Okuma Manuals 2771

Document number: AC-1587 (V3.
0)
SPINDLE DRIVE UNIT

MAINTENANCE MANUAL VAC5 (3rd Edition)
Pub No. 5603-E-R1 (SE41-075-R2) Sep. 2010
Approved Checked Checked Checked Checked Prepared

AC-1587 V3.0
Table of Contents
Revision History
Date of Applicable
Version Description
revision section
1st (V1.0) 2008.08.18 Newly created All
(1) Descriptions added for maintenance unit

used for conventional units (see below).
• VAC3-D11
• VAC4-D11
• VAC1-D3 to D11
• VAC2-D3 to D11
2nd (V2.0) 2009.07.20 All
(2) Clerical error corrected
(3) Changes made to unit names, etc.

• “VAC V”→”VAC5”
• “VAC IV”→”VAC4”
• “VAC III”→”VAC3”
(1) Corrections made following completion

of development of units below
• VAC5-D22-AIF
• VAC5-D30-AIF
• VAC5-D22
3rd (V3.0) 2010.05.27 All
(2) Corrections made to alarm no. table
(3) Changes made to unit names, etc.

• VAC5-D30→VAC5-D22
This manual discloses certain specifications (external drawings, external dimensions)

relating to units that are currently under development. Information indicated as being
“under development” should be used for reference purposes.
Units currently under development:
• VAC5-D6 (with EX card C1)
• Changes may be made to the specifications without prior notice following unit imp
rovements.
AC-1587 V3.0
Revision History
SAFETY PRECAUTIONS
The control system that is explained in this manual contains various electric components
and units. Please read this manual thoroughly and understand the electric wiring among
the electric components, units, and power supply to avoid unexpected bodily injuries and
malfunction or burnout of the electric components and units.
(1) Always turn off all the power supplies and discharge the electric charge
remaining inside the system before connecting or disconnecting the units.
Failure to follow this instruction may result in electric shock or other bodily injury
as well as malfunction or burnout of the units.
(2) Check the specifications of the power supply to be connected to the units.
Incorrect voltage or electrical polarity may cause unit malfunction or burnout.
(3) Check the inlet connections and outlet connections of all the units. Incorrect
connection may cause unit malfunction or burnout.
(4) Always connect the earth wires as well as the PE wires for the magnetic power
cabinet. Failure to follow this instruction may result in electric shock or other
bodily injury due to an earth leakage.
(5) Set the overcurrent protective device such as circuit breakers or fuses. Failure to
follow this instruction may result in fire or burnout of cables and units due to a
short circuit.
(6) If you make the cables to connect the units by yourself, always use the cable of
the size appropriate for load current especially for power cables. Insufficient
current capacity may cause a fire or burnout of the cables due to overheating.
(7) Select the dust-repellent water-proof type of magnetic power cabinet or control
box that houses various units. Dust or water may cause electric shock or other
bodily injury as well as the unit malfunction or burnout.
(8) Always use thermostats which are built-in the motors and units to protect the
mechanical device. Failure to follow this instruction may cause a fire or units
burnout.
Following caution signs are used in this manual to draw attention to information of
particular importance.
This sign is to indicate an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This sign is to indicate a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This sign is to indicate a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury or property damages.
This sign is to indicate general instructions for safe operation.
Keep this manual handy for reference.

Information in this document is subject to change without notice due to constant
improvements.
AC-1587 V3.0
Table of Contents
Table of Contents
SAFETY PRECAUTIONS
SECTION 1 INTRODUCTION 1
SECTION 2 CONFIGURATION AND CONNECTION 2

1. Configuration...................................................................................................... 2
2. Connection ....................................................................................................... 10
2-1. General connection diagram ...................................................................... 10
(1) When using VAC1 system ................................................................... 10
(4) When using externally sold system...................................................... 13
2-2. Connection diagram (standard type) ........................................................ 14

2-3. Connection diagram (winding changeover type) ...................................... 18

2-4. Spindle motor connection diagram............................................................. 21

(1) When a 16-pin universal MATE-N-LOK connector is used.................. 21
(2) When a 10-pin universal MATE-N-LOK connector is used.................. 22
(3) When a 9-pin universal MATE-N-LOK connector is used.................... 23
(4) When a dynamic connector is used ..................................................... 24
2-5. Encoder and connection diagram .............................................................. 25

(1) Analog magnetic type encoder connection diagram............................ 25
(2) Optical pulse generator........................................................................ 26
2-6. I/O control circuit connection diagram........................................................ 27

2-7. NC unit connection diagram....................................................................... 31

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AC-1587 V3.0
Table of Contents
Table of Contents
SECTION 3 OPERATION STATUS DISPLAY.............................................................. 35

1. Display variations until operation preparations are completed ........................ 37
2. Display in normal operation mode (control mode) ......................................... 38
3. Display in normal operation mode (winding status) ....................................... 39
4. Display in error status mode ............................................................................ 40
SECTION 4 TROUBLESHOOTING............................................................................... 41
1. Check points .................................................................................................... 41
2. Errors and their classifications ......................................................................... 42

2-1. Seven-segment LED display does not light. .......................................... 43
2-2. Seven-segment LED display is indicating an error. ............................... 44
2-3. The motor hunts ....................................................................................... 58
2-4. The motor does not run at the specified speed,
or the motor does not rotate. ................................................................. 59
2-5. The cutting force has dropped. .............................................................. 60
2-6. The acceleration or deceleration time has increased. ........................... 61
2-7. Vibration or noise is strong when the motor is running. ......................... 62
2-8. The motor decelerates suddenly and stops
even although no alarm has occurred. .................................................. 63
3. Recovery from errors ....................................................................................... 64
SECTION 5 MAINTENANCE AND INSPECTIONS ...................................................... 65

1. Maintenance tools ............................................................................................ 65
2. Procedures for inspecting and replacing fuses................................................ 66
3. Procedures for replacing the whole drive unit.................................................. 67
4. Procedures for inspecting the optical fiber cable
(only when using VAC2, VAC3 system) ........................................................ 68
5. Procedures for conducting a trial run ............................................................... 69
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AC-1587 V3.0
Table of Contents
Table of Contents
APPENDIX 1 FILES STORED ON CONTROL FLOPPY DISK ..................................... 70
APPENDIX 2 DESCRIPTION OF MONITOR TERMINALS........................................... 71

1. Monitor terminal layout ................................................................................... 71
2. Description of monitor terminal signals ............................................................ 73
APPENDIX 3 SWITCH AND VOLUME SETTINGS....................................................... 74
APPENDIX 4 SWITCH AND VOLUME SETTINGS IF USING EX CARD ..................... 77
APPENDIX 5 APPEARANCE AND WEIGHT OF UNIT................................................. 78
APPENDIX 6 IDENTIFICATION OF FIRMWARE VERSION ........................................ 85
APPENDIX 7 COMPATIBILITY TABLE ......................................................................... 88

1. When using VAC1 system ............................................................................... 88
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AC-1587 V3.0
SECTION 1 INTRODUCTION
SECTION 1 INTRODUCTION
This instruction manual describes how to maintain and inspect maintenance units
(VAC1, VAC2, VAC3, VAC4) for spindle drive units (VAC5).
Correspondences between conventional and maintenance units are shown in the
table below.
Table 1-1 Conventional units and maintenance units

Maintenance
Conventional unit Remarks
unit
VAC1-D3
VAC1-D6
VAC1-D8
VAC1-D6A
VAC5-D8-AIF *1)
VAC1-D8A
VAC1-D3B
VAC1-D6B
Analog VAC1-D8B
interface
VAC1-D11
VAC1-D11A VAC5-D11-AIF
VAC1-D11B
VAC1-D22A
VAC5-D22-AIF
VAC1-D22B
VAC1-D30A
VAC5-D30-AIF
VAC1-D30B
VAC2-D6A
VAC2-D8A
VAC5-D8-AIF *2)
VAC2-D6B
VAC2-D8B
VAC2-D11A
VAC5-D11-AIF
VAC2-D11B
VAC2-D22A
VAC5-D22-AIF
VAC2-D22B
Optical
interface VAC2-D30A
VAC5-D30-AIF
VAC2-D30B
VAC3-D6
VAC5-D6
VAC4-D6
VAC3-D11
VAC5-D11
VAC4-D11
VAC3-D22
VAC5-D22
VAC4-D22
*1) Capacities D3 to D8, D6A to D8A, and D6B to D8B for conventional unit VAC1
have been integrated into the corresponding maintenance unit VAC5-D8-AIF. All
capacities are specified by setting the switches on the unit. Refer to Appendix 3
for further details.
*2) Capacities D6A to D8A and D6B to D8B for conventional unit VAC2 have been
integrated into the corresponding maintenance unit VAC5-D8-AIF. All capacities
are specified by setting the switches on the unit. Refer to Appendix 3 for further
details.
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AC-1587 V3.0
SECTION 2 CONFIGURATION AND CONNECTION

1. Configuration
There are two types of VAC5 drive unit, an analog interface unit and an optical
interface unit, with the type dependent on the command form from the NC unit. Each
drive unit consists of a control PCB and power unit, and the product line is structured
as shown in the table below.
Analog interface unit type
Optical interface unit type
Table 2-1 VAC5 product line structure

Product code Product name Description Remarks
Reworked version of
U1216-0006-003-10 VAC5-D8-AIF
VAC1/II-D3/6/8A
Reworked version of
U1221-0006-003-10 VAC5-D11-AIF
Analog VAC1/II-D11A
interface Reworked version of
U1231-0006-003-10 VAC5-D22-AIF
VAC1/II-D22A
Reworked version of
U1236-0006-003-10 VAC5-D30-AIF
VAC1/II-D30A
Reworked version of
U1212-0006-001-12 VAC5-D6
VAC3-D6
Optical Reworked version of
U1222-0006-001-12 VAC5-D11
interface VAC3-D11
Reworked version of
U1233-0006-001-12 VAC5-D22
VAC3-D22
Fig. 2-2 VAC5 with extra cards (EX cards) product line structure
Product code Product name Description Remarks
Reworked version of
VAC5-D6 Under
TBD VAC3-D6
with EX card C1 development
with EX card C1
Reworked version of
Analog VAC5-D11 Under
TBD VAC3-D11
interface with EX card C1 development
with EX card C1
Reworked version of
VAC5-D30 Under
TBD VAC3-D22
with EX card C1 development
with EX card C1
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AC-1587 V3.0
*1) Wires can be connected to the terminal blocks ([EM2, EM1] and [STB2, STB1]) by removing the front cover
of the unit.
Fig 2-1. VAC5-D8-AIF Connector layout
of the unit.
Fig 2-2. VAC5--D11-AIF Connector layout
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*1) Wires can be connected to the terminal blocks (EM2 and EM1) by removing the front cover of the unit.
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Fig 2-5. VAC5-D6 Connector layout
of the unit.
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Under
development
(Reference)
Fig 2-8. VAC5-D6 (with EX card C1) Connector layout
Under
development
(Reference)
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Under
development
(Reference)
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2. Connection
2-1. General connection diagram
(1) When using VAC1 system

If using the VAC5 analog interface unit for the VAC1 system (analog interface),
connection for the entire unit will be as shown in the following diagram.
Fig 2-11. Complete connection diagram when using VAC1 system
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AC-1587 V3.0

If using the VAC5 analog interface unit for the VAC2 system (optical interface),
*1) For a built-in motor, no resolver is used.

*2) For a built-in motor, no fan motor is used.
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AC-1587 V3.0

If using the VAC5 optical interface unit for the VAC3 system (optical interface),

*3) Connector name when VAC5-D6 unit
*4) Connector name when VAC5-D11, VAC5-D22 unit
*5) Control print board name when VAC5-D6 unit
*6) Control print board name when VAC5-D11, VAC5-D22 unit
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(4) When using externally sold system

If using the VAC5 unit (with EX card C1) for an externally sold system,

*3) Connector name when VAC5-D6 unit (with EX card C1)
*4) Connector name when VAC5-D11, VAC5-D30 unit (both with EX card C1)
*5) Control print board name when VAC5-D6 unit (with EX card C1)
*6) Control print board name when VAC5-D11, VAC5-D30 unit (both with EX card C1)
Fig 2-14. Complete connection diagram when using externally sold system
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2-2. Connection diagram (standard type)

connection for the unit will be as shown in the following detailed diagram.
Fig 2-15. Detailed connection diagram when using VAC1 system (standard type)
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*3) Connection varies between the standard type and winding changeover type.
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Fig 2-18. Detailed connection diagram when using externally sold system (standard type)
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2-3. Connection diagram (winding changeover type)

winding connection will be as shown in the following detailed diagram.
Fig 2-19. Detailed connection diagram when using VAC1 system

(winding changeover type)
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2-4. Spindle motor connection diagram
(1) (When a 16-pin universal MATE-N-LOK connector is used)
OKUMA Part No. Type Maker

Connector E3702-791-010 MRP-20F01 Honda Tsushin
(A)
Contact E3761-791-001 MRPF102 Kogyo
Connector E3701-082-005 1-480438-0 Tyco
(B) Electronics
Contact E3761-082-001 61314-6 AMP

*3) Depending on the machine specifications, an intermediate terminal (intermediate connector) may be present
in the wiring.
Fig 2-22 Spindle motor connection diagram

(When a 16-pin universal MATE-N-LOK connector is used)
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AC-1587 V3.0
(2) When a 10-pin universal MATE-N-LOK connector is used

(A)
Connector E3701-082-059 1-480285-0 Tyco
(B) Electronics
Contact E3761-082-001 61314-6 AMP
in the wiring.

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AC-1587 V3.0
(3) When a 9-pin universal MATE-N-LOK connector is used

(A)
Connector E3703-082-010 350720-1 Tyco

(B) Electronics
Contact E3708-082-164 350689-7 AMP

in the wiring.

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AC-1587 V3.0
(4) When a dynamic connector is used

(A)
Connector E3702-082-040 178289-5 Tyco
(B) Electronics
Contact E3708-082-178 1-175217-2 AMP
in the wiring.
Fig 2-25 Spindle motor connection diagram (When a dynamic connector is used)
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2-5. Encoder and connection diagram
(1) Analog magnetic type encoder connection diagram

(A)
in the wiring.
Fig 2-26. Analog magnetic type encoder connection diagram
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(2) Optical pulse generator

(A)
(B) Connector E3702-701-003 RM15WTP-8S Hirose Electric
in the wiring.
Fig 2-27 Optical pulse generator
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2-6. I/O control circuit connection diagram


(A)
*1) winding changeover type only
Fig 2-28. Connection diagram for I/O control circuit when using VAC1 system
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AC-1587 V3.0

(A)
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(A)
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(A)
Fig 2-31. Connection diagram for I/O control circuit when using externally sold system
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2-7. NC unit connection diagram

Connector E3702-791-010 MRP-20F01
(A)
Contact E3761-791-001 MRPF102 Honda Tsushin
Kogyo
Connector E3702-791-012 MRP-50F01
(B)
Contact E3761-791-001 MRPF102
Fig 2-32. Connection diagram when using VAC1 system
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AC-1587 V3.0

(A)
Kogyo
Contact E3761-791-001 MRPF102
Fig 2-35. Connection diagram when using externally sold system
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AC-1587 V3.0
SECTION 3 OPERATION STATUS DISPLAY
The VAC5 drive unit displays operation/error status on the seven-segment LED
displays (green) on its front face. LED display has two display modes: normal
operation mode and error status mode. In the latter mode, the cause of a pending
alarm can be estimated from the displayed error number.
VAC5 drive units with firmware VAC4113 or a later version* installed are capable of
displaying both control and winding statuses in normal operation mode. For
instructions about how to identify the firmware version, see Appendix 6.
A lit LED; DC CHARGE (Orange) on the front face of the unit indicates that the main
circuit (high-voltage portion) is charged.
*This also applies to firmware version VAC5100 and later.
(1) Seven-segment LED (green)

(2) DC charge LED (orange)
Fig 3-1 VAC5 unit status indicator LED allocation
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AC-1587 V3.0
With the VAC5 unit (with EX card C1), however, LEDs EX1 to EX6 (green) are used
in addition to the seven-segment LED and DC charge LED described on the
previous page to indicate the sequence status during spindle home position
stoppage.
Under Under
development development
Under
(Reference) (Reference) development
(Reference)
(1) Seven-segment LED (green)

(2) DC charge LED (orange)
(3) LED EX1 to EX6 (green)
Fig 3-2 VAC5 unit status indicator LED allocation
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AC-1587 V3.0
1. Display variations until operation preparations are completed

Table 3-1. Display variations until operation preparations are completed
Firmware version Firmware version
VAC4112 or earlier version VAC4113 or later version
Before
turning on
the power
Just after the

power is
turned on
When the
NC unit is
launched
During the
charging of
the main
circuit
Operation
preparations
completed
With the VAC1 system, however, “01” will change to “02” immediately after
turning ON the power.
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AC-1587 V3.0
2. Display in normal operation mode (Control mode)

Control modes include spindle control mode, spindle/C-axis switching mode, and
C-axis control mode. The control status in each of these modes is displayed on the
left seven-segment LED display.
On a winding changeover type, the right seven-segment LED displays a winding
changeover command and a winding status. In the case of a standard type, it is kept
unlit. For further information, see Section 3.
This display function is available with firmware VAC4113 or a later version.
Table 3-2. Display in the normal operation mode (control mode)

Display on the
seven-segment LED Remarks
display
- When the spindle is at rest,
When a zero
“02” is displayed.
rotation
command is
issued
- During acceleration or
deceleration, the “03”
When a CW display flashes.
rotation
command is - When the spindle rotates at
issued a constant speed, “03”
stops flashing and remains
lit.
- During acceleration or
deceleration, the “04”
When a CCW display flashes.
rotation
command is - When the spindle rotates at
issued a constant speed, “04”
stops flashing and remains
lit.
When an
indexing
command is
issued
- When the mode is shifted

from the spindle control
mode to the C-axis control
When a C-axis mode, the “06” display
control starts flashing.
command is
issued - After the NC enters the
C-axis control mode, the
“06” display stops flashing
and remains lit.
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3. Display in normal operation mode (Winding status)

On a winding changeover type, the right seven-segment LED displays a winding
changeover command and a winding status. In the case of a standard type, it is kept
unlit. Shown below are the seven-segment display variations in conjunction with a
winding changeover command.
The left seven-segment LED display indicates the control status of the control mode.
For further information, see Section 2.
This display function is available with firmware VAC4113 or a later version.
Table 3-3. Display variations for a winding changeover command

(low speed high speed)
Display on the
Remarks
seven-segment LED display
- “H” is displayed on the
command indicator
During winding seven-segment LED
changeover display.
(low speed
high speed) - The entire status
indicator seven-segment
LED display flashes.
- When changing to the
high-speed winding is
When winding completed, the status
changeover is indicator seven-segment
completed LED display stops
flashing, and illuminates
the solid “H”.
Table 3-4. Display variations for a winding changeover command

(high speed low speed)
Display on the
Remarks
- “L” is displayed on the
During winding command indicator
seven-segment display.
changeover
(high speed
- The entire status
low speed) indicator seven-segment
LED display flashes.
- When changing to a
low-speed winding is
When winding completed, the status
changeover is indicator seven-segment
completed LED display stops
flashing and illuminates
the solid “L”.
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4. Display in error status mode

The left seven-segment LED display indicates “AL” standing for an alarm, and the
right one shows the alarm number.
Table 3-5. Display in the error status mode

Display on the
Remarks
- For alarm numbers and
Location of the their descriptions, see
alarm is 2-2 in Section 2.
displayed.
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AC-1587 V3.0
SECTION 4 TROUBLESHOOTING
Troubleshooting is described in the subsections 1 and 2, and procedures for

recovery from errors are shown in the subsection 3.
Do not touch the high-voltage portions. They are dangerous.

Before inspecting or repairing the power unit, record the codes indicated on the
seven-segment LED display.
Then, turn off the power and make sure that the DC CHARGE LED is turned off
before inspecting or repairing the power unit.
1. Check points
Before taking actions described in the subsection 2, check the points in the following
table.
Table 4-1. Check points

Checkpoint Check method Action
Power-supply voltage Verify that the input power-supply Adjust the input
voltage is within the permissible range power-supply voltage to
at input terminals R, S and T of the the permissible range.
drive unit.
Permissible range: 180 to 220V AC
(50/60 Hz)
Connector connection Check that the connectors *1 connected Properly connect the
to the drive unit are connected to the cables.
correct locations.
Check that the connectors *2 connected Tighten the screws to

to the drive unit are securely screwed. securely connect the
connectors.
*1, *2 The connectors connected to the unit are as follows for systems VAC1 to VAC3.
Connector *1 Connector *2
XB-EX(CN1) XB-EX(CN1)
When using VAC1 system XB-RES(CN3) XB-RES(CN3)
XB-EX(CN1) XB-EX(CN1)
When using VAC2 system XB-OPT(CNOFS) XB-EPG(CN13)
XB-EPG(CN13) XB-RES(CN3)
XB-RES(CN3)
VAC5-D6: VAC5-D6:
When using VAC3 system XB-OPT(CNOFS) XB-EPG(CN1)
XB-EPG(CN1) XB-CHG(CN12)
XB-CHG(CN12) XB-RES(CN11)
XB-RES(CN11) VAC5-D11, VAC5-D22:
VAC5-D11, VAC5-D22: XB-EPG(CN2)
XB-OPT(CNOFS) XB-CHG(CN1)
XB-EPG(CN2) XB-RES(CN3)
XB-CHG(CN1)
XB-RES(CN3)
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2. Errors and their classifications
In case of a failure, take proper actions against it referencing to the subsection

indicated in the table below.
For procedures for inspecting and replacing the components, see “5. MAINTENANCE
AND INSPECTIONS.”
Table 4-2. Error classifications

Subsection
Error
to refer to
2-1 Display on the seven-segment LED display
Seven-segment LED display does not light.Display on
2-2
the seven-segment LED display
2-3 Seven-segment LED display is indicating an error.
The motor does not run at the specified speed, or the
2-4
motor does not rotate.
2-5 The cutting force has dropped.
2-6 The acceleration or deceleration time has increased.
2-7 Vibration or noise is strong when the motor is running.

The motor decelerates suddenly and stops although no
2-8
alarm has occurred.
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2-1. Seven-segment LED display does not light.
Table 4-3
Cause Check method Action
The input power is Check whether input power Turn ON the breaker.
not being supplied. terminal breaker is OFF.
Check whether the input An earth fault has occurred
power terminal breaker has inside the unit. Replace the
tripped. unit.
Check whether the input Turn OFF the power and fully
power terminal bolts or tighten the bolts and screws.
screws are loose.
The power voltage See “Table 4-1. Check See Table 4-1.
is unusually low or points.”
high.
Power is not being Verify that all of the check Replace the unit.
supplied to the points above are showing
control PCB inside the proper values or
the power unit. properly set.
The control PC board
is faulty.

If checking the input power terminal bolt and screw tightness, first turn OFF the
power and ensure that the DC CHARGE LED has gone out.

Pay sufficient attention to checking the power voltage.
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2-2. Seven-segment LED display is indicating an error.
If the seven-segment LED display is indicating an error, refer to “4. Display in error
status mode” in Section 3 to check what alarm is pending, and take proper actions
according to the Table 4-4.
Table 4-4 (1/14)

Alarm No. Alarm name Cause Check method Action
1 PG count The gap between the Turn the spindle by hand Adjust the gap between the
magnetic encoder and to check the output signal magnetic encoder and detection
error
detection gear is too from the magnetic gear.
large. encoder.*1
The magnetic encoder Turn the spindle by hand When the magnetic encoder
sensor or detection to check the output signal output signal VZ1 ≠ VZ2:
gear is defective. from the magnetic
• Replace the magnetic encoder
encoder.*1
sensor.
• Detection gear (Z phase disc)
external dimensions defect
When the magnetic encoder
output signal t1 ≠ t2:
• Replace the magnetic encoder
sensor.
• Detection gear AB phase gear
and Z phase disc assembly
accuracy defect
Noise is superimposed Check whether the Replace the magnetic encoder

on the magnetic magnetic encoder signal signal wire.
encoder signal wire. wire shield is properly
connected.
The magnetic encoder Perform a magnetic Replace the magnetic encoder
Z phase signal has encoder signal wire signal wire.
been lost. continuity check.
The control PC board is Verify that all of the Replace the unit.
faulty. check points above are
showing the proper
values or properly set.
*1 For the method for checking output signals from the magnetic encoder, see Appendix 2.
44
AC-1587 V3.0
Table 4-4 (2/14)

2 Motor The resolver is Turn the motor by Replace the motor.
overspeed defective. hand to check the
output signal from the
resolver. *2
The gap between Turn the spindle by Adjust the gap between the magnetic
the magnetic hand to check the encoder and detection gear.
encoder and output signal from the
detection gear is too magnetic encoder. *3
large.
The magnetic Turn the spindle by When the magnetic encoder output
encoder sensor or hand to check the signal VZ1 ≠ VZ2:
detection gear is output signal from the
• Replace the magnetic encoder sensor.
defective. magnetic encoder. *3
• Detection gear (Z phase disc) external
dimensions defect
When the magnetic encoder output
signal t1 ≠ t2:
• Detection gear AB phase gear and Z
phase disc assembly accuracy defect
Noise is Check whether the Replace the magnetic encoder signal
superimposed on magnetic encoder wire.
the magnetic signal wire shield is
encoder signal wire. properly connected.
The connector of the Check whether the Properly connect the connector.
resolver or magnetic connector*4 is
encoder signal wire properly connected to
has a contact the unit and the motor.
failure.
The connector of Disconnect the Replace the resolver or magnetic
resolver or magnetic resolver or the encoder signal wire.
encoder signal wire magnetic encoder
has a contact signal wire and
failure. perform a continuity
check
The control PC Verify that all of the Replace the unit.
board is faulty. check points above
are showing the
proper values or
properly set.
*2 For the method for checking output signals from the resolver, see Appendix 2.
*4 Connector names are as shown below.
Connector name Connector name

VAC5-D8-AIF
VAC5-D11-AIF
XB-RES(CN3) XB-EPG(CN13)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D6 XB-RES(CN11) XB-EPG(CN1)
VAC5-D11
XB-RES(CN3) XB-EPG(CN2)
VAC5-D22
45
AC-1587 V3.0
Table 4-4 (3/14)

3 APA speed The gap between the Turn the spindle by Adjust the gap between the magnetic
(spindle magnetic encoder hand to check the encoder and detection gear.
overspeed) and detection gear is output signal from the
too large. magnetic encoder.*5
The magnetic Turn the spindle by When the magnetic encoder output
encoder sensor or hand to check the signal VZ1 ≠ VZ2:
detection gear is output signal from the
defective. magnetic encoder.*5
• Detection gear (Z phase disc) external
dimensions defect
When the magnetic encoder Z phase
signal is incorrect.
• Detection gear Z phase disc has a
scratch.
superimposed on the magnetic encoder wire.
magnetic encoder signal wire shield is
signal wire. properly connected.
The connector of the Properly connect the Properly connect the connector.
magnetic encoder connector*6.
has a contact failure.
The connector of Disconnect the Replace the magnetic encoder signal

magnetic encoder magnetic encoder wire.
signal wire is signal wire and
damaged. perform a continuity
check
The control PC board Verify that all of the Replace the unit.
is faulty. check points above
are showing the
proper values or
properly set.
4 CON speed The feed unit quantity is Check the setting of Correct the set value.
incorrect. the feed unit.
5 DIFF over The machine is Check for any Review the cutting conditions, or
overloaded. improper cutting remove the cause of the mechanical
conditions and errors system error.
in mechanical
components, such as
a lubrication unit.
are showing the
proper values or
properly set.
Connector name
VAC5-D8-AIF
VAC5-D11-AIF
XB-EPG(CN13)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D6 XB-EPG(CN1)
VAC5-D11
XB-EPG(CN2)
VAC5-D22
46
AC-1587 V3.0
Table 4-4 (4/14)

6 Resolver error The connector of the Check which of the Connect the connector into the correct
resolver is inserted connectors*7 on the position.
into a wrong position control PC board the
on the control PC connector is
board. connected to.
resolver has a connector*7 is
contact failure. properly connected to
the unit and the
motor.
The connector of Disconnect the Replace the resolver.
resolver or magnetic resolver and perform
encoder signal wire a continuity check
are showing the
proper values or
properly set.
The resolver is faulty. Make sure that the Replace the motor.
same alarm number
is displayed with a
new unit.
8 Communicatio The contact of the Verify that the Properly connect the connector.
n error connector of the connector is properly
optical fiber is inserted into the
incomplete. connector for optical
fiber on the control
PC board
XB-OPT(CNOFS).
Optical fiber cable is Check whether the Replace the optical fiber cable.
damaged. optical fiber cable is
damaged*8.
NC unit board*9 is Verify that all of the Replace the NC unit board.
faulty. check points above
are showing the
proper values or
properly set.
The control PC board is Verify that all of the Replace the unit.
faulty. check points above
are showing the
proper values or
properly set.

Connector name
VAC5-D8-AIF
VAC5-D11-AIF
XB-RES(CN3)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D6 XB-RES(CN11)
VAC5-D11
XB-RES(CN3)
VAC5-D22
*8 For the method for checking optical fiber cable, see Section 5, subsection 9.
*9 OSP5020: SPC6, OSP7000: TFP board
47
AC-1587 V3.0
Table 4-4 (5/14)

9 Command An undefined or Check Correct the NC software.
inexecutable communication
error
command was sent. causing the alarm.
10 Motor wire The contact between Verify that the Securely tighten the terminal screws.
overcurrent the motor power wire terminal screws are
and the terminal securely tightened.
block is incomplete.
The motor power wire Perform a continuity Replace the motor power wire.
is broken, check with the motor
short-circuited, or power wire
grounded. disconnected from
the drive unit and the
motor.
the unit and the
motor.
The motor is faulty. Measure the Replace the motor.
insulation between the
power wire terminal of
the motor and the
frame.
are showing the
The power unit is proper values or
faulty. properly set.

Connector name
VAC5-D8-AIF
VAC5-D11-AIF
XB-RES(CN3)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D11
XB-RES(CN3)
VAC5-D22
48
AC-1587 V3.0
Table 4-4 (6/14)

11 Inverter The motor power wire Perform a continuity Replace the motor power wire.
bridge short is broken, check with the motor
short-circuited, or power wire
grounded. disconnected from
the drive unit and the
motor.
The motor is faulty. Measure the Replace the motor.
resistance between
the power wire
terminal of the motor
and the frame with a
Megger tester.
(Winding changeover Inspect the magnet Replace the magnet switch or the relay
type) switch or the relay for magnet switch drive.
according to the
The magnet switch
maintenance manual
for winding
for the machine.
changeover or the
relay for magnet
switch drive is faulty.
or power unit is check points above
faulty. are showing the
proper values or
properly set.
12 Regenerator An instantaneous Check the power Turn on the motor after resetting.
IGBT power failure supply.
occurred when the
short
motor was turned off.
or unit is faulty. check points above
are showing the
proper values or
properly set.
13 Power circuit The power voltage is See Table 4-1. See Table 4-1.
unusually high.
abnormal
voltage
The power wire Turn off the power. Securely tighten the screws.
terminal screw is Verify that the power
loose. wire terminal screw is
securely tightened.
The motor data Check the switch Set the switch SW1 correctly.
selection is incorrect. SW1 setting.
The regenerative Verify that all of the Replace the unit.

circuit on the control check points above
PC board is faulty. are showing the
proper values or
properly set.
The windings inside Measure the Replace the motor.
the motor have resistance between
shorted. the motor windings.
The power supply Verify that alarm 13 is Shorten the power supply wiring route to
impedance is high. displayed only when the machine.
the motor decelerates
(The power supply Optimize the power supply capacity.
wiring route is too long.)
(The customer has
insufficient power
supply capacity.)
49
AC-1587 V3.0
Table 4-4 (7/14)

Input voltage The power voltage is
14 See Table 4-1. See Table 4-1.
drop or open low, or an open
phase phase occurs.
(15)
Replace the blown fuse(s).
One or more of the Check the fuses for
fuses F1R to F3T is blowing.
blown.
are showing the
Make sure that alarm

The power supply Shorten the power supply wiring route to
14 or 15 is displayed
impedance is high. the machine.
only during the
(The power supply acceleration or Optimize the power supply capacity.
wiring route is too long.) deceleration of the
(The customer has motor.
insufficient power
supply capacity.)
17 Power circuit The power voltage is See Table 4-1. See Table 4-1.
low.
low voltage
The power unit is faulty. Verify that all of the Replace the unit.
check points above are
showing the proper
50
AC-1587 V3.0
Table 4-4 (8/14)

19 Motor
The machine is Check the motor Review the operation program.
overload
overloaded. temperature.
The contact between Turn OFF the power Properly connect the wires.
the fan power wire and check the
and the terminal terminal block
block is incomplete. connections at the
unit side and motor
side.
The fan motor wire is Turn OFF the power Replace the motor.
damaged. and conduct a
continuity check for
the fan motor wire.
The motor cooling fan Verify that all of the Replace the motor cooling fan.
are showing the
proper values or
properly set.
Dust is accumulated Check for dust. Use the air blast or a vacuum cleaner to
at the motor cooling remove the dust.
fan, fan guard,
ventilating hole, etc.
the unit and the
motor.
The connector of Disconnect the Replace the resolver.
resolver or magnetic resolver and perform
encoder signal wire a continuity check
Thermal protector Measure the Replace the motor.
built in the motor is resistance between
faulty. the connector inside
the motor terminal box
and the thermal
protector terminal. If
the measured
resistance is , the
thermal protector is
faulty.
are showing the
proper values or
properly set.

Connector name
VAC5-D8-AIF
VAC5-D11-AIF
XB-RES(CN3)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D11
XB-RES(CN3)
VAC5-D22
51
AC-1587 V3.0
Table 4-4 (9/14)

20 Heat sink The heat sink cooling Verify that the heat Replace the unit.
overload fan is faulty. sink cooling fan starts
working when the
power is turned on.
The heat sink cooling Check the back of the Clean the heat sink cooling fan by air
fan is contaminated power unit for blowing or using a vacuum cleaner.
with dust. contamination.
The machine is Review the cutting conditions and tools.
―――――
overloaded.
The control PC board Verify that all of the
are showing the Replace the unit.
The power unit is
proper values or
faulty.
properly set.
Check VAC PBU Correct wrong data.
21 VAC data VAC PBU data file or
data or online change
NC online parameter
settings parameters.
values are faulty.
Excessive Verify that the Remove error elements, if any.
22 Mechanical error
in-VAC speed mechanical system is
command in normal condition.
52
AC-1587 V3.0
Table 4-4 (10/14)

23 Magnetic PG The connector of the Check which of the Connect the connector into the correct
error magnetic encoder connectors*12 the position.
signal wire is control PC board the
connected into a connector is
wrong position on the connected to.
control PC board.
The contact of the Check if the Properly connect the connector.
magnetic encoder connector*12 is
signal is incomplete. properly connected.
The gap between the Turn the spindle by Adjust the gap between the magnetic
magnetic encoder hand to check the encoder and detection gear.
and detection gear is output signal from the
too large. magnetic
encoder.*13
superimposed on the magnetic encoder wire.
magnetic encoder signal wire shield is
signal wire. properly connected.
The connector of Disconnect the signal Replace the magnetic encoder signal
magnetic encoder wire and perform a wire.
phase A and B signal continuity check
wire is damaged.
Magnetic encoder Turn the spindle by • Replace the magnetic encoder sensor.
sensor is faulty. hand to check the
output signal from the
magnetic
encoder.*13
24 Magnetic PG The magnetic Turn the spindle by Replace the magnetic encoder sensor
marker latch encoder sensor or hand to check the or detection gear.
data error detection gear is output signal from the
error defective. magnetic
encoder.*13

Connector name
VAC5-D8-AIF
VAC5-D11-AIF
XB-EPG(CN13)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D6 XB-EPG(CN1)
VAC5-D11
XB-EPG(CN2)
VAC5-D22
*13 For the method for checking output signals from the magnetic encoder, see
Appendix 2.
53
AC-1587 V3.0
Table 4-4 (11/14)

30 Excessive Cutting load is too Check whether the Review the cutting conditions and tools.
speed great. cutting tool cut into
deviation the workpiece and
stopped during heavy
cutting.
The motor power wire Check the motor Properly connect the motor power wire.
is damaged or has a power wire.
contact failure or the
wiring is incorrect.
The resolver signal Check the resolver Properly connect the resolver signal
wire is broken or has signal wire. wire.
a contact failure.
The magnetic Check the magnetic Properly connect the magnetic encoder
encoder signal wire is encoder signal wire. signal wire.
broken or has a
contact failure.
The motor data Check the switch Set the switch SW1 correctly.
selection is incorrect. SW1 setting.
are showing the
The motor is faulty. Verify that all of the Replace the motor.
check points above
are showing the
proper values or
properly set.
(Winding changeover Refer to the Replace the winding changeover
type) maintenance manual magnet switch or drive relay.
(Winding changeover provided with this
type)The winding machine and perform
changeover magnet an inspection.
contactor or drive
relay is faulty.
31 Winding Winding changeover Refer to the Replace the winding changeover
changeover magnet contactor or maintenance manual magnet switch or drive relay.
drive relay error provided with this
error
machine and perform
an inspection.
The I/O control circuit

Check I/O control Properly connect the wire.
signal wire is
circuit signal wire.
damaged or has a
contact failure.
are showing the
proper values or
properly set.
32 RAM error The control PC board Replace the unit.
is faulty. ―――――
41 Converter The power unit is Replace the unit.

faulty. ―――――
link error
54
AC-1587 V3.0
Table 4-4 (12/14)

42 Abnormal The power voltage is See Table 4-1. See Table 4-1.
inverter DC unusually high.
bus voltage
The power wire Turn the power OFF Securely tighten the screws.
terminal screw is and verify that the
loose. power wire terminal
screw is securely
tightened.
The power supply Verify that alarm 42 is Shorten the power supply wiring route to
impedance is high. displayed only when the machine.
the motor decelerates
(The power supply Optimize the power supply capacity.
wiring route is too long.)
(The customer has
insufficient power
supply capacity.)
The power voltage is See Table 4-1. See Table 4-1.
low, or
an open phase
occurs.
are showing the
proper values or
The power unit is properly set.
faulty.
47 Unit settings Unit settings are Check the switch Set the switches correctly.
faulty. settings.
48 Motor data Motor data settings Check the switch Set the switches correctly.
are faulty. settings.
settings
49 Unit/motor The unit settings and Check the switch Set the switches correctly.
data settings do not settings.
data settings
match.
50 Self-diagnosis The control PC board Replace the unit.
error is faulty. ―――――
55
AC-1587 V3.0
Table 4-4 (13/14)

The control PC board

is faulty.
One or more of the

Control board board-to-board
51
error connectors
connecting the
control PC board and
the power unit is
improperly inserted.
Abnormal
52 control voltage
±12 V/+24 V
OPF error
53
Abnormal
power for
58 magnetic
encoder
Abnormal
59 power for
encoder
Abnormal
60 control power The control PC board
+ 3.3 V is faulty.
Abnormal ――――― Replace the unit.
61 control power
5V
Gate signal
62 error
IR1 MAIN loop
70 error
IR2 MAIN loop
71 error
INT4 loop
72 error
INT3 loop
73 error
INT2 loop
74 error
IR3 MAIN loop
75 error
Access error
76
Parity error
78
Watchdog
79 error
56
AC-1587 V3.0
Table4-4 (14/14)
IRQ7 interrupt
80 IRQ4 interrupt
81 NMI interrupt
General
82 imparity
command
Slot imparity
83 command
CPU address
84 error
DMA address
error
85 DMAC/DTC
address error
Undefined trap
86 command
Undefined The control PC board
――――― Replace the unit.
87 interrupt is faulty.
88 DMAC
ITU
89 MTU
90 SCI
REF
91 BSC
92 A/D
System
93 reserve
94 User break
95 DTC
96 CMT
97 I/O
57
AC-1587 V3.0
2-3. The motor hunts
Table 4-5
The resolver signal wire Check the resolver signal wire. Properly connect the
has a contact failure or resolver signal wire.
is connected to a
incorrect terminal.
The motor power wire Check the motor power wire. Properly connect the
has a contact failure or motor power wire.
is connected to a
incorrect terminal.
The control PC board is

faulty. Verify that all of the check
points above are showing the Replace the unit.
The power unit is faulty. proper values or properly set.
(Winding changeover Refer to the maintenance Replace the magnet

type) manual provided with this contactor.
machine and inspect the
The motor power wire is
not properly connected magnet contactor.
to the magnet contactor
for high speed/low
speed.
(Winding changeover Refer to the electric drawing Properly connect the
type) provided with this machine and magnet contactor related
inspect the magnet contactor wiring.
The motor power wire is
not properly connected related wiring.
to the magnet contactor
for high speed/low
speed.
58
AC-1587 V3.0
2-4. The motor does not run at the specified speed, or the motor does not
rotate.
Table 4-6
The machine ready Check if the connector*1 is Properly connect the

complete signal has properly connected. connector.
been lost.
Check the signal (MRDY, Replace the signal cable.
MRDY-COM) continuity.
An alarm occurred at Seven-segment LED shows See subsection 2-2.

the unit. an error if a rotation
command is specified.
The motor power wire is Check the motor power wire. Properly connect the wire.
damaged or has a
contact failure or the
wiring is incorrect.
The resolver is faulty. Check the signal from the Replace the motor.
resolver.*2
The magnetic encoder Check the output signal from Replace the magnetic
unit is faulty. the magnetic encoder.*3 encoder sensor.

faulty. Verify that all of the check
points above are showing the Replace the unit.
The power unit is faulty. proper values or properly set.
(Winding changeover Refer to the maintenance Replace the winding

type) manual provided with this changeover magnet switch
The winding machine. or drive relay.
changeover magnet
switch or drive relay is
faulty.

Connector name
VAC5-D8-AIF
VAC5-D11-AIF
XB-EX(CN1)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D6 XB-CHG(CN12)
VAC5-D11
XB-CHG(CN1)
VAC5-D22
*2 For the method for checking output signals from the resolver, see Appendix 2.
For the winding changeover type, issue a winding command and speed command
within the permissible rotation range for both the high-speed winding and low-speed
winding.
High-speed winding: 0 – max. no. of motor rotations
Low-speed winding: 0 – max. no. of rotations for low-speed winding
Refer to the instruction manual provided with the machine for more specific values.
59
AC-1587 V3.0
2-5. The cutting force has dropped.
Table 4-7
A torque limit command Cancel the torque limit

is applied. ――――― command.
The cause of the Refer to the maintenance Refer to the maintenance

problem exists close to manual provided with this manual provided with this
the spindle of the machine. machine.
machine.
The control PC board is Verify that all of the check Replace the unit.
faulty. points above are showing the
proper values or properly set.
60
AC-1587 V3.0
2-6. The acceleration or deceleration time has increased.
Table 4-8
The load is heavy. Check the load (value) displayed Remove the cause of
on the NC screen. the heavy load.
A torque limit command is ――――― Cancel the torque limit

applied. command
The power voltage is See Table 4-1. See Table 4-1.
high.
The motor power wire is Check the motor power wire. Properly connect the
damaged or has a wire.
contact failure.
faulty. Verify that all of the check points
above are showing the proper Replace the unit.
The power unit is faulty. values or properly set.
The power supply Only the deceleration time Shorten the power
impedance is high. increases. supply wiring route to
the machine.
Refer to the instruction manual
provided with the machine. Optimize the power
supply capacity.
61
AC-1587 V3.0
2-7. Vibration or noise is strong when the motor is running.
As a method for locating whether the cause of a problem is present in the electric or
mechanical system, run the motor free (uncontrolled state). Follow the procedure
described below to run the motor free.
If “vibration or noise is still strong” even if the motor is running free, the cause of the
problem lies in the mechanical system, not the electric system.
(1) Run the motor with a rotation command given to it.
(2) Disconnect the optical fiber connector XB-OPT (CNOFS) of the drive unit.
(3) A communication error alarm is issued, and the motor starts to run free.
Table 4-9
The mounting of the Check the motor to see if it is Mount or couple the
motor is improper. properly mounted and coupled motor with the spindle
with the spindle. from the beginning.
The resolver signal wire Check the resolver signal wire. Replace the resolver.
is broken or has a
contact failure.
When using VAC1 Check the control signal wire Replace the control
system shielding. signal wire.
Noise is superimposed
on the magnetic
encoder signal wire.
The control PC board is Verify that all of the check points Replace the unit.
faulty. above are showing the proper
The power unit is faulty.
The motor is faulty. Verify that all of the check points Replace the motor.
above are showing the proper
When the motor is running in neutral (uncontrolled state), stay away from the rotating part
of the motor.
Exercise care not to apply excessive force to the root of the optical fiber connector
XB-OPT (CNOFS) of the drive unit when disconnecting it. Failure to follow this instruction
will cause the optical fiber to break.
Failure to follow this instruction will cause the optical fiber to break.
62
AC-1587 V3.0
2-8. The motor decelerates suddenly and stops even although no alarm
has occurred.
Table 4-10
The machine ready Check if the connector*1 is Properly connect the
complete signal has properly connected. connector.
been lost.
Check the signal (MRDY, Replace the signal

MRDY-COM) continuity. cable.

Connector name
VAC5-D8-AIF
VAC5-D11-AIF
XB-EX(CN1)
VAC5-D22-AIF
VAC5-D30-AIF
VAC5-D6 XB-CHG(CN12)
VAC5-D11
XB-CHG(CN1)
VAC5-D22
63
AC-1587 V3.0
3. Recovery from errors
If the seven-segment LED display is indicating an error, it is necessary to remove the

cause of the error and reset the alarm to recover from that error status.
Alarms are classified into four levels shown in the table below according to the
processing in case of an alarm and the recovering method.
Table 4-11
Alarm Processing in case
Recovering method Nature of alarm
level of alarm
The unit goes into Turn the machine An alarm, such as
alarm level 1 mode. power supply breaker that detected by the
Level 1a OFF and then ON CPU itself
[Immediately
shutoff] again, and start up (exception), that
the NC. requires hardware
initialization.
The unit goes into Turn off the NC An alarm that
alarm level 1 mode. power, and turn it on requires the
again to restart the initialization of
Level 1b [The shutoff of the NC. parameters, etc.
current after
deceleration to a
stop is standard
processing.]
The unit goes into An alarm that may
Press the reset
an alarm status in button on the NC occur under certain
the main mode*1 in cutting conditions,
operation panel.
which the alarm such as DIFF over.
[A reset command
Level 2 was issued. will be issued in
[The processing each mode.]
depends on the
main mode in which
an alarm is issued.]
The unit informs the Press the reset An overload-related
NC of the issuance button on the NC alarm.
of alarm level 3, operation panel.
Level 3 remains in normal [A reset command
operation for 30 will be issued in
seconds, and goes each mode.]
into alarm level 2.
*1 “Main mode” means velocity control mode (the mode executed with a regular
S command) or position control mode (the mode for C-axis control).
64
AC-1587 V3.0
SECTION 5 MAINTENANCE AND INSPECTIONS

1. Maintenance tools
The following table shows the instruments to be used for maintenance and inspections.
Table 5-1 Maintenance Tools

Name Specification Application Remarks
AC voltmeter 300 V Unit power voltage measurement
Commercial
Analog tester Fuse resistance check
tester
Large Motor wire, power wire disconnection
Unit cover removal
Screwdriver Medium
Motor wire, power wire disconnection
Small Connector securing screw removal

Unit motor wire, power wire
5 mm disconnection
Box wrench disconnection
8 mm
Unit power wire disconnection
10 mm Unit motor wire disconnection

6 mm Unit removal *1
8 mm disconnection
Hex wrench
Unit removal *1
10 mm disconnection
*1) A T-wrench (L: approx. 300 mm) is recommended for removing the unit securing
bolts at the back of the control panel.
65
AC-1587 V3.0
2. Procedures for inspecting and replacing fuses
The check and replacement methods for the fuses used in the respective drive
units are shown in Table 5-2 below. Use the rated fuses shown in Table 5-3.
Table 5-2 Fuse Check/Replacement Methods

Step Details Check Items
Turn OFF the power. Ensure that the unit DC

1
CHARGE LED has gone out.
Remove the fuse from the fuse Check whether the fuse element
2
holder. is blown.
Measure the resistance at both Normal: 0 [Ω]
3 ends of the fuse with a tester.
Blow: ∞[Ω]
Check the rated current of the
4 Replace the fuse if blown.
blown fuse.
Insert the fuse in the fuse holder. If the holder has a cover, do not
5
forget to replace it.
Step 1
After turning OFF the power, always ensure that the unit DC CHARGE
LED has gone out before disconnecting the motor and power wires.
Failure to do so may result in electric shock.
Table 5-3 Fuse Ratings

Unit Type Rated Current Remarks
VAC5-D8-AIF FR=5.0 [A]
VAC5-D11-AIF FS=5.0 [A]
VAC5-D22-AIF FR=5.0 [A]

FS=5.0 [A]
VAC5-D30-AIF FT=5.0 [A]
VAC5-D6 FR=5.0 [A]
VAC5-D11 FS=5.0 [A]
FR=5.0 [A]
VAC5-D22 FS=5.0 [A]
FT=5.0 [A]
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3. Procedures for replacing the whole drive unit
The following table shows the procedure for replacing the drive unit.
Table 5-4 Procedure for replacing the whole unit

Step Description Check Items
Turn off the power. Ensure that the unit DC CHARGE LED
1 has gone out.
2 Disconnect the optic fiber connector Only when using the optical interface unit
Ensure that the connection location is
Loosen the screws securing the
indicated on each connector.
3 connectors, and then disconnect the
connectors.
Disconnect the motor and power Ensure that the power wire number to
wires. which each power wire is to be connected
is indicated on each wire.
4
Take a record of the power wire numbers
and corresponding unit terminal block
names.
Replace the drive unit. Ensure that the unit type is correct.
5
Remove the cover and set the Refer to Appendices 3 and 4.

6 switches on the drive unit.
Connect the motor and power wires. Check the power wire numbers and unit
7
terminal block names recorded at step 4.
Connect each connector and tighten Ensure that each connector is connected
8 the securing screws. to the correct corresponding connector.
9 Attach the optic fiber. Only when using the optical interface unit
10 Perform a trial run.
Step 1
After turning OFF the power, always ensure that the unit DC CHARGE
LED has gone out before disconnecting the motor and power wires.
Failure to do so may result in electric shock.
Step 2
Avoid applying to much force to the base when handling the optical fiber
connector. Failure to do so may result in the optic fiber being broken, and
the NC will not start up when turning ON the power following unit
replacement.
Step 5
The drive unit is very heavy, and it is therefore recommended that a
crane or similar device be used to suspend the unit during removal or
attachment.
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AC-1587 V3.0
4. Procedures for inspecting the optical fiber cable (only when using VAC2,
VAC3 system)
As shown in the figure below, expose either optical fiber connector to light. The cable is
functioning if the other connector is lit.
Fig 5-1
Exercise care not to apply excessive force to the root of the optical fiber
connector. Failure to do so may result in the optic fiber being broken, and the
NC will not start up when the power is turned ON.
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AC-1587 V3.0
5. Procedures for conducting a trial run

Follow the procedure shown in the table below to conduct a trial run after
replacing the unit.
Table 5-5 Procedures for conducting a trial run

Step Description Remarks
Ensure that the unit type and switch Refer to Appendices 3 and 4.
1
settings are correct.
Turn ON the power (machine main
breaker) with the Emergency Stop button
pushed.
2 Ensure that the unit heat sink fan motor If the fan motor does not rotate, refer to
and motor cooling fan motor rotate. “Section 4 Troubleshooting”.
Ensure that the unit seven-segment LED Refer to Section 3.

displays “01”.
Turn ON the operation power and ensure If an alarm occurs and the NC does not
that the NC starts up. start up, refer to Section 4.
3
Ensure that the unit seven-segment LED Refer to Section 3.
displays “02”.
Release the Emergency Stop button and If the DC CHARGE LED (orange) does not
ensure that the unit DC CHARGE LED illuminate, refer to Section 4.
(orange) is illuminated.
4
Issue rotation commands to check the

clockwise and counterclockwise rotations.
Check for a noise when the If the electromagnetic contactor does not
5 electromagnetic contactor inside the unit activate, refer to Section 4.
activates.
Issue a rotation command (low speed) If there is significant vibration or noise
with the spindle override lowered in MDI during spindle rotation, refer to Section 4.
mode to check the spindle clockwise and
counterclockwise rotations.
6
Gradually raise the spindle override and
check the performance across the entire
speed range and in position control
mode.
Step 1
Always ensure that the switch settings are correct.
The motor will be damaged during a trial run if the settings are incorrect.
Step 6
When performing an operation check, ensure that the attachment, chuck
and claws on the spindle clutch are properly secured. The attachment,
chuck or claws may fly from the spindle if not secure during rotation,
representing a potential danger to those in the vicinity. Furthermore, take
care to prevent the spindle chuck colliding with the attachment or jig
when rotating the spindle.
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AC-1587 V3.0
APPENDIX 1 FILES STORED ON CONTROL FLOPPY DISK
APPENDIX 1 FILES STORED ON CONTROL FLOPPY DISK
The parameters for spindle motor control are stored in the files shown below.
- Common file
The parameters for spindle indexing, motor data, gear ratios, etc. are set in this file.
This file also holds parameters set by users (for example, parameters for spindle
indexing). Periodically make a backup copy of these parameters on floppy disk B.
- File for synchronized tapping specifications

The parameters for synchronized tapping, the number of gear steps, the permissible
synchronized tapping speed range in each gear, etc.
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AC-1587 V3.0
APPENDIX 2 DESCRIPTION OF MONITOR TERMINALS

The waveform of the VAC5 can be observed by connecting an oscilloscope to the
monitor terminals.
1. Monitor terminal layout (if using analog interface unit)
M1: Motor rotation count

M2: Motor output torque
M3: None
M4: None
A: Magnetic encoder A phase signal

B: Magnetic encoder B phase signal
Z: Magnetic encoder Z phase signal
R1: Resolver return signal

S1: Resolver excitation signal
IS: DC bus P side current

IR: DC bus N side current
IU: Motor current phase U

IV: Motor current phase V
GND: Connect oscilloscope common

Precautions when observing waveforms from the VAC5 CPU BOARD monitor
terminals.
The VAC5 CPU BOARD (hereafter referred to as “BOARD”) is equipped with a VAC1-IF
CARD (hereafter referred to as “CARD”), and therefore observation is not possible with
the unit cover removed.
When monitoring waveforms from the monitor terminals, turn OFF the power, ensure
that the DC CHARGE LED is out, remove the CARD, place the measurement probe
against the BOARD monitor terminals, and then observe the waveforms after inserting
the CARD again.
Fig A2-1 Monitor terminal arrangement (if using analog interface unit)
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AC-1587 V3.0
2. Monitor terminal layout (if using optical interface unit)
M1: Motor rotation count

M2: Motor output torque
M3: None
M4: None
A: Magnetic encoder A phase signal

B: Magnetic encoder B phase signal
Z: Magnetic encoder Z phase signal
R1: Resolver return signal

IS: DC bus P side current

IR: DC bus N side current
IU: Motor current phase U

IV: Motor current phase V
GND: Connect oscilloscope common
Fig A2-2 Monitor terminal arrangement (if using optical interface unit)
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AC-1587 V3.0
3. Description of monitor terminal signals

Monitor
Description Waveform (example)
terminal
Motor output torque

M1
Output voltage range: -10 to +10 V
Unit: Motor peak torque in 10 V
Motor rotation count

M2 Output voltage range: -10 to +10 V
Unit: Top speed (set in PBU) in 10 V
Magnetic encoder phase A signal

A Vpp in right figure: 2.6 to 4.6V
(3.3 V when gap is properly
adjusted)
Magnetic encoder phase B signal
B Vpp in right figure: 2.6 to 4.6V
(3.3 V when gap is properly
adjusted)
Magnetic encoder phase Z signal
Vz1 in right figure:1.4 V or over
Z
Vz2 in right figure: 0.5 V or over
t1 and t2 in right figure: 0.1 to 0.4T
(T varies according to the speed.)
Resolver signal
Vpp in right figure: 6.0 V (typ)
R1 T in right figure::Approx. 0.128ms
(7.81kHz)
(T slightly varies according to the
speed.)
Resolver magnetization signal

S1
S2 Vpp in right figure: Approx.17.6 V
T in right figure: 128 μs
IS DC bus current
IR
Unit: A
lU Motor current 0 ｔ
lV
Unit: A
(wavefore including ripper component
by PWM control.)
73
AC-1587 V3.0
APPENDIX 3 SWITCH AND VOLUME SETTINGS

The switches are volume trimmers are located on the VAC5 drive unit control PCB. The
switch and volume settings are shown in the following table.
Table A3-1 Switch and Volume Settings

Setting
Item Setting Details Remarks
Location
Select the motor data.
When using VAC1 system:
SW1 → Specify the VAC BOARD SW1 (8 pole) setting as is. *1)
When using VAC2/VAC3 system:
→ All OFF
Select the motor data.
SW2 → Specify the VAC BOARD SW2 1 to 4 settings as is.
→ All OFF
Set the current limit.
SW3 → Specify the VAC BOARD SW3 1 to 4 settings as is.
Switch When using VAC3 system:
→ All OFF
Set all auxiliary functions.
SW4
(Normal: All OFF)
SW5 All OFF
Set the firmware write mode.
SW6
(Normal: All OFF)
Set the current limit.
SW7 → Specify the VAC BOARD SW3 5 and 6 settings as is.
→ All OFF
1 - 3: Set the motor current detection constant.
SW8
4 : OFF
VR1 Set the torque limit level. *2)
Volume VR2 Set the speed amp gain for fixed position stoppage. *2)
VR3 Set the speed amp gain for speed control. *2)
*1) If the VAC BOARD SW1 setting is unknown, determine the setting from the “VAC
Properties Table” in “VAC Drive Unit Related Materials” (Japanese only) found by
accessing the following URL.
FA System Div. home page:
http://160.188.34.150/CNC/servo/default.htm
*2) Used if equipped with EX card when using the VAC1 system.
Specify the switch and volume settings correctly.
74
AC-1587 V3.0
Fig. A3-1 Switch and volume setting locations
75
AC-1587 V3.0
Fig. A3-2 Switch allocation and settings
76
AC-1587 V3.0
APPENDIX 4 SWITCH AND VOLUME SETTINGS WHEN EQUIPPED WITH EX CARD
APPENDIX 4 SWITCH AND VOLUME SETTINGS WHEN

EQUIPPED WITH EX CARD
Support for the VAC5 drive unit EX card is currently under development.
The relevant content in this manual will be disclosed once support for the EX
card is complete.
77
AC-1587 V3.0
APPENDIX 5 APPEARANCE AND WEIGHT OF UNIT
Fig A5-1 VAC5-D8-AIF unit external drawing
78
AC-1587 V3.0
79
AC-1587 V3.0
80
AC-1587 V3.0
Fig A5-5 VAC5-D6 unit external drawing
81
AC-1587 V3.0
82
AC-1587 V3.0
Under
development
(Reference)
Fig A5-8 VAC5-D6 unit (with EX card C1) external drawing
Under
development
(Reference)
83
AC-1587 V3.0
Under
development
(Reference)
84
AC-1587 V3.0
APPENDIX 6 IDENTIFICATION OF FIRMWARE VERSION
This appendix describes how to identify the version of the firmware installed in the
VAC5drive unit.
First, remove the front cover and find the stickers attached to the control PC board
shown below. The version of the firmware is printed on these stickers.
Please note that the firmware version will be updated following improvements or
the addition of functions. Refer to the “VAC Drive Unit Related Materials”
(Japanese only) found by accessing the following URL to see the firmware update
history.
FA System Div. home page:

http://160.188.34.150/CNC/servo/default.htm
Indicates the underlined

part of the firmware version
VAC5111.
Indicates the firmware

version VAC5111.
Fig A6-1 Firmware version indicator locations (if using analog interface unit)
85
AC-1587 V3.0

VAC5111.

version VAC5111.
Fig A6-2 Firmware version indicator locations (if using optical interface unit)
86
AC-1587 V3.0
Under
Under development
development Under
(Reference) development
(Reference)
(Reference)

VAC5111.

version VAC5111.
Fig A6-3 Firmware version indicator locations (if using unit with EX card C1)
87
AC-1587 V3.0
APPENDIX 7 COMPATIBILITY TABLE
The following table shows spindle drive unit (VAC1, VAC2, VAC3, VAC4, VAC5)
compatibility.
Please note that replacement is only possible by replacing the entire unit (set
replacement).
1. When using VAC1 system

Table A7-1 Drive Unit Compatibility Table (when using VAC1 system)
Spoiled unit
13 VAC5-D11-AIF
19 VAC5-D30-AIF
16 VAC5-D22-AIF
9 VAC5-D8-AIF
12 VAC1-D11B
18 VAC1-D30B
11 VAC1-D11A
14 VAC1-D22A
17 VAC1-D30A
15 VAC1-D22B
7 VAC1-D6B
8 VAC1-D8B
4 VAC1-D6A
5 VAC1-D8A
6 VAC1-D3B
10 VAC1-D11
1 VAC1-D3
2 VAC1-D6
3 VAC1-D8
Remark
1 A006-1200, 1100 VAC1-D3 △ △ △1

2 A006-1210, 1100 VAC1-D6 △ △ △ △1
3 A006-1215, 1100 VAC1-D8 △ △ △ △1
4 U1211-0006-001-10 VAC1-D6A ○ △ △ △1
5 U1216-0006-001-10 VAC1-D8A ○ △ △ △1
6 U1601-0006-001-10 VAC1-D3B ○ ○ △1
7 U1611-0006-001-10 VAC1-D6B ○ ○ ○ △1
8 U1616-0006-001-10 VAC1-D8B ○ ○ ○ △1
9 U1216-0006-003-10 VAC5-D8-AIF ○ ○ ○ ○ ○ ○ ○ ○ ○
Replacement
10 A006-1220, 1100 VAC1-D11 △ △ △ △

11 U1221-0006-001-10 VAC1-D11A ○ △ △ △
12 U1621-0006-001-10 VAC1-D11B ○ ○ ○ △
13 U1221-0006-003-10 VAC5-D11-AIF ○ ○ ○ ○
14 U1231-0006-001-10 VAC1-D22A △ △ △
15 U1631-0006-001-10 VAC1-D22B ○ ○ △
16 U1231-0006-003-10 VAC5-D22-AIF ○ ○ ○
17 U1236-0006-001-10 VAC1-D30A △ △ △
18 U1636-0006-001-10 VAC1-D30B ○ ○ △
19 U1236-0006-003-10 VAC5-D30-AIF ○ ○ ○
○ : Compatible
▲ : Compatible, but not substituted for one another in actual operations.
▲1 : Compatible, but not substituted for one another in actual operations.
When determining the model of substitute units, check the control panel
through hole dimensions (see APPENDIX 4).
88
AC-1587 V3.0

Spoiled unit
VAC5-D11-AIF
11 VAC5-D22-AIF
14 VAC5-D30-AIF
VAC5-D8-AIF
VAC2-D11B
10 VAC2-D22B
13 VAC2-D30B
VAC2-D22A
12 VAC2-D30A
6 VAC2-D11A
VAC2-D8B
VAC2-D6A
VAC2-D8A
Remark
VAC2-D6B
1
9
1 A006-1106-01-010 VAC2-D6A △ △ △1
2 U1216-0006-002-10 VAC2-D8A △ △ △1
3 U1611-0006-002-10 VAC2-D6B ○ ○ △1
4 U1616-0006-002-10 VAC2-D8B ○ ○ △1
5 U1216-0006-003-10 VAC5-D8-AIF ○ ○ ○ ○ ○
6 U1221-0006-002-10 VAC2-D11A △ △ △
Replacement
7 U1621-0006-002-10 VAC2-D11B ○ ○ △
8 U1221-0006-003-10 VAC5-D11-AIF ○ ○ ○
9 U1231-0006-002-10 VAC2-D22A △ △ △
10 U1631-0006-002-10 VAC2-D22B ○ ○ △
11 U1231-0006-003-10 VAC5-D22-AIF ○ ○ ○
12 U1236-0006-002-10 VAC2-D30A △ △ △
13 U1636-0006-002-10 VAC2-D30B ○ ○ △
14 U1236-0006-003-10 VAC5-D30-AIF ○ ○ ○
○ : Compatible
89
AC-1587 V3.0

Spoiled unit
VAC3-D22
VAC4-D22
VAC5-D22
VAC3-D11
VAC4-D11
VAC5-D11
VAC3-D6
VAC4-D6
VAC5-D6
Remark
9
1 U1212-0006-001-10 VAC3-D6 △ △ △
2 U1212-0006-001-11 VAC4-D6 △ △ △
3 U1212-0006-001-12 VAC5-D6 ○ ○ ○
Replacement
4 U1222-0006-001-10 VAC3-D11 △ △ △
5 U1222-0006-001-11 VAC4-D11 △ △ △
6 U1222-0006-001-12 VAC5-D11 ○ ○ ○
7 U1232-0006-001-10 VAC3-D22 △ △ △
8 U1233-0006-001-11 VAC4-D22 △ △ △
9 U1233-0006-001-12 VAC5-D 22 ○ ○ ○
○ : Compatible
90

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Document number: AC-1587 (V3.

SPINDLE DRIVE UNIT

Approved Checked Checked Checked Checked Prepared

(1) Descriptions added for maintenance unit

(3) Changes made to unit names, etc.

(1) Corrections made following completion

(3) Changes made to unit names, etc.

This manual discloses certain specifications (external drawings, external dimensions)

This sign is to indicate general instructions for safe operation.

Keep this manual handy for reference.

SECTION 2 CONFIGURATION AND CONNECTION 2

2-2. Connection diagram (standard type) ........................................................ 14

2-3. Connection diagram (winding changeover type) ...................................... 18

2-4. Spindle motor connection diagram............................................................. 21

2-5. Encoder and connection diagram .............................................................. 25

2-6. I/O control circuit connection diagram........................................................ 27

2-7. NC unit connection diagram....................................................................... 31

SECTION 3 OPERATION STATUS DISPLAY.............................................................. 35

2. Errors and their classifications ......................................................................... 42

3. Recovery from errors ....................................................................................... 64

SECTION 5 MAINTENANCE AND INSPECTIONS ...................................................... 65

APPENDIX 1 FILES STORED ON CONTROL FLOPPY DISK ..................................... 70

APPENDIX 2 DESCRIPTION OF MONITOR TERMINALS........................................... 71

APPENDIX 3 SWITCH AND VOLUME SETTINGS....................................................... 74

APPENDIX 4 SWITCH AND VOLUME SETTINGS IF USING EX CARD ..................... 77

APPENDIX 5 APPEARANCE AND WEIGHT OF UNIT................................................. 78

APPENDIX 6 IDENTIFICATION OF FIRMWARE VERSION ........................................ 85

APPENDIX 7 COMPATIBILITY TABLE ......................................................................... 88

Table 1-1 Conventional units and maintenance units

SECTION 2 CONFIGURATION AND CONNECTION

Analog interface unit type

Optical interface unit type

Table 2-1 VAC5 product line structure

Fig 2-2. VAC5--D11-AIF Connector layout

Fig 2-3. VAC5-D11-AIF Connector layout

Fig 2-4. VAC5-D30-AIF Connector layout

Fig 2-5. VAC5-D6 Connector layout

Fig 2-6. VAC5-D11 Connector layout

Fig 2-7. VAC5-D22 Connector layout

Fig 2-8. VAC5-D6 (with EX card C1) Connector layout

Fig 2-9. VAC5-D11 (with EX card C1) Connector layout

Fig 2-10. VAC5-D30 (with EX card C1) Connector layout

2-1. General connection diagram

(1) When using VAC1 system

Fig 2-11. Complete connection diagram when using VAC1 system

(2) When using VAC2 system

*1) For a built-in motor, no resolver is used.

Fig 2-12. Complete connection diagram when using VAC2 system

(3) When using VAC3 system

*1) For a built-in motor, no resolver is used.

Fig 2-13. Complete connection diagram when using VAC3 system

(4) When using externally sold system

*1) For a built-in motor, no resolver is used.

2-2. Connection diagram (standard type)

(1) When using VAC1 system

(2) When using VAC2 system

*1) For a built-in motor, no resolver is used.

(3) When using VAC3 system

*1) For a built-in motor, no resolver is used.