ARES SEIKI R450 WITH MELDAS 64M CONTROLLER FREEZING RANDOMLY

[aaroncswenson]

Hey everyone,
Having a problem with this machine freezing up randomly during regular program operation. No specific line or time, just freezes in whatever position it's at, and the spindle winds down. The control still shows spindle at programmed speed, and it's frozen at the line it stopped at. Also, I cannot reset program with the reset button, just have to shut down completely. Shutting down the machine completely, and restarting does fine. It boots up, can select the program and try to run it again, but it just happens again at some random point a few minutes into the program. Thinking it's a processor error, but unsure how to check. Any help would greatly appreciated.

[Al_The_Man]

A long shot is it could be the At-Speed or up-to-speed relay, when you program a move with a spindle command, the move waits for the up-to-speed signal from the drive.
This kind of fault may not show any outward signs of failure, therefore no alarm?
It it could be something in the drive itself shutting it down and hence the relay drops out.
I suspect a processor fault would give you an alarm?
Al.

[underthetire]

I've had 3 mori seikis with the m64 loose CPU boards. All had very random symptoms, but all showed up in spindle errors. They were all mills as well.

[aaroncswenson]

Hey all,
I appreciate the quick replies. I would head the direction of the spindle-at-speed relay, but the controller is what is freezing. I can't change menus, access diagnostics, anything. I have to shut the controller off completely and turn it back on to resume operation. When it freezes, it can be anywhere, including the middle of a cut, and the axis movement stops, the spindle winds down to a stop, yet the controller still shows the spindle at the programmed speed, as well as the spindle load before it froze. The cursor still blinks at the line it froze during operation, but no buttons work on the controller to reset the program, switch to diagnostics, anything. Only the power off button works at that point. I know the boards are all securely attached so I don't think a loose connection is the problem either, and I'm not getting any alarms, just locking up completely. I don't know anyone around here who services this machine either, so I'm kind of at a loss. Anyway, thanks again for the replies.

[camsys]

I've noticed this behavior on controllers that have a bad spot in memory.

Mitsubishi would service the controller and drives (Mitsubishi Electric Automation Inc. - MEAU Home)

[onthebumper]

It's probably a problem with the CPU card. Unfortunately it is one of the harder boards to change because it also contains the memory (Params, Programs, Tool Data, Ladder, Software....). Take a look at the control in the back of the machine. There is a single seven segment display. In a normal condition it should be flashing. If it is a solid number or symbol and does not change then more then likely the CPU card is bad.

Since the control is working at the moment I would take the time to make sure you back up everything including parameters and ladder (99 maintenance data, ALL1, ALL2, and ALL3).

[girishdk]

Hi,

If it is M64M, believe it has the HR113 CPU board, check if the WDER red LED glows during this problem. It is on the right hand side of the 7-segment display, in the bottom side of the CNC unit.
In this case, it could be the problem with the buffer ICs, need to contact Mitsubishi Service for repair or replacement of HR113 card.

Best Regards,
Girish

[aaroncswenson]

Hey all,
Appreciate all of the replies. It does glow the WDER light when the freezing occurs. It has also taken to throwing a coolant/magazine motor overload alarm upon startup and not allowing any type of program operation, but all handle operation works, and then it will freeze after sitting for a short time and have to be shut down. Guess i have to contact Mitsubishi at this point. Again, I appreciate all the helpful replies.