Ox
Diamond
- Joined
- Aug 27, 2002
- Location
- Northwest Ohio
Starting back to maybe Dec when she got cold out, on the cold mornings that would dip below 60* in the shop I started to git "X axis abnormal current" alarm upon boot-up.
???
I powered back down at the case and rebooted. Then it was fine. ???
Within a few days it had progressed into a "X AND Z axis abnormal current" alarms.
I had asked here if enyone had eny ideas and - nodda.
It has gotten to where it is not just the cold days enymore and will doo it every morning even at 70* inside overnight temps. There may have been one morning this last few days that it did not throw that larm?
This is on a "4 axis" lathe and it only does this on the X2 Z2 amp. I believe the amp ratt next door to it is the X1 Z1 amp and has never thrown such alarm - and is on the same power supply. This is actually an 8 axis / twin spindle lathe - so there is a whole bank of amps going on here and I am labeling them once I am dead sure what they feed. But I am 99% sure of the next door amp being the X1 Z1 amp.
I have been trying to run a job recently that is 98% live werk. My live tooling and turret index are the same motor as seems to be pretty common these days. A cpl weeks ago when when I first set this up, thigs were still cool and I don't recall having issues the first day. But the shop may have been below 70* inside yet at that time. But also as it was early on in the new program - I may not have had it running 100% yet and still been tweaking it? And thus not seeing near the duty cycle yet? By the next day things were slightly warmer as I remember and from that day on the machine would only run for two hrs in the morning before faulting out. It will continue to fault out the rest fo the day unless you power it down for hrs on end. So what I was doing was to run as long as possible in the morning untill it would fault out and then power down untill maybe 8 O'clock at night and giv'r another go. This is semi acceptable for this short job, but I have a much bigger 85-90% milling job to put on next. I would be werking my way through proving it out by now had my machine been running properly this last cpl weeks.
Generally the alarm is "Turret Bevel Gear" which would assume that the live toy bevel gears had not meshed properly upon turret indexing/seating and so the turret had not fully seated. I have had this alarm many times in the past - but is always just outta the blue and not overly problematic. However - it aint really a bevel gear meshing issue at all. Most of the time the turret is "lost" and still rotating. Appearing to be more of an encodeing issue? Sometimes the turret is seated and the live toys are meshed just fine with the same alarm.
Also - near as I can tell - and I am having a hard time believeing this - but it appears that the live toy/index motors for both turrets are running off the same amp. ??? However - I am not 100% sure on this... but if it is, and if my troubles are actually an overheat (duty cycle) issue - then it would not seem possible to split up the work between turrets ta make eny diff. ???
I installed an 8K MacKlean A/C on this last week. Got'r ratt chilly in there too! To my amazement not only did it not seem to make all the diff in the werld - but it didn't seem to make eny diff at all!
Started checking fans next. I found a cpl aux (non-Fanuc) outboard fans were simply stuck and once freed - ran fine.
The small inside fan on the power supply was dead. However - I had not been getting errors on the power supply - but rather the drive amp. Fri afternoon I replaced not only the bad inside fan but also went ahead and replaced the bigger outboard Fanuc fan as well. Not long after start-up it faulted out aggin. Thigs weren't looking promissing again. And this was NOT 2 hrs in!
I reset and tried to push it some more. To date all issues had been on the lower turret dooing mostly C werk on the main spindle. Fri evening it was throwing "Live tooling trq" faults a number of times. It is hard to take such a fault seriously when it has a 5/16 C/D and/or a .078 drill in the werk at the time eh?
I have not had eny alarms on the upper turret since then I don't think - and everything seems to be back to my new "normall".
Also - I don't think that I had mentioned this either - but up untill this time all the faults were durring an index and never a basic "overheat" that would occur at random times during a cut. I had still not gotten an over temp alarm - but faulting out during the cut was more inline with this. I HAVE had live toy overtemp alarms on a job a few yrs ago and on that job I would simply park the machine for an "X" minute dwell to have a bit of time to cool off before continueing. This is NOT the same situation that I have been having.
last night I left the power on to the case - in order to keep the A/C running as it is quite warm here now. (+80F in the shop) However when I came in around noon today - the temp in the case was 19C (Was running between 13 and 8 - depending on ambient temp previously) So that didn't look promissing. Not sure if the exchanger froze up maybe? Especially with the humidity all of a sudden higher? I did not pursue this one yet. Machine only ran for maybe an hr-1/2 at best this afternoon. More likely 1 hr.
I had left the O/H door open last week during the cool weather before I got the A/C on to git it cooled off below my comfort level for the benefit of the machine - and it DID make a notable difference. It ran for 3 hrs before faulting out this time! (That really was a big improvement!) But then I got the A/C on and it started warming up. (Less than 2 months to summer salstace - and then the snowy season will be headed back our way!
)
There is obviously a heat issue here - but I can't seem to figger out just where? If it was actually in the case it would (should?) have been fixed - or at least allowing a much longer duty cycle at this point I would like to think. ???
All the C werk is on the main spindle which looks to be on the same power supply as the live toys/turrets. But again - I have not had a power supply alarm - and besides - running these little live toys is nothing compared to starting and stopping the main spindle - which it hardly is dooing at all in this part. I am dooing a face and turn, drill/ream, a deburr-ream and cutoff is all - in an 8 minute cycle! I am not cranking the live toys enywhere near their speed limits either.
The only alarm number that I have found on the amps is #7 on thne live toy spindle amp = Overspeed per an internet search.
Machine is 2000 model yr with 18i. 25hp main and 15hp sub. Twin turrets and Y. Live toys every position. Units of interest are A06B-6087-H130 power supply and A06B-6078-H206#500 live toy spindle amp.
I am beginning to think that my trobles are actually outside the case. I am leaning towards the live toy motor heating up causing issues. As the turret is still going around in a "lost" scenario - the motor must be OK. But I am wondering if the encoder on the live toy/turret motor could be messing up as it heats up?
The colder actual shop temps would have impacted the motor encoder - with the A/C not having eny impact.
If you have had enough interest to read this far
- doo you have eny insight?
-------------
Think Snow Eh!
Ox
???
I powered back down at the case and rebooted. Then it was fine. ???
Within a few days it had progressed into a "X AND Z axis abnormal current" alarms.
I had asked here if enyone had eny ideas and - nodda.
It has gotten to where it is not just the cold days enymore and will doo it every morning even at 70* inside overnight temps. There may have been one morning this last few days that it did not throw that larm?
This is on a "4 axis" lathe and it only does this on the X2 Z2 amp. I believe the amp ratt next door to it is the X1 Z1 amp and has never thrown such alarm - and is on the same power supply. This is actually an 8 axis / twin spindle lathe - so there is a whole bank of amps going on here and I am labeling them once I am dead sure what they feed. But I am 99% sure of the next door amp being the X1 Z1 amp.
I have been trying to run a job recently that is 98% live werk. My live tooling and turret index are the same motor as seems to be pretty common these days. A cpl weeks ago when when I first set this up, thigs were still cool and I don't recall having issues the first day. But the shop may have been below 70* inside yet at that time. But also as it was early on in the new program - I may not have had it running 100% yet and still been tweaking it? And thus not seeing near the duty cycle yet? By the next day things were slightly warmer as I remember and from that day on the machine would only run for two hrs in the morning before faulting out. It will continue to fault out the rest fo the day unless you power it down for hrs on end. So what I was doing was to run as long as possible in the morning untill it would fault out and then power down untill maybe 8 O'clock at night and giv'r another go. This is semi acceptable for this short job, but I have a much bigger 85-90% milling job to put on next. I would be werking my way through proving it out by now had my machine been running properly this last cpl weeks.
Generally the alarm is "Turret Bevel Gear" which would assume that the live toy bevel gears had not meshed properly upon turret indexing/seating and so the turret had not fully seated. I have had this alarm many times in the past - but is always just outta the blue and not overly problematic. However - it aint really a bevel gear meshing issue at all. Most of the time the turret is "lost" and still rotating. Appearing to be more of an encodeing issue? Sometimes the turret is seated and the live toys are meshed just fine with the same alarm.
Also - near as I can tell - and I am having a hard time believeing this - but it appears that the live toy/index motors for both turrets are running off the same amp. ??? However - I am not 100% sure on this... but if it is, and if my troubles are actually an overheat (duty cycle) issue - then it would not seem possible to split up the work between turrets ta make eny diff. ???
I installed an 8K MacKlean A/C on this last week. Got'r ratt chilly in there too! To my amazement not only did it not seem to make all the diff in the werld - but it didn't seem to make eny diff at all!
Started checking fans next. I found a cpl aux (non-Fanuc) outboard fans were simply stuck and once freed - ran fine.
The small inside fan on the power supply was dead. However - I had not been getting errors on the power supply - but rather the drive amp. Fri afternoon I replaced not only the bad inside fan but also went ahead and replaced the bigger outboard Fanuc fan as well. Not long after start-up it faulted out aggin. Thigs weren't looking promissing again. And this was NOT 2 hrs in! I reset and tried to push it some more. To date all issues had been on the lower turret dooing mostly C werk on the main spindle. Fri evening it was throwing "Live tooling trq" faults a number of times. It is hard to take such a fault seriously when it has a 5/16 C/D and/or a .078 drill in the werk at the time eh?
I have not had eny alarms on the upper turret since then I don't think - and everything seems to be back to my new "normall".Also - I don't think that I had mentioned this either - but up untill this time all the faults were durring an index and never a basic "overheat" that would occur at random times during a cut. I had still not gotten an over temp alarm - but faulting out during the cut was more inline with this. I HAVE had live toy overtemp alarms on a job a few yrs ago and on that job I would simply park the machine for an "X" minute dwell to have a bit of time to cool off before continueing. This is NOT the same situation that I have been having.
last night I left the power on to the case - in order to keep the A/C running as it is quite warm here now. (+80F in the shop) However when I came in around noon today - the temp in the case was 19C (Was running between 13 and 8 - depending on ambient temp previously) So that didn't look promissing. Not sure if the exchanger froze up maybe? Especially with the humidity all of a sudden higher? I did not pursue this one yet. Machine only ran for maybe an hr-1/2 at best this afternoon. More likely 1 hr.
I had left the O/H door open last week during the cool weather before I got the A/C on to git it cooled off below my comfort level for the benefit of the machine - and it DID make a notable difference. It ran for 3 hrs before faulting out this time! (That really was a big improvement!) But then I got the A/C on and it started warming up. (Less than 2 months to summer salstace - and then the snowy season will be headed back our way!
)There is obviously a heat issue here - but I can't seem to figger out just where? If it was actually in the case it would (should?) have been fixed - or at least allowing a much longer duty cycle at this point I would like to think. ???
All the C werk is on the main spindle which looks to be on the same power supply as the live toys/turrets. But again - I have not had a power supply alarm - and besides - running these little live toys is nothing compared to starting and stopping the main spindle - which it hardly is dooing at all in this part. I am dooing a face and turn, drill/ream, a deburr-ream and cutoff is all - in an 8 minute cycle! I am not cranking the live toys enywhere near their speed limits either.
The only alarm number that I have found on the amps is #7 on thne live toy spindle amp = Overspeed per an internet search.
Machine is 2000 model yr with 18i. 25hp main and 15hp sub. Twin turrets and Y. Live toys every position. Units of interest are A06B-6087-H130 power supply and A06B-6078-H206#500 live toy spindle amp.
I am beginning to think that my trobles are actually outside the case. I am leaning towards the live toy motor heating up causing issues. As the turret is still going around in a "lost" scenario - the motor must be OK. But I am wondering if the encoder on the live toy/turret motor could be messing up as it heats up?
The colder actual shop temps would have impacted the motor encoder - with the A/C not having eny impact.
If you have had enough interest to read this far
- doo you have eny insight?-------------
Think Snow Eh!
Ox
Had to break my arm in three places to git apart the first time. 
It also semi requires that you git another machine like you already have and know so that you make the most of your experiences. (As well as the tens of 1000's of $ in live tools!)
