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GE Fanuc Automation

Computer Numerical Control Products

Series 0 / 00 / 0-Mate

Maintenance Manual

GFZ-61395E/07 November 1998

GFL-

Warnings, Cautions, and Notes

as Used in this Publication

Warning

Warning notices are used in this publication to emphasize that hazardous voltages, currents,

temperatures, or other conditions that could cause personal injury exist in this equipment or may

be associated with its use.

In situations where inattention could cause either personal injury or damage to equipment, a

Warning notice is used.

Caution

Caution notices are used where equipment might be damaged if care is not taken.

Note

Notes merely call attention to information that is especially significant to understanding and

operating the equipment.

This document is based on information available at the time of its publication. While efforts

have been made to be accurate, the information contained herein does not purport to cover all

details or variations in hardware or software, nor to provide for every possible contingency in

connection with installation, operation, or maintenance. Features may be described herein which

are not present in all hardware and software systems. GE Fanuc Automation assumes no

obligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory

with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or

usefulness of the information contained herein. No warranties of merchantability or fitness for

purpose shall apply.

©Copyright 1999 GE Fanuc Automation North America, Inc. All Rights Reserved.

SAFETY PRECAUTIONS B-- 61395E/

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DEFINITION OF WARNING, CAUTION, AND NOTE

This manual includes safety precautions for protecting the maintenance personnel (herein referred to as the user) and preventing damage to the machine. Precautions are classified into Warnings and Cautions according to their bearing on safety. Also, supplementary information is described as a Note. Read the Warning, Caution, and Note thoroughly before attempting to use the machine.

WARNING

Applied when there is a danger of the user being injured or when there is a danger of both the user being injured and the equipment being damaged if the approved procedure is not observed.

CAUTION

Applied when there is a danger of the equipment being damaged, if the approved procedure is not observed.

NOTE

The Note is used to indicate supplementary information other than Warning and Caution.

` Read this manual carefully, and store it in a safe place.

B-- 61395E/07 SAFETY PRECAUTIONS

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WARNINGS, CAUTIONS, AND NOTES RELATED TO CHECK OPERATION

WARNING

1. When checking the operation of the machine with the cover removed

(1) The user’s clothing could become caught in the spindle or other components, thus presenting a danger of injury. When checking the operation, stand away from the machine to ensure that your clothing does not become tangled in the spindle or other components. (2) When checking the operation, perform idle operation without workpiece. When a workpiece is mounted in the machine, a malfunction could cause the workpiece to be dropped or destroy the tool tip, possibly scattering fragments throughout the area. This presents a serious danger of injury. Therefore, stand in a safe location when checking the operation.

2. When checking the machine operation with the power magnetics cabinet door opened

(1) The power magnetics cabinet has a high--voltage section (carrying a mark). Never touch the high--voltage section. The high--voltage section presents a severe risk of electric shock. Before starting any check of the operation, confirm that the cover is mounted on the high--voltage section. When the high--voltage section itself must be checked, note that touching a terminal presents a severe danger of electric shock. (2) Within the power magnetics cabinet, internal units present potentially injurious corners and projections. Be careful when working inside the power magnetics cabinet.

3. Never attempt to machine a workpiece without first checking the operation of the machine. Before starting a production run, ensure that the machine is operating correctly by performing a trial run using, for example, the single block, feedrate override, or machine lock function or by operating the machine with neither a tool nor workpiece mounted. Failure to confirm the correct operation of the machine may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. 4. Before operating the machine, thoroughly check the entered data. Operating the machine with incorrectly specified data may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. 5. Ensure that the specified feedrate is appropriate for the intended operation. Generally, for each machine, there is a maximum allowable feedrate. The appropriate feedrate varies with the intended operation. Refer to the manual provided with the machine to determine the maximum allowable feedrate. If a machine is run at other than the correct speed, it may behave unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user. 6. When using a tool compensation function, thoroughly check the direction and amount of compensation. Operating the machine with incorrectly specified data may result in the machine behaving unexpectedly, possibly causing damage to the workpiece and/or machine itself, or injury to the user.

B-- 61395E/07 SAFETY PRECAUTIONS

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WARNINGS AND NOTES RELATED TO PARAMETERS

WARNING

1. When machining a workpiece for the first time after modifying a parameter, close the machine cover. Never use the automatic operation function immediately after such a modification. Instead, confirm normal machine operation by using functions such as the single block function, feedrate override function, and machine lock function, or by operating the machine without mounting a tool and workpiece. If the machine is used before confirming that it operates normally, the machine may move unpredictably, possibly damaging the machine or workpiece, and presenting a risk of injury. 2. The CNC and PMC parameters are set to their optimal values, so that those parameters usually need not be modified. When a parameter must be modified for some reason, ensure that you fully understand the function of that parameter before attempting to modify it. If a parameter is set incorrectly, the machine may move unpredictably, possibly damaging the machine or workpiece, and presenting a risk of injury.

SAFETY PRECAUTIONS B-- 61395E/

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WARNINGS RELATED TO DAILY MAINTENANCE

WARNING

1. Memory backup battery replacement

When replacing the memory backup batteries, keep the power to the machine (CNC) turned on, and apply an emergency stop to the machine. Because this work is performed with the power on and the cabinet open, only those personnel who have received approved safety and maintenance training may perform this work. When replacing the batteries, be careful not to touch the high--voltage circuits (marked and fitted with an insulating cover). Touching the uncovered high--voltage circuits presents an extremely dangerous electric shock hazard.

NOTE

The CNC uses batteries to preserve the contents of its memory, because it must retain data such as programs, offsets, and parameters even while external power is not applied. If the battery voltage drops, a low battery voltage alarm is displayed on the machine operator’s panel or CRT screen. When a low battery voltage alarm is displayed, replace the batteries within a week. Otherwise, the contents of the CNC’s memory will be lost. To replace the battery, see the procedure described in Section 2.6 of this manual.

SAFETY PRECAUTIONS B-- 61395E/

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WARNING

3. Fuse replacement

Before replacing a blown fuse, however, it is necessary to locate and remove the cause of the blown fuse. For this reason, only those personnel who have received approved safety and maintenance training may perform this work. When replacing a fuse with the cabinet open, be careful not to touch the high--voltage circuits (marked and fitted with an insulating cover). Touching an uncovered high--voltage circuit presents an extremely dangerous electric shock hazard.

B-- 61395E/07 PREFACE

p- 1

PREFACE

1.CRT/MDI display and operation

This chapter covers those items, displayed on the CRT, that are related to maintenance. A list of all supported operations is also provided at the end of this chapter.

2.Hardware

This chapter covers hardware--related items, including the hardware configuration, connection, and NC status indicated on printed circuit boards. A list of all units is also provided as well as an explanation of how to replace each unit.

3.Data input/output

This chapter describes the input/output of data, including programs, parameters, and tool compensation data, as well as the input/output procedures for conversational data.

4.Interface between the NC and PMC

This chapter describes the PMC specifications, the system configuration, and the signals used by the PMC.

5.Digital servo

This chapter describes the servo tuning screen and how to adjust the reference position return position.

6.Trouble shooting

This chapter describes the procedures to be followed in the event of certain problems occurring, for example, if the power cannot be turned on or if manual operation cannot be performed. Countermeasures to be applied in the event of alarms being output are also described.

APPENDIX

The appendix consists of a list of all alarms, as well as a list of maintenance parts. This manual does not provide a parameter list. If necessary, refer to the separate PARAMETER MANUAL.

This manual describes all optional functions. Refer to the manual provided by the machine tool builder for details of any options with which the installed machine tool is provided.

Description of

this manual

B-- 61395E/07 PREFACE

p- 3

The table below lists manuals related to the FANUC Series 0/00/0--Mate. In the table, this manual is marked with an asterisk (*).

List of related manuals

Manual name Specification number

FANUC Series 0/00/0-- Mate DESCRIPTIONS B-- 61392E FANUC Series 0/00/0-- Mate DESCRIPTIONS (Suppelement for Remote buffer) B-- 61392EN-- 1 FANUC Series 0/00/0-- Mate CONNECTION MANUAL (HARDWARE) B-- 61393E FANUC Series 0/00/0-- Mate CONNECTION MANUAL (FUNCTION) B-- 61393E-- 2 FANUC Series 0/00/0-- Mate FOR LATHE OPERATOR’S MANUAL B-- 61394E FANUC Series 0/00/0-- Mate FOR MACHINING CENTER OPERATOR’S MANUAL B-- 61404E FANUC Series 0/00/0-- Mate MAINTENANCE MANUAL B-- 61395E * FANUC Series 0/00/0-- Mate OPERATION AND MAINTENANCE HANDBOOK B-- 61397E FANUC Series 0/00/0-- Mate FOR LATHE PARAMETER MANUAL B-- 61400E FANUC Series 0/00/0-- Mate FOR MACHINING CENTER PARAMETER MANUAL B-- 61410E GRAPHIC CONVERSATION FOR MACHINING CENTER (Series 0-- MC, Series 0-- MF, Series 0-- Mate MF) OPERATOR’S MANUAL

B-- 61434E

FANUC PMC-- MODEL K/L/M PROGRAMMING MANUAL (LADDER LANGUAGE) B-- 55193E

FANUC Series 0/0-- Mate PROGRAMMING MANUAL (Macro Compiler / Macro Executer)

B-- 61393E-- 1

List of related manuals

Manual name Specification number

FANUC Series 0-- TD/MD DESCRIPTIONS B-- 62542EN FANUC Series 0-- TD/MD/PD/GCD/GSD CONNECTION MANUAL (HARDWARE) B-- 62543EN FANUC Series 0-- TD/MD/GCD/GSD CONNECTION MANUAL (FUNCTION) B-- 62543EN-- 1 FANUC Series 0-- PD CONNECTION MANUAL (FUNCTION) B-- 62973EN FANUC Series 0/00/0-- Mate FOR LATHE OPERATOR’S MANUAL B-- 61394E FANUC Series 0/00/0-- Mate FOR MACHINING CENTER OPERATOR’S MANUAL B-- 61404E FANUC Series 0-- PD OPERATOR’S MANUAL B-- 62974EN FANUC Series 0/00/0-- Mate MAINTENANCE MANUAL B-- 61395E * FANUC Series 0-- PD MAINTENANCE MANUAL B-- 62975EN FANUC Series 0-- TD/GCD PARAMETER MANUAL B-- 62550EN FANUC Series 0-- MD/GSD PARAMETER MANUAL B-- 62580EN

Related manuals

D Series 0/00/0-- Mate C

D Series 0-- D

B-- 61395E/07 Table of Contents

- c-

• SAFETY PRECAUTIONS s--
• PREFACE p--
• 1. DISPLAY AND OPERATION OF CRT/MDI
  • 1.1 FUNCTION KEYS AND SOFT KEYS
    • 1.1.1 Screen Transition Triggered by the Function Key
  • 1.2 POWER--ON SCREEN DISPLAY
  • 1.3 DIAGNOSTIC FUNCTIONS
    • 1.3.1 How to Display the Diagnosis Screen
    • 1.3.2 Display of the CNC Internal Status
  • 1.4 NC STATUS DISPLAYS
  • 1.5 LIST OF OPERATIONS
  • 1.6 CORRESPONDENCE BETWEEN ENGLISH AND SYMBOLIC KEYS
• 1. HARDWARE
  • 2.1 CONTROL UNIT
    • 2.1.1 Configuration of the Control Unit
  • 2.2 COMPLETE CONNECTION DIAGRAM
  • 2.3 INTER--MACHINE CONNECTION
    • 2.3.1 CRT/MDI Unit
    • 2.3.2 Reader/Puncher Interface
    • 2.3.3 Manual Pulse Generator
    • 2.3.4 I/O Link
    • 2.3.5 Servo Interface
    • 2.3.6 Serial Spindle Interface
    • 2.3.7 Analog Spindle Interface
    • 2.3.8 Position Coder Interface
    • 2.3.9 Remote Buffer Interface (Including FANUC DNC2 Interface)
    • 2.3.10 External Environmetal Requirements of Cabinet
    • 2.3.11 Installation Condition of CNC and Servo Unit
    • 2.3.12 Power Capacity
    • 2.3.13 Action Against Noise
  • 2.4 LEDS ON PRINTED--CIRCUIT BOARDS
  • 2.5 PRINTED--CIRCUIT BOARD UNIT LIST
    • 2.5.1 Structure
    • 2.5.2 Construction
  • 2.6 BATTERY REPLACEMENT METHOD
    • 2.6.1 CNC Memory Backup Battery Replacement
    • 2.6.2 Absolute Pulse Coder Batteries
  • 2.7 DETAILS OF POWER SUPPLY
    • 2.7.1 Details of Power Supply Unit A (A16B-- 1211-- 0850) (A16B-- 1210-- 0510)
    • 2.7.2 Details of Power Supply Unit B2 (A16B-- 1212-- 0110)
    • 2.7.3 Details of Power Supply Unit AI (A16B-- 1212-- 0100)
    • 2.7.4 CE Marking Correspond Details of Power Supply Unit AI (A16B-- 1212-- 0950)
    • 2.7.5 Fuses
  • 2.8 MAINTENANCE OF HEAT PIPE TYPE HEAT EXCHANGER
  • 2.9 REPLACING THE LCD BACKLIGHT (FOR 7.2” MONOCHROME LCD)
• 1. DATA INPUT/OUTPUT - Table of Contents B-- 61395E/ - c-
  • 3.1 DATA INPUT/OUTPUT
    • 3.1.1 Locating the File
    • 3.1.2 Outputting CNC Parameters
    • 3.1.3 PMC Parameter Output
    • 3.1.4 Program Output
    • 3.1.5 Offset Value Output
    • 3.1.6 Conversational Data Output
    • 3.1.7 CNC Parameter Input
    • 3.1.8 PMC Parameter Input
    • 3.1.9 Program Input
    • 3.1.10 Offset Value Input
    • 3.1.11 Conversational Data Input
    • 3.1.12 Parameters Related to Data Input/Output
    • 3.1.13 Displaying the Directory of Floppy Disk Files
    • 3.1.14 Reading the Files
    • 3.1.15 Outputting the Files
    • 3.1.16 Deleting the Files
    • 3.1.17 Changing the File Name
• 1. INTERFACE BETWEEN NC AND PMC
  • 4.1 PMC SCREEN
    • 4.1.1 PMC LAD Screen
  • 4.2 LIST OF SIGNALS
• 1. DIGITAL SERVO
  • 5.1 INITIAL SETTING THE SERVO PARAMETERS
  • 5.2 SERVO TUNING SCREEN
    • 5.2.1 Parameter Setting
    • 5.2.2 Displaying Servo Tuning Screen (Exa.: Incase of X axis)
  • 5.3 ADJUSTING THE REFERENCE POSITION (DOG METHOD)
    • 5.3.1 General
  • 5.4 DOGLESS REFERENCE POSITION SETTING
    • 5.4.1 General
    • 5.4.2 Operation
    • 5.4.3 Associated Parameters
• 1. TROUBLESHOOTING
  • 6.1 CORRECTIVE ACTION FOR FAILURES
    • 6.1.1 Investigating the Conditions Under which Failure Occurred
  • 6.2 POWER CANNOT BE SWITCHED ON
  • 6.3 NO MANUAL OPERATION NOR AUTOMATIC OPERATION CAN BE EXECUTED
  • 6.4 JOG OPERATION CANNOT BE DONE
  • 6.5 HANDLE OPERATION CANNOT BE DONE
  • 6.6 AUTOMATIC OPERATION CANNOT BE DONE
  • 6.7 CYCLE START LED SIGNAL HAS TURNED OFF
  • 6.8 NO DISPLAY APPEARS ON THE SCREEN WHEN THE POWER IS SWITCHED ON
  • 6.9 ALARM 85 TO 87 (READER/PUNCHER INTERFACE ALARM)
  • 6.10 REFERENCE POSITION DEVIATES - c- B-- 61395E/07 Table of Contents
  • 6.12 ALARM 3N0 (REQUEST FOR REFERENCE POSITION RETURN)
  • 6.13 ALARM 3N1 TO 3N6 (ABSOLUTE PULSE CODER IS FAULTY)
  • 6.14 ALARM 3N7 TO 3N8 (ABSOLUTE PULSE CODER BATTERY IS LOW)
  • 6.15 ALARM 3N9 (SERIAL PULSE CODER IS ABNORMAL)
  • 6.16 ALARM 400, 402, 406, 490 (OVERLOAD)
  • 6.17 ALARM 401, 403 406, 491 (*DRDY SIGNAL TURNED OFF)
  • 6.18 ALARM 404 AND 405 (*DRDY SIGNAL TURNED ON)
  • 6.19 ALARM 4N0 (EXCESSIVE POSITION ERROR AMOUNT DURING STOP)
  • 6.20 ALARM 4N1 (EXCESSIVE POSITION ERROR DURING MOVE)
  • 6.21 ALARM 4N4 (DIGITAL SERVO SYSTEM IS ABNORMAL)
  • 6.22 ALARM 4N6 (DISCONNECTION ALARM)
  • 6.23 ALARM 4N7 (DIGITAL SERVO SYSTEM IS ABNORMAL)
  • 6.24 ALARM 700 (OVERHEAT AT CONTROL SIDE)
  • 6.25 ALARM 704 (SPINDLE SPEED FLUCTUATION DETECTION ALARM)
  • 6.26 ALARM 408 (THE SPINDLE SERIAL LINK DOES NOT START NORMALLY.)
  • 6.27 ALARM 409 (SPINDLE ALARM)
  • 6.28 ALARM 998 (ROM PARITY ERROR)
  • 6.29 ALARMS 910 TO 916 (RAM PARITY ERRORS)
  • 6.30 ALARM 920 TO 922(WATCH DOG OR RAM PARITY)
  • 6.31 ALARM 941 (INCORRECTLY INSTALLED MEMORY PRINTED--CIRCUIT BOARD)
  • 6.32 ALARM 930 (CPU ERROR)
  • 6.33 ALARMS 945 AND 946 (SERIAL SPINDLE COMMUNICATION ERRORS)
  • 6.34 ALARM 960 (SUB--CPU ERROR)
  • 6.35 ALARM 950 (BLOWN FUSE)
• A. ALARM LIST APPENDIX
  • A.1 LIST OF ALARM CODES (CNC)
• B. LIST OF MAINTENANCE PARTS
  • B.1 MAINTENANCE PARTS
• 1. CONNECTION OF CRT/MDI UNIT FOR SERIES
  • C.1 INSTALLATION
  • C.2 CONNECTION - C.2.1 General Connection Diagram - C.2.2 Connector Layout Drawing - C.2.3 Connection of the CNC and the CRT/MDI - C.2.4 Connection of the CRT/MDI and Manual Pulse Generators - C.2.5 Connection of the CRT/MDI and the Battery Unit
  • C.3 OUTER VIEW - C.3.1 Outer View of CRT/MDI Unit
    • A HIGH--SPEED CPU C. MASTER PRINTED--CIRCUIT BOARD INCORPORATING

B-- 61395E/07 1. DISPLAY AND OPERATION OF CRT/MDI

DISPLAY AND OPERATION OF CRT/MDI

This chapter describes how to display various screens by the function keys. The screens used for maintenance are respectively displayed.

1.1 FUNCTION KEYS AND SOFT KEYS............. 2 1.2 POWER--ON SCREEN DISPLAY.................. 9 1.3 DIAGNOSTIC FUNCTIONS.................... 10 1.4 NC STATUS DISPLAYS........................ 16 1.5 LIST OF OPERATIONS........................ 17 1.6 CORRESPONDENCE BETWEEN ENGLISH AND SYMBOLIC KEYS............................ 21

B-- 61395E/07 1. DISPLAY AND OPERATION OF CRT/MDI

Screen transition triggered by the function key

in the AUTO or MDI mode

Program screen

Display of pro- gram contents

Display of current block and modal data

PRGRM CURRNT NEXT CHECK

PRGRM

PROGRAM SCREEN

AUTO (MDI)*

Display of current block and next block

Program being executed Absolute / relative coordinate value Distance to go modal values

Display of program number and se- quence number

FL.SDL

Command for MDI operation

[SCHDUL]

Setting of schedule

Program screen

PRGRM

(MDI)*

RSTR

Program restart

**

AUTO

BG--EDT

**

Back ground editing screen

Displayed in MDI mode Not displayed in MDI mode

1. DISPLAY AND OPERATION OF CRT/MDI B-- 61395E/

Program editing screen

Program memory and program direc- tory

PRGRM LIB C.A.P.

EDIT

Conversational programming screen

EDIT

Back ground edit- ing screen

Program screen

PROGRAM SCREEN Screen transition triggered by the function key

in the EDIT mode

Program screen

PRGRM

PRGRM

FLOPPY I/O

Program memory and program direc- tory

BG--EDT EX--EDT

Extended part pro- gram editing

**

**

Displayed if the floppy disk directory display option is supported and if the Floppy Cas- sette is specified as the input/output unit

Displayed if the above conditions are not satisfied