FANUC Series 16i/160i/160is-MODEL B, Series 18i/180i/180is-MODEL B, Series 21i/210i/210is-MODEL B. MAINTENANCE MANAUL

SAFETY PRECAUTIONS

This section describes the safety precautions related to the use of CNC units. It is essential that these precautions

be observed by users to ensure the safe operation of machines equipped with a CNC unit (all descriptions in this

section assume this configuration).

CNC maintenance involves various dangers. CNC maintenance must be undertaken only by a qualified

technician.

Users must also observe the safety precautions related to the machine, as described in the relevant manual supplied

by the machine tool builder.

Before checking the operation of the machine, take time to become familiar with the manuals provided by the

machine tool builder and FANUC.

Contents

1. DEFINITION OF WARNING, CAUTION, AND NOTE .

s-2

2. WARNINGS RELATED TO CHECK OPERATION .

s-3

3. WARNINGS RELATED TO REPLACEMENT .

s-5

4. WARNINGS RELATED TO PARAMETERS .

s-6

5. WARNINGS AND NOTES RELATED TO DAILY MAINTENANCE .

s-7

s-1

SAFETY PRECAUTIONS

B-63525EN/02

DEFINITION OF WARNING, CAUTION, AND NOTE

This manual includes safety precautions for protecting the maintenance personnel (herein referred

to as the user) and preventing damage to the machine. Precautions are classified into Warnings and

Cautions according to their bearing on safety. Also, supplementary information is described as a

Note. Read the Warning, Caution, and Note thoroughly before attempting to use the machine.

WARNING

Applied when there is a danger of the user being injured or when there is a danger of both the user

being injured and the equipment being damaged if the approved procedure is not observed.

CAUTION

Applied when there is a danger of the equipment being damaged, if the approved procedure is not

observed.

NOTE

The Note is used to indicate supplementary information other than Warning and Caution.

` Read this manual carefully, and store it in a safe place.

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B-63525EN/02

SAFETY PRECAUTIONS

WARNINGS RELATED TO CHECK OPERATION

WARNING

When checking the operation of the machine with the cover removed

(1) The user’s clothing could become caught in the spindle or other components, thus

presenting a danger of injury. When checking the operation, stand away from the machine

to ensure that your clothing does not become tangled in the spindle or other components.

(2) When checking the operation, perform idle operation without workpiece. When a

workpiece is mounted in the machine, a malfunction could cause the workpiece to be

dropped or destroy the tool tip, possibly scattering fragments throughout the area. This

presents a serious danger of injury. Therefore, stand in a safe location when checking the

operation.

When checking the machine operation with the power magnetics cabinet door opened

(1) The power magnetics cabinet has a high-voltage section (carrying a

mark). Never

touch the high-voltage section. The high-voltage section presents a severe risk of electric

shock. Before starting any check of the operation, confirm that the cover is mounted on

the high-voltage section. When the high-voltage section itself must be checked, note that

touching a terminal presents a severe danger of electric shock.

(2) Within the power magnetics cabinet, internal units present potentially injurious corners and

projections. Be careful when working inside the power magnetics cabinet.

Never attempt to machine a workpiece without first checking the operation of the machine.

Before starting a production run, ensure that the machine is operating correctly by performing

a trial run using, for example, the single block, feedrate override, or machine lock function or

by operating the machine with neither a tool nor workpiece mounted. Failure to confirm the

correct operation of the machine may result in the machine behaving unexpectedly, possibly

causing damage to the workpiece and/or machine itself, or injury to the user.

Before operating the machine, thoroughly check the entered data.

Operating the machine with incorrectly specified data may result in the machine behaving

unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the

user.

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SAFETY PRECAUTIONS

B-63525EN/02

WARNING

5. Ensure that the specified feedrate is appropriate for the intended operation. Generally, for each

machine, there is a maximum allowable feedrate. The appropriate feedrate varies with the

intended operation. Refer to the manual provided with the machine to determine the maximum

allowable feedrate. If a machine is run at other than the correct speed, it may behave

unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the

user.

6. When using a tool compensation function, thoroughly check the direction and amount of

compensation.

Operating the machine with incorrectly specified data may result in the machine behaving

unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the

user.

s-4

B-63525EN/02

SAFETY PRECAUTIONS

WARNINGS RELATED TO REPLACEMENT

WARNING

1. Always turn off the power to the CNC and the main power to the power magnetics cabinet. If

only the power to the CNC is turned off, power may continue to be supplied to the serve section.

In such a case, replacing a unit may damage the unit, while also presenting a danger of electric

shock.

2. When a heavy unit is to be replaced, the task must be undertaken by two persons or more. If

the replacement is attempted by only one person, the replacement unit could slip and fall,

possibly causing injury.

3. After the power is turned off, the servo amplifier and spindle amplifier may retain voltages for

a while, such that there is a danger of electric shock even while the amplifier is turned off. Allow

at least twenty minutes after turning off the power for these residual voltages to dissipate.

4. When replacing a unit, ensure that the new unit has the same parameter and other settings as the

old unit. (For details, refer to the manual provided with the machine.) Otherwise, unpredictable

machine movement could damage the workpiece or the machine itself, and present a danger of

injury.

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SAFETY PRECAUTIONS

B-63525EN/02

WARNINGS RELATED TO PARAMETERS

WARNING

1. When machining a workpiece for the first time after modifying a parameter, close the machine

cover. Never use the automatic operation function immediately after such a modification.

Instead, confirm normal machine operation by using functions such as the single block function,

feedrate override function, and machine lock function, or by operating the machine without

mounting a tool and workpiece. If the machine is used before confirming that it operates

normally, the machine may move unpredictably, possibly damaging the machine or workpiece,

and presenting a risk of injury.

2. The CNC and PMC parameters are set to their optimal values, so that those parameters usually

need not be modified. When a parameter must be modified for some reason, ensure that you

fully understand the function of that parameter before attempting to modify it. If a parameter

is set incorrectly, the machine may move unpredictably, possibly damaging the machine or

workpiece, and presenting a risk of injury.

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SAFETY PRECAUTIONS

WARNINGS AND NOTES RELATED TO DAILY

MAINTENANCE

WARNING

1. Memory backup battery replacement

When replacing the memory backup batteries, keep the power to the machine (CNC) turned on,

and apply an emergency stop to the machine. Because this work is performed with the power

on and the cabinet open, only those personnel who have received approved safety and

maintenance training may perform this work.

When replacing the batteries, be careful not to touch the high-voltage circuits (marked

and

fitted with an insulating cover).

Touching the uncovered high-voltage circuits presents an extremely dangerous electric shock

hazard.

NOTE

The CNC uses batteries to preserve the contents of its memory, because it must retain data such as

programs, offsets, and parameters even while external power is not applied.

If the battery voltage drops, a low battery voltage alarm is displayed on the machine operator’s panel

or CRT screen.

When a low battery voltage alarm is displayed, replace the batteries within a week. Otherwise, the

contents of the CNC’s memory will be lost.

To replace the battery, see the procedure described in Section 2.10 of this manual.

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SAFETY PRECAUTIONS

B-63525EN/02

WARNING

2. Absolute pulse coder battery replacement

When replacing the memory backup batteries, keep the power to the machine (CNC) turned on,

and apply an emergency stop to the machine. Because this work is performed with the power

on and the cabinet open, only those personnel who have received approved safety and

maintenance training may perform this work.

When replacing the batteries, be careful not to touch the high-voltage circuits (marked

and

fitted with an insulating cover).

Touching the uncovered high-voltage circuits presents an extremely dangerous electric shock

hazard.

NOTE

The absolute pulse coder uses batteries to preserve its absolute position.

If the battery voltage drops, a low battery voltage alarm is displayed on the machine operator’s panel

or CRT screen.

When a low battery voltage alarm is displayed, replace the batteries within a week. Otherwise, the

absolute position data held by the pulse coder will be lost.

To replace the battery, see the procedure described in Section 2.10 of this manual.

s-8

B-63525EN/02

SAFETY PRECAUTIONS

WARNING

3. Fuse replacement

Before replacing a blown fuse, however, it is necessary to locate and remove the cause of the

blown fuse.

For this reason, only those personnel who have received approved safety and maintenance

training may perform this work.

When replacing a fuse with the cabinet open, be careful not to touch the high-voltage circuits

(marked

and fitted with an insulating cover).

Touching an uncovered high-voltage circuit presents an extremely dangerous electric shock

hazard.

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B-63525EN/02

PREFACE

Description of

1.Display and operation

this manual

This chapter covers those items, displayed on the screen, that are related

to maintenance. A list of all supported operations is also provided at the

end of this chapter.

2.LCD-mounted type i series hardware

3.LCD-mounted type is series hardware

4.Stand-alone type i series hardware

5.Matters common to both LCD-mounted type and Stand-alone type

i series hardware

Chapters 2 to 5 describes the configuration of the hardware, lists the

hardware units, and explains how to replace printed-circuit boards.

6.Data input/output

This chapter describes the input/output of data, including programs,

parameters, and tool compensation data, aswell as the input/output

procedures for conversational data.

7.Interface between the CNC and PMC

This chapter describes the PMC specifications, the system configuration,

and the signals used by the PMC.

8.Embedded ethernet

This chapter describes the embedded ethernet.

9.Digital servo

This chapter describes the servo tuning screen and how to adjust the

reference position return position.

10.AC spindles

These chapters describe the spindle amplifier checkpoints, as well as the

spindle tuning screen.

11. Trouble shooting

This chapter describes the procedures to be followed in the event of

certain problems occurring, for example, if the power cannot be turned on

or if manual operation cannot be performed. Countermeasures to be

applied in the event of alarms being output are also described.

p-1

PREFACE

B-63525EN/02

Appendix

A. Alarm list

B. List of maintenance parts

C. Boot system

D. Memory card slot

E. LED display and maintenance of stand-alone type unit

F. Maintenance of open CNC (boot-up and IPL)

G. FSSB start-up procedure/materials

H. Notation of MDI keys

This manual does not provide a parameter list. If necessary, refer to the

separate PARAMETER MANUAL.

This manual can be used with the following models. The abbreviated

names may be used.

Applicable models

Model name

Abbreviation

FANUC Series 16i-TB

16i-TB

T series or

FANUC Series 160i-TB

160i-TB

T series (2-path control) *1

T series (3-path control) *2

FANUC Series 160is-TB

160is-TB

FANUC Series 16i-MB

16i-MB

M series or

FANUC Series 160i-MB

160i-MB

M series (2–path control) *1

FANUC Series 160is-MB

160is-MB

FANUC Series 18i-TB

18i-TB

T series or

FANUC Series 180i-TB

180i-TB

T series (2–path control) *1

FANUC Series 180is-TB

180is-TB

FANUC Series 18i-MB5

18i-MB5

FANUC Series 180i-MB5

180i-MB5

M series

FANUC Series 180is-MB5

180is-MB5

FANUC Series 18i-MB

18i-MB

FANUC Series 180i-MB

180i-MB

M series

FANUC Series 180is-MB

180is-MB

FANUC Series 21i-TB

21i-TB

FANUC Series 210i-TB

210i-TB

T series

FANUC Series 210is-TB

210is-TB

FANUC Series 21i-MB

21i-MB

FANUC Series 210i-MB

210i-MB

M series

FANUC Series 210is-MB

210is-MB

*1) With two-path control function

*2) With three-path control function (three-path with 2 CPUs)

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B-63525EN/02

PREFACE

NOTE

Some function described in this manual may not be applied

to some products.

For details, refer to the DESCRIPTIONS manual

(B-63522EN)

Related manuals of

The following table lists the manuals related to Series 16i, Series 18i,

Series 16i/18i/21i/160i/

Series 21i, Series 160i, Series 180i, Series 210i, Series 160is, Series

180is, Series

210is-MODEL B. This manual is indicated by

180i/210i/160is/180is/

asterisk(*).

210is-MODEL B

Related manuals of Series 16i/18i/21i/160i/180i/210i/

160is/180is/210is MODEL B

Specification

Manual name

number

DESCRIPTIONS

B-63522EN

CONNECTION MANUAL (HARDWARE)

B-63523EN

CONNECTION MANUAL (FUNCTION)

B-63523EN-1

Series 16i/18i/160i/180i/160is/180is-TB

B-63524EN

OPERATOR’S MANUAL

Series 16i/160i/160is-MB, Series 18i/180i/180is-MB5,

B-63534EN

Series 18i/180i/180is-MB OPERATOR’S MANUAL

Series 21i/210i/210is-TB OPERATOR’S MANUAL

B-63604EN

Series 21i/210i/210is-MB OPERATOR’S MANUAL

B-63614EN

MAINTENANCE MANUAL

B-63525EN

Series 16i/18i/160i/180i/160is/180is-MODEL B

B-63530EN

PARAMETER MANUAL

Series 21i/210i/210is-MODEL B PARAMETER MANUAL

B-63610EN

PROGRAMMING MANUAL

Macro Compiler/Macro Executor

B-61803E-1

PROGRAMMING MANUAL

C Language Executor PROGRAMMING MANUAL

B-62443EN-3

FANUC MACRO COMPILER (For Personal Computer)

B-66102E

PROGRAMMING MANUAL

CAP (T series)

FANUC Super CAPi T OPERATOR’S MANUAL

B-63284EN

FANUC Symbol CAPi T OPERATOR’S MANUAL

B-63304EN

MANUAL GUIDE For Lathe PROGRAMMING MANUAL

B-63343EN

MANUAL GUIDE For Lathe OPERATOR’S MANUAL

B-63344EN

CAP (M series)

FANUC Super CAPi M OPERATOR’S MANUAL

B-63294EN

MANUAL GUIDE For Milling PROGRAMMING MANUAL

B-63423EN

MANUAL GUIDE For Milling OPERATOR’S MANUAL

B-63424EN

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PREFACE

B-63525EN/02

Specification

Manual name

number

PMC

PMC Ladder Language PROGRAMMING MANUAL

B-61863E

PMC C Language PROGRAMMING MANUAL

B-61863E-1

Network

I/O Link-II OPERATOR’S MANUAL

B-62924EN

Profibus-DP Board OPERATOR’S MANUAL

B-62924EN

Ethernet Board/DATA SERVER Board

B-63354EN

OPERATOR’S MANUAL

FAST Ethernet Board/FAST DATA SERVER

B-63644EN

OPERATOR’S MANUAL

DeviceNet Board OPERATOR’S MANUAL

B-63404EN

PC function

Screen Display Function OPERATOR’S MANUAL

B-63164EN

Related manuals of

The following table lists the manuals related to SERVO MOTOR ai series

SERVO MOTOR ai series

Specification

Manual name

number

FANUC AC SERVO MOTOR ai series DESCRIPTIONS

B-65262EN

FANUC AC SERVO MOTOR ai series

B-65270EN

PARAMETER MANUAL

FANUC AC SPINDLE MOTOR ai series

B-65272EN

DESCRIPTIONS

FANUC AC SPINDLE MOTOR ai series

B-65280EN

PARAMETER MANUAL

FANUC SERVO AMPLIFIER ai series DESCRIPTIONS

B-65282EN

FANUC SERVO MOTOR ai series

B-65285EN

MAINTENANCE MANUAL

Related manuals of

The following table lists the manuals related to SERVO MOTOR a series

SERVO MOTOR a series

Specification

Manual name

number

FANUC AC SERVO MOTOR a series DESCRIPTIONS

B-65142

FANUC AC SERVO MOTOR a series

B-65150

PARAMETER MANUAL

FANUC AC SPINDLE MOTOR a series DESCRIPTIONS

B-65152

FANUC AC SPINDLE MOTOR a series

B-65160

PARAMETER MANUAL

FANUC SERVO AMPLIFIER a series DESCRIPTIONS

B-65162

FANUC SERVO MOTOR a series

B-65165

MAINTENANCE MANUAL

Either of the following servo motors and the corresponding spindle can

be connected to the CNC covered in this manual.

D FANUC SERVO MOTOR ai series

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B-63525EN/02

Table of Contents

SAFETY PRECAUTIONS .

s-1

PREFACE .

p-1

1. DISPLAY AND OPERATION .

1.1

FUNCTION KEYS AND SOFT KEYS

1.1.1

Soft Keys

1.2

SCREEN DISPLAYED IMMEDIATELY AFTER POWER IS TURNED ON

1.2.1

Slot Status Display

1.2.2

Setting Module Screen

1.2.3

Configuration Display of Software

1.3

SYSTEM CONFIGURATION SCREEN

1.3.1

Display Method

1.3.2

Configuration of PCBs

1.3.3

Software Configuration Screen

1.3.4

Module Configuration Screen

1.3.5

ID Information Screen (αi Servo Information Screen/αi Spindle Information Screen)

1.4

ALARM HISTORY SCREEN

1.4.1

Alarm History Screen

1.4.1.1

General

1.4.1.2

Screen Display

1.4.1.3

Clearing Alarm History

1.4.1.4

Alarm Display

1.4.2

System Alarm History

1.4.2.1

General

1.4.2.2

System alarm history screen (history list screen)

1.4.2.3

System alarm history screen (detail screen)

1.4.2.4

Parameter

1.5

EXTERNAL OPERATOR MESSAGES RECORD

1.5.1

Screen Display

1.5.2

Deletion of External Operator Messages Record

1.5.3

Parameter

1.5.4

Notes

1.6

OPERATION HISTORY

1.6.1

Parameter Setting

1.6.2

Screen Display

1.6.3

Setting The Input Signal or Output Signal to Be Recorded in The Operation History

1.6.4

Inputting and Outputting the Operation History Data

1.6.5

Notes

1.7

HELP FUNCTION

1.7.1

General

1.7.2

Display Method

1.8

DISPLAYING DIAGNOSTIC PAGE

1.8.1

Displaying Diagnostic Page

1.8.2

Contents Displayed

1.9

CNC STATE DISPLAY

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B-63525EN/02

1.10

WAVEFORM DIAGNOSTIC FUNCTION

100

1.10.1

Setting Parameters

100

1.10.2

Waveform Diagnostic Parameter Screen

101

1.10.3

Graphic of Wave Diagnosis data

104

1.10.4

Data Sampling for Storage Type Waveform Diagnosis

106

1.10.5

Outputting Waveform Diagnosis Data (Storage Type)

108

1.10.6

Notes

111

1.11

OPERATING MONITOR

112

1.11.1

Display Method

112

1.11.2

Parameters

113

1.12

LIST OF OPERATIONS

114

1.13

WARNING SCREEN DISPLAYED WHEN AN OPTION IS CHANGED

124

1.14

WARNING SCREEN DISPLAYED WHEN SYSTEM SOFTWARE

IS REPLACED (SYSTEM LABEL CHECK ERROR)

126

1.15

MAINTENANCE INFORMATION SCREEN

127

1.15.1

Screen Display and Operation

127

1.15.2

Maintenance Information Input/Output

130

1.16

COLOR SETTING SCREEN

131

1.16.1

Screen Display

131

1.16.2

Color Setting

131

1.16.3

Parameters

133

1.16.4

Notes

134

1.17

CONTRAST ADJUSTMENT

135

1.18

POWER MOTION MANAGER

138

1.18.1

Parameter

138

1.18.2

Screen Display

139

1.18.3

Parameter Input/Output

145

1.18.4

Notes

147

1.19

PERIODIC MAINTENANCE SCREENS

148

1.19.1

Overview

148

1.19.2

Screen Display and Setting

148

1.19.3

Status Screen Display and Setting

149

1.19.4

Setting Screen Display and Setting

154

1.19.5

Registered Data Input/Output

156

1.19.6

FANUC Two-Byte Character Code Table

158

2. LCD-MOUNTED TYPE i SERIES HARDWARE .

164

2.1

STRUCTURE

165

2.2

OVERVIEW OF HARDWARE

166

2.2.1

Series 16i/160is

166

2.2.2

Series 18i/180is

168

2.2.3

Series 21i/210is

169

2.3

TOTAL CONNECTION DIAGRAMS

170

2.4

CONFIGURATION OF PRINTED CIRCUIT BOARD CONNECTORS AND CARDS

175

2.4.1

FS16i/18i/21i Motherboard

175

2.4.2

Inverter PCBs and Connector Units

184

2.4.3

C Board, Serial Communication Board, Symbol CAPi T Board, and PMC-RE Board

187

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2.4.4

Sub-CPU Board

193

2.4.5

RISC Board

197

2.4.6

Data Server Board

200

2.4.7

Loader Control Board

204

2.4.8

HSSB Interface Board

208

2.4.9

I/O Link-II Board

211

2.4.10

PROFIBUS Board

213

2.4.11

Ethernet Board

215

2.4.12

DeviceNet Interface Board

219

2.5

LIST OF UNITS AND PRINTED CIRCUIT BOARDS

221

2.5.1

Basic Unit

221

2.5.2

Display Unit

221

2.5.3

MDI Unit

222

2.5.4

Printed Circuit Boards

223

2.5.5

I/O

227

2.5.6

Other Units

228

2.6

REPLACING THE MOTHERBOARD

229

2.7

REPLACING FUSE ON CONTROL UNIT

231

2.8

REPLACING BATTERY

232

2.9

REPLACING FAN MOTORS

236

2.10

REPLACING LCD BACKLIGHT

239

2.11

HEAT GENERATED IN EACH UNIT

243

3. LCD-MOUNTED TYPE is SERIES HARDWARE .

245

3.1

HARDWARE CONFIGURATION

246

3.2

HARDWARE OVERVIEW

246

3.3

TOTAL CONNECTION DIAGRAMS

246

3.4

FS160is/180is/210is MOTHERBOARD

247

3.5

CE CARD

258

3.6

INSTALLING AND REMOVING OPTIONAL BOARDS

259

3.6.1

Installing and Removing the Mother Board

259

3.6.2

Installing and Removing the CE Card

261

3.7

LIST OF UNITS AND PRINTED CIRCUIT BOARDS

264

3.8

REPLACING THE FUSE ON THE UNITS

265

3.9

REPLACING THE BATTERY

266

3.10

REPLACING THE FAN MOTOR

266

3.11

REPLACING THE LCD BACK-LIGHT

267

3.12

REPLACING THE TOUCH PANEL PROTECTION SHEET

267

3.13

BACKUP UNIT

268

4. STAND-ALONE TYPE i SERIES HARDWARE .

269

4.1

HARDWARE CONFIGURATION

270

4.2

HARDWARE OVERVIEW

271

4.2.1

Series 16i/160i/160is

271

4.2.2

Series 18i/180i/180is

273

4.2.3

Series 21i/210i/210is

274

4.3

TOTAL CONNECTION DIAGRAMS

275

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4.4

CONNECTOR AND CARD CONFIGURATIONS OF PRINTED CIRCUIT BOARDS

280

4.4.1

Main CPU Board of Series 16i/18i/21i/160i/180i/210i/160is/180is/210is

280

4.4.2

Sub-CPU Board

289

4.4.3

RISC Board, Data Server Board, RISC + Data Server Board

293

4.4.4

Loader Control Board

299

4.4.5

C Board, Serial Communication Board

302

4.4.6

HSSB Interface Board

303

4.4.7

Symbol CAPi T Board

307

4.4.8

I/O Link-II Board

308

4.4.9

Ethernet Board

309

4.4.10

DeviceNet Board

311

4.4.11

PROFIBUS Master Board

313

4.4.12

PROFIBUS Slave Board

314

4.4.13

FL-net Board

315

4.4.14

Main CPU Board of CNC Display Unit with PC Functions and PANEL i

316

4.4.15

Mother Board of CNC Display Unit for is Series

319

4.5

UNITS AND PRINTED CIRCUIT BOARDS

324

4.5.1

Basic Units

324

4.5.2

Printed Circuit Boards of Control Unit

324

4.5.3

LCD/MDI Unit

329

4.5.4

Other Units

330

4.5.5

CNC Display Unit with PC Functions and PANEL i

331

4.5.6

CNC Display Unit for is series CNC

334

4.6

MOUNTING AND REMOVING AN OPTION BOARD

335

4.6.1

Mounting and Removing the Main CPU Board and a Full-Size Option Board

335

4.6.1.1

Removing the board

335

4.6.1.2

Mounting the board

336

4.6.2

Mounting and Removing a Mini-Slot Option Board (Except DeviceNet Board)

337

4.6.2.1

Removing the board

337

4.6.2.2

Mounting the board

337

4.6.3

Mounting and Removing the DeviceNet Board

338

4.6.3.1

Removing the board

338

4.6.3.2

Mounting the board

338

4.7

MOUNTING AND REMOVING THE BACK PANEL

340

4.7.1

Removing the Panel

340

4.7.2

Mounting the Back Panel

340

4.8

REPLACING THE FUSE OF THE CONTROL UNIT

342

4.9

REPLACING THE BATTERY

343

4.10

REPLACING A FAN UNIT

347

4.11

REPLACING THE FUSE OF THE LCD UNIT

348

4.12

REPLACING THE LCD BACKLIGHT

349

4.13

HEAT GENERATION OF THE UNITS

351

5. MATTERS COMMON TO BOTH LCD-MOUNTED TYPE AND

STAND-ALONE TYPE i SERIES (HARDWARE) .

353

5.1

MOUNTING AND DEMOUNTING CARD PCBS

354

5.1.1

Demounting a Card PCB

355

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TABLE OF CONTENTS

5.1.2

Mounting a Card PCB

356

5.2

MOUNTING AND DEMOUNTING DIMM MODULES

357

5.2.1

Demounting a DIMM Module

358

5.2.2

Mounting a DIMM Module

358

5.3

MAINTENANCE OF HEAT EXCHANGER OF HEAT PIPE TYPE

359

5.4

LIQUID CRYSTAL DISPLAY (LCD)

363

5.5

DISTRIBUTED I/O SETTING

368

5.6

REPLACING FUSES ON VARIOUS UNITS

371

5.7

ENVIRONMENTAL CONDITIONS OUTSIDE CABINET

376

5.8

COUNTERMEASURES AGAINST NOISE

377

5.8.1

Separation of Signal Lines

377

5.8.2

Grounding

379

5.8.3

Signal Ground (SG) Connection of Control Unit

380

5.8.4

Noise Suppressor

382

5.8.5

Cable Clamping and Shielding

383

5.9

NOTES ON USING THE MDI UNIT

386

5.10

REPLACING THE MAINTENANCE PARTS OF CNC DISPLAY UNIT

FOR PC FUNCTIONS AND PANEL i

387

5.10.1

Replacing the Battery

387

5.10.2

Replacing the Fuse

389

5.10.3

Replacing the Fan

390

5.10.4

Replacing the LCD Back-Light

393

5.10.5

Replacing the Touch Panel Protection Sheet

394

5.11

REPLACING THE MAINTENANCE PARTS OF CNC DISPLAY UNIT

FOR is SERIES CNC

395

5.11.1

Replacing Procedure of Mother Board

395

5.11.2

Replacing the Fuse

396

5.11.3

Replacing the Battery

397

5.11.4

Replacing the Fan Motor

397

5.11.5

Replacing the LCD Back-Light

398

5.11.6

Replacing the Touch Panel Protection Sheet

398

5.11.7

Backup Unit

398

6. INPUT AND OUTPUT OF DATA .

399

6.1

SETTING PARAMETERS FOR INPUT/OUTPUT

400

6.2

INPUTTING/OUTPUTTING DATA

402

6.2.1

Confirming the Parameters Required for Data Output

402

6.2.2

Outputting CNC Parameters

403

6.2.3

Outputting PMC Parameters

404

6.2.4

Outputting Pitch Error Compensation Amount

404

6.2.5

Outputting Custom Macro Variable Values

405

6.2.6

Outputting Tool Compensation Amount

405

6.2.7

Outputting Part Program

405

6.2.8

Inputting CNC Parameters

406

6.2.9

Inputting PMC Parameters

407

6.2.10

Inputting Pitch Error Compensation Amount

408

6.2.11

Inputting Custom Macro Variable Values

408

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TABLE OF CONTENTS

B-63525EN/02

6.2.12

Inputting Tool Compensation Amount

409

6.2.13

Inputting Part Programs

409

6.3

INPUT/OUTPUT Super CAPi DATA

411

6.3.1

Input/Output of Conversational Data in a Lump (Super CAPi M)

411

6.3.2

Input and Output of Each File (Super CAPi M)

413

6.3.3

Input and Output of Each File (Super CAPi T)

413

6.4

INPUTTING/OUTPUTTING Symbol CAPi T

417

6.5

DUMP/RESTORE OF Symbol CAPi T DATA

419

6.5.1

Kind of Data in Sub Memory

419

6.5.2

Operation

419

6.6

CLEARING Symbol CAPi T DATA

420

6.6.1

Deleting File Name and Files

420

6.6.2

Clearing Symbol CAPi T Memory

421

6.7

DATA INPUT/OUTPUT ON THE ALL IO SCREEN

422

6.7.1

Setting Input/Output-Related Parameters

423

6.7.2

Inputting and Outputting Programs

425

6.7.3

Inputting and Outputting Parameters

429

6.7.4

Inputting and Outputting Offset Data

430

6.7.5

Outputting Custom Macro Common Variables

431

6.7.6

Inputting and Outputting Floppy Files

432

6.8

DATA INPUT/OUTPUT USING A MEMORY CARD

437

7. INTERFACE BETWEEN CNC AND PMC .

447

7.1

GENERAL OF INTERFACE

448

7.2

SPECIFICATION OF PMC

449

7.2.1

Specification

449

7.2.2

Address

450

7.2.3

System Reserve Area of Internal Relay

451

7.2.4

Execution Period of PMC

454

7.3

PMC SCREEN

457

7.3.1

PMC Menu Selection Procedure Using Soft Keys

457

7.3.2

PMCLAD Screen (PMC-SA1)

459

7.3.3

Ladder Diagram Display/Editing (PMC-SB7)

463

7.3.3.1

Ladder diagram display screen

463

7.3.3.2

Program list display screen

466

7.3.3.3

Selection monitor function (PMC-SB7)

468

7.3.3.4

Ladder diagram editing screen

472

7.3.3.5

Net editing screen

476

7.3.3.6

Signal trace function (PMC-SB7)

478

7.3.4

PMCDGN Screen

485

7.3.5

PMCPRM Screen

489

7.3.6

Setting Screen

492

7.3.7

Online Setting

494

7.3.7.1

Online setting screen

494

7.3.7.2

Setting of online connection

494

7.3.7.3

Communication Status

495

7.4

LIST OF SIGNALS BY EACH MODE

497

c-6

B-63525EN/02

TABLE OF CONTENTS

7.5

LIST OF INPUT/OUTPUT SIGNALS

499

7.6

LIST OF ADDRESSES

519

8. EMBEDDED ETHERNET FUNCTION .

599

8.1

EMBEDDED ETHERNET AND PCMCIA ETHERNET

600

8.2

LIST OF FUNCTIONS

601

8.2.1

FACTOLINK Function

601

8.2.2

FOCAS1/Ethernet Function

601

8.2.3

DNC1/Ethernet Function

603

8.2.4

FTP File Transfer Function

605

8.2.5

Functional Differences between the Embedded Ethernet Function and

the Ethernet Function Based on the Option Board

605

8.3

SETTING THE EMBEDDED ETHERNET FUNCTION

607

8.3.1

Parameter Setting of the FACTOLINK Function

607

8.3.1.1

Notes on using the FACTOLINK function for the first time

607

8.3.1.2

FACTOLINK parameter setting screen

608

8.3.1.3

Parameters

611

8.3.1.4

Using the FACTOLINK function on a small network

613

8.3.1.5

Configuring a large network

614

8.3.2

Parameter Setting of the FOCAS1/Ethernet Function

614

8.3.2.1

Notes on using the FOCAS1/Ethernet function for the first time

614

8.3.2.2

FOCAS1/Ethernet parameter setting screen

615

8.3.2.3

Using the FOCAS1/Ethernet function on a small network

619

8.3.2.4

Using the DNC1/Ethernet function on a small network

620

8.3.2.5

Configuring a large network

621

8.3.3

Parameter Setting of the FTP File Transfer Function

621

8.3.3.1

Notes on using the FTP file transfer function for the first time

621

8.3.3.2

FTP file transfer parameter setting screen

622

8.3.3.3

Parameters

625

8.3.3.4

Using the FTP file transfer function on a small network

626

8.3.3.5

Configuring a large network

627

8.3.4

Communication Parameter Input Method

627

8.4

SWITCHING BETWEEN THE EMBEDDED ETHERNET DEVICES

635

8.5

EMBEDDED ETHERNET OPERATIONS

637

8.5.1

FACTOLINK Function

637

8.5.2

FTP File Transfer Function

638

8.5.2.1

Host file list display

638

8.5.2.2

Host file search

641

8.5.2.3

Host file deletion

641

8.5.2.4

NC program input

642

8.5.2.5

NC program output

643

8.5.2.6

Input/output of various types of data

645

8.5.2.7

Checking and changing of the connection host

651

8.6

EMBEDDED ETHERNET ERROR MESSAGE SCREEN

653

8.7

EMBEDDED ETHERNET MAINTENANCE SCREEN

655

8.8

TROUBLESHOOTING

660

8.8.1

Check Items Related to Connection with the Hub

660

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TABLE OF CONTENTS

B-63525EN/02

8.8.2

Check Items Related to Connection with a Backbone

660

8.8.3

Checking the Setting of Each Parameter

661

8.8.4

Checking Communication

662

8.9

ERROR MESSAGES

665

8.9.1

EMB_ETH MASTER CTRL LOG Screen

665

8.9.2

EMB_ETH FOCAS1/ETHER LOG Screen

666

8.9.3

EMB_ETH FTP TRANSFER LOG Screen

666

8.9.4

EMB_ETH FACTOLINK LOG Screen

666

8.10

GLOSSARY FOR ETHERNET

667

9. DIGITAL SERVO .

669

9.1

INITIAL SETTING SERVO PARAMETERS

670

9.2

SERVO TUNING SCREEN

684

9.2.1

Parameter Setting

684

9.2.2

Displaying Servo Tuning Screen

684

9.3

ADJUSTING REFERENCE POSITION (DOG METHOD)

687

9.3.1

General

687

9.4

DOGLESS REFERENCE POSITION SETTING

690

9.4.1

General

690

9.4.2

Operation

690

9.4.3

Associated Parameters

691

9.5

αi SERVO WARNING INTERFACE

692

9.6

αi SERVO INFORMATION SCREEN

694

10. AC SPINDLE (SERIAL INTERFACE) .

698

10.1

AC SPINDLE (SERIAL INTERFACE)

699

10.1.1

Outline of Spindle Control

699

10.1.1.1 Method A of gear change for machining center

701

10.1.1.2 Method B of gear change for machining center (PRM 3705#2=1)

701

10.1.1.3 For lathe

701

10.1.2

Spindle Setting and Tuning Screen

702

10.1.2.1 Display method

702

10.1.2.2 Spindle setting screen

702

10.1.2.3 Spindle tuning screen

703

10.1.2.4 Spindle monitor screen

705

10.1.2.5 Correspondence between operation mode and parameters on spindle tuning screen

707

10.1.3

Automatic Setting of Standard Parameters

710

10.1.4

Warning Interface for the αi Spindle

711

10.1.5

αi Spindle Information Screen

713

10.2

AC SPINDLE (ANALOG INTERFACE)

717

10.2.1

Outline of Spindle Control

717

10.2.1.1 Block diagram

718

10.2.1.2 Calculation of S analog voltage and related parameters

719

10.2.1.3 Tuning S analog voltage (D/A converter)

721

11. TROUBLESHOOTING .

723

11.1

CORRECTIVE ACTION FOR FAILURES

725

c-8

B-63525EN/02

TABLE OF CONTENTS

11.1.1

Investigating the Conditions Under which Failure Occurred

725

11.2

NO MANUAL OPERATION NOR AUTOMATIC OPERATION CAN BE EXECUTED

727

11.3

JOG OPERATION CANNOT BE DONE

731

11.4

HANDLE OPERATION CANNOT BE DONE

735

11.5

AUTOMATIC OPERATION CANNOT BE DONE

740

11.6

CYCLE START LED SIGNAL HAS TURNED OFF

748

11.7

NOTHING IS DISPLAYED ON THE LCD WHEN THE POWER IS TURNED ON

750

11.8

THE DISPLAY ON THE LCD UNIT FLASHES

754

11.9

INPUT FROM AND OUTPUT TO I/O DEVICES CANNOT BE PERFORMED INPUT/

OUTPUT CANNOT BE PERFORMED PROPERLY

755

11.10

IN A CONNECTOR PANEL I/O UNIT, DATA IS INPUT TO AN UNEXPECTED ADDRESS . .

757

11.11

IN A CONNECTOR PANEL I/O UNIT, NO DATA IS OUTPUT TO AN EXPANSION UNIT . . .

758

11.12

ALARM 85 TO 87 (READER/PUNCHER INTERFACE ALARM)

759

11.13

ALARM 90 (REFERENCE POSITION RETURN IS ABNORMAL)

765

11.14

ALARM 300 (REQUEST FOR REFERENCE POSITION RETURN)

767

11.15

ALARM 401 (V READY OFF)

768

11.16

ALARM 404 (V READY ON)

772

11.17

ALARM 462 (SEND CNC DATA FAILED) ALARM 463 (SEND SLAVE DATA FAILED)

775

11.18

ALARM 417 (DIGITAL SERVO SYSTEM IS ABNORMAL)

778

11.19

ALARM 700 (OVERHEAT: CONTROL UNIT)

779

11.20

ALARM 701 (OVERHEAT: FAN MOTOR)

780

11.21

ALARM 704 (SPINDLE SPEED FLUCTUATION DETECTION ALARM)

782

11.22

ALARM 749 (SERIAL SPINDLE COMMUNICATION ERROR)

783

11.23

ALARM 750 (SPINDLE SERIAL LINK STARTUP FAILURE)

784

11.24

ALARM 5134 (FSSB: OPEN READY TIME OUT)

ALARM 5135 (FSSB: ERROR MODE)

ALARM 5137 (FSSB: CONFIGURATION ERROR)

ALARM 5197 (FSSB: OPEN TIME OUT)

ALARM 5198 (FSSB: ID DATA NOT READ)

787

11.25

ALARM 5136 (FSSB: NUMBER OF AMPS IS SMALL)

791

11.26

ALARM 900 (ROM PARITY)

794

11.27

ALARMS 910 AND 911 (SRAM PARITY)

796

11.28

ALARMS 912 TO 919 (DRAM PARITY)

799

11.29

ALARMS 920 AND 921 (SERVO ALARMS)

801

11.30

ALARM 926 (FSSB ALARM)

805

11.31

ALARM 930 (CPU INTERRUPT)

811

11.32

ALARM 935 (SRAM ECC ERROR)

813

11.33

ALARM 950 (PMC SYSTEM ALARM)

815

11.34

ALARM 951 (PMC WATCHDOG ALARM)

818

11.35

ALARM 972 (NMI ALARM ON AN OPTION BOARD)

819

11.36

ALARM 973 (NMI ALARM WITH AN UNKNOWN CAUSE)

820

11.37

ALARM 974 (F-BUS ERROR)

821

11.38

ALARM 975 (BUS ERROR)

824

11.39

ALARM 976 (LOCAL BUS ERROR)

825

11.40

SERVO ALARMS

826

11.41

SPC ALARMS

831

11.42

SPINDLE ALARMS

832

c-9

TABLE OF CONTENTS

B-63525EN/02

APPENDIX

A. ALARM LIST .

835

A.1

LIST OF ALARM CODES (CNC)

836

A.2

LIST OF ALARMS (PMC)

875

A.3

ALARM LIST (SERIAL SPINDLE)

900

A.4

ERROR CODES (SERIAL SPINDLE)

912

B. LIST OF MAINTENANCE PARTS .

914

C. BOOT SYSTEM .

915

C.1

OVERVIEW

916

C.1.1

Starting the Boot System

916

C.1.2

System Files and User Files

917

C.1.3

Boot Slot Configuration Screen

917

C.2

SCREEN CONFIGURATION AND OPERATING PROCEDURE

918

C.2.1

System Data Loading Screen

919

C.2.2

System Data Check Screen

921

C.2.3

System Data Delete Screen

923

C.2.4

SYSTEM DATA SAVE Screen

924

C.2.5

SRAM DATA BACKUP Screen

926

C.2.6

MEMORY CARD FILE DELETE Screen

929

C.2.7

MEMORY CARD FORMAT Function

930

C.2.8

LOAD BASIC SYSTEM Function

931

C.3

ERROR MESSAGES AND REQUIRED ACTIONS

933

D. MEMRY CARD SLOT .

936

D.1

OVERVIEW

937

D.2

MEMORY CARD TYPES (FUNCTIONS)

938

D.3

HARDWARE CONFIGURATION

939

E. LED DISPLAY AND MAINTENANCE OF STAND-ALONE TYPE UNIT .

941

E.1

OVERVIEW

942

E.2

LAYOUT OF THE 7-SEGMENT LED AND SWITCHES

943

E.3

OPERATION

944

E.3.1

Operation Before Power-On

944

E.3.2

Function Number

944

E.3.3

Seven-Segment LED Display

945

E.3.3.1

NC status display

945

E.3.3.2

LED display during automatic operation

945

E.3.3.3

LED display when the push switch is pressed

945

E.3.3.4

LED display when a system alarm is issued

946

E.3.3.5

Display on the 7-segment LED at power-on

947

E.3.4

Operation of Each Function

948

F. MAINTENANCE OF OPEN CNC (BOOT-UP AND IPL) .

950

F.1

OVERVIEW

951

c-10

B-63525EN/02

TABLE OF CONTENTS

F.2

CHANGING START SEQUENCES

952

F.3

EXPLANATION OF SCREENS

954

F.3.1

Boot Screen

954

F.3.1.1

System data manipulation

955

F.3.1.2

SRAM operation

956

F.3.1.3

File operation

957

F.3.2

IPL Screen

958

F.3.2.1

Functions on the IPL screen

959

F.4

OTHER SCREENS

961

F.4.1

CNC Alarm Screen

961

F.4.2

Status Screen (160i/180i/210i)

962

F.4.3

Option Setting Screen (160i/180i/210i Only)

964

G. FSSB START-UP PROCEDURE/MATERIALS .

965

G.1

OVERVIEW

966

G.2

SLAVE

967

G.3

AUTOMATIC SETTING

968

G.3.1

[Sample Setting 1] General Configuration (Semi-Closed Loop)

970

G.3.2

[Sample Setting 2] General Configuration (Closed Loop)

971

G.3.3

[Sample Setting 3] When the C-Axis is a Cs Axis

973

G.3.4

[Sample Setting 4] Tandem Control Configuration

975

G.3.5

[Sample Setting 5] When the Simple Electronic Gear Box (EGB) Function is Used

977

G.4

MANUAL SETTING 2

979

G.5

MANUAL SETTING 1

986

G.6

ALARMS

987

G.7

ACTIONS FOR TROUBLE ENCOUNTERED AT START-UP TIME

992

G.8

EXAMPLES OF SETTINGS USING OTHER CONNECTIONS

994

G.8.1

Example 1: Learning Control

994

G.8.2

Example 2: When a 2-Axis Amplifier is Shared by Two Paths

995

G.9

FSSB DATA DISPLAY

998

G.9.1

Amplifier Setting Screen

998

G.9.2

Axis Setting Screen

999

G.9.3

Amplifier Maintenance Screen

1000

H. NOTATION OF MDI KEYS .

1002

c-11

B-63525EN/02

1. DISPLAY AND OPERATION

DISPLAY AND OPERATION

This chapter describes how to display various screens by the function

keys. The screens used for maintenance are respectively displayed.

1.1

FUNCTION KEYS AND SOFT KEYS

1.2

SCREEN DISPLAYED IMMEDIATELY AFTER

POWER IS TURNED ON

1.3

SYSTEM CONFIGURATION SCREEN

1.4

ALARM HISTORY SCREEN

1.5

EXTERNAL OPERATOR MESSAGES

RECORD

1.6

OPERATION HISTORY

1.7

HELP FUNCTION

1.8

DISPLAYING DIAGNOSTIC PAGE

1.9

CNC STATE DISPLAY

1.10 WAVEFORM DIAGNOSTIC FUNCTION

100

1.11 OPERATING MONITOR

112

1.12 LIST OF OPERATIONS

114

1.13 WARNING SCREEN DISPLAYED WHEN

AN OPTION IS CHANGED

124

1.14 WARNING SCREEN DISPLAYED

WHEN SYSTEM SOFTWARE IS REPLACED

(SYSTEM LABEL CHECK ERROR)

126

1.15 MAINTENANCE INFORMATION SCREEN

127

1.16 COLOR SETTING SCREEN

131

1.17 CONTRAST ADJUSTMENT

135

1.18 POWER MOTION MANAGER

138

1.19 PERIODIC MAINTENANCE SCREENS

148

FANUC Series 16i/160i/160is-MODEL B, Series 18i/180i/180is-MODEL B, Series 21i/210i/210is-MODEL B. MAINTENANCE MANAUL - page 1