คู่มือการซ่อม FANUC SYSTEM INFORMATION


GE Fanuc Hotline Charlottesville 800-828-6151

GE Fanuc Fax on Demand 804-978-6883

Fanuc USA 888-326-8287 (888-FANUCUS)
?
Fanuc Technical Sales Fax# 847-898-5006

Another source for Fanuc parts is:
T.I.E
615-459-2848 Fax 615-459-7917
E-Mail partsales@isdn.net

Also:

www.surplus.com
817-469-7797 Fax 817-460-1553
2627 S. Cooper Street
Arlington, TX 76015

A good source for cables is Machine Tool Services. Their number is 480-985-1941. They can make the motor and feedback cables to length.

When a machine doesn't position correctly it can sometimes be because of electrical noise on the MLK (Machine Lock) signal.

The breakdown on the Fanuc part numbers is:
i.e. A06B-6079-H203#EM
A06B Identifies part as either a Motor or an Amplifier.
6079 Identifies Series, Serial or Digital.
H203 Identifies physical size and Capacity.
#EM Identifies part as one approved for the European Community (CE).



It is possible to troubleshoot with the Ladder even if you have a controller that does not display it. If you have a hard copy of the ladder, you can follow the instructions as you normally would by looking for the addresses in the diagnostics. For example:

-------| |-------------|/|------------------------------( )------
R551.2 F126.0 Y8.1

All of these can be found in Diagnostics.

0551 00000X00 = R551.2
0126 0000000X = F126.0
0008 000000X0 = Y8.1

If the instruction is --| |-- the corresponding diagnostic bit must be 1 for the instruction to be true.

If the instruction is --|/|-- the corresponding diagnostic bit must be 0 for the instruction to be true.

X and Y bits are checked the same as usual.

This is how a Box works in the Ladder:




____________________________________
| | | | |
| SUB | 2 | 3000 | R673 |
--| |---|/|---| 24 | | | |-----------( )----
| | | | |
|_______|_______|________|____________|

The first block identifies the box as a fixed timer.
The second block denotes the timer number.
The third block indicates the value of the timer in milliseconds.
The fourth block indicates an address which is acted upon by the timer.

The following is an example of a M Code box:
______________________________________
| SUB 4 | F151 |
| DEC | |
| | |
| | 8411 |
|________|_____________________________|

The first block identifies the box as a Decode module.
F151 is the address where the M Code is stored and will change with different\
M codes.
84 is the M Code designation (M84).
11 indicates what part of the M Code is to be decoded in this module
11 = Decode both High Order and Low Order (8 and 4)
10 = Decode High Order (8) only
01 = Decode low Order (4) only
The High Order can be decoded in one box and the Low Order in another.

The M Code is stored as BCD. 84 = 10000100


If a controller comes equipped with RAM chips, they must remain on the memory board. If they are removed, a RAM Parity Error is issued and will not go away even if you hold RESET/DELETE at power up.


The Fanuc Software Edition is the big number at the top of the first boot-up screen. Normally something like O667-****.


If the Absolute Position display resets to all zeros when the RESET button is pressed, check the MAN/ABS button. If it is set to MANUAL, the display will reset to zero depending on parameter settings.

If INCH = 0 on the Setting page the machine will be in Metric. It will interpret a numerical command as metric (i.e. G1 X50.0 equals 50mm). The position display will also be in Metric. If set to 1, the machine will be in Inch. This setting can be changed at any time, power does not have to be cycled.

One Kbyte of memory is equal to 1000 characters. When Fanuc sells memory, they sell it by the Kbyte. They will sometimes talk about memory in terms of Meters.

For most Fanuc controllers the ON/OFF switches on the CRT/MDI plug into the Input Unit. When you press the ON button, you are turning on the Input Unit. If everything is OK with the Input Unit and the controller in general, the Input Unit will latch through itself and the NC will come on and stay on. If there is a problem in the power circuits, it will not latch. Depending on the problem it will come on then shut off or not come on at all. Problems can be diagnosed based on which of these scenarios occurs.

The Fanuc equivalent to Mitsubishi Axis Release is Axis Detach.

The drive components of most Fanuc controllers are the same so the troubleshooting methods, Not Ready alarm, etc., shown below can be used.

When the main power is turned on the PSM (power supply module) displays two dashed lines, (steady) the Servo Amplifier displays a single dashed line, the Spindle Amplifier goes through it's sequence of displaying it's software information (normally a string of three) after which it displays two dashed lines (flashing). Now the NC power is turned on with the E-Stop in. The Spindle Amplifier display stops flashing, displays the two dashed lines on steady. The PSM and the Servo Amplifier display do not change. Now the E-Stop is pulled out. The PSM display goes immediately to 00. The Servo Amplifier display goes immediately to 0. If a spindle run command is entered such as pressing the CW or CCW Run button or entering M03, M04 etc., the Spindle display goes to 00 (steady). The spindle does not run because no speed command has been entered. The spindle speed setting is reset when power is cycled. If the spindle stop is pressed or Reset, etc., the Spindle display goes to two steady dashed lines. If the spindle run and spindle speed command are entered, the display goes to 00 and the spindle runs. If the E-Stop is pressed, the display goes to two steady dashed lines. If the NC power is turned off the display goes to 24 and the red LED (ALM) comes on.

Under normal operation, if you watch the PSM when the main power is turned off, you will see 02 displayed briefly and the ALM (red) LED will turn on for an instant.

When a machine is in a NOT READY state, there are three things to look at.

1. Are the drives and other control hardware and software ready?
2. Is the E-Stop activated?
3. Is the PMC generating a Not Ready condition?

If the memory becomes scrambled or is partially lost, the memory board must be cleared. In most cases it is only necessary to clear the parameter and offset memory, but sometimes the program memory must be cleared as well.
The procedure for clearing the parameter and offset memory is as follows:

1. Turn power to the controller off.
2. Press and hold the RESET key.
3. Turn the power back on.
4. Hold the RESET key until the screen comes up.
5. Release the RESET key.

If the controller will not come up, repeat the procedure holding the RESET key and the DELETE key while powering up. Should it ever be necessary to clear only the programs, perform the procedure holding only the DELETE key. In order to clear the program memory by powering up with the Delete key pressed, PWE may need to be set to 1.


If you do this you will lose all programs including the ATC Macro program.

The procedure for re-entering the parameters varies depending on the media at your disposal. (i.e. Handy File, PC with Procomm, etc.).
All end users should have at least one paper copy of the original parameters. If the end user does not have access to any of the media mentioned above, it will be necessary to load all of the parameters by hand. This method will take about an hour and require a lot of key presses. The procedure is:

Pressing and holding the P key and the CAN key while powering up the controller tells the CNC to ignore the programmed stroke (soft) limits. The CNC will ignore these limits for as long it runs until the machine is homed (ZRN). Any time this procedure is used, for example, to clear an over travel alarm the machine should be zero returned.


A "D" address in the controllers memory is a location in a data table. A Data Table is an area of memory set aside by Fanuc for the machine tool builder to store information to be accessed by the program..


On the SETTING page, making INCH equal 1 causes the display read in English while zero causes it to read in Metric. Either way, the actual measuring is not affected.

On some machines turning the NC power on will cause one or more of the servos to jump as much as .0003" due to shielding or other power problems. The display will zero when RESET is pressed.

Never turn off the NC power while data is being input via RS232. If this is done while inputting a program, the program memory will be scrambled and will have to be cleared. If you are communicating with the controller and wish to terminate, it is best to physically break the RS232 connection.

The maximum allowable voltage deviation on Fanuc controllers is -15% and +10%. Both the 5vdc and 24vdc outputs of the Power Supply must remain within +/- 5% to prevent an alarm.


If when trying to communicate with a Fanuc controller using Procomm, the data flows very slowly, check the setting for delay between characters and the setting for delay between lines. Sometimes it is necessary to put a value in one of them in order to communicate with a Mitsubishi or other controller but it will cause a Fanuc to slow way down. When working with a Fanuc, these should probably be set to zero.


The number of data bits for RS-232 communications on all Fanuc controllers is set at 7 and cannot be changed.

All communication between the NC and its I/O boards is serial whether through conventional wiring or fiber optic connection going all the way back to the 5 and 6 controllers. This means that if the status bits (Diagnostic or Ladder) show an Input (X) or Output (Y) going high you can be sure that this is communicated to and/or from the I/O board unless there is a complete failure of this circuit. In that case there should be several alarm conditions. If you have a machine on which some I/O functions operate (LED's, Relays, Switches, etc.) but others do not, either the I/O board is bad or there is a wiring problem in the wiring between the board and the devices. Also, be sure to check the power going to the I/O board, particularly the 24 volts at the six pin connector CDP.


Some inputs, such as Cycle Start, are not activated when their associated bit goes high but rather when it goes low after being high. That is, the address tied to the Cycle Start button is normally low or 0. When the Cycle Start button is pressed, it goes high or 1. If the button is pushed and held nothing happens. Only when the button is released and the bit goes low again does the cycle start. The importance of this is that if a machine executes a program on it's own without being commanded, it can't be caused by a Cycle Start button that is stuck, etc. You need to look either for an I/O problem which causes the signal to go high then low or for an internal control problem.


The cable pin outs for a DB-25 to DB-9 cable to perform DNC operation:

2 ------ 2
3 ------ 3
4 ------ 8
5 ------ 7
6 ------ 4
7 ------ 5
8 ----
|
|----
|
20---


If you get garbage on your PC when outputting parameters, etc., check the SETTING page to be sure that ISO = 1.

If a M, S, T alarm occurs on the CRT check the program to make sure there is not an M06 in it.


If a machine's controller shuts down at the end of a program or anytime M02 or M30 is executed, check the Auto Power Off function. This can be either a push button or it may be turned off and on through the Software Operators Panel. In some cases a Keep Relay may be assigned to this function.

In rare cases it is possible for all of the instructions on a rung to be satisfied but the output coil does not turn on because certain parameters have gotten scrambled. Typically, the ones scrambled will be those you cannot see so you might try clearing the memory then reloading the parameters. If you do not have a copy of the parameters you can backup the ones already in the controller and reload them by RS-232 or by typing them in. The mere act of clearing the memory may resolve the problem.


In order to communicate with a Fanuc controller via an RS-232 port the I/O Channel (Setting Page) must be set to either 0 or 1. Also make sure you are in MDI mode and that the Edit Key is on.

Baud Rate Settings:
1 = 50
2 = 100
3 = 110
4 = 150
5 = 200
6 = 300
7 = 600
8 = 1200
9 = 2400
10 = 4800
11 = 9600
12 = 19200


If the Relative position display zeros when the RESET button is pressed make sure the MAN/ABS button is in ABS.

For a controller that has board mounted ROM Never power the controller up with any of the ROM chips off of the board. Doing so will cause memory loss and scrambled memory. If this occurs, the memory must be cleared resulting in loss of parameters and programs. The same is true for replacing the memory back-up batteries. Control power must be on while batteries are being replaced.


The Macro Executor Cassette can write information to any part of the CRT. If you see data displayed which appears abnormal for a Fanuc controller you can try removing the cassette to see if the data is removed. One example is when OFST flashing and the Offset page being displayed on a lathe when the tool setter is down.

There is a strange condition that may arise if the program storage area becomes scrambled. On some machines if an ATC cycle (M06) is attempted, when the M6 is read in the ATC program, the controller will delete everything after the M6. This portion of the program will simply disappear. This condition has only been observed once to my knowledge and it was resolved by clearing the program storage area.

Fanuc
Page 2



0 SERIES CONTROLLER


Note: The memory back-up consists of three alkaline R20 "D" cells.

If com port is port 1, M5 is used. If com port is port 2, M74 is used.
To determine if com port is Port 1 or Port 2, trace the RS-232 cable from the serial port connector back to the CNC master PCB on 0-B controller or memory PCB on 0-controller and see if it is connected to M5 or M74.

Parameters associated with Port 1 are Param.2, 38, 522
Parameters associated with Port 2 are Param.50, 38, 253

If the Absolute Position display goes to some number other than 0.0000 when a reference return is made, check Parameter 10.7. If this only occurs on one axis, check the work coordinates (G54, G55, etc.) for the value that appears in the Absolute display.

You can set Parameter 397.7 to 1 to tell the controller to display the Spindle Amplifier alarm number on the CRT.

*** NOTE ***
It is very important that when changing parameters in order to facilitate communications that only those bits needing to be changed are changed. Never change a parameter that does not absolutely have to be. Especially where number 0038 is concerned. If parameter 0038 is originally 10000011, for example, you would change it to 11000011 and nothing else. ALWAYS record a parameter somewhere before making any change.

For serial communications on Port 1 settings are:
TVON = 0 Parameter 0002 1xxxxxx1
ISO = 1 0038 01xxxxxx
I/O = 0 0050 Not used
PWE= 1 0552 10
TAPEF= 0 0553 Not used


For serial communications on Port 2 settings are:
TVON = 0 Parameter 0002 Not used
ISO = 1 0038 xx01xxxx
I/O = 2 0050 1xxxxxx1
PWE= 1 0552 Not used
TAPEF= 0 0553 10

x - Does not matter how these bits are set.

Fanuc default protocol is 4800, E, 7, 2

TVON tells the controller whether or not to make a TV (Tape Vertical Parity) check when a program is registered in memory. 1 = Make check 0 = No check When set to 1, the controller will generate Alarm P/S 002 if one block (From one EOB to the next EOB) contains an odd number of characters. Parameter 18.6 determines whether or not a TV check is made on program comments.

TAPEF specifies the type of tape format. 1 = F10/F11 format after conversion. 0 = FSO standard format without conversion.


To receive programs or parameters in ASCII set:

I/O = 0
ISO = 1
Parameter 0002.0 = 1
Another Parameter associated with this is 51 bit3.

I/O can be set for 0, 1, 2 or 3. Changing this number provides Device information to the controller. This is similar to the Device settings on a Mitsubishi controller. Setting I/O for 0 tells the controller to set the device according to Parameter 38 bits 6 and 7. It also tells the control to set the Feed, Interface and Stop Bits according to Parameter 2 bits 7, 2 and 0 respectively. Lastly, it tells the controller to set the Baud Rate according to Parameter 552.

I/O set for 1 tells the controller to use Parameter 38 bits 6 and 7, Parameter 12 bits 7, 2 and 0. These correspond to the same bits on Parameter 2. I/O also tells the controller to set the Baud Rate according to Parameter 553.

I/O set for 2 tells the controller to use Port 2. (M74 on Memory board) Again, assuming RS232 as with I/O = 0 and I/O = 1, I/O set for 2 tells the controller to use Parameter 38 bits 4 and 5. The Feed Rate and Stop Bit settings will be according to Parameter 50 bits 7 and 0 respectively. The Baud Rate will be set according to Parameter 250.

I/O = 3 is for communicating via Port 3 and is almost never used. If for some reason it were used, the associated Parameters would be Parameter 38 bits 1 and 2, Parameter 51 bits 7 and 0, and Baud Rate Parameter 251. Parameter 38 bits 6 and 7 should be set for 0 and 1 respectively for RS232.

Normally a machine will come with I/O set for 0. Sometimes a situation may arise where you have a hardware problem which causes the 086 alarm. Many machines will come with Parameter 12 set for communication through a 4-20 milliamp interface instead of RS232. In this case if you change I/O to 1 the controller will use Parameter 12 settings rather than Parameter 2. If Parameter 12 is set for the 4-20 interface it will not look for the signals it usually looks for at the RS232 port so the 086 alarm will not be issued. Oddly enough, this set of conditions normally allow RS232 communication from the NC to the PC but not the other way. Although Alarm 086 almost always occurs due to a hardware problem, it is possible to generate it through operation error.

If the Memory Board does have a hardware problem preventing it from being able to communicate, it is probably either a Line Driver or Line Receiver IC. If the controller will receive but not send, there may be a bad Line Driver. If the reverse is true then there is likely a bad Line Receiver.

IC Specifications:
Driver - 75188
Receiver - 75189

These ICs are available from NTE. Their NTE designation is NTE75188 and
NTE75189. Both are described as an IC-DTL Quad Line Driver 14 Pin DIP.


The value of Parameter 552 for the following Baud rates
9600 11
4800 10
2400 9
1200 8
600 7
300 6
200 5
150 4
110 3
100 2
50 1

Changing parameters:

1. Go to MDI mode
2. Turn the Program Protect key off.
3. Press PARAM key
4. Press page down key
5. Cursor to PWE=0
6. Enter a 1
7. Press INPUT key
( Ignore alarm or press RESET and CAN simultaneously to clear. )
8. Press PARAM key
9. Press page down key
10. Cursor to desired parameter
11. Enter the desired value (i.e. 10001001)
12. Press the INPUT key

At this point the parameter has been changed and you should reset PWE to 0.

Changing Diagnostics:
Not all diagnostics can be changed but to change those that can be the procedure is the same as for changing parameters except that upon reaching step 8, the PARAM key should be pressed twice.

Note: To reach Parameters and Diagnostics more quickly than using the Cursor key, press the No. key and when prompted enter the desired Parameter or Diagnostic followed by the INPUT key. The cursor will advance to the this address.

If you have trouble communicating check to see if Parameter 2 Bit 2 is one or zero.

To send one from the controller:
1. Prepare the PC to receive the program.
2. Switch EDIT mode.
3. Press the PRGRM key.
4. Select the LIB soft key.
5. Key in the desired program beginning with an O.( i.e. O0025 )
6. Press the OUTPUT START key.
( OUTPUT should begin flashing in the lower right hand corner.)



The procedure for reloading parameters with a PC using Procomm is:

1. Switch to MDI mode.
2. Engage the Emergency Stop.
3. Press the PARAM key.
4. Press the Page Down key.
5. Cursor to PWE.
6. Press 1.
7. Press the INPUT key.
8. Cursor to TVON.
9. Press 0.
10. Press the INPUT key.
11. Cursor to ISO.
12. Press 1.
13. Press the INPUT key.
14. Press the Page Down key until you reach the parameter number 900.
15. Using the paper copy of parameters enter all of the 900 series parameters.
16. Page back to parameter number 212 and set according to paper copy.
17. Set parameters 2,38,50,552,and 553 according to corresponding port.
18. Connect the serial cable.
19. Press PARAM key.
20. Press [PARAM] soft key.
21. Press the INPUT key.(LSK should flash in the lower right corner.
22. Start Procomm.
23. Press the PC Page Up key.
24. Press number 7 key. (For ASCII)
25. Type in the filename that contains the CNC parameters and press Enter.
(The CNC should flash INPUT in the lower right corner)
(The PC should display the text and count lines until finished)
26. Power the controller down and back up for the parameters to take effect.

Another problem may be with Over Travel Alarms. These will occur if the Stroke Limit Parameters are lost. The Stroke Limits are stored in Parameters 700 to 707. These alarms are normally superseded by the position deviation alarms. On an M controller the stroke limit parameters are:

700 First Stored Stroke Limit X Axis
701 " " " " Y "
702 " " " " Z "
703 " " " " 4 "
704 Second Stored Stroke Limit X Axis
705 " " " " Y "
706 " " " " Z "
707 " " " " 4 "

On a T control they are:

700 First Stored Stroke Limit X Axis
701 " " " " Z "
702 " " " " 3 "
703 " " " " 4 "
704 Second Stored Stroke Limit X Axis
705 " " " " Z "
706 " " " " 3 "
707 " " " " 4 "

The Setting Range is 9999999 to -9999999. 700 to 703 will be set to a positive number. 704 to 707 will be set to a negative number. Set to 9999999 or -9999999 to open up stroke limits all the way. Most of the Pitch Error Compensation information is stored in Parameters in the 1000, 2000, and 3000 series and also in the 6000 series and must be re-entered after memory loss.

Also Diagnostics 300-699 (PMC Parameters) must be reloaded. The parameter for Backlash compensation is 535 for X, 536 for Y, and 537 for Z.

The red LED on the NC Power Supply indicates an alarm condition. It can mean either the power supply has an internal fault or an external output is shorted or grounded. To determine which it is disconnect all of the cables except CP1 which is the 200vac supply. Remove the power supply from the main board. Turn the power on. If the red LED still comes on the power supply is bad. If it stays off, there is a fault somewhere in the external circuit. The fault will normally be found in the machine wiring but quite often will be a defective I/O card.

On a 0 Control CP3 on the power supply goes to the NC power On/Off switches. CP15 supplies the 24vdc to the external machine I/O.

Parameter 24.0 = 0 tells the controller to ignore the ladder relative to PMC axis control.

Stroke limits are stored in Parameters 700 thru 707.
700 - X+
701 - Y+
702 - Z+
703 - 4+
704 - X-
705 - Y-
706 - Z-
707 - 4-
To open the limits all the way up enter 99999999 in the + parameter and -99999999 in the - parameter. If the command is being sent but the axis still will not move check the diagnostic 8. This is the axis interlock. In the case of a T controller bit 8.2 is X+

8.3 is X-
8.4 is Z+
8.5 is Z-

These bits are machine interlock signals. They are normally called +MIT1, -MIT1, +MIT2, -MIT2. This example is for a lathe so only two axes are shown. They are normally used only on a lathe and in most cases are tied to the Tool Setter probes, particularly on an Ecoca. If one of them is made the axis corresponding to it will not move in the direction which corresponds. No alarms are associated with these. They are Active Low inputs, so if the corresponding Diagnostic bit will be a 1 if the switch is open. In the case of the Ecoca, the 24 volt ground (DCN) is fed through the switch to the I/O board.

To view the Operating Monitor Screen,:
1. Press the OPR ALARM button.
2. Press the POS button.
3. Press the > (Scroll Right) button.
4. Press the MONI button.

Among the other information displayed here is the Axes load, the Spindle load and the Spindle speed. If you page through the screens you can get to the Software Operators Panel which allows you to use the arrow left and right keys to perform functions normally handled by the MTB switches and buttons. For example, Mode Select, Feed rate Override, Dry Run, etc.



The Spindle Orientation Parameter is 6531. The setting value is 0 to 4096. The amount entered depends on the number of degrees you want the spindle to turn. 4096/360 = .088, so if you are trying to adjust the orient position, increasing the value of the parameter by 1 will cause the spindle to stop .088 degrees further than before. If you want to change the orient position by 1 degree at a time, you would have to add or subtract 11.36 which cannot be entered into the parameter so you would use 11.

Depending on the MTB you may need to adjust Parameter 6577. Which parameter you adjust is determined by whether the machine uses the spindle motor encoder to orient or a Fanuc Position Coder or a magnetic pick up.

Parameter 19.3 sets the Tool Compensation System A or B/C. Most of the time it should be set to 0. On most machines if B/C system is selected the Z axis will, in Auto Mode, respond to G28 Z0 by going home then moving down the amount of the offset value of the tool in the spindle.

On a Model A Controller, the procedure for displaying the Program Library is:

1.Select EDIT Mode.
2.Press the "P" button until "P" is displayed.
3.With "P" flashing, press the Input button.

0-C Servo Alarms as Displayed on Servo Amplifier:

8, 9, A, b, C, d, e

Any of these in the LED display indicates an abnormal current alarm. Check the following parameters first:

8n04
8n06
8n10
8n40
8n41
8n74
8n98

IF THE PARAMETERS ARE SET CORRECTLY:

1. Place the machine in E-Stop.
2. Remove the motor leads from the amplifier.
3. Release the E-Stop.

IF AN ABNORMAL CURRENT ALARM OCCURS IMMEDIATELY:
Check for noise on the actual current waveform at IR and IS. If there is noise on the waveform check shielding and grounding. If the shielding and grounding are correct, there is probably a defective command cable or hardware defect in the CNC. If there is no noise on the waveform, the amplifier is probably defective.

IF AN ALARM OCCURS WHILE RUNNING THE MOTOR:
Check the motor and motor leads for shorting or grounding. If the motor and wiring is good, measure the actual current at IR and IS.

The procedure for reloading a "Brain Dead" 0 Control when you have a copy of the Parameters on Disk or PC is:

1. Set the E-Stop ON. (Button in)
2. Select MDI mode.
3. Set PWE = 1
4. Set Parameter 901 to the correct value.
5. Press the DELETE key when prompted to by the controller. (You must delete the files in order to continue)
6. Cycle power.
7. Set Parameter 38 to the correct value.
8. Make sure EIA/ISO = 1.
9. Make sure I/O = 0.
10. Cycle power.
11. Set the PC's protocol for 4800,E,7,2. (When parameters are lost, the controller defaults to this protocol)
12. Select EDIT mode.
13. With E-Stop in and Parameter Page selected, press EOB and INPUT together. (LSK will start to flash)
14. Send the Parameters from the PC. (When the data begins to flow, LSK will change to INPUT and flash)
15. When INPUT disappears, cycle power.
16. Select Diagnostics Page.
17. Release the E-Stop.
18. Press INPUT only.(LSK will flash)
19. Go to the PC and send the Diagnostics. (When data begins to flow, LSK change to INPUT and begin to flash)
20. When INPUT disappears, cycle power.
21. Set Keep Relays as required by the Machine Tool Builder.
22. Cycle power.

Remember that when working with a brain dead controller that the CRT may display EDIT mode regardless of what mode is actually selected so go ahead and put the machine in MDI mode and enter the necessary parameters.

If Alarm 085 is continually issued, double check the PC's protocol and check Parameters 2, 10, 38, and 552 to make sure the controller defaulted to 4800,E, 7,2.

When viewing the Diagnostics on a PC, N10300 = D0300 and so forth.

The timers are in milliseconds so a value of 1000 in a timer diagnostic equals one second. As an example, D320 and D325 are often used for a machines lube timer. D320 will be used for the time on while D325 will be for the time off. If D320 is set for 10000 and D325 is set for 1200000, the lube pump will turn on for ten seconds every twenty minutes.

When a dwell is executed, the X Axis Distance To Go display counts down the time left.

The parameters you need to calibrate the tool setter are 743- 746.

8., 9., A., b., C., d., E.
These are IPM alarms. Place the machine in E-Stop Wait about ten minutes. Release the E-Stop. If the cause of the alarm was IPM overheat, the alarm will not re-occur unless the ambient temperature is too high or the operating conditions are such as to cause a re-occurrence. If the alarm does recur as soon as the E-Stop is released, check for noise on the actual current waveform. If there is noise, check the shielding and grounding. If the shielding and grounding are good, there may be a defective cable or defect in the CNC. If there is no noise, the amplifier may be defective. If the alarm occurs while running the motor, check same as for over current alarms.

If you have a problem with the NC putting two rectangular characters in front of each block of data when uploading a program, try changing Parameter 70.7.


To access the Servo Monitor page:
1. Press PARAM/DGNOS button.
2. Press SV-PRM soft key.
3. Press Page Down button until you see the axis.

To find out the software information power up the NC in E-Stop mode. After a few seconds, it will be displayed.

Parameter 28.2 determines if the actual feed rate is displayed or not. If it equals 0, it is not displayed on the Position page or on the Program Check screen.

Parameter 14.2 works the same way for actual spindle speed and the current tool display.

If an axis continually over travels even after using P+CAN, try changing the soft limit parameter for the required direction of the axis to all nines. Keep in mind that the second and even third stored stroke limits may be set. If they are you must open them up as well.

The number of parts machined are stored in Parameter 779. This number as well as other parameters are stored in volatile memory and as such can be accidentally or purposely wiped out. If this happens, variable 3002 will be reset and you will not know how many Run Hours are on the machine.

The value in variable 3002 is in decimal form. Everything to the left of the decimal point is in one hour increments. Everything to the right is some fraction of an hour.

Variable 3901 stores the number of parts machined.

To display the value of Timers and Counters in Decimal instead of Binary Parameter 19.7 equal 1. If you change this bit you will have to cycle power (Alarm 000).

If you have several machine alarms along with Alarm 401, check for a loose I/O board. Sometimes Alarm 401 will be issued if the MCC contactor drops out and pulls back in quickly. This can be caused by any of the usual things that cause MCC to drop out (Door switch, E-Stop, Over travel switch, etc.). In this case an alarm condition may or may not be issued of the amplifier LED display. Also, in this case, the 401 alarm can be removed by pressing the Reset button.

Alarm 401 can be caused by a defective power supply module (PSM). This is a likely cause when there are no other alarms displayed. Normally in this case the CRT will also display NOT READY ALARM at the bottom of the screen but the MCC contactor will be pulled in. Also, the PSM and the Servo Amplifier will display the usual dashed lines as they do whenever the drive is in a NOT READY state. If the Reset button is continually pressed the alarm will go away but the drive will not become ready (0 will not be displayed). The indication that this will typically give is that everything is OK with the machine side and the drives but the CNC just does not realize it. Servo tuning on:

1. DGNOS/PARAM button.
2. SV-PRM soft key.

Servo screens:
(Using Ecoca SJ-35MC with main spindle as C axis as an example)

SERVO SETTING

X AXIS Z AXIS

INITIAL SET BITS 00000010 00000010
MOTOR ID NO. 18 20
AMR 00000000 00000000
CMR 1 2
FEEDGEAR N 1 1
(N/M) M 125 100
DIRECTION SET 111 -111
VELOCITY PULSE NO. 8192 8192
POSITION PULSE NO. 12500 12500
REF. COUNTER 8000 8000


C AXIS

INITIAL SET BITS 00000000
MOTOR ID NO. 0
AMR 00000000
CMR 2
FEEDGEAR N 0
(N/M) M 0
DIRECTION SET 0
VELOCITY PULSE NO. 0
POSITION PULSE NO. 0
REF. COUNTER 0


SERVO MOTOR TUNING

X AXIS

FUNC. BIT 00011000 ALARM 1 00000000
LOOP GAIN 3000 ALARM 2 00000000
TUNING ST. 0 ALARM 3 10000100
SET PERIOD 0
INT. GAIN 256
PROP. GAIN -1683
FILTER 0
VELOC. GAIN 150


Z AXIS

FUNC. BIT 00011000 ALARM 1 00000000
LOOP GAIN 3000 ALARM 2 00000000
TUNING ST. 0 ALARM 3 10000100
SET PERIOD 0
INT. GAIN 203
PROP. GAIN -1821
FILTER 0
VELOC. GAIN 150


C AXIS

FUNC. BIT 00000000 ALARM 1 00000000
LOOP GAIN 3000 ALARM 2 00000000
TUNING ST. 0 ALARM 3 00000000
SET PERIOD 0
INT. GAIN 0
PROP. GAIN 0
FILTER 0
VELOC. GAIN 100

Sometimes if you try to execute an MDI command by entering the command, pressing Insert and Cycle Start and the machine just sits there, usually with the Cycle Start light on it may be because the machine builder did not write the Cycle Start into the ladder for the MDI functions. In this case, try entering the command, pressing Input and Output Start.

When the values are in Binary, the eight bits work this way:

128 64 32 16 8 4 2 1
0 0 0 0 0 0 0 0

The setting unit is 50 milliseconds.

To designate 1000 milliseconds for example,

00010100 which is:
16+4 = 20 x 50 milliseconds = 1000 milliseconds

The largest number possible is:
11111111 which equals 12750.

To display the spindle speed on the CRT, make Parameter
6501.2 = 1.

The 0 controller operators manual (B-61404E/05) has a complete list of alarms including spindle alarms and self diagnostics. It also has Tape Reader operation and Tape Code list.

Fuse list as given in the 0 Control Operators Manual:

POWER SUPPLY

F11, F12 5A A60L-0001-0194#5.0 200VAC Input Power Supply
F13 3.2A A60L-0001-0046#3.2 Master PCB, Option PCB
F14 5A A60L-0001-0046#5.0 Not Used

ADDITIONAL I/O B1

F51 1.6A A60L-0001-0046#1.6 Protection from external defect on machine side 24vdc line.

INPUT UNIT PCB

F1, F2 10A A60L-0001-0901#P4100H 200 VAC Input Power Supply
F3 .3A A60L-0001-0172#dm03 Power On/Off Circuit

To execute Tool Length Measurement for the Z axis:
EOB, Z

When outputting parameters; press EOB and OUTPUT START together to send the 900 (option) parameters. This does not work when inputting parameters but you can use the EOB to allow input of other parameters while in E-Stop condition. If a 0 controller displays alarm 401 and 4n4 (414, 424, etc.) check the LED display on the servo amplifier. If it shows a 9, check the motor leads. Often a motor cable will become damaged causing two or more leads to short together or to ground out. Of course, this will allow an excessive current to flow in the output circuit of the amplifier. On most machines the motor/encoder cables lay in the bottom of the casting sometimes riding in energy chains. It is not uncommon for coolant, oil, etc to collect and eventually making the cable brittle and the back and forth motion causes cracks in the insulation. In this case, the alarms may be intermittent and also a given axis may generate the alarms while a different axis is the one in motion. What follows is the functioning of MCC on an Ecoca turning center with a 0-TC controller using Alpha drives.

MCC (KM101) is energized by L11 (220 vac) through terminals 1 and 3 of connector CX3 of the Power Supply Module and the normally open contact of KA24. KA24 is energized by 24 vdc through the normally closed contact of KA23 and the E-Stop button on the operators panel(SB1). KA23 is the X/Z Axis Spindle Safety Clutch Protection relay. It is held in by the I/O board, address Y52.3.

On a controller with Alpha drives they are connected this way:

The incoming 220 vac is supplied to CX1A pin 1 (220R) and CX1A pin 2 (220S) of the Power Supply Module. This 220 is passed by jumpers from CX1B pin 1 and CX1B pin 2 of the Power Supply Module to CX1A Pins 1 and 2 of the Spindle Amplifier. From this AC source the PSM generates 24vdc which is passed by jumpers from CX2B pins 1 and 2 to the Spindle Amplifier CX2A pins 1 and 2. This 24vdc is passed by jumper from the Spindle Amplifier CX2B pins 1 and 2 to the Servo Amplifier CX2A pins 1 and 2. This 24 volts powers the control components of the Spindle Amplifier and Servo Amplifier which allows them to operate when regardless of MCC. Once the controller is turned on and becomes Ready, MCC is energized. This applies 220 vac to terminals L1, L2 and L3 of the Power Supply Module. From this the AC source, the DC Link voltage is generated. This voltage is passed from the PSM terminals P and N by jumpers to the Spindle Amplifier terminals P and N then by jumpers to the Servo Amplifier terminals P and N. This voltage powers the drive components on both amplifiers. Serial communication is accomplished by connecting JX1B of the PSM to JX1A of the Spindle Amplifier then from JX1B of the Spindle Amplifier to JX1A of the Servo Amplifier. The last drive in this series must have a termination plug on it's JX1B connector.

Alarm 417 indicates that a parameter of the digital servo system is set
incorrectly. The parameters are, of course, dependent on the type of controller.

0 Control 16/18 Control

8n20 Motor Format Number 2020
8n22 Motor Rotation Direction 2022
8n23 Number of Pulses for Velocity Feedback 2023
8n24 Number of Pulses for Position Feedback 2024
269-274 Servo Axis Number 1023
8n84 Flexible Feed Gear Ratio 2084
8n85 Flexible Feed Gear Ratio 2085

When working with a Fanuc 0 Parameter Manual, it is important to note that the parameters are not 100% sequential, that is, they will be in order up to a point then they will change. So, if you're looking for parameter 124, for example, you won't find it listed after parameter 123. The book jumps from 123 to 130. Parameter 124 shows up 80 pages later following parameter 399. The parameter manual for the 18 controls is laid out sequentially.

The PLC (ladder) of 0 and older controllers cannot be input or output. In the case of a 0 control, it is stored on EPROMS so the chip has to be removed and programmed or replaced. It is very rare for one of these chips to fail but if you are really concerned about that happening your only recourse is to remove the chips from the memory board and make copies. If the memory board fails and you have to replace it, you must remove the chips from the old board to install on the new one.

The CRT is usually a Toshiba. It consists of a chassis, the picture tube Toshiba part number E8069PDA, a board Toshiba part number FW01165F-1. The Toshiba part number for the complete unit is D9MM-11A. The Fanuc part number for this assembly is A61L-0001-0093. The CRT assembly has two cables. One is CN1 which goes to CCX4 of the Graphic Card. The other is CN2 which goes to CP15 of the Power Unit. CN2 is a six pin connector. Pins 1 and 2 are not used. Pins 3 and 4 are -24vdc relative to pin 5 which is the common. Pin 6 is ground.

The memory capacity of an 0-D controller cannot be upgraded. This is due to the way the controller is designed and the system software. The amount of memory and many of the other options are determined at the time the controller is built and cannot be changed. In the case of memory, the memory board cannot be changed to get more memory.

If you walk up to a machine with a 0 controller and command G28 Z0, for example, the machine will normally go to the G54 Z position. If the G54 Z position is 0, the axis will go to it's home position (machine zero). If there is a positive number in G54 Z, the axis will probably over travel in the positive direction. If the value in G54 Z is, for example, -5.0000, the axis will go to a negative five inches from machine zero for the axis.

If a machine with a zero controller which when an offset value is entered, the value is added to the current setting rather than replacing it change parameter 1.4 (IOF) to 0. This is for an M controller. The description is AN OFFSET VALUE INPUT FROM THE MDI PANEL IN THE ABS MODE/INCREMENTAL MODE. The same parameter on a T controller is similar in function. Its name is ORC, when set to zero an offset value is entered as a diameter. When it equals 1 the value is specified as a radius value.

I/O SIGNAL LIST
M-Series and T-Series Combined

*ABSM Manual/Absolute signal G127.2
AFL Auxiliary Function signal G103.7
AL CNC Alarm signal F149.0
ALMA, ALMB Spindle Alarm signal F281.0, F283.3
AOV128, AOV16 1% Step Override signal G117.6, G116.4
AOV32, AOV64 G116.5, G116.6
ARSTA, ARSTB Alarm Reset signal G230.0, G234.0
B11 to B38 Second Auxiliary Function signal F155.0, F154.3
BAL Battery Alarm signal F149.2
BAL1 to BAL6 Absolute Pulse Coder Battery Alarm signal F159.0 to F159.5
BCLP B Axis Clamp signal F188.3
BDT Optional Block Skip signal G116.0

Alarm 008 cannot normally be found in the maintenance manual. It means that during programming there was an illegal use of program end. A program was registered without an M02, M30, etc. If you have trouble doing DNC operations with a 0 controller, try setting these parameters to the following settings which are being used for the Max-1Rebel at Redco Machine:

P38 01001010
P51 00000001
P55 00000000
P251 13
P914 00001010
I/O 3

In this case, set the PC for a baud rate of 38400.

If a zero control powers up with a blank screen or scrambled data it may be necessary to perform a memory clear by holding the RESET button and the DELETE button while powering up the controller. Before resorting to this, first try replacing the GRAPHIC card, if possible. You can also try disconnecting all cables from the boards except for the cable between the GRAPHIC card and the CRT. Another possible cause for this condition is either a bad master board, a bad memory board or both. I have seen cases where both boards are bad at the same time. The Master board of an 0-MC controller has six LEDs which indicate various control states. These LEDs are very useful in troubleshooting those alarms that are not displayed on the CRT. They are as follows:

L1 L2 L3

L4 L5 L6


NUMBER COLOR DESCRIPTION

L1 GREEN DOES NOT INDICATE ALARM, BLINKS DURING AUTOMATIC OPERATION
TURNS OFF WHEN ALARMS ARE PRESENT.


L2 RED ON DURING ALARM STATE. NORMALLY INDICATES AN ALARM WHICH IS
EXTERNAL TO THE MASTER BOARD, MEMORY BOARD, ETC. CHECK THE
CRT FOR ALARMS SUCH AS NOT READY, OVERTRAVEL, ETC.



L3 RED NO MEMORY CARD IS INSTALLED.



L4 RED A WATCHDOG TIMER ALARM HAS OCCURRED. THE MASTER BOARD OR
MEMORY BOARD MAY BE DEFECTIVE. SEE ALARM 920.
?
or

A SERVO ALARM HAS OCCURRED.

or

NO AXIS CARD HAS BEEN INSTALLED OR THE AXIS CARD IS DEFECTIVE.


L5 RED A WATCHDOG TIMER ALARM HAS OCCURRED IN THE SUB-CPU.
REPLACE THE SUB-CPU PCB or

A SERVO ALARM HAS OCCURRED FOR THE FIFTH OR SIXTH AXIS.


L6 RED A SYSTEM ALARM HAS OCCURRED. THE ANALOG INTERFACE CARD IS
DEFECTIVE.

or

THE DNC1 CARD IS DEFECTIVE.

or

THE SEVENTH OR EIGHTH AXIS CARD IS DEFECTIVE.

These six LEDs are in a single row from top to bottom on the following master
boards:

A20B-1002-0360
A20B-1003-0760
A20B-2000-0480
A20B-1003-0750
A20B-2000-0180
A20B-2001-0060
A20B-2001-0065

i.e.

L1
L2
L3
L4
L5
L6


The LEDs are located in three columns of two on the following master boards:

A20B-2000-0170
A20B-2000-0175
A20B-2001-0120
A20B-2002-0650

i.e.

L1 L2 L3

L4 L5 L6

9000 series programs such as ATC Macros are protected by parameter 10.4, if set for one, programs can not be viewed or edited.

Servo Tuning screen using the X axis as example:

FUN. BIT = Parameter 8103
LOOP GAIN = Parameter 517 or 512
TUNING SET = Used by automatic servo tuning function
SET PERIOD = Used by automatic servo tuning function
INT. GAIN = Parameter 8143
PROP. GAIN = Parameter 8144
FILTER = Parameter 8167
VELOC. GAIN = Parameter 8121 + 256 divided by 256 times 100
ALARM 1 = Diagnostic 720
ALARM 2 = Diagnostic 730
ALARM 3 = Diagnostic 760
ALARM 4 = Diagnostic 770
LOOP GAIN = Actual Loop Gain
POSITION ERROR = Actual position error (Diagnostic 300)
CURRENT % = Percent of rated value
SPEED RPM = Actual motor RPM

The eight bits of each alarm (1-4) correspond directly with the diagnostics to which they are associated. In the event of a servo alarm you can check the details of the alarm on the Servo Tuning page just as you would with the diagnostic. Alarm 1 is used to check the details of alarm 400 and 414 just as Diagnostic 720 is. Alarm 2 is for disconnection alarms and overload alarms. Alarm 3 and 4 are for checking the details of alarm 319.

If the Servo Tuning screen is not displayed by pressing the DGNOS PARAM button, the right CHAPTER key, SV PARA soft key the SV TUN soft key, check parameter 389.0 (SVS), it must be 0 for the screen to be displayed.

If none of the axes of a machine will move, check the diagnostic for the STLK signal. This signal, when set to 1, will prevent all axis movement. In the case of a 0 controller STLK is Diagnostic 120.1.

The M-Code which increments the parts counter is D40.3.If it is set to 1, the parts count will be incremented by M02 and/or M30. If it is set to 0, the M-Code can be specified. The allowable range is between M0-M255 but it can not be M98 or M99. The desired M-Code is specified in parameter 219. Parameter 600 stores the Parts Required while parameter 779 stores the Parts Preset.

On a 0 controller with Alpha drives, parameters 6560 - 6563 are used to adjust spindle gain for different gear ranges. They are especially useful for getting the spindle to be more rigid during orientation. On most machines only one or two of them are normally used and the standard setting is 1000.

On a 0T controller the value stored in the soft limit parameters (i.e. 705 for Z-) is equal to roughly 39 millionths (.000039).

0 Control with standard memory has a memory capacity of 32767 characters or 63 programs whichever comes first. Each instruction equals one character or block of memory. (i.e. M, G, 0, Z, etc.) When programming you can save memory by leaving out unnecessary things especially zeros. Instead of inserting M06 in a program it should be M6. Instead of Z-5.0 it should be Z-5. With a Parameter change you can even omit the decimal point when inputting units.

To search for a particular element in a program:
1. Go to EDIT mode.
2. Type in what you are searching for.
3. Press the Cursor UP button if what you are looking for is above your current position in the program. Cursor
DOWN button if what you are looking for is below your current position in the program. The memory Board
has four sockets for 256k memory chips.


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0 SERIES CONTROLLER cont'd




0-C Control Spindle Amplifier Alarms as displayed on Amp:

A0, A1 The control program is not running. Check for ROM not properly
installed or incorrect ROM. Possible defective PCB.

AL-01 The internal motor temperature is higher than the rating.
Check for the motor being overloaded, the cooling fan defective, poor
motor ventilation due to dirt or obstruction, motor overheat wires open,
invalid detector parameters, motor or thermostat defective.

AL-02 The actual motor speed deviates grossly from commanded speed.
Check the load meter to see if the load is too heavy, poor power connections,
incorrect accel/decel duration parameter setting, incorrect speed detector parameter
setting, IGBT module/IPM defective, speed feedback signal (cable).

AL-03 The fuse at the DC Link is blown.
Check the IGBT module/IPM.
This alarm will occur if an over current flows in this circuit.


AL-04 Input fuse blown. Input power open phase.
Detects missing fuse or momentary loss of power.
Check for open phase and power supply regenerative unit.

AL-05 Control power supply fuse blown.
Detects that control power supply fuse AF2 or AF3 is blown.
Check for control power supply short circuit.

AL-07 The actual motor speed exceeded 115% of the maximum allowable speed
setting (standard speed setting).
Check for incorrect speed detector parameter setting. 6511 Bit 0, 1 and 2. For 15 Control
it is Parameter 3011 Bit 0, 1 and 2. For 16/18 its 4011 Bit 0, 1 and2.

AL-08 High input voltage. Detects that switch is set for 200 VAC when incoming voltage is 230.

AL-09 The temperature of the main circuit heat sink has risen abnormally. Check for fan and/or
ventilation problem.

AL-10 Low input voltage. Detects drop in input power.

AL-11 Over voltage in DC Link. Detects abnormally high DC power supply voltage.

AL-12 Excessive current flowed in the DC Link, the main circuit power module (IPM) detected an error.
Check for a short circuit in the output circuit of the amplifier. The IGBT, IPM or the PCB may be
defective. Check the model-specific parameter settings.

AL-13 The memory inside the CPU is abnormal.
This check is made when the power is switched on. The PCB is probably defective.

AL-15 A sequence of switching operations was incorrect during speed range switching control
or spindle switching control. Check the contactor used for power line switching and in
particular the auxilary contact.

AL-16 The RAM is abnormal. This check is made when power is switched on.
Probably a defective PCB.

AL-19 The offset voltage for the U phase current detection circuit is too high. Check the connection
of the power to the PCB, the current detection circuit may be defective, the A/D converter may
be defective. In either case the PCB must be replaced.

AL-20 Same as for AL-19 but V phase.

AL-24 The serial communication data between the CNC and Spindle Amplifier is abnormal.
Check that the NC power is on, check the serial cable, the LSI chip may be defective or the
PCB with the LSI on it, the I/O Link adapter may be defective. This alarm is normal when the
NC power is off.

AL-25 Serial communication between the CNC and Spindle Amplifier stopped. Check same as above.

AL-26 The C's contouring control speed detection signal (detector on the motor side) is abnormal.
Check the feedback signal level with an oscilloscope, check the connections of the cable, check
the cable shield for proper grounding, the detection circuit may be defective, the parameter
setting for the C's contouring control detector. It is 6511 Bit 5. For 15 control it is 3011 Bit 5 and
for 16/18 control it is 4011 Bit 5.

AL-27 Position Coder signal error. The position coder or it's cable may be defective, signal may be
too low (adjust level), feedback cable may not be shielded properly, the detection circuit may be
defective. The C's contouring parameter setting may be incorrectly. It is 6501.2 For 15 control it
is 3001.2 For 16/18 it is 4001.2

AL-28 The C's contouring control speed detection signal (detector on the spindle side) is abnormal.
Check the same as for AL-27.

AL-29 Excessive load (at least 90% of the maximum output as set initially by a parameter) was applied
continuously for a certain period. Normally 30 seconds set by parameter. Motor is overloaded,
check the load meter, cutting conditions and tool.


AL-30 Input Circuit Over current. Over current flowing in input circuit. Check incoming power for over
voltage condition. Possibly bad Power Supply.


AL-31 The motor cannot rotate at the specified speed. It rotates at a very low speed or stops. Check if the
motor is physically locked, check if the speed feedback cable is defective, check the speed
feedback signal with an oscilloscope, check the power connections.

AL-32 The memory in the serial communication LSI chip is abnormal. The LSI chip is probably defective,
replace the PCB.


AL-33 Insufficient DC Link section charging. Detects insufficient charging of DC power supply voltage in
power circuit section when magnetic contactor in amplifier is turned on. Check for open phase or
defective charging resistor.

AL-34 A Parameter setting is invalid, check parameters.

AL-35 The value set in the gear ratio data parameter is greater than the limit allowed in the internal processing.
Incorrect gear ratio parameter setting, check if the specified gear ratio is too high. Spindle to Motor Gear
Ratio Parameter 6556 to 6559. For 15 controller it is 3056 to 3059. For 16/18 control it is 4056 to 4059.

AL-36 The error counter overflowed. Check if the values set in the gear ratio and position gain parameters
are too large. Check parameters above as well as 6560 to 6563 (Position gain during orientation),
6565 to 6568 (Position gain during servo mode/synchronization control of the spindle), 6569 to 6572
(Position gain during C's contouring control).

For 15 controller:

3060 to 3063
3065 to 3068
3069 to 3072

For 16/18 controller:

4060 to 4063
4065 to 4068
4069 to 4072

AL-37 When an emergency signal was entered, the motor did not decelerate, rather it accelerated or the
motor was kept excited even after the accel/decel duration time (normally 10 seconds as set by
parameter). Check that the speed detector parameter, 6511.0,1 and 2, is set for the speed detector
used. 3011.0,1 and 2 for 15. 4011.0,1 and 2 for 16/18. Check that the Accel/Decel duration parameter,
6582, is set correctly. 3082 for 15. 4082 for 16/18.

AL-39 The C's contouring control one rotation signal has not been detected correctly. Check that the feedback
signal level is sufficient and that the shield is properly grounded. Check that the parameter used
to specify the use of the C contouring control detector, 6503.4,6 and 7 is set properly. 3003.4,6 and 7
for 15. 4003.4,6 and 7 for 16/18.
PCB may be defective.

AL-40 The C's contouring control one rotation signal is not generated.
Check the cable and signal as above.
Check the offset of the C's contouring control one rotation signal with an oscilloscope and adjust as
necessary. PCB may be defective.

AL-41 The position coder one rotation signal was not detected correctly.
Same as AL-39.

AL-42 The position coder signal was not generated.
Check cable, shielding, position coder, PCB, etc.

AL-43 The position coder used for the main spindle during the differential speed mode was disconnected.
Check cable, shield, coder, etc. Check parameter 6500.5 (Setting for Differential Speed Mode
Functions). 3000.5 for 15. 4000.5 for 16/18.

AL-44 An A/D Converter error occurred. A/D Converter is probably defective, replace the PCB.

AL-46 The position coder signal was not detected correctly during thread cutting.
Same as AL-39.

AL-47 A pulse count for the position coder signal is abnormal.
Same as AL-39.

AL-49 During Differential Speed Mode, the sub-spindle motor speed converted from the main spindle motor
speed exceeded the limit. The differential speed is calculated by multiplying the main spindle motor
speed by the gear ratio. Make sure that the calculation does not exceed the maximum motor speed.

AL-50 During the synchronization control of the spindle, the calculation result for the speed command
exceeded the limit. The motor speed command is calculated by multiplying the spindle speed
command by the gear ratio. Make sure that the calculation result does not exceed the maximum
motor speed.

AL-51 Under voltage at DC Link section. Detects that DC power supply voltage of power circuit has dropped.

AL-52 ITP signal abnormality 1. Detects abnormality in synchronization signal (ITP signal) with CNC.

AL-53 ITP signal abnormality 2. The ITP signal (Sync Signal for Sync With the CNC) stopped. CNC error,
check the operation of the CNC. Serial communication LSI chip may be defective. If so, replace the PCB.

AL-54 It was detected that a high current flowed in the motor for a long period. Motor is overloaded or
accel/decel is too frequent. Check the load meter for overloading. Check if accel/decel was repeated
very frequently. Check cutting conditions.

AL-55 During spindle switching control or speed range switching control, there was a conflict between the
switch request signal (SPSL or RSL) and the power line state confirmation signal (MCFN, MFNHG,
or RCH, RCHHG). Switching unit (magnetic contactor for power line switching) may be defective.
Connections of magnetic contactor may be loose. Make sure the Parameters for the power line state
signals related to the spindle switch control and output switch control are set correctly.

6514.2 = Specifies the power line state signal for spindle switching control.
3014.2 for 15 and 4014.2 for 16/18.

6514.3 = Specifies the power line state signal for speed range switching control.
3014.3 for 15 and 4014.3 for 16/18.


AL-56 The cooling fan for the control circuit stopped. The cooling fan is probably defective.

AL-57 Control circuit is erroneous. Check connections and incoming AC. The Spindle Amplifier is probably
defective.

Accel/Decel Duration Parameter = 6582
For 15 Controller it is Parameter 3082 and 16/18 Control its 4082.

Speed Detector Parameter = 6511 Bit 0, 1 and 2
For 15 Controller it is Parameter 3011 Bit 0, 1 and 2. For 16/18 its 4011 Bit 0, 1 and 2.

0-C Control Power Supply Alarms as Displayed on Power Supply:

01 The main circuit power module (IPM) has detected and error.(PSM -5.5, -11) Over current flows into the
input of the main circuit.(PSM -15 to -30) The IGBT (or IPM) is defective, replace. The specification of the
AC Reactor does not match the Power Supply Module. Check the PSM and the specification of the AC
Reactor.

02 A cooling fan for the control circuit has stopped.
Check fans for proper rotation.

03 The temperature of the main circuit heat sink has risen abnormally. Check cooling fan and proper
ventilation of unit. Also check for overloading of the system.

04 In the main circuit, the DC voltage (DC Link) has dropped.
A small power dip may have occurred. The input power may be too low.
The main circuit power supply may have been switched off with an emergency stop state released.
Check the sequence.

05 The main circuit capacitor was not recharged within the specified time.
Too many SVM and/or SPM (Servo and/or Spindle) units may connected. Check the specification of the
PSM. The DC Link may be shorted. Check the connections. The recharge current limiting resistor may be
defective. Check the wiring board.

06 The input power supply is abnormal (Open phase).

07 In the main circuit, the DC voltage at the DC Link is abnormally high. The regenerated power may be
excessive. In this case, regeneration is impossible, the PSM does not have the capacity. The output
impedance of the AC power source may be too high. Check the output impedance. The regeneration
circuit may have failed. Check whether there is an Over voltage at check terminal IR or IS. May be
necessary to replace wiring board or PCB. The IGBT (or IPM) may be defective.

If a machining center will not allow you to move any of the axes in MDI or PROGRAM unless the spindle is running, you can change Parameter 24.2 (SCTO) to 0. This tells the NC not to check for the Spindle Speed Reached Signal.

The 900 series parameters on the O control are for Optional Parameters.

If a control indicates Alarm 407, 417, and 427 (Serial Servo Alarm for X,Y,Z) at the same time, the Memory is probably scrambled. Once scrambled, it must be cleared by cycling power and holding the Reset button. Remember to try this first without holding the Delete button to avoid clearing the Programs until it is absolutely necessary. If you must clear the entire memory, backup the programs and offsets first. To do this you may have to cycle the power while holding the Reset button. Then, enter the 900 series Parameters by hand, cycle power normally, enter the communication parameters by hand (10,552,etc.) Then backup up programs and offsets, then clear the whole memory by cycling the power while holding the Reset and Delete buttons. Anytime the memory is cleared, no matter what method you will use to re-enter the parameters, you should enter the 900 series first then cycle power normally, then enter all the other parameters. When entering the 900 series the control will give a 000 Alarm telling you to cycle power. You should cycle power each time this happens rather than waiting until all 900s have been entered. You will also receive alarms when loading the 900 parameters by hand telling you that the action you have chosen will destroy files. You have no choice but to continue on. If you do not so me of the 900 series parameters will not be entered and the control will not be properly set up. Normally, after losing the memory you will have Servo alarms which will prevent you from loading the parameters with a PC. These alarms are generated because when the memory is lost the Motor Model I.D. parameters 8120,8220, and 8320 to go to zero. The alarm results because zero is not a valid Motor I.D. number.

What you must do is:
1. Load the 900 parameters by hand.
2. Enter the motor model I.D. ( Parameter 8120,8220,8320 for X,Y,Z)
3. Make Parameter 8100.1,8200.1,8300.1 = 0. (This will cause the control to power up with the default values for
the Motor model selected in Parameter 8120,8220,8320 which will prevent the alarms.)
4. Cycle power.
5. Now the Digital Servo Parameter alarms should go away and you should be able to load the rest of the
parameters with the PC.

If you want to reload the parameters by RS232 but the alarms prevent it, try pressing the EOB button with INPUT.

Any time you are loading the parameters by hand it is helpful to set P64.5 to equal 1 so that the control won't switch from the Parameter page to the Alarm page every time the 000 Alarm is issued.

An important Parameter to be aware of is Parameter 38 bit 3. This bit should normally be a 1. If it is 0, the Data Search function is disabled so you will have to find parameters by paging through. Power must be cycled after this parameter is changed. Parameter 38.3 (FLKY) is the parameter which selects a full keypad or not. If you have a full keypad and this parameter is set for 0 instead of 1, the search function along with other features unique to the full keypad will be disabled.

An alarm that is commonly issued when parameters are lost is 520. This is an over travel alarm. Normally, you can get rid of it by setting parameter 15.2 to 1.

Another thing you will likely see when Parameters are lost is Alarms 410, 420 and 430. These alarms indicate a Position Deviation Error while machine is in a stop state. They correspond to X, Y and Z. These alarms will occur in cases where Parameters 593, 594 and 595 are lost. This is because the control is being told that it's maximum allowable position deviation is zero. This represents an unreasonable quantity. If you are trying to reload the parameters, you can remove the alarms by manually inputting the 593, 594 and 595. The Setting Range is 0 to 32767. These values are typically 500.

Pressing the E-Stop will not help with Serial Alarms such as 408 and 409. In the case of the 409 alarm, depending on the control you may get rid of this by setting Parameter 100 to it's proper value. Parameter 100 is the CMR (Command Multiply Ratio) for the X axis on both a T and M Control.

You may also get an Over Travel Alarm that won't go away if one of the axes is sitting on the reference switch when parameters are lost. You can often remove this alarm by setting Parameter 38 bit 0 to it's proper value. This bit changes the Input Address of the Deceleration signal on a T Control. If P38.0 = 0, the signals will be taken at X19.7 for DEC3 and X19.5 for DEC4. If P38.0 = 1, the signals are taken from X16.7 for DEC3 and X17.7 for DEC4. Parameter 38 also has to be set for proper communication to allow the loading of Parameters via RS232.

Setting Parameter 71.7 may cause Alarms 408 and 409 to issue but is nothing to be concerned about.

Normally when you change a parameter and receive the 000 alarm, you should go ahead and cycle power. The one exception to this is when loading the 8000 series parameters. If you change Parameter 8100, 8200 and 8300 for an M control, you get the 000 alarm. If you cycle power the control changes the parameter back so what you must do is set the whole series 8100 to 8200,8200 to 8300, etc., then cycle power. You may find this procedure necessary on other series of parameters as well.

Parameter 60.7 selects either color or monochrome display if you have a 9" CRT so if when you correct this parameter you will notice a big difference when you power back up. That is, if the control is equipped with a color CRT. So, if you lose parameters, don't be shocked when the monochrome display appears, it is temporary.
P60.7 = 0 Monochrome Display P60.7 = 1 Color Display

Sometimes you may have to work with Password Protect Parameters 797 and 798.

Servo Motor Parameters can be set up automatically if necessary. This is known as Auto Tuning. If you know the motor model I.D. you can enter it into Parameter 8120, 8220 or 8320 for X,Y or Z then change 8100.1,8200.1 or8300.1 to zero and cycle power to load the Fanuc motor default values.

The improper setting of any of the following parameters can cause a 4n0 of 4n1 alarm:

504-507
593-596
517
512-515
518-521
004-007
35.7
100-103
522-525
529
601-604
635
45.3
37.0-37.3

If Alarm 4n4 occurs continually, check the following parameters:

522-525
529
601-604
635
45.3
8100 Series

For Axis Feed rate problems check Parameters

504,505,506
518,519,520
559,560.561

Parameter 556 sets the maximum spindle speed in G96 (Constant Surface Speed). G97 cancels Constant Surface Speed Control.

If the Servo Setting Screen can not be displayed make sure that Parameter 389.0 = 0. For 16, 18, 20 and 21 controls it is Parameter 3111.0 = 1.

If an axis won't move in Jog mode on a 0 control you can give a move command in Jog mode while checking Diagnostic 116. This diagnostic indicates if the ladder (PMC) is sending the jog command to the CNC side.

To do a Forward Ladder Search on a 0 control, enter the address (i.e. Y82.2) and press INPUT.

On most 0 controls turning the NC power off while uploading or downloading programs will cause Alarm 101 to be issued when power is turned back on. If this happens you must clear the Program Memory.

On some 0 controls Diagnostics cannot be output.

1. Switch to MDI mode.
2. Engage the Emergency Stop.
3. Press the PARAM key.
4. Press the Page Down key.
5. Cursor to PWE.
6. Press 1.
7. Press the INPUT key.
8. Press the Page Down key until you reach parameter number 900.
9. Using the paper copy, enter all of the 900 series parameters.
(It is not necessary to enter the entire parameter. For example the parameter 00001000 can be entered as
1000, the parameter 00011100 can be entered as 11100 etc.)
10. At this point all other parameters can be entered.
11. Change PWE back to 0.
12. Power the control off and back on.

The M Code for Spindle Orient takes the form of a parameter usually P587.

If a 8. is displayed on a 0 Control Servo Amplifier There is an excessive current flowing in the output section of the servo amp. Disconnect the motor leads, if the alarm goes away the motor is shorted etc. If the alarm does not go away, there is an internal problem with the amplifier.

When working on problems with Servo or Spindle alarms, be sure to distinguish between information about velocity feedback and position feedback. This is especially important with the Spindle because there are normally more than one encoder involved, the motor encoder for velocity feedback and the orient pulse coder for position feedback. For example Alarm 409 refers to a loss of POSITION feedback so if you start chasing the motor encoder and cables you will waste a lot of time.

Typical cable configurations for 0C:

Spindle Amplifier:

JX4 -------------- EMPTY

JX1A ------------- JX1B (POWER SUPPLY)

JX1B ------------- JX1A (SERVO AMPLIFIER)

JY1 --------------- ?

JA7B ------------- OPTICAL I/O LINK ---------- COP5 (MEMORY BOARD)

JA7A ------------- EMPTY

JY2 -------------- ?

JY3 -------------- EMPTY

JY4 -------------- ?

JY5 No Plug


Servo Amplifier:

JX5 -------------- EMPTY

JX1A --------------JX1B (SPINDLE AMPLIFIER )

JX1B ------------- DUMMY PLUG

PWM1 ----------- M184 (AXES BOARD)
JV1B

PWM2 ----------- M187 (AXES BOARD)
JV2B

PWM3 ----------- M194 (AXES BOARD)
JV3B


Axes Board:
____________________________ PWM2 (SERVO AMPLIFIER)
| JV2B
|
M187 M184 -------------- PWM1 (SERVO AMPLIFIER)
JV1B


M197 M194 -------------- PWM3 (SERVO AMPLIFIER)
| JV3B
4th


____________________________ Y AXIS PULSE CODER
|
|
M188 M185 -------------- X AXIS PULSE CODER



M198 M195 -------------- Z AXIS PULSE CODER
|
4th


Memory Board:

M27 ------------- EMPTY

M12 M26 ------------- EMPTY
|
EMPTY


M3 CCX5 ------------ ?
|
?


M5 M74 ------------- EMPTY (COM PORT)
|
RS232 PORT


COP5 ------------ OPTICAL I/O LINK
CPA7 ------------ BATTERY PACK


On a 3 axis servo amplifier the output wiring normally appears as:

X Y Z

RED WHITE RED WHITE RED WHITE

BLACK GROUND BLACK GROUND BLACK GROUND


In addition to the alarm indicator, the PSM is equipped with five check
terminals. Below are their designation, positions, and normal values:

IR Corresponds to L1 (Phase R)
IS Corresponds to L2 (Phase S)
+24V Control Power +24vdc
+5V Control Power +5vdc
0V Control Common 0vdc

The nominal value of IR and IS will vary according to PSM model. Below is a
a list corresponding to available models:

Model Nominal Value Over current Alarm Level

PSM-5.5 25A/1V Depends on IPM alarm output
PSM-11 37.5A/1V " " " " "
PSM-15 50A/1V 300A/6V
PSM-26 75A/1V 450A/6V
PSM-30 100A/1V 600A/6V

IR and IS are check points which output a voltage proportional to the amount of current being drawn from the power supply. So on a PSM-11, for example, if you measure from Pin IR to Pin 0V and see 2vdc, the PSM is supplying 75 amps.

If the PIL indicator is off, check the +5V power circuit because the PIL circuit operates off of +5vdc.

An A Model control will not display the Ladder nor will it output the Diagnostics via RS232.

If you have an intermittent problem with a machine and you suspect that a switch is making or breaking when it is not supposed to or some other signal is changing states to cause the problem, you can set a trap to catch the signal changing. This trap will catch any bit that changes states in Diagnostics 000 to 699. To set the trap:

1. Go to Parameter 25 and clear it out (Change all bits to 0).
2. Go to Parameter 578.
3. Add 59344 (A constant) to the number of the Diagnostic you want to trap.
4. Enter this value into Parameter 578.
5. When the machine malfunctions go to Parameter 25.
6. A 1 will appear in the bit corresponding to the bit of the signal which changed states. This bit will remain set
even if power is cycled.

Example:

If you had a machine which was mis-positioning and you suspected the cause to be noise on the MLK (Machine Lock) signal G117.1 causing it to go high and cause a problem. You would go to Parameter 25, clear it out. Go to Parameter 578 and input 59461 (117+59344). The number 6075 will appear on the CRT. This is the result of 65536(Another Constant) minus 59461. Parameter 25 will now reflect any change in states of G117. The 8 bits in P0025 will correspond to the 8 bits of G117. So if you want to know if MLK changed, look at Parameter 25.1.

You can monitor more than one signal at a time because Parameter 579 and 26 work together in the same manner as 578 and 25.

The maximum amount of memory for a 0 control is 320 Meters which is 128 K Bytes.

To access the Macro Variables press the OFSET button and then the MENU soft key.

Parameter 636 stores the value of deceleration.
Parameter 59.1 and 59.4 are for Deceleration Function Active in G0 and G1.

Zero controls look ahead two or three blocks. When you have an alarms or other problem you may be able to catch it by using single block. When a program hangs up, the problem may be in the portion that was read ahead, two or three blocks from where the cursor is.

This screen is also available on some 0 controls. To access the screen:

1. DGNOS/PARAM button.
2. SP-PRM soft key.
3. SP. MON soft key.

For problems involving the RESET button on a zero control you can try working with Parameter 391.7 (NOCLR) and P45.6 (CLER). Both of these parameters have to do with what happens when the RESET button is pressed. Certain settings will cause some Modal commands to be cleared when it is pressed, for example. The same thing is true with Parameter 2401.7 (NCM) on a 10 control.

Also keep in mind that 4n4 (in the case of 0 control) is one of those alarms that you can check Diagnostic number D721 for an indication of what the problem may be. In the example above, a 1 would be displayed at bit 4 of D721 (HCAL).

When working on machines like a Yang that uses a 0-TD or 0-MD control, keep in mind that they may not have an EDIT key (hardware) to prevent editing of programs. In this case you have to use the KEY function of the Software Operators Panel.

On machines that do not have a program protect key, press the Alarm button three times to access the Setting screen and toggle the KEY with arrow buttons.


Normally in order to either type in or load the Diagnostic Parameters via RS-232 you must have the Edit Key turned off (edit enabled). If not, you will be able to type the Diagnostics in but when you press the
Input button, they will be removed from the screen but the value will not change.

In order to clear the program storage memory area of a zero control you must first turn on the PWE then hold the DELETE key while the NC is powering up.

For alarms 502 and 503 on a machine with the 0i control, make sure the second or third stroke limits have not been turned on accidentally. The parameter is 1310.0 for the second stored limits and 1310.1 for the third. 1 turns the limits on and 0 turns them off.

The drivers for RS-232 on some 0 control memory boards will be 75C188 and 75C189 instead of 75188 and 75189. These chips will be surface mount instead of PDIP.

You can be fairly certain if there is a problem with the drives, I/O board, even CPU or system software causing a Not Ready state, the control will be aware of it and will issue either an NC alarm or show an alarm number on a drive LED display or both. If the machine is NOT READY but no alarms condition is indicated by the control, then the Not Ready state is being caused by something external to the control. The only exception may be a failure of the Ladder (PMC) software or it's firmware but this is extremely rare. If the control checks out, check the E-Stop circuit. Does the machines E-Stop circuit check out to the extent that there appears to be no external E-Stop being generated? With most machines, as in the example above, you can determine if the this circuit is ok by checking the potential across terminals 1 and 3 of connector CX3. The E-Stop circuit will either close to supply voltage to CX3 or will close to pass the voltage from CX3 to MCC. You can also short across the two CX3 terminals to see if the machine becomes ready but you must be careful since the PMC may have the machine in a NOT READY state and forcing MCC on could cause serious damage. Now, if the drives and the E-Stop circuit check out, turn your attention to the PMC. The way that E-Stop is generated through the PMC is by acting on the signal *ESP. The address for *ESP is X21.4 on the machine side and G121.4 on the CNC side. This should always equal 1. If X21.4 is 1 but G121.4 is 0, the E-Stop circuit is ok but this is not being relayed to the CNC. With most machines, as above, the same components that complete the circuit for MCC also supply the input to X21.4 but some machines will use different circuits for the two. X21.4 (*ESP) and G121.4 (*ESP) must be 1 for the machine to be in a READY state. G121.5 (*SP) is the Feed Hold signal, it should also be 1. When the machine is in E-Stop this will be 0. Don't let it sidetrack your troubleshooting. In addition to the above circuitry, you must be aware of CX4. CX4 of the Power Supply Module also will place the control in a Not Ready condition. In order for the control to be in a ready state, pin 3 of CX4 (+24V) must be connected to pin 2 of CX4 (ESP) through some external circuit. In the case of the example above, this is done with a normally open contact (pins 5 and 9) of KA24. To sum up. in order for a machine to be in a Ready state, pins 2 and 3 of CX4 must be connected, pins 1 and 3 of CX3 must be closed within the Power Supply Module and X21.4 must be 1.

An important parameter to be aware of is parameter 452 for the X axis, 453 for the Y axis and 454 for the Z axis. Fanuc calls these secret parameters. What they do is store the number of pulses recorded for the Absolute Pulse Coder when it is at home. If you replace an absolute pulse coder you can reset the zero point without working with this parameter and the machine will run but off the wall intermittent problems can occur. For example, the machine may have over travel alarms when powering up even while the machine is in the middle of it's travel. Also, an axis may misposition but only once every few days, weeks or months. Another situation that might arise is the machine will pick up the correct offset 99.99% of the time but once in a blue moon will not. Glen says he has seen cases where resetting the parameter will fix the problem. The parameter is reset by changing it to zero and zero returning the machine. The control will give the 000 alarm so you will have to cycle power.

Troubleshoot alarm 3n9 with Diagnostics 760-767 and 770-777. Diagnostics 760 for first axis; 761 for second axis; 770 for first axis; 771 for second axis, etc.

760-767 7 6 5 4 3 2 1 0
CSAL BLAL PHAL RCAL BZAL CKAL SPHL

CSAL The serial pulse coder is defective. Replace it.

BLAL The battery voltage is low. Replace the batteries.

SPHL The serial pulse coder or feedback cable is defective. Replace the serial pulse coder or cable.

RCAL The serial pulse coder is defective. Replace it.

BZAL The pulse coder was supplied with power for the first time. Make sure that the battery is connected.
Turn the power off, then turn it on again and perform a reference position return.

CKAL The serial pulse coder is defective. Replace it.

PHAL The serial pulse coder or feedback cable is defective, replace the pulse coder or cable.


770-777 7 6 5 4 3 2 1 0
DTERR CRCERR STBERR


DTERR The serial pulse coder encountered a communication error. The pulse coder, feedback cable or
feedback receiver circuit is defective. Replace the pulse coder, feedback cable or NC axis board.

CRCERR The serial pulse coder encountered a communication error. The pulse coder, feedback cable or
feedback receiver circuit is defective. Replace the pulse coder, feedback cable or NC axis board.

STBERR The serial pulse coder encountered a communication error. The pulse coder, feedback cable or
feedback receiver circuit is defective. Replace the pulse coder, feedback cable or NC axis board.

In order to retrieve data from a variable, you have to execute a macro program. For example, to find the
number of hours the machine has been run (cycle start lamp on):

O3737;
G65 P9100;
M30;

O9100;
#500=#3002;
M30;

The run time data is stored in variable 3002 but can not be directly viewed. This is the only way to access it. After running program O3737, you can go to variable 500 (#500) and read the data.

On the 18 control the same procedure works (#500=#3002) but the control has to have CUSTOM MACRO B. Anytime a machine does not want to execute a function, especially in MDI, spindle start, feed rate commands, override, MPG, etc, try doing the same function from the CRT/MDI and/or the Software Operators Panel instead of the machine operators panel. If the command or function works by the CRT/MDI or Software Operators Panel but not the machine panel, it may point to a problem with the machine panel, power supply to the panel, wiring or even the ladder.

Some information in the control is stored in the form of System Variables. These variables store things such as the amount of time the Cycle Start lamp has been on, the current axes position, current time, date. Some alarms are stored in system variables. These variables and their values cannot be seen or accessed directly. Generally speaking, the only variables which can be seen or manipulated are Common Variables. These variables are numbered from #100 - #149 and #500 - #531. As an option, #150 - #199 and #532 - #999 are available. Variables #1 - #33 are local variables. They an only be used within a Macro to hold data such as the results of operations. When the power is turned on, these variables are set to null. When a macro is called, arguments are assigned to local variables. System Variables are numbered from #1000 and up. If you need information stored in a system variable and you know which one it is stored in you can access it by moving it from the system variable address to a common variable address. This is done by writing and executing a program. What follows is an example of how to access how long (in hours) the Cycle Start lamp has been turned on.

O9101;
#500 = #3002;
M30;

This reads like (Variable 500 equals variable 3002).

The # and = symbols are entered by pressing the SHIFT key. In the case of #, press SHIFT then M. For =, press SHIFT then S. When you press the SHIFT key you should see this symbol displayed ^. If it is not displayed, there is likely a problem with the keypad.

After running the program, the value stored in #3002 can be seen by looking at #500. In order to see #500:

1. Press OFSET button.
2. Press MACRO soft key.
3. Page to #500.

When a value is moved from a variable to #500 it replaces whatever is already there.

The value of Common Variables can be changed to another value including 0. To do this, cursor to the variable, type the desired value, press INPUT. This can be done from any mode.

If G98 does not allow the axes to move without the spindle running, make parameter 24.2 =0.

To change the accel/decel time of the spindle motor use parameter 6580. A typical setting for this parameter is 70.

If a control locks up so that nothing on the keypad or operator's panel works while a DNC operation is underway, the problem is probably the PC, cable or communications software. Of these three the most likely one is the cable. You must be careful when using the usual troubleshooting methods. Normally when a control freezes during program execution you can check Diagnostic 700 to find out why but in this case if the machine was in motion when the cable caused the lock up, you may well see bit 3 (CINP) is turned on but the In-Position check is not the cause of the lock up but simply a symptom.

For rigid tapping problems on a machine with a 0M control look in the Operation and Maintenance Handbook, there is an entire section of parameters just for rigid tapping. If you don't have the handbook check parameters:

214-217
400-405
686-688

In particular look at parameter 688, this is the parameter for backlash compensation only during rigid tapping. Keep in mind that other problems can be backlash in the spindle motion, that is, delay in reversing direction due to belts, gears, etc. Also, check the separate pulse coder, it's belt could be slipping, etc.

To enable/disable Feed Hold and Single Block in rigid tapping, parameter 397.3 (RGMFH). 0 for enable, 1 is for disable.

Most of the time if you are working with a 0-Mate control, there will be no Ladder display. In some cases you can turn the ladder on by changing bit 2 of parameter 60.

Be careful changing parameter 38, there are some bad things that can happen. If you set 38.3 wrong it may cause the CRT to not display data as it is entered.

The Axis Servo Motor information is stored in Parameters 8100-8125, 8200-8225 and 8300-8325 for X,Y and Z.

In order to use more than one M-Code in the same block, make Parameter 65.7 equal 1.

On some 0 and 18 controls, the Work Shift Coordinate is not shown on a separate page but rather on the Work Coordinate page. When on this page it may show up as

WORK COORDINATES

NO. (SHIFT) NO. (G55)
00 X _.____ 02 X _.____
Y _.____ Y _.____
Z _.____ Z _.____



NO. (G54) NO. (G56)
01 X _.____ 03 X _.____
Y _.____ Y _.____
Z _.____ Z _.____

Fanuc, GE Fanuc, and General Numeric controls are basically the same. For example, a General Numeric GN0 is for all intents and purposes a Fanuc 0. Generally speaking, the manual numbers, part numbers, etc. are all the same. The only difference is in the first few characters. As an example, the part number for a Fanuc 0 Operators Manual is B61404E. The same manual for a General Numeric GN0 is GN61404E and GE Fanuc 0 control is GFZ61404E.

ATC Macros are 9000 programs and cannot be sent or received unless Parameter 10 Bit 4 is zero. If you
have ATC trouble you may want to check the 6500 series parameters.

Setting Parameters REVX and REVY should both be 0 under normal conditions. When set to 1 the axis direction will be reversed. One condition that can arise from this setting being wrong is that when a program is started and the axis tries to move to the G54 position it may travel until the soft limit is reached. This over travel condition is a result of the mirror image function. Setting the parameter back to 0 will fix the problem but you must perform reference point return after changing the parameter.

When you are loading Parameters or Diagnostics via RS232, you should see LSK flashing after you press INPUT until the control begins receiving the data. Once the data is present at the input of the control, you should see INPUT start flashing.

When Parameter SEQ (On the Setting Screen) is set to 1 the control will insert the sequence numbers automatically.


In order to receive parameters and diagnostics at the PC in text form you must make EIA/ISO = 1 (ISO).

If you can upload but not download or vise versa, there is almost definitely a hardware problem with the Memory board.
FANUC
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This is a very old control which does not have a CRT. Data input is accomplished by scrolling across the LED display with the Address buttons until you are beneath the appropriate code (M, S, T, X, Y, Z, etc.) Once you are under the code letter, use the keypad to enter the desired value and press the Input button.

To check for an Alarm, scroll to ALM. If an alarm is present the corresponding LED will be lit in the Alarm window (OH, OT, etc.) The OT indicates an over travel condition. With a 5TC control, the power supply for both axes is mounted on the X axis servo amplifier. These amplifiers are DC Servo Units. To see if the power supply is operating properly, check the test points on either unit. Pin 17 should be -15vdc, Pin 16 should be +15vdc, Pin 15 should be +24vdc. All measurements are referenced to Pin 14, 0vdc.

The incoming AC is supplied to the rear of the servo. The MCC contactor is also located here. MCC has a different meaning on the older controls. On the newer controls, MCC is one large contactor which supplies power to all of the servo amps and the spindle amp whenever the control is in a ready state. On this control, each axis and the spindle controller are equipped with their own MCC which may or may not be energized at the same time depending on the state of the NC. Terminals 1 and 2 on the Servo Unit should be about 170-210 VAC while terminals 3 and 4 should be around 100 VAC.

In order to change parameters on the Series 5 you must place the PRM/NOR toggle switch in the PRM position.

The parameters on a Series 5 are easily scrambled. Look for the software version on the upper IC's on the CPU board. The software is typically numbered 130,135,153,etc.

The Velocity Control Units (Servos) have a toggle switch to select either 50 or 60 hertz operation.

When the control is operating normally, you should be able to observe the following at power up.

1. Power comes on; after about two seconds the servos are sent the position ready signal (PRDY) 24vdc.

2. Once the servos are ready they send the signal to the NC. You should hear the MCC's energize and stay
energized. If they energize and then drop back out there is a problem with one of the servos.

A problem with one servo will disable the PRDY causing the other MCC's to drop out. You can isolate this condition by removing the fuses on the rear of the servo. In most cases these will be 15 amp fuses. The NC is not aware if these fuses are present or not so removing them will prevent the servo from sending a fault signal thereby allowing the control to come up. Even if the fuses are removed while the NC is in a ready state it will remain in a ready state. These fuses may be purchased from Fanuc USA for about $6.00. The part number for the 15 amp fuses is PL4150/SFAB250/402G. Also, these fuses have a contact which close when the fuse is blown. Closing of this contact will prevent the control from coming up but will not generate an alarm. Even momentary closure of this contact will cause both servos to drop out and stay out.

This is very important! If you have a machine that will not come up but the ALARM LED is off as well as the READY LED you almost certainly have either a servo problem or an E-Stop condition.(E-Stop button, Over Travel, etc.) When you have a true servo fault, the ALARM LED will be on and there will be a 1 under SV in the diagnostics.

The Series 5 control has the capability of storing just one program in battery backed RAM, but it can be a long one ( 10 or 20 meters). This RAM board was an option that most controls were ordered without. If it is present on a control it can be recognized as a board riding "piggy-back" on one of the two main boards.

A Series 5 control has no RS-232 ability, but there are aftermarket devices which will interface with the Tape Reader. The tape readers Baud Rate is 300.

To return to G Code programming from Conversational programming, press the soft key at the far left of the screen several times. When in graphics, press the PRGRM key on the keypad then use the soft key. Most Spindle functions are controlled by the MTB. They are controlled by affecting the values of the 6000 series parameters and by setting Diagnostic bits.

On a Mazak with a 5M control, if the control skips M Codes or does not execute them properly try replacing one of the I/O modules particularly the M-FIN module.




6 SERIES CONTROLLER


When working on a machine with a Series 6 control it may be set up so that an over travel switch will cause a 400 series servo alarm. In this case, the PRDY LED will be turned off.

There is no keystroke combination to have the NC ignore the soft limits. The values are stored in the 140 to 160 range of parameters.

If the power supply keeps going in to fault status (red LED), you must first eliminate external causes by removing the wires from the 5 and 24 volt terminals. The cause of the fault when the external sources have been removed is almost always the voltage stabilizer. The stabilizer is connected to the power supply by a cable that runs from CP1 on the power supply to CP34 on the voltage stabilizer. If you remove this
cable from either unit before turning the power on, the power supply won't fault. After the power has been on for a while the components will warm up, then you can turn the power off, reconnect the cable and power up again.

Some machines with Fanuc controls, particularly older controls like 5 and 6 controls will use scales on the axes either with or without a pulse coder. On those machines not using a pulse coder they will typically have a tacho-generator for velocity feedback. The scale may be made by a manufacturer such as Heidenhain but often it will be a Fanuc induction scale. These are known as Inductosyn scales and sometimes referred to as resolvers. If the axis has the scale and a pulse coder it is easier to troubleshoot servo and positioning problems. When the axis has a scale, it uses the scale for positioning rather than the pulse coder. So if you have a positioning problem you can detach the scale (parametrically) and use the pulse coder for positioning. If the positioning problem goes away either the scale, its wiring or the Resolver/Inductosyn board is bad. This board conditions the signal from these peripheral devices for use by the NC. In the case of a Series 6 control, this board plugs into the Master Board. Also, in the case of a Series 6, the parameter for removing the scale is P316.0 for the X axis, P316.1 for the Y axis and P316.2 for the Z axis. This is also very useful in troubleshooting axis movement problems such as jerked or rough motion which can be caused by poor feedback. A 1 in the parameter means a scale is used for position feedback, 0 means a pulse coder is used. On the Res/Inductosyn board, you will find a 20 pin Honda connector for each axis. In the case of a three axis machine they are C31 for X, C34 for Y and C37 for Z. You will also find two circular connectors at the bottom of the board for each axis. Referring to the above example, C32 and C33 are for X, C35 and C36 are for Y and C38 and C39 are for Z. The machine can actually be run with the scale detached and using the pulse coder but, of course, will require either Grid Shift adjustment or re-touching of tools. Every control has this ability although the parameter numbers will vary from control to control. When troubleshooting servo problems on an axis such as rough or jerked movement you can swap the command and feedback cables just as you would with a machine using pulse coders. In the case of a machine using a pulse coder for positioning an axis you must swap the command cable which in most cases will be CN1 on the servo amplifier. In addition you must swap the feedback cable which normally runs from the pulse coder to the axes card. The number or name of this connector varies from control to control and also by axis. You have to swap both. Assuming the machine is standard setup such that the all axes have the same pulse coder (resolution, etc.), and the motor directions are set the same the axis swapped with will move when the other axis in the swap is commanded to move. This will allow you to either rule in or rule out either the mechanical or control part of the servo system as the cause of a given problem. In the case of a machine using the scales, the same is true with the exception that there are more cables to swap. You have to swap CN1 as well as the 20 pin Honda connector and the two circular connectors. For example, if you had a problem with the Z axis of a machine you could swap the Z axis with the Y axis. First swap CN1 between the two axes. Then switch C34 with C37. Next switch C35 and C36 with C38 and C39. Anytime you swap cables, make sure you DO NOT REFERENCE RETURN (ZRN) the machine. Obviously, this would cause problems since if the Z axis attempts to reference return, the Y axis will be moving so the Z axis decel switch will never be reached. Another test is to swap the feedback cables at the RES/INDUCTOSYN board and the motor leads at the servo amplifiers. In this case when you give the command for the X axis to move, for example, the Y axis would move, the Y feedback would be sent to the X axis feedback circuits. You will be using the X axis amplifier, axis control board or X axis section of this board and the X axis parameters to control the Y axis. This will eliminate these things as the cause of the problem. Another component to be aware of when these scales are used is a Fanuc board normally found close to the scale reader. This is a pre-amplifier and can sometimes cause problem. The reader is a four wire device. The wires are labeled A, B, C and D. Fanuc calls the reader a slider and sometimes the term will be applied to the complete scale. C31, C33 and C35 are connected to the X, Y and Z sliders. C32, C34 and C36 are connected to the X, Y and Z pre-amplifiers. The RES/INDUCTOSYN board Fanuc number is A20B-0008-0461. The connectors from left to right looking at the front of the board are:

C32 C33 C35 C36 C38 C39

The Tach feedback comes in on the Honda 20 pin connectors C31 for X, C34 for Y and C37 for Z.

On a 6M control if you have certain servo alarms, particularly SV008, you can try to swap just the top board of the drive rather than the entire drive. This can be done by removing only two cables. If you experience new alarms, it may be necessary to change the shorting pins on the boards to make them match how they were before the boards were swapped. This is probably due to a mismatch between either the control or the parameters for that axis and the shorting pin configuration. When this alarm occurs an axis designation will be displayed along with the alarm. The alarm means that the axis position deviated by an amount greater than the value set in parameter 1829 while the axis was stopped (not moving). If the axis position deviates while in motion the parameter where the value is stored is 1828.

The drives on this control use a single Honda 20 pin connector for both the command and feedback. This cable goes from the drive to the Main Board.

The Grid Shift Parameters for X, Y and Z on a 6M control are 82, 83 and 84 respectively.


6M Controller

If parameter 318.7 is set to 0 the 9000 series programs will be protected and cannot be viewed or edited. If parameter 319.7 is set to 0 the 8000 series programs are protected and cannot be viewed or edited. M-Codes can be attached to specific programs by using parameters 320-332. Certain program numbers are assigned to the parameters, parameter 320 is assigned to program number 9001, parameter 321 is assigned to 9002, etc. The way this works is that, for example, if you assign a value of 70 to parameter 320, when M70 is commanded the control will call up and execute program 9001.

To view the PC parameters on a 6M control that does not have an NC/PC button, press the PARAM button twice then enter the number of the parameter you want to access. Press INPUT. It may be necessary to use put N in front of the number. I.E. N2001. In order to change the value of the parameter you must put a P before the number. I.E. P0

On machines that will controls such as the 6M which use a spindle amplifier with an orientation board, the IN POSITION LED (LED 6) should be on whenever the spindle is within one degree of it's orientation position. If this LED does not come on after spindle orientation is performed the SPINDLE ORIENTATION COMPLETION SIGNAL will not be output form the CNC. In this case, any function which is waiting for this signal to turn on will not be able to activate. If the spindle is in position but the LED is off you can adjust RV7 IN-POSITION to bring it on.

The axis interlock signals for a 6M control are:

ITX - G96.4
ITY - G97.4
ITZ - G98.4

These are active low signals so a value of 0 will allow axis motion. In the case of a machine that uses hardware inputs to interlock the axes:

ITX - X32.4
ITY - X33.4
ITZ - X35.4

Of course, these are the Fanuc defined and recommended addresses but the machine builder can define their own addresses.

On a 6T control the Backlash Parameters are 115 for X and 116 for Z.

For alarm 087 on 6T control check parameter 310.5 for I/O device 1 or parameter 311.5 for I/O device 2. If set to 1, control codes are not used. In most cases setting does not matter but in a few it does.

310.5 = RSCB1
311.5 = RSCB2.





10 SERIES CONTROLLER


To monitor the Servo Current on a 10 control you must measure the voltage at pins IR and IS on the servo amplifier. RV1 on this drive is the Gain adjustment. RV3 is the Offset adjustment. You normally will not adjust RV2. You monitor the Servo Error at Diagnostic 3000 and adjust these pots to correct error. To make the best parts especially circles these numbers should be the same. You should first adjust the + and - values to make them equal one axis at a time. Then adjust to X equal Z when doing linear interpolation. If the servo error is out of adjustment you will normally see an ellipse from 45 degrees to 225 degrees or from 275 to 135.

In order to get to the Diagnostics you must:
1. Press the LEFT CHAPTER button. (Beside the soft keys)
2. Press SERVICE.
3. Press DIAGNOS.

To search a program:
1. Select EDIT mode.
2. Press the Left Chapter button.
3. Enter the program number and press FW.SRCH

The Servo Parameters are located in the 1600 to 1800 series.

On a Fanuc 10 control, especially on a Mori-Seiki, the Page function is not immediately obvious. There may be four arrow over buttons. If this is the case, you page up by pressing the two upper cursor buttons at the same time. To page down you press the two lower cursor buttons at the same time.

Also, on a 10 control the PWE is Parameter 8000.0. Go to this parameter and make it 1. The alarm cannot be cancelled with Reset/Cancel.

On a 10 control, the TGM LED indicates a problem on the second axis of a dual amplifier. TGL indicates a problem on the first axis. The TG of the TGL and TGM stands for Tacho Generator. This alarm can also be
caused by a problem with the pulse coder or it's cable. Also is possible for the motor to be shorted or under excessive load, especially if the OV led comes on along with the TGM or TGL.

If on a lathe, for example, you remove the X axis pulse coder connection then turn the power on, the TGL LED will come on. Likewise for the Z axis and TGL.


When working on a 10 control that has no display of the CRT, check the CRT/MDI power supply. This is the bottom board of the CRT/MDI unit. There are three fuses on this board. If the 3.2 amp fuse blows, you will not have any display. Another thing to check is the OPT. INTERFACE board. A problem with the board or the fiber optic cables or the cables reversed will cause no display. In this case, both the Red and Green LEDs on the Main board will possibly be off. If CP21 is disconnected at the time of NC power on, the Green LED will be on as normal but the NC will not be ready and the main board will display A. Under normal conditions when the NC is ready it should display 1. If you have a display of the CRT but it flickers, the CRT/MDI (bottom board) is probably bad. This board is A02B-1001-0160. The top board is A02B-1000-0800. COP1 of the Main board goes to COP3 of the CRT/MDI unit. COP2 of the Main board goes to COP4 of the I/O board. The three fuses on the CRT/MDI are 3.2 amp, .3 amp and .3 amp.

If the Input Unit of a 10 control alarms on power up (Red LED on the Input Unit):

1. Disconnect output connectors (CP3, CP4, CP11, etc.) to determine if the problem is internal or external to the
input unit.

2. If the alarm does not occur with all connectors removed but occurs if CP11 is connected alone, begin
troubleshooting for a problem with the NC power supply or an output of that power supply.

3. The NC power supply can removed from the main board while leaving the cables still connected to it. Try
powering up like this. If the alarm goes away, you can assume the problem is with the main board or one
of its outputs. Re-install the power supply, remove all cables from the main board and if the alarm does not
occur, re-connect the cables one at a time until the alarm occurs, then pursue that cable. If the alarm
occurred with the power supply removed from the main board, begin eliminating cables. If the alarm occurs
with every cable removed except for CP11, the power supply is bad.

A problem in the circuit of CP24 will cause a watchdog alarm. Both the red and the green LED will be on and a C will be displayed. CP14 goes to CP51 of the I/O board.

Fanuc 10 controllers use Keep Relays like an 18 controller.

When changing parameters, they can be changed as individual bits by highlighting the bit. You have to use the arrow keys to move the highlight around.


On a Fanuc 10 control, if the control powers up with a screen which displays:

RAM TEST:END
ROM TEST:END
LOAD SYSTEM LABEL:END
CHECK SYSTEM LABEL:END


1. DUMP MEMORY
2. -
3. CLEAR FILE
4. SETTING
5. -
6. END IPL
?

This means the controller is powering up in IPL mode, the RAM and ROM chips are probably okay but the parameters have most likely been lost or scrambled. In this case, type 99 at the prompt and press the INPUT key. You will be prompted AXIS? At this time, enter the number of controlled axes on the machine and press the INPUT button. You will then be prompted OPTION 01?, at this time you must enter the option parameters 01-032. On the hard copy of parameters, these may be in the form of an eight bit binary number but when manually entered must be in the form of hexadecimal.

When the control is in IPL mode a 0 will be displayed on the Master Board. A 1 is displayed during normal operation.

To send and receive data:
1. Press the PROGRAM soft key.
2. Press the + soft key (right chapter).

The READ and PUNCH soft keys are now shown. If not, look for a TEXT soft key and press it. This should only be necessary id the DIR.MEM soft key has been pressed.

This control has Line Driver and Line Receiver chips like a 0 control. These are soldered to the Main Board. If Fanuc comes in and replaces them they will install sockets so that they can be more easily replaced in the future.

There is a six pin connector on the Input Unit. The connector is labeled CP2. Two of the pins are R and S (220 volts). One pin is ground. Two pins go to a contact in the Power Supply where it is labeled CP11. When the NC power on button is pressed, a relay in the Power Supply is energized. If everything is OK with the power supply, it stays energized. When the button is released, the power stays on.

On most 10M controls, the incoming AC to the NC goes first to the Input Unit via the transformer A80L-0001-0176 terminals A and B (200).These go to terminals R and S on the Input Unit. This transformer has a number of taps on the primary. They are:

550
480
460
440
415
380
240
230
220
200
COM


Parameter 5220 is the positive stroke limit for X,Y and Z.
5221 is the negative stroke limit.


On a machine with a Fanuc 10M control, the RS-232 cable goes directly to connector CD1 on the top board of the CRT/MDI unit (A20B-1000-0800). This connector is a 20 pin Honda female. On most machines, they use nine of the pins on the control side, ten pins on the machine (25 pin D female) side. Below is the pin information.

Controller side Machine side ( PC side )

N/C 1 (PG Protective Ground)
9 2 (TD Transmit Data)
8 3 (RD Receive Data)
20 4 (RTS Request to Send)
19 5 (CTS Clear to Send)
18 6 (DSR Data Set Ready)
17 7 (SG Signal Ground)
16 8 (DCD Data Carrier Detect)
5 20 (DTR Data Terminal Ready)
14 25 (BUSY Busy)

Pin 1 on the machine side is connected to the machine ground.

Pin 7 on machine side and pin 17 on Control side are connected to the shield as well as each other.

When data is being input to a 10 or 15 control, it does not flash LSK.

To search a parameter on a 10, 11 or 12 control:

1. Press the SERVICE soft key.
2. Press the PARAMETER soft key.
3. Enter the desired parameter number.
4. Press the INP-NO soft key.
5. Press the INPUT button.


The two manuals necessary to troubleshoot problems on a 10M control are the 10M Maintenance Manual (B54815E) and the 10M Operation Appendix Manual (B54810E).

On controls with a Master Board, particularly a 10M control, a lower case "c" indicates that the board is not communicating with the other boards through the optical link. In this case you will normally find that the green LED on the board (LK2) and the red LED (LK1) will both be on. The status of the LEDs on the I/O board may be green (DC4) is off and red (DC5) is on. As with many other problems on these controls, a power supply could be the culprit. You must check the individual voltages for the proper level. Remember that these voltages have a very tight tolerance. Usually when this alarm state occurs, the outward indication is that the display freezes where it is, pushing any button has no effect.

If the LED display on the Main (Master) board displays what looks like a lower case "c", this is a watchdog alarm. It has several causes but one notable cause is a problem with one or more of the regulated voltages. These are +24v, +5v, 15v and -15v. They can be monitored at test points TJ2, TJ3, TJ4 and TJ5 respectively. The voltage can be monitored at TJ6. Use one of the GND test points instead of the chassis ground for a reference. There is a slight difference in the readings. There are several of these points and they are all common to one another. These voltages must be within a very tight tolerance.

When a control is operating normally, the LED will display "1". LK1 (RED) will be off. LK2 (GRN) will be on. The green LED (DC4) on the I/O board should also be on when things are normal. The red LED is DC5.

The part number of the Power Supply is A16B-1219-0510-01. The part number of the Input Unit is A14B-0076-B001.

The battery pack plugs into the main board at CA6. Its pin outs are:
1 - + (White)
2 - - (Black)
3 - Empty
4 - Shield
5 - Empty
6 - Empty

To toggle between the comments and addresses in the ladder of a 10T control, press the soft key ADDRESS or SYMBOL.




11 SERIES CONTROLLER


To access the Ladder on an 11 control, press the NC/PC button then press the PCLAD soft key.

Signal Names:

SA Servo Ready
This signal can be monitored at Diagnostic 500.6 equals 1 when the servos are ready.

A 1 in the LED display on the Master Board of the 11 control means that the control is ready. This does not necessarily mean that the machine is ready, just the control. For example, a problem on the machine side could have an axis interlock turned on so the machine would not be able to move but there would still be a 1 on the display. The interlock signals (i.e. *ITX, *ITY, *ITZ, *IT4) are provide for the OEM to use for various reasons. Many machine builders will tie their ATC ready signal to all of these inputs.

On the 11 control these signals are:

*ITX 400.4
*ITY 402.4
*ITZ 404.4

When working with the Diagnostics on an 11 control be aware that they will differ depending on the type of interface. There are three types:

BMI (Basic Machine Interface)
FS3 (Fanuc System)
6M

To determine which you have check Parameter 2001 Bit 5 and 6.

2001.5 = 0 for BMI
2001.5 = 1 and 2001.6 = 0 for FS3
2001.5 = 1 and 2001.6 = 1 for 6M


To search for a D address:

1. Press NC/PC button
2. Press the PCDGN soft key
3. Type the address (i.e. D33)
4. Press the W Search soft key

The information in these tables is very important. Make sure after a loss of memory that this information is correct. If the value in Address 026 of Control Data Table on an eleven control is wrong, the axes will not ZRN.

To access Data Tables:
1. Press NC/PC button
2. Press PCPRM soft key
3. Press DATA soft key

To do a Ladder search:

1. Access ladder
2. Type in address (i.e. G65.0)
3. Press W search


15 SERIES CONTROLLER


To release an axis on this control, such as a rotary table make Parameter 0012.7(RMVx) 1. This is a setting parameter. This parameter is only valid when Parameter 1005.7(RMBx) = 1.

PWE on the Fanuc 15 works the same as on a 10 control. Parameter 8000.0 has to equal 1. If this bit will not change, make sure you are on the Setting Page and not the Parameter Page. You cannot change the bit on the Parameter Page unless it has already been changed on the Setting Page.

This can be a little tricky. The best method is:

1. Press the SETTING soft key.
2. Press the CHAPTER soft key.
3. Press the GENERAL soft key.
4. Press the PAGE UP button one time.

On an 11 control as well as an 18, parameter 1850 is the Grid Shift parameter. Parameter 1816 is the reference counter capacity. Parameter 1850 should be set to the value in 1816 or less. If you are trying to adjust 1850 and have trouble make sure 1850 is less than 1816. Also make sure you are adjusting the parameter in the correct direction. For the vast majority of machines where reference return is in the positive direction you must increase the value to shift the axis further away from the decel dog. Sometimes you may reach a point while adjusting where the axis stops responding to small changes in the parameter and after increasing the value a certain amount the axis jumps several millimeters. Again, make sure you are not in a situation where you need to decrease the value rather than increase it. If this is not the case then you may have gone as far as you can go with the Grid Shift and may need to either move the decel dog or the pulse coder. If the reason you
are adjusting this parameter in the first place is because you replaced the pulse coder then, of course, you should look at it first. On most machines the pulse coder will employ a coupling that can only go two ways, either the correct way or 180 degrees out. In this case try removing the pulse coder and putting it back on 180 degrees out relative to the motor. Parameter 1850 is a metric value and the amount that the axis moves is dependent upon the ball screw pitch.
Fanuc
Page 5

18 SERIES CONTROLLER


In order to view and edit 9000 series programs, you must change Parameter 3202.5 (NE9) from 1 to 0.

On most 18 controls, it is very easy to turn on the Custom Macro B option. Simply change Parameter 9933.7 from 0 to 1. The NC will prompt you to cycle the NC power (Alarm 000). This is normal.

To change the PWE on an 18 control:

1.Press the OFFSET/SETTING button.
2.Press the SETING soft key.
3.Cursor to PARAMETER WRITE = 0
4.Enter a 1.
5.Press INPUT button.
6.Press RESET button and CAN button at the same tie to clear alarm 100.

The Option Parameters on an 18 Control can be viewed the same as any other control. They begin at 9900.

The timers take the form of T numbers.

To completely zero all position displays on:

To reach the Tool Life Management screen on an 18M control, press the OFFSET button then press the RIGHT ARROW button the soft key panel until you see the soft key option then press the appropriate soft key. If this does not work try just pressing the OFFSET button repeatedly until you get to the Tool Life Management screen.

When troubleshooting problems the diagnostics which are equivalent to Diagnostic 700 on a 0 control start at Diagnostic 000.


000 WAITING FOR FIN SIGNAL- An auxiliary function is being executed.
001 MOTION - Travel command of cycle operation is being executed.
002 DWELL - A dwell is being executed.
003 IN-POSITION CHECK - In-position check is being done.
004 FEEDRATE OVERRIDE 0% - Feed rate override is 0%.
005 INTERLOCK/START LOCK - Interlock or start lock is input.
006 SPINDLE SPEED ARRIVAL CHECK - Waiting for spindle speed arrival signal.
010 PUNCHING - Data is being output through reader/puncher interface.
011 READING - Data is being input through the reader/puncher interface.
012 WAITING FOR (UN) CLAMP - Waiting for the end of index table indexing.
013 JOG FEEDRATE OVERRIDE 0% - Manual feed rate override is 0%.
014 WAITING FOR RESET, ESP, RRW OFF - NC is in reset state.
015 EXTERNAL PROGRAM NUMBER SEARCH - Ext. program number search is being done
016 BACKGROUND ACTIVE - Background is being used.

Diagnostics for checking cause of certain alarms:

Details of Alarm 350 Serial Pulse Coder

DGN 0202 7 6 5 4 3 2 1 0
CSA BLA PHA RCA BZA CKA SPH

CSA Hardware of serial pulse coder is abnormal.

BLA Battery voltage is low (warning).

PHA Serial pulse coder or feedback cable is erroneous.

RCA Serial pulse coder is faulty. Counting of feedback cable is erroneous.

BZA Battery voltage became 0. Replace the battery and set the reference position.

CKA Serial pulse coder is faulty. Internal block stopped.

SPH Serial pulse coder or feedback cable is faulty. Counting of feedback cable is erroneous.

Details of Alarm 351 Serial Pulse Coder

DGN 0203 7 6 5 4 3 2 1 0
DTE CRC STB

DTE Communication failure of serial pulse coder. There is no response.

CRC Communication failure of serial pulse coder.
Transferred data is erroneous.

STB Communication of serial pulse coder. Transferred data is erroneous.


Details of Alarm 417 Digital Servo

DGN 0200 7 6 5 4 3 2 1 0
OVL LV OVC HCA HVA DCA FBA OFA

OVL Overload alarm.

LV Insufficient voltage alarm.

OVC Over current alarm.

HCA Abnormal current alarm.

HVA Over voltage alarm.

DCA Discharge alarm.

FBA Feedback disconnection alarm.

OFA Overflow alarm.

DGN 0201 Refer to Maintenance Manual for table.

DGN 0204 7 6 5 4 3 2 1 0
RAM OFS MCC LDA PMS

OFS A/D conversion of current value of digital servo is abnormal

MCC Contacts of electro-magnetic contactor of servo amplifier is blown

LDM LED of serial pulse coder is abnormal

PMS Number of feedback pulses are in error because serial pulse coder C or feedback cable is faulty

To access the Conversational side:

1. Select EDIT mode.
2. Press the PROG button.
3. If the control has conversation, you will see a C.A.P soft key.
4. Either enter a new program number or search an existing one in the usual manner.
5. Press the C.A.P soft key.

If a lathe with an 18T control does not execute a M,S or T function when the block they are in is searched in Auto (Memory) mode, check parameters 3409.7, 3402.6 and 5000 to 5006.

If you have trouble maintaining a constant lead when threading with G92 or G76, check parameter 1626 and 1627. These two parameters affect the accel and the decel of the servos during the two cycles. Often a machine will have a larger value such as 100 which allows you to make good threads only at low rpm like 200 or so. Changing the value to something like 30 or 32 will let you make good threads at close to 1000 rpm.

If the screen turns all green and/or goes blank, the Graphic Card is probably bad. The card plugs into the Main Board.

A standard 18 control has a three slot backplane (Power Supply, CPU, I/O) In order to have the Graphics option, the backplane must have at least four slots. In this case there will be a Graphics card plugged into the chassis.

When working in the ladder of an 18 control, you may not be able to find the Keep Relays listed as K numbers. Often they are listed as PMCS numbers. For example, K5.5 may be listed as PMCS55.

The Ladder of an 18 control can be backed up and restored with a Flash Rom (SRAM) card (PCMIA). If you want to edit the ladder, you will need software from Fanuc. It is called FAPT LADDER III. The price as of 5/3/01 is $1331.00.

The ladder is designated as Pmc-rb. When it is stored it is done so as a DOS file. In this case it requires an extension. The most common extensions are Pmc-rb.000 and Pmc-rb.txt.

Run Time information etc. can be accessed by pressing the OFFSET SETTING button then the SETING soft key, then page down. The info is:

PARTS TOTAL =
PARTS REQUIRED =
PARTS COUNT =
POWER ON = H M
OPERATING TIME = H M S
CUTTING TIME = H M S
FREE PURPOSE = H M S
CYCLE TIME = H M S

DATE =
TIME =

To access the variables on an 18 control, press the OFST/SETING button twice, if the machine has Custom Macro B there will be a MACRO soft key, press it to view the variables.

The run hours (#3002) reset to 0 after reaching 9544.

Variable 3002 is in one hour increments.

To access the Mirror Image function:

1.Press the OFFSET/SETTING button.
2.Press the SETING soft key.

You will see:

MIRROR IMAGE X = 0 (0: OFF 1: ON)
MIRROR IMAGE Z = 0 (0: OFF 1: ON)

To access the Keep Relays:

1.Press the SYSTEM button.
2.Press the PMC soft key.
3.Press the PMCPRM soft key.
4.Press the KEEPRL soft key.

A useful troubleshooting tool Diagnostic 200. To access it:
1.Press SYSTEM button.
2.Press PMC soft key.
3.Press PMCDGN soft key.
4.Press STATUS soft key.
5.Type D200.
6.Press SEARCH soft key.

The spindle orientation parameter is 4077. This depends on whether the machine uses a Fanuc position coder, magnetic pickup or proximity switch. Normally if a machine uses a proximity switch to orient, the position will not be adjustable by parameter. The switch has to be physically moved.

To access Work Shift:
1.Press OFFSET/SETTING button.
2.Press the + soft key (Right Chapter) twice.
3.Press the W.SHFT soft key.


To cancel the Relative Position:
1.Press the POS button twice or until ACTUAL POSITION Relative is shown.
2.Press U,V or W. The one you pressed will start flashing and some new
soft key options will be shown.
3.Press the INPUT button or the ORIGIN soft key to cancel position.


If a machine will not execute a program ( automatic operation) and the Cycle Start lamp is not lit, check the following diagnostics:

7 6 5 4 3 2 1 0
G0043 DNC1 MD4 MD2 MD1

This diagnostic indicates the Mode selected. A 1 means the mode is selected, in this case look for a one at bit 0 unless in DNC mode. If attempting automatic operation during DNC, look for a 1 at bits 0 and 5.

MD1 = Memory Mode

If memory mode is selected with the Mode Select switch, check the mode signal with the PMCDGN.

7 6 5 4 3 2 1 0
G0007 ST

ST = Cycle Start

If the cycle start lamp does not light when the button is pressed, check
G0007.

7 6 5 4 3 2 1 0
G0008 *SP

*SP = Feed Hold

If the program will not execute when Cycle Start is pressed but the cycle start lamp comes on (status display of CRT shows STRT) check Diagnostics 000-015. Under normal operation, they should all be zero.

000 WAITING FOR FIN SIGNAL
001 MOTION
002 DWELL
003 IN-POSITION CHECK
004 FEEDRATE OVERRIDE 0%
005 INTERLOCK/START LOCK
006 SPINDLE SPEED ARRIVAL CHECK
010 PUNCHING
011 READING
012 WAITING FOR (UN)CLAMP
013 JOG FEEDRATE OVERRIDE 0%
014 WAITING FOR RESET, ESP, RRW OFF
015 EXTERNAL PROGRAM NUMBER SEARCH.

000 WAITING FOR FIN SIGNAL
An auxiliary function (M,S,T or B) specified in a program is being executed and has not finished. Check the diagnostics associated with the auxiliary function.

G0005 7 6 5 4 3 2 1 0
BFIN TFIN SFIN MFIN

MFIN = M function finish signal
SFIN = S function finish signal
TFIN = T function finish signal
BFIN = 2nd auxiliary function finish signal

F0007 7 6 5 4 3 2 1 0
BF TF SF MF

MF = M function strobe signal
SF = S function strobe signal
TF = T function strobe signal
BF = 2nd auxiliary function strobe signal


G0008 7 6 5 4 3 2 1 0
MF3 MF2

MF2 = Second M function strobe signal
MF3 = Third M function strobe signal
The second and third M functions are enabled only when bit 7 of parameter #3404(M3B) is set to 1.

001 MOTION
CNC is reading an axis command in a program and giving the command to the axis.

002 DWELL
CNC is reading a dwell command (G04) in a program and is executing the dwell command.

003 IN-POSITION CHECK
Positioning to a specified position is not completed. Whether or not positioning is complete is determined by the servo position error. Check the position error amount with Diagnostic 300. When an axis is in position, the position error will be almost zero. When the machine is in the commanded position within the IN-POSITION WIDTH amount the positioning is said to be complete. The IN-POSITION WIDTH is set in parameter 1826. If the machine does not position within this window troubleshoot the servo system in accordance with alarm 400, 4n0 and 4n1. Generally speaking, parameter 1826 is for positioning in Rapid Traverse. In cutting feed it is a little more complicated. If parameter 1801.4(CCI) is set to 0, the in-position area for cutting feed is set in parameter 1826. In other words, it is the same as for rapid. If parameter 1801.4 is 1, the in-position area is determined by the setting of parameter 1801.5(CIN).

* If 1801.5 = 0, use the value in parameter 1827 if the next block is also for cutting feed or use the value in 1826
if the next block is not for cutting feed.

* If 1801.5 = 1, use the value in parameter 1827 regardless of the next block. (The setting of parameter 1826 is used for rapid traverse, the setting of parameter 1827 is used for
cutting feed.

A typical value for parameter 1826 on a machining center is about 20 detection units on all axes. It is also more or less normal for 1826 and 1827 to be set the same. For a turning center, a normal setting might be 20 for 1826 on both axes and about 300 for 1827.

004 FEEDRATE OVERRIDE 0%
Check feed rate override signal at Diagnostics G0012 and G0013.

G0012 7 6 5 4 3 2 1 0
*FV7 *FV6 *FV5 *FV4 *FV3 *FV2 *FV1 *FV1

The feed rate override switch generates a binary number which is proportional to the feed rate selected and can be monitored with this diagnostic.


G0013 7 6 5 4 3 2 1 0
*AFV7 *AFV6 *AFV5 *AFV4 *AFV3 *AFV2 *AFV1 *AFV0

G0013 is the 2nd feed rate override signal. If the MTB incorporates this function the user can override the feed rate in finer increments. This requires the addition of a second override switch or use of a switch with more contacts.

INTERLOCK/START LOCK
Interlock signal or start lock signal is input.

G0007 7 6 5 4 3 2 1 0
STLK

When bit 1 = 1, Start Lock signal is input.

G0008 7 6 5 4 3 2 1 0
*IT

When bit 0 = 0, the interlock signal is input.


G0130 7 6 5 4 3 2 1 0
*IT8 *IT7 *IT6 *IT5 *IT4 *IT3 *IT2 *IT1

When one of the bits is 0, the interlock signal is input for the corresponding axis (1-8).


G0132 7 6 5 4 3 2 1 0
+MIT4 +MIT3 +MIT2 +MIT1

G0134 7 6 5 4 3 2 1 0
-MIT4 -MIT3 -MIT2 -MIT1

*MITn Interlock signal is input for the corresponding axis and direction when the bit is 0. The individual bits do
not have the asterisk in their symbol but all eight are active low inputs.


G0124 7 6 5 4 3 2 1 0
DTCH8 DTCH7 DTCH6 DTCH5 DTCH4 DTCH3 DTCH2 DTCH1

DTCHn When one of the bits equals 1, the control axis detach signal for the corresponding axis is input. The
axis will be in an interlock state because it has been detached.

Also Parameter 0012 (RMVx) This parameter enables the control axis detach function for the corresponding axis.

The axis can be detached by either the CNC or PMC.

The axis detach function for an axis is valid when one of the following bits corresponding to the axis is 1.

F0110 7 6 5 4 3 2 1 0
MDTCH8 MDTCH7 MDTCH6 MDTCH5 MDTCH4 MDTCH3 MDTCH2 MDTCH1

The Axis Detach Function is valid when Parameter 1005.7 is 1.

Also, with regard to the Interlock Function:

Parameter 3003

3003 7 6 5 4 3 2 1 0
DIT ITX ITL

ITL 0 = Interlock signal (*IT) is valid.
ITX 0 = Interlock signal (*ITn) is valid.
DIT 0 = Interlock signal (+/-MITn) is valid.

006 SPINDLE SPEED ARRIVAL CHECK
The CNC is waiting for the spindle speed arrival signal to be input. The spindle has not reached the speed commanded in the program.

G0029 7 6 5 4 3 2 1 0
SAR

When this signal is 0, the spindle has not reached the commanded speed.

This function is valid when Parameter 3708.0 = 1.

013 MANUAL FEEDRATE OVERRIDE IS 0% (Dry Run)
Normally, manual feedrate override function is used for jog feed but when the DRN (dry run) signal turns on during automatic operation, override values set with these signals become valid to the following speed set by a parameter.

G0046 7 6 5 4 3 2 1 0
DRN

The Dry Run rate is stored in parameter 1410. It is the dry run rate when the override value is 100%.

The override value consists of 16 bits (2 diagnostics). The diagnostics are G0010 and G0011. If all 16 bits are 0, the override value is 0%. Likewise, if they all are 1, override is 0%.

G0010 7 6 5 4 3 2 1 0
*JV7 *JV6 *JV5 *JV4 *JV3 *JV2 *JV1 *JV0

G0011 7 6 5 4 3 2 1 0
*JV15 *JV14 *JV13 *JV12 *JV11 *JV10 *JV9 *JV8


The following table shows the relationship between the bits and the override value:

*JV15 *JV0 Override value
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0.00%
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0.01%
1 1 0 1 1 0 0 0 1 1 1 0 1 1 1 1 100.00%
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 655.34%
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.00%


014 NC IS IN A RESET STATE

The 18 control is like a Mitsubishi control in that the backlash compensation for Rapid and for controlled feed are treated separately. That is, Parameter 1851 is for G01 backlash comp, 1852 is for rapid.
Generally speaking, a value of 11 or 12 will compensate for about .0005". There is no need to cycle power after changing the parameter. The backlash compensation is ALWAYS applied and in every mode.

To do Background Edit while the program is running
1.Press the (OPRT) soft key.
2.Press the BG-EDT soft key.
3.Press the DIR soft key. (To view the programs)
4.Enter the program number.
5.Press the Cursor down.
6.Edit the program.

When done, press the (OPRT) soft key then the BG-END soft key to go back to the program being run.

When the control is executing a Dwell command, DWL is displayed at the bottom of the screen.

On some 18i controls, the keypad is small and somewhat limited. In this case it may not have buttons for parentheses. You can access the parentheses by changing a parameter. The parameter is 3204.2, once set there will be a soft key for the left parenthesis and one for the right parenthesis when in EDIT mode.

Parameter 4003.0 determines what type of sensor is used for spindle orientation, magsensor, proximity switch, etc.

The following describes observations of a Macome system on a Takumi machine with an 18 controller:

If the magnetic pickup is mounted upside down relative to the magnet, when spindle orientation is commanded the spindle will search back and forth from one side of the magnet to the other across the face of the magnet. If the sensor is moved closer to and further away from the magnet, the distance (number of degrees) that the spindle moves will increase and decrease proportionally. Once the sensor is moved far enough the spindle will rotate continually until alarm 751:FIRST SPINDLE ALARM DETECTION(AL-42) is displayed. AL-42 will be displayed on the spindle amplifier LED display. If the pickup (sensor) and magnet are both mounted upside down, the spindle will behave basically the same thing except that it will search from one side of the magnet through nearly a complete revolution to the other side rather than Just across the face as in the case of the sensor being upside down. I don't know how the machine would behave with the magnet alone upside down. Obviously, when talking about the sensor and the magnet both being upside down, seems to make no sense (they should cancel out) but it does make sense when you consider the North/South pole orientation of the two devices and their movement relative to one another depending upon spindle direction. If the two are upside down, the are fine relative to each other but the approach direction of the poles changes. The bottom line is, the magnet has to be oriented properly relative to the sensor and both must be oriented properly relative to the spindle orientation direction. Normally, if the pre-amplifier, spindle amplifier or cable fails the alarm will occur without the spindle every slowing down or searching. It will behave as if there is no magnet on the spindle at all. There is no adjustment of the control for signal detection level. If the magsensor is disconnected from the spindle amplifier altogether when M19 is commanded the spindle will run at the orientation speed, usually 200 rpm. There will be no alarms, it will just keep running You can monitor the signals output from the pre-amplifier with an oscilloscope. They are five volt pulses whose duration is relative to the rotation speed of the spindle. Below are the pin outs:

JY3 AMP

5 ----------------- A
14 ----------------- D
1 ----------------- F
3 ----------------- E
12 ----------------- C
7,16 ----------------- B
10 ----------------- SHIELD

Pin B is the zero volt input from the spindle amplifier, Pin C is the five volt input. Pins D and E are zero volt (common) signals. Pins A and F are the output signals, their phase relationship is important for the proper operation of the circuit. JY3 is a Honda PCR-E20FS connector with a Honda PCS-V20L housing. The pre-amp connector is a Tajimi TRC116-12A10-7M.

On an 18 control if the LCD displays no information, only the backlighting check the small connector that goes from the screen to the video card mounted to the back of the LCD. This connector is hard to see and if it comes loose no information will be displayed.

On the 18 I/O board 24vdc for operating the relays, lamps, etc., is supplied by the machine side. Typically, both the +24 volt and the 0 volt components will come into the I/O board on more than a half dozen pins of each connector (C70, C71, etc.). The Fanuc symbol for the positive side is 24A. The symbol for the negative component is 0V. All of the 0V pins on the board end up at the backplane of the control on check pins GND1 and GND2 which tie to all of the chassis grounds on the control and the drives. Also, these pins tie to several of the pins on each connector on the CPU board such as JA1, JA3, etc.

In order to get the NC Parameters (Keep Relays, etc.) from an 18 control, you must make Keep Relay 17.1 equal 1. Then:

1. Press the SYSTEM button.
2. Press the PMC soft key.
3. Press right CHAPTER button.
4. Press the I/O soft key.
5. Cursor to DEVICE, press the FDCAS soft key.
6. Press the WRITE (PUNCH) soft key.
7. Press the PARAM soft key.
8. Press the EXEC soft key.

If you get alarm I/O OPEN ERROR 20 when you try to output the PMC, it means that the RS-232 cable connection is open.

Sometimes the Baud Rate the control uses for this will be different than the rate it is set for in terms of normal RS-232 functions. For this function it can only be set for either 4800 or 9600. If Keep relay 17.1 equals zero, some of the above soft keys will not be displayed. The Ladder can also be sent in and out this way but it can take as much as an hour. In this case you would press the LADDER soft key instead of the PARAM. Of course, you load the information in the same way you send it out except that you would press READ instead of WRITE. If you have an SRAM disk you can input and output the entire content of the control memory much faster using it.

If you get the alarm "DATA READ ERROR" while inputting the NC Parameters send the file to a text editor and make sure the delete all of the characters on the top line except for the percent sign.

These parameters when viewed with an editor should start with a % (percent sign) then N60000. It should end at about N65000.

On the 18i control you can change the baud rate, stop bits, etc., for transfer of the PMC by pressing the SPEED soft key. This soft key is on the same page with the EXEC soft key. Once this has been pressed, there will be a screen like this:

BAUD RATE = 2
(0:1200, 1:2400, 2:4800, 3:9600, 4:19200)

PARITY = 0
(0:NONE, 1:ODD, 2:EVEN)

STOP BITS = 1
(0:1 BIT, 1:2 BIT)

There is no provision for data bits.

If you have trouble with the LCD/MDI unit of an 18 control not displaying information check the fuse on the circuit board on the back of the LCD screen This fuse is small and black, it looks more like a shorting pin than a fuse. The newer LCD/MDI unit A02B-0222-C161/TBR is not completely compatible with the older A02B-0222-C151/TBR. That is, if you try to swap only the PCB or the screen from on to the other, bolt hole patterns do not match, etc. If the control issues the alarm "DATA IS OUT OF RANGE" while loading the parameters in from a PC, it means that one or more of the parameters has exceeded it's allowable range. For example many parameters have a setting value from 0 - 32767, no other value is allowed. If you try to enter a value of 50000, for instance, this alarm will be issued. Normally, the control will continue to take the parameters even after the alarm is issued.

The following procedure is for a control that has lost all of its parameters:

Machine must be in E-Stop condition. Once the memory is cleared the control will turn PWE on.

1. Clear the memory (RESET+DELETE while powering up).
2. Load the Option Parameters (9900 - 9990) by hand.
3. Cycle NC power.
4. Set the communication parameters (Baud Rate, etc.) by hand.
5 .Load in the basic parameters (N0000 - N9952).
a. SYSTEM button
b. PARAM soft key.
c. (OPRT) soft key.
d. Right Chapter button.
e. READ soft key.
f. EXEC soft key.
6. Cycle NC power.
7. Load PMC parameters (N60000 - N66999).
a. SYSTEM button.
b. PMC soft key.
c. Right Chapter button.
d. I/O soft key. The I/O soft key will only be displayed if Keep Relay K17.1 equals 1. On some controls may
have to set K900.1 to 1 if the Keep Relays go that high. Normally, they only go to K19.
e. Cursor to DEVICE.
f. FDCAS soft key.
g. Cursor to FUNCTION.
h. READ soft key.
i. EXEC soft key.
8. Load Pitch Error Parameters (N1000 - N11023).
a. Same as basic parameters except you press the PITCH soft key.

To send the basic parameters out of the control, perform item 5, steps a-f except that you press WRITE instead of READ. The same holds true for the other parameters allowing that you will have to press the PUNCH soft key. Also you will have to press either the ALL soft key or the NON-0 soft key depending on whether you want to send out all of the parameters or just the ones which are set to something besides 0. There may be certain advantages at certain times for using NON-0 but generally I would always use the ALL option.

Clearing the control memory (RESET+DELETE) clears all of the parameters and the G. DATA and resets the communication parameters for CH0 to 4800 Baud Rate and two stop bits. It does not clear the C. DATA. Removing the battery and letting the memory die does the same thing as clearing.

To set the display for English on an 18 control make parameter 3102 = 0. Making any of the bits of this parameter = 1 causes the display to be in some language other than English.

Parameter 1815.5 must be set to 1 for any axis that uses an Absolute Pulse Coder.

You can set the keep relay K17.1 in just about any mode as long as the control is in E-Stop condition.

Keep Relay K17.1 causes the STOP soft key to be displayed. This soft key allows you to stop the PLC from executing. Once stopped it can be started again by pressing the RUN soft key.

Machines with turrets which have 18 controls sometimes use values in G DATA. Typically, the value will be a decimal value which is the same as the number of tool stations on the turret. For example, a machine with an eight station turret might have a value of 8 in D0000 of the G DATA. You must be careful when loading in the PMC because this may clear the G DATA. Clearing the memory will definitely clear this data so it is good practice to write these down along with Keep Relays etc. when loading in parameters. Also, doing a memory clear will wipe out the Keep Relays.

To access the G DATA:
1. Press the SYSTEM button.
2. Press the PMC soft key.
3. Press the PMCPRM soft key.
4. Press the DATA soft key.
5. Press the G DATA soft key.

If the commanded spindle speed does not match the actual speed you can try adjusting parameter 3741. You may need to adjust 3742, 3743 or 3743 if the machine has a geared head.

For alarm 751 SERIAL SPINDLE ALARM AL-27 or 750 SERIAL SPINDLE ALARM AL-34 check the Keep Relays. This is particularly true on a machine with more than one spindle such as a live tooling machine since having the Keep Relays set the wrong way can have the control look in the wrong place for the serial terminator.

To delete multiple blocks from a program:
1. Go to the first block to be deleted using the search function.
2. Once there, enter an instruction from the last block to be deleted.
(This can be any instruction, T-Code, G-Code, etc.)
3. Press the DELETE button. The control will delete from the location of the cursor to the block of the first
instance of the instruction you enter just as it goes to the first instance when searching.

When working with a machine which has more than one spindle as in the case of a live tooling machine, the spindles are considered S1, S2 and S3. When working with the spindle parameters you will note the following format.

4077 S1 100
S2 0
S3 0

The example above demonstrates how the parameter for spindle orientation position shift appears. S1 is for the main spindle. Typically, the live tool spindle would be S2.

Alarm 151 TOOL GROUP NUMBER NOT FOUND, this alarm is normally issued if a tool number higher than the value set in parameter 6810 (18 control) is called.

Many functions such as axis control, spindle amplifier communication, etc. are performed by modules on the Main Board (CPU). These modules are plugged into Simm sockets. One of these modules controls the CRT. The 40 pin DIP is the system boot software similar to the BIOS of a PC. One of the modules is a FLASH module which typically holds four Intel FLASH chips. This module contains the ladder diagram. In addition, there is a DRAM module which holds the system RAM and a PMC module.

If you want to change the M-Code that operates the parts counter you need to work with parameters 6700 and 6710. If parameter 6700.0 (PCM) equals 0, M02, M30 or an M-Code specified by parameter 6710 will cause
the parts counter to increment. If it equals 1, only the M-Code specified in parameter 6710 will cause the counter to increment. Enter the number of the desired M-Code onto parameter 6710 without the M. Valid numbers are 0-255 but M98 and M99 are not valid.

At CNC power-on, the spindle parameters are sent from the CPU to the spindle amplifier via the serial interface. The parameters are also sent to the amplifier after the spindle alarm 749 has occurred and been reset regardless of the reason for the alarm (spindle amplifier shutdown or signal noise).

In some cases, if parameter 71.3 is set wrong for the control's software it can cause generation of watchdog alarm 920 when the program is run in graphic mode. The alarm has to do with the control looking for an LSI chip that isn't there.

Parameter 6710 sets the number of the M-Code which increments the Part Counter.

The Servo Tuning screen again using the X axis as an example:

FUNCTION BIT = Parameter 2003
LOOP GAIN = Parameter 1825
TUNING SET = Used by automatic servo tuning function
SET PERIOD = Used by automatic servo tuning function
INTEGRAL GAIN = Parameter 2043
PROP. GAIN = Parameter 2044
FILTER = Parameter 2067
VELOC. GAIN = Parameter 2021 + 256 divided by 256 times 100
ALARM 1 = Diagnostic 200
ALARM 2 = Diagnostic 201
ALARM 3 = Diagnostic 202
ALARM 4 = Diagnostic 203
ALARM 5 = Diagnostic 204
LOOP GAIN = Actual Loop Gain
POSITION ERROR = Actual Position Error (Diagnostic 300)
CURRENT % = Percent of rated value
SPEED RPM = Actual motor RPM

If the Servo Tuning screen is not displayed by pressing the SYSTEM button, right CHAPTER key, SV PARA soft key, then the SV TUN soft key, check parameter 3111 (SVS), it must be 1 for the screen to be displayed.

If need an I/O board with the part number A16B-2202-0721 which is often unavailable, it can be replaced with part number A16B-2202-0720. The only difference is that the 721 has more outputs.

When working with the soft limit parameters for an 18 control, parameter 1320, 1321, etc., a value of 10000 = .4000 inches.

For Alarm 401 check the terminator at JX1B.

On an 18 control to change a Keep Relay the RAM WRITE ENABLE must equal 1.
To do this:

1. Press the SYSTEM button.
2. Press the PMC soft key.
3. Press the PMCPRM soft key.
4. Press the SETING soft key.

You must be in MDI mode and the PWE must be turned on.

If the conditions are not met, the control will display WRITE PROTECT when you attempt to change the Keep Relay.

If a machine with an 18 control continually over travels after being re-gridded you can try this. Change parameter 1860 to 0 then cycle power and zero return re-grid if necessary. I have no idea what this does but it sometimes works. The things that will cause a machine to keep losing it's grid is a crash and looseness.

The Fanuc 18 I/O boards are resistant to shorted outputs so if you have an output on a machine not working, for example, a relay that won't energize, make sure there is no short condition such as a shorted transient diode. In this case the relay will not energize but it will not harm the board.

If the LCD display is blank, check the Main Board. If the #2 red LED is on, the LCD Unit is probably bad. In some cases the Main Board or the Power Supply may be bad but it is probably the LCD Unit itself. This LED normally indicates that the CPU was interrupted during boot-up but I think a bad LCD will make the Main Board suspect an interrupt.

The option parameter for circular interpolation on a lathe is 9937.0, once this is turned on use G17 along with G02 or G03 for the XpYp plane. Use G18 for the XpZp plane and G19 for the YpZp plane.

You can upload and download the PMC and the LADDER at a baud rate faster than 4800 (up to 19200) by pressing the SPEED soft key and changing the protocol. On this screen you can also change the parity, the stop bits and the write code (ASCII, ISO).

The parameter for the second reference point (G30) for a 16/18 control is parameter 1241.

In order to retrieve data from a variable, you have to execute a macro
program. For example, to find the number of hours the machine has been run (cycle start lamp on). This will only work if the machine has CUSTOM MACRO B.

O3737;
G65 P9100;
M30;

O9100;
#500=#3002;
M30;

The run time data is stored in variable 3002 but can not be directly viewed. This is the only way to access it. After running program O3737, you can go to variable 500 (#500) and read the data.

On an 11 control as well as an 18, parameter 1850 is the Grid Shift parameter. Parameter 1816 is the reference counter capacity. Parameter 1850 should be set to the value in 1816 or less. If you are trying to adjust 1850 and have trouble make sure 1850 is less than 1816. Also make sure you are adjusting the parameter in the correct direction. For the vast majority of machines where reference return is in the positive direction you must increase the value to shift the axis further away from the decel dog. Sometimes you may reach a point while adjusting where the axis stops responding to small changes in the parameter and after increasing the value a certain amount the axis jumps several millimeters. Again, make sure you are not in a situation where you need to decrease the value rather than increase it. If this is not the case then you may have gone as far as you can go with the Grid Shift and may need to either move the decel dog or the pulse coder. If the reason you are adjusting this parameter in the first place is because you replaced the pulse coder then, of course, you should look at it first. On most machines the pulse coder will employ a coupling that can only go two ways, either the correct way or 180 degrees out. In this case try removing the pulse coder and putting it back on 180 degrees out relative to the motor. Parameter 1850 is a metric value and the amount that the axis moves is dependent upon the ball screw pitch.

The feedback from the spindle position sensor, in the case of a 16 or 18 control comes in on connector JY2 or JY4, JY2 for a machine with a built-in spindle. If one of the signals is missing, alarm 750 or 751 will likely be generated. In some instances it can be generated simply by turning the spindle by hand. The important signals are PA1 and PB1. These are sine waves that are out of phase with one another, they should be present when the spindle rotates. PA1 and PB1 are the complements to PA and PB. MZ is the one revolution pulse and MZ1 is it's complement. When alarm 750 or 751 is active, the 5vdc supply to the encoder (sensor) may be removed. Below are the pin outs for JY2:

PIN SIGNAL

1 MZ
2 MZ1
5 PA
6 PA1
7 PB
8 PB1
9 +5V
12 0V
14 0V
16 0V
18 +5V
20 +5V

Connectors JA7B and JA7A are command cables. JY1 is the output to the load meter.

The parameter to set the Baud Rate on an 18 or 21 control when the I/O channel is set to 0 is parameter 103. The setting value is the same as other Fanuc controls:

1 = 50
2 = 100
3 = 110
4 = 150
5 = 200
6 = 300
7 = 600
8 = 1200
9 = 2400
10 = 4800
11 = 9600
12 = 19200

To set the absolute position on a machine with absolute pulse coders:

1. Move the axes to the desired or required position.
2. Select MDI mode.
3. Set PWE=1.
4. Access Parameter 1815.
5. Set Parameter 1815.4 to 1 for each axis.
6. Cycle NC power.

Anytime this parameter equals 0, the position has been lost and the alarm requesting ZRN will be issued. The battery for the pulse coder is located on the Servo Amplifier. In the case of a dual amp, one battery will hold the position for both axes. The battery is Lithium and not rechargeable. Fanuc recommends that if the power will be off of the machine for a long period you should disconnect the battery. Apparently, the control must disconnect the battery from the pulse coder and power it with the NC power whenever NC power is on.


The Spindle Monitor page of an 18 control displays control signals that are being input and output. For example, when the spindle is in orientation you would see:

Control Input ORCM MRDY *ESP

Control Output SST SDT ORAR

*ESP should always be present during normal operation.

To get to the Spindle Monitor page:

1. SYSTEM button.
2. Right Chapter button.
3. (SP-PRM) soft key.

Even though an axis may appear to be in position according to the position display, it may not be in position as far as the control is concerned. The control's in-position window is very, very narrow. This window is specified by parameter and can be changed but shouldn't be. If an axis pulls high current while at rest, it may not be in position. To check this, go to the Servo Tuning page. On an 18 control:

1. SYSTEM button.
2. PARAM soft key.
3. RIGHT CHAPTER button.
4. SV-PRM soft key.
5. SV-TUN soft key.


Setting Parameters REVX and REVY should both be 0 under normal conditions. When set to 1 the axis direction will be reversed. One condition that can arise from this setting being wrong is that when a program is started and the axis tries to move to the G54 position it may travel until the soft limit is reached. This over travel condition is a result of the mirror image function. Setting the parameter back to 0 will fix the problem but you must perform reference point return after changing the parameter.

When you are loading Parameters or Diagnostics via RS232, you should see LSK flashing after you press INPUT until the control begins receiving the data. Once the data is present at the input of the control, you should see INPUT start flashing.

When Parameter SEQ (On the Setting Screen) is set to 1 the control will insert the sequence numbers automatically.

In order to receive parameters and diagnostics at the PC in text form you must make EIA/ISO = 1 (ISO).

To copy the ladder to and from a Flash disk you must access the BOOT SYSTEM. This is done by holding the two rightmost soft keys while powering up the NC. When this is done the CNC does not boot.

During a Rapid movement in a program, placing the Feed rate Override switch at 0% will cause axis movement to stop if parameter 1401.4 (RFO) is set to 1. If set to 0, axis movement will not stop.

Fanuc
Page 6


ALARMS





Communication Alarms

Alarm 086 means that the Data Terminal (DTR) is not ready. There is an IC on the memory board which supplies a voltage signal to this pin to indicate that the terminal is ready. Sometimes this chip will go out.

If an 086 alarm occurs when attempting to communicate with a PC, there is most likely a problem with the communication cable. Also when uploading and downloading make sure the program edit key is in the correct position. One of the most important aspects of the serial communications is the cable. It must be right or the control will not attempt to communicate. This includes the position of the jumpers. The control looks for a short between pins 6 and 20 of the connector so if you don't have a Fanuc cable a crude test of the control can be done by shorting these two pins before trying to initiate communication. If pins 6 and 20 are not shorted you will most definitely get an alarm 086. Below are the indications of a control which is functioning normally while a RS-232 tester and Fanuc cable are connected without a PC or other device connected.

IDLE STATE TRANSMITTING RECEIVING

TD ------- OUT TD ------- GREEN TD -------- OUT
RD ------- OUT RD ------- GREEN RD -------- OUT
CD ------- OUT CD ------- OUT CD -------- GREEN
DTR ----- RED DTR ----- GREEN DTR ------ GREEN
DSR ----- RED DSR ----- GREEN DSR ------ GREEN
CTS ----- RED CTS ----- GREEN CTS ------ GREEN
RTS ----- RED RTS ----- GREEN RTS ------ GREEN

Again, these indications are with no external device connected and will
differ once one is.



Alarm 087 occurs when the stop bits are set incorrectly or the PC is not responding to the controls request to stop transmission. It may also occur if you mistakenly try to transmit Parameters to the Diagnostic page or Programs to the Parameter page, etc.

Alarm 085 is almost always the result of improper setting of the Baud Rate.

086 alarm means that the DR signal is not present at the port.


If you continually get Alarm 087 when you are trying to input programs thru RS-232 communication, check the Edit key position, on some machines it can cause the alarm. The Edit key address is G122.3, it should be 1 to avoid the alarm.

If alarm 087 keeps occurring when trying to send information such as programs to the control, make sure that TVON is set to 0.

If you try to do DNC operations with the I/O setting for 0, alarm 086 will be issued.

3n0 (300, 310, 320, etc.)
NTH AXIS ORIGIN RETURN
Manual reference position return is required for the nth axis.

3n1 (301,311,321,etc.)
APC ALARM: NTH AXIS COMMUNICATION
Nth axis APC communication error. Failure in data transmission. Possible causes include a faulty APC, cable or servo interface module.

3n2 (302,312,322,etc.)
APC ALARM: NTH AXIS OVERTIME
Nth axis APC overtime error. Failure in data transmission. Possible causes include a faulty APC, cable or servo interface module.

3n3 (303,313,323,etc.)
APC ALARM: NTH AXIS FRAMING
Nth axis APC framing error. Failure in data transmission. Possible causes include a faulty APC, cable or servo interface module.

3n4 (304,314,324,etc.)
APC ALARM: NTH AXIS PARITY
Nth axis APC parity error. Failure in data transmission. Possible causes include a faulty APC, cable or servo interface module.

3n5 (305,315,325,etc.)
APC ALARM: NTH AXIS PULSE ERROR
Nth axis APC pulse error alarm. APC alarm. APC or cable may be faulty.

3n6 (306,316,326,etc.)
APC ALARM: NTH AXIS BATTERY VOLTAGE 0
Nth axis APC battery voltage has decreased to a low level so that the data cannot be held. Battery or cable may be faulty.

3n7 (307,317,327,etc.)
APC ALARM: NTH AXIS BATTERY LOW 1
Nth axis APC battery voltage reaches a level where the battery must be renewed. Replace the battery.

3n8 (308,318,328,etc.)
APC ALARM: NTH AXIS BATTERY LOW 2
Nth axis APC battery voltage has reached a level where the battery must be renewed (including when the power is off).

Serial Pulse Coder (SPC) Alarms

3n9 (309,319,329,etc.)
SPC ALARM: NTH AXIS PULSE CODER
The nth axis (axis 1-8) pulse coder has a fault.


Alarm 3n9 SPC is normally the result of a loss of communications between the serial pulse coder and the control. In practice, the problem which causes this alarm is almost always a bad connection. Quite often the cause is that the military style connector has backed off of the encoder or there is coolant in this connector. However, the cause can be a bad encoder or a failed cable. The n will be replaced with a number such as 319, 329 etc., to indicate which axis has a problem and the affected axis will also be named in the alarm.

Alarm 002 TV PARITY ALARM is issued when there is an odd number of characters in a block of information which is being input via RS-232. It will only be generated if the TV CHECK parameter on the Setting page is set to 1. This parameter can also be set by changing parameter 0.0 (TVC). This is important to know because if parameter 0.0 is set to 1 in a copy of parameters you are trying to load into the control, as soon as the control reads in TVC it will generate alarm 002. In this case you would see that LSK would flash as it normally does then when the parameters start coming in the control flashes INPUT only for a second then goes into an alarm state. Often the alarm goes unnoticed because you may be loading the parameters in under an alarm state
E-Stop, etc. so alarms are already present. The fact that some parameters are read into the control and immediately take effect can cause other problems. This might cause a problem if you are loading in parameters in which the baud rate is set for something other than the rate you are communicating at.





Spindle Alarms

On most machines without a spindle speed pot pressing spindle start in JOG mode causes the spindle to run at the last speed commanded in a program or in MDI.


One alarm which is more or less common is number 4. This indicates a blown fuse at the input to the spindle drive.

The older AC SPINDLE SERVO UNITS don't have a segmented LED display. In order to indicate alarms it uses four individual LED's arranged horizontally and numbered: 8 4 2 1
Together these generate a binary number from 1 to 15. These numbers correspond to the following alarms:

AL-01 THE MOTOR OR SERVO UNIT IS OVERHEATED (THERMOSTAT)
AL-02 THE SPEED DEVIATED SUBSTANTIALLY FROM THE SPEED COMMAND DUE TO OVERLOAD,
FOR EXAMPLE, CAUSING EXCESSIVE SPEED ERROR.
AL-03 THE ELECTRIC DISCHARGE CIRCUIT IS ABNORMAL.
AL-04 NOT USED
AL-05 NOT USED
AL-06 THE SPEED OF THE MOTOR EXCEEDED MAXIMUM RATINGS (ANALOG DETECTION METHOD)
AL-07 THE SPEED OF THE MOTOR EXCEEDED MAXIMUM RATINGS (DIGITAL DETECTION METHOD)
AL-08 THE POWER SUPPLY VOLTAGE IS TOO HIGH.
AL-09 NOT USED
AL-10 THE VOLTAGE OF +15 SUPPLY IS ABNORMALLY LOW.
AL-11 THE DC LINK VOLTAGE IS ABNORMALLY HIGH.
AL-12 DC LINK CURRENT IS ABNORMALLY HIGH.
AL-13 NOT USED
AL-14 NOT USED
AL-15 NOT USED

Alarm AL-20 indicates a fault in the Logic Circuit of the Spindle Amp. When any alarm in the range of 16 to 23 occurs, the problem could be either a bad Spindle Amplifier or bad Parameters.

Alarm AL-12 almost always indicates a bad Transistor Module. This module is mounted on the heat sink behind the two boards. It's inputs consist of the DC Bus Voltage and the control gates B1 through B6. It's output is the motor voltage U,V, and W. The manual describes AL-12 as an abnormal current in the DC circuit. The DC circuit it refers to is the DC Bus. One of the first things you should check is the DC voltages on the board. +5, +/-15, and +24. With intermittent problems you should put a scope on the test points and look for noise.

There are two wires which come in on the top right hand corner of the amp, T1 and T2. Never remove these with power on or power up with them off. Doing so can have catastrophic consequences for the Transistor Module.

Also, if the amplifier is powered when the transistor module is defective the Logic board may be damaged.


ALARM LIST FOR SPINDLE AMPLIFIER

AL-01 Motor is Overheated (Thermostat).
AL-02 Speed Deviation is excessive. Actual speed versus Commanded speed.
AL-03 Fuse F7 at DC Link is blown.
AL-04 Fuse F1, F2, or F3 at AC input is blown.
AL-06 Motor has exceeded the Maximum Rated Speed. (Analog System Detection)
AL-07 Motor has exceeded the Maximum Rated Speed. (Digital System Detection)
AL-08 Power Supply voltage is too high.
AL-09 The Heat Sink is overheated.
AL-10 The +15 VDC is abnormally low.
AL-11 The voltage at the DC Link is abnormally high.
AL-12 The current at the DC Link is abnormally high.
AL-13 Arithmetic and Peripheral circuit parts are in an abnormal condition.
AL-14 The ROM is in an abnormal condition.
AL-16 Arithmetic and Peripheral circuit parts are in an abnormal condition.
to
AL-23

Some of the above alarms also apply to the Power Supply Module. You can tell by the description which ones may or may not.

If a machine issues the 751 alarm when spindle orient is commanded while the spindle is running but not when commanded from a standstill, check the ATC macro to be sure M5 has not been removed. If the spindle is running at an RPM which is significantly higher than the spindle orientation speed it may not be able to make the transition from running to orientation in time to prevent the alarm.

Alarm 751 SERIAL SPINDLE ERROR AL-27 can be caused by a parameter being set wrong but before chasing this make sure that the spindle encoder is connected on the motor end as well as the amplifier side. Also, if the machine uses a separate position pulse coder, make sure it is connected on both ends.

408
SPINDLE SERIAL LINK START FAULT
This alarm is generated when the spindle control unit is not ready for starting correctly when the power is turned on in the system with the serial spindle. The possible causes are:

1. Parameter set incorrectly.
2. An improperly connected optic cable or the spindle control unit's power is off.
3. When the NC power was turned on under alarm conditions other than SU-01 or AL-24 which are shown on
the LED display of the spindle control unit. In this case, turn the spindle amplifier power off and perform
power up again.
4. Improper combination of hardware.
This alarm does not occur after the system including the spindle control unit is activated.

409
SPINDLE ALARM DETECTION
A spindle amplifier alarm occurred in a system with a serial spindle. The alarm is indicated as "AL-XX" (where XX is a number) on the display of the spindle amplifier. Setting parameter 397.7 causes the spindle amplifier alarm number to appear on the CRT/LCD.

If an excessive spindle alarm occurs during rigid tapping, the relevant alarm for the tapping feed axis is displayed.

704
SPINDLE OVERHEAT
Spindle overheat was detected by the spindle speed fluctuation detection function (T series).


945
SERIAL SPINDLE COMMUNICATION ERROR
The hardware configuration is incorrect for the serial spindle or a communication alarm occurred. Check the hardware configuration of the spindle. Also, check that the hardware for the serial spindle is connected securely.

945
SERIAL SPINDLE COMMUNICATION ERROR
The hardware configuration is incorrect for the serial spindle or a communication alarm occurred. Check the hardware configuration of the spindle. Also, check that the hardware for the serial spindle is connected securely.

946
SECOND SERIAL SPINDLE COMMUNICATION ERROR
Communication is impossible with the second serial spindle. Check that the second serial spindle is connected securely.

If you have an alarm on an Alpha spindle amplifier, the problem may actually be the power Supply Module even though there is no alarm displayed on the PSM. This is especially true in the case of alarm 03 (AL-03) on the spindle amp. This alarm can be issued if the PSM is not outputting the DC Link voltage but also is not issuing an alarm.

Alarm 751 FIRST SPINDLE ALARM DETECTION, On a machine that uses the high resolution encoder (normally on a lathe with live tooling) check the spindle amplifier. If the alarm code on the amplifier is AL-39, this indicates the failure to detect the one rotation signal for the Cs contouring control. This alarm typically occurs when the C axis is commanded to a specific position. Most of the time this means that the two sensors of the high resolution encoder are not properly aligned, Fanuc has to make the necessary adjustment. It can also be caused by a problem, of course, with the encoders, the drum which is attached to the spindle or the cables, particularly the cable shielding. You also must consider the spindle amplifier itself. In one case the problem was found to be that the belts for the spindle motor had been made too tight causing just enough deflection between the encoders and the drum to generate the alarm every time a C axis position was commanded. In addition, the alarm would occur if the C axis was run even in manual mode above a given speed. This problem was solved by loosening the belts a little.

For Alarm 751 with AL-46, everything is the same but this alarm means that the fault was detected while in "thread cutting" operation.

In either case the problem may be with how eccentric the drum is relative to the sensors. According to Fanuc the run out of the drum must be within five microns (.0002"). Also the drum must be square with the face of the sensor to within 20 microns. The face of the sensor should be centered with the magnetic strip of the drum.


If you have alarm AL-07 on the Power Supply (PSM) and AL-11 on the Spindle Amplifier, there could be a problem with the regenerative circuit of the Spindle Amp. This situation is normally evident when the spindle is ramping down, in particular, from a high RPM. This is because when the spindle decelerates from a high rate of speed, there is a lot of CEMF to dissipate. If there is a problem with the amplifier which prevents it from being dissipated it can cause an DC Link over voltage condition on the spindle amplifier (alarm 11). When the Power Supply sees this high voltage at it's DC output it looks like a blown fuse of the DC Link (alarm 07).

On the Alpha series Spindle Amplifier, the cooling fan has a detection circuit. If the fan stops, the control will generate Alarm 409.





Power Supply Alarms


AL-01 on the Power Supply Module means that the incoming AC is adequate but the DC Link voltage is low. This normally indicates that the PSM is defective but you can disconnect the DC Link from the drives to determine if the voltage is being pulled down by one of them. When you have the AL-01 you should have AL-30 on the Spindle Amplifier since AL-30 means there is a problem with the input power circuit. If you disconnect the DC Link completely you may get AL-07 because the PSM thinks the fuse is blown. You may have to try to keep one of the drives connected.

AL-02 on the PSM (power supply module) means there is a problem with the amplifier's cooling fan.

AL-03 means the temperature of the heat sink of the power supply has risen too high.

AL-04 means the DC Link voltage has dropped.

AL-05 means the incoming AC is abnormal (open phase) or the main capacitor did not charge in the specified amount of time. The DC Link may be shorted or the recharge current limiting resistor is defective.

AL-06 means the incoming AC is defective (open phase).

AL-07 means the DC Link is too high. There could be excessive power being regenerated or the impedance of the AC supply is too high, an incoming AC variation of more than 7% can cause this or a defective regeneration unit.


System Alarms

The 950 PMC SYSTEM ALARM can be caused by a problem with the I/O, particularly if an external voltage is applied to the I/O system.


The 911 RAM PARITY ERROR alarm may mean that the Memory board has failed but it may also mean simply that the parameters have been lost due to a bad battery. The only way to find out is to do a memory clear. Turn the NC off, hold the RESET and the DELETE button, turn the NC back on while holding both buttons. If the alarm goes away and is replaced with servo alarms, etc. then the Memory board is probably ok. At this point you must follow the procedures for bringing back a brain dead control. If the CRT is flashing BAT, go ahead and install new batteries before you start.


910
MAIN RAM PARITY
The RAM parity is related to low order bytes. Replace the memory PC board.

911
MAIN RAM PARITY
This RAM parity error is related to high order bytes. Replace the memory PC board.

912
SHARED RAM PARITY
This parity error is related to low order bytes of RAM shared with the digital servo circuit. Replace the axis control PC board.

913
SHARED RAM PARITY
This parity error is related to high order bytes of RAM shared with the digital servo circuit. Replace the axis control PC board.

914
SERVO RAM PARITY
This is a local RAM parity error in the digital servo circuit. Replace the axis control PC board.

915
LADDER EDITING CASSETTE RAM PARITY
This RAM parity error is related to low order bytes of the ladder editing cassette. Replace the cassette.

916
LADDER EDITING CASSETTE RAM PARITY
This RAM parity error is related to high order bytes of the ladder editing cassette. Replace the ladder editing cassette.

920
WATCHDOG ALARM
This is a watchdog timer alarm or a servo system alarm for axes 1-4. Replace the axis or master control PCB.

921
SUB CPU WATCHDOG ALARM
This a watchdog timer alarm related to the sub CPU board or a servo system alarm for axis 5 or 6. Replace the sub CPU board or the axis 5/6 control PCB.

922
7/8 AXIS SERVO SYSTEM ALARM
This is a servo system alarm related to axis 7 or 8. Replace the axis 7/8 control PCB.

930
CPU ERROR
This is a CPU error. Replace the master PCB.

940
PC BOARD INSTALLATION ERROR
PC board installation is incorrect. Check the specification of the PC board.

941
MEMORY PCB CONNECTION ERROR
The memory PCB is not connected correctly. Check that the PCB is connected securely.

945
SERIAL SPINDLE COMMUNICATION ERROR
The hardware configuration is incorrect for the serial spindle or a communication alarm occurred. Check the hardware configuration of the spindle. Also, check that the hardware for the serial spindle is connected securely.

946
SECOND SERIAL SPINDLE COMMUNICATION ERROR
Communication is impossible with the second serial spindle. Check that the second serial spindle is connected securely.

950
FUSE BLOWN ALARM
a fuse has blown. Replace the fuse (+24E F14).

960
SUB CPU ERROR
This is a sub CPU error. Replace the CPU PCB.

998
ROM PARITY
This is a ROM parity error. Replace the ROM board in which the error occurred.

Generally speaking, anytime you have Parity alarms or most any 900 series alarm the first step required is normally to clear out the memory by holding the RESET and DELETE buttons while turning on the NC power. This will delete all parameters and programs.


Alarms 910 to 914 (RAM PARITY ERROR) will occur if the RAM chips are removed and replaced even with the power off because of the battery back-up.

Alarm 950 FUSE BREAK (+24E:FX14) means that F14 the 5.0 amp fuse is blown. This is the bottom fuse on the front of the Power Unit. It's labeled +24E.




1000
EXTERNAL ALARM
This alarm was detected by the PMC ladder program. Refer to the relevant manual from the machine builder for details.



Servo Alarms


Placing the Control in E-Stop will remove the servo alarms allowing you to enter the parameters by hand, but remember that if you are in E-Stop you can not communicate via RS232.



If a machining center keeps issuing the 430 alarm while performing a peck drill cycle, check that the drill is sharp. This is especially true for softer materials such as aluminum and plastic. If the drill is dull, the rotation of the spindle can pull the head into the work making it difficult for the Z axis motor to stop within its In-position width setting. This causes the 430 alarm.

Sometimes you might see an alarm that says SOFT THERMAL (i.e., 436 X AXIS SOFT THERMAL). This alarm is normally seen during referencing (zero return). It basically means that the axis is loading up while traversing slowly. A common cause of this is for chips to build up between the table and the motor or the bearing housing. When this happens, in most cases, the motor is able to compact the chips enough to make it almost home but the current required is very high causing the alarm.

Alarm 436 can be generated for any axis, the control will specify on screen which axis is at fault. if for some reason an axis is not specified, check the LED display on the amplifiers.


In the case of Servo Alarms always confirm that MCC is energized. For an 18 control this normally requires that the 24vdc on CX4 is routed through the machine and back to ESP. On most machines this is accomplished by connecting the normally open contacts of a relay to CX4. This relay is energized by the E-Stop circuit. MCC is normally energized by passing the 220vac through CX3 to the coil of MCC and back out to another phase of 220. In turn MCC supplies 220vac to power the PSU.

If you get AL-12 on an amplifier, try powering up with the motor leads off of the amp. If you still get AL-12 the amplifier is almost certainly bad.

If you have trouble with alarm 329:SPC and you check the cable and it rings good, keep in mind that the maximum allowable resistance for the 5 volt signal on each conductor is only .5 ohms.

Remember that when dealing with these Serial alarms as well as some other Servo Alarms, after you enter the correct Parameters, the alarm will not go away until you have cycled not just the NC power but the power to the amplifiers as well so you must turn the machine completely off.

About 90% of the time alarm 4n0 indicates a bad motor, but in some cases it may be an axis board, drive, or cable problem. If you suspect a drive, it is usually easier and better to physically swap with another axis than to swap cables. If you do swap cables, be sure to swap both motor cables and encoder cables. The encoder cables can be swapped at the Axes PCB.

If alarm 4n1 will not go away after completely cycling power, check the 24 VDC which is "daisy chained" to the Spindle and Servo amps. As a last resort, try removing and replacing the connector under power.


In the case of alarm 414 with an indication of 8. on the servo amplifier, check the motor power cable for that amplifier. A conductor (U,V,W) that is going to ground can cause this condition. Sometimes you may see this situation on a machining center with a multiple axis amplifier and you might suspect that the amp is bad because the X axis will issue the 414 alarm when the Y axis moves. What may be, in fact, happening is that as the Y axis moves it drags the X axis motor power cable into a position where it grounds out, since on an X over Y machine the X axis motor cables run through a flexible wireway that moves with the Y axis. If alarm 414 occurs, check Diagnostic 200 and Diagnostic 204.
Two bits of Diagnostic 204 apply to alarm 414, they are bit 5 and 6. Bit 5 is
MCC, Bit 6 is OFS.

Seven bits of Diagnostic 200 apply to alarm 414, they are bit 0(OFA), 1(FBA), 2(DCA), 3(HVA, 4(HCA), 5(OVC), 6(LV).

OFA = Overflow alarm.
FBA = Disconnection alarm.
DCA = Discharge alarm. LED 4 or 5 lights.
HVA = Over current alarm. LED 1 lights.
HCA = Abnormal current alarm. LED 8 lights.
OVC = Over current alarm.
LV = Low voltage alarm.

All of the bits above should be 0. A 1 indicates a fault of that bit.

Diagnostic 200 applies to 16, 18 and 0 controls.

The OFA bit can be set if certain parameters in the 1800 series are set wrong. (16/18 control)

A problem with one of the drives will almost certainly generate alarm 401.

Quite often when you have the 401 VRDY OFF alarm it means that the servo has not had power supplied to it by the energizing of MCC. A common cause for this is an E-Stop condition which prevents the power supply from sending power to the servo unit. In this case there will be no alarms displayed on the amplifier. If you watch the drives during the NC power on sequence, you can see it power is sent to the drive then MCC drops back out which may indicate a problem with the amplifier which the amp cannot detect or a problem with either the CPU or the communication between the amp and CPU. IF the MCC contactor never energizes, look for a machine side problem such as the E-Stop


Alarm 411, 421, 431 means that there was an excessive deviation between the commanded position and the actual position during axis movement. The amount of deviation which generates the alarm is defined by parameter. There are two things to look at first when the alarm occurs, does the motor actually move when commanded or not. If the motor does move a little then the alarm is issued, check the mechanical portion of the axis for tightness. If the axis is too tight the motor can usually turn just a bit before everything binds up then the alarm is issued because the motor is not able to reach the commanded position. You have to go by the actual motion of the motor since the position display will typically change with the commanded movement before actual motor movement takes place. If the motor never moves at all check the output of the servo amplifier. If the motor winding is open or the cable is broken, etc. the motor will, of course, not move at all then the alarm will issue. In this case the position display will change with the commanded movement then after the alarm is issued, the display will return to the position displayed before the movement was commanded. Again the amount the axis will move before the alarm is issued is defined by parameter but a typical distance is .050".


400
SERVO ALARM: 1, 2th AXIS OVERLOAD
1-axis, 2-axis overload signal is on. Refer to diagnostics 720 or 721 for details.

401
SERVO ALARM: 1, 2th AXIS VRDY OFF
1-axis, 2-axis servo amplifier READY signal (DRDY) went off.

402
SERVO ALARM: 3, 4th AXIS OVERLOAD
3-axis, 4-axis overload signal is on. Refer to diagnostics 722 or 723 for details.

403
SERVO ALARM: 3, 4th AXIS VRDY OFF
3-axis, 4-axis servo amplifier READY signal (DRDY) went off.

404
SERVO ALARM: NTH AXIS VRDY ON
Even though the nth axis (axis 1-8) READY signal (MCON) went off, the servo amplifier READY signal (DRDY) is still on. Or, when the power was turned on DRDY went on even though MCON was off. Check that the axis card and servo amplifier are connected.

405
SERVO ALARM: ZERO POINT RETURN FAULT
Position control system fault. Due to an NC or servo system fault in the reference position return, there is the possibility that reference return position return could not be executed correctly. Try again from the manual reference position return.

406
SERVO ALARM: 7, 8TH AXIS OVERLOAD 7, 8TH AXIS VRDY OFF
7-axis, 8-axis overload signal is on. Refer to diagnostics 726 or 727 for details. 7-axis, 8-axis servo amplifier READY signal (DRDY) went off.

4n0
SERVO ALARM: NTH AXIS EXCESS ERROR
The position deviation value when the nth axis stops is larger than the set value. This value must be set in parameter for each axis.

4n1
SERVO ALARM: NTH AXIS EXCESS ERROR
The position deviation value when the nth axis moves is larger than the set value. This value must be set in parameter for each axis.

4n3
SERVO ALARM: NTH AXIS LSI OVERFLOW
The contents of the error register for the nth axis exceeded +/- 2 to the 31st power. This error usually occurs as the result of an improperly set parameter.

4n4
SERVO ALARM: NTH AXIS DETECTION RELATED ERROR
Nth axis digital servo system fault. Refer to diagnostic 720-727 for details. For the 4n4 alarm, there is a troubleshooting flow chart in the Fanuc Maintenance Manual. When the alarm occurs you need to check Diagnostics 720 to 724 to determine if the problem is low voltage, high voltage, etc.


4n5
SERVO ALARM: NTH AXIS EXCESS SHIFT
A speed higher than 4000000 units was attempted to be set in the nth axis. This error occurs as a result of improperly set CMR.

4n6
SERVO ALARM: NTH AXIS DISCONNECTION
Position detection system fault in the nth axis pulse coder (disconnection).

4n7
SERVO ALARM: NTH AXIS PARAMETER INCORRECT
This alarm occurs when the nth axis is in one of the following conditions (digital servo system alarm).

1. The value set in parameter 8n20 (motor form) is out of the specified limit.

2.A proper value (111 or -111) is not set in parameter 8n22 (motor revolution direction).

3. Illegal data (a value below 0, etc.) was set in parameter 8n23 (number of speed feedback pulses per motor
revolution).

4. Illegal data (a value below 0, etc.) was set in parameter 8n24 (number of feedback pulses per motor
revolution).

5. Parameters 8n84 and 8n85 (flexible feed gear ratio) have not been set.

6. An axis selection parameter (from 269-274) is incorrect.

7. An overflow occurred during parameter computation.

490
SERVO ALARM: 5TH AXIS OVERLOAD
5-axis, 6-axis overload signal is on. Refer to diagnostics 724 or 725 for details.

491
SERVO ALARM: 5TH, 6TH AXIS VRDY OFF
5-axis, 6-axis servo amplifier READY signal (DRDY) went off.

494
SERVO ALARM: 5TH, 6TH AXIS VRDY ON
The axis card ready signal (MCON) for axes 5 and 6 is off but the servo amplifier ready signal (DRDY) is not. Alternatively, when the power is applied the DRDY is on but the MCON is not. Make sure the axis card and amplifier are connected.

495
SERVO ALARM: 5TH, 6TH AXIS ZERO POINT RETURN
This is a position control circuit error. It is likely that a return to the reference position failed because of an error in the NC or the servo system. Retry a return to the reference position.


When working on newer controls, 16, 18 etc., be aware that the alarm numbers do not work the same as they did on the 0 controls. Using the 400 series alarms as an example, alarms 400 through 405 mean the same thing on both controls after that the two controls diverge. Alarm 410 on the 16/18 is the same as alarm 4n0 on the 0. The difference is that in the case of the 16/18 the failed axis will be displayed on the screen with the 410. In the case of the 0 control the n will be replaced with the number that identifies the failed axis. It's important to be aware of this but you need to look very closely at the alarm section of the manual.


Alarm 401 indicates that the VRDY signal is off. In other words, a servo amplifier is not ready to run. You have to determine if the amplifier is off because there is something wrong with it or if there is an external cause. The most likely external cause is a problem with the 100 VAC supplied to the amplifier. If this is missing the amplifier will not power up. The problem is that this can quickly become a chicken or the egg problem. An easy way to find the culprit is to have someone turn the NC on while you watch the amplifier. If the DRDY (Green LED) comes on then goes back off, there is something wrong with the amplifier. If it never comes on at all, the trouble is external to the amp. In the case of an Alpha drive, the alarm number displayed on the amplifier will normally get you going in the right Anytime you have Alarm 419, check the Servo Motor cables, especially the motor lead cable. This alarm is often a bad connection.

If the machine is in E-Stop mode, the 100 VAC will not be present. The electrical drawings for the machine should show this circuit as well as how it ties in with MCC etc.

The above condition does not apply to Alpha drives.

Anytime a machine displays Alarms 400, 408, 418 and 424 (maybe more if the machine has more axes), check the LED displays on the amplifiers. If they are all blank, the AC Link is probably missing. This comes in on CX1A of the power supply and goes out on CX1B to CX1A of the spindle amplifier. For most applications, this is where the 220 vac stops. This AC voltage is typically 220 and is normally fed directly to the power supply through two fuses. This is determined by the machine builder and it is rare for the voltage to go through anything but a fuse. This voltage is converted to 24 VDC which is fed from connector CX2B of the power supply to CX2A of the spindle amplifier from CX2B of the spindle amplifier to CX2A of the first servo amplifier and so on. This 24 VDC is what supplies the power to all of the other drives to power the
LEDs, control circuits, etc.


PMC Alarms

600
PMC ALARM: INVALID INSTRUCTION
An invalid instruction interrupt occurred in the PMC.

601
PMC ALARM: RAM PARITY
A PMC RAM parity error occurred.

602
PMC ALARM: SERIAL TRANSFER
A PMC serial transfer error occurred.

603
PMC ALARM: WATCHDOG
A PMC watchdog timer alarm occurred.

604
PMC ALARM: ROM PARITY
A PMC ROM parity error occurred.

605
PMC ALARM: OVER STEP
The maximum allowable number of PMC ladder program steps was exceeded.

606
PMC ALARM: I/O MODULE ASSIGNMENT
The assignment of I/O module signals is incorrect.

607
PMC ALARM: I/O LINK
An I/O link error occurred. The details are listed below.

607 010
* Communication error (SLC master internal register error)

607 020
* An SLC RAM bit error occurred (verification error).

607 030
* An SLC RAM bit error occurred (verification error).

607 040
No I/O unit has been connected.

607 050
32 or more I/O units are connected.

607 060
* Data transmission error (no response from slave).

607 070
* Communication error (no response from the slave).

607 080
* Communication error (no response from the slave).

607 090
An NMI (for other than alarm codes 110 to 160) occurred.

607 130
* An SLC (master) RAM parity error occurred (detected by hardware).

607 140
* An SLC (slave) RAM parity error occurred (detected by hardware).

607 160
* SLC (slave) communication error.
* AL0 : Watchdog timer
DO clear signal received

* IR1 : CRC or framing error
Watchdog timer alarm
Parity error

* indicates a hardware error.



Overtravel Alarms


An OVERTRAVEL ALARM as well as some other problems can occasionally be cured by resetting the Grid. The procedure for resetting the Grid is as follows:

1. Turn the control off
2. Press the P key and the Can key simultaneously while turning the control back on
3. Hold both keys until the final screen is displayed
4. Turn the control off again
5. Turn the control back on normally

This is especially useful for over travel alarms since this procedure causes the control to ignore stored stroke limits. An important point to remember is that after performing this procedure, the control must be turned off and back on normally. The reason is that after resetting the grid the stroke limits will be ignored for as long as the power remains on no matter how long that may be. This will prevent the machine from stopping when a stroke limit has been reached, a potentially dangerous condition. Cycling power normally causes the control to once again check stored stroke limits. Also, performing a Zero Return will put the stroke limits back into effect. Make sure this zero return is done at a low feed rate (i.e. 25%) just in case the axis misses the ZRN switch. If the axis misses the switch and the stroke limits are turned off, the axis will crash.



5n0
OVERTRAVEL: +N
Exceeded the nth axis + side stored stroke limit 1, 2.
The 5n0 alarm is generated due to an over travel of either the first or second stroke limit.


5n1
OVERTRAVEL: -N
Exceeded the nth axis - side stored stroke limit 1, 2.

5n2
OVERTRAVEL: +N
Exceeded the nth axis + side stored stroke limit 3.

5n3
OVERTRAVEL: -N
Exceeded the nth axis - side stored stroke limit 3.

5n4
OVERTRAVEL: +N
Exceeded the nth axis + side hardware OT. (M series)

5n5
OVERTRAVEL: -N
Exceeded the nth axis - side hardware OT. (M series)

5n4
OVERTRAVEL AT +N AXIS
The tool moved beyond stored stroke limit 4 in the positive direction of the nth axis. (T series)

5n5
OVERTRAVEL AT -N AXIS
The tool moved beyond stored stroke limit 4 in the negative direction of the nth axis. (T series)

520
OVERTRAVEL AT -Z AXIS
The tool moved beyond the hardware over travel position in the positive direction of the Z axis.

590
TOOL POST INTERFERENCE ALARM AT +X AXIS
A tool post interference alarm was issued while the tool was moving in the positive direction along the X axis.

591
TOOL POST INTERFERENCE ALARM AT -X AXIS
A tool post interference alarm was issued while the tool was moving in the negative direction along the X axis.

592
TOOL POST INTERFERENCE ALARM AT +Z AXIS
A tool post interference alarm was issued while the tool was moving in the positive direction along the Z axis.

593
TOOL POST INTERFERENCE ALARM AT -Z AXIS
A tool post interference alarm was issued while the tool was moving in the negative direction along the Z axis.

If an axis will zero return okay, but issues a soft limit over travel alarm when you try to execute G28, check the value of the second stored stroke limit. It should normally be 0.


If an axis continually over travel, while trying to perform reference return there a few things you can work with. Of course, the easiest thing to try is making the soft limits ineffective by holding P and CANCEL while powering up the NC. This works in the majority of the cases. Sometimes you come across a machine which needs this procedure performed every time the machine is turned on. Normally this can be corrected by moving the decel dog in toward the center of travel just a very small amount, as little as .020 is often far enough. From time to time you may have a situation where this does not work or a case where using P + CAN causes the machine to hit the hard limit switch. For these machines, it may be necessary to adjust the Grid Shift Parameter. When an axis is reference returned, it moves toward the decel dog, the dog is contacted, the axis goes into decel until the switch drops off of the other side of the dog, the NC issues the one revolution signal which causes the motor to make one full revolution, the axis then moves a specified distance, then looks for the encoder marker pulse and stops at this point, it is now at home. The specified distance is determined by the Grid Shift Parameter. Parameter 508 in the case of the X axis of a 0 controlled machine. If this value is set too high, the axis will over travel when trying to reference return because the soft limit value defines a distance from a point in this travel prior to the execution of grid shift. In other words, the soft limit is how far the axis can travel from the reference return point not including the distance traveled due to execution of grid shift. The Grid Shift Parameter allows you to set the reference point as close to the soft travel limit of the axis without having to spend forever doing trial and error moving the decel dog. If you set the Grid Shift Parameter to 0, the axis will stop moving immediately after the motor executes the one revolution and finds the marker. As far as adjustment, you should determine the physical limit of the axis, set the hard limit switch such that the axis can come to a complete stop from maximum feed rate before reaching this physical limit. Set the soft limit parameter so that the axis can come to a complete stop from maximum feed rate before contacting the hard limit switch. Finally set the Grid Shift Parameter such that the Reference Point is as close as possible to the soft limit. Keep in mind that the position of the decel dog will shift everything in the chain except the hard and physical limits.


Other Alarms

When alarm 401 occurs without any obvious cause and the drives simply display -- (Not Ready), the PSM (Power Supply Module) may be at fault. This may have to do with the fact that the serial cable which is used for communication with the servo amplifiers, spindle amplifiers, etc. connects to the power supply.

In the event of an Alarm 90 (Abnormal Reference Position Return) which keeps occurring, one of the following parameters could be set incorrectly:

518-521
559-562
517
533
3.4
534
1.5

If you have a problem with a machine that issues 011 NO FEEDRATE COMMANDED, at times when no feed movement is being commanded, particularly during a tool change, make sure that G1 is not modal. A good practice is to program a G0 in a program before the tool change either as a preparatory command, in the block with the tool index or yet another way is to make parameter 3402.0(G0) = 0 so the control will power up in G0 mode.

Also, when parameters are lost, Parameter 517 (Loop Gain) will become 1. In this case, Alarm 410 or 420 or 430 will be generated but this parameter will not cause all three at once. The typical value for this parameter is 3000.

700
OVERHEAT: CONTROL UNIT
Control unit overheat. Check that the fan motor operates normally, check the air filter.


M-Net Alarm

899
M-NET INTERFACE ALARM
This alarm is related to a serial interface for an external PMC. The details are listed below.

899 0001
Abnormal character (character other than transmission codes) received.

899 0002
"EXT" code error.

899 0003
Connection time monitor error (parameter 464).

899 0004
Polling time monitor error (parameter 465).

899 0005
Vertical parity or framing error detected.

899 0257
Transmission timeout error (parameter 466).

899 0258
ROM parity error

899 0259
Overrun error detected.

Others
CPU interrupt detected.

On a Fanuc control a Not Ready indication without the presence of an alarm usually means that the E-Stop circuit is open. On most machines, the hard limit switches are tied in series with the E- Stop circuit.

Under some conditions alarm 128 ILLEGAL MACRO SEQUENCE NUMBER may be issued while trying to do DNC operations. In this case, it has nothing to do with a macro but rather it's caused by a baud rate mismatch.

In the Ladder, alarms have the address designation A.

On most controls, turning the NC power off while uploading/downloading programs will cause Alarm 101. In this case the program memory will have to be cleared.

Fanuc
Page 7

Diagnostics

Some other Diagnostics to check when you have problems are:
M SERIES T SERIES
G138.3 External Deceleration Signal X- G138.3 X-
G138.0 External Deceleration Signal X+ G138.0 X+
G138.4 External Deceleration Signal Y- G138.4 Z-
G138.1 External Deceleration Signal Y+ G138.1 Z+
G138.5 External Deceleration Signal Z-
G138.2 External Deceleration Signal Z+

MAN/ABS Signal G127.2

M SERIES
X016.5 Deceleration Signal for Reference Return X
X017.5 Deceleration Signal for Reference Return Y
X018.5 Deceleration Signal for Reference Return Z
X019.5 Deceleration Signal for Reference Return 4

T SERIES
X016.5 Deceleration Signal for Reference Return X
X017.5 Deceleration Signal for Reference Return Z
X018.5 Deceleration Signal for Reference Return 3
X019.5 Deceleration Signal for Reference Return 4

F150.5 Manual Data Input Start Signal

F149.7 CNC Ready Signal

G115.0 Miscellaneous Function Completion Signal

G120.0 External Program Input Start Signal M Series

G117.0 External Program Input Start Signal T Series

F188.0 Tool Change Signal

M SERIES
G105.0 Servo Off Signal X
G105.1 Servo Off Signal Y
G105.2 Servo Off Signal Z
G105.3 Servo Off Signal 4

T SERIES
G105.0 Servo Off Signal X
G105.1 Servo Off Signal Z
G105.2 Servo Off Signal 3
G105.3 Servo Off Signal 4

F149.1 Reset Signal

G120.4 Spindle Speed Reached Signal

G120.5 Spindle Orientation Signal

G120.6 Spindle Stop Signal

F148.5 Automatic Operation Start Signal

F148.4 Automatic Operation Halt Signal

G103.7 Miscellaneous Function Lock Signal

F178.7 Feed Hold Signal

The following table is very useful:

If the Edit Protect key is on you can input characters on the buffer line
but they will not be inserted into the program.

Following is the meaning of the Diagnostics 700 - 723.


D700 7 6 5 4 3 2 1 0
CSCT CITL COV2 CINF CDWL CMTN CFIN

A 1 in the bit means the following:

CSCT
Control is waiting for the speed arrival signal of the spindle to turn on.

CITL
Interlock is turned on.

COV2
Override is 0%.

CINF
In-position check is done.

CDWL
Dwell is being executed.

CMTN
Move command is being executed in automatic operation mode.

CFIN
M,S,T functions are being executed.


D701 7 6 5 4 3 2 1 0
CRST CTRD CTPU

A 1 in the bit means the following:

CRST
Emergency Stop, External Reset, or Reset Button on MDI panel is turned on.

CTRD
Data is being input via Reader/Punch Interface.

CTPU
Data is being output via Reader/Punch Interface.


D712 7 6 5 4 3 2 1 0
STP REST EMS RSTB CSU

A 1 in the bit means the following:

STP
Stops pulse distribution. Is set for the following reasons.
1.External reset button is turned on.
2.Emergency stop button is turned on.
3.Feed Hold button is turned on.
4.Reset button on MDI panel is turned on.
5.Manual mode (JOG,HANDLE,STEP) is selected.
6.Other alarms exist.
STP is useful for when Automatic operation won't execute.

REST
This flag is set when the External Reset, Emergency Stop, or Reset button is
turned on.

EMS
This flag is set when the Emergency Stop button is turned on.

RSTB
This flag is set when the Reset button is turned on.

CSU
This flag is set when the Emergency Stop button is turned on or a Servo
Alarm occurs. Check Diagnostics 800 - 803.

D800 - SVERRX
SVERRX

D801 - SVERRZ
SVERRY

D802 - ------
SVERRZ

D803 - ------
SVERR4

D720 7 6 5 4 3 2 1 0
OVL LV OVC HCAL HVAL DCAL FBAL OFAL

A 1 in the bit means the following:

OFAL
An overflow alarm has occurred.

FBAL
A wire disconnection alarm has occurred.

DCAL
An alarm of regenerative discharge circuit has occurred.

HVAL
An over voltage alarm has occurred.

OVC
An excessive current alarm has occurred.

LV
An under voltage alarm has occurred.
OVL
An overload alarm has occurred. (Alarm 400 - 402 ) Power transistor heat sink or Discharge unit overheat or motor overload.

400,402 = Overload Alarm OVL OH or thermostat of AC servo motor functions.

Corresponding LEDs.

ALARM LED
DCAL DC
HVAL HV
HCAL HC
LV LV
OVL OH

Diagnostic 720 is for the X Axis, 721 Y Axis, 722 Z Axis, 723 4th Axis.

D27 7 6 5 4 3 2 1 0
(T) PCS ZRNM ZRNL
(M) PCS ZRN4 ZRNN ZRNM ZRNL

A 1 in the bit means the following:

ZRNL
One rotation signal of pulse coder for L axis is on.

ZRNM
One rotation signal of pulse coder for M axis is on.

ZRNN
One rotation signal of pulse coder for N axis is on.

ZRN4
One rotation signal of pulse coder for 4th axis is on.

PCS
One rotation signal of pulse coder for spindle is on.

This table is helpful for self diagnostics:

DGN No. DISPLAY DATA

000-022 Input signals from machine tool.
(Output signal from receiver. No. 016-022 are effective without PMC.)

027 One revolution signal from pulse coder and position coder.

048-053 Output signals to machine tool.

080-086 Output signals to machine tool. Output signals to driver.
(These numbers cannot be used without PMC)

100-147 Input signals from machine tool (PMC).
(No. 116-122 are effective without PMC)

148-199 Output signals to machine tool (PMC)
(no. 148-153 are effective without PMC)

200-249 Window data from PMC to CNC.

250-299 Window data from CNC to PMC.

700,701 Status of the CNC when it appears not to be working in automatic operation.

712 Automatic operation stop and pause conditions.

720-723 Alarm contents of servo system.

800 Position Deviation amount of X axis.

801 " " " " Y (M) Z (T)

802 " " " " Z (M)

803 " " " " 4th axis.

820 X axis machine tool position from the reference point.

821 Y (M) Z (T) axis machine tool position from the reference point.

822 Z (M) axis machine tool position from the reference point.

823 4th axis machine tool position from the reference point.


Diagnostic 720 is for the first (usually X) axis, 721 is the second (Y for a mill, Z for a lathe) etc.

720 Bit 6 = LV (Low Voltage at the Servo Amplifier)
5 = OVC (Over current in the Servo Motor)
4 = HC (Abnormal Current in the Servo Amplifier)
3 = HV (Over Voltage at the Servo Amplifier)
2 = DC (Regenerative Discharge at the Servo Amplifier)



Also check the Servo Amp for and LED indication of the alarm.

If you have one of these bits turned on but there is no LED indication on the amplifier, check the amps operating voltages.

+20V +20V +/- 2V
+24V +24V +/- 2V
-15V -15V +/- .75V
+15V +15V +/- .75V
+5V +5V +/- .25V

If any of the voltages are abnormal check the 220VAC supply.

Another useful diagnostic:

D820 Distance from Reference Point X axis (Detection Units)
D821 Distance from Reference Point Z axis

The Diagnostic or Keep Relay lists of some machines will show certain bits as UNUSED or NOT USED. Quite often this will indicate that those bits are Fanuc defined. They may have significance to the operation of the control as it relates to the operation of the machine. This becomes important if you load the PMC into the control and the bits get reset.


You have to be very careful about changing Keep Relays and Diagnostics because of how machine builders use them throughout the ladder. Setting these wrong can cause some bizarre behavior. In the case of an Ecoca SJ-20 this can mean the turret will index fine at home (G28 U0 W0) but will hang up any where else. In this case, the hang up is not as simple as the turret not starting the index or a turret alarm being issued, it may cause the turret to overshoot in one direction or the other or both or undershoot in one direction or both or to undershoot on one tool but overshoot another, etc.

Bit 7 of Diagnostic 760-767 does not indicate and alarm when a serial pulse coder is used it should be 1.

Sometimes a machine with a Fanuc control will use data bits in the ladder to function as diagnostic bits or keep relays. These will be denoted with D (i.e. D0009.6). This is a G.DATA bit and works like a keep relay, in that, making its value equal 1 will normally have the effect of enabling something in the ladder, but just as with keep relays this is determined by the instruction which is associated with the data bit. An important point is that the G.DATA values are displayed as decimal numbers and normally you will be changing only one bit as previously mentioned D0009.6 so you will have to convert the bit that needs to be changed to a decimal number and enter it, if the current value of the address (D0009) is 0 or add the new value to the current value if it is something other than 0. For example, if you are trying to enable some function in the ladder (parts catcher, bar feeder, etc.) and the instruction that has the function disabled is D0009.6 and this instruction is an Examine On instruction (this is explained later) then you will need to change the value of D0009.6 from 0 to 1. The first thing you need to know is how to convert the bit information to decimal. When you look at the G.DATA table you will see:

G.DATA

NO. ADDRESS DATA
0000 D0000 16
0001 D0001 0
0002 D0002 64

etc... these are merely examples.

Scroll down to the data address you need to change. A data value of 16 is equivalent to a binary value of 00010000. The bits are assigned decimal values based on their position in the eight bit binary number. The least significant bit (first from the right) is assigned a value of 1, the next bit from the right is assigned a value of 2, the third bit is assigned a value of 4 and so on until the most significant bit (first from the left) is assigned a value of 128.

Decimal 128 64 32 16 8 4 2 1
Binary 0 0 0 0 0 0 0 0

So, using our example of D0009.6, if the current value of D0009 is equal to 0 you would change bit 6 to 1, bit six has been assigned a value of 64 so you would enter 64 as the value for D0009. If, however, the current value of D0009 was something other than 0, let's say, 32 which tells us that D0009.5 equals 1 you would have to add to the two values together to avoid setting bit 5 to 0. So just add the 64 to the 32 and enter a decimal value of 96. The control interprets this and sets bits 5 and 6 to 1. Changing a bit from 1 to 0 is the same, just using subtraction instead of addition.

Most of the Keep Relays used on a control are used by the machine builder but
there are a few which are defined and used by Fanuc, they are K16, K17(K900),
K18(K901) and K19(K902). These are reserved for use by the PMC control soft-
ware and cannot be used for any other purpose.


7 6 5 4 3 2 1 0
K16 MWRTF2 MWRTF1


Servos


If you have an axis problem you can insert a dummy plug into the Servo Amp axis plug to loop back the signals to differentiate between a true axis problem and an amplifier problem.


For excessive axis noise and vibration adjust the Servo Tuning Parameters. The Proportional Gain parameter is the most effective but normally requires a large change in value to produce a noticeable result. Adjusting the Filter Parameter can help sometimes. Adjusting either too far will cause the Excessive Servo Error alarm.

To access the Servo Tuning parameters:
1. SYSTEM
2. DGNOS
3. Right Chapter button.....


If the displayed position does not match the actual movement, check the Servo Parameter Page. In particular check the Feed gear and Ref. Counter values.

If the Feed gear number is set too low, the machine will display a position greater than the actual movement. If the number is too high, the machine will display a position less than the actual movement.

Check terminals of dual servo amplifier are:
0V 0 volts
5V Control Power +5V (+5 +/- 0.25)
IRL R Phase motor current of L axis
ISL S Phase motor current of L axis
IRM R Phase motor current of M axis
ISM S Phase motor current of M axis

When tuning a servo, increase the gains one at a time. Increase until the motor starts to vibrate while at rest then decrease the value by 20%.

When working with an older Servo Amplifier(Velocity Control Unit), there are three adjustments to be aware of. These are potentiometers RV1, RV2 and RV3. In the event of an amplifier which drives more than one motor these will be arranged RV1-RV3 from top to bottom and X to Z from left to right. Adjustment of these is almost always necessary after replacing an amplifier with a new one or even when putting a repaired one back in to service. In this case, also be aware of the jumpers or shorting pins on the drive which may be different as well. It's a good idea to record these settings before sending the unit to Fanuc. RV1 is the Gain adjustment. The most obvious symptom of a need for adjustment of this one is rough or jerky movement of the motor. RV2 adjusts the position deviation amount while the axis is at rest. Ideally, this should be zero and is easily attainable with this adjustment. The exception is for a gravity axis such as the X axis on a turning center. The deviation will normally move between 1 and 2 due to the effects of gravity. The deviation amount can be monitored by diagnostic function. In the case of a zero control on a lathe this is Diagnostic 800 for the X axis and 801 for the Z axis. Once this is adjusted for zero or very close to it, the deviation amount in each direction will be the same value. This adjustment is critical to operation of the machine because if the position deviation amount is too great, the machine will not operate as it should. Programs will not execute in MDI or AUTO. The spindle will not run, etc. The determining factor in this is the value set it Parameter 500 for X, 501 for Z. This parameter is the In Position Width. The control compares the value of this parameter to the value in Diagnostic 800, 801, etc. If the value in the diagnostic exceeds the value set in the parameter bit 3 of Diagnostic 700 is set to 1. Diagnostic 700.3 is the IN-POSITION CHECK (CINP). If this bit is set to 1, automatic operation will not execute. Another thing you will find is that commands whether given in Auto or MDI will not be performed. For example, if you command M3 in MDI mode, press Cycle Start, the Cycle Start lamp will turn on, BUF will be displayed on the CRT showing that the command was read into the memory buffer but will not be acted upon. The same is true for a tool (T) command or speed (S) command. In addition, the spindle will not start. A more or less typical value for the In-Position Width is 20. This is in Detection Units. RV3 adjusts the deviation amount while the axis is in motion. The difference between actual position and commanded position while in motion is known as LAG and is relative to feedrate. As the feedrate increases so too does the lag. Sometimes the lag can become excessive and cause servo problem. To adjust the lag, move the axis while watching Diagnostic 800, 801, etc. Rotate RV3 clockwise to decrease the amount of deviation.

Newer Fanuc motors always come with a pulse coder but there was a time when they could be bought without one. Typically this is true for controls Series 6 and older. The number on the nameplate indicates if a pulse coder is supplied or not. The part of the number that determines this is the last two digits. If the last two are either 05 or 25, no pulse coder is supplied. There may be other numbers which fit this description but motors with these two numbers never have pulse coders. It is hard to determine by physical appearance if a pulse coder is supplied because the motors use the same end cap and cable connector for the tacho-generator so a motor with a tach will look the same from the outside as one with a pulse coder.

If you replace the motor or pulse coder on a Fanuc servo motor you must perform a grid shift for the axis unless you can put the pulse coder back in the same location radially relative to the axis position. This is very hard to do in some cases because of the coupling device not being keyed, etc. This is normally a problem only when the entire motor is replaced. Generally speaking, the pulse coders have a slot across the face of the shaft which matches a slot in the shaft of the motor by way of a driver that goes between them. In this case, as long as the the motor's position is not change between the time that the pulse coder is removed and replaced then there are only two possibilities. Either the axis position will be correct or the pulse coder will be out by 180 degrees which will result in an error of half a revolution of the ball screw. Sometimes the error can go unnoticed if the machine operator goes ahead and re-touches the tools on that axis without checking actual position first and if they are not using all of the travel on the axis.

Servo parameter settings are determined by the Motor I.D. number. This is a two digit number which is defined by parameter. In the case of a 0 control, it is set in parameter 8120 for the X axis, 8220 for Y, 8320 for Z, etc. To determine the correct setting for a motor, look at the table in the Maintenance Manual.

The Motor ID number for the A06B-145-B077 is 10, A06B-146-B077 is 27 and A06B-147-B077 is 20.

The pins of the motor connector for the Alpha series are:

A - U
B - V
C - W
D - Ground

When looking at the connector (motor) face on, the pin to the right of the notch is pin A, below it is pin B, to it's left is pin C, above it is pin D.

The resistance from any of the windings of a Fanuc motor to it's frame should be 100 megohms or higher. A reading of 10 to 100 megohms indicates that the winding has begun to deteriorate but operation should be, for the most part, normal. A reading of 1 to 10 megohms indicates considerable deterioration but the motor will still run although likely abnormally. A reading of less than 1 megohm cannot be tolerated, the motor must be replaced.

An important thing to know about Fanuc servo motors is that unlike a normal AC motor, they use permanent magnets. This gives them exceptional positioning ability and controllability but they do have a down side, in that, the magnets can become demagnetized or the poles may become scrambled. When this happens the motor will exhibit one or more of the following symptoms:

1. Cogging (when the motor is rotated by hand you feel notches similar to the way a DC motor feels).
2. Motor pulls high current even under little or no load.
3. Motor has no torque (in extreme cases it can be stalled by holding the shaft with your hand.
4. Motor rotation feels rough or jerky.

A common cause for this condition is if the motor gets too hot. Also, a servo amplifier can fail in such a way as to cause this problem. In either case, magnets can be re-magnetized by a either Fanuc or a company in Chicago called Endeavour Technologies.

Another thing to know about these motors is that they are like a DC motor in that if one of the windings is shorted internally or if two of the output phases of the amplifier are shorted together the cogging effect will be present. In this case the motor will normally be harder to turn than it is when the poles are demagnetized or are scrambled.

The following pin outs are typically of a Fanuc Alpha I64 pulse coder:

Honda Connector Cannon Plug
(M185, M188, etc.)

1 --------------------------------- N
2 --------------------------------- T
4 --------------------------------- J
5 --------------------------------- K
6 --------------------------------- H
14 ------------------------------- F
15 ------------------------------- G
16 ------------------------------- A
17 ------------------------------- D
20 ------------------------------- H

You will notice that both pin 6 and pin 20 of the Honda connector are connected to pin H of the Cannon (military style) plug. Typically what you will find is that pin H has no connection to the pulse coder. Pin H is used as a tie point for the two wires. This is preferable to connecting a jumper between the two pins at the Honda connector.

The magnets used in Fanuc Alpha series motors are Neodymium Ferrite.

When trying to determine the compatibility of motors:

A06B-XXXX-XXXX

A06B identifies it as an Alpha motor.

The next two numbers identify the range of models.
03 - a1/3000
a2/2000
a2/3000
a65/2000
a100/2000
a150/2000
01 - a3/3000
a6/2000
a6/3000
a12/2000
a12/3000
a22/1500
a22/2000
a22/3000
a30/2000
a30/3000
a40/2000
a40/2000 (with fan)
013 a300/2000
a400/2000

Of these the most common found on YCI, Takumi, etc. is the a22.

The next two numbers define the specific model.
71 - a1/3000
72 - a2/2000
73 - a2/3000
23 - a3/3000
27 - a6/2000
28 - a6/3000
42 - a12/2000
43 - a12/3000
46 - a22/1500
47 - a22/2000
48 - a22/3000
51 - a30/1200
52 - a30/2000
53 - a30/3000
57 - a40/2000
58 - a40/2000 (with fan)
31 - a65/2000
32 - a100/2000
33 - a150/2000
7 - a300/2000
8 - a400/2000

The first number after the B indicates the type of output shaft.
0 - Taper Shaft
1 - Taper Shaft with brake
5 - Straight Shaft
6 - Straight Shaft with brake

The taper shaft is considered the standard configuration.

On models a1 and a2 the brake is 2 Nm.
On models a3 and a6 the brake is 8 Nm.
On models a12, a22, a30 and a40 the brake is 35 Nm.
On models a65, a100 and a150 the brake is 100 Nm.

The next two numbers indicate the type of pulse coder supplied with the motor

75 - Pulse Coder aA64
77 - Pulse Coder aI64
88 - Pulse coder aA1000


If a Fanuc servo amplifier has S1 and S2 (shorting pins), normally S1 will be empty and S2 will be shorted. If S2 is not shorted the result may be that when the axes attempt to move, the position display will count but the servo motors will not move. In the case of a gravity axis, it may oscillate once the brake releases.

If you are working on a motor or encoder problem and you need the machine on with a cable disconnected, you can power the control up with the E-stop engaged to avoid the generation of servo alarms. This is very useful for looking at and changing parameters and diagnostics which cannot be when a servo alarm is active.

When the Alpha drives power up they will flash the software version on the LED display. For example, it will flash a 10 for 9010 or 20 for 9020, etc.

If an axis jumps and jerks for several seconds after the axis command is removed, check the Motor ID parameter. If it gets changed, the axis can behave this way.

Some motor horsepowers:

a22/1500 4 HP
a22/2000 5 HP
a22/3000 5.9 HP

a30/1200 4.4 HP
a30/2000 6.7 HP
a30/3000 7.1 HP

All of Fanuc's motor data can be found in the Servo Descriptions manual, part number B65142E.


On an Alpha series servo amplifier that controls three axes the motor terminal configuration is:

1st axis (X) 2nd axis (Y) 3rd axis (Z)

U V | U V | U V
| |
W G | W G | W G

G = Ground


Fanuc Beta series motors are not as smooth as Alpha series. On a machine that uses Beta series for axis control, you may notice roughness. In most cases, this is normal.

With Beta series drives the parameters are stored in the drive so if you
replace the drive the parameters will go with it.

To save and restore Power Mate CNC Manager parameters to Beta Servo Drives:

This is required when replacing a Beta drive and applies to the following
controls.

16iA,18iA,21iA,16iB,18iB,21iB,20i,16,18,21,0i,Powermate-iD and Powermate-iH.

1. Make NC PRM 960.3 (PMN) = 0 (Enables PMM function).
2. Select where parameters are to be saved (to save to memory card on i series controls make PRM 960.2
(MD2) = 0 and PRM 960.1 (MD1) = 1, to save as a part program make PRM 960.1 = 0).
3. Set parameter 8760 to the program number you want the parameters to be stored as. Note 1.
4. Press the SYSTEM button then the RIGHT CHAPTER button until the Power Motion Manager screen is
displayed.
5. Press the SYSTEM soft key.
6. Press the PARAM soft key.
7. Press the OPRT soft key.
8. Press the RIGHT CHAPTER button. READ and PUNCH soft keys will be displayed.
9. Select EDIT mode.
10.To save parameters from Beta drive to CNC press the READ soft key, press the ALL soft key then the EXEC
soft key.
11.To restore the parameters from the CNC to the Beta drive press the PUNCH soft key, press the ALL soft key
then the EXEC soft key.

Parameter 960.0 (SLV) determines how many slaves are displayed on the screen when the Power Motion Manager is selected.

0 = One slave.
1 = Up to four slaves with the screen divided into four.

Parameters 960.1 (MD1) and 960.2 (MD2) set the slave parameter input/output destination.
MD1 = 0, MD2 = 0, destination is the part program storage.
MD1 = 1, MD2 = 0, destination is the memory card.

Parameter 960.3 (PMN) sets the status of the power motion manager function.
0 = Enabled
1 = Disabled (Communication with slaves is not performed).

Note 1: The program under which the parameters will be stored is derived by multiplying the number of the Beta drive I/O link group by 10 and adding the result to the value in parameter 8760. So if the group number is 2 and the value of parameter 8760 is 9000, then 9000 + (2 x 10) = 9020, the parameters will be stored in program O9020.


On the older servo amplifiers, the TGLS indicator (red LED) is for tacho generator loss of signal. It normally comes on when either the motor or tach is disconnected from the amplifier. Some machines will have a contactor which disconnects the motor from the drive when the NC is off or the machine is in E-Stop, etc which will cause the LED to be on. The motor output on these drives is at terminals 5,6,7 and 8. Terminals 5 and 6 will be tied together at the drive and 7 and 8 will be tied together.

For a machine with Alpha drives if MCC does not energize and there is not an E-Stop condition, check that connector K9 (JX1B) for the SPM or SVM has been attached at the end of the connection chain. There may be a problem with the cable that connects JX1A on the Spindle or Servo Module and JX1B on the Power Supply Module. Also check pins 1 and 3 of CX3. These pins correspond to the normally open contact of the MCC driving relay which energizes MCC.




Axes


Fanuc controls do not have an Axis Release parameter like a Mitsubishi control but an axis can be designated as unused by the control. Fanuc calls this clamping and it is accomplished by placing a jumper between the DRDY and the MCON signal of the axis not being used. The number of the connector will vary depending on which control and/or axis card is used. As an example, to clamp the X axis on a zero control you would short pins 7 and 12 of M34 or M184. When this is done the axis in question still has to have it's parameters to prevent generation of an alarm.


One way to perform grid shift is to:

1. Set the Grid Shift Parameter to 0.
2. Zero return the axis.
3. Measure the distance from where the axis referenced to where the actual physical home is supposed to be.
4. Remove the decimal point and enter this value into the Grid Shift Parameter.

This only works if you know where the home is supposed to be. Some machines will have marks for this purpose, normally two arrows on the axis which line up with one another.


When working with problems regarding G28, axes at home, etc., be aware of the signals ZPX (F94.0) and ZPZ (F94.1) for the X and Z axes in the case of a lathe. These signals turn on when the reference position has been established. These signals are typically used by the builder to turn on the axis home lamps. Also be aware of the signals F120.0 and F120.1.

When working with parameters whose setting unit is specified as detection units it helps to know what a detection unit is. A detection unit is the smallest increment of movement that can be expressed (Least Command Increment). To find out what this unit is, you must observe the position of the machine in metric mode. In most cases you can go to the position page and observe the MACHINE position which is almost always in metric. Otherwise you will have to go to the SETTING page and change the machine to metric mode. The LCI is determined by how many places there are to the right of the decimal point. If there are three places to the right the Least Command Increment is 1/1000th of a millimeter. In this case when you enter a value into a parameter that is specified in detection units, if you enter a value of 1000, you have actually entered a value of one millimeter, etc.

Position Deviation while the axis is at rest is known as OFFSET and when it is excessive, can cause a number of problems.

If a machine will not execute axis motion in controlled feed (G01), try to run in Dry Run mode. In this mode the control does not care about the spindle in executing G01.

Even though an axis may appear to be in position according to the position display, it may not be in position as far as the control is concerned. The control's in-position window is very, very narrow. This window is specified by parameter and can be changed but shouldn't be. If an axis pulls high current while at rest, it may not be in position. To check this, go to the Servo Tuning page. If you can't get any axis to move on a control, check the Machine Lock (MLK) signal. Normally this signal must be high to allow for axis motion. In some cases you may have a switch supplied by the machine builder for Machine Lock.
If a wire is broken at the switch, etc nothing will move but the spindle will run, M functions will execute, etc.


For information concerning Grid Shift refer to GE Fanuc document ST940819 GRIDSHFT.DOC

Fanuc
Page 8

Spindles

The motor leads for the electric fan motor on the spindle motor are FMA and FMB.

When troubleshooting the older analog spindle amplifiers you need the AC ANALOG SERVO UNIT MAINTENANCE MANUAL B-54765E.


When troubleshooting a Spindle problem be aware that some machine tool builders set a Diagnostic bit to cause the spindle to run at a low speed (i.e. 50 RPM) when the door is open.

A symptom of a bad Spindle Encoder is that when given a run command, the motor moves slowly while making a screeching noise. When the Stop command is given the motor moves quickly in the opposite direction briefly.

The Serial Spindle information is stored in the 6000 series parameters.

You can determine if a spindle is a serial spindle by the model number. If the number is A06B-6063 to A06B-6088 it is a serial spindle.

When working with the AC Spindle manual the top parameter number is for the main spindle, the bottom number is for the second (Sub) spindle.
i.e. 0C
6120
3378

If a Spindle motor coasts to a stop rather than braking, check for loose belts or some other reason that would cause the pulley to slip. The reason for this is that the spindle stopping is a one shot deal. When the command is given to stop, the spindle amplifier applies a braking signal to the motor until it senses zero speed. If the belt can slip, the motor will stop and the braking signal will be removed. Once the motor is no longer in a braking condition, it is put in motion again by the momentum of the spindle and is ignored by the spindle amp.

Some machines use a Fanuc Position Coder driven by a belt on the Spindle. Parameter 6501.2 must be a 1 to turn the position coder on. If the position coder is turned off or is faulty, many of the spindle functions will not operate such as Constant Surface Speed, Rigid Tapping, etc. Another symptom of this condition is that the axes will not move when commanded to in G99 mode (Feed per Rev). Also, with most machines using the position coder, its output supplies the signal for the Actual Spindle Speed in the Program Check Screen. In this case the speed usually can still be viewed on the Operating Monitor Screen. This signal is being supplied by the spindle's motor encoder.

The position coder normally connects directly to the spindle Amplifier on JY4.

Most Fanuc AC Spindle motors have a gear on the back of the motor whose teeth are monitored by a proximity detector for position and velocity feedback. Normally, the connector for this connector consists of 6 conductors. They are Red, White, Yellow, Black, Blue, and Green. If this detector fails, the motor will usually respond to a speed command by trying to run slowly, sometimes in the wrong direction, while making a screeching noise. When commanded to stop, it may run very fast in the opposite direction and then either stop or go into an Alarm condition.

The older Digital Spindle Drive has a 5 digit LED display. In Run mode this displays the motor speed (Not spindle speed). In order to view Parameters:

1. Hold all four buttons until FFFFF flashes.
2. Release all buttons.
3. Hold MODE button in while pressing either the Up or Down button.
(The parameter number will be displayed in order i.e. F01,F02,etc.)
4. Release the MODE button.
(The Parameter value will be displayed)

If you have a spindle drive which has lost its Parameters you can try these just to get started:

F0 0
F1 0
F2 0
F3 0
F4 0
F5 0
F6 0
F7 100
F8 5
F9 0
F10 125
F11 147
F12 128
F13 209
F14 196
F15 60
F16 15
F17 3
F18 50
F19 10
F20 40
F21 50
F22 50
F23 100
F24 100
F25 30
F26 30
F27 30
F28 30
F29 128
F30 0
F31 0
F32 10
F33 10
F34 10
F35 100
F36 16
F37 90
F38 0
F39 0
F40 0
F41 64
F42 10
F43 16
F44 10
F45 5
F46 30
F47 8
F48 71
F49 56
F50 73
F51 2
F52 127
F53 11

To initialize the NVRAM:

1. Power down.
2. Move shorting pin (S1) to TEST position.
3. Power on.
4. Hold all four switches until FFFFF is displayed.
5. Hold the MODE button and press the UP button until FC-22 is displayed.
6. Hold the DATA SET button until GOOD is displayed.
7. Power down.
8. Move shorting pin back to normal position.
9. Power on.

This procedure is necessary when the NVRAM has been replaced or when alarm 17 or 23 has occurred. Anytime you have an alarm which will not go away, you can try this. Alarm AL-23 must be cleared this way, it will not go away by cycling power.


PARAMETRIC FUNCTIONS
(The values in parentheses are Standard Settings)

F-00 Display of Spindle RPM

F-01 1 = Use (MRDY) Machine Ready Signal
0 = Do not use MRDY
(1)

F-02 1 = Use Override Function
0 = Do not use Override Function
(1)

F-03 Setting of Override Range
1=120%
0=100%
(1)

F-04 Setting of Speed Command Voltage
1 = Use of D/A Converter
(0) 0 = External Analog Command


F-05 Setting of Maximum RPM
(*) Standard Specification High Speed Specification
0=5000 RPM 0=10000 RPM
1=6000 RPM 1=12000 RPM
2=15000 RPM
3=20000 RPM


F-06 Pattern Setting of Output Limit
(0) 0=No output limiting
1=Output is limited only at acceleration/deceleration.
2=Output is limited only during normal running not at accel/decel.
3=Output is limited at accel/decel and during normal running.

F-07 Setting of limit value at output limit.
(100)

F-08 Setting of delay time before shut off of motor.
(5) Delay Time = (Set Value x 40 milliseconds).


F-09 1 = Motor is shut off by Machine Ready Signal (MRDY).
(0) 0 = Motor is not shut off by MRDY.

F-10 Velocity Deviation Offset Adjustment at Forward Rotation Command
(128)


F-11 Velocity Deviation Offset Adjustment at Reverse Rotation Command. (SRV)
(128)

F-12 Velocity Deviation Offset Adjustment at Orientation Command. (OCR)
(128)

F-13 RPM Adjustment of Forward Rotation.
(*)

F-14 RPM Adjustment of Reverse Rotation.
(*)

F-15 RPM at Command Voltage of 10vdc. RPM= Setting x 100rpm.
(*)

F-16 Detection Range of Speed Arrival Signal (SAR)
(15) Detection Range = Within +/- Setting, in percent of, commanded RPM.

F-17 Detection Level of Velocity Detection Signal.
(3) Detection Level = Less than Setting, in percent, of commanded RPM.

F-18 Torque Limit.
(50) Torque Limit = Less than Setting, in percent, of Maximum Output.

F-19 Acceleration/Deceleration Time.
(10) Time = Setting, in seconds.

F-20 Limiting of Regenerated Power (Adjustment of Deceleration Time).
(60) Setting Range = 0 -100

F-21 Velocity Control Phase Compensation P: High Gear (CTH-1)
(50)

F-22 Velocity Control Phase Compensation P: Low Gear (CTH-0)
(50)

F-23 Velocity Control Phase Compensation P at Orientation: High Gear
(100)

F-24 Velocity Control Phase Compensation P at Orientation: Low Gear
(100)

F-25 Velocity Control Phase Compensation I: High Gear (CTH-1)
(30)

F-26 Velocity Control Phase Compensation I: Low Gear (CTH-0)
(30)

F-27 Velocity Control Phase Compensation I at Orientation: High Gear
(30)

F-28 Velocity Control Phase Compensation I at Orientation: Low Gear
(30)

F-29 Velocity Detection Offset
(128)

F-30 Adjustment of RPM Display
(3990)

F-31 Setting of Rigid Tap Mode
(0)

F-32 Setting of Normal Motor Voltage
(10)

F-33 Setting of Motor Voltage during Orientation
(10)

F-34 Setting of Motor Voltage during Rigid Tapping
(100)

When the Spindle is given an S command it is multiplied by the Override signal (50-120%), the result is sent to the drive as a speed command. It is sent in either Binary or BCD form. If it is sent as Binary, it is received at pins 33-44 of CN1 on the drive. If it is sent as BCD, it is received at pins 33-40. In either case this signal is derived by turning outputs on or off generating ones or zeros. In older controls this was done by a Magnetic Sequencer. On newer controls it is done by the drivers on the I/O board. Typically the driver will turn on and apply 0v to the pin (current sinking). In some cases this driver can fail and the speed override will be ineffective. Also the same driver may be responsible for sending the signal which tells the drive to use the override signal rather than the variable resistor (speed pot). In this case, the speed pot will control the spindle speed regardless of mode selected.(Jog, MDI, etc.)

Older Spindle Amplifiers have three terminals labeled
0M SM LM. These correspond to: 0M - 0 volts
SM - Spindle Speed (0-10 VDC)
LM - Spindle Load (0-10 VDC)

If after the NC power has been turned on, the LED display of the Spindle amplifier does not go to 00 but instead it continues to flash --, check the following:

1. Only one spindle amp is installed but the dip switch setting is such that the NC is looking for two amps. Dip switch 1 should be set to off.

2. The NC parameters are set in such a way that an Alpha series (Serial Spindle) can be used. Check the
parameters related to Serial Spindle (6500).

3. Check the cable connections especially the I/O Link.

Spindle Amplifier DIP Switches:

SPM -2.2 to -11 Types I and II have no jumper plug or DIP switches.

SPM -15 to -30 Types I and II and SPM -11 to -30 Type III have 7 DIP switches. Their functions are as follows:

S1 If two SPMs are connected to one serial interface cable, S1 is set to ON in one SPM and to OFF in the
other. Factory setting is OFF.

S2 If an analog filter is used at the load meter output, S2 is set to ON. If not, it is set to OFF.
Factory setting is ON.

S3 If an analog filter is used at the speed meter output, S3 is set to ON. If not, it is set to OFF. Factory setting is ON.

S4,S5 Reference switch (external reference signal receive function) setting for the main spindle.

S4 ON/S5 OFF Reference switch of NPN type (Pull up)
S4 OFF/S5 ON " " " PNP " (Pull down)
S4 OFF/S5 OFF The external reference signal receive function.

S6,S7 Reference switch (external reference signal receive function) setting for sub-spindle.

S6 ON/S7 OFF Reference switch of NPN type (Pull up)
S6 OFF/S7 ON " " " PNP " (Pull down)
S5 OFF/S7 OFF The external reference signal receive function is not used.

On an AC Spindle Servo Unit alarms are indicated by the use of four LEDs. They are mounted on the top board and labeled 8 4 2 1. They are used in combination to indicate alarms 1 to 15. The alarm numbers correspond closely to those on all spindle amplifiers. A full description of the alarms along with much more information can be found in the manual B53425E. If you have problems with an AC analog servo unit, check the AC Servo Unit Maintenance Manual B-54765E.

If a spindle coasts to a stop check for a blown fuse on the regenerative circuit in the spindle amp.

On machines with older spindle drives, the spindle orientation is done by adjusting pots on an orientation board instead of parameters. In this case, the control will normally not have 6000 series parameters.

Once the Fanuc control orients it remembers the position as long as the power is on so if you adjust the parameter you must cycle power.


Another mistake commonly made when troubleshooting spindle amplifier problems is to be sure that the amplifier is receiving a run command and speed command. You can always check diagnostic signals to determine if the spindle is being commanded to run but if you look carefully there are other clues available. For example, on most machines anytime the spindle is commanded to run something will change such as a light being turned on a CW or CCW button. Generally speaking, if there is something wrong with a Fanuc module, it will give some sort of alarm. Also, if a run command is received at the amplifier, the amplifier will give some indication of it. All of this is so important because a lot of machines give absolutely no indication of a problem with an ATC or pallet changer for example. Normally when there is a problem with the ATC or pallet changer, etc the amplifiers will be in a ready state but will seem to ignore a spindle command. Another thing that makes it so tough is that even though these kinds of problems will not let the spindle run, most other functions are normal such as axis movement, etc. The one thing that may be inhibited sometimes along with the spindle is Z axis movement, especially in the case of an ATC problem.

If a spindle motor exhibits noise or roughness at a certain RPM, you can try to determine if the cause is electronic or mechanical by removing the feedback cable while the spindle is running. This will cause it to coast to a stop. Just be sure not to plug the cable back in while under power.

On an Analog Spindle Drive you can check the command signal input at test points CH2 and 0V. This is a 0-10 VDC signal. You can check the spindle motor feedback at CH3 and CH4.

For problems with orientation, first check to see if the machine uses an orientation board. If it does there is a procedure for adjustment. The usefulness of the procedure is based, in large part, on what type of orientation device the machine employs, proximity switch, magsensor, separate pulse coder, etc. For problems that concern the final position of the spindle after orientation there are three rotary selector switches on the orientation board for altering this position. They are 16 position switches designated SW1, SW2 and SW3. They can be used in combination to shift the final position of the spindle to any point radially in one revolution within .088 degrees. The following description of the adjustment assumes an orientation device whose output is 4096 pulses per revolution and a pulley ratio between the spindle motor, orientation device and spindle drive pulley of 1:1. SW1 will effectively divide the 4096 pulses by 16 so that each division of movement of this switch will cause the position to shift by 256 pulses or 22.5 degrees. SW2 will divide the 256 pulses by 16 so that each division of movement will shift the position by 16 pulses or 1.4 degrees. SW3 will divide the 16 pulses by 16 so that each division of movement will shift the position by 1 pulse of .088 degrees. As far as the direction of adjustment, generally, if the rotary switch is turned in the clockwise position the spindle will stop later in it's travel, and so a counterclockwise adjustment will cause the spindle to stop sooner in its rotation.

The LED's on the orientation board:

No. Symbol Color Description
LED 1 ORIENTATION Green Lights when orientation command (ORCM1, 2 on) is input.

LED 2 LOW Green Lights when clutch switching signal *CTH contact is closed. It means that clutch LOW is selected.

LED 3 IN-POSITION Green Lights when orientation end signal ORAR1-2 is sent.
ADJUST

LED 4 IN-POSITION Green Lights when spindle enters within one pulse width of orientation
command position. Adjust OFFSET adjustment RV3/RV5 so that
LED 4 lights at gear HIGH/LOW and the stop positions at GEAR
HIGH and LOW coincide with one another.


The following adjustment procedure is for addressing problems such as hunting and roughness, etc. during spindle orientation. You can adjust only those items which appear to need adjusting but for best result you should do all seven steps.

1. Speed feedback voltage OFFSET (RV1)
Check at TSA2 and CH14 (TSA2)
Adjust RV1 until TSA2 voltage becomes 0vdc +/- 1mvdc.

2. Gear HIGH position gain (RV2)
Check with spindle motion or at CH14. Set the gain to the maximum within a range where the spindle does
not overshoot.

3. Gear HIGH offset (RV3)
Check at LED4 (ADJUST)
Adjust RV3 until LED 4 lights or flickers.

4. Gear LOW position gain (RV4)
Check with spindle motion or CH14
Set the gain to the maximum within a range where the spindle does not overshoot.

5. Gear LOW offset (RV5)
Check at LED 4 (ADJUST)
Adjust RV5 until LED 4 lights or flickers.

6. Speed loop gain (RV6DC) (In case of DC spindle motor)
Check at CH14
Make sure that the motor is not hunting. Rigidity increases during stopping when the pot is turned clockwise.

7. Speed loop gain (RV6AC) (In case of AC spindle motor).
Same as above.


If a spindle stalls during a cut on a machine with a high/low geared head, check the gear confirmation switches. A loose wire etc. can cause the signal to be lost and the spindle to drop out due to vibration, etc.

There are three Gain pots on the spindle orientation board A20B-0008-0030/04C, RV6, RV9 and RV12. RV6 sets the gain for High Gear, RV9 sets the gain for Low Gear. RV12 sets the overall gain. To achieve the maximum gain, turn RV12 clockwise during orientation position stop until the spindle motor starts to oscillate, then turn it counter-clockwise until the oscillation just stops.

Gain is also related to the setting of jumper SH04. The highest gain, as well as the highest orientation rpm, is achieved when the jumper is removed from the board. The next highest gain and rpm occurs when pins 1 and 2 are jumpered. The lowest gain/rpm setting is between pins 2 and 3.

The MS PEAK (RV2) pot can be used as an electronic method of adjusting the gap between the magnet and the magsensor.

When the sensor fails it is possible that the spindle will continuously rotate when spindle orientation (M19) is commanded. Nothing will stop the spindle rotation such as Reset, etc. Emergency stop will stop the spindle. In some cases you can command a spindle movement (i.e., M3 S500) while the orientation is in progress, the spindle will assume the commanded speed and can then be stopped by using the reset button. If the sensor fails, it is common to see that when the spindle is rotating continuously the MS PEAK LED and the IN POSITION FINE LED will illuminate each time the magnet passes but the IN POSITION and SLOW DOWN LEDs will not.

When working with the Spindle Servo Unit A20B-6044-H021, you may find as many as nine different PCBs used with this one amplifier. They are A20B-0009-0530, A20B-0009-0531........A20B-0009-0538. These boards are all identical, the only difference is in how the jumpers are set from the factory for different drives.

If you replace the spindle main PCB, you have to check the jumper settings. You also have to swap the ROM chip which contains the system software for the drive. This chip will be labeled MD25 ROM on the board.

Also, when working with one of these spindle drives, if when the spindle is oriented it has no torque the problem could be with the gain pot (RV12), SH04 or with the orientation board itself. In some cases the problem could be with the Gain H pot (RV6) or the Gain L pot (RV9). This is a little more complicated since some machines always orient in the same gear, typically low gear, so only RV9 would be effective. With other machines, they orient in whichever gear was last in use so you have to see if the spindle orients fine in one gear but not the other and adjust the corresponding pot. Having said all of this, a problem in which the motor has little or no torque during orientation but is ok otherwise is almost always a defective spindle PCB (A20B-0009-....)
In this case, you will normally be able to turn the spindle by hand while it is in orientation stop. In many cases when the spindle is oriented alarm AL02 will be generated. Another thing you may find in this situation is that if when the spindle is oriented, you apply consistency pressure to the spindle by trying to lightly turn it you may feel the spindle resist turning then release then resist over and over. This is due to the Orientation Time Over function which causes the orientation to be released if orientation stop position is not reached and maintained in a set period of time.

When an orientation board gets out of adjustment it can take some patience to get it back but it should not be extremely difficult. Normally when an orientation board fights you too much there is something wrong. If during the course of troubleshooting you replace the sensor, make sure to position it properly relative to the magnet. If you mount it upside down you may notice many of the symptoms above but by adjusting the orientation board you can get to a condition where the spindle almost orients but it wants to inch around. If you increase the gain enough the spindle will start rotating continuously but it's motion will be jerky. You will also notice that only the MS PEAK and the IN-POSITION FINE LEDs come on while the spindle is rotating, the IN-POSITION LED (RV6) never comes on.

When troubleshooting, you don't normally have to concern yourself with LED4 SLOWDOWN. If the spindle is not moving when M19 is commanded, slowdown is not used so the LED will not come on. If, however, the spindle is running at a speed higher than the orientation speed when M19 is commanded you should see the slowdown LED come on.

LED1 (ORIENTATION) should come on when orientation is commanded and stay on.

When the spindle has been in orientation position for a set period of time, LED6 IN-POSITION will come on and stay on, this indicates that the spindle is within one degree of orientation position. If the spindle is within .1 degree of orientation position, LED5 IN-POSITION FINE will come on. It is not necessary for LED5 to come on for the orientation completion signal to be transmitted but LED6 must be on.

LED7 TEST MODE is a red LED. This LED is on when jumper SH01 is engaged. This places the board in test mode for adjustment purposes. When this jumper is installed, pressing SW1 on the orientation board will cause the spindle to orient. It will orient again every time it is pressed. This feature is not always enabled by the MTB, most notably Mori-Seiki.

If spindle orientation position is not achieved in the set amount of time, the Orientation Time Over function will cause the spindle to release from orientation.

RV5 and RV8 adjust the slowdown time in high and low gear respectively.

RV11 POSITION SHIFT adjusts the final position during orientation stop but it can only change this position by one degree since the position itself is defined by the center of the magnet.

When adjusting the gap between the sensor and the magnet they do not have to be very close to each other. There can be as much as an inch of clearance and the magsensor will work properly. With most machines, if you move the sensor back as far as possible using all of the adjustment provided by the MTB you will still be close enough to the magnet. Just don't get too close, keep in mind that as the spindle turns, the ends of the magnet can hit the sensor if they are too close.

When a PCB is sent to Fanuc and they determine that the board is un-repairable they will put epoxy over the first eight numbers of the part number and will write NR on the board. This is to prevent the board from being sent in for repair or as a core exchange and wasting time with an un-repairable board.

Orientation board jumpers:

SH01 Places the board in Test Mode.

SH02 If pins 1 and 2 are shorted, the spindle motor rotates clockwise (as viewed from the motor shaft end)
when orientation is commanded after turning on NC power and before the spindle is otherwise
commanded.

If pins 2 and 3 are shorted, the spindle motor rotates counter-clock wise respective of the above conditions.

The above is true only when pins 1 and 2 of SH03 are shorted. Any other setting condition of SH03 overrides the setting of SH02.

SH03 If pins 1 and 2 are shorted, the spindle motor orients in the direction it was rotating just prior to the spindle orientation command is given. This setting essentially makes the setting of SH02 effective. If pins 2 and 3 are shorted, the spindle motor always rotates in the counter clockwise direction (as viewed from the motor shaft end). If neither of the pins are shorted, the spindle motor always rotates in the clockwise direction for orientation

SH04 If neither of the pins are shorted, the spindle orientation occurs at a set gain/speed (typically 300 rpm). If pins 1 and 2 are shorted, the initial orientation speed is limited to 1/3. If pins 2 and 3 are shorted, the initial orientation speed is limited to 2/3.

SH05 Pins 1 and 2 are shorted for a DC Spindle Servo Unit.
Pins 2 and 3 are shorted for an AC Spindle Servo Unit.


The older spindle amplifiers have a large board that is hinged and can be swung out by removing the two screws. Make sure the power is off since the screws are very short and will fall into the amp. Behind the board in the upper left hand corner are two five amp glass fuses. These two fuses are for the fan on the amplifier and the spindle motor (terminals FMA and FMB). If one of them blows the amp will not power up (PIL lamp will be off). This green LED should always be on when the three phase power is applied. Normally in this case no spindle alarms will be issued by the CNC unless a spindle command is given. On many machines there may be a spindle error lamp that will come on as a function of the ladder. In most of these cases the alarm is generated by a fault contact output from the amp which is tied to the I/O
board as an input (X address).


Normally, if a magsensor is used with a Fanuc control it will be made by Macome. The part number will typically be BKO-C1730H02 for the Sensor and BKO-C1730H01 for the Pre-amplifier which is mounted near the sensor and connected by a cable. The output of the pre-amp goes to JY3 of the Spindle Amp.

On a 0 controlled machine with a geared spindle, if the speed displayed does not agree with the actual values you alter with parameter 540 for low gear and 541 for high gear. Program a spindle speed of 1000 RPM for each gear range and adjust the parameter until the display reads 1000 RPM.

Some machines if a spindle speed is commanded in MDI then while running the Mode is switched to Jog, MPG, etc., the speed commanded will be dropped and the spindle will assume the speed selected by the speed pot.

Some Fanuc spindle motors have a dual winding for low and high speed. In this case two contactors must be supplied by the machine builder to do the switching between windings, however the spindle amplifier determines which one is energized a any given moment. If a problem occurs in the switching circuit of the amplifier, alarm AL-15 may be generated. On an amplifier which does not have this switching circuit, AL-15 normally means the spindle amp is just defective.

In addition to the above, the Fanuc control can also use the switching function to control two spindle motors with one spindle amplifier.

Pins 1, 2 and 20 of JY1 on the spindle amplifier are for the input of the manual speed reference (analog).



Power Supplies

If a Fanuc Control's power source is a GFI circuit, it should be one designed for use with inverters. The reason for this is that the Servo Amplifier and the Spindle Amplifier use an IGBT Pulse Width Modulation Control method. High frequency current leaks to ground through the stray capacitance in the motor windings, power lines, and amplifier chassis. A GFI designed for use on inverters is protected against such malfunctions. The same situation occurs on power circuits supplied with a leakage protection relay. The protective (earth) ground should be connected to the terminal marked PE.

The minimum capacity for the power for supplying a Fanuc Control is:

Power Supply Model -5.5 -11 -15 -26 -30
9KVA 17KVA 22KVA 37KVA 44KVA


On the Power Supply Module if the LED indication is (-) the PSM is waiting for the *MCON signal.


When working on the PSM, if the PIL (Power On Indicator) is on and the ALM (Alarm Indicator) is off but (--) is displayed, MCC is off. If the PIL is on, the ALM is off and 00 is displayed, the Power Supply is ready. When the PIL is off, check the voltage and connection of CX1A. Check FU1 and FU2 of the control PCB. If FU2 is blown, make sure that the control power is connected to CX1A and not mistakenly connected to CX1B. If this connection is correct and FU2 continues to blow, the control PCB is probably defective. Make sure that the 24vdc circuit is not shorted. The PIL indicator is, of course, a 5 volt LED so check the 5vdc supply.


A good indicator of a bad Power Supply Module is that when the incoming AC power is removed the capacitor charged LED goes off instantly instead of bleeding down slowly.


The same number displayed on the LED display of a servo amplifier versus a power supply module can and usually does mean different things. For example, a 9 on the power supply module indicates an overheated heat sink while a 9 on a servo amplifier indicates excessive current in the output circuit.

Older Fanuc controls had a Power Supply (rack) and a separate Input Unit. Newer controls have a Power Unit which is a Power Supply with a built in Input Unit.

No DC Link voltage is generated when the machine is in E-Stop mode

Phase converters are not recommended for Fanuc controls because the power output is usually not suitable. For Fanuc controls the phase to phase voltages must be within 7 percent of each other and the phase angle must be within 12 degrees of 120 degrees.

The main three phase power to a Fanuc power supply is switched on through MCC. The 200 volts for the control functions should be supplied at all times. The control needs this power to turn on and allow MCC to energize.

When working with a Fanuc Power Unit (NC power supply), it is important to remember that the NC power ON/OFF buttons are not like most on/off switches. The power OFF switch is a normally closed switch but it does not feed the ON switch. Both switches are fed from a common point of the power supply but the output of each switch connects to a different point on the power supply. This is why sometimes a Fanuc control can be turned on by the power ON switch but cannot be turned off by the power OFF switch. In these cases the Power Unit is almost always at fault. In the case of the 18 control the connector in question is CP4. Pin A3 of CP4 is the common, pin A2 is POWER OFF and pin A1 is POWER ON.

The information above applies also to the 0 control with the exception that instead of connector CP4 pins A3, A2 and A1 it is CP3 pins 3, 2 and 1.




Programming

Generally speaking Canned Cycle for Bolt Hole Pattern is not provided on Fanuc controls. If one is desired, you can make one if you have Custom Macro B.

G65 can be used to call a 9000 program which contains the needed program for the cycle. The format, using 9100 as an example, is:

G65 P9100
Notice the O can be omitted in the program name. This is known as a Simple Call and is much like calling a subprogram with M98. You can specify an argument and number of repetitions.

You can also create a new G Code by using what is called Macro Call using G Code. There is a group of Parameters and program numbers associated with this type. They are:

Program number Parameter
O9010 6050
O9011 6061
O9012 6052
O9013 6053
O9014 6054
O9015 6055
O9016 6056
O9017 6057
O9018 6058
O9019 6059

These are pairs and are always associated with one another. When a G Code number is specified in one of the parameters, it's associated program is called when the G Code is executed. For example:

If the value of Parameter 6050 equals 100, when G100 is executed in a program number O9010 will be called. As with the Simple Call above, a number of repetitions from 1 to 9999 as well as an argument specified. Two types of argument are available, either Argument Specification I or II. The type specified is automatically determined by the addresses used. In the case of an 18 control, more can be found about this procedure in section 16 of the Series 16-18 Operators' Manual.

A Macro can also be called with an M Code. It works the same as above using the following program numbers and parameters.

O9020 6080
O9021 6081
O9022 6082
O9023 6083
O9024 6084
O9025 6085
O9026 6086
O9027 6087
O9028 6088
O9029 6089


To execute Constant Surface Control:
G96 P1 S______;

P1=X axis P2=Y axis P3=Z axis S=Spindle RPM

If P is omitted the NC assumes P0. P0 is the axis assigned in Parameter 41.4 and 41.5. If the S command is omitted, spindle RPM = the last G96 command.

To cancel Constant Surface:
G97 S______;

The S command here becomes the new spindle speed.

S commands specified with G96 command are assumed to be zero until either M03 or M04 is seen in the program.

When executing G96, the Work Coordinate System must be set so that the center of the rotating axis is zero.

G92 S_____; clamps the speed during G96 to avoid exceeding maximum spindle speed.

For problems with Work Shift and Absolute position, keep in mind G50.


To test for Helical Interpolation operation:

G02 I2. Z-10. F50.;
M30;

This should cause the Z axis to move to 10 inches from it's current position as X and Y interpolate a 4 inch circle. If the axes are truly interpolating, the Z axis will reach it's position at the same instant that X and Y reach the end point. To reverse the process:

G03 I2. Z10. F50.;
M30:

Remember that G02 and G03 are always specified as incremental commands.

G99 can only be made effective from Auto mode, not MDI.

When using G50 to clamp the spindle speed, specify it in a block after the initial M3 or M4. For example:

M3 S500;
G50 S2000;


To DNC with a Fanuc control, as with other controls, you must have a full wire cable. The cable normally used to load parameters, etc will not work. The pins that are shorted with this configuration are used for flow control.

The buffer of a zero control will only hold a block or two of data at one time. When doing DNC, the control will take in ten characters then have the PC stop sending while these are processed then will request more.

Most machine tool builders number their programs in the 9000 series. These programs come with the machine and are not meant to be edited or downloaded. Some builders will disable manipulation of these programs with parameter 10 bit 4 and you can change this bit in order to access these programs. Other builders will write their software to prevent you from accessing the program no matter what you do. As far as Fanuc controls in general, if you can't display a programs contents on the CRT you cannot transmit it or alter it.

The procedure for loading a program from a PC is:

1. Switch to EDIT mode.
2. Press the PRGRM key.
3. Select the I/O soft key.
4. Select the READ soft key.
( LSK should begin flashing in the lower right hand corner)
5. Begin transmission from the PC.

Programs cannot be sent or received while an alarm condition exists.

Programs cannot be received by the control unless the Key is set to a one. This can be checked at Diagnostic 122 Bit 3.


Some G Codes are always active at power up and cannot be changed. For example G98 or G99. G98 is Feed Per Minute. G99 is Feed Per Revolution. If you are working with a lathe it will almost always come up in G99. If you want to run in Feed Per Minute you have to program G98.

G20 and G21 can be selected for power up by parameter. With G20/G21 the mode you power down in is the mode the control powers up in. To change back and forth manually, command it in MDI.

If a control will not execute G01 on a lathe, make sure it is not in G99. If G99 is active when a G01 is commanded, the spindle must be running or the machine must be in DRY RUN. G99 is Feed/Rev. G98 is Feed/Min. To test this you can command G01 then turn the spindle by hand. Also you can look at the right hand side of the CRT while in MDI/PGM mode and see if G99 is active. Most lathes power up in G99.

When programming in G99 mode, the Feed rate you enter is distance for the axis to move per revolution of the spindle so it should be a very small number such as F.001.

G43 specifies the tool offset in the positive direction.
G44 specifies the tool offset in the negative direction.
If G43 is commanded, the tool offset called must be a negative number or the machine will over travel in the positive direction.

G54 calls up the first Coordinate system which is usually the X,Y, and Z reference points (Machine Home). You can put different values in G55, G56, etc. When one of these are called, these values will set the new coordinate system.

When you program a Fanuc controlled machine to Rigid Tap you must give preparatory commands such as G98 (FEED PER REVOLUTION). This is unnecessary on a Mitsubishi control. Below is a program that will work on a Mitsubishi control.

G54;
M29 S400;
G84 G98 X0 Y0 Z-.75 R.1 F.083 ,R1;
G80;
M30;

You can also try this format:

G95;
M03 S400;
M29 S400;
G84 Z-1. R.1 F.083;
G94;
G80;

Be sure to return the machine to FEED PER INCH.

To search for a point in a program, switch to edit mode, enter the sequence number or T Code etc. that you want to go to and press the cursor down key. You can do the same thing in Auto mode but you can only search for a sequence number. If program restart is enabled you can restart the program after either search by being in Auto mode and pressing Cycle Start.

When trying to program in CAP if you have trouble with alarms like EXCEEDED NUMBER OF PROCESSES or PROCESS NOT FOUND it may be a memory amount or memory allocation problem. Try freeing up some memory to solve problem.

A Macro can also be called with an M Code. It works the same as above using the following program numbers and parameters.

O9020 6080
O9021 6081
O9022 6082
O9023 6083
O9024 6084
O9025 6085
O9026 6086
O9027 6087
O9028 6088
O9029 6089


G05 P01 turns on High Speed Machining, G05 P00 turns it off. While in G05, all commands are considered to be incremental.