AMP-0041

Fadal Amplifier AMP-0041 Specifications

Part Number AMP-0041 

NEW Glentek Rotary Amplifier
Requires 5000 line encoder, AC Brushless motor.
Used with Fadal AC rotaries  

Important Testing Before Replacing Amplifier
1) Measure the motor wires Ohmic value to ensure a bad motor did not damage the amplifier.
Note: swapping a good amplifier with a bad motor could damage the good amplifier. This is why we recommend the Ohmic test before swapping amplifiers.

Measure the Ohmic value of the three motor wires labeled RST as follows:
First to Ground.
  Measure motor wire labeled R to Ground, the ohmic value should be 1 to 10 Megaohms
  Then measure wire S to Ground and wire T to Ground."
  These three combination should be the same as the other brushless motors in your machine.

Second, Motor Wire To Motor Wire.
  Measure the Ohmic value between R to S, S to T then R to T
  The value should be 1 to 2 Ohms 
If the values are correct you can proceed to the next test step.

2) Put a mark on the bad amplifier and swap it with with one of the other working amplifiers.
There are two possibilities:
   a) The problem moves to the other axis then the amplifier needs to be replaced.
   b) The problem stayed with the original axis. This shows that the amplifier is not the problem. It could be with the motor encoder or wiring.

About The Brushless Amplifier Adjustments
All brushless amplifiers need adjustment after installation. There are three pots that will need to be adjusted:

1) Compensation Pot
The Comp. affects how fast or stiff the servo becomes. The system is designed to be adjusted on the edge of instability. You’ll turn the Pot until the axis buzzes then back off until it stops.

2) Signal Gain Pot
The Signal Pot affects how the amplifier coverts the input signal to an RPM value. To low and the machine won’t get up to the Rapid Traverse speed and generate a MOTOR OVERLOAD fault; to high and the machine will sound to crisp and “bang” as it moves.

3) Balance Pot 
The Balance Pot adjusts the performance of the Signal pot so as to be the same in both directions.

Note: At Power-On, the Axis Controller card will try to rotate the motor as a power-up test. Failure to rotate causes an ERROR #1 or #3. When installing a new amplifier, this Error E-stop can be caused because the amplifier cannot rotate the motor until adjusted correctly. Check initial adjustments before powering on. If this continues, rotate the SIGNAL Pot. more CW and try again.

This test can be temporally eliminated until adjustments made by installing a jumper at J8 of the 1010 axis controller card. When using the J8 Jumper, it’s a good practice to power up the machine with the E-stop button down then release it manually, watching for any possible run away condition when the system powers up.

Steps to Adjust the AMP-0041
First verify if your machine has Glass Scale feed back, they must be disconnected if present:

Check the SCALE 10 pin connector to see if the scale cable is plugged in.
Location of axis control boards in the Mother Board 
Slot 9   The X-Axis Controller Board (1010)
Slot 10 The Y-Axis Controller Board (1010)
Slot 11 The Z-Axis Controller Board (1010)
Slot 12 The B-Axis Controller Board (1010)
Slot 13 The A-Axis Controller Board (1010)

If the SCALE receptacle is empty or has a "dummy plug" then you do not have scales. Proceed to Steps For Adjusting The Amplifier.

If the cable is installed, power down the machine, remove the cable, and then power up the machine.

Steps For Adjusting The Amplifier:
1) Turn the Loop Gain potentiometer all the way clockwise (a clicking sound will be heard when the pot has reached the limit).

2) Slowly turn the Compensation potentiometer counter clockwise until the axis motor produces a High frequency vibration (Buzz), then turn the potentiometer clockwise until it stops buzzing the clockwise another 1 and 1/2 turns.

3) Begin cycling the machine to adjust the Signal Gain and Balance potentiometers.

Enter the following program if adjusting an X, Y or Z axis:

N1 M91 M49 G91 F150.
N2 G9 G1 X-3.Y-3.Z-3.
N3 X3.Y3.Z3.
N4 M99 P2

Enter the following program if adjusting a Rotary axis amplifier. First select the Feedrate using the ratio table on the last page and use it in line 2 of the program below for the F*** value.

N1 M91 M49 G91
N2 G9 A-90. G1 F####
N3 A90.
N4 M99 P2

4) Press AUTO, to start the program running.

5) Turn the Signal Gain potentiometer until the CNC display of the axis to be adjusted reads the correct following error count while running the program.

Clockwise will reduce the following error and counterclockwise will increase the value. The following error is the number displayed to the right of the position display value.

For Metric Ball Screws the target value is 302.

For Inch Ball Screws and Rotary tables the target value is 595.

Use the SETP command to check the current Ball Screw type if you’re not sure about which Ball Screw you may have.

The goal of the adjustment is to match the other axes so the system is dynamically balanced with all the XYZ axes. It’s not required to be exactly set the value, it can be; +- 10 counts, in most cases. However it does somewhat affect the contouring accuracy; the closer the better.

NOTE: If your machine is displaying the axis load %, you’ll need to use the SETP command to change the display setting parameter for “Display the axis following error or Load?” and set it to FOLLOWING ERROR. This setting only affects the display; nothing else.

6) Press the SLIDE HOLD key and adjust the Balance potentiometer of the amplifier to read between 0 - 1.

7) Press the START key and the program will start again. Verify that the following error is still correct starting from step 4 above.

8) Press the SLIDE HOLD key to stop the machine. Press the MANUAL key and then type SETCS and HO, to send the machine home. Adjustment of the amplifier is complete.

Rotary Feedrate Selection Table

Note for Rotary Scales:
When disconnecting the rotary scale to adjust the amplifier, you must verify the SETP axis ratio has the correct mechanical ratio. For example the TR65 B axis normally has the SETP set to a 180 to 1 ratio (when using the scale). It must be temporally set to 90:1 to adjust the amplifier without the scale feedback. Using the SETP command, set the B axis ration back to 180 to 1 after adjusting the amplifier. Changing the ratio requires cycling the power to the machine (off/on).