the error occurs.

I've read through the manual, particularly the Theory of Operation document for the spindle speed controller and have found the following to be true:

1. I can run the spindle manually either CC or CCW, by depressing the appropriate contactor in the power cabinet. I can also increase/decrease the speed using contactors K1 & K2, or the manual adjustment knob on the front (but only as long as my finger is on the spindle contactor).

2. I can detect the pulse from the proximity sensor on Pin 27 of the Voltak board and the frequency of pulses appears to vary appropriately with increasing or decreasing speed.

3. By programming a certain RPM for the spindle through the console, I can manually manipulate the contactors to get the red LED (H2) to illuminate--indicating that the spindle is running at the programmed RPM.

4. The only other light on the Voltak board is the green LED (H1) that seems to just be a power-on indicator.

I really can't proceed with the spindle adjustment procedure described in the document because I can't get the spindle to stay on by itself.

Any troubleshooting help or advice would be MUCH appreciated!

-jbmozer

[skullworks]

When it does fire up - is it rotating the correct direction? - After the move when they hooked up the 3 phase your direction could be CCW when it should be CW.

Easy way to test is if the coolant pump is running the correct direction also.

[jbmozer]

When it does fire up - is it rotating the correct direction? - After the move when they hooked up the 3 phase your direction could be CCW when it should be CW.

Thanks for the response. Actually, you are right that the 3 phase was hooked up incorrectly and the spindle *was* running backwards. However, we've since fixed that and still have the same servo fault problem.