00C8 ALM８８ SV ENC COM A servo encoder communication error was detected. 00C9
7. ABSOLUTE ENCODER
The motor detector of the TPC-Jr uses an absolute encoder that uses a lithium battery for backup.
If this lithium battery for backup has a problem, “ALM７５ SV ENC BU” (ABS encoder backup error) is given when the power of the TPC-Jr is turned on.
The battery is attached inside the motor cover of the rotary table. When the cannon plug for the motor detector is disconnected during maintenance or other purpose, the same alarm is given.
At this time setup the absolute encoder following the procedure below:
7-1. Absolute Encoder Explanation
The absolute encoder for the motor detector of the TPC-Jr remembers the current position as backup using a lithium battery. This lithium battery is in the rotary table.
Accordingly, even if the cable connecting the TPC-Jr and the rotary table is disconnected, the absolute encoder of the motor is backed up by the lithium battery inside the motor cover.
The connection diagram for the encoder in the rotary table is shown below:
7-2. Check
As shown in the connection diagram above, the lithium battery is attached to the 《B》 pin and the
《C》 pins for the cannon plug of the motor cable.
Remove the cannon plug on the rotary table side and measure the battery voltage using a tester.
When it is 3.2V or more, it is normal.
【Note】 Be careful not to make a short circuit with the lead rod of the tester.
7-3. Replacement
1) Remove the motor cover of the rotary table.
The lithium battery is attached inside this cover.
2) Remove the red and a black lead wires from the battery and remove the battery.
3) Connect the lead wires from the new lithium battery with solder.
Wind vinyl tape onto the connection to avoid making short circuits.
4) After replacing the lithium battery, setup of the absolute encoder and the first reference point is required.
▲ ▼
※ ER17500V/3.6V lithium battery by TOSHIBA is used.
Lithium batteries of rating 3.6V by other manufacturer can also be used.
Be careful of the life of the battery.
※ The life of the lithium battery being used is 10 years or more.
7-4. Setup of the Absolute Encoder and the First Reference Point
After replacing the lithium battery, setup of the absolute encoder and the first reference point is required. The procedure is shown below:
7-4-1. Setup of the absolute encoder 1) Turn on the TPC-Jr’s power.
Either alarm below is given.
・ “ALM７５ SV ENC BU” (ABS encoder backup error):
Follow the procedure starting 6) below.
・ “ALM９１ SV EC MTL” (ABS encoder multi-turn limit value does not match):
Follow the procedure starting 2) below.
2) Reset the alarm with the key, and select the program mode with the or key.
3) Select the parameter setting display screen with the and keys, and press the keys: , , , , , , to enable parameter change.
4) Re-enter Parameter 119: multi-turn limit value with the key.
5) Turn off the power and turn it on again. (“ALM９１ SV EC MTL” is indicated. Follow 6) below.）
6) Reset the alarm with the key, and select the program mode with the or key.
7) Select the parameter setting display screen with the and keys, and press the keys: , , , , , , to enable parameter change.
8) Press the and keys to show the absolute encoder reset display screen.
9) Press the key to reset the absolute encoder.
10) Turn off the power once and then, turn it on again to check that no alarm is given.
The setup is completed.
After the setup of the absolute encoder, the first reference point is required to be set.
For setting the first reference point, refer to “7-4-2. Setting the first reference point.”
【Note】 If no alarm is indicated, and you want only to reset the absolute encoder, follow the procedure above starting from 6).
Ｐａｒａｍｅｔｅｒ
ＡＢＳ Ｅｎｃｏｄｅｒ ｒｅｓｅｔ ？
９ 2ndF
１ ９
Ｎ ９ ９ θ CR
2ndF
CR
▲ ▼
▲ ▼
ZRN M
7-4-2. Setting the first reference point 1) Turn on the TPC-Jr power.
2) Select the JOG mode with the or key, and determine the first reference point using a dial gauge or other tool.
Determine the first reference point in the positive area. If it is set in the negative area, backlash compensation is made and the positioning may be inaccurate. (Except for a special case like a tilting-axis rotary table.)
3) Select the PROG mode with the or key.
4) Select the parameter setting display screen with the and key, and press the keys: ， ， ， ， ， ， to enable parameter change.
5) Press the and keys to display the first reference point setting display screen.
6) Press the key to memorize the first reference point.
7) Turn off the TPC-Jr power.
8) Turn on the power again, and execute return to the first reference point to check the position.
Ｐａｒａｍｅｔｅｒ ＭＺＲＮ Ｐｏｓｉｔｉｏｎ ｓｅｔ ？
8. MAINTENANCE
8-1. Opening & Closing the Top Cover of the TPC-Jr
1) To prevent receiving an electrical shock, turn off the TPC-Jr power, and remove the power plug for the CN1.
2) Remove the three small set screws ① on the rear of the TPC-Jr.
3) Remove the two small set screws ② and the one small set screw ③ on the side of the TPC-Jr.
4) Raise the whole cover to remove it.
※ To attach the cover, follow the procedure of removing in the reverse order.
■ Before opening the top cover of the TPC-Jr control unit, turn off the breaker on the switchboard, turn off the TPC-Jr power, and remove the CN1 (power connector).
！ WARNING
①
① ①
Position of the small set screws for the control unit cover
②
②
③
Main board assembly
Main board connector 8-2. Replacing the Main Board Assembly
If replacing the main board assembly is required because of a malfunction or other reasons, replace it following the procedure below:
1) Note all the parameters and programs.
2) Turn off the TPC-Jr’s power to prevent receiving an electrical shock, and remove the power connector for the CN1.
3) Open the top cover referring to Section “9-1. Opening/Closing the TPC-Jr Top Cover.”
4) Remove all the connectors (J1~J9) from the main board.
5) Remove the six small screws ① and remove the main board assembly.
6) Attach the new main board assembly.
7) Connect the connectors removed in 4) above.
8) Attach the top cover referring to Section “9-1. Opening/Closing the TPC-Jr Top Cover.”
9) Attach the power connector for the CN1, and turn the power on.
10) Enter the parameters and programs noted in 1) above, turn off the power once, then turn it on again.
11) Check each operation. Replacing the main board is completed.
【Note】 When making a note of the parameters, be sure to note the description of 《Parameter 200, 201》. These parameters are for the reference point offset for the absolute encoder.
！ CAUTION
① ① ①
① ① ①
Positions of small set screws for the main board assembly
■ Only an engineer or a fixer who has a special knowledge should replace the inner parts.
CR 8-3. Replacing the Servo Unit
If replacing the servo unit is required because of a malfunction, follow the procedure below:
1) Turn off the TPC-Jr’s power to prevent receiving an electrical shock, and remove the CN1 power connector.
2) Open the top cover following the procedure in “9-1. Opening/Closing the Top Cover of the TPC-Jr.”
3) Remove the connectors CN1~CN3 connected to the servo unit.
4) Remove the electrical cables from the servo unit terminal block.
The servo unit terminal block is a connector type. It can be removed easily.
The grounding wire is secured with a small screw. Use a cross-headed tip screwdriver to remove it.
5) Remove the two small screws ① that fix the servo unit on the rear side of the TPC-Jr, and remove the servo unit.
6) Attach the new servo unit and assemble the parts in the reverse order of disassembling.
7) Turn on the power.
8) Re-enter Parameters 100~199 by pressing the key, and turn the power off once, then, turn it on again.
9) Check each operation. Replacing the servo unit is complete.
※ An absolute encoder alarm may be given in the procedure 7) or 8) above. If the alarm is given, after entering the parameter in the procedure 8), setup the absolute encoder again.
Servo unit
Detail of connectors and terminal block
■ An engineer or a fixer who has a special knowledge should replace the inner parts.
！ CAUTION
① ①
Positions of the small set screws for servo unit
Position of the fan for G2
♦ APPENDIX
◆ OPERATION PANEL _______________________________________________ Appendix-2
◆ DISPLAY INDICATION EXAMPLE _____________________________________ Appendix-2
◆ TPC-Jr Operation__________________________________________________ Appendix-3
◆ PROGRAM CODES ________________________________________________ Appendix-5
◆ PARAMETERS ____________________________________________________ Appendix-7
◆ ALARMS________________________________________________________ Appendix-10
◆ DGN ADDRESSES ________________________________________________ Appendix-12
◆ OPERATION PANEL
◆ DISPLAY INDICATION EXAMPLE Program indication
The program of the TPC-Jr is indicated in two lines.
TPC-Jr status / work number indication
TPC-Jr status indication RDY/ALM
Work number indication W□□□□
Sub-program number indication S□□□□
Current position / remaining
amount indication POS/REM
Control indication
Return to the reference point indication MZRN/WZRN/TZRN
Over-travel indication OT
Machine lock indication MLK
File rewriting FILE
ST SP
Operation keys Program edit keys Operation mode indication LED / Switch
ZRNW
Function Mode Operation
Return to the
reference point S/M
: to the first reference point : to the second reference point
（Parameter setting/manual setting are possible.）
Operation start S/M Program 1 begins operation with the key.
Operation stop A/S/M key: stop key: re-start key: cancel Machine lock A/S ＋ keys: machine lock on/off
Jog feeding JOG While the or key is pressed, the rotary table moves in the direction of “;” or “-.“
Jog feedrate JOG Select the desired feedrate from 0 ~ 9 with the numeral keys.
Jog step feeding JOG A stroke on the or key conducts step feeding of the rotary table in the “+” or “-“ direction.
Jog step feeding
amount JOG After pressing the key, set the desirable angle with the numeral keys.
※ Program Edit operation
Function Mode Operation
Second function － Pressing the key makes the right bottom functions in small letters effective.
Work number
F0 means the fast feedrate, and F1~F9 mean cutting feedrate.
To enter the feedrate for F1~F9, press the and keys.
R code setting PROG
Press the key, and then, enter the R code with the numeric keys.
To set the repeat number of the R code, use the G code.
For detail, refer to “◆PROGRAM CODE.”
θ code setting PROG
Press the key, and then enter the positioning angle. To enter the decimal point, press the key.
By pressing the key, the sign can be changed.
Paragraph/
Save PROG To start a new paragraph of the program, press the key. In the PROG mode, the program is saved by this operation.
Screen scroll C/P While the or key is pressed, the program display scrolls up or down.
2ndF ６
※ Program Edit operation
Function Mode Operation
1-block insertion PROG
To insert one block, press the and keys. “Insert?” is displayed. Then, press the key.
1-block deletion PROG
To delete one block, press the and keys. “Delete?” is displayed. Then, press the key.
Directory
indication C/P
To display the registered work numbers and the specification block numbers, press the and keys.
The unused memory block number is shown at the end. (To see the next page, press the key.)
Program copy PROG
To copy the data in a unit of work number, press the and the keys.
Enter the work number to be copied and press the key.
Then, enter the work number of the copy destination and press the key to execute. To start copying, press the key.
Serial channel PROG
To store a program or a parameter in the external components, press the and the keys.
The program I/O components shall be prepared by the customer.
Feedrate setting PROG To enter the F1~F9 feedrate, press the and keys.
(In the CHECK mode, only confirmation is possible.) Parameter
setting PROG To set various system parameters, press the and keys.
(In the CHECK mode, only confirmation is possible.) User parameter
setting PROG
To set the data for various pitch error compensation or spot compensation, press the and keys.
(In the CHECK mode, only confirmation is possible.)
2ndF
+/-※ Other key operations
Function Mode Operation
Current position
To return to the display screen to the coordinate from the first reference point during the current position being indicated, press the and keys.
Program
indication A/S/M
To return to the display screen to the program indication while the current position or the remaining amount is being indicated, press the and keys.
Second reference point setting JOG
To set the second reference point, move to the desired position, press the and keys. “WZRN POS SET?” is indicated.
In the AUTO, SINGLE, or the MDI mode, only monitoring is possible.
In the CHECK or PROG mode, output signals can be controlled on/off.
Display contrast
adjustment CHECK To adjust the contrast of the LCD, press the and keys.
Adjust the contrast with the key and execute with the key.
Clear/reset To reset an alarm and each second function, or clear the current value, press the key.
◆ PROGRAM CODES
※ PROGRAM CODE W code
Work number (Program number) Setting range：0000~9999
(Up to 100-work numbers can be registered.) N code Block number
Setting range：000~999 G code Operation executing command
G0~G4: Operation command G5~G9: Auxiliary command F code Feedrate selection command
F0: Fast feedrate F1~F9: Cutting feedrate R code Auxiliary command for the G code
θ code Movement amount command
Commanded angle/indexing point number, etc.
※ G0~G4: Operation command
Indexing point number on a circle (360°)
±000001～±999999div G2:
Arc-indexing point number command
Indexing point number and number of repetition
Number of rotary table revolutions 000～045
(360°×R)
Angle commanded
±000.000°～±360.000°
(The total amount of movement is 360°×
R +θ)
G4:
Reference point return command
000: Return to the first reference point
001: Return to the second reference point
002: Return to the third reference point
Not required.
※ G5~G9: Auxiliary command
G code R code θ code
G5: Subprogram call command
return command Not required Not required
G7: Program end
command Not required Branch destination
000～999 G8: Declaration
command Not required Reference coordinate
±000.000°～±360.000°
000: No operations Not required
001: Clamp OFF Not required
002: Clamp ON Not required
003: Dwell OFF Not required
004: Dwell ON Dwell time
001～999 (×10ms) 005: Indexing group control OFF Not required 006: Indexing group control ON Not required 007: One-directional positioning OFF Not required 008: One-directional positioning ON Not required 009: Completion signal control OFF Not required
010: Completion signal control ON Completion signal selection 0 1 1
FIN1 FIN2 011: Program display switch Not required
012: Current position display switch command
＋Current position reset command
Not required G9: Declaration
command
013: Remaining angle display command Not required
◆ PARAMETERS Parameter
address Parameter Change Standard value Factory-set
value 000 System parameter function selection 1 ON 00000000
001 System parameter function selection 2 OFF 00000000 002 System parameter function selection 3 OFF 00000000
003 Reserved - 00000000
004 System parameter function selection 5 ON 00000000
005 Reserved - 00000000
010 Work number called at power ON ON 0
011 Block number called at power ON. ON 0
012 Default feeding speed by jog operation ON 1 013 Default feeding amount by jog step
operation
ON 1 020 Selection of extended functions OFF 00000000
021 Selection of stop/interlock input functions OFF 00000000 022 Selection of a/b contacts for external output signal OFF 00000000 023 Selection of external output signal ON 00000000 030 Pulse width for output signal 1 (FIN1) ON 50 031 Pulse width for output signal 2 (FIN2) ON 50 034 Original position signal output range 1 ON 0 035 Original position signal output range 2 ON 0
036 Reserved - 0
037 Reserved - 0
038 Delayed time for reading B signal input ON 0
039 Contrast data ON 8
040 Selection of serial channel code ON 00000000 041 Selection of serial channel remote mode OFF 00000000 042 Selection of serial channel control ON 00000000 043 Selection of serial channel operation ON 00000000
050 Serial channel baud rate ON 4800
Parameter
address Parameter Change Standard value Factory-set
value 100 Servo specification selection 1 OFF 00000010
101 Servo specification selection 2 OFF 00000000 102 Servo specification selection 3 OFF 00000000 103 Servo specification selection 4 OFF 00000002 104 Servo specification selection 5 OFF 00000110
105 Reserved - 00000000
106 Reserved - 00000000
110 Position loop gain ON 60
111 Speed loop gain ON 60
112 Speed loop integral time constant ON 1000
113 Load inertia ratio ON 0
114 Speed bias ON 0
115 Speed bias summing width ON 7
116 Total reduction ratio OFF 60
117 Numerator of electronic gear ratio OFF 1500 118 Denominator of electronic gear ratio OFF 16384
119 Multi-turn limit OFF 59
120 Positioning completion range ON 10
121 Over-flow level for positioning deviation counter
ON 40
122 Maximum motor feedrate ON 3000
123 Acceleration/deceleration time ON 200
124 Reserved - 0 132 Over-travelling amount during
one-directional positioning
137 Clamping/unclamping completion time-out ON 20
138 Reserved - 0
139 Reserved - 0
150 Servo specification selection 6 OFF 00000000 151 Servo specification selection 7 OFF 00000004 152 Servo specification selection 8 OFF 00000000
Parameter
address Parameter Change Standard value Factory-set
value
160 2nd position loop gain ON 40
161 2nd speed loop gain ON 40
162 2nd speed loop integral time constant ON 2000
163 Feed forward gain ON 0
164 Feed forward filter time constant ON 0
165 Mode switch operation level:
Torque command
ON 200 166 Mode switch operation level:
Speed command
ON 3000 167 Mode switch operation level:
Acceleration
ON 0 168 Mode switch operation level:
Deviation pulse
ON 0
169 Speed feedback compensation ON 100
170 Torque command filter ON 100
171 Torque limit in forward operation ON 800
172 Torque limit in reverse operation ON 800
173 Emergency stop torque ON 800
174 Operation retaining time at instantaneous power failure
ON 20
175 Regenerative resistance capacity OFF 0
176 Notch filter switch ON 0
177 Notch filter frequency ON 2000
178 Reserved - 0
179 Reserved - 0
200 Offset amount for an absolute encoder
（ABSRN)
OFF (auto-set) 201 Offset amount for an absolute encoder
（ABSPS)
OFF (auto-set)
◆ ALARMS 1) Program alarms
Alarm
number Alarm message Explanation
ALM１ PS N Program syntax error. The N code is invalid.
ALM２ PS G Program syntax error. The G code is invalid.
ALM３ PS F Program syntax error. The F code is invalid.
ALM４ PS R Program syntax error. The R code is invalid.
ALM５ PSθ Program syntax error. Theθcode is invalid.
ALM６ Nest error An attempt was made to call subprograms nested at nine levels or more.
Alternatively, there is no destination to which a subprogram returns.
ALM７ No sub prg There is no subprogram to be called.
ALM８ Loop over An attempt was made to execute 20 blocks or more using G5 to G9.
ALM９ W No error An attempt was made to set a work number jump, or block number, but there is no work or block number to be called.
ALM１０ No program A program is not entered for the specified work number ALM１１ Buff full Program edit RAM is full.
ALM１２ File full The program file area is full.
ALM１３ Dir full The program directory is full.
ALM１５ Copy err 1 The work number (program) to be copied could not be found.
ALM１６ Copy err 2 A work number (program) is already present at the copy destination.
ALM１８ CL time out Timeout occurs in clamping/Unclamping confirmation completion ALM１９ W protected Programs are write-protected.
2) Serial channel alarms Alarm
number Message Explanation
ALM２０ Format err The program entered over the general serial channel is in an invalid format.
ALM３０ SV Rx PE Parity error during reception at the servo channel ALM３１ SV RX FE Framing error during reception at the servo channel ALM３２ SV Rx OR Overrun error during reception at the servo channel ALM３３ SV Rx FULL The buffer is full during reception at the servo channel.
ALM３４ SV Tx/Rx Reception error on the servo side ALM３５ SV Address Address error on the servo side ALM３６ SV Data Data error on the servo side ALM３７ SV Retry Re-sending error on the servo side
ALM４０ SCH Rx PE Parity error during reception at the general-purpose serial channel ALM４１ SCH Rx FE Framing error during reception at the general-purpose channel ALM４２ SCH Rx OR Overrun error during reception at the general-purpose channel ALM４３ SCH Rx FULL The buffer is full during reception at the general-purpose channel.
ALM４６ SCH CMD Err Command error during reception in the remote mode ALM４７ SCH DATA Err Data error during reception in the remote mode
ALM４６ SCH CMD Err Command error during reception in the remote mode ALM４７ SCH DATA Err Data error during reception in the remote mode