Monthly Archives: May 2015

Fanuc Spindle Amp Alarm Codes for Alpha Series

Fanuc Spindle Amp Alarm codes for amplifiers that start with part number A06B-6088, A06B-6102, and A06B-6078.

“A” Program Rom abnormality (Not Installed)

AL-01 Motor Overheat

AL-02 Excessive speed deviation

AL-03 DC Link fuse blown

AL-04 Input fuse blown

AL-05 Control power supply

AL-06 Over Speed

AL-07 Excessive Speed

AL-08 High Input Voltage

AL-09 Excessive load on main circuit section

AL-10 Low input voltage

AL-11 Over-voltage in DC link section

AL-12 Over-current in DC link section

AL-13 CPU Internal data memory abnormality

AL-15 Spindle switch/output switch alarm

AL-16 RAM Abnormality

AL-18 Program ROM checksum error

AL-19 Excessive U phase current detection circuit offset

AL-20 Excessive V phase current detection circuit offset

AL-24 Serial transfer data error

AL-25 Serial transfer data stopped

AL-26 Disconnection of speed detection signal for C’s contouring control

AL-27 Position coder signal disconnection

AL-28 Disconnection of position detection signals for C’s contouring control

AL-29 Short-time overload

AL-30 Input circuit over current

AL-31 Speed detection signal disconnection motor restraint alarm

AL-32 Abnormality in RAM internal to LSI for serial data transfer

AL-33 Insufficient DC link section charging

AL-34 Parameter data setting beyond allowable range of values

AL-35 Excessive gear ratio data setting

AL-36 Error counter overflow

AL-37 Speed detector parameter setting error

AL-39 Alarm for indicating failure in detecting 1-rotation signal for C’s contouring control

AL-40 Alarm for indicating 1-rortation signal for C’s contouring control not detected

AL-41 Alarm for indicating failure in detecting position coder 1-ratation signal

AL-42 Alarm for indication position coder 1-rotation not detected

AL-43 Alarm for indicating disconnection of position coder signal for differential speed mode

AL-46 Alarm for indicating failure in detecting position coder 1 rotation signal in thread cutting operation

AL-47 Position coder signal abnormality

AL-48 Position coder 1-rotation signal abnormality

AL-49 The converted differential speed is to high

AL-50 Excessive speed command calculation value in spindle synchronization control

AL-51 Under voltage at DC link section

AL-52 ITP signal abnormality 1

AL-53 ITP signal abnormality 2

AL-54 Overload current alarm

AL-55 Power line abnormality in spindle switching/output switching

AL-56 Cooling fan error.

Emerson Commander SK Trip Codes

Commander SK Trip Codes

 

HF01 to HF03
Not used
HF04
Low DC bus at power up- may indicate an AC Input or pre-charge problem
HF05
No internal handshake signal from second processor (DSP) at start up
HF06
Unexpected interrupt
HF07
Watchdog failure
HF08
Interrupt crash (code overrun)
HF09 to HF10
Not used
HF11
Access to the EEPROM failed- tried to read stored parameter data but failed
HF12 to HF19
Not used
HF20
Power stage – code error Tried to read power board and read back erroneous
HF21
Power stage – unrecognized frame size
HF22
Overcurrent detection at power up- possible output short or bridge failure
HF23
DSP software overrun
HF24
Not Used
HF25
DSP Communications failure- communication from main to 2nd processor
HF26
Soft start relay failed to close; or soft start monitor failed; or braking
IGBT short circuit at power up
HF27
Power stage thermistor fault
HF28
Power circuit thermistor 2 or 3 fault Internal fan fault on size 3 only
HF29
Fan failure (current too high – only on drives with a fan) see note below
HF30
Not used
HF31
Internal Cap Bank Fan failure- check for fan rotation/blockage Size 4 and up
HF32
Power circuit temperature feedback multiplexer failure

Unidrive SP SM-EZ Motion HF Trips

This guilde is meant to help clear SM-EZ Motion HF Trips on a Unidrive SP drive from Emerson Control Techniques. The SM-EZ motion module is used with SP drives and is programmed using Power Tools Pro. It allows users to create specific motion profiles such as indexing, home routines, electronic gearing, and many others. An HF (hardware fault) can be generated by the drive if there is a problem with the solutions module. The drive will display the trip as SLX.HF. It is sometimes possible to correct this trip without replacing the module. The EZ Motion program in the module may become corrupt which can cause this type of trip. Clearing the program and setting the module back to factory settings may resolve the trip. Before clearing the module a drive reset and power cycle should be performed.

They could correct the trip as well.

Module Clearing Procedure

1. Ensure the module is installed in any slot

2. Enter 19237 at #18.01

3. Cycle power to the drive

4. The drive will trip SLX.ER on power up. This is a 107 “No Program” trip

5. Press the red reset button to clear the SLX.ER trip

6. Reload your EZ Motion program back into the drive.

The HF trip could be resolved at this point.

Simodrive F15 Alarm Code – Cause and Solution

Recently a customer sent in a Siemens Simodrive for repair when they were getting an F15 Alarm on the unit. The description for this alarm is as follows:

– F–15 Drive converter
– Overtemperature
     – Drive converter overloaded
(incorrect motor/converter assignment, incorrect load duty cycle,
clock cycle frequency too high)
      – Ambient temperature too high
      – Fan in the IM module failed
      – Defective temperature sensor in the IM module

Normally, this Simodrive F15 Alarm is in reference to the fans in the unit failing, which in turn causes an over temperature issue in the unit. This is normally caused by the fans not being cleaned out regularly which causes them to jam, which can then short out other internal boards in the unit. This was the case for the unit the customer sent in, so we took apart the unit, replaced the fans, and replaced several internal boards that had shorted. A picture of what the dirty fans looked like is below, we would highly recommend routine cleaning of them to prevent drive failure.

Simodrive Dirty Fan

Fanuc Alpha Power Supply Fault Codes

These codes and troubleshooting apply to Fanuc power supplies that begin with part number A06B-6077, A06B-6081, and A06B-6087. On the LED display for these units a “-” will mean that the power supply is not ready while a “0” means that the power supply is powered up correctly. If it reads something other than these two then the power supply has an alarm that needs to be corrected. Below is the list of Fanuc Alpha Power Supply fault codes.

Alarms
AL-01 : Overcurrent in the Main Power Module.
AL-02 : Cooling Fan Stopped.
AL-03 : The temperature of the main circuit heat sink has risen abnormally.
AL-04 : The DC Voltage has dropped.
AL-05 : The main Capacitor was not recharged within the specified time.
AL-06 : The Input Power Supply is Abnormal.
AL-07 :  In the main circuit the DC Voltage is abnormally high

A common alarm on installation of a new alpha power supply is a AL-05.
If you have this alarm we recommend double checking the bus bar connector at the top of the power supply to make sure it is fully connected.

Fanuc AC Spindle Amp Alarms

Recently we had a customer running a Fanuc A06B-6044-H030 spindle unit which was throwing an alarm code. With these spindle units the alarm diagnosis is slightly convoluted, so we wanted to do a post explaining how to read the Fanuc AC spindle amp alarms on the top of these units along with the corresponding faults that the alarms relate to. On these AC spindle units that start with A06B-6044 the fault is shown through the four red LED lights on the top of the spindle card that has a part number similar to A20B-1000-0690. Above the LED lights there are the numbers 8, 4, 2, and 1. If you have a fault in your spindle amp, one or more of the lights will go on, and you just need to add the corresponding numbers to get your alarm code. If only the light under the 4 is on that means an alarm 4, and if the 8 and 1 lights are on it is an alarm 9. This alarm will help to diagnose where the problem in your system is.

Here is a list of the alarm codes and what the possible causes/solutions for the alarms would be.

Alarm 01 (AL-01) Motor Overheat
Causes:
Damaged motor fan, overload, motor cooler is dirty, loose connection.
Solution:
Replace parts, clean cooler, check connections, review cutting conditions.

Alarm 02 (AL-02) Excessive Speed Deviation
Causes
Overload, transistor module is damaged, loose connections, error with speed feedback signal, blown fuse.
Solution:
Replace parts, check connections, review cutting conditions.

Alarm 03 (AL-03) Blown Fuse in DC Link Section
Causes:
Indicates that the fuse F7 in DC link is blown
Solution:
Check power transistors and replace fuse.

Alarm 04 (AL-04) Input fuse blown / Input power open phase
Causes:
Defective transistor module, blown fuse.
Solution:
Replace parts, replace fuse.

Alarm 05 (AL-05) Control Fanuc Power Supply Fuse Blown. AF2 or AF3
Causes:
Defective PCB, Abnormal power supply voltage.
Solution:
Check power supply, replace Fanuc Board, replace fuse.

Alarm 07 (AL-07) Excessive Speed
Causes:
Incorrect parameter setting.
Solution:
Reset parameter value.

Alarm 08 (AL-08) High Input Voltage
Causes:
AC power supply too high, incorrect setting of toggle switch for voltage setting.
Solution:
Change setting from 200V to 230V.

Alarm 09 (AL-09) Heat sink is overheated
Causes:
Cooling fan is defective, overload, dust and dirty.
Solution:
Replace fan, review cutting conditions, clean parts.

Alarm 10 (AL-10) +15V power voltage is low
Causes:
Drop in input power, momentary power failure.
Solution:
Correct case and reset alarm.

Alarm 11 (AL-11) Overvoltage of DC Link Circuit
Causes:
High power impedance, PCB or transistor module are defective.
Solution:
Check AC power, replace damaged Fanuc part.

Alarm 12 (AL-12) Overcurrent flows to DC Link Circuit
Causes:
Output terminals or internal motor of motor is shorted, defective PCB or transistor module.
Solution:
Check connections, replace damaged parts.

Alarm 13 (AL-13) CPU Inter Data Memory Alarm
Replace PCB

Alarm 14 (AL-14) ROM Is Defective
Cause:
ROM not mounted, not mounted correctly or fault
Solution:
Check EPROM.

Troubleshooting Faults of Fanuc Alpha Servo Drives

This troubleshooting guide is in reference to Fanuc drives that begin with part number A06B-6079, A06B-6080, and A06B-6096 and is meant to help troubleshoot Fanuc alpha drive faults. If a drive status alarm appears on the 7 segment display, where the “-” refers to drive not ready (Waiting for an Emergency Stop signal to power up) and “0” refers to drive powering up correctly. Any other number or letter on this status display is an alarm code. One of the more common faults is an Alarm 8.i Here are some tips to check to see what the issue may be when an alarm comes up on your drive.

1 – Check the link: (A06B-6079 drives only). A A06B-6079 drive can give a fault if the S1 Link is in the wrong position, so check the S1 – JV Connections (Type A Interface) and S2 – JS Connections (Type B Interface). An incorrect setting will cause an Alarm “8”.

2 – Check the wiring: A L motor is wired in the lower terminals and a M motor is wired in the upper terminals, both as U/V/W/E. JV1B connected from the L command plug of the axis card, JV2B from the M command plug. JX1A connected from previous drive, JX1B connected to the next drive in the line. The last drive in the line has a terminator in JX1B. 24v/0v/ESP connected into CX1A from the previous drive, out of CX1B to the next drive in the line.

3 – Disconnect motor cable: Meggar the motor to check the readings.

4 – Power machine on: Do this while it is in emergency stop. The drive is faulty if alarm occurs, expect a “-” reading.

5 – Release Emergency Stop: Power the machine up after releasing the stop. If alarm occurs, power the machine off and remove motor wires U/V/W/E (Note – this is dangerous on a vertical axis, brake release, slide drops etc). Release Emergency Stop and power the machine up. The drive is faulty if alarm occurs, expect “0” reading.

6 – An additional test can be performed for equally sized 6079/6080 amplifiers H201 SVM2-12/12          H301 SVM2-12/12/12 H203 SVM2-20/20          H302 SVM3-12/12/20 (L&M) H206 SVM2-40/40          H303 SVM3-12/20/20 (M&N) H208 SVM2-80/80          H304 SVM3-20/20/20 (L/M&N) The suspect axis can be run from the other amplifier in the drive ie X drives M amplifier, Y drives L amplifier. To do this swap round a – X & Y Motor cables U/V/W/E (at the drive) and b – X & Y Command cables (at the drive) (6096 requires parameters changing to swap X & Y round). The drive is faulty if the alarm remains the same as before the test. For example Alarm “8” is reported on a 6079-H201 drive using JV connections Steps 1~5 above, have been performed and still alarm “8”. Remove the motor wires from the lower terminals and reconnect into the upper terminals, upper into lower. Remove JV1B and insert into JV2B, JV2B into JV1B. Retest the machine. The drive is faulty if the same alarm occurs, ie alarm “8” The fault lies elsewhere on the machine if another alarm occurs, ie alarm “9”. In this example the drive has detected an overcurrent from the L axis, alarm “8” Swapping the cables over allowed a different amplifier to control the axis. An “8” alarm would remain if the same drive circuitry detected the overcurrent. A “9” would occur if the overcurrent was detected using the other drive circuitry in the amplifier and the fault would be caused externally from the drive.

Fanuc Spindle Alarms for Troubleshooting

Alarm # Led Display Content of FANUC SPINDLE Alarms
8 4 2 1

1

o

Motor Overheat

2

o

Speed deviates from commanded speed

3

o

o

Regenerative fault

6

o

o

Excess Motor Speed Analog

7

o

o

o

Excess Motor Speed Digital

8

o

Voltage higher than specified

9

o

o

Radiator for power semiconductor overheat

10

o

o

+15Volt Supply is low

11

o

o

o

DC Link voltage is high

12

o

o

DC Link current is high

13

o

o

o

CPU and peripheral parts are defective

14

o

o

o

ROM is defective

Alarm List for A06B-6044-Hxxx

Alarm List for the following Drives:

  • Model 3 thru Model 40   A06B-6044-Hxxx
Alarm # Led Display Content of Alarms
8 4 2 1

1

o

Motor Overheat

2

o

Speed deviates from commanded speed

3

o

o

Fuse F7in DC link is blown out.

4

o

Fuses F1,F2,F3 for AC input blown out.

5

o

o

Fuses AF2 or AF3 on PCB are blown out.

6

o

o

Excess Motor Speed Analog

7

o

o

o

Excess Motor Speed Digital

8

o

Voltage higher than specified (24v)

9

o

o

Radiator for power semiconductor overheat

10

o

o

+15Volt Supply is low

11

o

o

o

DC Link voltage is high

12

o

o

DC Link current is high

13

o

o

o

CPU and peripheral parts are defective

14

o

o

o

ROM is defective

15

o

o

o

o

Option circuit fault.

Digital AC Spindle Drive

Alarm List for A06B-6055-Hxxx

Alarm List for the following drives:

  • Model 3 thru 22    A06B-6055-Hxxx

 

Alarm Display Alarm Content

AL-01

Motor Overheated

AL-02

Speed deviates from commanded speed

AL-03

Fuse F7in DC link is blown out.

AL-04

Fuses F1,F2,F3 for AC input blown out.

AL-06

Excess Motor Speed Analog

AL-07

Excess Motor Speed Digital

AL-08

Voltage higher than specified (24v)

AL-09

Radiator for power semiconductor overheat

AL-10

+15v power supply is abnormally low

AL-11

DC Link voltage is high

AL-12

DC Link current is high

AL-13

Data memory for CPU abnormal

AL-16

RAM in NVRAM is abnormal

AL-17

ROM in NVRAM is abnormal

AL-18

Check sum alarm of ROM

AL-19

Excessive alarm of U phase current detection circuit offset

AL-20

Excessive alarm of V phase current detection circuit offset

AL-21

Excessive alarm of velocity command circuit offset.

AL-22

Excessive alarm of velocity detection circuit offset.

AL-23

Excessive alarm of ER circuit offset.

AL-14

ROM is abnormal

AL-15

Spindle selection control circuit is abnormal.

Alarm List for A06B-6059-Hxxx

Alarm List for the following drives:

  • Model 1S thru 3S   A06B-6059-Hxxx

 

Alarm # Meaning

AL-01

Motor Overheat

AL-02

Speed deviates from commanded speed

AL-03

24v Fuse is blown. (before PCB edition 09A)

AL-04

AL-05

AL-06

Excess Motor Speed Analog

AL-07

Excess Motor Speed Digital

AL-08

Over voltage

AL-09

Overheat of radiator

AL-10

Low voltage of input power.

AL-11

Excessive high voltage of DC link

AL-12

Abnormal current of DC link

AL-13-15

AL-16-23

Defective arithmetic circuit and peripheral circuit

No indication

Defective ROM

Alarm List for A06B-6059-Hxxx

Alarm List for the following drives:

  • Model 6S-26S    A06B-6059-Hxxx

 

Alarm # Meaning

AL-01

Motor Overheat

AL-02

Speed deviates from commanded speed

AL-03

24v Fuse is blown. (before PCB edition 09A)

AL-04

Open phase of input power.

AL-05

AL-06

Excess Motor Speed Analog

AL-07

Excess Motor Speed Digital

AL-08

Over voltage

AL-09

Overheat of radiator

AL-10

Low voltage of input power.

AL-11

Excessive high voltage of DC link

AL-12

Abnormal current of DC link

AL-13

Defective arithmetic circuit

AL-14

Defective ROM

AL-15

Defective optional circuit.

AL-16-23

Defective arithmetic circuit and peripheral circuit

No indication

Defective ROM