[MITYDR]

I have an orientation problem I hope I can get help with.

The machine is a 1996 TV-3O with a 8O2 (5Om) control, 10 tool drum.
When M19 (or M192) is input, the spindle spins at 2495rpm, until reset.
M3, M4 and M5 all work fine. I have checked the clamp sensor on top
of the spindle, traced it's wire to the back and it is plugged in and working.
I went to the spindle motor and checked all connections there. Bumped
them all loose and re-tightened just to make sure. Checked all cable / wires
between motor and drive, they all seem fine.

The motor is a SJ-PL7.5-04 with internal encoder MBE1024-3-T(A).

I am new to this machine, this control. I have some literature but no factory
ladder or wire diagram. I do have the parameters and have set-up communication
to / from the machine. The orientation aparrently worked correctly before
I got this machine. I ran tool changes and spindle rpms at the place I picked
it up, with tools in and out of the spindle. Also, apparently, tools must be in the
spindle when running it. After getting it to where it's at, it no longer orientated
to the correct position and one of the tools in the drum was not orientated?

What happened mechanically with no tools in the spindle, the washer on top
was touching the push-down bolts for tool un-clamp. So spindle on, (with no tool),
washer gets caught after a bit and spins up, pushes pullstud mechanisms down
into spindle. This locked the spindle up to a rate that was not turnable by hand.
Got the washer backed off. Got all the things back in place. Spindle would
orientate but in random positions (like it was doing when I first hooked it up).
I tried adjusting the washer rotation thinking that the switches near it were for
orientation. It had no effect. Spindle was still just doing random positions.
Then it settled on straight 90 deg from where it should be. I shut things down
for the night. Went to check parameters to see if I could adjust this position.
Next day put washer back down tight against the lock nut. Adjusted the push
down screws that push on the washer (they were now exactly where they were
to start with. And now I get the spindle run away.

I've tried to put the washer back. no effect.
Returned it to it's position. still the same.
This makes it so I cant home to Z 2nd home or home the tool changer. Means no worky.

I called Mitsubishi and the tech there thinks it is the encoder. Actually, they suggested
a new motor? lol. He said a new encoder was 750 and it needs installed with a scope.
Or I can send the motor in and have it installed and why not have the whole thing rebuilt?

That's why I think I need to do more checking elsewhere.

I think the motor is fine. I also think the encoder may be ok, but not sure.
The motor has either been out or serviced before. I can tell because one
of the wire screws were almost stripped. The date on the encoder is 1995.

I know this is a ton of information. Someone told me to go into detail. Nuff said?

Please help if you can.

What bit can I look at to see if the encoder is giving a pulse?
What possibly could be switched on in the ladder that could be wrong?

[Al_The_Man]

Are you sure there is not an encoder on the actual spindle?
That is where the orient is done?
There is usually a pulse generator on the motor back to the drive and the spindle encoder back to the controller, then a grid shift parameter is used to orient to exact position.
Al.

[MITYDR]

Thanks Al,
Yes the encoder is on the top of the motor.
I'm wondering if the Z-pulse is there or not.
Mitsubishi is calling me back with bit that should
change with rotating the spindle by hand. The pdf
manual has a bit but that one may not be correct
because there is another machine I can check against
and it's number doesnt change either.

[MITYDR]

Also,
on the DIAG IN/OUT (SPINDLE MONITER) page;
If I do rotate the spindle by hand the speed is fed back to the (rpm)
with even very light movements. (that's why I think encoder may be ok.)

[underthetire]

Rpm is calculated by the A B phase of the encoder, z phase is the 1 rev count. I don't have much of my TV 30 stuff any longer but I can dig through and see what's left. Just be thankful its not the TV400!

I'm guessing it's the z phase of the encoder, really need to put a scope on it before spending lots of money in parts.

[MITYDR]

Thanks underthetire,
Also, I was just trying to move it around in z and reset Z zero at Z zero. Just in case somethings messed up with the position interferance. I had to move machine to the very top to access the back panel of the motor earlier. Was wonding if I missed a step getting it back down ito regular movement area and that was interlocking something.
Anyway, I tried M19 again (still not working)

I got an alarm M01 OPERATION ERROR 0004 Z

I have an incomplete alarm list. Know what that is?

[Al_The_Man]

According to the manual, M01 0004 "external interlock has been activated" in this case for the Z?
It sounds like it does not see Z in the right place for the Sp. orient?
Al.

[underthetire]

It won't allow spindle movement above ATC height since its a drum AtC. Did you change the Z reference position in the ABS servo page?

[MITYDR]

I did the Y1C2 to get the machine up to take the cover off the motor to check the wiring. I powered the machine off in a Z +5.000 position and logged the distance to the table. After checking the connections. Powered back up and brought it back down to zero. The (M19) still in run away mode as before I started). I reset Z0 at Z zero per mitsubishi tech. I must mention, the positions show in inches. Input is in metric.

[MITYDR]

Nothing Zero returns now. 1st or 2nd home. No alarms?

[MITYDR]

Also, the position page shows in inches (work offset, machine position, dist to go) but the tool offsets have omly 3 decimal places and the work offset page, the decimal place is off one position (Y-6.235 would be entered as Y-62.35).

So....

The orientation is a issue but there are others.