explain this:
the drive knows that it stopped -???? what is on FR-SF LED indicator when it stopped?
The FR-SF shows 0 rpm no alarm, if you sit there and wait for it to happen you can watch the rpm change (reads the same on the control), I would also expect the spindle to coast to a stop but it is almost like it got an M5 command. <script src="https://adservice.google.com/adsid/integrator.sync.js?domain=www.practicalmachinist.com" ></script><script >processGoogleTokenSync({"newToken":"FBS"},5);</script>
what is more likely happening is FR-SF stops AC motor for some reason ( could be loss of communication through BUS cable with NC control, black cable that connects all servo and spindle ) and after that doesnt update NC on AC motor status, like SPINDLE UP TO SPEED. So NC basically doesnt understand what is happening with AC motor.
We already tried swapping the cable from another machine.
You have R2105 , bit 2 M5017 relay - WAITING CUTTING FEED UNTIL SP. UP TO SPEED parameter ( 1 is valid) means , if you make it 1 machine wont move axis unless spindle up to speed. If it moves when spindle stopped means, NC has no feedback from FR-SF
Mazak told me because we were not using mazatrol the control doesn't care that the spindle stopped I will have to try the r2105
the other thing is R2140/5 is SPINDLE UP TO SPEED PERCENTAGE, NC always is looking for spindle RPM feedback.
Same as above
how do you get rid of the issue? Main power cycling? if yes, then when it happens again have a look on VERSION screen, if you can see Spindle drive software version ( means machine is still talking to FR-SF) if version number is missing, no communication at all.
I can just restart the spindle as there is no alarm, I thought it might have been program related but I have seen it happen in mdi or jog mode. The worst part is sometimes the machine will run for a week (3 shifts) with no problems, and sometimes it happens multiple times a day.
Have a look when it stops inside PLC ladder on signal -\\- X245, that is NC --> PLC signal that spindle is UP TO SPEED. If that signal is ON when SPINDLE stopped that it means NC wasnt updated properly.