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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.
Fanuc End
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