Author: baiyuzhan

Posted on by — Leave a comment

ADSEN Variable Frequency Drive ADS-V Series User Manual Operation Guide

I. Introduction to Operation Panel Functions

The operation panel of the ADSEN Variable Frequency Drive (VFD) ADS-V series serves as a crucial interface for user interaction with the device. The panel typically includes multiple function keys and a display screen, allowing users to perform operations such as start, stop, frequency setting, and parameter modification. The main function keys on the panel include:

  • Run Key: Starts the VFD operation.
  • Stop/Reset Key: Stops the VFD operation or resets it after a fault occurs.
  • Forward/Reverse Switch Key: Switches the running direction of the VFD.
  • Set Key: Enters the parameter setting mode.
  • Display/Shift Key: Cycles through different parameters such as output frequency, current, temperature, etc., in display mode.

1.1 Initializing Parameters (Restoring Factory Settings)

To restore all parameters of the VFD to factory settings, users can follow these steps:

  1. Press the “Set” key to display “Pr000”.
  2. Use the “Increase” or “Decrease” key to adjust to “Pr013” (parameter reset) and set the value to “01”.
  3. Press the “Confirm” key (usually the “Jog” key) to confirm the reset.
  4. At this point, the VFD will restore to factory settings, and all user-set parameters will be cleared.

1.2 Setting and Removing a Password

To protect the parameter security of the VFD, users can set a password to prevent unauthorized access. The specific steps are as follows:

  1. Enter the parameter setting mode and locate “Pr000” (parameter lock).
  2. Set the value to “1” to enable password protection.
  3. To remove the password, set it to “0”.

1.3 Setting Parameter Access Restrictions

After setting the parameter lock in “Pr000”, users can prevent others from modifying the parameters. A setting of “0” indicates invalid, while “1” indicates valid. Users must unlock before modifying parameters.

II. External Terminal Forward/Reverse Control and External Potentiometer Frequency Speed Adjustment

2.1 External Terminal Forward/Reverse Control

To achieve external terminal forward/reverse control, users need to wire the following terminals:

  • X1 Terminal: Run control signal.
  • X2 Terminal: Reverse control signal.
  • X3 Terminal: Stop control signal.

Parameter Settings:

  1. Set “Pr001” to “1” to select external terminal control.
  2. Set “Pr044” to “02” to assign X1 as run.
  3. Set “Pr045” to “03” to assign X2 as reverse.
  4. X3 terminal can be set as stop.

2.2 External Potentiometer Frequency Speed Adjustment

Connect the external potentiometer to the following terminals:

  • FV Terminal: Frequency setting input.
  • GND Terminal: Ground.

Parameter Settings:

  1. Set “Pr001” to “1” to select external terminal control.
  2. Set “Pr002” to “1” to select external potentiometer for frequency setting.
  3. Set “Pr072” to the desired maximum frequency (e.g., 50Hz).

With these settings, users can adjust the output frequency of the VFD using an external potentiometer.

III. Fault Codes and Troubleshooting

The ADSEN VFD ADS-V series provides multiple fault protection functions. Common fault codes and their troubleshooting methods are as follows:

3.1 Common Fault Codes

  • OU-1: Overvoltage during acceleration
    • Troubleshooting: Check the grid voltage and extend the acceleration/deceleration time.
  • OU-2: Overvoltage during deceleration
    • Troubleshooting: Extend the deceleration time or install a braking resistor.
  • FB: Fuse blown
    • Troubleshooting: Send for factory repair.
  • OH: VFD overheat
    • Troubleshooting: Check if the fan is blocked and ensure the ambient temperature is normal.
  • OL-1: VFD overcurrent or overload
    • Troubleshooting: Check if the load is too large and reset the parameters.
  • LV: Undervoltage
    • Troubleshooting: Check if the input voltage is normal.

3.2 Fault Handling

In the event of a fault, immediately press the stop key and record the fault code. Users should refer to the manual for corresponding checks and troubleshooting based on the fault code. If the fault cannot be resolved, contact professional technicians for repair.

IV. Summary

The user manual of the ADSEN VFD ADS-V series provides a detailed operation guide. Users should be familiar with the functions of the operation panel and fault troubleshooting methods during daily operations. By properly setting parameters and conducting effective maintenance checks, the normal operation of the VFD can be ensured, and its service life can be extended. In practical applications, if any issues are encountered, users should refer to the manual for resolution or contact professionals for support.

Posted on by — Leave a comment

Operation Guide for Ruishen Inverter RCP900 Series User Manual

I. Introduction to Operation Panel Functions and Parameter Initialization

The Ruishen Inverter RCP900 series is equipped with an intuitive and user-friendly operation panel, which integrates a data display area, command source indicators, forward/reverse indicators, and various other functions. Through this panel, users can easily perform parameter settings, working status monitoring, operation control, and other operations of the inverter.

RCP900正面图片

Parameter Initialization:

Before using the RCP900 series inverter, it is sometimes necessary to initialize the parameters to restore the factory settings. This can be achieved by setting the function code PP-01. Setting PP-01 to 1 will restore the inverter’s factory parameters (excluding motor parameters). This step is particularly important for resolving inverter faults caused by incorrect parameter settings.

Password Setting and Removal:

To protect the inverter settings from unauthorized changes, the RCP900 series inverter supports password protection. Users can set a password by configuring the function code PP-00. To remove the password, simply set PP-00 to 0. The password protection feature effectively prevents unauthorized operations and ensures the safety and stability of the inverter’s operation.

Parameter Access Restriction:

In addition to password protection, the RCP900 series inverter also supports parameter access restriction functionality. Users can select which parameter groups or specific parameters can be accessed and modified by configuring the function codes PP-03 and PP-04. This feature allows users to flexibly control access permissions to the inverter parameters based on actual needs, enhancing the security of device management.

RCP900 Side Image

II. Terminal Forward/Reverse Control and External Potentiometer Speed Regulation

Terminal Forward/Reverse Control:

The RCP900 series inverter supports forward/reverse control of the motor through terminals. The specific wiring method is as follows: Connect the forward control signal to the DI1 terminal, the reverse control signal to the DI2 terminal, and the common terminal to the COM terminal. In terms of parameter settings, it is necessary to set P0-02 (Run Command Selection) to 1 (Terminal Command), P4-00 (DI1 Terminal Function Selection) to 1 (Forward Run), and P4-01 (DI2 Terminal Function Selection) to 2 (Reverse Run). After completing these settings, the motor’s forward/reverse control can be achieved by controlling the electrical level status of the DI1 and DI2 terminals.

External Potentiometer Speed Regulation:

The RCP900 series inverter also supports speed regulation through an external potentiometer. The specific wiring method is as follows: Connect the output end of the external potentiometer to the AI1 terminal and the GND terminal to the inverter’s GND terminal. In terms of parameter settings, it is necessary to set P0-03 (Main Frequency Command Input Selection) to 4 (AI3 Panel Potentiometer). After completing these settings, the motor speed can be adjusted by adjusting the resistance value of the external potentiometer.

RCP900 Standard Wiring Diagram

III. Fault Code Meaning Analysis and Troubleshooting

During operation, the RCP900 series inverter may encounter various faults. When a fault occurs, the inverter will display the corresponding fault code. Below are some common fault codes, their meanings, and troubleshooting methods:

  • Err02: Acceleration Overcurrent. Possible causes include grounding or short circuit in the output circuit, incorrect motor parameter settings, etc. Solutions include troubleshooting peripheral issues, performing motor parameter identification, etc.
  • Err03: Deceleration Overcurrent. Possible causes are similar to those of acceleration overcurrent. Solutions also include troubleshooting peripheral issues, increasing deceleration time, etc.
  • Err05: Acceleration Overvoltage. Possible causes include high input voltage, short acceleration time, etc. Solutions include adjusting the input voltage, increasing the acceleration time, etc.
  • Err14: IGBT Overheat. Possible causes include high ambient temperature, fan failure, etc. Solutions include lowering the ambient temperature, replacing the fan, etc.

For the above fault codes, users can adopt corresponding solutions based on the inverter’s display information, combined with fault phenomena and possible causes. If the issue cannot be resolved, it is recommended to contact Ruishen Inverter’s technical support personnel or professional maintenance personnel for assistance.

IV. Conclusion

The Ruishen Inverter RCP900 series user manual provides a detailed operation guide, including operation panel function introduction, parameter initialization, password setting and removal, parameter access restriction, terminal forward/reverse control, external potentiometer speed regulation, fault code meaning analysis, troubleshooting methods, and other content. By carefully reading and understanding the user manual, users can better master the inverter’s usage methods and maintenance skills, ensuring the normal operation of the equipment and extending its service life. At the same time, users should flexibly utilize the inverter’s various functions based on actual needs to achieve more efficient and stable motor control.

Posted on by — Leave a comment

HOLIP Frequency Converter HLP-SV Series User Manual Operation Guide

I. Introduction to Operation Panel Functions and Parameter Settings

Introduction to Operation Panel Functions

The operation panel (LCP operator) of the HOLIP HLP-SV series frequency converter provides an intuitive interface for users to set parameters and monitor operations. The operation panel mainly includes a display screen, function keys, navigation keys, potentiometers, and indicators. The display screen shows current parameters, converter status, and other data. The function keys are used to select menus and execute operations. The navigation keys allow for setting, switching, and changing operations within parameter groups, parameters, and parameter internals. The potentiometer is used to adjust motor speed in manual mode. The indicators show the operating status of the converter, such as power access, warnings, and alarms.

HLP-SV power on standby state

Initializing Parameters

To initialize the converter parameters, users can set parameter 14-22 to 2 to restore the converter to factory defaults. This operation will reset all parameters except parameters 15-03 (operating hours counter), 15-04 (overheat count), and 15-05 (overvoltage count) to their factory default values. Before performing this operation, ensure that important parameter settings have been backed up.

Setting and Removing Passwords

To prevent unauthorized parameter modifications, users can set a password. Parameter 0-60 can be used to set a password for the main menu, with a range of 0-999. After setting the password, only by entering the correct password can protected parameters be modified. To remove the password, simply set parameter 0-60 to 0.

Physical image on the right side of HLP-SV

Setting Parameter Access Restrictions

The HOLIP frequency converter provides parameter access restriction functions. Users can control the activation and editing permissions of different menus by setting parameters 0-10, 0-11, and 0-12. For example, setting parameter 0-10 to 1 or 2 can activate Menu 1 or Menu 2, respectively. Setting parameter 0-11 to 1 or 2 allows editing of Menu 1 or Menu 2, respectively. Setting parameter 0-12 to 20 enables parameter association between Menu 1 and Menu 2, ensuring that parameters that cannot be changed during operation can be synchronized between the two menus.

II. Terminal Forward/Reverse Control and External Potentiometer Speed Regulation

Terminal Forward/Reverse Control

To achieve motor forward/reverse control, users need to connect external control signals to the digital input terminals of the converter. Typically, terminals 18 and 19 are used to control motor forward and reverse, respectively. The specific wiring method is as follows:

  • Forward: Connect the external control signal to terminal 18 (DI1) and the common terminal (COM).
  • Reverse: Connect the external control signal to terminal 19 (DI2) and the common terminal (COM).

Additionally, set the functions of terminals 18 and 19 to “Start” and “Reverse” in parameters 5-10 and 5-11, respectively. Also, set the motor rotation direction to “Bidirectional” in parameter 4-10.

External Potentiometer Speed Regulation

External potentiometer speed regulation is a commonly used speed control method. Users can change the motor speed by rotating the potentiometer. The specific wiring method is as follows:

  • Connect one end of the external potentiometer to the +10V power terminal of the converter (e.g., terminal 50).
  • Connect the other end of the external potentiometer to the analog input terminal of the converter (e.g., terminal 53) and ground (GND).

Then, select “Voltage Signal” as the input signal type for terminal 53 in parameter 6-19, and set the source of Reference Value 1 to “LCP Potentiometer” in parameter 3-15. By rotating the external potentiometer, users can adjust the motor speed in real-time.

HOLIP-SV standard wiring diagram

III. Fault Codes and Their Solutions

The HOLIP HLP-SV series frequency converter has comprehensive protection functions. When a fault occurs, the converter will display the corresponding fault code. The following are some common fault codes, their meanings, and solutions:

  • W/A 2: Signal Float Zero Fault
    • Meaning: This fault occurs when the converter detects that the float zero value of terminal 53 or 60 is less than 50% of the set value.
    • Solution: Check if the signal line connection is normal and ensure a stable signal source.
  • W/A 4: Power Phase Loss
    • Meaning: There is a phase loss or excessive voltage imbalance at the power supply terminal.
    • Solution: Check the power input line and power supply voltage for normalcy.
  • W/A 7: Overvoltage
    • Meaning: The intermediate circuit voltage (DC) exceeds the converter’s overvoltage limit.
    • Solution: Check if the power supply voltage is too high, connect a braking resistor, or activate “Braking Function/Overvoltage Control” in parameter group 2.
  • W/A 9: Converter Overload
    • Meaning: The converter’s electronic thermal protection indicates that the converter is about to disconnect due to overload.
    • Solution: Check if the mechanical system is overloaded, adjust the load, or increase the converter capacity.
  • W/A 10: Motor Overheat
    • Meaning: The electronic thermal relay (ETR) protection device indicates motor overheat.
    • Solution: Check the motor load and motor parameter settings for correctness, reduce the load, or improve the cooling conditions.
  • A 16: Output Short Circuit
    • Meaning: There is a short circuit in the motor terminal or motor.
    • Solution: Check if the motor insulation is damaged and eliminate the short circuit fault.

The above are only some fault codes and their solutions. Users can refer to the fault code table in the converter user manual for troubleshooting other faults encountered during use.

IV. Conclusion

The HOLIP HLP-SV series user manual provides detailed operation guides and troubleshooting methods for users. By familiarizing with the functions of the operation panel and parameter setting methods, users can easily initialize the converter, set passwords, restrict parameter access, achieve forward/reverse control and external potentiometer speed regulation, and more. At the same time, understanding common fault codes and their solutions helps users quickly troubleshoot and resolve converter faults, ensuring normal equipment operation.

Posted on by — Leave a comment

FANUC Servo Drive βISVSP A06B Maintenance Guide: Troubleshooting No Display Issues

FANUC servo drives, specifically the βISVSP A06B series, are widely used in various automated equipment, providing efficient and precise motor control. However, in practical use, various faults may arise, with one of the most common being the lack of display. A non-functional display is often caused by power issues, control circuit problems, or hardware malfunctions. This article explores the maintenance approach for resolving no display issues in FANUC servo drives, focusing on troubleshooting steps and solutions.

I. Fault Phenomenon: No Display

The no display fault in FANUC servo drives refers to a situation where the device powers on, but the panel displays no information. The indicator lights might be completely off, or the screen may be unresponsive, suggesting that there could be problems with the control circuits, display module, or power supply module inside the drive. If not addressed in a timely manner, this issue could prevent the device from starting or executing control instructions, which can negatively impact production efficiency.

II. Troubleshooting Approach

When encountering a no display issue in a servo drive, it’s essential to systematically check the device. Below are the common troubleshooting steps:

1. Check Power Supply Input

The first step is to verify if the power supply to the servo drive is functioning correctly. Power is the foundation for all electronic devices, and any instability or interruption in the power supply can prevent the drive from functioning properly.

  • Check the Power Voltage: Use a multimeter to check the voltage at the input terminals of the servo drive, confirming that it falls within the specified range. The FANUC servo drive typically requires a three-phase AC input voltage within a certain range.
  • Check Power Connections: Verify that the power supply cables are correctly connected and not damaged or disconnected. Poor power contact can lead to unstable voltage supply, which can result in no display issues.

2. Check Fuses and Circuit Breakers

Servo drives are equipped with fuses or circuit breakers to prevent damage from excessive current. If a fuse blows or the circuit breaker trips, the device will fail to operate properly.

  • Check the Fuse: Open the servo drive and inspect the fuses in the power section. If the fuse is blown, replace it with one of the same rating.
  • Check the Circuit Breaker: Some servo drives come with an internal circuit breaker that trips in case of voltage abnormalities or overcurrent. If the circuit breaker has tripped, reset it manually.

3. Check the Main Control Circuit

If the power supply is fine, the next step is to inspect the servo drive’s main control circuit. The control circuit acts as the brain of the servo drive, and any malfunction in this area could result in a non-responsive display.

  • Check the Control Chip: The control chip is usually located centrally on the circuit board and is responsible for processing input signals and controlling the operation of the drive. Look for signs of overheating, burning, or damage around the chip. Use an oscilloscope or multimeter to check the power supply voltage and signal output of the chip to ensure it’s functioning properly.
  • Check Circuit Connections: The circuit board in the servo drive is connected to various modules via connectors. Check if any connectors are loose or disconnected, as poor connections can prevent signals from transmitting correctly.

4. Check the Display Module and Signal Transmission

The display module is responsible for showing system status information to the operator. If the display module fails, it could lead to a no display situation.

  • Check the Display Screen: Inspect the power supply input terminals and signal transmission lines to the display screen to ensure they are properly connected. If the display module itself is faulty, it may need to be replaced.
  • Check Signal Transmission: If the display module appears intact, the issue could lie with the signal transmission. Inspect the signal lines between the main control board and the display module to ensure that signals are properly transmitted.

5. Check Capacitors and Power Filtering Circuits

Capacitors and filtering circuits help stabilize the voltage supply, especially for high-frequency currents. If the capacitors are damaged, the power supply could become unstable, affecting the drive’s operation.

  • Check the Capacitors: Look for signs of bulging, leakage, or aging in the capacitors. If a capacitor is faulty, it should be replaced with one of the same model.
  • Check the Filtering Circuits: The components in the filtering circuits may also be damaged, which can cause unstable voltage output. Inspect these components and replace them as necessary.

III. Common Fault Analysis and Solutions

1. Unstable Power Supply Leading to No Display

An unstable power supply voltage can prevent the drive from starting properly. In this case, check the stability of the power supply and ensure the voltage is within the specified range. If issues are found with the power supply, it may be necessary to replace the power module or reconnect the power supply.

2. Control Circuit Malfunction

A malfunctioning control circuit can prevent the system from starting or lead to a no display issue. Typically, this fault requires replacing damaged components. Commonly damaged components include control chips, integrated circuits, and resistors.

3. Display Module Failure

If the display module itself is faulty, it could be due to issues with the backlight, circuit board, or the display screen. Inspect the power input terminals and signal transmission lines to confirm the issue. If the display screen is damaged, replacing the display module will likely resolve the problem.

4. Capacitor or Filtering Circuit Issues

Damaged capacitors can cause unstable power, affecting the drive’s operation. Replacing faulty capacitors or repairing the filtering circuits should solve this issue.

IV. Conclusion

The no display issue in FANUC servo drives βISVSP A06B series is typically related to power problems, control circuit failures, or display module malfunctions. Through systematic troubleshooting and careful inspection, the problem can usually be pinpointed and resolved. During maintenance, special attention should be paid to power stability, circuit connections, and the condition of critical components. For more complex issues, professional diagnostic tools may be required, and damaged components should be replaced to restore the device to normal operation. Timely and effective maintenance ensures the long-term stability and performance of FANUC servo drives, helping to maintain production efficiency.

Posted on by — Leave a comment

User Manual Guide for Vacon NXS_NXP Series Inverters

I. Introduction to the Operating Panel Functions

The Vacon NXS_NXP series inverters are equipped with an intuitive and user-friendly operating panel, providing users with a convenient interface for operation and monitoring. The operating panel typically includes a display screen, multiple function buttons, and status indicators. The display screen is used to show the current operating status, parameter values, and fault information. The function buttons are used for navigating menus, modifying parameter values, resetting faults, and other operations. The status indicators display the running status of the inverter, such as running, stopped, alarming, and faulting.

NXP physical image

II. How to Initialize Parameters (Specific Parameters)

Before using the Vacon NXS_NXP series inverters, users may need to initialize the parameters to ensure all settings are at their default values. The initialization process usually includes restoring the factory settings of the inverter. Users can follow these steps to initialize the parameters:

  1. Enter the System Menu: First, access the system menu (usually labeled as M6) through the operating panel.
  2. Select Parameter Sets: In the system menu, find the parameter set option (typically labeled as S6.3.1).
  3. Restore Factory Defaults: In the parameter set option, select the “Load Factory Defaults” option and confirm the execution. This will restore all parameters of the inverter to their factory settings.

III. How to Set and Reset Passwords (Specific Parameters)

To protect the settings of the inverter from unauthorized changes, the Vacon NXS_NXP series inverters provide a password protection feature. Users can follow these steps to set and reset passwords:

  1. Setting a Password:
    • Enter the system menu (M6).
    • Find the password setting option (usually labeled as S6.5.1).
    • Enter the password value (typically ranging from 1 to 65535) through the buttons on the operating panel.
    • Confirm the password setting.
  2. Resetting a Password:
    • Enter the system menu (M6).
    • Find the password setting option (S6.5.1).
    • Enter the current password (if already set).
    • Set the password value to 0 and confirm the execution. This will disable the password protection feature.
NXS-NXP actual wiring diagram

IV. How to Set Parameter Access Restrictions (Specific Parameters and Operations)

In addition to password protection, the Vacon NXS_NXP series inverters also provide a parameter access restriction feature, allowing users to restrict access and modification of specific parameters. Users can follow these steps to set parameter access restrictions:

  1. Enter the System Menu (M6).
  2. Find the Parameter Lock Option (usually labeled as S6.5.2).
  3. Enable Parameter Lock: Set the parameter lock option to “Locked” and confirm the execution. This will restrict access and modification of most parameters.
  4. Disable Parameter Lock: When needing to modify locked parameters, first set the parameter lock option to “Unlocked” and confirm the execution.

V. How to Achieve External Terminal Forward/Reverse Control and External Potentiometer Speed Regulation

The Vacon NXS_NXP series inverters support motor forward/reverse control through external terminals and speed regulation through external potentiometers. Users need to set the following parameters and connect corresponding terminals:

  1. Forward/Reverse Control:
    • Parameter Settings: No specific parameter settings are required, but ensure the control signal source is set to external terminal control (P3.1=1).
    • Wiring: Connect the external forward button or switch to DIN1 (or the designated forward input terminal), and connect the external reverse button or switch to DIN2 (or the designated reverse input terminal).
  2. External Potentiometer Speed Regulation:
    • Parameter Settings: Ensure AI1 (or the designated analog input terminal) is set to accept analog voltage or current signals (specific settings depend on the potentiometer type).
    • Wiring: Connect the output end of the potentiometer to AI1 (or the designated analog input terminal), and connect the common terminal of the potentiometer to AI1- (or the corresponding common terminal).

VI. Fault Codes and Their Solutions

The Vacon NXS_NXP series inverters feature comprehensive fault diagnosis capabilities. When a fault is detected, the inverter will display the corresponding fault code and fault information. The following are some common fault codes, their meanings, and solutions:

  1. Fault Code F01: Overcurrent
    • Meaning: Motor current exceeds the rated value.
    • Solution: Check if the motor load is too heavy, and check for short circuits or grounding in the motor and cables.
  2. Fault Code F02: Overvoltage
    • Meaning: DC bus voltage is too high.
    • Solution: Check if the power supply voltage is too high, extend the deceleration time, or increase the braking resistor.
  3. Fault Code F03: Ground Fault
    • Meaning: Motor or cable grounding.
    • Solution: Check the insulation resistance of the motor and cables.
  4. Fault Code F05: Charging Switch Fault
    • Meaning: Charging switch failure.
    • Solution: Check the charging switch and its connection lines, and replace the charging switch if necessary.

(Note: The above are only examples of some fault codes. For a complete list of fault codes and solutions, please refer to the inverter user manual.)

Through this guide, we hope to help users better understand and use the Vacon NXS_NXP series inverter user manual, achieving efficient and safe frequency control.

Posted on by — Leave a comment

Commitment of Longi Electromechanical Company to Protect Customers’ Privacy Rights

Our company attaches great importance to the protection of personal information of both existing and potential customers. The specific protection measures are as follows:

Advanced Encryption Technology: We employ advanced encryption technology to ensure the security of customer information during transmission and storage, preventing unauthorized third parties from obtaining it.

Strict Access Control: We limit the number of employees who can access customer information, and only authorized personnel are allowed to access relevant data, ensuring the confidentiality of the information.

Clear Privacy Policy: We have a clear privacy policy that details how we collect, use, and store customer information. We regularly update our privacy policy to ensure compliance with the latest legal and regulatory requirements. You can view our privacy policy by clicking [insert privacy policy link here].

Compliant Data Usage: We only use customer information when necessary to provide services and products, and we do not sell or share customer information with third parties unless explicitly agreed to by the customer.

Employee Security Training: We provide regular security training to our employees to ensure they understand and comply with data protection regulations, enhancing their awareness of information security.

Reasonable Data Retention: We only retain customer information for as long as permitted by law, and when customer information is no longer needed, we securely delete or anonymize it to prevent misuse.

Through these measures, we are committed to providing a safe and reliable environment for the protection of personal information. If you have any questions or need further assistance, please feel free to contact us.

Posted on by — Leave a comment

Operation Guide for Instar-Tech AE200H Series Frequency Converter User Manual

I. Introduction to Operation Panel Functions

The Instar-Tech AE200H series frequency converter features a concise and straightforward operation panel design, facilitating intuitive operation and monitoring. The main function keys and indicator lights on the operation panel include:

  • RUN Key: Press this key to start the frequency converter. In programming mode, this key can be used as a shift key.
  • JOG Key: Press this key to enter jogging mode and switch between forward and reverse rotation.
  • STOP Key: Press this key to stop the frequency converter. After a fault alarm, pressing this key can reset the system.
  • PROG Key: Press this key to enter the function setting mode. After modification, press it again to exit the setting mode.
  • DATA Key: In programming mode, press this key to confirm the function code and parameter content. After modification, press it again to save the data.
  • UP Key and DOWN Key: In programming mode, use these keys to adjust the numerical values of function codes and parameter data.
  • Shift Key (<< / REV): In programming mode, use this key to shift during parameter data modification.

Additionally, the operation panel has multiple indicator lights to display the operating status of the frequency converter, such as the RUN, STOP, FWD, and REV indicators.

Function diagram of AE200H operation panel

II. Password Setting and Parameter Access Restrictions

To protect the frequency converter’s settings from unauthorized modification, the AE200H series provides a password setting function. Users can set a password to restrict access and modification of frequency converter parameters. The specific steps are as follows:

  1. Set Password: Enter programming mode, locate the user password parameter (e.g., P.089), and set a non-zero value as the password.
  2. Enter Password: When modifying parameters, the system will prompt for a password. Only by entering the correct password can you access the parameter modification interface.
  3. Eliminate Password: To eliminate the password, simply reset the user password parameter value to 0.

Furthermore, the AE200H series frequency converter offers parameter access restriction functions. Users can set different access levels to restrict different users’ access to frequency converter parameters.

III. Parameter Initialization

If users need to restore the frequency converter to its factory settings, they can perform a parameter initialization operation. The specific steps are as follows:

  1. Enter programming mode.
  2. Locate the factory reset parameter (e.g., P.XXX, refer to the user manual for specific codes) and set its value to 1.
  3. Press the DATA key to save the setting and restart the frequency converter.

After restarting, the frequency converter will return to its factory settings, and all user-set parameters will be cleared.

IV. Terminal Forward/Reverse Control and External Potentiometer Speed Regulation

The AE200H series frequency converter supports motor forward/reverse control through external terminals and speed regulation through an external potentiometer. The specific settings and wiring methods are as follows:

  1. Terminal Forward/Reverse Control
    • Parameter Setting: No special setting is required; ensure correct wiring.
    • Wiring Method: Connect the forward control terminal (e.g., S1) and reverse control terminal (e.g., S2) to the corresponding contacts in the control circuit. By controlling the on/off status of these contacts, you can achieve motor forward/reverse rotation and stopping.
  2. External Potentiometer Speed Regulation
    • Parameter Setting: Locate the speed control mode selection parameter (e.g., P.XXX) and set its value to external given.
    • Wiring Method: Connect the output terminal of the external potentiometer to the speed regulation input terminal of the frequency converter (e.g., AI1 or AI2). By adjusting the resistance value of the potentiometer, you can change the output frequency of the frequency converter, thereby achieving motor speed regulation.

V. Fault Codes and Solutions

The AE200H series frequency converter features comprehensive fault diagnosis capabilities. When a fault occurs, the corresponding fault code will be displayed on the screen. Here are some common fault codes, their meanings, and solutions:

  1. OC1/OC2/OC3: Overcurrent during acceleration/deceleration/constant speed.
    • Meaning: The output current of the frequency converter exceeds the rated value.
    • Solution: Check if the motor load is excessive, check the power line connection for good contact, and check if the frequency converter parameter settings are reasonable (e.g., acceleration/deceleration time, overload protection).
  2. OU1/OU2/OU3: Overvoltage during acceleration/deceleration/constant speed.
    • Meaning: The input voltage of the frequency converter is too high or the braking resistor is damaged.
    • Solution: Check if the power supply voltage is stable and inspect the braking resistor for damage or poor connection.
  3. UV: Undervoltage on the bus.
    • Meaning: The input voltage of the frequency converter is lower than the rated voltage.
    • Solution: Check if the power supply voltage is normal and inspect the power line connection for good contact.
  4. OL1: Motor overload.
    • Meaning: The motor load is excessive or the motor parameter settings are incorrect.
    • Solution: Check if the motor load is excessive and verify the motor parameter settings (e.g., rated current, power).
  5. OH2: Frequency converter overheat.
    • Meaning: The internal temperature of the frequency converter is too high.
    • Solution: Check if the frequency converter installation environment is well-ventilated and inspect the cooling fan for normal operation.
AE200H standard wiring diagram

VI. Conclusion

This article provides a detailed operation guide for the Instar-Tech AE200H series frequency converter, covering the introduction to operation panel functions, password setting and parameter access restrictions, parameter initialization, terminal forward/reverse control, external potentiometer speed regulation, fault codes and solutions, and other related content. We hope this guide will help users better understand and utilize this series of frequency converters to ensure their efficient and stable operation.

Posted on by — Leave a comment

The Meaning and Solutions for AL-24 Alarm on FANUC αi Series Spindle Amplifiers

In the maintenance and repair of CNC machine tools, fault alarms are a common occurrence. For equipment using FANUC αi series spindle amplifiers, the AL-24 alarm is a typical code. This article will explore the meaning of this alarm, possible causes, and solutions, providing theoretical support and practical guidance for CNC servo system repairs.

AL-24

1. Meaning of the AL-24 Alarm

According to FANUC’s official documentation, the AL-24 alarm indicates that the serial communication data between the CNC (Computer Numerical Control system) and the spindle amplifier module contains errors. This alarm typically occurs when there is an abnormality in the communication link between the CNC and the spindle amplifier. It is important to note that this alarm does not necessarily indicate hardware failure; in most cases, it is caused by communication issues or external interference.

Scenarios Triggering the Alarm

  • The CNC is powered off while the spindle amplifier remains energized.
  • Serial communication is disrupted, causing data transmission errors.
  • Communication cables are loose, damaged, or poorly connected.

2. Possible Causes of the AL-24 Alarm

When diagnosing the AL-24 alarm, the investigation should focus on the communication link, cable conditions, and hardware status. Common causes include:

1. Communication Noise Interference

Serial data transmission between the CNC and the spindle amplifier may be disrupted by external electromagnetic noise, resulting in data errors and triggering the AL-24 alarm.

2. Cable Issues or Connection Problems

The communication cable is a critical link between the CNC and the spindle amplifier. Possible issues include:

  • Cable aging or internal breakage.
  • Loose or improperly secured connectors.
  • In the case of fiber optic communication, damaged optical connectors or modules.

3. Bundling of Communication and Power Cables

When communication cables are bundled with spindle or servo motor power cables, high-frequency currents may cause electromagnetic interference, affecting communication stability.

4. Hardware Malfunction

Hardware-related issues that may trigger the AL-24 alarm include:

  • Faulty internal circuit boards in the spindle amplifier module (SPM).
  • Damaged communication interface boards or modules in the CNC control system.

5. Parameter Configuration Issues

Incorrect communication parameter settings in the spindle amplifier or CNC can also lead to communication failures.

A06B-6140-h055

3. Solutions for the AL-24 Alarm

When addressing the AL-24 alarm, follow these steps for systematic troubleshooting:

1. Verify CNC Power Status

Check whether the CNC is properly powered. If the CNC is off, the spindle amplifier cannot establish communication, which is a normal reason for the alarm.

  • Action: Ensure the CNC is fully powered and there are no additional alarm codes.

2. Inspect Communication Cables

Communication cables are crucial for the connection between the CNC and the spindle amplifier. Diagnosing cable issues is a key step.

  • Steps:
    • Inspect the cable’s exterior for damage or aging.
    • Ensure connectors are securely plugged in.
    • For fiber optic communication, check the cleanliness of the optical connectors and the condition of the optical modules.
  • Actions:
    • Replace the communication cable and reconnect.
    • If optical modules are faulty, contact the supplier for replacement.

3. Address Noise Interference

Communication stability can be compromised by noise interference, particularly when communication cables are bundled with power cables.

  • Steps:
    • Check the routing of communication cables to ensure they are separated from power and servo cables.
    • Use well-shielded cables or add shielding to existing cables.
  • Actions: Separate communication cables from power cables to maintain a safe physical distance.

4. Examine the SPM Module

The internal circuit board of the spindle amplifier (SPM) may fail due to aging or external impact.

  • Actions:
    • Inspect the SPM module for physical damage or burn marks.
    • Contact FANUC support for repair or replacement if the module is faulty.

5. Validate CNC Hardware

If the SPM is functioning correctly, check the communication interface boards or modules on the CNC side.

  • Actions:
    • Replace the relevant communication boards and test.
    • Check the CNC’s alarm log for related issues.

6. Correct Parameter Settings

Incorrect communication parameters may prevent successful communication between the CNC and the SPM.

  • Actions:
    • Reconfigure communication parameters based on the equipment model and manual.
    • Ensure communication speed, protocols, and other settings match between the SPM and CNC.

4. Preventive Measures

To reduce the likelihood of AL-24 alarms, consider the following preventive measures:

  1. Regular Cable Inspection:
    • Ensure communication cables are free from aging, breakage, or damage.
    • Use durable, high-quality shielded cables.
  2. Optimize Cable Routing:
    • Keep communication cables separate from power lines to avoid interference.
  3. Routine Hardware Maintenance:
    • Inspect the SPM and CNC hardware regularly and replace aging components promptly.
    • Clean amplifier and cable interfaces to prevent dust accumulation.
  4. Environmental Control:
    • Minimize strong electromagnetic interference around the equipment.
    • Provide adequate cooling for amplifiers and control cabinets.

Conclusion

The AL-24 alarm, a common fault code in FANUC αi series spindle amplifiers, primarily reflects communication abnormalities between the CNC and the spindle amplifier. By understanding its meaning, identifying causes, and following a structured troubleshooting process, maintenance personnel can quickly resolve the issue. Additionally, implementing preventive measures can significantly reduce the occurrence of such alarms, ensuring long-term stability and performance of the equipment.

Posted on by — Leave a comment

WEICHI Servo SD710 Series User Manual Operation Guide

I. Introduction to Servo Operation Panel Functions and Basic Settings

1.1 Panel Function Introduction

The WEICHI Servo SD710 series operation panel features a concise and clear design, including mode selection keys (MODE/SET), up/down adjustment keys (UP/DOWN), data shift keys (DATA/SHIFT), and some function keys. These keys allow users to easily switch modes, set parameters, display statuses, and more.

SD710 front

1.2 Setting Passwords and Parameter Access Restrictions

To ensure the security of the servo system, the SD710 series provides password protection functionality. Users can set the access permissions for function code parameters through parameter PnE1D’s system switch 3. The specific steps are as follows:

  1. Enter Auxiliary Functions: Press the MODE/SET key to select auxiliary functions and adjust to Fn010 using the UP/DOWN keys.
  2. Set Password: Press the DATA/SHIFT key for about one second to enter the parameter setting state, and adjust the parameter value using the UP/DOWN keys. Press the MODE/SET key to confirm after setting.

1.3 Realizing Jog Operation

Jog operation is a commonly used function in servo debugging. The SD710 series provides two modes: JOG (speed jog) and program JOG (position jog). The specific implementation steps are as follows:

  1. JOG Mode:
    • Press the MODE/SET key to select auxiliary functions and adjust to Fn005.
    • Set the jog speed (Pn500) using the UP/DOWN keys, and press the MODE/SET key to enter the servo ON state.
    • Press the UP key (forward rotation) or DOWN key (reverse rotation) to start jog operation.
  2. Program JOG Mode:
    • Press the MODE/SET key to select auxiliary functions and adjust to Fn006.
    • Set the relevant parameters for program JOG (such as Pn502 operation mode, Pn503 movement distance, etc.).
    • Press the MODE/SET key to enter the servo ON state and start program JOG operation.
SD710 Side

1.4 Setting Brake and Over-travel

Brake Setting:

  • Set the relevant delay times for brake activation through parameters Pn009 and Pn010 to ensure that the brake can actuate timely when the motor stops.

Over-travel Setting:

  • Connect external limit switches to the P-OT and N-OT pins of the CN1 terminal to achieve over-travel protection in positive and negative directions.
  • Alternatively, enable the soft limit function internally through parameter Pn00D.W and set the absolute position limit switch.

1.5 Regenerative Braking Setting

Regenerative braking is an important safety protection function in servo systems. The SD710 series provides options for both built-in and external regenerative braking resistors. Users can set the resistance and capacity of the built-in braking resistor through parameters PnE0B and PnE0C. For external braking resistors, correct connection according to the wiring diagram in the drive manual is required, and the corresponding resistance should be set through parameters.

II. External Pulse Position Mode Forward and Reverse Positioning Control

2.1 Terminal Connections

To realize external pulse position mode forward and reverse positioning control, the relevant pins of the CN1 terminal need to be connected correctly. The specific connections are as follows:

  • Pulse Input: Connect to the PUL+ and PUL- pins of CN1.
  • Direction Input: Connect to the DIR+ and DIR- pins of CN1.
  • Enable Input: Connect to the S-ON pin of CN1.

2.2 Parameter Settings

  1. Control Mode Selection: Set parameter Pn000.X to 0 to select position control mode.
  2. Position Command Source Selection: Set parameter Pn200 to 0 to select external pulse sequence as the position command source.
  3. Electronic Gear Ratio Setting: Set parameters Pn204 (numerator) and Pn206 (denominator) according to actual needs to determine the number of pulses per motor revolution.
  4. Jog Speed Setting (optional): Set parameter Pn500 for using the jog function during debugging.

After completing the above settings, pulse signals can be sent through an external pulse generator to realize forward and reverse positioning control of the servo motor.

SD710 Position Mode Standard Wiring Diagram

III. Fault Codes and Solutions

The WEICHI Servo SD710 series drive provides a wealth of fault codes to help users quickly locate problems. The following are some common fault codes and their solutions:

  • ER.020: User function code parameter and checksum error. Solution: Check if the parameter settings are correct and re-initialize the parameters after re-powering.
  • ER.100: Drive overcurrent. Solution: Check if the motor and drive are overloaded, and check if the motor power line connection is poor.
  • ER.320: Regenerative overload. Solution: Check if the regenerative braking resistor is connected correctly and if the resistance is appropriate; reduce the load or increase the braking resistor.
  • ER.400: Overvoltage. Solution: Check if the power supply voltage is stable and if it exceeds the rated voltage range of the drive.
  • ER.410: Undervoltage. Solution: Check if the power supply voltage is too low and ensure that the power supply voltage is within the allowable range of the drive.

For other fault codes, users can refer to the fault code table in the drive manual and perform corresponding checks and troubleshooting according to the prompts.

IV. Conclusion

The WEICHI Servo SD710 series user manual provides detailed operation guides and parameter setting instructions, helping users quickly get started and achieve efficient and stable servo control. By correctly setting panel parameters, connecting external terminals, and promptly handling fault codes, users can fully leverage the performance advantages of the SD710 series to meet the needs of various industrial applications.

Posted on by — Leave a comment

Comprehensive Guide to FANUC Servo System Troubleshooting and Repair（DB DELAY FAILURE）

FANUC servo systems, widely used in industrial automation, are renowned for their reliability and precision. However, like any sophisticated equipment, they can experience faults that require systematic diagnosis and repair. This guide focuses on two common faults: “NEED REF RETURN” (Absolute Pulse Coder Alarm) and “DB RELAY FAILURE” (Dynamic Brake Relay Issue), along with general troubleshooting techniques.

DB DELAY FAILURE

1. “NEED REF RETURN” Alarm

Fault Description

The “NEED REF RETURN” alarm indicates that the absolute position data of the encoder is lost or the axis requires a reference return operation. This typically happens when:

  • The encoder battery voltage is low or the battery has failed.
  • The system loses its absolute position data due to a power interruption or improper initialization.

Repair Process

  1. Check the Encoder Battery:
    • Replace the battery if its voltage is below the specified threshold (typically 3.6V for FANUC systems).
    • Ensure the battery is replaced with the power ON to prevent loss of encoder data.
  2. Perform Reference Return:
    • Access the machine’s control interface and initiate the reference return operation for the affected axes.
    • Follow the machine tool builder’s specific procedures for homing operations.
  3. Inspect Encoder Wiring:
    • Verify that the encoder cables are securely connected and free from damage.
    • Check for continuity and signal integrity using a multimeter or oscilloscope if necessary.
  4. Reset the Alarm:
    • Once the reference return is completed, reset the alarm via the machine control panel.
A06B-6240-H105

2. “DB RELAY FAILURE” Alarm

Fault Description

The “DB RELAY FAILURE” alarm indicates an issue with the Dynamic Brake (DB) relay, responsible for safely braking the motor during stop or emergency stop conditions. Possible causes include:

  • A malfunctioning DB relay (burnt coil or damaged contacts).
  • Faults in the relay driver circuit.
  • Open or damaged connections in the DB circuit.

Repair Process

  1. Visual Inspection:
    • Open the servo amplifier and inspect the relay for signs of burning, discoloration, or physical damage.
    • Check the PCB for any visible defects such as burnt traces or damaged components.
  2. Test the DB Relay:
    • Use a multimeter to measure the resistance of the relay coil. A functional relay typically has a specific resistance value (e.g., tens to hundreds of ohms). If open or short-circuited, the relay needs replacement.
    • Inspect the relay contacts for proper operation and absence of welding or pitting.
  3. Inspect the Driver Circuit:
    • Check the transistors or ICs driving the DB relay for shorts or open circuits.
    • Use an oscilloscope to verify the control signal to the relay during operation.
  4. Verify DB Resistor and Wiring:
    • Ensure the dynamic braking resistor is intact and its connections are secure.
    • Measure the resistor’s value and compare it with the specifications.
  5. Replace Faulty Components:
    • Replace the relay or driver components if faults are detected.
    • Ensure replacement parts are genuine and match the original specifications.
  6. Reset and Test:
    • After repairs, reset the system and perform operational tests to confirm the alarm is cleared and the DB relay functions correctly.
A06B-6079-H207

3. General Troubleshooting Techniques

LED Indicators

  • Check the LED status on the servo amplifier front panel. LED patterns often provide diagnostic information about the amplifier’s status and errors.

Error Codes

  • Refer to the system’s maintenance manual for detailed descriptions of error codes.
  • FANUC manuals, such as the GFZ-65195EN/01, provide comprehensive troubleshooting steps for each alarm code.

Electrical Checks

  • Measure power supply voltages to ensure they are within specified ranges.
  • Inspect connectors, cables, and PCB traces for continuity and integrity.

Parameter Verification

  • Confirm that the servo parameters are set correctly. Incorrect parameters can lead to operational issues and alarms.

4. Preventive Maintenance Tips

  1. Regular Battery Replacement:
    • Schedule periodic checks and replacements for the encoder battery to avoid position loss.
  2. Keep Components Clean:
    • Clean the servo amplifier and surrounding areas to prevent dust and debris accumulation.
  3. Inspect Wiring:
    • Regularly inspect cables and connectors for wear, corrosion, or loose connections.
  4. Follow Manufacturer Guidelines:
    • Always adhere to FANUC’s maintenance and operational guidelines for optimal system performance.
A06B-6079-H207 power board and fault relay location

Conclusion

By understanding the causes and systematic repair methods for alarms like “NEED REF RETURN” and “DB RELAY FAILURE,” maintenance engineers can ensure minimal downtime and enhanced reliability of FANUC servo systems. Regular preventive maintenance further helps in avoiding recurring issues and extending the life of these critical components.

Comprehensive Guide to FANUC Servo System Troubleshooting and Repair

FANUC servo systems, widely used in industrial automation, are renowned for their reliability and precision. However, like any sophisticated equipment, they can experience faults that require systematic diagnosis and repair. This guide focuses on two common faults: “NEED REF RETURN” (Absolute Pulse Coder Alarm) and “DB RELAY FAILURE” (Dynamic Brake Relay Issue), along with general troubleshooting techniques.

1. “NEED REF RETURN” Alarm

Fault Description

The “NEED REF RETURN” alarm indicates that the absolute position data of the encoder is lost or the axis requires a reference return operation. This typically happens when:

  • The encoder battery voltage is low or the battery has failed.
  • The system loses its absolute position data due to a power interruption or improper initialization.

Repair Process

  1. Check the Encoder Battery:
    • Replace the battery if its voltage is below the specified threshold (typically 3.6V for FANUC systems).
    • Ensure the battery is replaced with the power ON to prevent loss of encoder data.
  2. Perform Reference Return:
    • Access the machine’s control interface and initiate the reference return operation for the affected axes.
    • Follow the machine tool builder’s specific procedures for homing operations.
  3. Inspect Encoder Wiring:
    • Verify that the encoder cables are securely connected and free from damage.
    • Check for continuity and signal integrity using a multimeter or oscilloscope if necessary.
  4. Reset the Alarm:
    • Once the reference return is completed, reset the alarm via the machine control panel.

2. “DB RELAY FAILURE” Alarm

Fault Description

The “DB RELAY FAILURE” alarm indicates an issue with the Dynamic Brake (DB) relay, responsible for safely braking the motor during stop or emergency stop conditions. Possible causes include:

  • A malfunctioning DB relay (burnt coil or damaged contacts).
  • Faults in the relay driver circuit.
  • Open or damaged connections in the DB circuit.

Repair Process

  1. Visual Inspection:
    • Open the servo amplifier and inspect the relay for signs of burning, discoloration, or physical damage.
    • Check the PCB for any visible defects such as burnt traces or damaged components.
  2. Test the DB Relay:
    • Use a multimeter to measure the resistance of the relay coil. A functional relay typically has a specific resistance value (e.g., tens to hundreds of ohms). If open or short-circuited, the relay needs replacement.
    • Inspect the relay contacts for proper operation and absence of welding or pitting.
  3. Inspect the Driver Circuit:
    • Check the transistors or ICs driving the DB relay for shorts or open circuits.
    • Use an oscilloscope to verify the control signal to the relay during operation.
  4. Verify DB Resistor and Wiring:
    • Ensure the dynamic braking resistor is intact and its connections are secure.
    • Measure the resistor’s value and compare it with the specifications.
  5. Replace Faulty Components:
    • Replace the relay or driver components if faults are detected.
    • Ensure replacement parts are genuine and match the original specifications.
  6. Reset and Test:
    • After repairs, reset the system and perform operational tests to confirm the alarm is cleared and the DB relay functions correctly.

3. General Troubleshooting Techniques

LED Indicators

  • Check the LED status on the servo amplifier front panel. LED patterns often provide diagnostic information about the amplifier’s status and errors.

Error Codes

  • Refer to the system’s maintenance manual for detailed descriptions of error codes.
  • FANUC manuals, such as the GFZ-65195EN/01, provide comprehensive troubleshooting steps for each alarm code.

Electrical Checks

  • Measure power supply voltages to ensure they are within specified ranges.
  • Inspect connectors, cables, and PCB traces for continuity and integrity.

Parameter Verification

  • Confirm that the servo parameters are set correctly. Incorrect parameters can lead to operational issues and alarms.

4. Preventive Maintenance Tips

  1. Regular Battery Replacement:
    • Schedule periodic checks and replacements for the encoder battery to avoid position loss.
  2. Keep Components Clean:
    • Clean the servo amplifier and surrounding areas to prevent dust and debris accumulation.
  3. Inspect Wiring:
    • Regularly inspect cables and connectors for wear, corrosion, or loose connections.
  4. Follow Manufacturer Guidelines:
    • Always adhere to FANUC’s maintenance and operational guidelines for optimal system performance.

Conclusion

By understanding the causes and systematic repair methods for alarms like “NEED REF RETURN” and “DB RELAY FAILURE,” maintenance engineers can ensure minimal downtime and enhanced reliability of FANUC servo systems. Regular preventive maintenance further helps in avoiding recurring issues and extending the life of these critical components.

FANUC servo systems, widely used in industrial automation, are renowned for their reliability and precision. However, like any sophisticated equipment, they can experience faults that require systematic diagnosis and repair. This guide focuses on two common faults: “NEED REF RETURN” (Absolute Pulse Coder Alarm) and “DB RELAY FAILURE” (Dynamic Brake Relay Issue), along with general troubleshooting techniques.

1. “NEED REF RETURN” Alarm

Fault Description

The “NEED REF RETURN” alarm indicates that the absolute position data of the encoder is lost or the axis requires a reference return operation. This typically happens when:

  • The encoder battery voltage is low or the battery has failed.
  • The system loses its absolute position data due to a power interruption or improper initialization.

Repair Process

  1. Check the Encoder Battery:
    • Replace the battery if its voltage is below the specified threshold (typically 3.6V for FANUC systems).
    • Ensure the battery is replaced with the power ON to prevent loss of encoder data.
  2. Perform Reference Return:
    • Access the machine’s control interface and initiate the reference return operation for the affected axes.
    • Follow the machine tool builder’s specific procedures for homing operations.
  3. Inspect Encoder Wiring:
    • Verify that the encoder cables are securely connected and free from damage.
    • Check for continuity and signal integrity using a multimeter or oscilloscope if necessary.
  4. Reset the Alarm:
    • Once the reference return is completed, reset the alarm via the machine control panel.

2. “DB RELAY FAILURE” Alarm

Fault Description

The “DB RELAY FAILURE” alarm indicates an issue with the Dynamic Brake (DB) relay, responsible for safely braking the motor during stop or emergency stop conditions. Possible causes include:

  • A malfunctioning DB relay (burnt coil or damaged contacts).
  • Faults in the relay driver circuit.
  • Open or damaged connections in the DB circuit.

Repair Process

  1. Visual Inspection:
    • Open the servo amplifier and inspect the relay for signs of burning, discoloration, or physical damage.
    • Check the PCB for any visible defects such as burnt traces or damaged components.
  2. Test the DB Relay:
    • Use a multimeter to measure the resistance of the relay coil. A functional relay typically has a specific resistance value (e.g., tens to hundreds of ohms). If open or short-circuited, the relay needs replacement.
    • Inspect the relay contacts for proper operation and absence of welding or pitting.
  3. Inspect the Driver Circuit:
    • Check the transistors or ICs driving the DB relay for shorts or open circuits.
    • Use an oscilloscope to verify the control signal to the relay during operation.
  4. Verify DB Resistor and Wiring:
    • Ensure the dynamic braking resistor is intact and its connections are secure.
    • Measure the resistor’s value and compare it with the specifications.
  5. Replace Faulty Components:
    • Replace the relay or driver components if faults are detected.
    • Ensure replacement parts are genuine and match the original specifications.
  6. Reset and Test:
    • After repairs, reset the system and perform operational tests to confirm the alarm is cleared and the DB relay functions correctly.

3. General Troubleshooting Techniques

LED Indicators

  • Check the LED status on the servo amplifier front panel. LED patterns often provide diagnostic information about the amplifier’s status and errors.

Error Codes

  • Refer to the system’s maintenance manual for detailed descriptions of error codes.
  • FANUC manuals, such as the GFZ-65195EN/01, provide comprehensive troubleshooting steps for each alarm code.

Electrical Checks

  • Measure power supply voltages to ensure they are within specified ranges.
  • Inspect connectors, cables, and PCB traces for continuity and integrity.

Parameter Verification

  • Confirm that the servo parameters are set correctly. Incorrect parameters can lead to operational issues and alarms.

4. Preventive Maintenance Tips

  1. Regular Battery Replacement:
    • Schedule periodic checks and replacements for the encoder battery to avoid position loss.
  2. Keep Components Clean:
    • Clean the servo amplifier and surrounding areas to prevent dust and debris accumulation.
  3. Inspect Wiring:
    • Regularly inspect cables and connectors for wear, corrosion, or loose connections.
  4. Follow Manufacturer Guidelines:
    • Always adhere to FANUC’s maintenance and operational guidelines for optimal system performance.

Conclusion

By understanding the causes and systematic repair methods for alarms like “NEED REF RETURN” and “DB RELAY FAILURE,” maintenance engineers can ensure minimal downtime and enhanced reliability of FANUC servo systems. Regular preventive maintenance further helps in avoiding recurring issues and extending the life of these critical components.