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IndustryArena Forum > CNC Plasma, EDM / Waterjet Machines > EDM Discussion General Topics > Need help getting a Fanuc Robocut Alpha running
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  1. #1
    Join Date
    May 2010
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    61

    Need help getting a Fanuc Robocut Alpha running

    Good morning!
    We bought a 1993 FANUC Robocut Alpha 0a machine with Fanuc 16WA controller a few years ago and are just now getting to powering it up ( long story..). It was running before it was moved as I saw it running. When we power it up now we are getting some errors. When the guy unhooked the wiring he took pictures and marked everything and from what I can tell it is back like it was. The alarms I am getting are
    510 Which the books says it Overload signal for X axis motor
    516 Which the book says is for X axis digital servo detection system
    520 Overload signal for Y axis
    526 Y axis digital servo detection system.

    It also says the the cause is indicated but Alarm 2 for the 510 and 520 errors and Alarm 1 for the 516 and 526 errors.
    I have looked at these and cant really figure it out. I assume that where the 1 is on the Alarms tells what t he cause is but on Alarm 2 the spots where the 1 is don't have anything listed.

    When I bring up the Alarms on the screen here is what I see
    Alarm 1 10000000
    Alarm 2 00101001
    Alarm 3 10000000
    Alarm 4 00000000
    Alarm 5 01100000

    If someone can help me decipher all of this and point me in a direction to start checking things I would appreciate it.

  2. #2
    Join Date
    Mar 2016
    Posts
    322

    Re: Need help getting a Fanuc Robocut Alpha running

    Did U figured it out? I have the same problem with exactly the same machine.

    I've found information, that cloned alarms for all drives can be caused by Power Supply Unit, Also alarms 510 and 520 (in my case also 530 &540 for UV axes) disappeared when I corrected first parameter in Servo settings to same value for all drives (in my case 1011).

    BTW.: would You be so kind and share books?

  3. #3
    Join Date
    May 2010
    Posts
    61

    Re: Need help getting a Fanuc Robocut Alpha running

    Quote Originally Posted by steryd View Post
    Did U figured it out? I have the same problem with exactly the same machine.

    I've found information, that cloned alarms for all drives can be caused by Power Supply Unit, Also alarms 510 and 520 (in my case also 530 &540 for UV axes) disappeared when I corrected first parameter in Servo settings to same value for all drives (in my case 1011).

    BTW.: would You be so kind and share books?
    I haven't gotten it figured out yet but will look at those servo settings and see what they are. From what little I could figure out all of the settings looked to be right except for maybe the ones that automatically turn the water on. Got busy in the shop and haven't gotten back to it yet.

    As for books I'll see what I can do.

    Thanks!

  4. #4
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    I have also worked a little today with it.
    These change of servo settings "help" randomly for a short time. I had a little help today from mopre experienced guy, and it occured that one of the servo amplifiers make a mess. After unplugging the encoders one of amplifers got up with errrors onit. And after shutting the other one it came with waiting for rdy - sign. So hopefully i found the problem.

  5. #5
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    Another day - another Idea.

    I had a little discussion with Fanuc Guys Here today. They said that these servos are not very problematic and there is very little risk that one of the amplifiers got down. And especially it's most unlikely that both of servo amplifiers got down simultaneously (as I thought earlier) and in this case one should not have an affect for other's work as long as they have a proper power supply. According to them it is a question of proper configuration, cause some data could have been lost during long period of power disconnection.
    As I understand it needs some initialization of settings of steering for proper connectivity between modules. Hopefully i can afford their help. Anyway in my case it means that problem stays unsolved till end of holidays.

  6. #6
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    One problem solved- the servo amplifiers are alive. Tomorrow I will be checking if they are working with machine.
    The problem was built in power supply. Each of the amplifiers has on the board a supply FANUC A14L-0102-0002, and both in my case was damadged by problems of electrolitic capacitors. Most of low voltage capacitors was definitely dry and one or two leaked out, what damadged some more elements. Luckily multi voltage transformer was ok. This power supplies are quite expensive- piece costs bit more than 100 bucks in China. In Poland about 300. As i spoke with my electronic specialist, it is as simple supply as possible, only problem is it has multi voltages outputs- 0, 5, 24, +15, -15, and separate 0, 15v pare. If can find alternative cheaper it can be replaced i thought about few smaller supplies for all the voltages to put there, but the guy fixed both for me for few dollars.
    Now time for tests of power site. Hopefully IGBT's will be ok.

  7. #7
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    Few days of testing the drives and they are working fine so far. I ordered one of the multi votage supplies just in case, cause the electronic guy said that one is in poor condition and may fail any time. Now i have short vacation and will start working at this cutter after that.

  8. #8
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    Did U succed to run this machine? Mine has first cutout done already, had some more to fix ofcourse.
    I have completely diffetent question.- is the roller next to brake roller (smallone on short lever) pushed by spring or just set by finger? In my machine it takes any position i setand pushing it to brake makes it only being stuck with no force at all. Is it normal?

  9. #9
    Join Date
    May 2010
    Posts
    61

    Re: Need help getting a Fanuc Robocut Alpha running

    Been a while but got busy and haven't been back to machine till now. Don't know what I did but now I have no alarms and I can move things around manually. I have water to the bottom jet for running wire but nothing on top yet, As the machine sat for a while I will have to clear the tubes and hoses I'm sure, ( What I had to do on bottom one) Realize I have very limited experience with Fanuc controls as the mill I usually run is Anilam and conversational. I have the books to this EDM but they don't tell you alot of the basics. Like how to change from one program to the other, or how to home the machine. Right now I have the machine position part flashing red so I am assuming that I need to home it some how. Can someone tell me where to look for simple instructions like that? The guy who used to run this mill moved like 150 miles away and most others in the area are Mitsubishi so I'm not sure how similar they are.

  10. #10
    Join Date
    May 2010
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    61

    Re: Need help getting a Fanuc Robocut Alpha running

    I haven't made it to actual cutting yet but did get it at least off the alarms. Not sure what I did but came in and turned it on and it was working so I'm not going to argue I am getting red flashing on the relative positioning and got a 048 relative position error when I tried running one of the programs on the machine. Can't find anywhere in the manual where it tells how to Home the machine or whatever it needs done to get that off of there. I think once I get that then I can start working with it. What is the procedure for that?

  11. #11
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    U need to pres REF button (the led on it wil get lid) and then push X+ andit will move to ref point (override not 0) the same With Y+. U and V are set by moving to both limits (as far as I remember buttons have to be pressed all the time axis moves)
    Then u have to set the vertical position for U and V.
    As for water most of thrash are gathered in valves and flow regulatirs, and jets ofcourse.
    Be aware that pumps shouldnt work with no water. I ended up with new main pump :/ luckily not horribly expensive.

  12. #12
    Join Date
    May 2010
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    61

    Re: Need help getting a Fanuc Robocut Alpha running

    Ok so here is what I have so far. I got everything moving about 2 weeks ago but couldn't figure out how to home it or whatever it is, which you sent me info on how to do that. Came back first of last week and it was back to doing nothing again. No alarm messages but nothing moved and all. Got busy and finally looking at it now. After booting it about 4 times it is finally moving again. Talked to a tech guy and he said probably some dirty connections in servos, ( yellow boxes in cabinet on the side.) Probably still going to clean them good but now I did what you said with the X+ and Y+ and REF button. Ref on position screen is still flashing red. Once I get the top and bottom over there do I have to set the U and V before it will stop flashing? is there a button I need to hit after getting them in position? Sorry for all the questions but it's hard to find someone around here that knows anything about this machine. Most everything is Mitsubishi in this area.

  13. #13
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    When U ser all axes it will stop flashing. I referenced XYUV but not sure if there is any matter about the sequence.
    Did U reset the drives first? (Restart machine with set initial bit sequence in servo tuning screen)

  14. #14
    Join Date
    May 2010
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    61

    Re: Need help getting a Fanuc Robocut Alpha running

    Yes finally got them homed and actually got it to run in auto mode one of the programs that was loaded on the machine. Just in air not cutting but it's progress Now to figure out setting the start point and getting the plumbing and water working right. Slow but sure, making progress

  15. #15
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    Look out for buttons POS and D POS. They make hi voltage present during manual work. If U wuold try to set vertical position with it using electrical setter it get burned. For auto setting and measurements u need to set conditions of wire tension adn feed required and EDM power just for ready.
    Start point is written by G92 but note the values of machine coords of start point just i case of power loss or some other malfunctions.

  16. #16
    Join Date
    May 2010
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    61

    Re: Need help getting a Fanuc Robocut Alpha running

    Thanks! I sure appreciate all the help. I have the manuals that come with it but they aren't real clear on some of the simple procedures to run things. Gonna work on plumbing to get the water flowing tomorrow, once I get that I'll get back to starting cutting things.

  17. #17
    Join Date
    May 2010
    Posts
    61

    Re: Need help getting a Fanuc Robocut Alpha running

    Ok so I have looked at manuals and even have one for a B series machine but simple stuff isn't working. Like loading another program from the list. If I had time to work on it all the time it would be good but I'm doing this in between jobs Is the G92 position written from the base machine zero? As in mine is like g92 x1.36 y0.0 but it's on the other side of the table from where machine home is. I did find out that I know a couple of guys who ran this same machine years ago so I"m gonna look them up this week hopefully.

    Again I really appreciate all your help. Hopefully one day I can help you with something as weil. Sending you a PM with my email .

  18. #18
    Join Date
    Mar 2016
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    322

    Re: Need help getting a Fanuc Robocut Alpha running

    U just need to set G92 with no coords in start position row. It can be with G0 or G1 or other move commands it Just will set the start position point in the positions list (there are relative positions, absolute positions, start point and hold point on the list)
    Start point is stored in Machine coordiinates and can be called after error ocured to fix wire break or other problems.
    To load another program U need to write O(prog number) and up or down arrow in edit or mem mode in directory scree. EG. O2134^

    Its no problem i learn it as well. I ordered complete set of manuals from FANUC store but as far they sent me just technology table and conversional programming manual. Other parts (except for parts cat) I have just many pieces most in German.

  19. #19
    Join Date
    May 2010
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    61

    Re: Need help getting a Fanuc Robocut Alpha running

    Thanks for the info!
    I've come a long way since I last talked to you. Can load programs, figured out how to set my start point, Lot of the general stuff. Went to cut a piece the other day and the wire hit the metal and sparked but not a lot and wound up breaking the wire. Decided to stop and clean the heads and all. Thought I had but naw, more to it that I thought. Top contact was bad corroded and a groove in it. Bottom was a little better but not much. Anyway, finally got stuff cleaned and went to thread the wire. Now this is old wire, as in been sitting on the machine for at least 3 yrs that I know of so that might be the problem.
    What the heck is the secret to pushing the wire through till it gets to the rollers?? Now when I burn it or break it it curls up really bad and that might be it but I have the water jet thing on and all and it gets hung up and can't get it through. I tried for like 45 minutes and said heck with it and came home.

    Any ideas are appreciated

  20. #20
    Join Date
    Mar 2016
    Posts
    322

    Re: Need help getting a Fanuc Robocut Alpha running

    I also had an old wire at the start and it was disaster. Now i bought new one quite good quality and it's much better, but must say it's not my favourite part of working with this machine.
    Also i have to say that i'm newbee in this part, so I'm not the first person to give advice.
    Anyway U surently need to cut wire with cigarette lighter while pulling it, so it will have nice cone at the end of the wire, and about 300mm (~1ft) straight line. Then while pushing it into low guide it should go qiute smooth. While pushing it through part the hole should be about 5mm so wire don't have a place to bend. Then only hard thing is to aim into the lower guide.
    And of course everything needs to be clean. And did i mention about cleaning?

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