Gallery of pictures showing the process that it takes to rebuild a Fanuc motor, part number A06B-0128-B675#7008.
Original pictures of the motor. Fan is dirty, all sides show significant use.
Upon disassembling the FANUC servo motor, the residue was found in the stator prompting the removal of the motor shaft. This would have caused a short in the stator once running.
The finished product, after the motor is rebuilt and fully tested.
HF82 – Large option module missing:
The trip would be expected if one of the UD7x large option modules is removed while
the Drive is powered up. If this trip occurs at any other time than the case above, then
there is a problem with either the large option module or the UD90A control PCB.
HF83 – Power Board Code Failure:
This trip means that the UD90A control PCB could not recognize the power rating of
the power PCB it is connected to.
On Unidrive Sizes 1 to 4, the trip is probably due to the power PCB in the Drive but a
problem with the UD90A control PCB could also cause this trip.
On a Unidrive Size 5 the trip is caused by either UD99 PCB or the UD90A PCB. The
interconnects between the PCBs could also cause this trip and should be checked.
HF84 -Current Offset Trim Failure:
This trip means there is a problem with the current feedback on the Drive.
On Unidrive Sizes 1 to 4, the trip is probably due to the power PCB in the Drive but a
problem with the UD90A control PCB could also cause this trip.
On a Unidrive Size 5 the trip is cause by either UD99 PCB or the UD90A PCB. The
interconnects between the PCBs could also cause this trip and should be checked.
HF88 – Watchdog Failure:
This trip can result from a faulty UD7x Co-Processor.
With power off, remove Co-Processor and re-apply
power.
Hardware Faults are typically fatal. If powering down and letting the drive sit for 5
minutes before re-application of Power does not clear the HF Fault it would require
Drive repair.
We recently shipped out two Fanuc A16B-3200-0040 boards to a customer and upon installation, they received a Fanuc CHECKSUM error on their control. Here are the notes that we use to troubleshoot this Fanuc error which can be used to try and solve the problem.
There are two common causes for this problem. The first and most likely is TP communications. If you see 3-5 “_” appear under the checksum number, and no red LED’s on the CPU, then this is the problem. This means that 1/2 the communications signal is missing. Swap the Pendant and cable (Cable is probably crushed or cut), and everything should hopefully be great. There is a possibility of damage on the CPU side, however.
MRO Electric and Supply has new and refurbished FANUC CNC and FANUC Robotics parts available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com
The second is a corruption of software on the CPU. This will result in the middle red LED (going from memory, so it might be a different LED) on the CPU turning on. The only way to recover from this is to dump in an image, or reload core & put in your most recent backup. Corruptions can occur from the backup battery being dead, noisy power being supplied, or any major power glitch while the system is on (power loss, lightning strike, etc.)
A modular, flexible architecture and an extensive range of networks and Fieldbus communication devices combine to make Modicon Quantum an ideal automation platform for continuous or semi-continuous industrial processes, as well as for large infrastructures.
The product of more than 25 years experience in the field of redundancy systems, Modicon Quantum is the perfect solution for applications that require high control system availability. This offer is therefore inherently suited to critical applications, such as petrochemicals, metals, cement, energy, tunnels, airports and water treatment. It can be used in many fields from Food & Beverage to the pharmaceutical industry. Certified by TUV Rheinland Group and IEC61508 complaint, some modules of the Modicon Quantum can be used in applications where functional safety is necessary. A configuration which combines functional safety and redundancy is also available.
This automation platform provides unrivalled treatment capacity together with an expandable memory size. It can receive the complete project, deal with very complex data structures, time and date stamping of diagnostics information as well as storage of recipes and traceability of information.
A Modicon Quantum automation platform configuration uses the following product families: Rack, Power supply, Central processing unit, Communication, Input/Output, Analogue, and Metering. The representative configuration selected consists of the following 15 modules mounted on a 16 slot rack 140XBP01600: 140CPU67161, 140CPS11420, 140ACI04000, 140ACO02000, 140ACO13000, 140ATI03000, 140CRP93200, 140DAI54000, 140DDI35300, 140DDI84100, 140DDO35300, 140DRA84000, 140ERT85410, 140NOE77101, 140XBE10000.
The environmental impact of this referenced configurations is representative of the impacts of the other possible configurations for which the same technology is used. The environmental analysis was performed in conformity with ISO 14040 “Environmental management: Life cycle assessment – Principle and framework”. This analysis takes the stages in the life cycle of the product into account.
The infeed modules are used to connect the drive group to the line supply. The infeed/regenerative feedback module (I/R module) and the module for the unregulated infeed (UI module) are used to input power into the DC link. Further, the I/R, UI, and the monitoring module also provide the electronics power supply for the connected modules. The infeed modules do not have any comprehensive overload protection. Such overload protection must be provided by the configuration and correct setting of the current values in the control boards.
For the UI module, when the motor brakes, the drive (such as the Siemens Simodrive series) energy injected into the DC link is converted into heat in the braking resistors and dissipated to the environment. These braking resistors are either integrated or mounted. When required, one or more additional pulsed resistor modules (PR modules) can be used within the limits specified when engineering the system. This module is used for the following applications:
– Machines with few or short braking cycles, low braking energy
– Drive groups with limited dynamic demands, in particular for the main spindle drive
I/R modules and HF/HFD commutating reactors form the step-up converter (7 kHz) for controlling the DC link voltage and enabling a regenerative feedback. This module is used for the following applications:
– Machines with high dynamic requirements placed on the drives
– Frequent braking cycles and high braking energy
– Control cabinet designs optimized for low operating costs
The monitoring module contains a complete electronics power supply for the equipment bus and the central monitoring functions for a separate drive group. The power is normally supplied from the 3-ph. 400 to 480 V AC line supply. For emergency retraction in case of a power failure, the power supply can also be connected to the DC link in parallel. The monitoring module is required if a higher number of drive modules in a group exceeds the electronics power supply of the infeed module (I/R or UI module). The monitoring module also allows groups of drive modules to be created in multiple cabinet compartments or tiers.
The I/R, UI, and monitoring module are located at the first module at the left in the drive group. The mounting surface for the line supply infeed and drive modules, as well as the commutating reactors and line filter, must be mounted to the mounting panels through a low-resistance connection (e.g. galvanized plates and panels). Line filters, line filter modules, and shielded cables are available in order to comply with the CE requirements regarding the radio interference voltage limit values. Shield terminal plates are available to meet EMC requirements when using shielded power cables. The overvoltage limiter module is required so that the line supply and infeed modules are implemented in conformance with UL.
In the “standby mode” of the line supply infeed, pule inhibits the power modules, terminal 63 should also be used to inhibit the pulses in the infeed. The DC link remains at the non-regulated level: this means that when the pulses are enabled, it is immediately regulated and is ready to operate. The cycle indicated above also applies to the starting frequency of the power supply (from the line supply or X181). The maximum starting frequency for the power supply is five times within a five minute period.
The Modicon Quantum series has a variety of communication interface modules which are listed and described below.
RIO Modules (CRA/CRP)
– Quantum RIO head and drop modules use a S908-based networking I/O configuration. Communication is done via single or dual coaxial cabling u to 15,000 feet away. This configuration supports a mix of the following product lines:
When Quantum RIO is required, the Modicon Quantum interface modules controller may support up to 31 RIO drops. In an RIO configuration, an RIO head module is connected with a coaxial cable to RIO drop modules at each remote drop.
DIO Module (CRA)
– Quantum DIO is implemented over a Modbus Plus network. The CPU or NOMs module may be the network head via their Modbus Plus ports. The Quantum DIO Modbus Plus drop adaptors are specifically designed to link Quantum I/O modules to the head via twisted pair shielded cable (Modbus Plus). The DIO drop modules also provide the I/O with power (maximum 3A) from a 24VDC or a 115/230VAC source. Each DIO network supports up to 63 distributed drops using repeaters.
Network Option Module (NOM)
– Quantum NOM modules provide extended communication capabilities for the Quantum system within a Modbus Plus configuration.
Modbus Plus on Fiber Module (NOM)
– Quantum Modbus Plus on Fiber modules provides connectivity to Modbus Plus nodes by fiber cable without fiber optic repeaters and allows the creation of a pure fiber optic network or a mixed fiber optic/twisted-pair network (with the use of a 490NRP254 Fiber Optic Repeater).
Ethernet TCP/IP (NOE) Modules
– Quantum Ethernet TCP/IP modules make it possible for a Quantum controller to communicate with devices on an Ethernet network using TCP/IP – the de facto standard protocol. An Ethernet module may be inserted into an existing Quantum system and connected to existing Ethernet networks via fiber optic or twisted pair cabling.
SY/MAX Ethernet Modules (NOE)
– Quantum-SY/MAX-Ethernet modules are Quantum CPU network option modules that can be placed in a Quantum backplane to connect to Quantum controllers to SY/MAX devices and applications.
MMS-Ethernet Modules (NOE)
– Quantum-MMS-Ethernet modules are Quantum CPU network option modules that can be placed in a Quantum backplane to connect Quantum controllers to MMS devices and applications.
InterBus Interface Module (NOA)
– The Quantum InterBus is the interface module to the InterBus bus. The InterBus bus is a Fieldbus network designed for I/O blocks and intelligent devices used in manufacturing. It offers a master/slave topology that permits deterministic I/O servicing over its 13 km twisted pair network.
LonWorks Modules (NOL)
– Quantum NOL modules provide connectivity between a Quantum controller and a LonWorks network, based on Echelon’s LonWorks technology. The NOL module is offered in three models for different transceiver types, and supports three twisted-pair media types with different network topologies or data transfer speeds.
Profibus Interface Module (CRP)
– Quantum Profibus module is the interface module to Profibus-DP networks. The interface modules use Type A, shielded twisted pair to join inline connectors, with or without service ports and bus terminators.
AS-I Interface Module
– Quantum AS-i modules provide connectivity between a Quantum controller and AS-i networks. AS-i bus cable is an unshielded flat two-wire link on which communication and power are transmitted to connected devices. The media insulation is self-healing to accommodate junction block removal.
The Modicon Quantum system is a special purpose computing system with digital processing capabilities. Modicon Quantum is designed for real-time control in industrial and manufacturing applications in a module, expandable architecture employing the following modules.
– CPU
– I/O
– I/O Network Interface
– Intelligent/Special Purpose I/O
– Simulator (XSM)
– Battery
– Backplanes
– CableFast Cabling
Quantum Power Supplies are used to supply system power to all modules inserted into the backplane, including CPU modules, Interface modules, and I/O modules. Depending upon the system configuration, the option exists of using the power supply in three different modes. The three modes are:
– Standalone: For 3A, 8A, or 11A configurations that do not require fault tolerant or redundant capabilities.
– Standalone Summable: For configurations consuming more than the rated current of one supply, two summing power supplies can be installed on the same backplane.
– Redundant: For configurations requiring power for uninterrupted system operation. Two redundant power supplies are required for redundancy.
The Quantum CPU is a module residing on the Quantum local I/O backplane. The CPU is a digitally operating electronic system, which uses a programmable memory for the internal storage of user interactions. These instructions are used to implement specific functions such as logic, process sequencing, timing, coupling, and arithmetic. These instructions allow control through digital and analog outputs, for various types of machines and processes. The Quantum CPU serves as a bus master controlling the local, remote, and distributed I/O of the Quantum system.
Quantum I/O modules are electrical signal converters that convert signals to and from field devices to a signal level and format, which can be processed by the CPU such as limit switches, proximity switches, temperature sensors, solenoids, and valve actuators. All I/O modules are optically isolated to the bus, ensuring safe and trouble-free operation. All I/O modules are also software configurable.