Category: LS

Posted on by — Leave a comment

LS Mecapion APD‑VP20 Servo Drive Absolute‑Zero Restoration — A Complete Maintenance Guide (S&T TNL‑120V Vertical Lathe Turret Case)

Applies to: Fanuc Series 0i‑TC CNC + S&T TNL‑120V vertical turning lathe. The turret axis uses an LS Mecapion APM‑SG20MKX1‑SNT servo motor driven by an APD‑VP20(SNT) servo amplifier. The motor is equipped with a TS5643N1 multi‑turn absolute encoder (2048 P/R).

Symptom: The internal lithium battery of the LS drive failed → drive raised AL‑14/AL‑15 absolute‑data/battery errors → the customer, suspecting a bad encoder, loosened the flexible coupling between encoder and motor → the encoder zero position no longer matches the motor’s electrical 0° → even after replacing the battery, absolute position is offset and the Fanuc CNC continues to alarm, rendering the machine inoperable.

APD-VP20(SNT)AT

Contents

  1. System architecture & fault background
  2. Relationship between absolute encoders and electrical 0°
  3. Root‑cause chain analysis
  4. Tools & safety preparation
  5. Step‑by‑step restoration workflow
       5.1 Replacing the drive battery
       5.2 Mechanical realignment of the coupling
       5.3 Drive parameter & menu operations
       5.4 Rebuilding the reference point inside Fanuc
  6. In‑depth explanations of key menus
       6.1 PC‑806 Z POS Search
       6.2 PC‑811 ABS Encoder Set
       6.3 HSIN/HSOUT handshake for absolute data
  7. Commissioning and verification
  8. Preventive measures & maintenance tips
  9. FAQ
  10. Closing remarks
AL_01

1 System Architecture & Fault Background

1.1 Machine configuration

  • Machine: S&T TNL‑120V vertical turning center with 8‑station turret.
  • Control: Fanuc Series 0i‑TC. Spindle and linear axes use standard FANUC α drives. The turret axis, however, is an LS Mecapion solution supplied by the OEM (S&T) for cost optimisation.
  • Turret servo package:
    • Drive: APD‑VP20(SNT) AC servo amplifier (200 – 230 VAC, 3‑phase).
    • Motor: APM‑SG20MKX1‑SNT, 2 kW @ 1 000 rpm, absolute encoder, IP‑65, with brake.
    • Encoder: TS5643N1 multi‑turn absolute optical/magnetic hybrid, ABZ incremental outputs + serial multi‑turn data.
    • Signal exchange with Fanuc is via dry‑contact and PMC bits for turret index, clamp/unclamp and axis ready.
S&T Machine Tool

1.2 Absolute‑backup battery

The APD‑VP20 houses a 3 V lithium cell (CR‑1/2AA or equivalent) that keeps encoder multi‑turn data and drive parameters alive. Low voltage triggers:

  • AL‑14 ABS Data Error
  • AL‑15 ABS Battery Error
  • AL‑16/17 Multi‑turn overflow

If the machine is powered with a dead battery the drive locks, Fanuc does not receive “Servo Ready” and the turret axis reports an alarm.

TS5643N1 Encoder

2 Absolute Encoders vs. Electrical Zero

  • Electrical 0° — the reference angle for vector control, aligned with the rotor magnetic poles.
  • Mechanical zero (Z‑pulse) — one pulse per revolution supplied by the encoder and factory‑aligned to electrical 0°.
  • Multi‑turn count — stores the number of revolutions, maintained by battery or Wiegand energy harvesting.

Any movement of the encoder housing with respect to the motor shaft (loosening the flex coupling, removing fixing screws, etc.) destroys that alignment → field‑orientation fails → over‑current or inability to find the Z pulse.

3 Root‑Cause Chain Analysis

StepTriggerConsequence
①Battery diesAL‑15, absolute data invalid
②Encoder suspected faulty, coupling loosenedEncoder shifted relative to rotor
③Re‑assembled randomlyZ‑pulse no longer equals electrical 0°
④Battery replaced but no calibrationDrive still alarms, cannot Servo‑On
⑤CNC continues to alarmTurret cannot index, machine down

4 Tools & Safety Preparation

  • 3 V CR‑1/2AA lithium cell (original or Panasonic welded type).
  • Phillips and Allen keys, torque driver.
  • Manual pulse generator (MPG) or low‑speed jog via PLC panel.
  • Insulated gloves, multimeter, oscilloscope (optional to watch Z‑pulse).
  • LS Loader PC utility + RS‑232 cable (optional).

Wait 5 minutes after power‑off until the ‘CHARGE’ LED is out (< 50 V DC bus) before opening the cabinet.

APM-SG20MKK1-SNT MOTOER

5 Step‑by‑Step Restoration Workflow

5.1 Replace the Drive Battery

  1. Open the electrical cabinet → remove the small cover on top of the APD‑VP20 → pull out the old cell.
  2. Inspect for corrosion → insert new cell, mind polarity.
  3. Power up and verify AL‑15 clears. If still present, check PC‑802 Battery Test shows > 2.7 V.

5.2 Mechanical Realignment of the Coupling

  1. Loosen the two M3/4 screws of the flexible coupling on the encoder side — leave them finger‑tight.
  2. On the drive keypad select PC‑806 Z POS Search → press ENTER.
    • The motor rotates ~ 5 rpm forward; it stops at the first Z‑pulse.
  3. This is the encoder’s Z position but may not match electrical 0°. Use an oscilloscope or monitor Iq current to find the minimal torque point; gently rotate encoder housing until current dips and no over‑current trip occurs.
  4. Tighten coupling screws to 0.8 N·m.

5.3 Drive Parameter & Menu Operations

turret

For multi‑turn absolute encoders only:

  1. Run PC‑811 ABS Encoder Set; display shows “reset” for 5 s → writes new zero.
  2. AL‑14/16 should now clear.
  3. Check feedback position in PC‑401 ~ PC‑408; should read 0 or near.
  4. Re‑enable SVON; drive READY should be true and the axis can jog.

5.4 Rebuild Fanuc Reference Point

  1. In Fanuc PMC I/O diagnose page confirm LS READY bit (e.g., X/G0122) is ON.
  2. MDI: G28 T0 or OEM macro to home turret.
  3. PARAM > 1815 bit APZ set to 1 to store the new absolute zero.
  4. Power cycle; verify no SV420 TURRET REF LOST or SV041 AXIS ZRN alarms.
Fanuc Electric Control Cabinet

6 Key Menu Details

6.1 PC‑806 Z POS Search

  • Scans ABZ for the Z‑pulse.
  • If no Z within 10 s drive trips AL‑08 (position sensor fault). Check encoder wiring or [PE‑204] resolution = 2048.

6.2 PC‑811 ABS Encoder Set

  • Saves current single‑turn & multi‑turn counts as zero.
  • Clears AL‑14/16 flags and battery warning.

6.3 HSIN / HSOUT Handshake

  • If the PLC reads absolute coordinates via ABSCALL, request with SVON=OFF, set ABSCALL=ON. Reset to OFF when finished.
  • PLC toggles HSIN every 2 bits read, until 30 bits complete; avoids G28 homing but most shops prefer G28 for simplicity.
FANUJC Series OI-TC

7 Commissioning & Verification

  1. Set drive Torque Limit = 10 %; jog ±10 turns, observe MONIT1 < ±5 A.
  2. Execute T0101 → T0202 index cycle; single‑shot index, no clunk.
  3. Run > 100 continuous tool change cycles; confirm temperature & alarm count = 0.

8 Preventive Measures & Maintenance Tips

  • Log battery voltage every 6 months. Replace when < 2.8 V.
  • Apply thread‑locker to coupling screws; yearly torque check.
  • Backup all Fanuc parameters (including 9000 macros) and LS drive menus to both USB & cloud.
  • Prohibit unauthorised encoder disassembly; if required, mark mating parts or 3D‑scan the position.

9 FAQ

  1. Can we convert to an incremental encoder to avoid batteries?
    Incremental is supported, but you must rewrite Fanuc PMC logic for turret indexing and home every power‑cycle — not recommended.
  2. How to clear AL‑03 phase error?
    Redo Z POS Search and adjust coupling; also verify motor phases U‑V‑W match drive outputs.
  3. Can absolute data be backed up via RS‑232?
    LS Loader backs up menu parameters but not encoder EEPROM; multi‑turn info relies on the battery only.

10 Closing Remarks

This guide compiles a full troubleshooting‑calibration‑verification workflow for LS APD‑VP drives suffering absolute‑zero loss due to battery failure and mechanical disassembly, using the S&T TNL‑120V turret as a real‑world case. Following the four major steps herein you can restore turret operation within 2 hours and avoid repeated strip‑down.

Key takeaway: Replace batteries proactively & mark mechanical alignment. If disassembly is unavoidable, use the drive’s built‑in Z capture + ABS reset to re‑establish zero, then make the CNC store the new reference — fix it once, fix it right.

Posted on by — Leave a comment

Operation Guide for LS Inverter LSLV-M100 Series User Manual

I. Introduction to Operation Panel Functions and Password Setting/Locking

Introduction to Operation Panel Functions

The operation panel of the LS Inverter LSLV-M100 series integrates display and operation functions, facilitating intuitive operation and monitoring for users. The panel primarily consists of a digital tube display, indicator lights, and buttons. The digital tube is used to display operating status and parameter information, while the indicator lights indicate the current working status, such as running, forward rotation, reverse rotation, etc. The button section includes commonly used function buttons such as run, stop, and fault reset, as well as direction buttons and a confirmation button for parameter setting.

Password Setting and Elimination

To prevent unauthorized parameter modifications, the LSLV-M100 series inverter provides a password protection function. The specific steps for setting a password are as follows:

  • Enter the configuration function group: First, access the configuration function group (typically identified by P700 series codes) through the panel operations.
  • Select the password registration parameter: Within the configuration function group, locate the password registration parameter (e.g., P701).
  • Enter the password: Use the panel’s direction buttons and confirmation button to input the password, which must consist of 1 to 16 hexadecimal characters.
  • Save the settings: After inputting, press the confirmation button to save the settings.

The method for eliminating the password is similar to setting it. Simply change the password in the password registration parameter to the initial password (usually 0000) or leave it blank.

Front image of LSLV-M100

Parameter Locking

In addition to password protection, the LSLV-M100 series inverter also offers a parameter locking function. By locking the parameters, unintentional changes can be prevented. The specific steps are as follows:

  • Enter the configuration function group: Same as for setting the password, first access the configuration function group.
  • Select the parameter locking parameter: Locate the parameter locking parameter (e.g., P702).
  • Lock the parameters: Set the parameter locking parameter to 1 to lock all settable parameters.
  • Unlock the parameters: When needing to modify parameters, set the parameter locking parameter to 0 and enter the password to unlock.

II. Forward/Reverse Control via Terminals and Speed Adjustment with External Potentiometer

Forward/Reverse Control via Terminals

The LSLV-M100 series inverter supports forward/reverse control through multifunction input terminals. The specific wiring and settings are as follows:

  • Wiring: Connect the forward control signal to a multifunction input terminal (e.g., IN1) and the reverse control signal to another multifunction input terminal (e.g., IN2).
  • Parameter settings:
    • Enter the input terminal function group (e.g., P300 series).
    • Set the forward control terminal function (e.g., P301) to 1 (forward rotation).
    • Set the reverse control terminal function (e.g., P302) to 2 (reverse rotation).
    • In the operation group (e.g., P000 series), set the run command source to external terminals.
LSLV-M100 standard wiring diagram

Speed Adjustment with External Potentiometer

External potentiometer speed adjustment is a commonly used method, where the output frequency of the inverter is changed by adjusting the resistance of the external potentiometer. The specific wiring and settings are as follows:

  • Wiring: Connect the two ends of the external potentiometer to the analog input terminals of the inverter (e.g., V1 and GND).
  • Parameter settings:
    • Enter the input terminal function group.
    • Set the analog input terminal function to voltage input (e.g., set P310 to 1 for voltage input).
    • In the operation group, set the frequency setting method to analog input (e.g., set P003 to 2 for analog voltage input).

III. Fault Codes and Solutions

The LSLV-M100 series inverter features a comprehensive fault code display function, helping users quickly identify fault causes. Below are some common fault codes, their meanings, and solutions:

  • OC (Overcurrent): Indicates that the inverter’s output current exceeds the rated value. Possible causes include excessive load, motor stall, etc. Solutions include checking the load condition and adjusting the acceleration/deceleration time.
  • OV (Overvoltage): Indicates that the DC bus voltage of the inverter is too high. Possible causes include excessive input voltage and faulty braking resistor. Solutions include adjusting the input voltage and checking the braking resistor.
  • UV (Undervoltage): Indicates that the input voltage of the inverter is too low. Possible causes include unstable power supply voltage and phase loss in the input power supply. Solutions include checking the power supply voltage and the input power lines.
  • OH (Overheat): Indicates that the temperature of the inverter’s heatsink is too high. Possible causes include high ambient temperature and faulty cooling fan. Solutions include reducing the ambient temperature and replacing the cooling fan.

For the above faults, users can follow the fault troubleshooting process outlined in the manual to identify and resolve issues one by one based on the inverter’s fault code prompts.

Side image of LSLV-M100

IV. Conclusion

As a high-performance variable frequency speed control device, the LSLV-M100 series inverter provides a detailed operation guide and fault troubleshooting methods in its user manual. By familiarizing themselves with the functions of the operation panel, mastering password setting and locking, understanding the wiring and settings for forward/reverse control via terminals and speed adjustment with an external potentiometer, and grasping the solutions to common fault codes, users can operate and maintain the inverter more efficiently, ensuring its stable operation and optimal performance.

Posted on by — Leave a comment

LS Inverter SV-iGxA Series User Manual Usage Guide

I. Introduction to the Operation Panel Functions and Parameter Settings

Operation Panel Functions

The LS Inverter SV-iGxA series features an intuitive operation panel that includes RUN, STOP/RESET, up and down arrow keys, as well as a confirmation key. The panel’s 7-segment LED display provides clear visual feedback on operational data and parameter settings. Here’s a detailed look at the functions of the operation panel:

  • RUN Key: Starts the motor when pressed.
  • STOP/RESET Key: Stops the motor during operation and resets fault conditions when pressed after a fault occurs.
  • Arrow Keys: The up and down arrow keys are used to navigate through parameters and adjust their values.
  • Confirmation Key: Confirms parameter settings and saves changes.
  • 7-Segment LED Display: Shows operational data such as output frequency, output current, and fault codes.
SV-IGXA main circuit wiring diagram

Parameter Initialization

To initialize the parameters to their factory default settings, follow these steps:

  1. Navigate to Parameter H93: Use the arrow keys to select parameter H93 (Parameter Initialization) in the function group 2.
  2. Set Initialization Value: Press the confirmation key to enter the setting, then use the arrow keys to select the desired initialization level (e.g., 1 for initializing all parameter groups).
  3. Confirm Initialization: Press the confirmation key again to save the setting and initialize the parameters.

Reading, Writing, and Copying Parameters

The SV-iGxA series supports reading and writing parameters using a remote panel or communication interface.

  • Reading Parameters:
    1. Navigate to parameter H91 (Parameter Read) in the function group 2.
    2. Press the confirmation key to initiate the parameter read process.
    3. Follow the prompts on the remote panel or software interface to complete the read operation.
  • Writing Parameters:
    1. Navigate to parameter H92 (Parameter Write) in the function group 2.
    2. Press the confirmation key to initiate the parameter write process.
    3. Follow the prompts on the remote panel or software interface to upload the new parameter settings to the inverter.
SV-IGXA Terminal Wiring Diagram

Setting a Password and Locking Parameters

To enhance security, the SV-iGxA series allows users to set a password and lock specific parameters.

  • Registering a Password:
    1. Navigate to parameter H94 (Password Registration) in the function group 2.
    2. Press the confirmation key to enter the setting.
    3. Use the arrow keys to input the desired password (in hexadecimal format).
    4. Press the confirmation key to save the password.
  • Locking Parameters:
    1. Navigate to parameter H95 (Parameter Lock) in the function group 2.
    2. Press the confirmation key to enter the setting.
    3. Use the arrow keys to select the desired lock level (e.g., locking all parameters by setting H95 to 0xFFFF).
    4. Press the confirmation key to save the setting and lock the parameters.

II. Terminal Control and Potentiometer Speed Regulation

Terminal Forward/Reverse Control

To achieve forward/reverse control via terminal inputs, the following parameters need to be configured:

  • drv (Drive Mode): Set to 1 to enable terminal control.
  • drC (Motor Rotation Direction Selection): Select the desired rotation direction (F for forward, r for reverse).
  • I17-I18 (Multi-Function Input Terminal Definitions): Assign the FX (forward) and RX (reverse) commands to specific terminals (e.g., P1 for FX and P2 for RX).

Required Wiring:

  • FX Terminal: Connect to a normally open (NO) contact to start the motor in the forward direction.
  • RX Terminal: Connect to a normally open (NO) contact to start the motor in the reverse direction.
  • CM (Common) Terminal: Provide a common ground connection for all input terminals.

Potentiometer Speed Regulation

For speed regulation using a potentiometer, the following parameters need to be configured:

  • Frq (Frequency Mode): Set to 3 to enable potentiometer input for frequency control.
  • I6-I10 (V1 Input Parameters): Configure the voltage range and corresponding frequency for the potentiometer input.
    • I7 (V1 Input Minimum Voltage): Set to the minimum voltage output by the potentiometer.
    • I8 (V1 Input Minimum Frequency): Set the frequency corresponding to the minimum voltage.
    • I9 (V1 Input Maximum Voltage): Set to the maximum voltage output by the potentiometer.
    • I10 (V1 Input Maximum Frequency): Set the frequency corresponding to the maximum voltage.

Required Wiring:

  • V1 Terminal: Connect to the output of the potentiometer.
  • CM Terminal: Provide a common ground connection for the V1 terminal.
  • 10V Terminal (if applicable): Provide a 10V reference voltage for the potentiometer (not required for potentiometers with built-in reference voltage).

By configuring the above parameters and wiring the terminals correctly, the SV-iGxA series inverter can be easily controlled via external inputs for forward/reverse operation and speed regulation using a potentiometer.