FANUC AC SERVO MOTOR Alpha is, AC SERVO MOTOR Alpha i series MAINTENANCE MANUAL
FANUC AC SERVO MOTOR @*s series
@
FANUC AC SERVO MOTOR @* series
FANUC AC SPINDLE MOTOR
FANUC SERVO AMPLIF
IER @* series
MAINTENANCE MANUAL
* series
B-65285EN/03
Ȧ No part of this manual may be reproduced in any form.
Ȧ All specifications and designs are subject to change without notice.
In this manual we have tried as much as possible to describe all the
various matters.
However , we cannot describe all the matters which must not be done,
or which cannot be done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in
this manual should be regarded as ”impossible”.
B-65285EN/03 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
The "Safety Precautions" section describes the safety precautions
relating to the use of FANUC servo motors, spindle motors, and servo
amplifiers (power supply modules, servo amplifier modules, and
spindle amplifier modules). Users of any servo motor or amplifier
model are requested to read the "Safety Precautions" carefully before
using the servo motor or amplifier.
The users are also requested to read an applicable specification manual
carefully and understand each function of the motor or amplifier for
correct use.
The users are basically forbidden to do any behavior or action not
mentioned in the "Safety Precautions." They are invited to ask FANUC
previously about what behavior or action is prohibited.
Contents
1.1 DEFINITION OF WARNING, CAUTION, AND NOTE.........s-2
1.2 FANUC AC SERVO MOTOR αis/αi series
FANUC AC SPINDLE MOTOR αi series................................s-3
1.2.1Warning ...........................................................................s-3
1.2.2Caution ...........................................................................s-6
1.2.3Note ...........................................................................s-7
1.3 FANUC SERVO AMPLIFIER αi series ...................................s-9
1.3.1Warnings and Cautions Relating to Mounting ..................s-9
1.3.1.1 Warning.............................................................s-9
1.3.1.2 Caution ............................................................s-11
1.3.1.3 Note .................................................................s-13
1.3.2Warnings and Cautions Relating to a Pilot Run ..............s-14
1.3.2.1 Warning...........................................................s-14
1.3.2.2 Caution ............................................................s-15
1.3.3Warnings and Cautions Relating to Maintenance ...........s-16
1.3.3.1 Warning...........................................................s-16
1.3.4.2 Caution ............................................................s-18
1.3.4.3 Note .................................................................s-19
s-1
SAFETY PRECAUTIONS B-65285EN/03
1.1 DEFINITION OF WARNING, CAUTION, AND NOTE
This manual includes safety precautions for protecting the user and
preventing damage to the machine. Precautions are classified into
Warning and Caution according to their bearing on safety. Also,
supplementary information is described as a Note. Read the Warning,
Caution, and Note thoroughly before attempting to use the machine.
WARNING
Applied when there is a danger of the user being
injured or when there is a damage of both the user
being injured and the equipment being damaged if
the approved procedure is not observed.
CAUTION
Applied when there is a danger of the equipment
being damaged, if the approved procedure is not
observed.
NOTE
The Note is used to indicate supplementary
information other than Warning and Caution.
* Read this manual carefully, and store it in a safe place.
s-2
B-65285EN/03 SAFETY PRECAUTIONS
1.2 FANUC AC SERVO MOTOR α
αis/ααααi series
αα
FANUC AC SPINDLE MOTOR ααααi series
1.2.1 Warning
WARNING
- Be safely dressed when handling a motor.
Wear safety shoes or gloves when handling a motor as you may
get hurt on any edge or protrusion on it or electric shocks.
- Use a crane or lift to move a motor from one place to another.
A motor is heavy. If you lift the motor by hand, you may get a
backache, or you may be seriously injured when you drop the
motor. A suitable crane or lift must be used to move the motor.
(For the weight of motors, refer to their respective specification
manuals.)
When moving a motor using a crane or lift, use a hanging bolt if
the motor has a corresponding tapped hole, or textile rope if it has
no tapped hole.
If a motor is attached with a machine or any other heavy stuff, do
not use a hanging bolt to move the motor as the hanging bolt
and/or motor may get broken.
- Before starting to connect a motor to electric wires, make
sure they are isolated from an electric power source.
A failure to observe this caution is vary dangerous because you
may get electric shocks.
- Be sure to secure power wires.
If operation is performed with a terminal loose, the terminal block
may become abnormally hot, possibly causing a fire. Also, the
terminal may become disconnected, causing a ground fault or
short-circuit, and possibly giving you electric shocks. See the
section in this manual that gives the tightening torque for
attaching power wires and short-bars to the terminal block.
- Be sure to ground a motor frame.
To avoid electric shocks, be sure to connect the grounding
terminal in the terminal box to the grounding terminal of the
machine.
- Do not ground a motor power wire terminal or short-circuit it
to another power wire terminal.
A failure to observe this caution may cause electric shocks or a
burned wiring.
(*) Some motors require a special connection such as a winding
changeover. Refer to their respective motor specification
manuals for details.
s-3
SAFETY PRECAUTIONS B-65285EN/03
WARNING
- Do not supply the power to the motor while any terminal is
exposed.
A failure to observe this caution is very dangerous because you
may get electric shocks if your body or any conductive stuff
touches an exposed terminal.
- Do not bring any dangerous stuff near a motor.
Motors are connected to a power line, and may get hot. If a
flammable is placed near a motor, it may be ignited, catch fire, or
explode.
- Do not get close to a rotary section of a motor when it is
rotating.
You may get your clothes or fingers caught in a rotary section, and
may be injured. Before starting a motor, ensure that there is no
stuff that can fly away (such as a key) on the motor.
- Do not touch a motor with a wet hand.
A failure to observe this caution is vary dangerous because you
may get electric shocks.
- Before touching a motor, shut off the power to it.
Even if a motor is not rotating, there may be a voltage across the
terminals of the motor.
Especially before touching a power supply connection, take
sufficient precautions.
Otherwise you may get electric shocks.
- Do not touch any terminal of a motor for a while (at least 5
minutes) after the power to the motor is shut off.
High voltage remains across power line terminals of a motor for a
while after the power to the motor is shut off. So, do not touch any
terminal or connect it to any other equipment. Otherwise, you may
get electric shocks or the motor and/or equipment may get
damaged.
- To drive a motor, use a specified amplifier and parameters.
Driving a motor with other than the specified combinations of an
amplifier and parameters may cause the motor to perform an
unexpected operation; for example, the motor may get out of
control, or produce excessively high torque. This may result in the
motor or machine being damaged. Also, an object such as a
workpiece or tool may fly off due to excessive rotation, possibly
causing injury.
s-4
B-65285EN/03 SAFETY PRECAUTIONS
- Do not touch a regenerative discharge unit for a while (at
least 30 minutes) after the power to the motor is shut off.
A regenerative discharge unit may get hot when the motor is
running.
Do not touch the regenerative discharge unit before it gets cool
enough. Otherwise, you may get burned.
- Do not touch a motor when it is running or immediately after
it stops.
A motor may get hot when it is running. Do not touch the motor
before it gets cool enough. Otherwise, you may get burned.
- Ensure that motors and related components are mounted
securely.
If a motor or its component slips out of place or comes off when
the motor is running, it is very dangerous.
- Be careful not get your hair or cloths caught in a fan.
Be careful especially for a fan used to generate an inward air flow.
Be careful also for a fan even when the motor is stopped, because
it continues to rotate while the amplifier is turned on.
- When designing and assembling a machine tool, make it
compliant with EN60204-1.
To ensure the safety of the machine tool and satisfy European
standards, when designing and assembling a machine tool, make it
compliant with EN60204-1. For details of the machine tool, refer
to its specification manual.
s-5
SAFETY PRECAUTIONS B-65285EN/03
1.2.2 Caution
CAUTION
- FANUC motors are designed for use with machines. Do not
use them for any other purpose.
If a FANUC motor is used for an unintended purpose, it may
cause an unexpected symptom or trouble. If you want to use a
motor for an unintended purpose, previously consult with
FANUC.
- Ensure that a base or frame on which a motor is mounted is
strong enough.
Motors are heavy. If a base or frame on which a motor is mounted
is not strong enough, it is impossible to achieve the required
precision.
- Be sure to connect motor cables correctly.
An incorrect connection of a cable cause abnormal heat
generation, equipment malfunction, or failure. Always use a cable
with an appropriate current carrying capacity (or thickness). For
how to connect cables to motors, refer to their respective
specification manuals.
- Ensure that motors are cooled if they are those that require
forcible cooling.
If a motor that requires forcible cooling is not cooled normally, it
may cause a failure or trouble. For a fan-cooled motor, ensure that
it is not clogged or blocked with dust and dirt. For a liquid-cooled
motor, ensure that the amount of the liquid is appropriate and that
the liquid piping is not clogged.
For both types, perform regular cleaning and inspection.
- When attaching a component having inertia, such as a pulley,
to a motor, ensure that any imbalance between the motor and
component is minimized.
If there is a large imbalance, the motor may vibrates abnormally,
resulting in the motor being broken.
- Be sure to attach a key to a motor with a keyed shaft.
If a motor with a keyed shaft runs with no key attached, it may
impair torque transmission or cause imbalance, resulting in the
motor being broken.
s-6
B-65285EN/03 SAFETY PRECAUTIONS
1.2.3 Note
NOTE
- Do not step or sit on a motor.
If you step or sit on a motor, it may get deformed or broken. Do
not put a motor on another unless they are in packages.
- When storing a motor, put it in a dry (non-condensing) place
at room temperature (0 to 40°°°°C).
If a motor is stored in a humid or hot place, its components may
get damaged or deteriorated. In addition, keep a motor in such a
position that its shaft is held horizontal and its terminal box is at
the top.
- Do not remove a nameplate from a motor.
If a nameplate comes off, be careful not to lose it. If the nameplate
is lost, the motor becomes unidentifiable, resulting in
maintenance becoming impossible.
For a nameplate for a built-in spindle motor, keep the nameplate
with the spindle.
- Do not apply shocks to a motor or cause scratches to it.
If a motor is subjected to shocks or is scratched, its components
may be adversely affected, resulting in normal operation being
impaired. Be very careful when handling plastic portions, sensors,
and windings, because they are very liable to break. Especially,
avoid lifting a motor by pulling its plastic portion, winding, or
power cable.
- Do not conduct dielectric strength or insulation test for a
sensor.
Such a test can damage elements in the sensor.
- When testing the winding or insulation resistance of a motor,
satisfy the conditions stipulated in IEC60034.
Testing a motor under a condition severer than those specified in
IEC34 may damage the motor.
- Do not disassemble a motor.
Disassembling a motor may cause a failure or trouble in it.
If disassembly is in need because of maintenance or repair, please
contact a service representative of FANUC.
- Do not modify a motor.
Do not modify a motor unless directed by FANUC. Modifying a
motor may cause a failure or trouble in it.
s-7
SAFETY PRECAUTIONS B-65285EN/03
NOTE
- Use a motor under an appropriate environmental condition.
Using a motor in an adverse environment may cause a failure or
trouble in it.
Refer to their respective specification manuals for details of the
operating and environmental conditions for motors.
- Do not apply a commercial power source voltage directly to a
motor.
Applying a commercial power source voltage directly to a motor
may result in its windings being burned. Be sure to use a specified
amplifier for supplying voltage to the motor.
- For a motor with a terminal box, make a conduit hole for the
terminal box in a specified position.
When making a conduit hole, be careful not to break or damage
unspecified portions.
Refer to an applicable specification manual.
- Before using a motor, measure its winding and insulation
resistances, and make sure they are normal.
Especially for a motor that has been stored for a prolonged period
of time, conduct these checks. A motor may deteriorate depending
on the condition under which it is stored or the time during which
it is stored. For the winding resistances of motors, refer to their
respective specification manuals, or ask FANUC. For insulation
resistances, see the following table.
- To use a motor as long as possible, perform periodic
maintenance and inspection for it, and check its winding and
insulation resistances.
Note that extremely severe inspections (such as dielectric strength
tests) of a motor may damage its windings. For the winding
resistances of motors, refer to their respective specification
manuals, or ask FANUC. For insulation resistances, see the
following table.
MOTOR INSULATION RESISTANCE MEASUREMENT
Measure an insulation resistance between each winding and
motor frame using an insulation resistance meter (500 VDC).
Judge the measurements according to the following table.
Insulation resistance Judgment
100MΩ or higher Acceptable
10 to 100 MΩ The winding has begun deteriorating. There is no
problem with the performance at present. Be sure
to perform periodic inspection.
1 to 10 MΩ The winding has considerably deteriorated.
Special care is in need. Be sure to perform
periodic inspection.
Lower than 1 MΩ Unacceptable. Replace the motor.
s-8
B-65285EN/03 SAFETY PRECAUTIONS
1.3 FANUC SERVO AMPLIFIER α
αi series
αα
1.3.1 Warnings and Cautions Relating to Mounting
1.3.1.1 Warning
WARNING
- Check the specification code of the amplifier.
Check that the delivered amplifier is as originally ordered.
- Mount a ground fault interrupter.
To guard against fire and electric shock, fit the factory power
supply or machine with a ground fault interrupter (designed for
use with an inverter).
- Securely ground the amplifier.
Securely connect the ground terminal and metal frame of the
amplifier and motor to a common ground plate of the power
magnetics cabinet.
- Be aware of the weight of the amplifier and other
components.
Control motor amplifiers and AC reactors are heavy. When
transporting them or mounting them in the cabinet, therefore, be
careful not to injured yourself or damage the equipment. Be
particularly carefull not to jam your fingers between the cabinet
and amplifier.
- Never ground or short-circuit either the power supply lines or
power lines.
Protect the lines from any stress such as bending. Handle the ends
appropriately.
- Ensure that the power supply lines, power lines, and signal
lines are securely connected.
A loose screw, loose connection, or the like will cause a motor
malfunction or overheating, or a ground fault.
Be extremely careful with power supply lines, motor power lines,
and DC link connections through which a large amount of current
passes, because a loose screw (or poor contact in a connector or
poor connection between a connector terminal and a cable) may
cause a fire.
- Insulate all exposed parts that are charged.
s-9
SAFETY PRECAUTIONS B-65285EN/03
WARNING
- Never touch the regenerative discharge resistor or radiator
directly.
The surface of the radiator and regenerative discharge unit
become extremely hot. Never touch them directly. An appropriate
structure should also be considered.
- Close the amplifier cover after completing the wiring.
Leaving the cover open presents a danger of electric shock.
- Do not disassemble the amplifier.
- Ensure that the cables used for the power supply lines and
power lines are of the appropriate diameter and temperature
ratings.
- Do not apply an excessively large force to plastic parts.
If a plastic section breaks, it may cause internal damage, thus
interfering with normal operation. The edge of a broken section is
likely to be sharp and, therefore, presents a risk of injury.
s-10
B-65285EN/03 SAFETY PRECAUTIONS
1.3.1.2 Caution
CAUTION
- Do not step or sit on the amplifier.
Also, do not stack unpacked amplifiers on top of each other.
- Use the amplifier in an appropriate environment.
See the allowable ambient temperatures and other requirements,
given in the corresponding descriptions.
- Protect the amplifier from corrosive or conductive mist or
drops of water.
Use a filter if necessary.
- Protect the amplifier from impact.
Do not place anything on the amplifier.
- Connect the power supply lines and power lines to the
appropriate terminals and connectors.
- Connect the signal lines to the appropriate connectors.
- Do not block the air inlet to the radiator.
A deposit of coolant, oil mist, or chips on the air inlet will result in
a reduction in the cooling efficiency. In some cases, the required
efficiency cannot be achieved. The deposit may also lead to a
reduction in the useful life of the semiconductors. Especially,
when outside air is drawn in, mount filters on both the air inlet and
outlet. These filters must be replaced regularly.
So, an easy-to-replace type of filter should be used.
- Before connecting the power supply wiring, check the supply
voltage.
Check that the supply voltage is within the range specified in this
manual, then connect the power supply lines.
- Ensure that the combination of motor and amplifier is
appropriate.
- Ensure that valid parameters are specified.
Specifying an invalid parameter for the combination of motor and
amplifier may not only prevent normal operation of the motor but
also result in damage to the amplifier.
- Ensure that the amplifier and peripheral equipment are
securely connected.
Check that the magnetic contactor, circuit breaker, and other
devices mounted outside the amplifier are securely connected to
each other and that those devices are securely connected to the
amplifier.
s-11
SAFETY PRECAUTIONS B-65285EN/03
CAUTION
- Check that the amplifier is securely mounted in the power
magnetics cabinet.
If any clearance is left between the power magnetics cabinet and
the surface on which the amplifier is mounted, dust entering the
gap may build up and prevent the normal operation of the
amplifier.
- Apply appropriate countermeasures against noise.
Adequate countermeasures against noise are required to maintain
normal operation of the amplifier. For example, signal lines must
be routed away from power supply lines and power lines.
s-12
B-65285EN/03 SAFETY PRECAUTIONS
1.3.1.3 Note
NOTE
- Keep the nameplate clearly visible.
- Keep the legend on the nameplate clearly visible.
- After unpacking the amplifier, carefully check for any
damage.
- Mount the amplifier in a location where it can be easily
accessed periodic inspection and daily maintenance.
- Leave sufficient space around the machine to enable
maintenance to be performed easily.
Do not place any heavy objects such that they would interfere
with the opening of the doors.
- Keep the parameter table and spare parts at hand.
Also, keep the specifications at hand. These items must be stored
in a location where they can be retrieved immediately.
- Provide adequate shielding.
A cable to be shielded must be securely connected to the ground
plate, using a cable clamp or the like.
s-13
SAFETY PRECAUTIONS B-65285EN/03
1.3.2 Warnings and Cautions Relating to a Pilot Run
1.3.2.1 Warning
WARNING
- Before turning on the power, check that the cables connected
to the power magnetics cabinet and amplifier, as well as the
power lines and power supply lines, are securely connected.
Also, check that no lines are slack.
A loose screw, loose connection, or the like will cause a motor
malfunction or overheating, or a ground fault. Be extremely
careful with power supply lines, motor power lines, and DC link
connections through which a large amount of current passes,
because a loose screw (or poor contact in a connector or poor
connection between a connector terminal and a cable) may cause a
fire.
- Before turning on the power, ensure that the power magnetics
cabinet is securely grounded.
- Before turning on the power, check that the door of the power
magnetics cabinet and all other doors are closed.
Ensure that the door of the power magnetics cabinet containing
the amplifier, and all other doors, are securely closed. During
operation, all doors must be closed and locked.
- Apply extreme caution if the door of the power magnetics
cabinet or another door must be opened.
Only a person trained in the maintenance of the corresponding
machine or equipment should open the door, and only after
shutting off the power supply to the power magnetics cabinet (by
opening both the input circuit breaker of the power magnetics
cabinet and the factory switch used to supply power to the
cabinet). If the machine must be operated with the door open to
enable adjustment or for some other purpose, the operator must
keep his or her hands and tools well away from any dangerous
voltages. Such work must be done only by a person trained in the
maintenance of the machine or equipment.
- When operating the machine for the first time, check that the
machine operates as instructed.
To check whether the machine operates as instructed, first specify
a small value for the motor, then increase the value gradually. If
the motor operates abnormally, perform an emergency stop
immediately.
- After turning on the power, check the operation of the
emergency stop circuit.
Press the emergency stop button to check that the motor stops
immediately, and that the power being supplied to the amplifier is
shut off by the magnetic contactor.
s-14
B-65285EN/03 SAFETY PRECAUTIONS
- Before opening a door or protective cover of a machine to
enable adjustment of the machine, first place the machine in
the emergency stop state and check that the motor has
stopped.
s-15
SAFETY PRECAUTIONS B-65285EN/03
1.3.2.2 Caution
CAUTION
- Note whether an alarm status relative to the amplifier is
displayed at power-up or during operation.
If an alarm is displayed, take appropriate action as explained in
the maintenance manual. If the work to be done requires that the
door of the power magnetics cabinet be left open, the work must
be carried out by a person trained in the maintenance of the
machine or equipment. Note that if some alarms are forcibly reset
to enable operation to continue, the amplifier may be damaged.
Take appropriate action according to the contents of the alarm.
- Before operating the motor for the first time, mount and
adjust the position and speed sensors.
Following the instructions given in the maintenance manual,
adjust the position and speed sensors for the spindle so that an
appropriate waveform is obtained.
If the sensors are not properly adjusted, the motor may not rotate
normally or the spindle may fail to stop as desired.
- If the motor makes any abnormal noise or vibration while
operating, stop it immediately.
Note that if operation is continued in spite of there being some
abnormal noise or vibration, the amplifier may be damaged. Take
appropriate corrective action, then resume operation.
- Observe the ambient temperature and output rating
requirements.
The continuous output rating or continuous operation period of
some amplifiers may fall as the ambient temperature increases. If
the amplifier is used continuously with an excessive load applied,
the amplifier may be damaged.
- Unless otherwise specified, do not insert or remove any
connector while the power is turned on. Otherwise, the
amplifier may fail.
s-16
B-65285EN/03 SAFETY PRECAUTIONS
1.3.3 Warnings and Cautions Relating to Maintenance
1.3.3.1 Warning
WARNING
- Read the maintenance manual carefully and ensure that you
are totally familiar with its contents.
The maintenance manual describes daily maintenance and the
procedures to be followed in the event of an alarm being issued.
The operator must be familiar with these descriptions.
- Notes on replacing a fuse or PC board
1) Before starting the replacement work, ensure that the circuit
breaker protecting the power magnetics cabinet is open.
2) Check that the red LED that indicates that charging is in
progress is not lit.
The position of the charging LED on each model of amplifier
is given in this manual. While the LED is lit, hazardous
voltages are present inside the unit, and thus there is a danger
of electric shock.
3) Some PC board components become extremely hot. Be
careful not to touch these components.
4) Ensure that a fuse having an appropriate rating is used.
5) Check the specification code of a PC board to be replaced. If
a modification drawing number is indicated, contact FANUC
before replacing the PC board.
Also, before and after replacing a PC board, check its pin
settings.
6) After replacing the fuse, ensure that the screws are firmly
tightened. For a socket-type fuse, ensure that the fuse is
inserted correctly.
7) After replacing the PC board, ensure that it is securely
connected.
8) Ensure that all power lines, power supply lines, and
connectors are securely connected.
- Take care not to lose any screws.
When removing the case or PC board, take care not to lose any
screws. If a screw is lost inside the nit and the power is turned on,
the machine may be damaged.
s-17
SAFETY PRECAUTIONS B-65285EN/03
WARNING
- Notes on replacing the battery of the absolute pulse coder
Replace the battery only while the power is on. If the battery is
replaced while the power is turned off, the stored absolute
positioning data will be lost. Some series servo amplifier modules
have batteries in their servo amplifiers. To replace the battery of
any of those models, observe the following procedure: Open the
door of the power magnetics cabinet; Leave the control power of
the power supply module on; Place the machine in the emergency
stop state so that the power being input to the amplifier is shut off;
Then, replace the battery. Replacement work should be done only
by a person who is trained in the related maintenance and safety
requirements. The power magnetics cabinet in which the servo
amplifier is mounted has a high-voltage section. This section
presents a severe risk of electric shock.
- Check the number of any alarm.
If the machine stops upon an alarm being issued, check the alarm
number. Some alarms indicate that a component must be replaced.
If the power is reconnected without first replacing the failed
component, another component may be damaged, making it
difficult to locate the original cause of the alarm.
- Before resetting an alarm, ensure that the original cause of
the alarm has been removed.
- Contact FANUC whenever a question relating to
maintenance arises.
- Notes on removing the amplifier
Before removing the amplifier, first ensure that the power is shut
off. Be careful not to jam your fingers between the power
magnetics cabinet and amplifier.
s-18
B-65285EN/03 SAFETY PRECAUTIONS
1.3.3.2 Caution
CAUTION
- Ensure that all required components are mounted.
When replacing a component or PC board, check that all
components, including the snubber capacitor, are correctly
mounted. If the snubber capacitor is not mounted, for example, the
IPM will be damaged.
- Tighten all screws firmly.
- Check the specification code of the fuse, PC board, and other
components.
When replacing a fuse or PC board, first check the specification
code of the fuse or PC board, then mount it in the correct position.
The machine will not operate normally if a fuse or PC board
having other than the correct specification code is mounted, or if a
fuse or PC board is mounted in the wrong position.
- Mount the correct cover.
The cover on the front of the amplifier carries a label indicating a
specification code. When mounting a previously removed front
cover, take care to mount it on the unit from which it was
removed.
- Notes on cleaning the heat sink and fan
1) A dirty heat sink or fan results in reduced semiconductor
cooling efficiency, which degrades reliability. Periodic
cleaning is necessary.
2) Using compressed air for cleaning scatters the dust. A
deposit of conductive dust on the amplifier or peripheral
equipment will result in a failure.
3) To clean the heat sink, do so only after turning the power off
and ensuring that the heat sink has cooled to room
temperature. The heat sink becomes extremely hot, such that
touching it during operation or immediately after power-off
is likely to cause a burn. Be extremely careful when touching
the heat sink.
s-19
SAFETY PRECAUTIONS B-65285EN/03
1.3.3.3 Note
NOTE
- Ensure that the battery connector is correctly inserted.
If the power is shut off while the battery connector is not
connected correctly, the absolute position data for the machine
will be lost.
- Store the manuals in a safe place.
The manuals should be stored in a location where they can be
accessed immediately it so required during maintenance work.
- Notes on contacting FANUC
Inform FANUC of the details of an alarm and the specification
code of the amplifier so that any components required for
maintenance can be quickly secured, and any other necessary
action can be taken without delay.
s-20
B-65285EN/03 PREFACE
PREFACE
Organization of this manual
This manual describes information necessary to maintain FANUC
servo amplifier αi series products, such as a power supply module,
servo amplifier module, and spindle amplifier module and FANUC
servo motor αis/αi series and FANUC spindle motor αi series
products.
Part I explains the start-up procedure, and part II focuses on
troubleshooting.
Part III explains the maintenance for servo motor and spindle motor.
The abbreviations listed below are used in this manual.
Product name Abbreviations
FANUC Series 15i FS15i
FANUC Series 16i FS16i
FANUC Series 18i FS18i
FANUC Series 21i FS21i
FANUC Series 0i FS0i
FANUC Power Mate i-D
FANUC Power Mate i-H
Power Supply Module PSM
Servo Amplifier Module SVM
Spindle Amplifier Module SPM
PMi
Series 15
Series 16i, 18i, 21i, 0i, PM
i
* In this manual, the parameter numbers of servo parameters are
sometimes indicated without CNC product names as follows:
Servo parameter function name or bit
No. 1877 (FS15i)
i
No. 2062 (FS16i)
Overload protection coefficient (OVC1)
* The manuals shown below provide information related to this
manual. This manual may refer you to these manuals.
FANUC SERVO AMPLIFIER αi series Descriptions B-65282EN
FANUC AC SERVO MOTOR αis/αi series Descriptions B-65262EN
FANUC AC SPINDLE MOTOR αi series Descriptions B-65272EN
FANUC AC SERVO MOTOR αis/αi series Parameter Manual
B-65270EN
FANUC AC SPINDLE MOTOR αi series Parameter Manual
B-65280EN
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B-65285EN/03 TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PRECAUTIONS.......................................................................... s-1
PREFACE.................................................................................................. p-1
I. START-UP PROCEDURE
1 OVERVIEW ............................................................................................3
2 CONFIGURATIONS ...............................................................................4
2.1 CONFIGURATIONS ......................................................................................5
2.2 MAJOR COMPONENTS................................................................................7
2.2.1 Power Supply Modules............................................................................................ 7
2.2.2 Servo Amplifier Modules........................................................................................ 8
2.2.3 Spindle Amplifier Modules ..................................................................................... 9
3 START-UP PROCEDURE....................................................................11
3.1 START-UP PROCEDURE (OVERVIEW) ....................................................12
3.2 CONNECTING THE POWER ......................................................................13
3.2.1 Checking the Voltage and Capacity of the Power................................................. 13
3.2.2 Connecting a Protective Ground............................................................................ 14
3.2.3 Selecting the Ground Fault Interrupter That Matches the Leakage Current......... 14
3.3 INITIALIZING SERVO PARAMETERS........................................................15
4 CONFIRMATION OF THE OPERATION..............................................16
4.1 POWER SUPPLY MODULE........................................................................17
4.1.1 Checking the Status LEDs..................................................................................... 18
4.1.2 Check Terminal on the Printed-circuit Board ....................................................... 19
4.1.3 The PIL LED (Power ON Indicator) Is Off........................................................... 21
4.1.4 Checking Method when Magnetic Contactor Is not Switched On........................ 22
4.2 SERVO AMPLIFIER MODULE ....................................................................23
4.2.1 Checking the STATUS Display ............................................................................ 24
4.2.2 VRDY-OFF Alarm Indicated on the CNC Screen ................................................ 25
4.2.3 Method for Observing Motor Current ................................................................... 26
4.3 SPINDLE AMPLIFIER MODULE .................................................................29
4.3.1 STATUS Display................................................................................................... 30
4.3.2 Troubleshooting at Startup .................................................................................... 31
4.3.2.1 The PIL LED (power-on indicator) is off...........................................................31
4.3.2.2 The STATUS display is blinking with "--." .......................................................32
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4.3.2.3 The motor does not turn..................................................................................... 33
4.3.2.4 A specified speed cannot be obtained. ...............................................................33
4.3.2.5 When cutting is not performed, the spindle vibrates, making noise. .................. 34
4.3.2.6 An overshoot or hunting occurs. ........................................................................34
4.3.2.7 Cutting power weakens or acceleration/deceleration slows down...................... 35
4.3.3 Status Error Indication Function ........................................................................... 36
4.3.4 Checking the Feedback Signal Waveform ............................................................ 39
4.3.4.1 Mi, MZi, and BZi sensors ..................................................................................40
4.3.4.2 α position coder S ..............................................................................................41
4.3.5 Spindle Check Board............................................................................................. 42
4.3.5.1 Spindle check board specifications ....................................................................42
4.3.5.2 Check board connection..................................................................................... 42
4.3.5.3 Check terminal output signals ............................................................................44
4.3.6 Observing Data Using the Spindle Check Board .................................................. 46
4.3.6.1 Overview............................................................................................................ 46
4.3.6.2 Major characteristics .......................................................................................... 46
4.3.6.3 Observation method ...........................................................................................46
4.3.6.4 Specifying data to be monitored......................................................................... 47
4.3.6.5 Address descriptions and initial values (SPM)...................................................48
4.3.6.6 Principles in outputting the internal data of the serial spindle............................49
4.3.6.7 Data numbers .....................................................................................................53
4.3.6.8 Example of observing data.................................................................................56
4.3.7 Checking Parameters Using the Spindle Check Board.......................................... 57
4.3.7.1 Overview............................................................................................................ 57
4.3.7.2 Checking parameters .......................................................................................... 57
4.3.8 Observing Data Using the SERVO GUIDE .......................................................... 58
4.3.8.1 Overview............................................................................................................ 58
4.3.8.2 Usable series and editions ..................................................................................58
4.3.8.3 List of spindle data that can be observed using the SERVO GUIDE................. 58
4.3.8.4 About the spindle control and spindle status signals..........................................59
4.3.8.5 Example of observing data.................................................................................60
5 PERIODIC MAINTENANCE OF SERVO AMPLIFIER..........................61
5.1 BATTERY FOR THE ABSOLUTE PULSECODER......................................62
5.2 PERIODIC MAINTENANCE OF SERVO AMPLIFIER .................................69
II. TROUBLESHOOTING
1 OVERVIEW ..........................................................................................75
2 ALARM NUMBERS AND BRIEF DESCRIPTIONS ..............................76
2.1 FOR Series 15i ............................................................................................77
2.1.1 Servo Alarm........................................................................................................... 77
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2.1.2 Spindle Alarm........................................................................................................ 79
2.2 FOR Series 16i, 18i, 20i, 21i, 0i, AND Power Mate i...................................81
2.2.1 Servo Alarm........................................................................................................... 81
2.2.2 Spindle Alarm........................................................................................................ 83
3 TROUBLESHOOTING AND ACTION ..................................................85
3.1 POWER SUPPLY MODULE (PSM, PSMR) ................................................86
3.1.1 Alarm Code 1 (PSM)............................................................................................. 86
3.1.2 Alarm Code 2 (PSM, PSMR) ................................................................................ 87
3.1.3 Alarm Code 3 (PSM)............................................................................................. 87
3.1.4 Alarm Code 4 (PSM, PSMR) ................................................................................ 87
3.1.5 Alarm Code 5 (PSM, PSMR) ................................................................................ 88
3.1.6 Alarm Code 6 (PSM, PSMR) ................................................................................ 88
3.1.7 Alarm Code 7 (PSM, PSMR) ................................................................................ 88
3.1.8 Alarm Code 8 (PSMR) .......................................................................................... 89
3.1.9 Alarm Code A (PSM)............................................................................................ 89
3.1.10 Alarm Code E (PSM, PSMR)................................................................................ 89
3.1.11 Alarm Code H (PSMR) ......................................................................................... 90
3.2 SERVO AMPLIFIER MODULE ....................................................................91
3.2.1 Alarm Code 1......................................................................................................... 93
3.2.2 Alarm Code 2......................................................................................................... 93
3.2.3 Alarm Code 5......................................................................................................... 93
3.2.4 Alarm Code 6......................................................................................................... 94
3.2.5 Alarm Code F ........................................................................................................ 94
3.2.6 Alarm Code P ........................................................................................................ 94
3.2.7 Alarm Code 8......................................................................................................... 95
3.2.8 Alarm Codes 8., 9., and A. .................................................................................... 96
3.2.9 Alarm Codes 8., 9., and A. .................................................................................... 96
3.2.10 Alarm Codes b, c, and d ........................................................................................ 97
3.2.11 Alarm Code "-" Blinking....................................................................................... 98
3.2.12 Alarm Code U........................................................................................................ 99
3.2.13 Alarm Code L ...................................................................................................... 100
3.3 SERVO SOFTWARE .................................................................................101
3.3.1 Servo Adjustment Screen .................................................................................... 101
3.3.2 Diagnosis Screen ................................................................................................. 103
3.3.3 Overload Alarm (Soft Thermal, OVC)................................................................ 104
3.3.4 Feedback Disconnected Alarm............................................................................ 105
3.3.5 Overheat Alarm ................................................................................................... 106
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3.3.6 Invalid Servo Parameter Setting Alarm............................................................... 106
3.3.7 Alarms Related to Pulsecoder and Separate Serial Detector............................... 107
3.3.8 Other Alarms ....................................................................................................... 110
3.4 SPINDLE AMPLIFIER MODULE ...............................................................112
3.4.1 Alarm Code 01..................................................................................................... 112
3.4.2 Alarm Code 02..................................................................................................... 113
3.4.3 Alarm Code 03..................................................................................................... 114
3.4.4 Alarm Code 06..................................................................................................... 114
3.4.5 Alarm Code 07..................................................................................................... 115
3.4.6 Alarm Code 09..................................................................................................... 116
3.4.7 Alarm Code 12..................................................................................................... 117
3.4.8 Alarm Code 15..................................................................................................... 118
3.4.9 Alarm Code 18..................................................................................................... 118
3.4.10 Alarm Codes 19 and 20 ....................................................................................... 118
3.4.11 Alarm Code 21..................................................................................................... 119
3.4.12 Alarm Code 24..................................................................................................... 119
3.4.13 Alarm Code 27..................................................................................................... 120
3.4.14 Alarm Code 29..................................................................................................... 121
3.4.15 Alarm Code 31..................................................................................................... 122
3.4.16 Alarm Code 32..................................................................................................... 122
3.4.17 Alarm Code 34..................................................................................................... 122
3.4.18 Alarm Code 36..................................................................................................... 123
3.4.19 Alarm Code 37..................................................................................................... 123
3.4.20 Alarm Code 41..................................................................................................... 124
3.4.21 Alarm Code 42..................................................................................................... 124
3.4.22 Alarm Code 46..................................................................................................... 124
3.4.23 Alarm Code 47..................................................................................................... 125
3.4.24 Alarm Code 50..................................................................................................... 125
3.4.25 Alarm Codes 52 and 53 ....................................................................................... 126
3.4.26 Alarm Code 54..................................................................................................... 126
3.4.27 Alarm Code 55..................................................................................................... 126
3.4.28 Alarm Code 56..................................................................................................... 126
3.4.29 Alarm Code 66..................................................................................................... 127
3.4.30 Alarm Code 69..................................................................................................... 127
3.4.31 Alarm Code 70..................................................................................................... 127
3.4.32 Alarm Code 71..................................................................................................... 127
3.4.33 Alarm Code 72..................................................................................................... 127
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3.4.34 Alarm Code 73..................................................................................................... 128
3.4.35 Alarm Code 74..................................................................................................... 128
3.4.36 Alarm Code 75..................................................................................................... 128
3.4.37 Alarm Code 76..................................................................................................... 129
3.4.38 Alarm Code 77..................................................................................................... 129
3.4.39 Alarm Code 78..................................................................................................... 129
3.4.40 Alarm Code 79..................................................................................................... 129
3.4.41 Alarm Code 81..................................................................................................... 130
3.4.42 Alarm Code 82..................................................................................................... 131
3.4.43 Alarm Code 83..................................................................................................... 131
3.4.44 Alarm Code 84..................................................................................................... 132
3.4.45 Alarm Code 85..................................................................................................... 132
3.4.46 Alarm Code 86..................................................................................................... 132
3.4.47 Alarm Code 87..................................................................................................... 132
3.4.48 Alarm Code 88..................................................................................................... 132
3.4.49 Alarm Codes A, A1, and A2................................................................................ 132
3.4.50 Alarm Code b0..................................................................................................... 133
3.4.51 Alarm Codes C0,C1, and C2 ............................................................................... 133
3.4.52 Alarm Code C3.................................................................................................... 133
3.4.53 Other Alarms ....................................................................................................... 134
3.5 αCi SERIES SPINDLE AMPLIFIER MODULE ..........................................135
3.5.1 Alarm Code 12..................................................................................................... 135
3.5.2 Alarm Code 35..................................................................................................... 136
4 HOW TO REPLACE THE FUSES AND PRINTED CIRCUIT
BOARDS ............................................................................................137
4.1 HOW TO REPLACE THE FUSES AND PRINTED CIRCUIT BOARDS ....138
4.1.1 Ordering Number of Printed Circuit Board......................................................... 139
4.1.2 Fuse Locations..................................................................................................... 140
4.1.2.1 PSM .............................................................................................................. 140
4.1.2.2 SVM .............................................................................................................. 141
4.1.2.3 SPM ..............................................................................................................142
4.2 HOW TO REPLACE THE FAN MOTOR.................................................... 143
4.2.1 Internal-Fan Motor Replacement Procedure Common to 60, 90, and 150 mm
Wide Units........................................................................................................... 143
4.2.2 External-Fan Motor Replacement Procedure for 60 and 90 mm Wide Units ..... 144
4.2.3 External-Fan Motor Replacement Procedure for 150 mm Wide Unit................. 145
4.2.4 External-Fan Motor Replacement Procedure for 300 mm Wide Unit................. 146
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III. MOTOR MAINTENANCE
1 SERVO MOTOR MAINTENANCE......................................................149
1.1 RECEIVING AND KEEPING AC SERVO MOTORS .................................150
1.2 DAILY INSPECTION OF AC SERVO MOTORS .......................................151
1.3 PERIODIC INSPECTION OF AC SERVO MOTORS ................................153
1.4 REPLACING THE PULSECODER ............................................................156
1.5 SPECIFICATION NUMBERS OF REPLACEMENT PARTS......................158
2 SPINDLE MOTOR MAINTENANCE...................................................159
2.1 PREVENTIVE MAINTENANCE .................................................................160
2.2 MAINTENANCE PARTS............................................................................163
2.3 ALLOWABLE RADIAL LOAD ....................................................................167
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