TÀI LIỆU HƯỚNG DẪN BẢO TRÌ SỬA CHỮA - Bộ Servo Amplifier Fanuc - Ai Series (FANUC AC Servo Amplifier Motor Maintenance Manual B-65285EN_04) Full. | Cộng đồng Kỹ thuật cơ điện Việt Nam EBOOKBKMT

This manual describes information necessary to maintain FANUC Servo Amplifier αi series products, such as a Power Supply, Servo Amplifier, and Spindle Amplifier and FANUC Servo Motor αi s/αi series and FANUC Spindle Motor αi series products.

Part I explains the start-up procedure, and part II focuses on troubleshooting.

Part III explains the maintenance for servo motor and spindle motor.

TABLE OF CONTENTS

SAFETY PRECAUTIONS........................................................................... S-1

1.1 DEFINITION OF WARNING, CAUTION, AND NOTE................................. s-2

1.2 FANUC AC SERVO MOTOR αis/αi series

FANUC AC SPINDLE MOTOR αi series .................................................... s-3

1.2.1 Warning .................................................................................................................s-3

1.2.2 Caution ..................................................................................................................s-5

1.2.3 Note .......................................................................................................................s-6

1.3 FANUC SERVO AMPLIFIER αi series ....................................................... s-8

1.3.1 Warnings and Cautions Relating to Mounting ......................................................s-8

1.3.1.1 Warning ......................................................................................................... s-8

1.3.1.2 Caution........................................................................................................... s-9

1.3.1.3 Note.............................................................................................................. s-10

1.3.2 Warnings and Cautions Relating to a Pilot Run ..................................................s-10

1.3.2.1 Warning ....................................................................................................... s-10

1.3.2.2 Caution......................................................................................................... s-11

1.3.3 Warnings and Cautions Relating to Maintenance ...............................................s-12

1.3.3.1 Warning ....................................................................................................... s-12

1.3.3.2 Caution......................................................................................................... s-13

1.3.3.3 Note.............................................................................................................. s-13

PREFACE ....................................................................................................p-1

I. START-UP PROCEDURE

1 OVERVIEW ............................................................................................. 3

2 CONFIGURATIONS ................................................................................ 4

2.1 CONFIGURATIONS ...................................................................................... 4

2.2 MAJOR COMPONENTS ............................................................................... 5

2.2.1 Power Supply ...........................................................................................................5

2.2.2 Servo Amplifier ........................................................................................................6

2.2.3 Spindle Amplifier .....................................................................................................8

3 START-UP PROCEDURE..................................................................... 11

3.1 START-UP PROCEDURE (OVERVIEW) .................................................... 11

3.2 CONNECTING THE POWER ...................................................................... 11

3.2.1 Checking the Voltage and Capacity of the Power..................................................11

3.2.2 Connecting a Protective Ground ............................................................................12

3.2.3 Selecting the Ground Fault Interrupter That Matches the Leakage Current ..........12

3.2.4 Checking the Phase Sequence of the Fan Motor Power Supply.............................12

3.3 INITIALIZING PARAMETERS ..................................................................... 12

4 CONFIRMATION OF THE OPERATION .............................................. 13

4.1 POWER SUPPLY ........................................................................................ 13

4.1.1 Checking the Status LEDs (Power Supply)............................................................14

4.1.2 Check Terminal on the Printed-circuit Board.........................................................14

4.1.3 The PIL LED (Power ON Indicator) Is Off............................................................16

4.1.4 Checking Method when Magnetic Contactor Is not Switched On .........................16

4.2 SERVO AMPLIFIER .................................................................................... 17

4.2.1 Checking the STATUS Display (Servo Amplifier)................................................18

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4.2.2 VRDY-OFF Alarm Indicated on the CNC Screen .................................................18

4.2.3 Method for Observing Motor Current ....................................................................19

4.3 SPINDLE AMPLIFIER ................................................................................. 22

4.3.1 STATUS Display (Spindle Amplifier) ...................................................................23

4.3.2 Troubleshooting at Startup .....................................................................................23

4.3.2.1 The PIL LED (power-on indicator) is off. ...................................................... 23

4.3.2.2 The STATUS display is blinking with "--.".................................................... 23

4.3.2.3 The motor does not turn. ................................................................................. 24

4.3.2.4 A specified speed cannot be obtained. ............................................................ 24

4.3.2.5 When cutting is not performed, the spindle vibrates, making noise. .............. 25

4.3.2.6 An overshoot or hunting occurs. ..................................................................... 25

4.3.2.7 Cutting power weakens or acceleration/deceleration slows down.................. 25

4.3.3 Status Error Indication Function ............................................................................26

4.3.4 Checking the Feedback Signal Waveform .............................................................29

4.3.4.1 αi M sensor, αi MZ sensor, and αi BZ sensor................................................ 30

4.3.4.2 Analog αi CZ sensor....................................................................................... 31

4.3.4.3 α position coder S ........................................................................................... 32

4.3.5 Spindle Check Board..............................................................................................32

4.3.5.1 Spindle check board specifications ................................................................. 32

4.3.5.2 Check board connection.................................................................................. 33

4.3.5.3 Check terminal output signals......................................................................... 33

4.3.6 Observing Data Using the Spindle Check Board ...................................................35

4.3.6.1 Overview......................................................................................................... 35

4.3.6.2 Major characteristics ....................................................................................... 35

4.3.6.3 Observation method ........................................................................................ 35

4.3.6.4 Specifying data to be monitored ..................................................................... 36

4.3.6.5 Address descriptions and initial values (Spindle Amplifier) .......................... 36

4.3.6.6 Principles in outputting the internal data of the serial spindle ........................ 37

4.3.6.7 Data numbers .................................................................................................. 39

4.3.6.8 Example of observing data.............................................................................. 41

4.3.7 Checking Parameters Using the Spindle Check Board ..........................................42

4.3.7.1 Overview......................................................................................................... 42

4.3.7.2 Checking parameters....................................................................................... 42

4.3.8 Observing Data Using the SERVO GUIDE ...........................................................42

4.3.8.1 Overview......................................................................................................... 42

4.3.8.2 Usable series and editions ............................................................................... 42

4.3.8.3 List of spindle data that can be observed using the SERVO GUIDE ............. 43

4.3.8.4 About the spindle control and spindle status signals ...................................... 44

4.3.8.5 Example of observing data.............................................................................. 45

II. TROUBLESHOOTING

1 OVERVIEW ........................................................................................... 49

2 ALARM NUMBERS AND BRIEF DESCRIPTIONS .............................. 50

2.1 FOR Series 15i ....................................................................................................... 50

2.1.1 Servo Alarm ...........................................................................................................50

2.1.2 Spindle Alarm.........................................................................................................51

2.2 FOR Series 16i, 18i, 20i, 21i, 0i, AND Power Mate i ....................................... 54

2.2.1 Servo Alarm ...........................................................................................................54

2.2.2 Spindle Alarm.........................................................................................................55

2.3 FOR Series 30i/ 31i/32i ......................................................................................... 58

2.3.1 Servo Alarm ...........................................................................................................58

2.3.2 Spindle Alarm.........................................................................................................59

2.4 FOR Series 0i-D .......................................................................................... 61

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2.4.1 Servo Alarm ...........................................................................................................61

2.4.2 Spindle Alarm.........................................................................................................62

3 TROUBLESHOOTING AND ACTION................................................... 64

3.1 POWER SUPPLY (αiPS, αiPSR) ................................................................. 64

3.1.1 No LED Display (αiPS, αiPSR) .............................................................................64

3.1.2 Alarm Code 1 (αiPS)..............................................................................................64

3.1.3 Alarm Code 2 (αiPS, αiPSR) ..................................................................................65

3.1.4 Alarm Code 3 (αiPS)..............................................................................................65

3.1.5 Alarm Code 4 (αiPS, αiPSR) ..................................................................................65

3.1.6 Alarm Code 5 (αiPS, αiPSR) ..................................................................................66

3.1.7 Alarm Code 6 (αiPS, αiPSR) ..................................................................................66

3.1.8 Alarm Code 7 (αiPS, αiPSR) ..................................................................................66

3.1.9 Alarm Code 8 (αiPSR) ............................................................................................66

3.1.10 Alarm Code A (αiPS).............................................................................................67

3.1.11 Alarm Code E (αiPS, αiPSR) .................................................................................67

3.1.12 Alarm Code H (αiPSR) ...........................................................................................67

3.1.13 Alarm Code P (αiPS, αiPSR)..................................................................................67

3.2 SERVO AMPLIFIER .................................................................................... 68

3.2.1 Alarm Code 1 .........................................................................................................69

3.2.2 Alarm Code 2 .........................................................................................................69

3.2.3 Alarm Code 5 .........................................................................................................69

3.2.4 Alarm Code 6 .........................................................................................................69

3.2.5 Alarm Code F .........................................................................................................70

3.2.6 Alarm Code P .........................................................................................................70

3.2.7 Alarm Code 8 .........................................................................................................70

3.2.8 Alarm Codes 8., 9., and A. .....................................................................................70

3.2.9 Alarm Codes 8., 9., and A. .....................................................................................71

3.2.10 Alarm Codes b, c, and d .........................................................................................71

3.2.11 Alarm Code "-" Blinking........................................................................................71

3.2.12 Alarm Code U ........................................................................................................72

3.2.13 Alarm Code L .........................................................................................................72

3.2.14 DB Relay Error (CNC Message "Alarm SV0654") ...............................................73

3.3 SERVO SOFTWARE................................................................................... 73

3.3.1 Servo Adjustment Screen .......................................................................................73

3.3.2 Diagnosis Screen ....................................................................................................74

3.3.3 Overload Alarm (Soft Thermal, OVC)...................................................................75

3.3.4 Feedback Disconnected Alarm...............................................................................76

3.3.5 Overheat Alarm ......................................................................................................77

3.3.6 Invalid Servo Parameter Setting Alarm..................................................................77

3.3.7 Alarms Related to Pulsecoder and Separate Serial Detector ..................................78

3.3.8 Other Alarms ..........................................................................................................79

3.4 SPINDLE AMPLIFIER ................................................................................. 81

3.4.1 Alarm Code 01 .......................................................................................................81

3.4.2 Alarm Code 02 .......................................................................................................81

3.4.3 Alarm Code 03 .......................................................................................................82

3.4.4 Alarm Code 06 .......................................................................................................82

3.4.5 Alarm Code 07 .......................................................................................................83

3.4.6 Alarm Code 09 .......................................................................................................83

3.4.7 Alarm Code 10 .......................................................................................................83

3.4.8 Alarm Code 12 .......................................................................................................84

3.4.9 Alarm Code 13 .......................................................................................................84

3.4.10 Alarm Code 14 .......................................................................................................84

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3.4.11 Alarm Code 15 .......................................................................................................85

3.4.12 Alarm Code 16 .......................................................................................................85

3.4.13 Alarm Code 17 .......................................................................................................85

3.4.14 Alarm Code 18 .......................................................................................................85

3.4.15 Alarm Codes 19 and 20 ..........................................................................................85

3.4.16 Alarm Code 21 .......................................................................................................86

3.4.17 Alarm Code 22 ......................................................................................................86

3.4.18 Alarm Code 24 .......................................................................................................86

3.4.19 Alarm Code 27 .......................................................................................................86

3.4.20 Alarm Code 29 .......................................................................................................87

3.4.21 Alarm Code 31 .......................................................................................................88

3.4.22 Alarm Code 32 .......................................................................................................88

3.4.23 Alarm Code 34 .......................................................................................................88

3.4.24 Alarm Code 36 .......................................................................................................88

3.4.25 Alarm Code 37 .......................................................................................................89

3.4.26 Alarm Code 41 .......................................................................................................89

3.4.27 Alarm Code 42 .......................................................................................................90

3.4.28 Alarm Code 43 .......................................................................................................90

3.4.29 Alarm Code 46 .......................................................................................................90

3.4.30 Alarm Code 47 .......................................................................................................90

3.4.31 Alarm Code 49 ......................................................................................................91

3.4.32 Alarm Code 50 .......................................................................................................91

3.4.33 Alarm Codes 52 and 53 ..........................................................................................92

3.4.34 Alarm Code 54 .......................................................................................................92

3.4.35 Alarm Code 55 .......................................................................................................92

3.4.36 Alarm Code 56 .......................................................................................................92

3.4.37 Alarm Code 61 .......................................................................................................92

3.4.38 Alarm Code 65 .......................................................................................................93

3.4.39 Alarm Code 66 .......................................................................................................93

3.4.40 Alarm Code 67 .......................................................................................................93

3.4.41 Alarm Code 69 .......................................................................................................93

3.4.42 Alarm Code 70 .......................................................................................................94

3.4.43 Alarm Code 71 .......................................................................................................94

3.4.44 Alarm Code 72 .......................................................................................................94

3.4.45 Alarm Code 73 .......................................................................................................94

3.4.46 Alarm Code 74 .......................................................................................................95

3.4.47 Alarm Code 75 .......................................................................................................95

3.4.48 Alarm Code 76 .......................................................................................................95

3.4.49 Alarm Code 77 .......................................................................................................95

3.4.50 Alarm Code 78 .......................................................................................................96

3.4.51 Alarm Code 79 .......................................................................................................96

3.4.52 Alarm Code 80 .......................................................................................................96

3.4.53 Alarm Code 81 .......................................................................................................96

3.4.54 Alarm Code 82 .......................................................................................................97

3.4.55 Alarm Code 83 .......................................................................................................97

3.4.56 Alarm Code 84 .......................................................................................................98

3.4.57 Alarm Code 85 .......................................................................................................98

3.4.58 Alarm Code 86 .......................................................................................................98

3.4.59 Alarm Code 87 .......................................................................................................98

3.4.60 Alarm Code 88 .......................................................................................................98

3.4.61 Alarm Code 89 .......................................................................................................98

3.4.62 Alarm Code 90 ......................................................................................................99

3.4.63 Alarm Code 91 ......................................................................................................99

3.4.64 Alarm Code 92 .....................................................................................................100

3.4.65 Alarm Codes A, A1, and A2 ................................................................................100

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3.4.66 Alarm Code b0 .....................................................................................................100

3.4.67 Alarm Codes C0,C1, and C2 ................................................................................101

3.4.68 Alarm Code C3.....................................................................................................101

3.4.69 Alarm Code C4....................................................................................................101

3.4.70 Alarm Code C5....................................................................................................101

3.4.71 Alarm Code C7....................................................................................................101

3.4.72 Alarm Code C8....................................................................................................101

3.4.73 Alarm Code C9....................................................................................................102

3.4.74 Alarm Code d0 ....................................................................................................102

3.4.75 Alarm Code d1 ....................................................................................................102

3.4.76 Alarm Code d2 .....................................................................................................102

3.4.77 Alarm Code d3 ....................................................................................................103

3.4.78 Alarm Code d4 .....................................................................................................103

3.4.79 Alarm Code d7 .....................................................................................................103

3.4.80 Alarm Code d9 .....................................................................................................103

3.4.81 Alarm Code E0 .....................................................................................................103

3.4.82 Alarm Code E1 ....................................................................................................104

3.4.83 Other Alarms ........................................................................................................104

3.5 αCi SERIES SPINDLE AMPLIFIER MODULE .......................................... 105

3.5.1 Alarm Code 12 .....................................................................................................105

3.5.2 Alarm Code 35 .....................................................................................................106

4 REPLACING AMPLIFIER COMPONENTS......................................... 107

4.1 REPLACEMENT OF A FAN MOTOR ........................................................ 107

4.2 REPLACING BATTERY FOR ABSOLUTE PULSECODERS .................... 112

4.2.1 Overview ..............................................................................................................112

4.2.2 Replacing Batteries...............................................................................................112

4.2.3 Replacing the Batteries in a Separate Battery Case..............................................113

4.2.4 Replacing the Battery Built into the Servo Amplifier ..........................................113

4.2.5 Notes on Replacing a Battery (Supplementary Explanation) ...............................115

4.2.5.1 Battery connection modes ............................................................................. 115

4.2.5.2 Connecting the battery for the α series motor............................................... 115

4.2.5.3 Notes on attaching connectors ...................................................................... 116

4.3 HOW TO REPLACE THE FUSES ............................................................. 118

4.3.1 Fuse Locations......................................................................................................119

4.3.1.1 Power Supply ................................................................................................ 119

4.3.1.2 Servo Amplifier ............................................................................................ 119

4.3.1.3 Spindle Amplifier.......................................................................................... 120

III. MOTOR/DETECTOR/AMPLIFIER PREVENTIVE

MAINTENANCE

1 MOTOR/DETECTOR/AMPLIFIER PREVENTIVE MAINTENANCE ... 124

1.1 LIST OF MANUALS RELATED TO MOTORS AND AMPLIFIERS ............ 124

1.2 PREVENTIVE MAINTENANCE OF MOTORS AND DETECTORS ........... 125

1.2.1 Warnings, Cautions, and Notes on Preventive Maintenance of Motors and

Detectors...............................................................................................................125

1.2.2 Preventive Maintenance of a Motor (Common to All Models)............................127

1.2.2.1 Main inspection items ................................................................................... 127

1.2.2.2 Periodic cleaning of a motor ......................................................................... 130

1.2.2.3 Notes on motor cleaning ............................................................................... 130

1.2.2.4 Notes on the cutting fluid (informational) .................................................... 130

1.2.3 Routine Inspection of a Spindle Motor with a Through Hole ..............................131

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1.2.4 Preventive Maintenance of a Built-in Spindle Motor and Spindle Unit...............131

1.2.4.1 Routine inspection of the FANUC-NSK spindle unit................................... 132

1.2.4.2 Maintenance of the FANUC-NSK spindle unit ............................................ 132

1.2.4.3 Test run of the FANUC-NSK spindle unit.................................................... 133

1.2.4.4 Storage method of the FANUC-NSK spindle unit........................................ 133

1.2.5 Preventive Maintenance of a Linear Motor..........................................................133

1.2.5.1 Appearance inspection of the linear motor (magnet plate) ........................... 133

1.2.6 Maintenance of a Detector....................................................................................134

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

actions ........................................................................................................... 134

1.2.6.2 Alarms for separate detectors and troubleshooting actions........................... 135

1.2.6.3 Detailed troubleshooting methods ................................................................ 135

1.2.6.4 Maintenance of βiS motor Pulsecoders......................................................... 137

1.3 PREVENTIVE MAINTENANCE OF SERVO AMPLIFIERS ....................... 138

1.3.1 Warnings, Cautions, and Notes on Operation of Servo Amplifiers .....................138

1.3.2 Preventive Maintenance of a Servo Amplifier .....................................................141

1.3.3 Maintenance of a Servo Amplifier .......................................................................142

1.3.3.1 Display of the servo amplifier operation status............................................. 142

1.3.3.2 Replacement of a fan motor .......................................................................... 144

1.4 REPLACING BATTERY FOR ABSOLUTE PULSECODERS .................... 145

1.4.1 Overview ..............................................................................................................145

1.4.2 Replacing Batteries...............................................................................................146

1.4.3 Replacing the Batteries in a Separate Battery Case..............................................146

1.4.4 Replacing the Battery Built into the Servo Amplifier ..........................................147

IV. MOTOR MAINTENANCE

1 SERVO MOTOR MAINTENANCE ...................................................... 151

1.1 SERVO MOTOR MAINTENANCE PARTS ................................................ 151

1.1.1 Pulsecoder ............................................................................................................151

1.1.2 Cooling Fan ..........................................................................................................152

1.2 REPLACING COOLING FANS .................................................................. 153

1.2.1 Replacing a Cooling Fan ......................................................................................153

1.2.1.1 αiS 50 with Fan, αiS 60 with Fan, and αiF 40 with Fan .............................. 153

1.2.1.2 αiS 100 with Fan and αiS 200 with Fan (including HV) ............................. 156

1.2.1.3 αiS 300 and αiS 500 (including HV)............................................................ 156

1.2.1.4 αiS 1000HV .................................................................................................. 157

1.2.1.5 αiS 2000HV and αiS 3000HV...................................................................... 157

2 SPINDLE MOTOR MAINTENANCE PARTS ...................................... 158

2.1 MAINTENANCE PARTS............................................................................ 158

APPENDIX

A MEASURING SERVO MOTOR WAVEFORMS (TCMD, VCMD) ........ 165

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