Mitsubishi M70 S03 Alarm

[semenov419]

Hello to all.

Well do not even know where to begin wit this, but really hope some one has experience with the problem I am facing for the past 6 month.

We have a milling center with live tooling TCK-45H equipped with Mitsubishi M70.
Past summer our operator called me in since the machine was giving S03 spindle alarm. (Feedback error 1 0042 S1). On a spindle start machine would give this error and stop the spindle. After contacting the manufacturer, it was concluded that the problem is with the external encoder. Prior to that we checked the spindle motor encoder where it was fine showing the RPM's etc.

Soon after a manufacturer has sent us a new encoder along with the ring that goes on to the spindle shaft. After installing and setting new parameters for encoder on the M70 side (parameter 13019), we are still getting the same error and on top of that S03 (Feedback error 2 0043 S1). Well two new encoders later we are still at the same problem.

What was done:

1. Checked the motor encoder - looks to be fine
2. Replaced 3 external encoders
3. Replaced external encoder to CN3 cable
4. Replaced CN3 connectors
5. Played with encoder positioning over the ring
6. Checked A+ A B+ B and Z- Z signals with oscilloscope signals look to be as per digrams
7. Changed settings for encoder frequency with all ranges.

So in over 6 month period we are no where with machine dead in the water with S03 alarm. Attached is an image with all the errors.

Any comments or suggestions will be appreciated. Thank you in advance.

P.S. Another issue that began to happen in the process is that live tooling turret would unlock when changing tools but will not move to the tool selected. And when you switch controls from MDI to JOG or Hand wheel, it will return with a message that tool magazine need zero return. Beats me

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[semenov419]

Just an update.

9 month later problem is finally solved. 3 encoders later we got the spindle to work. Solution to this lied on the surface and who would have though that operator of the machine should have been tortured from day one. Anyway after trying all kinds of setting, parameters and installation positioning for the encoder, re soldering wires on the cable, we finally decided to do an unorthodox thing. Just out of the blue we decided to try and switch + and - contacts on the A+ A- signal despite the connection diagram was telling exactly the opposite. And to our surprise the darn thing worked. So the problem lied in the settings in the controller that were changed but were not told about by operator. Apparently, before the alarm, our operator decided that he wants spindle to work in mirror mode, rather than changing the programming. May be this helps someone one day. Regards

P.S. Wires were re soldered back to where they supposed to be and setting was changed to the correct ones - everything works fine.

[hemanth007]

You could have changed the Feedback polarity parameters in spindle rather going for a wire change of ab Z phases with their opposite polarity.

13019 parameter Bit 4

Contact me in future for any problems

Regards
Hemanth.p
+91 9962328434

[semenov419]

You could have changed the Feedback polarity parameters in spindle rather going for a wire change of ab Z phases with their opposite polarity.

13019 parameter Bit 4

Contact me in future for any problems

Regards
Hemanth.p
+91 9962328434

Goodday Hemmanth

Thank you very much for pointing it out. As for wires it was kind of let's see what happens thing, that eventually pinpointed the problem. So at this point we are soldering everything back as it was and changing the settings.

As for the other problem, we do have one, and given the opportunity may be you can help resolve it.
This same machine is equipped with 12 station power turret by Lioshing. Once in a while it was giving us a problem with zero position, where we would have to set it again and again. (M77 tool magazine maintenance mode, M29 - M83 Unlock the turret, rotate turret to the zero position mark, M84 lock then implement zero return M74, machine reboots and whola it's set - but once in a while we had to go in to diag menu and use modal output to control X227 lock, x228 unlock, and y224 commands since M codes would not work, on top of that we would be missing alarm messages on the screen even though controller would have one blinking). Well while dealing with the spindle problem, we ran in to the issue where turret stopped changing tools, when given the command, X and Z axis would move it to the set position, then turret unlocks and nothing happens afterwords, meaning that servo will not rotate the turret to the set tool, but rather unlocked turret will rotate under the weight of the heaviest tool and that is just about it. In the mean time controller blinks with A90 alarm (zero return not complete) and once in a while A25 alarm. We tried setting zero position with the method described above but we can not get past M84 command. When implementing M84 turret will not lock, thus we can not implement M74 command that sets zero position. Again and again we tried with no result, began checking the wires and indeed found one bad contact that was fixed, but besides having all the messages appear on the screen (i mentioned that we were missing alarm messages from the turret) this did not do much for the issue itself. I did play with X227 x228 and y224 and could have messed up the settings, looking at the latter monitor it seems that those commands are backwards, but I am not a pro to claim it the right reading. Also while playing with X and Y commands couple of times we had a message servo resistor overheat - so i am thinking may be the servo went and that is where our problem is.
Thank you in advance.

[hemanth007]

It seems like there is a Ladder programming mistake.

IS the turret running now?? Or is the problem appearing intermittently.

MY company specialises on Mitsubishi Service . But turret problem is mostly related to manufacturer , and it differs from machine to machine.

IF problem is intermittent we can solve by changing ladder sequence.

Goodday Hemmanth

Thank you very much for pointing it out. As for wires it was kind of let's see what happens thing, that eventually pinpointed the problem. So at this point we are soldering everything back as it was and changing the settings.

As for the other problem, we do have one, and given the opportunity may be you can help resolve it.
This same machine is equipped with 12 station power turret by Lioshing. Once in a while it was giving us a problem with zero position, where we would have to set it again and again. (M77 tool magazine maintenance mode, M29 - M83 Unlock the turret, rotate turret to the zero position mark, M84 lock then implement zero return M74, machine reboots and whola it's set - but once in a while we had to go in to diag menu and use modal output to control X227 lock, x228 unlock, and y224 commands since M codes would not work, on top of that we would be missing alarm messages on the screen even though controller would have one blinking). Well while dealing with the spindle problem, we ran in to the issue where turret stopped changing tools, when given the command, X and Z axis would move it to the set position, then turret unlocks and nothing happens afterwords, meaning that servo will not rotate the turret to the set tool, but rather unlocked turret will rotate under the weight of the heaviest tool and that is just about it. In the mean time controller blinks with A90 alarm (zero return not complete) and once in a while A25 alarm. We tried setting zero position with the method described above but we can not get past M84 command. When implementing M84 turret will not lock, thus we can not implement M74 command that sets zero position. Again and again we tried with no result, began checking the wires and indeed found one bad contact that was fixed, but besides having all the messages appear on the screen (i mentioned that we were missing alarm messages from the turret) this did not do much for the issue itself. I did play with X227 x228 and y224 and could have messed up the settings, looking at the latter monitor it seems that those commands are backwards, but I am not a pro to claim it the right reading. Also while playing with X and Y commands couple of times we had a message servo resistor overheat - so i am thinking may be the servo went and that is where our problem is.
Thank you in advance.

[semenov419]

It seems like there is a Ladder programming mistake.

IS the turret running now?? Or is the problem appearing intermittently.

MY company specialises on Mitsubishi Service . But turret problem is mostly related to manufacturer , and it differs from machine to machine.

IF problem is intermittent we can solve by changing ladder sequence.

Well just now we partially solved that one. There were two wires disconnected inside the MR-J3SCNS plug on the J3 servo side. Before removing the plug completely we did improvised on the connection and I was able to execute Zero return command and it worked like a charm and no messages on amplifier nor on screen. Then tried to change tools but that did not happen. Servo did not rotate the turret, just unlocked. I guess after we replace the plug we will try again, see what happens. If servo will not respond then that will be another adventure.

I will keep you posted on that one. And thank you for getting back to me.

P.S. For the previous comment about the parameter 13019 I do not really know how to change bits. I usually go in to maintenance screen and from there to parameter number and all I have is option to set the value, usually its a single number 0 or 1 or 2. In our case parameter 13019 is the frequency of the encoder we have it at 16348 or something like that.

[hemanth007]

Sorry, for the parameter number its 13017. But if u have revered polarity buy soldering wires its ok to use it the way you did.

Keep me updated when problem comes after u are done with replacing the turret Encoder connector.