Fadal
Manuals - Complete Documentation Resource
Spindle Drive - One
of the most common problems with a spindle drive running in the
Vector mode is caused by the spindle motor encoder. Missing encoder
pulses will basically confuse the drive and cause vector
miscalculations which result in too much current output to the
motor. One sign is that the load meter will usually "peg" or
pulsate. Another sign is the RPM will not be stable. Too
often the drive is misdiagnose as being "bad" when it's actually the
encoder causing the problem.
The
best method of testing is to use a oscilloscope to view the A/B
channels. Pulse errors can easily be detected. With our
new Baldor H2 drive, we simply switch the drive into open loop Inverter
mode and you can see the encoder RPM calculations changing
erratically with the drives diagnostics feature. With the
older Baldor drives, as you rotate the spindle, the drive keypad
will display the calulated rpm.
One simple way to manually test an encoder is by using a FLUKE meter, set it
to AC input. When checking from the encoder supply power common to one of the
A+,A-,B+,B- encoder signals on the spindle drive encoder input
terminal, you should
see approximately 2.8 VAC when turning the spindle at the
orientation speed. The digital pluses look like an AC voltage
to a FLUKE meter.
Another important way to test the encoder is by checking the state
of each channel. With a voltmeter in the DC setting, from
encoder supply power ground to the A+ encoder input, you should
measure either 0 or 3.5 VDC. The state is either high or low.
If A+ is high (3.5 volts) then the A- channel must be low; A+ and A-
can never be the same. The same logic goes for the B+ and B-
channels. If you rotate the spindle and let it stop, you'll
should see the states changing.
Spindle Drive Functional Diagram:
Link for more information about the Spindle Drive System and
possible failiures.
Testing Motor Encoders - A
simple way to test the motor encoder is by using the control
diagnostics.
At ENTER NEXT COMMAND enter the DI command then type G 0 3000 and
press ENTER to begin the diagnostics. They are menu driven and
easily navigated. Locate the function TEST ENCODERS (1010-4).
The display shows the encoder data for all the axis boards.
Press the Emergency Stop button and rotate the motor by turning the
Ballscrew. The counter will change if the encoder is sending
pulses. All the encoder ports are the same, so you can move
the connector to another board to verify that the board itself is
not a problem. The axis motors have one index pulse per
revolution, this is used only one time for the Cold Start procedure.
The spindle encoder does not have an index pulse.
To exit Diagnostics; you'll need to power off/on the machine.
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