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FANUC AC SERVO MOTOR ai series, AC SPINDLE MOTOR ai series, SERVO AMPLIFIER ai series. MAINTENANCE MANUAL - page 6

1.MOTOR/DETECTOR/AMPLIFIER MOTOR/DETECTOR/AMPLIFIER

PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE

B-65285EN/04

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-65352EN)" 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.

1.2.4.1 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.

1.2.4.2 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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1.2.4.3 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.

1.2.4.4 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).

1.2.5

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.

1.2.5.1 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 cause

Deformation or bulge of the magnet plate or

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

softening of the resin

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

1.2.6

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.

1.2.6.1 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 data

Check the effect

- Noise

(1)

ERROR(INT)

alarm

of noise.

453: SPC SOFT

Position - pole data

- Pulse coder failure

Replace the

(3)

DISCONNECT ALARM

error

- Entry of cutting fluid

Pulsecoder.

1.2.6.2 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)

1.2.6.3 Detailed troubleshooting methods

(1) Checking the effect of noise

Check CNC diagnosis information No.356 (Built-in detector), No.357 (Separate detector).

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

(3)-1 Pulse coder replacement procedure

Bolt fastening the Pulsecoder cover M3

<1> Remove the four M4 hexagon socket head cap

screws fastening the Pulsecoder. The M3 bolts

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

Attach the Pulsecoder in such a direction that the

power connector of the servo motor and the feedback

cable of the Pulsecoder face the same direction or that

Adjust the connection parts

the thermistor connection parts of the servo motor

and Pulsecoder match each other (see the figure at

Pulse coder

Servo motor

left).

<4> Fastening the Pulsecoder with the four M4 hexagon socket head cap screws. (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 or 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 to check that the connector does

not come off. Do not pull the cable.

(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.

1.2.6.4 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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1.3.2

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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1.3.3

Maintenance of a Servo Amplifier

1.3.3.1 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.

(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.

Not ready status

Nameplate

The main circuit is not supplied with power (magnetic contactor is off);

emergency stop state.

When blinking: Power is off.

Ready status

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

power supply is ready for operation.

When blinking: Power is off.

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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(2) Servo amplifier

STATUS LED

STATUS

Description

position

display

The STATUS LED is off.

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

Nameplate

power circuit is defective.

The control power is short-circuited (- blinks).

Blink

Cable failure

Waiting for the READY signal from the CNC.

Ready status

The servo motor is excited.

Alarm status

The alarm type is indicated by the character displayed.

(3) Spindle amplifier

STATUS LED

STATUS

Description

position

display

The STATUS LED is off.

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

power circuit is defective.

After control power is turned on, the spindle software series is displayed

(for approx. 1 second).

The last two digits of the spindle software series number are

Nameplate

displayed.

The spindle software version is displayed (for approx. 1 second following

the display of the spindle software series).

[Display] 01,02,03,⋅ ⋅ ⋅

→ [Version] A, B, C,⋅ ⋅ ⋅

The CNC is not powered on (- - blinks).

Blink

Blink

Waiting for serial communication and parameter loading completion.

Parameter loading completed

The motor is not excited.

Ready status

The spindle motor is excited.

Alarm status

The alarm type is indicated by the character displayed.

Error status (invalid sequence or parameter setting error)

The error type is indicated by the character displayed.

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1.3.3.2 Replacement of a fan motor

(1) Fan motor for internal cooling

Replace the internal fan motor, according to the procedure shown in the figure below.

When replacing the fan motor, be careful about the direction of the fan motor (air blow direction), the

direction of the connector, etc.

Air blow direction

Fan unit

(2) Remove the fan

(1) Hold the two tabs

and get the fan unit

unit by pulling it

White Black Red

upward.

off the latch.

Fan unit (60-mm-wide)

Tab

Tab

Be careful about the

connector key direction.

Fan unit (90-mm-wide)

Red

Black

White

Be careful about the

connector key direction.

Fan unit (150-mm-wide)

* Be careful about the fan motor and connector directions.

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(2) Fan motor for cooling the external radiator

<1> Remove the two sheet metal mounting screws (for the 60-mm-wide model only), and detach the

fan motor from the unit together with the sheet metal.

<2> Remove the fan motor mounting screws (two for one fan motor and four for two fan motors).

<3> Remove the connector mounting screws (two and four for the 300-mm-wide model).

When replacing the fan motor, be careful about the direction of the fan motor (air blow direction), the

direction of the connector, etc.

Sheet metal mounting screws

Fan motor

Fan motor

Fan motor

Connector mounting screw

Connector mounting screw

Connector mounting screw

mounting screw

mounting screw

mounting screw

Air blow

Air blow

Air blow

direction

direction

direction

60 mm wide/90 mm wide

150 mm wide

300 mm wide

1.4

REPLACING BATTERY FOR ABSOLUTE PULSECODERS

1.4.1

Overview

• When the voltage of the batteries for absolute Pulsecoders becomes low, alarm 307 or 306 occurs, with

the following indication in the CNC state display at the bottom of the CNC screen.

Alarm 307 (alarm indicating the voltage of the battery becomes low) :

The indication "APC" blinks in reversed display.

Alarm 306 (battery zero alarm) :

The indication "ALM" blinks in reversed display.

• When alarm 307 (alarm indicating the voltage of the battery becomes low) occurs, replace the battery

as soon as possible. In general, the battery should be replaced within one or two weeks, however, this

depends on the number of Pulsecoders used.

• When alarm 306 (battery zero alarm) occurs, Pulsecoders are reset to the initial state, in which absolute

positions are not held. Alarm 300 (reference position return request alarm) also occurs, indicating that

reference position return is required.

• In general, replace the batteries periodically within the service life listed below.

-

A06B-6050-K061 or D-size alkaline dry cells (LR20) : Two years

(for each six-axis

configuration)

-

A06B-6073-K001 : Two years (for each three-axis configuration)

-

A06B-6114-K504 : One year (for each three-axis configuration)

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NOTE

The above values indicate the estimated service life of batteries used with FANUC

absolute Pulsecoders. The actual battery service life depends on the machine

configuration based on, for example, detector types. For details, contact the

machine tool builder.

1.4.2

Replacing Batteries

To prevent absolute position information in absolute Pulsecoders from being lost, turn on the machine

power before replacing the battery. The replacement procedure is described below.

<1> Ensure that the power to the servo amplifier is turned on.

<2> Ensure that the machine is in the emergency stop state (the motor is inactive).

<3> Ensure that the DC link charge LED of the servo amplifier is off.

<4> Detach the old batteries and attach new ones.

The replacement of the batteries in a separate battery case and the replacement of the battery built into the

servo amplifier are described below in detail.

WARNING

• The absolute Pulsecoder of each of the αi/αiS series servo motors and the βiS

series servo motors (βiS0.4 to βiS22) has a built-in backup capacitor. Therefore,

even when the power to the servo amplifier is off and the batteries are replaced,

reference position return is not required if the replacement completes within less

than 10 minutes. Turn the power on and replace the batteries if the replacement

will take 10 minutes or more.

• To prevent electric shock, be careful not to touch metal parts in the power

magnetics cabinet when replacing the batteries.

• Because the servo amplifier uses a large-capacitance electrolytic capacitor

internally, the servo amplifier remains charged for a while even after the power is

turned off. Before touching the servo amplifier for maintenance or other purposes,

ensure your safety by measuring the residual voltage in the DC link with a tester

and confirming that the charge indication LED (red) is off.

• Be sure to replace the batteries with specified ones. Pay attention to the battery

polarity. If a wrong type of battery is used or a battery is installed with incorrect

polarity, the battery may overheat, blow out, or catch fire, or the absolute position

information in the absolute Pulsecoders may be lost.

• Ensure that the battery connector is inserted in the correct position.

1.4.3

Replacing the Batteries in a Separate Battery Case

Use the following procedure to replace the batteries in the battery case.

<1> Loosen the screws on the battery case and detach the cover.

<2> Replace the batteries in the case (pay attention to the polarity).

<3> Attach the cover to the battery case.

Battery case

(with a cover)

A06B-6050-K060

Batteries

Four A06B-6050-K061 batteries

or D-size alkaline dry cells

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CAUTION

• Four D-size alkaline dry cells (LR20) that are commercially available can be used

as batteries. A set of four A06B-6050-K061 batteries is optionally available from

FANUC.

• Replace all the four batteries with new ones. If old and new batteries are mixed,

the absolute position information in the absolute Pulsecoders may be lost.

1.4.4

Replacing the Battery Built into the Servo Amplifier

Use the following procedure to replace the special lithium battery.

<1> Detach the battery case.

<2> Replace the special lithium battery.

<3> Attach the battery case.

CAUTION

• Purchase the battery from FANUC because it is not commercially available. It is

therefore recommended that you have a backup battery.

• When the built-in battery is used, do not connect BATL (B3) of connector

CXA2A/CXA2B. Also, do not connect two or more batteries to the same BATL (B3)

line. These connections are dangerous because battery output voltages may be

short-circuited, causing the batteries to overheat.

• Install the battery in the servo amplifier in a direction that allows slack in the cable.

If the battery cable is under tension, a bad connection may occur.

• If the +6 V pin and 0 V pin are short-circuited, the battery may overheat, blow out,

or catch fire, or the absolute position information in the absolute Pulsecoders may

be lost.

• When inserting the connector, align it to the connector pins.

[Connecting the battery]

The battery for the αi series amplifiers is mounted at the front of each of the amplifiers.

[αi series]

Insertion direction

Cable side

Red: +6 V

Connector

Black: 0 V

CX5X

Battery

+6 V

Battery case

0 V

Battery case

[Battery sets and outlines]

Battery ordering

Manufacturer

Battery case ordering

Applicable servo amplifier

Outline

drawing number

model number

drawing number

αi series 60/90 mm width

A06B-6114-K505

A06B-6114-K504

BR-2/3AGCT4A

(Note)

(Panasonic)

αi series 150/300 mm width

A06B-6114-K506

- 147 -

1.SERVO MOTOR

B-65285EN/04

MOTOR MAINTENANCE

MAINTENANCE

1 SERVO MOTOR MAINTENANCE

1.1

SERVO MOTOR MAINTENANCE PARTS

1.1.1

Pulsecoder

The following lists the ordering specification numbers for maintenance.

(1) Pulsecoder: ordering specification

Motor model

Motor specification

Pulsecoder: ordering specification

X=0

A860-2000-T301

αiA1000

Standard specification

A06B-02aa-BccX

X=1

A860-2005-T301

αiI1000

Standard specification

(aa, cc : Any)

αiS series

X=2

A860-2001-T301

αiA16000 Standard specification

αiF series

X=0

A860-2000-T321

αiA1000

IP67 specification

A06B-02aa -BccX #0100

X=1

A860-2005-T321

αiI1000

IP67 specification

(aa, cc : Any)

X=2

A860-2001-T321

αiA16000 IP67 specification

(2) Oldham's coupling: ordering specification

Motor model

Motor specification

Oldham's coupling: ordering specification

αiS series

A06B-02aa-BccX

A290-0501-V535

αiF series

(aa, cc, X : Any)

- 151 -

1.SERVO MOTOR

MAINTENANCE

MOTOR MAINTENANCE

B-65285EN/04

1.1.2

Cooling Fan

The following lists the ordering specification numbers of cooling fan units.

αiS 50 with Fan, αiS 60 with Fan, αiF 40 with Fan

Fan unit: ordering

Motor model

Model name

Motor specification

Remark

specification

A06B-0275-BXaX

αiS 50/3000 with Fan

A06B-0276-BXaX

αiS 50/3000HV with Fan

(X :Any, a=1 or 3)

αiS series

A06B-0278-BXaX

200VAC

αiS 60/3000 with Fan

A06B-0241-K053

αiF series

A06B-0279-BxaX

1-phase

αiS 60/3000HV with Fan

(X :Any, a=1 or 3)

A06B-0257-BXaX

αiF 40/3000 with Fan

(X :Any, a=1 or 3)

αiS 100 to αiS 500

Fan unit: ordering

Motor model

Model name

Motor specification

Remark

specification

αiS 100/2500 with Fan

A06B-0285-BX1X

αiS 200/2500 with Fan

A06B-0288-BX1X

200VAC

αiS 300/2000

A06B-0292-BX1X

A290-0281-V053

3-phase

αiS 500/2000

A06B-0295-BX1X

(X : Any)

A06B-0286-BX1X

αiS series

αiS 100/2500HV with Fan

A06B-0289-BX1X

αiS 200/2500HV with Fan

A06B-0293-BX1X

αiS 300/2000HV

400VAC

A06B-0290-BX1X

A290-0281-V054

αiS 300/3000HV

3-phase

A06B-0296-BX1X

αiS 500/2000HV

A06B-0297-BX1X

αiS 500/3000HV

(X : Any)

αiS 1000HV to αS 3000HV

Fan unit: ordering

Motor model

Model name

Motor specification

Remark

specification

A06B-0298-BX1X

αiS 1000/2000HV

A290-0298-V054

(X : Any)

A06B-0098-BXXX

αiS 1000/2000HV

A290-0098-V051

(X : Any)

AC400V

αiS series

A06B-0099-BXXX

αiS 1000/3000HV

A290-0098-V050

3-phase

(X : Any)

A06B-0091-BX4X

αiS 2000/2000HV

A06B-0092-BX4X

A290-0091-T054

αiS 3000/2000HV

(X : Any)

- 152 -

1.SERVO MOTOR

B-65285EN/04

MOTOR MAINTENANCE

MAINTENANCE

1.2

REPLACING COOLING FANS

This section describes how to replace cooling fan units.

For each motor, replace the cooling fan unit according to the procedure.

CAUTION

Before replacing a fan motor, remove the power lead to the fan motor and check

that the rotation of the fan motor stops.

If the load on the fan motor is high or an invalid phase sequence is made for a

3-phase fan motor, the fan motor may overheat and stop. If the power lead is

connected, the fan motor suddenly starts rotating when recovered from

overheating.

1.2.1

Replacing a Cooling Fan

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

(1) Removing a cooling fan unit

<1> Remove six M6 pan head machine screws fastening the fan cover and remove the front fan cover.

You need only to loosen the pan head machine screws indicated by the arrow in the figure.

M6 pan head

Fan cover

machine screw

<2> Remove the cooling fan unit from the motor.

Cooling fan unit

- 153 -

1.SERVO MOTOR

MAINTENANCE

MOTOR MAINTENANCE

B-65285EN/04

(2) Mounting a cooling fan unit

<1> Remove six M6 pan head machine screws from a new cooling fan unit and remove the front fan

cover.

You need only to loosen the pan head machine screws indicated by the arrow in the figure.

M6 pan head

Fan cover

machine screw

<2> Assemble the cooling fan unit and motor.

Align the inside of the sheet metal of the cooling fan unit with the side of the motor and touch the

end of the sheet metal with the back of the motor. (See the figure below.)

Cooling fan unit

End of sheet metal

Inside of sheet metal

Back of motor

- 154 -

1.SERVO MOTOR

B-65285EN/04

MOTOR MAINTENANCE

MAINTENANCE

<2> Mount the fan cover and tighten the six M6 pan head machine screws.

(Appropriate torque: 2.5 to 2.8 Nm)

M6 pan head

machine screw

- 155 -

1.SERVO MOTOR

MAINTENANCE

MOTOR MAINTENANCE

B-65285EN/04

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

(1) Removing a cooling fan unit

Remove the four M6 hexagon socket head cap screws fastening the fan unit and remove the fan unit.

(2) Mounting a cooling fan unit

Apply adhesive for fastening (moderate strength) to the four M6 hexagon socket head cap screws and

mount the fan unit. (Appropriate torque: 3.0 to 3.5 Nm)

Fan unit

Move backward by at least 5 mm.

M6x20 (4 screws)

1.2.1.3 αiS 300 and αiS 500 (including HV)

(1) Removing a cooling fan unit

Remove the four M6 hexagon socket head cap screws fastening the fan unit and remove the fan unit.

(2) Mounting a cooling fan unit

Apply adhesive for fastening (moderate strength) to the four M6 hexagon socket head cap screws and

mount the fan unit. (Appropriate torque: 3.0 to 3.5 Nm)

Fan unit

Move backward by at least 7 mm

M6x20 (4 screws)

- 156 -

1.SERVO MOTOR

B-65285EN/04

MOTOR MAINTENANCE

MAINTENANCE

1.2.1.4 αiS 1000HV

(1) Removing a cooling fan unit

Remove the four hexagon socket head cap screws fastening the fan unit and remove the fan unit.

M6x40: 4 screws (A06B-0298-BXXX)

M10x40: 4 screws (A06B-0098-BXXX, A06B-0099-BXXX)

(2) Mounting a cooling fan unit

Apply adhesive for fastening (moderate strength) to the four hexagon socket head cap screws and

mount the fan unit.

Appropriate torque: 9.6 to 13Nm (M6), 19 to 26Nm (M10)

Move backward by at least 15 mm

Fan unit

M6x40 or M10x40

1.2.1.5 αiS 2000HV and αiS 3000HV

(1) Removing a cooling fan unit

Remove the eight M6 hexagon socket head cap screws fastening the fan unit and remove the fan unit.

(2) Mounting a cooling fan unit

Apply adhesive for fastening (moderate strength) to the eight M6 hexagon socket head cap screws and

mount the fan unit. (Appropriate torque: 9.6 to 13 Nm)

Move backward by at least 8 mm

Fan unit

M6x40 (8 screws)

- 157 -

2.SPINDLE MOTOR

MAINTENANCE PARTS

MOTOR MAINTENANCE

B-65285EN/04

2 SPINDLE MOTOR MAINTENANCE PARTS

2.1

MAINTENANCE PARTS

(1) Parts of the terminal box (αiI, αiIP, and αCi series 200V type)

Model

Terminal box assembly

Lid of terminal box

αiI 1/10000, αiI 1/15000

αiI 1.5/10000, αiI 1.5/20000

A290-1402-T400

A290-1402-V410

αC1/6000i

αiI 2/10000, αiI 2/20000

αiI 3/10000, αiI 3/12000

A290-1404-T400

A290-1402-V410

αC2/6000i, αC3/6000i

αiI 6/10000 to αiI 15/7000

αiI 6/12000 to αiI 15/12000

αiIP 12/6000 to αiIP 22/6000

A290-1406-T400

A290-1406-V410

αiIP 12/8000 to αiIP 22/8000

αC6/6000i to αC15/6000i

αiI 18/7000, αiI 22/7000

A290-1410-T400

A290-1410-V410

αiI 18/10000, αiI 22/10000

A290-1410-T401

A290-1410-V410

αiIP 30/6000 to αiIP 50/6000

αiI 30/6000, αiI 40/6000

A290-1412-T400

A290-1040-V402

αiI 50/5000

A290-1414-T400

A290-1040-V402

αiIP 60/5000

A290-0833-T400

A290-1040-V402

NOTE

The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

(2) Parts of the terminal box (αiIT and αiIL series 200V type)

Model

Terminal box assembly

Lid of terminal box

αiIT 1.5/20000

A290-1402-T400

A290-1402-V410

αiIT 2/20000, αiIT 3/12000

A290-1404-T400

A290-1402-V410

αiIT 6/12000, αiIT 8/12000

A290-1406-T400

A290-1406-V410

αiIT 8/15000, αiIT 15/10000

αiIT 15/15000

A290-1410-T402

A290-1410-V410

αiIT 22/10000

A290-1410-T401

A290-1410-V410

αiIL 8/20000

A290-1487-T400

A290-1406-V410

αiIL 15/15000, αiIL 26/15000

A290-1489-T400

A290-1410-V410

NOTE

The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

- 158 -

2.SPINDLE MOTOR

B-65285EN/04

MOTOR MAINTENANCE

MAINTENANCE PARTS

(3) Parts of the terminal box (αiI and αiIP series 400V type)

Model

Terminal box assembly

Lid of terminal box

αiI 1/10000HV, αiI 1.5/10000HV

A290-1502-T400

A290-1402-V410

αiI 2/10000HV, αiI 3/10000HV

A290-1504-T400

A290-1402-V410

αiI 6/10000HV to αiI 22/7000HV

A290-1406-T400

A290-1406-V410

αiIP 15/6000HV, αiIP 22/6000HV

αiIP 40/6000HV, αiIP 50/6000HV

A290-1410-T401

A290-1410-V410

αiI 30/6000HV, αiI 40/6000HV

A290-1412-T400

A290-1040-V402

αiI 50/5000HV

A290-1414-T400

A290-1040-V402

αiI 60/5000HV, αiIP 60/5000HV

A290-0860-T403

A290-1040-V402

αiI 75/5000HV

A290-1516-T400

A290-1040-V402

αiI 100/5000HV

A290-1516-T410

A290-1040-V402

αiI 100/5000HV(Large terminal box type)

A290-1532-T410

A290-1532-V402

αiI 100/4000HV

A290-0884-T401

A290-1040-V402

αiI 150/5000HV

A290-1532-T400

A290-1532-V402

NOTE

The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

(4) Parts of the terminal box (αiIT and αiIL series 400V type)

Model

Terminal box assembly

Lid of terminal box

αiIT 1.5/20000HV

A290-1502-T400

A290-1402-V410

αiIT 2/20000HV, αiIT 3/12000HV

A290-1504-T400

A290-1402-V410

αiIT 6/12000HV, αiIT 8/12000HV

A290-1406-T400

A290-1406-V410

αiIT 15/15000HV, αiIT 22/10000HV

αiIL 8/20000HV

A290-1597-T400

A290-1406-V410

αiIL 15/15000HV, αiIL 26/15000HV

A290-1595-T400

A290-1410-V410

NOTE

The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

- 159 -

2.SPINDLE MOTOR

MAINTENANCE PARTS

MOTOR MAINTENANCE

B-65285EN/04

(5) Fan motor parts (αiI, αiIP, and αCi series 200V type)

Exhaust

Model

Fan assembly (*1)

Fan cover

Fan motor

direction

αiI 1/10000, αiI 1/15000

A290-1402-T500

A90L-0001-0537/R

Rear

αiI 1.5/10000, αiI 1.5/20000

A290-1402-X501

αC1/6000i

A290-1402-T501

A90L-0001-0537/F

Front

αiI 2/10000, αiI 2/20000

A290-1404-T500

A90L-0001-0538/R

Rear

αiI 3/10000, αiI 3/12000

A290-1404-X501

αC2/6000i, αC3/6000i

A290-1404-T501

A90L-0001-0538/F

Front

αiI 6/10000, αiI 8/8000

A290-1406-T500

A90L-0001-0515/R

Rear

αiI 6/12000, αiI 8/10000

A290-1406-X501

αiI 8/12000

A290-1406-T501

A90L-0001-0515/F

Front

αC6/6000i, αC8/6000i

αiI 12/7000 to αiI 22/7000

αiI 12/10000 to αiI 22/10000

A290-1408-T500

A90L-0001-0548/R

Rear

αiIP 12/6000 to αiIP 22/6000

A290-1408-X501

αiIP 12/8000 to αiIP 22/8000

A290-1408-T501

A90L-0001-0548/F

Front

αC12/6000i to αC22/6000i

αiI 30/6000, αiI 40/6000 (*2)

A290-1412-T510

-

-

Rear

αiIP 30/6000 to αiIP 50/6000 (*2)

A290-1412-T511

-

-

Front

A290-1414-T510

-

-

Rear

αiI 50/5000 (*2)

A290-1414-T511

-

-

Front

A290-0832-T510

-

-

Rear

αiIP 60/5000 (*2)

A290-0832-T511

-

-

Front

NOTE

1 These drawing numbers include fan motors.

2 In case of exchange these fan motors, please change fan assembly (fan motor

with fan cover) unit.

3 The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

(6) Fan motor parts (αiIT series 200V type)

Model name

Fan assembly (*1)

Fan cover

Fan motor

αiIT 1.5/20000

A290-1463-T500

A290-1402-X501

A90L-0001-0537/RL

αiIT 2/20000, αiIT 3/12000

A290-1464-T500

A290-1404-X501

A90L-0001-0538/RL

αiIT 6/12000

A290-1466-T500

A290-1406-X501

A90L-0001-0515/RL

αiIT 8/12000, αiIT 8/15000

αiIT 15/10000, αiIT 15/15000

A290-1469-T500

A290-1408-X501

A90L-0001-0548/RL

αiIT 22/10000

NOTE

1 These drawing numbers include fan motors.

2 The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

- 160 -

2.SPINDLE MOTOR

B-65285EN/04

MOTOR MAINTENANCE

MAINTENANCE PARTS

(7) Fan motor parts (αiI and αiIP series 400V type)

Exhaust

Model

Fan assembly (*1)

Fan cover

Fan motor

direction

A290-1502-T500

A90L-0001-0539/R

Rear

αiI 1/10000HV, αiI 1.5/10000HV

A290-1402-X501

A290-1502-T501

A90L-0001-0539/F

Front

A290-1504-T500

A90L-0001-0540/R

Rear

αiI 2/10000HV, αiI 3/10000HV

A290-1404-X501

A290-1504-T501

A90L-0001-0540/F

Front

A290-1506-T500

A90L-0001-0519/R

Rear

αiI 6/10000HV, αiI 8/8000HV

A290-1406-X501

A290-1506-T501

A90L-0001-0519/F

Front

αiI 12/7000HV, αiI 15/7000HV

A290-1508-T500

A90L-0001-0549/R

Rear

αiI 22/7000HV

A290-1408-X501

αiIP 15/6000HV, αiIP 22/6000HV

A290-1508-T501

A90L-0001-0549/F

Front

αiI 30/6000HV, αiI 40/6000HV (*2)

A290-1512-T510

-

-

Rear

αiIP 40/6000HV, αiIP 50/6000HV(*2)

A290-1512-T511

-

-

Front

αiI 60/5000HV (*2)

A290-0883-T510

-

-

Rear

αiIP 60/5000HV (*2)

A290-0883-T511

-

-

Front

A290-1514-T510

-

-

Rear

αiI 50/5000HV (*2)

A290-1514-T511

-

-

Front

αiI 75/5000HV, αiI 100/5000HV (*2)

A290-1516-T500

-

-

Rear

A290-0780-T512

-

-

Pedestal-side

A290-0780-T514

-

-

intake

αiI 100/4000HV (*2)

A290-0780-T513

-

-

Pedestal-side

A290-0780-T515

-

-

exhaust

A290-0884-T500

-

-

Rear

αiI 150/5000HV (*2)

A290-1532-T500

-

-

Rear

NOTE

1 These drawing numbers include fan motors.

2 In case of exchange these fan motors, please change fan assembly (fan motor

with fan cover) unit.

3 The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

(8) Fan motor parts (αiIT series 400V type)

Model name

Fan assembly (*1)

Fan cover

Fan motor

αiIT 1.5/20000HV

A290-1563-T500

A290-1402-X501

A90L-0001-0539/RL

αiIT 2/20000HV, αiIT 3/12000HV

A290-1564-T500

A290-1404-X501

A90L-0001-0540/RL

αiIT 6/12000HV, αiIT 8/15000HV

A290-1566-T500

A290-1406-X501

A90L-0001-0519/RL

αiIT 15/15000HV, αiIT 22/10000HV

A290-1569-T500

A290-1408-X501

A90L-0001-0549/RL

NOTE

1 These drawing numbers include fan motors.

2 The above table may not apply to motors of which motor drawing number ends

with B9xx. Contact your FANUC service representative.

- 161 -

A.MEASURING SERVO MOTOR

B-65285EN/04

APPENDIX

WAVEFORMS (TCMD, VCMD)

A MEASURING SERVO MOTOR

WAVEFORMS (TCMD, VCMD)

To use a servo motor in a good performance condition for a long time and prevent any failure from

occurring, the TCMD and VCMD waveforms of the servo motor can be checked as diagnosis.

(1) Observation of torque command (TCMD) and speed command (VCMD) waveforms

Check whether there is no abnormality in the waveforms.

For how to measure the TCMD and VCMD waveforms, refer to the FANUC AC SERVO MOTOR αi

series Parameter Manual (B-65270EN).

The waveforms vary according to the operating conditions such as load and cutting speed. Note that

you should make comparisons under the same condition (for example, during fast traverse to the

reference position or low-speed cutting).

(2) Diagnosis by waveforms

Check the measured waveforms to see whether:

<1> The peak current is within the limit to the current in the amplifier during rapid traverse,

acceleration, or deceleration.(TCMD)

The limit to the amplifier current is listed below.

Limit to the amplifier

current

Measured waveform

(TCMD)

0

Ö The motor used to accelerate/ decelerate with the amplifier current within the limit (the

acceleration/deceleration torque used to be sufficient), but something is wrong now. If this

is the case, the probable causes are:

• The load conditions in the machine have changed because of changed friction or reduced

machine efficiency after long period of use.

• Motor failure

Increased friction

Reduced efficiency

- 165 -

A.MEASURING SERVO MOTOR

WAVEFORMS (TCMD, VCMD)

APPENDIX

B-65285EN/04

[Table 1]

Models

Current value

αiS2/5000HV, αiS2/6000HV, αiS4/5000HV, αiS4/6000HV

10Ap

αiS2/5000, αiS2/6000, αiS4/5000, αiS4/6000

20Ap

αiF1/5000, αiF2/5000, αiF4/4000HV, αiF8/3000HV

αiS8/4000HV, αiS8/6000HV, αiS12/4000HV,

40Ap

αiF4/4000, αiF8/3000, αiF12/3000HV, αiF22/3000HV,

αiS8/4000, αiS8/6000, αiS12/4000, αiS12/6000HV, αiS22/4000HV, αiS22/6000HV,

αiS30/4000HV, αiS40/4000HV, αiS50/2000HV, αiS60/2000HV,

80Ap

αiF12/3000, αiF 22/3000,

αiS12/6000, αiS22/4000, αiS22/6000, αiS30/4000, αiS40/4000, αiS50/2000, αiS60/2000,

160Ap

αiF30/3000, αiF40/3000, αiF40/3000 with fan

αiS50/3000HV with fan,

180Ap

αiS100/2500HV, αiS100/2500HV with fan, αiS 200/2500HV, αiS 200/2500HV with fan

αiS50/3000 with fan,

αiS100/2500, αiS100/2500 with fan, αiS200/2500, αiS200/2500 with fan,

360Ap

αiS300/2000HV, αiS500/2000HV

αiS300/3000HV, αiS500/3000HV

540Ap

αiS300/2000, αiS500/2000, αiS1000/2000HV

360Ap x 2 (Note)

αiS1000/3000HV, αiS2000/2000HV, αiS3000/2000HV

360Ap x 4 (Note)

NOTE

More than one Servo Amplifier is used for one motor.

<2> The waveform has ripple during constant-speed feeding (VCMD).

Ripple

Measured waveform

(VCMD)

0

<3> The current waveform has ripple or jumps when the motor is not rotating (VCMD).

Ripple

Measured waveform

(VCMD)

0

If you find anything unusual in relation to the above items <1> to <3>, contact your FANUC service

staff.

- 166 -

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