Yaskawa YASNAC PC NC Maintenance Manual

YASNAC PC NC

Maintenance Manual

Contents

Chapter 1: General Installation and Electrical Connection		................... 1-1
1.1	Component Arrangement ............................................................	1-1
1.2	General Specifications ................................................................	1-5
Chapter 2: Routine Inspection ...............................................................		2-1
2.1	Routine Inspection ......................................................................	2-1
2.2 Battery.........................................................................................		2-1
2.3	Servo Motor ................................................................................	2-3
2.4	Fan ..............................................................................................	2-4
2.5	Touch Screen ..............................................................................	2-5
2.6	Control Panel ..............................................................................	2-6
Chapter 3: Maintenance Instruments .....................................................		3-1
Chapter 4: Troubleshooting ...................................................................		4-1
4.1	Maintenance Data .......................................................................	4-1
The VS-626M5 .....................................................................................		4-80
4.2	Notes For Safe Operation .........................................................	4-80
4.3	Receiving ..................................................................................	4-86
4.4	Installation ................................................................................	4-90
4.5	Wiring .......................................................................................	4-93
4.6	Operation ................................................................................	4-128
4.7	Digital Operator ......................................................................	4-133
4.8	Maintenance And Inspection ..................................................	4-147
4.9	Troubleshooting ......................................................................	4-149
Chapter 5: Adjustments .........................................................................		5-1

Chapter 6: Module/Unit Replacement ...................................................		6-1
6.1 CPU Rack ...................................................................................		6-1
6.2	CRT Display Unit .......................................................................	6-8
6.3	Floppy Disk Drive Unit ............................................................	6-17
6.4	NC Power Supply .....................................................................	6-18
6.5	Handheld Remote Machine Pendant.........................................	6-19
6.6 Noise Filter ...............................................................................		6-20
Chapter 7: Memory Option ....................................................................		7-1
7.1	Part Numbers ..............................................................................	7-1
7.2	RAM DIMM Installation ............................................................	7-1
Chapter 8: Fixed File Operations ............................................................		8-3
8.1	NC Data Handling ......................................................................	8-3
8.2 Yasnac PC NC CPU Rack BIOS Setup ....................................		8-59
8.3	PLC Label in Diagnosis and Parameter Screens ......................	8-69
8.4	CNC Card Software Update .....................................................	8-72
8.5	Manual Page Customization .....................................................	8-82
8.6	Properties File Customization...................................................	8-84

Chapter 1: General Installation and Electrical Connection	PC NC Maintenance Manual

Chapter 1: General Installation and

Electrical Connection

This section addresses the basic system: configuration, specifications, enclosure design, electrical connections, and installation.

1.1 Component Arrangement

The YASNAC PC NC unit is composed of two boards: JCP20 and JFC20 (JZNC-JFC10). (Refer to the figure below.) The PC NC unit is inserted into a PC extended bus (ISA) inside the personal computer (PC) case. The I/O module, servo unit, spindle drive, and motor are the same as those of the YASNAC J100 CNC UNIT.

Figure 1.1: The YASNAC PC NC Unit

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PC NC Maintenance Manual	Chapter 1: General Installation and Electrical Connection

FDD Mouse

PC NC case

PC

ISA bus

JFC10

DC +24V power

I/O Module

Monitor with Touch screen

Keyboard

Feeding servo unit

Spindle drive unit

High voltage

Machine

Feeding

motor

Spindle motor

Device on machine side

Figure 1.2: The YASNAC PC NC System Structure Diagram

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Chapter 1: General Installation and Electrical Connection	PC NC Maintenance Manual

CPU R AC K UNIT		Connection Between Devices
						CRT
							KEYBO AR D
		HDD	DA TA
ATX			PW R				M O USE
M O THER									TB3
BO ARD							FDD
						DATA		P W R
	ID E I/F
	K B D						TS
	C OM 2						CO NTRO L		TO UC H
	FD D
									SCREEN
						SE RVO O N
	C OM 1
PS/2 M O USE						SH UT DO W N
	LPT1			DC
				O UT
	VID EO				24VDC FO R	M ACH IN E
					M ACHINE I/O			M AC HINE O P. PANEL I/O
	CARD					CO NTRO L
						SIG NA LS
PCI			VIDEO		CN1~6 I/O B OA RD		CN14	CN5
									I/O BO ARD CN1	HPG
					FO R M ACHINE SIG NAL
									FO R M ACHINE
					(FC 8X X)
									O P . PN L.
					CN11
									(JS P02/04)
					CN13		CN12	CN3	CN7,8,9
	JFC 20
			CN01						M A CHINE PANEL
					S ENSO R SIG NAL
			CN02							SIG NALS
			CN03				SERVO UNIT		SG M G -
			CN04			SG D C -**AJA			**A2AB*
ISA									M
			CN05			4C N		3C N
						1C N
							Z AXIS
						52C N
								2C N	PG
						51C N
						SG D C -**AJA			M
						4C N		3C N
FAN 1	JCP20-1					1C N
			CN11				Y AXIS
						52C N
			CN12					2C N	PG
						51C N
			CN13
CPU			CN14			SG D C -**AJA
FAN									M
						4C N		3C N
						1C N	X AXIS
						52C N
								2C N	PG
						51C N
FA N3		CASE FAN				INVERTER UNIT			UAASK*-**FZ*
							C1M R -M 5N			FA
						4C N			M
		PC PO W ER								N
						1C N
		SUPPLY
	O UT		O UT			52C N
			PG S					2C N	PG
		INPUT	(P OW ER			51C N
			G O O D
			S IG NA L)
					C O NVERTER UNIT
						C1M R -M R 5N
									REACTO R
			NC PO W ER		5C N			R /S/T	X0100**
			SUPPLY
			INPU T O UTPU T					A1/A2
				INPUT PO W ER UNIT
				TB2		S VM
				TB1
				NFB
			AC230V	SVM		A1/A2

Figure 1.3: Detail Connection of PC NC Unit With Various Devices.

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PC NC Maintenance Manual	Chapter 1: General Installation and Electrical Connection

Connector Layout NC Side

The following figure provides a detailed Connectors Layout of the YAS-

NAC JZNC-JFC10 board.

Servo controller connector (CN01)

I/O module connector (CN02)

Power good signal connector (CN03)

Interruption setting short pin (S11)

Memory address setting rotary switch (S12)

I/O module power output verification LED

I/O module power output connector (CN04)

I/O module power input connector (CN05)

I/O module power input verification LED attery power reply supply connector (CN06)

Battery

	Servo controller I/O connector (CN11)
	Power On/Off connector (CN12)
	Fuse (HM03, 0.3A) (F1)
	RS232C connector (CN14)
	Direct IN/OUT connector (CN14)
	System load switch (S1)
	System load switch (S1)
	(from top: 1, 2, 3, 4)
	Battery alarm LED
LITHIUM	System load rotary switch (S1)

Figure 1.4: Detailed Layout of the YASNAC JZNC-JFC10 Board

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Chapter 1: General Installation and Electrical Connection	PC NC Maintenance Manual

Connector Layout (PC Side)

Figure 1.5: Connector Layout of the PC NC CPU Rack (top view)

1.2 General Specifications

The enclosure must be designed to meet all of the following conditions.

Table 1.1: Specifications

Item					Specifications
Ambient Conditions		Temperature*		Storage and	-15oC to +65oC
				Transportation
				Operating	PC NC unit	0oC to +53oC
				(around	I/O module
				enclosure)	Servo Amplifier
					14” Color monitor with touch
					screen
		Humidity			20% to 80% RH (with operation)
					10% to 90% RH (with non-operation)
		Vibration during operation			Less than 4.9m/s
		Others			Free from dust, coolant, or organic solvent
		PC NC Unit input power supply			+24VDC+10% 180V-264VAC
		Power Supply Unit			Input power supply voltage: 180V ~ 264VAC
		UPS000004			Frequency: 47Hz to 63Hz
					Momentary interruption: 0.5 cycle (0VDC)
Note:	Avoid installing the control panel in a location subject to direct sunlight, near heat generating

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PC NC Maintenance Manual	Chapter 1: General Installation and Electrical Connection

devices, or outdoors, even if the ambient temperature is within the specified range.

Design of the enclosure should be made on the basis that the average temperature increase of air within the enclosure (containing the PC NC unit and other compo-

nents) should be 10oC below the external air temperature.

(1) Temperature Increase within the Enclosure (Average Temperature Increase)

The internal temperature increase (sheet metal enclosure) is generally as follows: where,

∆Τ: Internal temperature increase (oC)

P:Heat generation in enclosure (W)

qe:	Enclosure heat percolation ratio (W/oC)
k:	Heat transit ratio of sheet metal (W/m2oC)
6W/m2oC: With internal cooling fan
4W/m2oC: Without internal cooling fan
A:	Efficient heat diffusion area of enclosure (m2)

Area capable of diffusing heat in surface area of the enclosure (Excluding area contacting other devices)

Example: Allowable heat generation in the enclosure with internal circulating fan

1200

All dimensions in millimeters	800
		700

Figure 1.6: Enclosure Dimensions

Efficient heat diffusion area is independently located, so bottom area is excluded.

A=4.16m2.

If the heat generation in the enclosure is supposed to be 246W (113W in the

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Chapter 1: General Installation and Electrical Connection	PC NC Maintenance Manual

CNC portion, 104W in the servo portion, and 29W in the I/O portion):

∆Τ=		P			P
				=	k.A
		qe
	246						o
		6					= 9.9 ( C)
			x 4.16

Therefore, the above value is within the temperature increase value.

When it exceeds 10oC, separate cooling countermeasures must be arranged.

(2) Heat Exchanger Cooling Capacity

Yaskawa can provide heat exchangers where the cooling capacity is insufficient even with a circulating fan mounted in the enclosure.

Table 1.2: Heat Exchangers

Heat Exchanger	Cooling Capacity	External Dimensions (mm)
REX1550	100W /10oC	295 width x 890 height x 50 depth
HEATEX02	250W /10oC	440 width x 924 height x 50 depth

The heat generation indicated in the above table is the allowable heat generated when the internal temperature increase in the enclosure is limited to under 10oC.

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PC NC Maintenance Manual	Chapter 1: General Installation and Electrical Connection

Example: Allowable Heat Generated in the Enclosure with Heat Exchanger

The amount of internal heat generated to make the internal temperature under 10oC when the enclosure is equipped with a HEATEX02 Heat Exchanger is expressed by the following equation:

P= k.A.∆Τ+ 250 W/10 oC

=6 x 4.16 x 10 + 250

=499 W/10 oC

Therefore, the amount of internal heat generated must be less than 499W.

(3)Mounting Heat Exchanger

The heat exchanger must be mounted on the enclosure provided by the machine tool builder, as shown in the figure below. Mount the exchanger so that the internal air is drawn from the upper portion and discharged through the lower portion, while the external air is drawn in from the lower portion and discharged through the upper portion.

Internal air

Enclosure

External air

Heat exchanger

Figure 1.7: Mounting of Heat Exchanger on the Machine Builder’s Enclosure

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Chapter 1: General Installation and Electrical Connection PC NC Maintenance Manual

(4) Heat Generation by Respective Units

Table 1.3: Heat Generation

			Total Heat	Internal Heat	Minimum Wind
	Unit	Type			Velocity for
			Generation (W)	Generation (W)
					Cooling
	PC NC rack	JZNC-JPCRKM_-_	—	—	—
	14” Color CRT with	JZNC-JPCOP-_ _ _	—	—	—
	Touchscreen
	I/O Module	JANCD-FC810*	29	29	0
		JANCD-FC860*	29	29	0
		JANCD-FC861*	14.5	14.5	0
	Converter	CIMR-MR5N23P7	84	44	2.5
		CIMR-MR5N25P5	84	44
		CIMR-MR5N27P5	119	61
		CIMR-MR5N2011	152	70
		CIMR-MR5N2015	204	88
		CIMR-MR5N2018	273	108
		CIMR-MR5N2022	335	132
		CIMR-MR5N2030	392	160
	Spindle Inverter	CIMR-MR5N23P7	84	44	2.5
		CIMR-MR5N25P5	185	58
		CIMR-MR5N27P5	244	77
		CIMR-MR5N2011	307	89
		CIMR-MR5N2015	454	119
		CIMR-MR5N2018	565	144
		CIMR-MR5N2022	717	180
		CIMR-MR5N2030	869	219
	Reactor	UZBA-B 20A 0.53 mH	35	35	0
		UZBA-B 30A 0.35 mH	45	45	0
		UZBA-B 40A 0.265 mH	50	50	0
		UZBA-B 60A 0.18 mH	65	65	0
		UZBA-B 80A 0.13 mH	75	75	0
		UZBA-B 90A 0.12 mH	90	90	0
		UZBA-B 120A 0.09 mH	90	90	0
		UZBA-B 160A 0.07 mH	100	100	0

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PC NC Maintenance Manual Chapter 1: General Installation and Electrical Connection

Table 1.3: Heat Generation (Continued)

			Total Heat	Internal Heat	Minimum Wind
	Unit	Type			Velocity for
			Generation (W)	Generation (W)
					Cooling
		SGDC-05AJ A	28	10	2.5
		SGDC-10AJ A	48	12
	Servo Unit	SGDC-15AJ A	73	15
		SGDC-20AJ A	108	18
		SGDC-30AJ A	148	22
		SGDC-50AJ A	208	28

1.The heat generated by the CNC unit varies depending on the addition of options. The heat generated by the I/O module varies with I/O status.

2.Internal heat generation is the heat remaining inside of the enclosure when the fin of the servo is exposed outside of the enclosure, and when the external air is applied to the fin at greater than 2.5m/s

3.The thermal design of the enclosure to house the servo unit varies with machine specifications, but is acknowledged to use a value of 70% of the load factor.

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Chapter 2: Routine Inspection	PC NC Maintenance Manual

Chapter 2: Routine Inspection

This chapter includes the requirements to maintain optimum operating conditions over time.

2.1 Routine Inspection

The table below details routine inspection of the PC NC.

Table 2.1: Routine Inspection

	Area	Inspect Item	Frequency	System	Remarks
				OFF/ON*
	Battery	Verify battery alarm	At power on	ON	If alarm LED is on, replace battery.
		LED is on.
	Servo motor	Vibration and noise	Daily	ON	Feel by hand; listen by ear.
		Motor contamina-	Daily (or as	ON and OFF	Visual inspection
		tion and damage	required)
	Fan	Air flow	Monthly	ON and OFF	Feel by hand; listen by ear.
	Touch screen	Clean	Daily	ON and OFF	Use clean rag.
		Calibrate	Monthly	ON	Use Calibration Screen.
	Control panel	Verify doors are	Daily	OFF	Visual inspection
		tightly closed.
		Verify tight fit, no	Monthly	OFF	Visual inspection
		gaps in the side
		plates, and door
		gaskets are not
		worn.

*With the exception of inspections made while the NC is in the energized state (i.e., external cleanliness, vibration, noise, etc.), turn off the source power supply to the NC before undertaking routine maintenance service. To remove power completely from the NC, turn off the main circuit breaker on the power panel of the machine.

2.2Battery

To determine whether the battery must be replaced, and replacement directions, follow the steps below.

1. Press the Power OFF button.

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PC NC Maintenance Manual	Chapter 2: Routine Inspection

2.Turn OFF the door interlock switch, if provided. (The power can be turned ON with the door open.)

3.Open the door to view the NC rack.

4.Turn the power ON. If the Battery Alarm LED is displayed in the Message Bar on the top portion of the screen, the battery must be replaced within 16 hours. Do not use commercially-available batteries. Contact a Yaskawa customer service representative.

5.If the battery must be replaced, turn the power OFF. Remove the battery from the battery holder.

6.Place the new battery in the holder and set the connector. (Note: the direction of the connector is unimportant; however, poor connection may result in a lack of conduction.). Refer to the figure below.

Correct

Correct

Incorrect

Figure 2.1: Battery Connection

Figure 2.2: Replacement Battery

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Chapter 2: Routine Inspection	PC NC Maintenance Manual

Note: • Replace the battery as soon as possible after the power goes OFF to avoid data loss.

•Do not turn the power ON and OFF in rapid sequence.

•Wait 4 to 5 seconds after the power has been turned ON before turning the power OFF.

7.With the power ON, ensure that the “Message Alarm” display on the CRT and the red LED at the front of the JZNC-JFC10 PCB is OFF.

Note: If the “Message Alarm” display on the CRT or the red LED on the front are still illuminated, the probable cause is improper battery connection, or a defective battery.

When alarms 2121 or higher (encoder battery errors) occur, DGN #35024 (*BALM) is not output. When DGN #35024 (*BALM) is output, the LED goes on only when the CMOS backup battery is exhausted. This battery differs from the encoder batter.

2.3 Servo Motor

Inspect the servo motor daily as follows.

Table 2.2: Servo Motor Inspection

Inspect Item	Remarks
Vibration and noise	Vibration can be checked by resting the hand on the motor.
	Noise can be checked by using a listening stick. Contact mainte-
	nance personnel immediately when any abnormality is found.
Motor contamination and damage	Visually check the motor exterior. If dirt or damage are
	observed, inspect the motor by removing the machine cover.
	Refer to the machine manufacturer’s manual.

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PC NC Maintenance Manual	Chapter 2: Routine Inspection

2.4 Fan

Verify the CPU rack cooling fan is running by placing a hand on the outside case in the path of the airflow.

Figure 2.3: CPU Rack and Fan

If the cooling fan speed falls below 2000rpm, a “Slow Fan” warning message appears. When this occurs, open the CPU rack and check the fan for any obstacles that may inhibit the fan rotation. If no obstacles are present, call a Yaskawa customer service representative.

If the CPU rack cooling fan speed falls below 1800rpm, a “Fan Alarm of CNC Unit” message appears. When this occurs, Cycle Start is not possible. Open the CPU rack and check the fan for any obstacles that may inhibit the fan rotation. If no obstacles are present, call a Yaskawa customer service representative.

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Chapter 2: Routine Inspection	PC NC Maintenance Manual

2.5 Touch Screen

Clean the touch screen daily. Select PC Settings from the Utilities Menu. Select the Touch Screen Cleaning button. When the screen below appears, proceed to clean the touch screen.

1.Ensure there are no metal or other hard particles on the touch screen that may scratch the screen.

2.Use a general purpose liquid glass cleaner and a clean rag.

3.Never spray glass cleaner directly onto the touch screen. Always spray onto the clean rag.

4.Wipe the touch screen completely.

5.When finished, press the Escape key.

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PC NC Maintenance Manual	Chapter 2: Routine Inspection

2.6 Control Panel

Details of the standard cabinet are explained below. Questions on customized cabinets should be referred to the manual issued by the machine manufacturer.

Follow the steps below for routine daily maintenance of the control panel.

1.Inspect the door(s) daily to ensure tight closure. The control panel is constructed as a dust-proof, sheet-steel enclosure with gasketed doors to keep out dust and oil mists. Keep the door(s) tightly closed at all times.

2.Following inspection of the control with the door open, close the door and fasten the door locks (two per door) securely using the key provided (Number YE001). When opening (counter-clockwise rotation) or closing (clockwise rotation), insert the key all the way into the keyhole and turn until it clicks (approximately a quarter-turn). The key can be removed from an open or closed position.

Left-hand Hinge Door

Right-hand Hinged Door

open position

closed position

closed position

open position

Figure 2.4: Open and Closed Positions

Note: If the optional door interlocking switch is provided, opening the door shuts off the main power supply and stops all operations.

The following monthly maintenance must be performed.

1.Inspect the gaskets on the rims of the front and rear doors for openings or damage.

2.Inspect the inside of the enclosure; clean it if necessary.

3.Look for any opening in the door base when the doors are tightly shut.

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Chapter 3: Maintenance Instruments	PC NC Maintenance Manual

Chapter 3: Maintenance Instruments

Measuring instruments, tools, and replacement parts are described in this chapter.

Table 3.1: Measuring Instruments

	Name	Allowable Measuring	Purpose
		Range
	Tester	10 to 33VAC (at 40 to 100Hz)	To measure AC power voltages
		Tolerance: ±2%
		Several mV to 100VDC	To measure DC power voltages
		Tolerance: ±2%
	or multi-purpose digital meter
		Up to multiples of 10MΩ	To measure currents

The only required tools are those listed below.

•Phillips screwdrivers (large, medium, and small)

•Standard screwdrivers (medium and small)

•ROM extractor: IC extractor model GX-6

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PC NC Maintenance Manual	Chapter 3: Maintenance Instruments

Maintenance/replacement parts are:

•Fuse model HMO3, 0.3A; approximate mass: 0.4g

•NC card fuse

•CPU rack fuse: 1A 250V 3AG fast-acting type glass body cartridge fuse; or 250V 3AG fast-acting type glass body cartridge fuse

Note: The current CPU rack fuse is 1A Littlefuse #312001, but will change to 3A Littlefuse #312003 fuse per ECO #N-9910-020.

•Motherboard battery: coin-type 3V lithium battery, part # Mitsubishi #CR2032, or Maxell #CR2032

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Chapter 4: Troubleshooting	PC NC Maintenance Manual

Chapter 4: Troubleshooting

4.1 Maintenance Data

To locate the cause of problems or when contacting your Yaskawa customer service representative for advice, users must precisely understand the actual situation. To minimize the downtime, check the following points carefully.

CAUTION

•When an alarm occurs, eliminate the fault and assure operation safety before resetting it. Failure to observe this caution could result in equipment malfunction.

•For details on the machine-related sequence, refer to the machine tool manual.

Checking the Status of Problems

(1) Understanding the Situation

To identify the nature of the problem, first check the following items.

•Type of operation that causes a problem.

Do other types of operations not cause problems?

•Q Details of problems

How, frequency (always or sometimes), and when?

•Unusual situation when the problem occurred.

•Was there an unusual external occurrence (such as power failure or lightning) when the problem occurred?

•Timing of problem occurrence.

Did the problem occur during or after the operation of the keys, or in a specific operation mode?

(2)Check Items

(a)Problems related with axis feed and spindle drive Check the following items.

•Indication status of the LEDs on the drive unit

•Fuses and breakers

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PC NC Maintenance Manual	Chapter 4: Troubleshooting

•Timing of problem occurrence – when the power is turned ON, during acceleration, during deceleration or during fixed speed spindle rotation, etc.?

(b)Problems related to part program

Record the program block data, offset data, workpiece coordinate system offset data, coordinate system setting data, etc.

Checking the NC Information

Aside from the specific problem, the following information must be obtained regarding the hardware environment.

•Machine tool builder’s name

•Delivery date of machine tool

•Type and model name of the machine tool

•Type and model name of the NC and units

Example

NC unit	YASNAC PC NC
Servo drive	SGDC-AJA
Servo motor	SGMG
Spindle drive	CIMR-M5N20155
Spindle motor	UAASKD-11HB11

Display of Alarm Information

If an alarm occurs, the top priority alarm number and alarm comment are displayed in the normal display area disregarding the selected mode and the screen.

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Chapter 4: Troubleshooting	PC NC Maintenance Manual

Cause of Alarm and Corrective Action

The following shows the listing of YASNAC PC NC alarms.

Table 4.1: Alarm Numbers and Classification

Number	Contents	Stop Mode	Output	How To Reset
0000 to	Errors related to edit and operation	Block stop	Input error	Reset
0049	Occurring in the background mode		alarm
	also.
0050 to	Errors related to edit and operation	Block stop	Input error	Reset
0099	Not occurring in the background		alarm	Power OFF for #0050 and #0051
	mode.
0100 to	Program error	Block stop	Input error	Reset
0499			alarm
1000 to	Program error	Block stop	Input error	Reset
1099	DNC, COMS total, etc.		alarm
2000 to	Machine related error	Stop after	Alarm	Reset operation after removing the
2199	OT, reference point return, machine	deceleration,		cause. With the alarm caused by
	ready, in-position, etc.	or immediate		the machine ready signal, if it
		stop		occurs in the first power ON opera-
				tion, it is automatically reset.
3000 to	Servo and spindle related alarm	Immediate	Alarm	Reset after removing the cause.
3299	ESP, CPU mutual monitoring	stop, or serve,		With the SVOFF alarm, it is auto-
		OFF		matically reset by the SVON.
8000 to	Memory check error	Immediate	Alarm	For maintenance
8049	Watchdog timer error	stop, or serve		CPU halt
	Offline error	OFF		Switching to the maintenance
				screen
9000 to	Error occurring in background edit-	Not stopped	Back-	Reset or with reset soft-key
9049	ing (basically the same as with 0000		ground
	to 0049)		error
			output
No number	Battery error	Not stopped	No output	Changing the battery
indication	Encoder alarm
BAT
indication
BAT, AXIS
No number	Key operation error, edit operation	Not stopped	Warning	Next key operation
indication	error (not serious operation error)
Warning
message

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PC NC Maintenance Manual	Chapter 4: Troubleshooting

Troubleshooting (1)

(1)Alarm Number 1099 (High Temperature)

Table 4.2: Countermeasures - Alarm #1099 (High Temperature)

Cause	Check Item	Countermeasures
Ambient temperature of the	Open the NC unit door to check	If the fan is faulty, it must be
NC rack exceeded the	whether the cooling fan is operating	replaced. Contact your Yaskawa
specified value* due to the	correctly.	customer service representative.
failure of the cooling fan.	• Ensure that air is blowing out	If the cooling duct is blocked,
* 70ºC ± 3ºC when mea-	through the ventilation port of	remove the interfering object and
sured above CPS-18.	the cooling duct.	start the cooling fan.
	• Ensure that the ventilation port
	of the cooling duct is not
	blocked.
Internal temperature of the	Allow the power supply unit to cool	The power supply unit must be
power supply unit is high.	by turning OFF the power with the	changed. Contact your Yaskawa
	PC NC unit door opened. If the	customer service representative.
	alarm occurs even after the power
	supply unit has been cooled for 30
	minutes, the power supply unit is
	faulty.
Ambient temperature of the	Measure the ambient temperature.	This is not the failure of the NC
l NC unit is high.*	• If the NC unit is placed in direct	unit. Remove the cause.
*: Allowable temperature	sunlight, the NC unit tempera-
range for operation is	ture may exceed the allowable
0 to 40ºC.	limit.

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Chapter 4: Troubleshooting	PC NC Maintenance Manual

(2)Alarm Numbers 2061 to 2068 (Reference Point Return Area Error)

Table 4.3: Troubleshooting - Alarm #2061 ~ 2068 (Reference Point Return Area Error)

	Cause			Check Item		Countermeasures
	The reference	Deceleration limit switch (DECLS)				Return the axis to a position on
	point return start	#3073 DO (1st axis)			Execute reference	the deceleration LS or away
	point is at the					from it and, then execute refer-
		#3073 D1		(2nd. axis)	point return again
	zero point side					ence point return once again.
		#3073 D2		(3rd axis)	while observing the
	of the decelera-
		#3073 D3		(4th axis)	I/O signal monitor
	tion limit switch.	#3073 D4		(5th axis)	screen
		If reference point return is started from a point
		located at the reference point side of DECL (point
		C) as shown below, an alarm occurs.
		Note:	This error check is not made before the
			execution of manual reference point
			return after the power is turned ON.
	Approach	Compare the setting for the approach feedrate				Change the setting for param-
	feedrate is too	parameter with the parameter list.				eters pm2521 to pm2525 to an
	fast.					appropriate value.

(3)Alarm Numbers 2071 to 2078, 2081 to 2088 (Reference Point Return Position Error)

Table 4.4: Troubleshooting - Alarm Numbers 2071 ~ 2078, 2081 ~ 2088

(Reference Point Return Position Error)

Cause	Check Item	Countermeasures
Alarm in manual reference	Determine whether the error occurs every	Contact a Yaskawa customer
point return operation	time.	service representative.
Alarm in automatic reference	G28: Determine whether the alarm	Contact a Yaskawa customer
point return operation	occurs every time.	service representative.
	G27: Check the point specified in the	Review the program.
	program to determine whether it
	agrees with the zero point.

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PC NC Maintenance Manual	Chapter 4: Troubleshooting

(4)Alarm Numbers 2101 to 2108 (P-SET Error)

The P-SET alarm occurs if the error between the position specified in the program and the actual machine position is larger than the value set for parameterspm1321 (1st axis) to pm 1325 (5th axis) in the following modes of operation.

At the completion of positioning in G00, G27, G28, G29, G30, etc., error detect ON (1/O monitor parameter #3004 D4 = 1), and G04 (dwell).

If error pulses have been accumulated, check the number of accumulated pulses on the Error Pulse Display Screen before contacting a Yaskawa customer service representative.

(5)Alarm Number 3000 (Servo Power Not Ready)

Table 4.5 Troubleshooting - Alarm #3000 (Servo Power Not Ready)

Cause	Check Item	Countermeasures
Secondary power supply is not	If the NC RESET switch is depressed	Press the POWER ON but-
applied	after depressing the POWER ON but-	ton again.
	ton once, or after clearing the emer-
	gency stop or alarm state, the alarm
	message is displayed. This does not
	indicate the occurrence of an alarm.
With the secondary power ON,	Verify the following on the I/O monitor	Contact your Yaskawa
I/O input specification is not	screen:	customer service
turned ON (for automatic servo	#3005 DO = 1 (SVON)	representative.
power ON)	#3503 DO = 1 (SVONS)
Emergency stop signal stays	Determine whether alarm Number	Reset the emergency stop
ON.	3002 is displayed (#3503 D4 = 1) on	input signal.
	the screen.
The secondary power ON sig-	Check the alarm indication for other	Take appropriate mea-
nal is turned OFF due to some	alarms.	sures by referring to the
other alarm.		alarm code.

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Chapter 4: Troubleshooting	PC NC Maintenance Manual

(6)Alarm Number 3001 (Control Not Ready)

The PC NC executes self-diagnosis after power ON. This alarm occurs when the positioning error checked during this self-diag- nosis exceeds the values set for parameters pm 1321 (1st axis) to pm1325 (5th axis).

Table 4.6: Troubleshooting - Alarm Number 3001 (Control Not Ready)

	Cause	Check Item	Countermeasures
	Machine axes have moved.	Select the error pulse display screen	Contact a Yaskawa customer
		from the present position display	service representative.
		screen in the common process and
	PG signal remains output.		PG or AC servo must be
		check the error pulse value.
			changed. Contact a Yaskawa
			customer service representative.

(7)Alarm Numbers 3041 to 3048 (Excessive Follow-up Error)

If the follow-up error between the command values and the actual position values exceeds 120% of the error in rapid traverse (100%) operation, this alarm occurs. Check the values set for parameters pm1671 to pm1675, pm1681 to pm1685 and contact a Yaskawa customer service representative.

(8)Alarm Number 3051 (Excessive Follow-up Error: Spindle)

If the follow-up error between the command values and the actual position values exceeds the value set for parameter pm1351, this alarm occurs. Check the values set for parameter pm1351 and contact a Yaskawa customer service representative.

(9)Alarm Numbers 3061 to 3068 (Overload)

Table 4.7: Troubleshooting - Alarm Numbers 3061 ~ 3068 (Overload)

Cause	Check Item	Countermeasures
Cutting conditions	Determine whether the alarm occurred during	Turn OFF the power and
	machining.	allow the servomotor to cool.
		Then change to lighter
		machining conditions and
		restart the operation.
Guideways are not lubri-	Inspect the guideways to determine whether	Contact the machine
cated properly, causing	they are lubricated properly.	tool builder, or a Yaskawa
heavy axis movements.		customer service representa-
		tive.

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PC NC Maintenance Manual	Chapter 4: Troubleshooting

(10) Alarm Numbers 3081 to 3088 (Broken PG Cable)

The A and B phase signal cables are checked for breakage.

Table 4.8: Troubleshooting - Alarm Numbers 3081 ~ 3088 (Broken PG Cable)

Cause	Check Item	Countermeasures
Signal cables between the	Ensure that the cable connectors are	If they are loose or disconnected,
NC and the AC servo drive	plugged into the connectors securely.	re-connect them correctly.
unit are broken or loose.
Faulty PG cable breakage	Determine whether the alarm occurs in	Contact your Yaskawa
detection circuit.	the first pressing of the POWER ON	customer service representative.
	button even when the cables are con-
	nected correctly.
Error in motor type param-	Determine whether the motor type set-	Correct the setting for the motor
eter setting	ting parameters (pm 1061 to pm 1065)	type parameters (pm1061 to
	has been set to “0”.	pm1065).

(11) Alarm Number 3091 (Broken Spindle PG Cable)

The A, B, and C phase signal cables are checked for breakage.

Table 4.9: Troubleshooting - Alarm Number 3091 (Broken Spindle PG Cable)

Cause	Check Item	Countermeasures
Signal cables between the	Ensure that the cable connectors are	If they are loose or discon-
NC and the AC servo drive	plugged into the connectors securely.	nected, re-connect them cor-
unit are broken or loose.		rectly.
Faulty PG cable breakage	Determine whether the alarm occurs in	Contact a Yaskawa customer
-detection circuit	the first pressing of POWER ON button	service representative.
	even when the cables are connected
	correctly.
Faulty PG	If an alarm occurs during low speed	Contact a Yaskawa customer
	operation, the PG may be faulty.	service representative.

(12) Alarm Numbers 3121 to 3125 (Excessive Speed)

This alarm is detected if the motor speed exceeds 1.2 times the maximum motor speed.

Contact a Yaskawa customer service representative.

(13)Alarm Numbers 3161 to 3165 (Absolute Error)

Malfunction of the absolute encoder is detected. Contact a Yaskawa customer service representative after checking the following:

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Chapter 4: Troubleshooting	PC NC Maintenance Manual

•Whether the alarm occurs immediately after the control power is turned ON.

•Whether the alarm is cleared when the power is turned OFF and then turned ON again.

•Whether the battery alarm occurs at the same time.

(14)Alarm Numbers 3181 to 3185 (Position Error)

Malfunction of the PG pulse (counter in the absolute encoder) is detected. Contact your Yaskawa customer service representative after checking the following:

•Whether the alarm occurs immediately after the control power is turned ON.

•Whether the alarm occurs frequently during operation.

(15)Alarm Numbers 3201 to 3205 (Servo Drive Unit Communication Error)

Communication error between the NC and the AC servo drive unit is detected. Contact your Yaskawa representative.

(16)Alarm Numbers 3301 to 3305 (Overcurrent)

Contact your Yaskawa customer service representative after checking the following:

•Whether the alarm occurs immediately after the control power is turned ON.

•Whether the alarm occurs after turning ON the main power.

(17)Alarm Number 3311 to 3315 (MCCB Trip)

•Contact your Yaskawa customer service representative after checking the following:

•Whether the alarm occurs immediately after the control power is turned ON.

•Whether the alarm occurs after turning ON the main power.

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