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Biesse Rover 321 Inverter Problem

12/15/19

Dear all,
I have an intermittent problem on the 321R's spindle motors. The machine is equipped with 2 spindle motors controlled by a single Control Techniques CD750 mkII inverter (only 1 operates at a time).

The motors fail to start or are interrupted mid-operation (while the machine axes continue running until the PLC throws an error and a stop command). The fault occurs regardless of motor loading.

The 321's controller shows errors S02 (PLC stop command issued), S0130 (inverter timeout "exhausted"), and xx91 (inverter did not power spindle motor).
The VFD's display does not show any errors - status remains rdy (ready).

I'm worried that the problem is intermittent, the machine might run for several hours without a hitch, then fail to start the spindle on the next operation, or it might happen on the first start-up for the day, as well as mid-operation (very concerning as there is latency before the PLC shuts down the axis drives and we might bend/brake tools, etc).

Has anyone encountered a similar problem? Am I correct in suspecting the inverter, although it does not display any errors? Is it possible that an external/internal trip situation is occurring that is not communicated back to the Rover's controller, nor displayed on the VFD's control box?

Thank you,
N

12/18/19 #3: Biesse Rover 321 Inverter Problem ...

Dropout

Member

Could be the signal to the VFD is interrupted somehow.

Will the axis move if the spindle doesn't start?

12/22/19 #4: Biesse Rover 321 Inverter Problem ...

cabinetmaker

I used to open the door to the cabinet. It was an overheating problem for me

12/27/19 #5: Biesse Rover 321 Inverter Problem ...

Nikola Plamenov

Hi all,

Dropout: the PLC and VFD are talking, I probed the RS485 lines and got valid data in both directions. If the link was down, the controller would throw a different error.
Unfortunately, yes, there are cases when the spindle stops during a routine but the axes continue until the controller processes the error, requiring constant supervision.

Cabinetmaker: no thermal issues as far as i can see. The fault can occur at the first startup for the day or at some random point during machining.

As I said, I have tried to capture the data between the PLC and VFD for signs of stop commands or odd behavior. I can only record one direction (VFD->PLC or vise versa) at a time, but I have been able to record several fault cases and have a hex dump of the comms. No smoking gun though.

Thank you

12/27/19 #6: Biesse Rover 321 Inverter Problem ...

Mark T

Website: http://www.cnccustomservices.com

The problem being intermittent and the configuration of one inverter driving both electrospindles makes me wonder if the perhaps your PLC just needs to be reset?
I am assuming this is an NC481 / RT480 control based on the error configuration.
Below is the process

How to reset the PLC on the RT480 control

1. Old PLC versions (12 or smaller)

� Go to the Editor page
� Press the window key
� Select PLC
� Select the PLC softkey
� Select the EDIT softkey
� Find the line that says:

INSTR OPER.1 OPER.2
FILL 1000 1077

� Change the 1077 to 1177
� Halt the PLC
� Put the PLC back in GO
� Press STOP + RESET (usually more than once)
� Go back to the PLC page
� Put the 1177 back to 1077
� Halt the PLC
� Put it back in GO
� Press STOP + RESET

2. New PLC versions (larger than 12)

� Make sure the machine is in emergency
� Make sure that the PLC is in GO
� Go to the manual page
� Press simultaneously the keys 1 and 5 (from left) of the PLC keyboard
� If this operation has been correctly executed you will have the errors xx68 and xx36
� Halt the PLC
� Put it back in go

1/1/20 #7: Biesse Rover 321 Inverter Problem ...

cabinetmaker

I can remember having to reload the eprom chip for the controller once

Not difficult @ all

Russ Walton @ Biesse can help you do this

1/3/20 #8: Biesse Rover 321 Inverter Problem ...

Nikola Plamenov

Mark T: Thank you for the suggestion and through instructions; these procedures are not listed in the documentation, despite it being a complete set. I wonder what other (IMO essential) troubleshooting information is not available to us.
We were able to reset the PLC as per your procedure, although the edited line had a different value in Operand 2 (1076 instead of 1077). I do not fully understand how these steps reset the PLC, but the issue seems to be resolved at the moment. Thank you once again.

Cabinetmaker: if you are referring to the PLC EEPROM, yes, re-flashing it would have been the next troubleshooting step. Mark's procedure for resetting the controller seems to have cleared the problem for the time (TBD after work starts next week).

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