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0 SERIES CONTROLLER
Note: The memory back-up consists of three alkaline R20 "D" cells.
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.
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.
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TAPEF specifies the type of tape format. 1 = F10/F11 format after conversion. 0 = FSO standard format without
The information on this and subsequent pages is intended to supplement and reinforce the knowledge of competent
conversion.
machinists and technicians. The authors of this website are in no way lialble for damage or injury resulting from the
improper use of the instructions contained herein.
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.
Changing parameters:
1. Go to MDI mode
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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.
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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:
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.
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)
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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:
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
The procedure for reloading a "Brain Dead" 0 Control when you have a copy of the Parameters on Disk or PC is:
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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.
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.
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 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.
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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.
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
C AXIS
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X AXIS
Z AXIS
C AXIS
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 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.
POWER SUPPLY
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ADDITIONAL I/O B1
F51 1.6A A60L-0001-0046#1.6 Protection from external defect on machine side 24vdc line.
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.
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.
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
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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.
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
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
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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
or
or
or
or
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.
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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.
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).
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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.
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