Optimum Reliability in Motion Control SERVO DRIVE TYPE OPERATION AND MAINTENANCE MANUAL ALPHA SERVO DRIVE INDEX 11AR
Preface Thank you for purchasing a SANDEX product. These instructions cover installation procedures, linkage procedures, and maintenance precautions to be followed to ensure maximum performance from this product. Please read these instructions carefully before installing or trial operating of this product. After unpacking, make sure the product delivered fits your ordering specifications.
0=Single phase 200 to 230VAC for 7AR & 9AR 1=Three phase 200 to 230VAC for 11AR & 15AR 2=Three phase 380 to 480VAC for 11AR & 15AR f: Controller Type of controller Availability: 0=Standard x=Special requirements g: Cable Type of cables Availability: 0=3 meters length, w/o conduit 1=5 meters length, w/o conduit 2=10 meters length, w/o conduit 3=15 meters length, w/o conduit 4=3 meters length, w/ conduit 5=5 meters length, w/ conduit 6=10 meters length, w/ conduit 7=15 meters length, w/ conduit Y=Connectors O
Safety Precautions S ymbols to ensure the safe and proper use of the Variax The following symbols are used this manual where safety precautions must be observed. Read and understand the meanings of these symbols to ensure the safe and proper use of Variax. Failure to obey these precautions can cause machine problems, accidents, or other unexpected behavior. Warning Caution Indicates a potentially hazardous situation, which may result in death or serious injury.
Contents PREFACE SAFETY PRECAUTIONS SAFETY PRECAUTIONS 3 SYMBOLS TO ENSURE THE SAFE AND PROPER USE OF THE VARIAX 3 1. OPERATING THEORY 6 2. HANDLING YOUR SANDEX SANDEX 7 2.1 IDENTIFYING ALPHA SERVO LAYOUT 7 3. TRANSPORTATION AND AND ENVIRONMENT 3.1 3.2 3.3 3.4 SHIPPING CONDITION TEMPERATURES MOISTURE DUST 8 8 8 8 8 4. INSTALLATION 10 4.1 CASING MAIN BODY 4.2 DRIVER 10 10 4.2.1 STORAGE CONDITIONS 4.2.2 INSTALLATION SITE 4.2.3 ORIENTATION 4.2.4 WIRING THREE PHASE 200VAC 200VAC 4.2.
5.6 DATA SWITCH SETTINGS 22 6. HANDLING PROCEDURES PROCEDURES FOR THE OUTPUT SHAFT 6.1 TABLE TYPE OUTPUT 23 7. LUBRICATION 4.5 7.2 7.3 7.4 23 24 PURPOSE OF LUBRICATION LUBRICATION OIL SELECTION PRECAUTIONS PRECAUTIONS LUBRICATING OIL VISCOSITY VISCOSITY’S RECOMMENDED LUBRICATING LUBRICATING OIL 24 24 25 25 8. FILLING AND REPLACING REPLACING LUBRICATING OIL OIL 26 8.1 REFILLING LUBRICATING OILS SCHEDULE 8.2 OIL REPLACEMENT SCHEDULE 26 26 9. LUBRICATION GREASES GREASES 27 9.
Unit 2 Handling your Sandex 1. Operating theory SANDEX units operate based on the following principal. A globoidal cam is mounted onto the input shaft. This cam interlocks with the turret portion of the output shaft. The turret has cam followers along its perimeter, which are in contact with the tapered ribs on the cam. This contact or pressure is called the preload. Turning the input shaft rolls the cam followers along the rib surfaces thereby rotating the turret according to the curve of the cam.
Unit 2 Handling your Sandex 2. Handling your SANDEX Over 90% of the mechanical failures reported with roller gear cam equipment comes from careless or improper handling. Improper handling not only reduces the life of your SANDEX unit, it can also affect the performance of both the SANDEX unit and your machine. 2.1 Identifying Alpha Servo layout Roller Drive Servomotor Fixed hollow flange Installation surface for indexing table. Installation for fixed table.
Unit 3 Transportation and environment 3. Transportation and Environment 3.1 Shipping condition (1) All SANDEX products are thoroughly inspected after the final assembly. Only those products that pass this inspection are shipped. (2) Before shipped, each SANDEX unit is filled with lubrication oil in accordance to the customer’s operating speed and environment. (3) A rust preventative solution is applied to the input /output shafts, key, and mounting surface.
Unit 3 Transportation and environment oil seal may wear and thereby cause oil leaks. This is particularly evident when chemicals are used. Chemicals can also cause and or accelerate rust and corrosion. When using your SANDEX unit in dusty areas, you should consider using protective covers made from stainless steel or plastic. If the location for your SANDEX unit is very dusty, the air outlet in the oil fill port may become an entrance into the housing.
Unit 4 Installation 4. Installation Another crucial factor to the performance of your SANDEX unit is the operating environment. Make an early review of the location for your SANDEX unit and take any corrective actions necessary. 4.1 Casing main body (1) Always use the lifting bolt holes provided on the housing of your SANDEX unit. Do not lift the unit using the input or output shafts as this can affect the precision of the equipment, or worse, affect the life of the machine.
Unit 4 Installation 4.2.2 Installation Site The following precautions apply to the installation site Situation Installation Precaution Installation in a Control Panel Design the control panel size, unit layout, and cooling method so the temperature around the servo amplifier does not exceed 55°C (131°F).
Unit 4 Installation 4.2.
Unit 4 Installation 4.2.
Unit 4 Installation 4.3 Controller 4.3.1 Mounting the MP940 1. Insert the two mounting tabs on the bottom of the MP940 into the mounting holes on the lower right side of the SGDH. 2. Pressing in the direction of the arrows, insert the mounting tabs on the top of the MP940 into the mounting holes on the top right side of the SGDH. 3. Insert the MP940 module fixing spring into the hole on the top of the SGDH. 4.
Unit 4 Installation 4.3.2 Connection of Peripheral Devices Switch Box Or PLC Motor power, and encoder are standard cables that are supplied by Sankyo America Inc. The I/O connections are made by one of two options (see 4.4.2). The source power cables will be supplied by the customer.
Unit 4 Installation 4.4 Wiring 1.) Power Supply Connector Cable Supplies DC +24V 400mA power supply to the MP940 module. The connectors use a screw-mount terminal block BL3, 5/3F-AU (Weidmuller, Inc.). Pin# Signal Name Name 3 +24V +24VDC input 2 GND 0V 1 FG Frame ground 2.) Input Cable Preparing Procedure Use a twisted pair with a wire size of AWG#24 to AWG#20 when connecting the 24VDC power supply and MP940 Module power supply connector.
Unit 4 Installation 4.4.1 I/O Circuits 17.4-28.8VDC 5.
Unit 4 Installation 4.4.2 Controller I/O connections The pigtail cable, and the cable with terminal block are available options for your connection Note: N/A connections are not needed for the Alpha Servo application.
Unit 5 Operation 5.Operation Generally, automated machinery using SANDEX units are complicated in design. This is based on the large number of linkage involved. Such machinery generally uses the cams and linkages for obtaining overlapped movements. However, one will almost always encounter interference problems if he operates the equipment prematurely. To avoid this type of problem, the input drive should be test turned by hand, as each component is mounted. 5.
Unit 5 Operation 5.3 I/O timing chart while in jog mode A) Input Signals 1) Servo ON: This signal will activate the driver and await user commands. If there are no errors the ready output signal will also be activated. 2) Auto/Jog: This signal will cause the controller to go into jog mode and await a start signal. 3) Start: While in jog mode this signal will start the rotation of the motor’s output shaft. When this signal is not present the motor will stop rotating.
Unit 5 Operation 5.4 I/O timing chart while in automatic mode C) Input Signals 1) Servo ON: This signal will activate the driver and await user commands. If there are no errors the ready output signal will also be activated. 2) Auto/Jog: This signal is not activated causing the controller to begin auto mode and await a start signal. 3) Start: While in auto mode this signal will start the preprogrammed motion that was written by Sankyo America.
Unit 5 Operation 5.5 Indexing time vs. stops chart Index time- # Stops chart 3.5 3.0 Index time in seconds 2.5 2.0 1.5 1.0 0.5 0.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 # Stops 5.6 Data switch settings Program# 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3 bit Data 2 bit 1bit 0bit Stops 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On On 22 Index Angle [degree] 360 180 120 90 72 60 51.
Unit 6 Handling Procedures 6. Handling procedures for the output shaft The output shaft on an indexing drive is subject to momentous torque during starting and stopping. Therefore, the shaft must be torsionally rigid. To maintain positioning accuracy, the output shaft must have minimal run out. The run out on a standard SANDEX is within 0.02 mm (.0008 ). Note The SANDEX is designed to show accuracy as it stops. When aligning shafts, do so after repeated indexing and make sure the shaft is in a dwell.
Unit 7 Lubrication 7. Lubrication Lubrication is an effective and vital means for maintaining the life of your SANDEX unit. Lubrication can minimize wear by reducing friction between rolling members, removing friction heat, and preventing rust on rolling surface. The statistical life of the SANDEX unit is based on rolling fatigue. However, these statistics are valid only when wear, vibration, and mechanical seizure are kept at a minimum.
Unit 7 (4) (5) Lubrication Viscosities differ according to the operating speed and size of the indexing drive involved. Choose the proper viscosity from the following table. The viscosity you choose should also meet the ambient temperature requirements of your SANDEX unit. The following table gives the viscosity for a standard temperature range from 0 to 40 degrees Celsius(32 104°F). Consult Sankyo for usage outside of this range. 7.
Unit 8 Filling and replacing lubricating oil 8. Filling and replacing lubricating oil Lubrication is a crucial factor for maintaining the operating life of your SANDEX unit. These units feature a high level of precision, and a resistance to friction. However, improper lubrication can reduce the life of the unit. When filling the unit with oil, make sure to prevent foreign particles such as drilling chips, dust, or water from entering the unit.
Unit 9 Lubricating greases 9. Lubrication greases SANDEX units use an oil bath lubricating system. In certain mounting positions, the bearings sit above the oil level. In this case, a sealed lubricating device is installed exclusively for the bearings and grease nipples are attached wherever grease must be reapplied. Note, your SANDEX has already been greased prior to initial operation. Apply grease every 2000 to 4000 hours of operation. 9.
Unit 11 Repairs and maintenance 10. Repairs and maintenance One of the advantages of the SANDEX unit is that it is easy to handle. However, improper use can affect the life and performance of your SANDEX unit. The following items explain basic repair and maintenance procedures. (1) Periodically, check for backlash in the input and / or output systems. Backlash that goes unnoticed may develop even further over the years. Check for red rust as this indicates the occurrence of fretting corrosion.
Unit 11 Repairs and maintenance 10.1 Yaskawa Driver and Controllerdisplay codes Display Value A.- Description Normal Operation A.02 Parameter Breakdown A.03 Main Circuit Encoder Error A.04 Parameter Setting Error A.05 Servomotor and Amplifier Combination Error A.10 Overcurrent or Hat Sink Overheated A.30 Regeneration Error Detected A.32 Regenerative Overload A.40 Overvoltage A.41 Undervoltage A.51 Overspeed A.71 Overload: High Load A.72 Overload: Low Load A.
Unit 11 Repairs and maintenance A.Cb Encoder Echoback Error A.CC Multiturn Limit Disagreement A.d0 Position Error Pulse Overflow A.F1 Power Line Open Phase If any of these errors occur please contact: CPF00 Digital Operator Transmission Error CPF01 Digital Operator Transmission Error A.91 Overload Warning A.92 Regenerative Overload Warning A.E? Option Board Error 30 Sankyo America Inc.
Unit 11 Repairs and maintenance 10.
Unit 11 Repairs and maintenance 10.
10655 State Route 47, P.O. Box 4338 Sidney, Ohio 45365-4338 Telephone: (937) 498-4901 Fax: (937) 498-9403 E-mail: sales@sankyoamerica.com Web Site: http://www.sankyoamerica.
