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FANUC Series 30i-MODEL B, 31i-MODEL B, 32i-MODEL B. MAINTENANCE MANUAL - page 21

10.TROUBLESHOOTING

B-64485EN/01

SERIES 30I GXXXX

SYS_ALM194 IO LINK I ALARM

IO LINK I

2008/11/18 12:00:00

EMBEDDED SOFTWARE SYSTEM ERROR(40XX-XXXX)

PC054 I/O LINK I

ABNORMAL POWER SUPPLY

-----< ERROR POSITION >-------------------------------

CH1 / UNIT3(GROUP2) : I/O UNIT-A

------------------------------------------------------

MA=03,FF,00,00,00,80 ME=00,00 GE=10,00 TOC=02 TTOC=05

RT=0,0,3,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0

G02 RC=03 RT=05 H=00001000,00001000,00001000,00000000

PAGE UP OR DOWN (PAGE 1 / 5)

Power failure alarm display for the third unit (group 2) on channel 1

SERIES 30I GXXXX

SYS_ALM194 IO LINK I ALARM

IO LINK I

2008/11/18 12:00:00

EMBEDDED SOFTWARE SYSTEM ERROR(40XX-XXXX)

PC055 I/O LINK I

I/O LINK I SENDING DATA FAILURE

-----< ERROR POSITION >-------------------------------

CH1 / UNIT2(GROUP1) <-> UNIT3(GROUP2)

UNIT2 : I/O UNIT-A

UNIT3 : ID=0xA5

------------------------------------------------------

MA=03,FF,00,00,00,80 ME=00,00 GE=10,00 TOC=02 TTOC=05

RT=3,3,3,3,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0

G00 RC=03 RT=05 H=00001000,00001000,00001000,00000000

G01 RC=04 RT=05 H=00011000,00011000,00011000,00011000

G02 RC=03 RT=05 H=00111000,00111000,00111000,00000000

G03 RC=03 RT=05 H=00110000,00110000,00110000,00000000

PAGE UP OR DOWN (PAGE 1 / 5)

Alarm display for communication between the second unit (group 1) and third unit (group 2) on channel 1

- 582 -

10.TROUBLESHOOTING

B-64485EN/01

10.26 LEDS ON UNITS SUPPORTING I/O LINK i

10.26.1 Meanings of LEDs on units supporting I/O Link i

The standard I/O Link i incorporates three LEDs, “LINK” (green), “ALM” (red), and “FUSE” (red) for

each unit separately. These LEDs indicate the states of the units.

The following table lists the ON/OFF states of the LEDs and their meanings.

LED ON/OFF state

ON and OFF duration

Steadily OFF

Steadily ON

Blink (1:1)

ON

= approx. 0.5 sec, OFF = approx. 0.5 sec

Blink (3:1)

ON

= approx. 1.5 sec, OFF = approx. 0.5 sec

Blink (1:3)

ON = approx. 0.5 sec, OFF = approx. 1.5 sec

Blink (1:1 at high speed)

ON = approx. 0.25 sec, OFF = approx. 0.25 sec

LED「LINK」(green)

The “LINK” (green) LED indicates the state of communication. The following table lists the meanings of

LED states.

Operation

LED state

Meaning

Fault location and action

mode

OFF

Power OFF

Power ON

ON

(before communication

Common

start)

Blink

Communication is at halt because of an alarm. Identify the

(1:1 at high

Communication at halt

cause according to the states of the red LED stated below or

speed)

information displayed on the CNC screen.

Blink

Communication in

I/O Link

(1:3)

progress

Blink

Communication in

(1:1)

progress

Communication in

I/O Link i

Blink

progress

(3:1)

(Dual check safety in

use)

デュアル・チェック・セイフティ使用 -> 「Dual check safety in use」と訳しました。

- 584 -

B-64485EN/01

10.TROUBLESHOOTING

LED「ALM」(red)

The “ALM” (red) LED indicates an alarm in the unit of interest or a unit subsequent to it. The following

table lists the meanings of LED states.

Operation

LED state

Meaning

Fault location and action

mode

Normal state or power

Common

OFF

OFF

It is likely that the hardware may be defective. Replace the

I/O Link

ON

Alarm

unit.

It is likely that the hardware may be defective. Replace the

ON

Alarm

unit.

Check for a defective cable or a poor cable connection

Broken wire between the

Blink

between JD1A on the unit of interest and JD1B on a unit

unit of interest and a unit

(1:1)

subsequent to that unit. Alternatively, it is likely that there may

subsequent to it

be noise. Check to see if there is noise around the cable.

I/O Link i

Power failure (including

instantaneous power

Blink

Identify and remove the cause of a power failure in a unit

failure) in a unit

(3:1)

subsequent to the unit of interest.

subsequent to the unit of

interest

Blink

A status alarm, such as a DO ground fault, has occurred.

Status alarm

(1:3)

Identify and remove the cause of the alarm.

LED「FUSE」(red)

The “FUSE” (red) LED indicates whether there is a blown fuse. The following table lists the meanings of

LED states.

Operation

LED state

Meaning

Fault location and action

mode

Fuse normal or power

OFF

Common

OFF

ON

Blown fuse

Replace the fuse.

- 585 -

10.TROUBLESHOOTING

B-64485EN/01

10.26.2 Unit’s LED on I/O Link i

The following shows the ON/OFF state of the LED for each unit on I/O Link i and the state of the unit

inferred from the ON/OFF state. The ON/OFF state of each LED is represented using the symbols in the

following table.

ALM

LINK

FUSE

■

■

■

□

Steadily OFF

■

Steadily ON

Blink (1:1)

ON = approx. 0.5 sec, OFF = approx. 0.5 sec

Blink (3:1)

ON = approx. 1.5 sec, OFF = approx. 0.5 sec

▲

Blink (1:3)

ON = approx. 0.5 sec, OFF = approx. 1.5 sec

Blink (1:1 at high speed)

ON = approx. 0.25 sec, OFF = approx. 0.25 sec

(1) If all LEDs for each unit are steadily OFF:

No power is supplied to the units.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

□

□

□

□

□

□

□

□

□

□

□

□

□

□

(2) If “LINK” for each unit is steadily ON:

Power is being supplied to each unit but I/O Link i has not begun communication.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

■

□

□

■

□

□

■

□

□

■

□

□

■

□

- 586 -

B-64485EN/01

10.TROUBLESHOOTING

(3) If “LINK” for each unit is blinking at an ON:OFF ratio of 1:1 or 3:1:

I/O Link i is normally communicating with the units. For a unit being used as dual check safety,

“LINK” blinks at an ON:OFF ratio of 3:1.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

☆

□

□

☆

□

□

☆

□

□

☆

□

□

☆

□

ALM

LINK

FUSE

□

★

□

The state of a unit using

dual check safety

(4) If “ALM” for any unit is blinking at an ON:OFF ratio of 1:1:

It is likely that there may be a disconnected communication path (due to a defective communication

cable or a poor cable connection) or an abnormal condition (due to noise) between the unit of

interest and the unit immediately subsequent to that unit.

In this case, “LINK” for each unit previous to the point of disconnection blinks at 1:1 (high speed)

and “LINK” for each unit subsequent to the point of disconnection is ON.

Check for a defective cable, a poor cable connection, and surrounding noise between JD1A on the

unit for which “ALM” is blinking at 1:1 and JD1B on the unit immediately subsequent to that unit.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

☆

◎

□

□

■

□

□

■

□

(5) If “ALM” for any unit is blinking at an ON:OFF ratio of 3:1:

(i)

If all the LEDs for the unit immediately subsequent to the unit for which “ALM” is blinking at

3:1 are OFF:

It is likely that there may be an abnormal voltage in the unit for which all the LEDs are OFF.

In this case, “LINK” for each unit previous to the unit having an abnormal voltage blinks at 1:1

(high speed) and “LINK” for each unit subsequent to that unit is ON.

For units for which all the LEDs are OFF, check that their voltage are normal.

- 587 -

10.TROUBLESHOOTING

B-64485EN/01

Power failure

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

★

◎

□

□

□

□

□

■

□

(ii) If “LINK” for the unit immediately subsequent to the unit for which “ALM” is blinking at 3:1

is ON:

It is likely that an instantaneous power failure may have occurred in the unit immediately

subsequent to the unit for which “ALM” is blinking at 3:1.

In this case, “LINK” for each unit previous to the unit where the instantaneous power failure

may have occurred blinks at 1:1 (high speed) and “LINK” for the unit where the instantaneous

power failure may have occurred and each unit subsequent to that unit is ON.

For the unit immediately subsequent to the unit for which “ALM” is blinking at 3:1, check for

any instantaneous power failure.

Instantaneous pow er

f ailure → Pow er recovery

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

★

◎

□

□

■

□

□

■

□

(iii) If “FUSE” for the unit immediately subsequent to the unit for which “ALM” is blinking at 3:1

is ON:

It is likely that a fuse may have blown in the unit for which “FUSE” is ON.

In this case, “LINK” for each unit previous to the unit having a blown fuse blinks at 1:1 (high

speed) and “LINK” for each unit subsequent to that unit is ON.

Replace the fuse for the unit for which “FUSE” is ON. See Chapter 4 for explanations about

how to replace the fuse.

Blow n fuse

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

★

◎

□

□

□

■

□

■

□

- 588 -

B-64485EN/01

10.TROUBLESHOOTING

(6) If “LINK” is blinking at 1:1 (high speed) for all units:

(i)

If “ALM” for any unit is ON:

It is likely that there may be an alarm condition in the unit for which “ALM” is ON. Replace

the unit of interest, because its hardware may be defective.

Alarm

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

■

◎

□

□

◎

□

□

◎

□

(ii) If “ALM” is OFF for all units:

It is likely that there may be an abnormal condition due to noise or the master may have an

abnormal condition. Check also alarms displayed on the screen.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

□

◎

□

□

◎

□

□

◎

□

(7) If “ALM” for any unit is blinking at 1:3:

It is likely that there may be a status alarm for the unit for which “ALM” is blinking at 1:3.

Status alarm

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

☆

□

□

☆

□

▲

☆

□

□

☆

□

□

☆

□

NOTE

Status alarms indicate a unit’s abnormal conditions, such as DO ground fault and

DOCOM failure. For details, see Subsection 4.2.1.

- 589 -

10.TROUBLESHOOTING

B-64485EN/01

10.26.3 Unit’s LED on I/O Link

The I/O Link-only units incorporate no “LINK” (green), “ALM” (red), or “FUSE” (red) LED. Explained

below are the meanings of the LEDs for units supporting I/O Link i when they communicate using I/O

Link.

(1) If all LEDs for each unit are steadily OFF:

No power is supplied to the units.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

□

□

□

□

□

□

□

□

□

□

□

□

□

□

(2) If “LINK” for each unit is steadily ON:

Power is being supplied to each unit but I/O Link has not begun communication.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

■

□

□

■

□

□

■

□

□

■

□

□

■

□

(3) If “LINK” for each unit is blinking at an ON:OFF ratio of 1:3:

I/O Link is normally communicating with the units.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

▲

□

□

▲

□

□

▲

□

□

▲

□

□

▲

□

- 590 -

B-64485EN/01

10.TROUBLESHOOTING

(4) If all LEDs for any unit are OFF:

It is likely that a power failure may have occurred in the unit for which all LEDs are OFF.

In this case, “LINK” for each unit other than the unit of interest blinks at 1:1 (high speed).

Check to see if the power supply voltage for the unit of interest is normal.

Pow er failure

(permanent)

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

□

□

□

□

◎

□

□

◎

□

(5) If “LINK” for any unit is ON and “LINK” for each of the other units is blinking at 1:1 (high speed):

It is likely that an instantaneous power failure may have occurred in the unit for which “LINK” is

ON.

Check to see if an instantaneous power failure has occurred in the unit of interest.

Instantaneous pow er

f ailure → Pow er recovery

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

□

■

□

□

◎

□

□

◎

□

(6) If “LINK” for each unit is blinking at 1:1 (high speed):

(i)

If “ALM” for any unit is ON:

It is likely that there may be an alarm condition in the unit for which “ALM” is ON. Replace

the unit of interest, because its hardware may be defective.

Alarm

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

■

◎

□

□

◎

□

□

◎

□

- 591 -

10.TROUBLESHOOTING

B-64485EN/01

(ii) If “ALM” is OFF for all units:

It is likely that there may be a broken cable, an abnormal condition due to noise, or a failure in

the master. Check also alarms displayed on the screen.

30i/31i/32i-B

First unit

Second unit

Third unit

Fourth unit

Fifth unit

(master)

(group 0)

(group 1)

(group 2)

(group 3)

(group 4)

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

ALM

LINK

FUSE

□

◎

□

□

◎

□

□

◎

□

□

◎

□

□

◎

□

- 592 -

11.MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE

B-64485EN/01

11.1 LIST OF MANUALS RELATED TO MOTORS AND

AMPLIFIERS

Details of individual motors and amplifiers are described in the manuals listed in the table below. Before

performing periodic inspection or any other maintenance work, consult with the machine tool builder and,

if necessary, obtain the latest version of the corresponding manual shown in the list. The information

about the specifications of each device, such as the weight and winding resistance value, is given in the

relevant "DESCRIPTIONS" manual.

Specification

Manual name

Type of manual

number

FANUC AC SERVO MOTOR αi series

DESCRIPTIONS

B-65262EN

FANUC AC SERVO MOTOR βis series

DESCRIPTIONS

B-65302EN

FANUC SYNCHROUNOUS BUILT-IN SERVO MOTOR DiS series

DESCRIPTIONS

B-65332EN

FANUC LINEAR MOTOR LiS series

DESCRIPTIONS

B-65382EN

FANUC AC SPINDLE MOTOR αi series

DESCRIPTIONS

B-65272EN

FANUC AC SPINDLE MOTOR βi series

DESCRIPTIONS

B-65312EN

FANUC BUILT-IN SPINDLE MOTOR BiI series

DESCRIPTIONS

B-65292EN

FANUC SYNCHROUNOUS BUILT-IN SPINDLE MOTOR BiS

DESCRIPTIONS

B-65342EN

series

FANUC - NSK SPINDLE UNIT series

DESCRIPTIONS

B-65352EN

FANUC SERVO AMPLIFIER αi series

DESCRIPTIONS

B-65282EN

FANUC SERVO AMPLIFIER βi series

DESCRIPTIONS

B-65322EN

FANUC AC SERVO MOTOR αi series

FANUC AC SERVO MOTOR βi series

PARAMETER MANUAL

B-65270EN

FANUC LINEAR MOTOR LiS series

FANUC SYNCHRONOUS BUILT-IN SERVO MOTOR DiS series

FANUC AC SPINDLE MOTOR αi/βi series

PARAMETER MANUAL

B-65280EN

BUILT-IN SPINDLE MOTOR Bi series

FANUC AC SERVO MOTOR αis/αi series

AC SPINDLE MOTOR αi series

MAINTENANCE MANUAL

B-65285EN

SERVO AMPLIFIER αi series

FANUC AC SERVO MOTOR βis series

AC SPINDLE MOTOR βi series

MAINTENANCE MANUAL

B-65325EN

SERVO AMPLIFIER βi series

FANUC SERVO AMPLIFIER βi series

MAINTENANCE MANUAL

B-65395EN

FANUC SERVO GUIDE

OPERATOR’S MANUAL

B-65404EN

FANUC AC SERVO MOTOR αis/αi/βis series

SERVO TUNING

B-65264EN

PROCEDURE (BASIC)

- 594 -

B-64485EN/01

11.MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE

11.2 PREVENTIVE MAINTENANCE OF MOTORS AND

DETECTORS

11.2.1 Warnings, Cautions, and Notes on Preventive Maintenance of

Motors and Detectors

This subsection contains the safety precautions for motor and detector preventive maintenance, which are

classified into "warnings", "cautions", and "notes" according to their bearing on safety. Make sure that

you understand and comply with these precautions when carrying out the maintenance work.

WARNING

•

Make sure that you are safely dressed and have a safe working environment when

performing preventive maintenance for a motor.

-

Be dressed safely, e.g. by wearing gloves and safety shoes, to protect against injury due to an

edge or protrusion and electric shock.

-

Have the work done by more than one person, where possible, so that immediate action can be

taken if an accident occurs when handling a motor.

-

A motor is heavy. When moving it, use a crane or other appropriate equipment to protect

against injury. For information about the weight of the motor, refer to its DESCRIPTIONS

manual (shown earlier).

-

Clothes or fingers can be caught in a rotating motor or come into contact with a moving part of

it. Standing in the direction of motor rotation (direction of motion) can pose a risk of injury.

Before rotating a motor, check that there is no object that is thrown away by motor rotation.

•

Be careful about electric shock, fire, and other accidents.

-

Do not handle a motor with a wet hand.

-

To prevent electric shock, make sure that no conductive object, such as a terminal, is exposed

when the motor is powered on.

-

Before touching a motor or any surrounding part, check that the power is shut off and take

appropriate safety precautions.

-

High voltage remains across power line terminals of a motor even after the power is shut off

(for at least five minutes). Do not touch a motor in such a condition or connect it to other

equipment.

-

A loose or disconnected terminal, short-circuited terminals, or a terminal connected to the

ground can cause overheating, spark, fire, or damage to the motor. Take appropriate

precautions to prevent these accidents.

-

When placed near any inflammable object or material, a motor can be ignited, catch fire, or

explode. Avoid placing it near such object or material.

•

Do not disassemble or modify a motor.

Motors such as linear motors, synchronous built-in servo motors, and synchronous built-in spindle

motors contain very strong magnets. If electronic medical apparatus comes near, these motors can

cause the apparatus to malfunction, potentially putting the user's life in danger. Also, disassembling

or modifying a motor can cause a failure, regardless of the type of motor. Do not disassemble or

modify a motor in any way not specified by FANUC.

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CAUTION

• Ensure that the specified cooling conditions are met.

If the specified cooling conditions are not met (the motor is insufficiently or excessively cooled), the

motor can fail. Problems that can cause a motor failure, such as liquid piping clog, leakage, and fan

motor trouble, should be eliminated through periodic inspection. Do not drive the motor when the

cooling system is in an abnormal condition.

• Do not change the system configuration.

Do not change the configuration of the system when it is running normally. Doing so can cause an

accident or failure. If you disconnect a cable for maintenance or some other purpose, take an

appropriate measure, such as putting a mark on it, to ensure you can restore the original state.

• Use the tapped holes of a motor only to move the motor.

Do not use the tapped holes of a motor to lift or move any other object along with the motor. Doing

so can damage the motor. Depending on the type of motor, the place and direction in which the

motor can be lifted may be predetermined. For details, refer to the DESCRIPTIONS manual of the

motor (shown earlier).

• Do not touch a motor when it is running or immediately after it stops.

A motor may get hot when it is running. Do not touch the motor before it gets cool enough.

Otherwise, you may get burned.

NOTE

• Do not remove a nameplate from a motor.

The nameplate is used to identify the motor during maintenance work. If a nameplate comes off, be

careful not to lose it.

• Do not step or sit on a motor, and avoid applying shock to a motor.

Any of these acts can deform or break the motor or affect its component, crippling the normal motor

operation. Do not put a motor on top of another motor.

• Comply with the specified conditions when conducting an electric test (winding

resistance test, insulation resistance test, etc.) for a motor or other device or

supplying power.

-

Conduct an electric test according to the specified method. Conducting such a test by any

method that is not specified can damage the motor.

-

Do not conduct a dielectric strength test or insulation test for a Pulsecoder or other detector, or

do not apply a commercial power source voltage. Doing so can destroy the internal elements.

• Perform preventive maintenance

(inspection of the external appearance,

measurement of winding resistance, insulation resistance, etc.) and cleaning on a

regular basis.

To use a motor safely throughout its entire service life, perform preventive maintenance and

cleaning on a regular basis. Be careful, however, because excessively severe inspection (dielectric

strength test, etc.) can damage its windings. For information about winding resistance values, refer

to the DESCRIPTIONS manual of the motor (its specification number is shown in this manual).

Information about insulation resistance is given later in this manual.

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NOTE

• This manual is focused on the preventive maintenance work to be performed for

a single FANUC motor or detector alone. The information contained herein may

not apply depending on the type or configuration of the machine. When reading

this manual, refer to the manual of the machine as well. If you have any

questions or doubts, do not act on your own; please contact the machine tool

builder or FANUC.

• For detailed information about a motor, see the manual list shown earlier and, if

necessary, obtain the latest version of the corresponding manual.

11.2.2 Preventive Maintenance of a Motor (Common to All Models)

This subsection describes the common preventive maintenance items to be handled regardless of the

model of the motor. For the items specific to a particular motor model, see one of the subsequent

subsections that pertains to that particular motor model.

CAUTION

• The preventive maintenance method differs from machine to machine in many

respects. Depending on the machine in use, it may be difficult for the user to

perform periodic inspection or cleaning. If you are not sure about anything as to

preventive maintenance, consult with the machine tool builder and ensure that

you can perform periodic inspection and cleaning.

• The machine should be used within the scope of specification defined by the

machine tool builder. Using the machine in any way that is outside the specified

scope can reduce the motor's service life or cause a failure.

11.2.2.1 Main inspection items

The following table summarizes the main inspection items for a motor. If any of these items is found to

be abnormal, stop the use of the machine immediately and fix the abnormal part by repairing or

replacing it. At the same time, identify and remove the cause and take a measure to prevent its

recurrence. If it is difficult to take a preventive measure or to prevent its recurrence, consult with the

machine tool builder or FANUC.

Appearance of

Crack or

-

Check the motor for any scar, crack, deformation, bulge, etc.

the motor

deformation

-

If the interior of the motor is visible or there is interference with a

peripheral component, it is imperative to replace the motor or the

peripheral component.

-

A light peel-off or scar of the surface may be repairable; consult with

FANUC.

Wet or dirty part

-

If you find any wet or dirty part, clean it immediately.

-

A preventive measure is needed if the part in question remains wet

continually due to cutting fluid or dew condensation.

Operating

Temperature,

-

Comply with the operating conditions of the machine. For details of the

conditions

humidity, etc.

operating conditions of a specific motor, refer to the corresponding

DESCRIPTIONS manual. Generally, the ambient temperature should

be 0°C to 40°C (or 30°C for a spindle unit) and dew condensation is not

allowed. In a place subject to severe vibration, the components of the

motor may be broken.

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Connection

Cable

-

Check for any cable sheath damage, exposed conductor, damaged

state

conduit or cable bearing, abnormal bending, loose terminal, etc.

-

If there is any trace of fluid flowing, the fluid may have entered the

inside of the motor or connector. It is necessary to make a check and

take a measure to prevent recurrence.

Connector/terminal

-

Check for any cracked, exposed, loose, or removed terminal or

connector, etc.

-

Fluid causes a failure; be sure to remove fluid.

-

A scarred or damaged connector or terminal needs to be replaced. In

the case of a resin molded motor, such as a linear motor, the motor

needs to be replaced.

Operation of

Noise/vibration

-

Check for any abnormal noise or vibration not only when the motor is

the motor

running (the spindle is rotating) but also when it is stopped.

-

Abnormal noise heard when the motor is rotating indicates an

abnormality of the bearing or a failure inside the motor.

Movement

-

Check that the motor operates normally and smoothly.

-

If the circuit breaker trips at the same time the motor starts to operate,

it indicates abnormal motor windings.

Heat

Check whether the motor does not overheat during the normal operation

cycle.

Note: While the motor is running or immediately after it is stopped, the

motor surface may become very hot. Instead of touching the motor directly

by hand, use a thermolabel, surface thermometer, etc.

Electric

Winding resistance

If the resistance value exceeds the specified range, the motor needs to be

characteristics

replaced.

of the motor

Note: When conducting winding resistance measurement, disconnect the

motor from the amplifier and measure the resistance at the power line or

connector closest to the motor.

Insulation

For the measuring method and judgment criteria, see the table that follows.

resistance

Cooling fan

Noise/vibration

-

Check that the fan blows air normally without causing abnormal noise

(for a model

or vibration.

with a fan

-

If abnormal noise is heard even when the motor is stopped, it indicates

motor)

a fan motor failure.

Movement

-

If the power is on and if the fan does not operate or the fan blades

cannot be moved even manually, or if the fan blades are rotating but no

cooling wind is blown out, the fan motor may have cutting chips or

sludge accumulated in it and needs to be cleaned.

-

If the fan does not operate normally for any other reason, the fan motor

needs to be replaced.

Forcible

Dew condensation

-

Check that forcible cooling does not cause dew condensation on the

cooling unit

(over-cooling)

motor surface. Dew condensation is likely particularly when the cooling

(when using an

unit continues to run after the machine is stopped. In that case, be sure

external

to make this check.

cooling unit

-

Dew condensation or water drop on the motor surface can reduce the

such as liquid

motor's service life. It is necessary to wipe it dry and take a measure to

cooling unit)

prevent recurrence.

Liquid

-

Check the cooling pipe for leakage or clog. Do not drive the motor

leakage/clog

unless the leakage or clog is fixed.

-

Liquid leakage from a spindle motor with a through hole indicates a

failure of the coolant joint. In this case, the joint needs to be replaced.

-

In the case of liquid leakage from a linear motor (coil slider), the linear

motor (coil slider) needs to be replaced.

-

If the motor gets wet due to liquid leakage or any other cause, it is

necessary to clean and dry the motor and perform electric

characteristic checks (winding resistance/insulation resistance).

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Insulation resistance measurement

The following table shows the judgment criteria to be applied when measuring insulation resistance

between winding and frame using a megohmmeter (500 VDC).

Insulation resistance

Judgment

100 Ω or higher

Acceptable

The winding has begun deteriorating. There is no problem with the performance at

10 to 100 Ω

present. Be sure to perform periodic inspection.

The winding has considerably deteriorated. Special care is in need. Be sure to perform

1 to 10 Ω

periodic inspection.

Lower than 1 Ω

Unacceptable. Replace the motor.

If insulation resistance drops sharply during a short period of time or if the circuit breaker trips, the

cutting fluid or other foreign matter may have entered the inside of the motor or cable. In that case,

contact the machine tool builder or FANUC for instructions.

CAUTION

• Let the motor dry and cool to room temperature before winding or insulation

resistance is measured. Otherwise, not only an accurate measurement cannot

be performed but also the motor may be damaged.

• The winding or insulation resistance measurement should be performed on the

motor alone, with its power line disconnected.

Measuring insulation resistance with the motor connected to the amplifier may

damage the amplifier.

• During insulation resistance measurement, applying voltage to the motor for a

long time may further deteriorate the insulation of the motor. Therefore, the

measurement of insulation resistance should be performed in a minimum

amount of time where possible.

• When disconnecting the power line and other cables, take an appropriate

measure, such as labeling, to ensure that they can be restored to their original

state.

11.2.2.2 Periodic cleaning of a motor

Periodic cleaning is necessary to remove an accumulation of cutting chips or sludge that may eventually

cause a failure. Also, leaving the cutting fluid or other chemical substance attached for a long time can

reduce the motor's service life substantially. When forcible cooling is provided by a liquid or air cooling

unit, check the unit for pipe clog, fan failure, etc. and perform cleaning periodically to ensure that the

coolant flows smoothly and that the motor is cooled properly.

WARNING

Depending on the type of motor, the handling may involve a risk and require

safety education in advance. Also, some machines are difficult for users to clean

on their own. If you are to clean the motor, consult with the machine tool builder

in advance with regard to the cleaning method, safety education, etc.

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11.2.2.3 Notes on motor cleaning

A motor is an electric product, which is incompatible with most kinds of fluid. When removing cutting

chips, sludge, cutting fluid, etc. during cleaning, note the following.

Note on cleaning

Measure

Do not sprinkle or spray detergent or any other fluid over the motor (including its

Do not sprinkle fluid.

peripheral components), or do not wash the motor by submerging it in such fluid.

Do not wash by

When cleaning the motor, use a cloth moistened with a small amount of neutral

submerging.

detergent so that the fluid does not enter the inside the motor.

Solvent may damage the motor; do not use one. If the dirt is difficult to remove with

neutral detergent, use a cloth moistened with a small amount of industrial alcohol

Do not use solvent.

(e.g., IPA). Be careful, however, because rubbing with force or repeatedly may

damage the coated or resin surface.

If the motor is wet or moistened after cleaning, dry it before supplying power and

Do not leave the motor

before performing electric tests. When drying the motor in an oven, make sure that

wet or moistened.

the temperature is below 40°C and that hot air does not blow directly against the

motor.

11.2.2.4 Notes on the cutting fluid (informational)

Depending on the type of cutting fluid used, the motor and amplifier may be affected greatly. Take due

care because, even if you ensure that they do not come into direct contact with the fluid, a mist or

atmosphere of the fluid can cause the problems described below.

Type of cutting fluid

Expected problem

requiring care

Some types of cutting fluid contain highly active sulfur. If such cutting fluid enters the

Cutting fluid containing

inside of the motor or amplifier, it causes copper, silver, and other kinds of metal to

highly active sulfur

corrode, leading to a component failure.

Some types of cutting fluid containing such substance as polyalkylene glycol have

Synthetic cutting fluid

very high permeability. Such cutting fluid permeates into the inside of the motor,

with high permeability

causing insulation deterioration or component failure.

Some types of cutting fluid that enhance their alkaline property using such substance

Highly alkaline,

as alkanolamine remain highly alkaline - pH10 or higher - when diluted. If such

water-soluble cutting

cutting fluid is left attached for a long time, its chemical change will deteriorate the

fluid

resin and other materials of the motor and amplifier.

Other types of cutting fluid not mentioned above may cause various unexpected problems. If any problem

arises for which the cutting fluid is thought to be responsible, consult with the machine tool builder or

FANUC.

11.2.3 Preventive Maintenance of a Built-in Spindle Motor and

Spindle Unit

This subsection contains the safety precautions you need to bear in mind when performing preventive

maintenance for a built-in spindle motor (BiI or BiS Series) or the FANUC-NSK spindle unit. In some

cases, the work may involve a life-threatening risk or cause substantial damage. Make sure that you fully

understand these safety precautions before carrying out the work.

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WARNING

•

Do not disassemble the spindle. Particularly, the rotor of a synchronous built-in

spindle motor (BiS Series) uses strong permanent magnets. The strong magnet

force may cause injury or medical appliance malfunction.

•

Do not operate a synchronous built-in spindle motor with an external engine.

Doing so is very dangerous because it makes the motor act as a power

generator, generating high voltage. A power outage is also dangerous because

the motor runs freely and, again, generates high voltage. As a safety precaution,

a sub module SM (SSM) is connected between motor and amplifier. Do not

disconnect the SSM under any circumstances. Also, connect the machine frame

to the ground to prevent electric shock.

•

A synchronous built-in spindle motor may perform a pole position detection

operation when it receives the first rotation command after it is powered on or

recovers from an alarm. The pole position detection operation takes 20 to 60

seconds to complete, during which the spindle behaves oddly, e.g., rotating

clockwise and counterclockwise alternately in rapid succession. This

phenomenon is not abnormal. During the detection operation, do not touch or

look down at the spindle, which is a dangerous act.

CAUTION

Performing a test run described in Chapter 3, "TEST RUN METHOD", in Part IV,

of "FANUC - NSK SPINDLE UNIT series DESCRIPTIONS (B-65352)" and the

inspection and maintenance work described in this manual is the condition for

guaranteeing the operation of the FANUC-NSK spindle unit. Be sure to perform

the test run and inspection and maintenance work as instructed.

11.2.3.1 Routine inspection of the FANUC-NSK spindle unit

Perform the following routine inspections every day at the start of operation so that stable performance

can be obtained from the spindle.

Item

Check

1

Check if the axis, when turned manually, rotates lightly and smoothly.

WARNING When turning the axis manually, be sure to turn off the power to the machine.

2

Check if cuttings and coolant residuals are attached to the periphery of a slinger.

3

Check if dust such as cuttings is attached to the spindle taper portion.

4

For operation at 15,000 min^-1 or more immediately after power-up, increase the speed gradually

by using the spindle override function. (This substitutes for a simple test run.)

5

Check if an abnormal sound is generated.

6

Check if an abnormal vibration is generated.

7

Check if an abnormal heat is generated.

11.2.3.2 Maintenance of the FANUC-NSK spindle unit

A FANUC-NSK spindle unit with a grease unit requires periodical maintenance for consumable/wear

parts, such as supplying grease. Depending on the use frequency of and damage to parts, maintenance

generally becomes necessary after two years of machine operation or 10,000 hours of spindle

operation. Contact FANUC or the machine tool builder when maintenance becomes necessary. Also, an

effective way to reduce the machine down time due to maintenance is to prepare spare parts; consult with

the machine tool builder.

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11.2.3.3 Test run of the FANUC-NSK spindle unit

If any of the following cases applies, be sure to contact the machine tool builder and perform a test run as

described in Chapter 3, "TEST RUN METHOD", in Part IV, of "FANUC - NSK SPINDLE UNIT

series DESCRIPTIONS (B-65352EN)".

-

If the spindle unit is rotated for the first time after it is unpacked or attached to the machine

-

If the machine or spindle unit has undergone transportation or relocation

-

If the spindle unit alone has been stored for a period longer than six months or has not been used for

one month or more after installation

CAUTION

FANUC assumes no responsibility for any damage resulting from the failure to perform a

test run or improper use of the spindle unit.

11.2.3.4 Storage method of the FANUC-NSK spindle unit

Apply rust-proof oil to the surface of the spindle unit, pack the spindle unit, and store the packed spindle

unit at a location that satisfies the conditions described below. Also, follow the "This Side Up" and "No

Pile Up" instructions indicated on the pack surface.

-

Indoor well ventilated place not exposed to direct sunlight (place where the temperature varies little,

the room temperature is within 5°C to 40°C, and the humidity is 35% to 85% RH)

-

Place on the shelf subject to little vibration and dust (Do not place the spindle unit directly on the

floor; vibration and dust can damage the bearing or other parts of the spindle.)

Before using the spindle unit after a storage period of one month or more, make necessary checks, such as

measuring winding and insulation resistance, examining the appearance for rust and other problems, and

checking whether the axis can be turned manually. Depending on the storage period, a test run may be

necessary (described earlier).

11.2.4 Preventive Maintenance of a Linear Motor

The magnet plate of a linear motor contains very strong magnets. When performing the maintenance work,

make sure all those engaged in the work fully understand the potential risks involved.

WARNING

• The FANUC linear motors use very strong magnets. Improper handling of the

motor is very dangerous and can lead to a serious accident. Particularly, a

person wearing a pacemaker or other medical apparatus should stay away from

the linear motor; otherwise, the apparatus may malfunction, potentially resulting

in a life-threatening accident.

• Those who will come near or touch a linear motor for maintenance work should

receive safety education in advance. For details, contact the machine tool builder

or FANUC.

11.2.4.1 Appearance inspection of the linear motor (magnet plate)

Perform an appearance inspection as well during cleaning or other maintenance work. A crack, chip,

deformation, or any other abnormality in appearance of the motor can lead to a serious failure in the

not-so-distant future. If you find any such abnormality, be sure to report it to the machine tool builder. A

scratch or other slight scar on the motor surface can also be a sign of future trouble and needs to be

addressed with care. Some suggested appearance inspection items for the magnet plate are described

below.

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* For the coil slider (the side to which the power line is connected), see "Main inspection items"

earlier in this manual.

Appearance of the magnet plate (which may have a stainless cover)

Appearance inspection item

Measure

Crack or chip in the magnet plate resin

The magnet plate needs to be replaced. If unattended, it can

Deformation or bulge of the magnet plate or

cause trouble in the not-so-distant future. If the problem is

softening of the resin

extremely minor, consult with the machine tool builder or FANUC.

The magnet is exposed, or the resin or

The magnet plate needs to be replaced urgently.

magnet is floating

Foreign matter may have entered into the motor, or interference

Scratch on the magnet plate

between parts is likely. It is necessary to eliminate the cause and

take a measure to prevent recurrence.

Floating, bulging, or deformed stainless

The cover or magnet plate needs to be replaced.

cover

11.2.5 Maintenance of a Detector

CAUTION

• Detectors such as Pulsecoders are precision equipment. When handling a

detector, avoid applying shock to it. Also, exercise care to prevent cutting

powder, dust, cutting fluid, or other foreign matter from attaching to it.

• Make sure that all connectors are connected properly and securely. A

connection failure can cause an alarm or some other problem.

• If the detector and/or connectors are not installed securely, cutting fluid may

enter the inside of the detector, making it necessary to replace the detector. In

that case, contact the machine tool builder or FANUC.

NOTE

If you use a detector not manufactured by FANUC, contact the machine tool

builder or detector manufacturer for detailed information on the detector.

11.2.5.1 Alarms for built-in detectors (αi and βi Pulsecoders) and

troubleshooting actions

These alarms concern built-in detectors that are connected directly to the control unit (CNC/servo

amplifier).

Based on the alarm number and description, take an appropriate action as described in the following

subsection, "Detailed troubleshooting methods".

Detailed

Alarm No.: Alarm

Description

Possible cause

Action

troubleshooting

method

-

Communication

361: ABNORMAL PHASE

error in the

- Pulse coder failure

Replace the

(3)

DATA(INT)

Pulsecoder

- Noise

Pulsecoder.

(4)

-

ID data error

Check the effect

364: SOFT PHASE

- Noise

of noise.

(1)

Position data alarm

ALARM(INT)

- Entry of cutting fluid

Replace the

(3)

Pulsecoder.

Replace the

365: BROKEN LED(INT)

LED disconnection

- Pulse coder failure

(3)

Pulsecoder.

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Detailed

Alarm No.: Alarm

Description

Possible cause

Action

troubleshooting

method

Small internal signal

- Pulse coder failure

Replace the

(3)

366: PULSE MISS(INT)

amplitude

- Noise

Pulsecoder.

(4)

Position data count

- Pulse coder failure

Replace the

(3)

367: COUNT MISS(INT)

error

- Noise

Pulsecoder.

(4)

- Cable disconnection

Check the cable.

(2)

368: SERIAL DATA

Communication

- Pulse coder failure

Replace the

(3)

ERROR(INT)

interruption

- Noise

Pulsecoder.

(4)

369: DATA TRANS.

Communication

Check the effect

- Noise

(1)

ERROR(INT)

data alarm

of noise.

453: SPC SOFT

Position - pole data

- Pulse coder failure

Replace the

(3)

DISCONNECT ALARM

error

- Entry of cutting fluid

Pulsecoder.

11.2.5.2 Alarms for separate detectors and troubleshooting actions

These alarms concern separate detectors that are connected to the control unit via a separate detector

interface unit (SDU).

Based on the alarm number and description, take an appropriate action as described in the following

subsection, "Detailed troubleshooting methods".

Detailed

Alarm No.: Alarm

Description

Possible cause

Action

troubleshooting

method

380: BROKEN LED(EXT)

LED disconnection

Position data count

382: COUNT MISS(EXT)

error

Replace the

Small internal

- Detector failure

(4)

383: PULSE MISS(EXT)

detector.

signal amplitude

384: SOFT PHASE

Position data alarm

ALARM(EXT)

Check the cable.

- Cable disconnection

Check the effect

(2)

385: SERIAL DATA

Communication

- Noise

of noise.

(1)

ERROR(EXT)

interruption

- Detector failure

Replace the

(4)

detector.

386: DATA TRANS.

Communication

Check the effect

- Noise

(1)

ERROR(EXT)

data alarm

of noise.

381: ABNORMAL PHASE

(EXT)

For details, contact the machine tool builder or detector manufacturer.

387: ABNORMAL

ENCODER(EXT)

11.2.5.3 Detailed troubleshooting methods

(1) Checking the effect of noise

Check the value on the diagnostics data No. 356 (for a built-in detector) or 357 (for a separate detector) of

the CNC unit.

Normally, 0 is displayed. However, if the position data from the Pulsecoder becomes unstable due to

noise or some other factor, this value is incremented. The value is cleared when the CNC unit is powered

off. Immediately after the power is turned on, 0 is displayed.

(2) Checking the cable

Check whether the feedback cable is not disconnected and whether the connector is properly plugged.

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(3) Replacing the Pulsecoder

× Do not loosen

Bolt fastening the Pulsecoder cover M3

(3)-1 Pulse coder replacement procedure

<1> Remove the four M4 hexagon socket head cap

screws fastening the Pulsecoder. The M3 bolts

○ Remove

Bolt fastening the Pulsecoder M4

fastening the Pulsecoder cover do not need to

be loosed. (See the figure at right.)

<2> Remove the Pulsecoder and Oldham's coupling

(see the following figure).

Oldham's coupling

<3> Set the new Pulsecoder and Oldham's coupling on

the motor. Adjust the direction of the mate

Oldham's coupling to that of the Oldham's

coupling so that the teeth are engaged.

Push in the Pulsecoder until the O ring fits in the

joint between the motor and Pulsecoder. Take care

O ring

so that the O ring of the Pulsecoder is not bitten.

Mate Oldham's coupling

Thermistor connector

Adjust the connector direction

ttach the Pulsecoder in such a direction that the

power connector of the servo motor and the

feedback cable of the Pulsecoder face the same

Adjust the connection parts

direction or that the thermistor connection parts of

the servo motor and Pulsecoder match each other

Pulse coder

Servo motor

(see the figure at left).

<4> Fastening the Pulsecoder with the four M4 hexagon socket head cap screws in the reverse order of

removing the Pulsecoder (<1>). (Appropriate torque: 1.5 Nm)

(3)-2 Feedback cable plugging procedure

Plug in the feedback cable connector, as instructed in the

procedure below, and check that the connector is securely

connected.

<1> Check the plugging side and key direction.

Main key

Coupling nut

Check that the plugging side is free of foreign matter,

such as dirt and oil.

Straight type

Right angle type

<2> Plug in the feedback cable connector.

Hold the connector, as shown in the figure at

right. Plug in the connector until you hear a

click.

Caution)

Do not hold the coupling nut.

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<3> Check the connection condition.

1.

Check that the arrow mark of the

connector is at the center, as shown in

the figure at right. If the arrow mark is

not at the center, turn the coupling nut

manually until the mark comes to the

appropriate position.

2.

Hold the connector by the same part as in <2>, and pull it lightly toward you to check that the

connector does not come off. Do not pull the connector with force.

(4) If troubleshooting is difficult for the user

If the problem is difficult for the user to troubleshoot because it is due to a detector failure or noise,

consult with the machine tool builder or FANUC.

11.2.5.4 Maintenance of βiS motor Pulsecoders

Problems concerning the Pulsecoders of the motors listed in the table below require the maintenance

(replacement) of the entire motor (it is not possible to maintain the Pulsecoder alone).

Motor model

Motor specification

Remarks

βiS 0.2/5000

A06B-0111-Bx03

x=1,2,4,5

βiS 0.3/5000

A06B-0112-Bx03

βiS 0.4/5000

A06B-0114-Bx03#0y00

x=1,2,4,5 y=0,1

βiS 0.5/6000

A06B-0115-Bx03#0y00

βiS 1/6000

A06B-0116-Bx03#0y00

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B-64485EN/01

11.MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE

11.3 PREVENTIVE MAINTENANCE OF SERVO AMPLIFIERS

11.3.1 Warnings, Cautions, and Notes on Preventive Maintenance of

Servo Amplifiers

This subsection contains the safety precautions on preventive maintenance of a servo amplifier (a generic

term to refer to the power supply, servo amplifier, spindle amplifier, and other sub modules of a motor

drive unit). These precautions are classified into "warnings", "cautions", and "notes" according to their

bearing on safety. Make sure that you understand and comply with these precautions when carrying out

the maintenance work.

WARNING

•

Make sure that you are safely dressed and have a safe working environment when

performing preventive maintenance for a servo amplifier.

-

Be dressed safely, e.g. by wearing gloves and safety shoes, to protect against injury due to an

edge or protrusion and electric shock.

-

Have the work done by more than one person, where possible, so that immediate action can be

taken if an accident occurs when handling a motor.

-

A servo amplifier and AC reactor contain heavy components. Be careful when transporting

them or mounting them on the power magnetic cabinet. Also be careful not to get your fingers

caught between the power magnetics cabinet and servo amplifier.

•

Before turning on the power, check that the door of the power magnetics cabinet and

all other doors.

-

Ensure that the door of the power magnetics cabinet containing the servo amplifier, as well as

all other doors, are closed and locked except during maintenance work.

•

When the need arises to open the door of the power magnetics cabinet, only a person trained in

the maintenance of the corresponding machine or equipment should do the task after shutting

off the power supply to the power magnetics cabinet by opening both the input circuit breaker

of the power magnetics cabinet and the factory switch used to supply power to the cabinet.

•

Be careful about electric shock, fire, and other accidents.

-

If the machine must be operated with the door open for adjustment or some other purpose, the

operator must keep his or her hands and tools well away from any dangerous voltages. Such

work must be done only by a person trained in the maintenance of the machine or equipment.

-

Ensure that the door of the power magnetics cabinet is locked so that the door cannot be opened

by anyone, except service personnel or a qualified person trained in maintenance to prevent

electric shock, when the servo amplifier is powered on.

-

When the need arises for an operator to open the door of the power magnetics cabinet and

perform an operation, ensure that the operator is sufficiently educated in safety or that a

protective cover is added to prevent the operator from touching any dangerous part.

-

The servo amplifier contains a large-capacity electrolytic capacitor in it and remains charged

for a while after the power is shut off. Before touching the servo amplifier for maintenance or

some other purpose, measure the residual voltage of the DC link connection using a tester and

check that the red LED for indicating charging is in progress is not lit, in order to ensure safety.

-

After wiring, be sure to close the servo amplifier cover.

-

A loose screw or poor connector contact can cause a motor malfunction or overheating,

connection to ground, or short-circuit. Be extremely careful with power supply lines, motor

power lines, and DC link connections through which a large electric current flows, because a

loose screw or poor connector contact may lead to a fire. Tighten screws and connectors using

the specified screw tightening torque.

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11.MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE

B-64485EN/01

-

The surfaces of the regenerative discharge unit and heat radiator may become very hot. Do not

touch them directly by hand.

• When operating the machine for the first time after preventive maintenance, check

that the machine operates as instructed.

-

To check whether the machine operates as instructed, first specify a small value for the motor

and then increase the value gradually. If the motor operates abnormally, perform an emergency

stop immediately.

-

When pressing the emergency stop button, check that the motor stops immediately and that the

power being supplied to the amplifier is shut off by the magnetic contactor.

• Notes on alarms

-

If the machine stops due to an alarm, check the alarm number. Depending on the alarm issued,

if the power is supplied without replacing the failed component, another component may be

damaged, making it difficult to identify the original cause of the alarm.

-

Before resetting an alarm, ensure that the original cause of the alarm has been removed.

• If the motor causes any abnormal noise or vibration while operating, stop it

immediately.

-

Using the motor in spite of the abnormal noise or vibration may damage the servo amplifier.

• Do not disassemble or modify a servo amplifier.

Do not disassemble or modify a servo amplifier in any way not specified by FANUC; doing so can

lead to a failure.

CAUTION

•

Notes on servo amplifier replacement and wiring

-

The work of servo amplifier replacement and wiring should be carried out by a person trained

in the maintenance of the machine and equipment concerned.

-

When replacing a servo amplifier, check that the combination of the amplifier and the motor is

appropriate.

-

Check that the servo amplifier is securely mounted on the power magnetics cabinet. If there is

any clearance between the power magnetics cabinet and the surface on which the amplifier is

mounted, dust entering the gap may hinder the normal operation of the servo amplifier.

-

Ensure that the power supply lines, motor power lines, and signal lines are each connected to

the correct terminal or connector.

-

Unless otherwise instructed, do not unplug a connector and plug it back with the power on;

doing so may cause the servo amplifier to fail.

-

When mounting or unmounting the servo amplifier, exercise care not to get your fingers caught

between the servo amplifier and power magnetics cabinet.

-

Take care not to lose track of removed screws. Turning on the power with any lost screw left in

the unit may damage the machine.

-

Exercise care to prevent the power supply lines and motor power lines from being connected to

the ground or being short-circuited.

-

Protect the lines from any stress such as bending. Handle the line ends appropriately.

•

Be careful about the handling of a servo amplifier.

-

Do not disassemble a servo amplifier. Doing so poses the risk of electric shock, because the

capacitor may remain charged.

-

Do not apply shock to a servo amplifier. Doing so may damage its components, potentially

causing the amplifier to malfunction.

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B-64485EN/01

11.MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE

-

Do not apply an excessively large force to plastic parts. If a plastic section breaks, it may

damage internal parts, thus hindering normal operation or leading to a risk of injury due to a

broken section.

• Be careful about the operating environment of a servo amplifier.

-

Prevent conductive, combustible, or corrosive foreign matter, mist, or drops of water from

entering the inside of the unit. The entry of any such material may cause the unit to explode,

break, malfunction, etc.

-

Exercise care to prevent cutting fluid, oil mist, cutting chips, or other foreign matter from

attaching to the radiator or fan motor exposed to the outside of the power magnetics cabinet.

Otherwise, the servo amplifier may become unable to meet its specifications. The service lives

of the fan motor and semiconductors can also be reduced.

• Clean the heat sink and fan motor on a regular basis.

-

Replace the filter of the power magnetics cabinet on a regular basis.

-

Before cleaning the heat sink, shut down the power and ensure that the temperature of the heat

sink is as cool as the room temperature. The heat sink is very hot immediately after power

shutdown, touching it may cause burn injury.

-

When cleaning the heat sink by blowing air, be careful about dust scattering. Conductive dust

attached to the servo amplifier or its peripheral equipment can lead to a failure.

NOTE

• Make sure that there is sufficient maintenance clearance around the doors of the

machine and equipment.

• Do not step or sit on the servo amplifier, or do not apply shock to it.

• Do not remove a nameplate from a motor.

-

The nameplate is necessary to identify the servo amplifier during maintenance work.

-

If a nameplate comes off, be careful not to lose it.

NOTE

• This manual is focused on the preventive maintenance work to be performed for

a FANUC servo amplifier. The information contained herein may not apply

depending on the type or configuration of the machine. When reading this

manual, refer to the manual of the machine as well. If you have any questions or

doubts, do not act on your own; please contact the machine tool builder or

FANUC.

• For detailed information about a servo amplifier, see the manual list shown

earlier and, if necessary, obtain the latest version of the corresponding manual.

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11.MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE

B-64485EN/01

11.3.2 Preventive Maintenance of a Servo Amplifier

To use a servo amplifier safely throughout its entire service life, perform daily and periodic

inspections.

CAUTION

• The preventive maintenance method differs from machine to machine in many

respects. Depending on the machine in use, it may be difficult for the user to

perform periodic inspection or cleaning. If you are not sure about anything as to

preventive maintenance, consult with the machine tool builder and ensure that

you can perform periodic inspection and cleaning.

• The machine should be used within the scope of specification defined by the

machine tool builder. Using the machine in any way that is outside the specified

scope can reduce the servo amplifier's service life or cause a failure.

Inspection

Inspection interval

Inspection item

Judgment criterion

part

Routine

Periodic

Ambient

Around the power magnetics cabinet: 0°C - 45°C

V

temperature

Inside the power magnetics cabinet: 0°C - 55°C

Humidity

V

90% or below RH (dew condensation not allowed)

There shall be no dust or oil mist attached near the

Dust/oil mist

V

servo amplifier.

The cooling fan shall be operating normally without

Operating

Cooling air path

V

the air flow being interrupted.

environment

- No abnormal noise or vibration shall be present

Abnormal

that has not been experienced in the past.

V

vibration/noise

- Vibration near the servo amplifier shall be 0.5 G

or less.

200-V input type: Within 200 - 240 V

Supply voltage

V

400-V input type: Within 400 - 480 V

There shall be no abnormal noise or smell, and

General

V

there shall be no dust or oil mist attached.

Screw

V

There shall be no loose screw.

- There shall be no abnormal vibration or noise,

Servo

Fan motor ^{(NOTE 1, 2)}

V

and the fan blades shall be rotating normally.

amplifier

- There shall be no dust or oil mist attached.

Connector

V

There shall be no loose or broken connector.

There shall be no sign of overheating or sheath

Cable

V

deterioration (discoloration pr crack).

The machine operator's panel or screen shall not

Absolute ^{(NOTE 2)}

CNC

V

display the alarm indicating the battery voltage of

Pulse coder battery

the absolute Pulsecoder is low.

Magnetic contactor

V

The contactor shall not rattle or chatter.

External

Ground fault

V

The interrupter shall be able to trip.

equipment

interrupter

AC reactor

V

There shall be no hum.

NOTE

1 Fan motors are periodic-replacement parts. It is recommended to inspect fan

motors on a routine basis and replace them in a preventive manner.

2 Fan motors and batteries are periodic-replacement parts. It is recommended to

keep spare parts.

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B-64485EN/01

11.MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE

11.3.3 Maintenance of a Servo Amplifier

11.3.3.1 Display of the servo amplifier operation status

The STATUS LEDs on the front of the servo amplifier indicate the operation status of the servo amplifier

(whether it is operating normally, the type of alarm, etc.). Use these LEDs for maintenance, inspection,

troubleshooting, etc.

CAUTION

A servo amplifier failure may arise from a combination of multiple causes, in

which case it can be difficult to identify all those causes. Handling the failure in

an improper way may worsen the problem. It is therefore important to analyze

the failure status minutely and identify the true cause or causes of the failure.

There may be cases in which the failure appears to have been fixed but later

recurs or cause a more serious trouble. If you are not sure about the root cause

of or corrective action for a failure, do not act on your own; please contact the

machine tool builder or FANUC for instructions on proper action.

[αi series]

(1) Power supply

STATUS

STATUS LED position

Description

display

The STATUS LED is off.

Control power has not been supplied, cable is faulty, or control

power circuit is defective.

Nameplate

Not ready status

The main circuit is not supplied with power (magnetic contactor is

off); emergency stop state.

Ready status

The main circuit is supplied with power (magnetic contactor is on);

the power supply is ready for operation.

Warning state (The dot at the lower right lights.)

The power supply has failed; an alarm has occurred after a certain

time of operation.

The warning type is indicated by the character displayed.

Alarm status

The alarm type is indicated by the character displayed.

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