FP2NC z axis shudder and fault when using rapids

rimcanyon · Monday at 12:54 PM

I have been having a problem using G0 to move my table up (Z-) on my FP2NC for a few years now. If I dial back the speed to 50% no problem, but at full speed the machine shudders and faults if I do a Z- move of 75mm. I cleaned the tachs and recently adjusted the Bosch cards drift and tach settings after upgrading to D4. The behavior was the same when the machine was running on D2. What else to check?

AlfaGTA · Monday at 1:35 PM

I would check the max voltage that you get on the servo control input when doing rapids. (Input X31:1 and X31:2)
My guess is that the Z servo is running too fast, likely being fed more than 10v at rapid.

As a quick check, try swapping the Z axis cards ( both amplifier and regulator) from the other machine.
Note: the axis cards on the X and Y axis are the same, the Z card is different (resistor)
Also, DO NOT mix the the two different styles of regulator board with the two different styles of amplifier boards, DAMAGE WiIL RESULT!!!!!!!
Late style regulator boards(piggy back resistor board) can only be run with the late amplifier board

Cheers Ross

rimcanyon · Monday at 5:06 PM

The large green cabinet and all the console boards have been swapped in from Rich's machine, and I am seeing the same behavior before and after the swap.

AlfaGTA · Monday at 5:25 PM

Including the Bosch cards?
What is the control voltage to the servo cards when doing a rapid?
Cheers Ross

AlfaGTA · Monday at 5:39 PM

When you say “it faults” exactly are the indications?
Error code, E stop?
Does it make any noise, maybe a sort of machine gun sound?
Does it happen going both directions(up/down) ?
Cheers Ross

rimcanyon · Tuesday at 5:57 PM

Yes, Bosch cards are from Rich's machine, they were swapped as part of the large green cabinet. Yes E-stop and yes machine gun sound.. The control takes a minute or so to reinitialize after. Error displayed is 14. Voltage at X21 pins 1 and 2 is around 6V DC. Only happens when the knee is moved up using G0. I can use mode 5 to move the knee up even with very high speed. The problem started a couple of years ago, and it was 90% resolved by cleaning the Z axis tacho. I will try cleaning it again.

rklopp · Tuesday at 6:05 PM

How's your Z gib clearance? Any signs of nascent galling disease?

AlfaGTA · Tuesday at 7:34 PM

Sounds like you are provoking the Z axis overload clutch.
Clutch might need adjustment or you have developed higher than normal friction. Ways or lube could be an issue.
Could try cycling the axis over full travel while cycling the lube pump.
Should feel lube oil on the inside faces of the box.
Could try the rapids again with the “over oil”
What are you using for way oil?
Check the “rock”of the X slide at three heights of the Z slide (upper 1/3, mid,and lower1/3. Use test indicator to read movement of X (knee) as you go full right and full left on the X.

Cheers Ross

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