Category: Manufacturers

Setting the Sensor Gap on your Fanuc Spindle Motor

Brian Hughes Leave a comment

Today we will be helping you with your installation of a spindle motor. Alarms are caused by tensions issues with the belt – either being too tight or too loose in relation to the sensor. MRO Electric and Supply offers both new and refurbished FANUC Spindle amps, troubleshooting on our blog for a wide variety of parts, and repair services on any product we offer.

Steps for fixing the sensor gap

  1. Disconnect the wiring inside of the terminal box.
  2. Next take out the 4 bolts that hold the shroud/fan to the motor.
  3. Remove the screws from the cover of the sensor on the motor.
  4.  Loosen the screws holding the sensor in place until you have enough room to be able to slide a piece of paper between the gear and sensor.
  5. Tighten the 2 screws that hold the sensor in place to make sure they do not rub against each other at all.
  6. Fasten the sensor cover back to the sensor and tighten accordingly.
  7. Reattach the shroud and the fan to the motor.
  8. Configure the wiring back to what it was originally.

fanuc cnc

Now that the sensor for your FANUC Spindle amp is corrected, it should work properly. If you are still having issues we recommend looking throughout our blog as we have many articles based on helping the user troubleshoot any and all issues with their motor.

Sometimes you may not have the necessary equipment to make a diagnosis on your motor, but we do. MRO Electric and Supply offers high quality repair services on all motors so you don’t have to worry about it. Please take a look at our website to see all available brands and parts we can service for you.

MRO Electric and Supply has new and refurbished FANUC CNC parts available. For more information, please call 800-691-8511 or email sales@mroelectric.com.

Diagnosing your FANUC Current Alarm

Brian Hughes Leave a comment

If you are getting a high current alarm on your FANUC motor, it is going to be caused by either the motor itself, the drive, or a cable. To begin the process of figuring out which alarm you are receiving you must disconnect the leads from the motor. Try powering it up and look to see if the alarm LED is lit. Fanuc alarms include the HC LED, alarm 8/9/A/B for Servo motors, and alarm 12 for Spindle motors.

  • If you no longer are seeing an alarm, the motor is most likely bad.
  • If you have powered the motor and are receiving the alarm, the issue is most likely with the drive.

Because you have disconnected the leads from the motor, you are able to use an ohm meter/megger to monitor the power levels of the cable and motor, and make sure they are working as intended. Using a megger will help you decide if your motor is grounded correctly where an ohm reader will let you know if your motor has shorted.

Using your ohm meter check for shorts both leg-to-leg and leg-to-ground on each of the legs. The leg-to-leg readings should be consistently low between every leg while the leg-to-ground readings will stay open. The megger is used to check between the leg and ground to see if the problem could be with the terminal box on the motor or any cables connected to it.

Sometimes you may not have the necessary equipment to make a diagnosis on your motor or to troubleshoot, but we do. MRO Electric and Supply offers high quality repair services on all motors so you don’t have to worry about it. Check out our website to see all available brands and parts we can service for you.

MRO Electric and Supply has new and refurbished FANUC CNC parts available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

Repairing your Modicon Magelis HMI

Brian Hughes 1 Comment

Any amount of downtime is too much for most companies. Parts will break from time to time, and repairs will be necessary. Here at MRO Electric and Supply we are dedicated to providing the best service making sure that your downtime is minimal. Human Interface Terminals(HMIs) are a crucial part of any automation process nowadays, so it is important to make sure it is working correctly. Along with selling both new and remanufactured products, MRO Electric and Supply offers both repair and exchange services.

modicon hmi

Modicon was the first manufacturer to release programmable logic controllers onto the market, and since have been one of the top brands for PLC’s. MRO Electric and Supply have all the parts necessary to run the Magelis HMI at it full potential, including panels, cables, controllers, adapters and any software that may be needed. Along with repairs, we handle installations and programming of drives and controllers so that you don’t have to.

We also offer the option to retrofit your old machines with newer interfaces for the most up-to-date applications and processes. By fitting existing HMI’s with new interfaces you are able to add years to the life span of your automation set up. It is a lot easier to update and fix your existing displays and HMIs than taking the time and money to purchase and fit new parts.

All of our repairs come with a 12 month guarantee. Our repair service is based on doing the right job, and getting your part back to you as soon as possible. Every part we refurbish is tested to make sure they work the way they are supposed to. Our factory-trained technicians have many years working with Modicon products.

For a free Modicon Magelis HMI repair quote, please email sales@mroelectric.com or call 800-691-8511.  For more information on our Modicon repair capabilities, you can visit our Modicon Repair page.
KUKA Controllers lineup

KUKA Error Codes

Joe Kaminski 4 Comments

 KUKA robotics offers a broad range of robotics controllers and other robotics parts for a variety of industries including CNC machining, surface processing, loading usage, and much more. One common challenge with operating robotics controllers is understanding what the error codes mean, that they display when they encounter an issue. Listed below are common KUKA error messages that you may encounter while troubleshooting issues with KUKA controllers. These codes are applicable to all KUKA controllers, including the KRC1, KRC2, KRC3, and the KRC4.

Common KUKA KRC1, KRC2, KRC3, and KRC4 Error Codes

Error Code 14 – SOFTPLC: @P1@

Error Code 284 – Accu–voltage at <kps number> below <voltage level> during last buffering

  • Cause
    • The accu voltage was too low at the last switch off to buffer the
      shutdown.
    • The accu is not charged correctly anymore.
    • The accu is too old or broken.
  • Effect
    • Eventually loss of reference.
    • Cold boot.
    • Active commands inhibited
  • Remedy
    • Exchange accu.

Error Code 310 – Safety Circuit for drives not ready

  • Cause
    • Safety circuit is telling drives not to move.
    • Faulty X11
    • Faulty ESC board
    • Faulty KPS 600
  • Remedy
    • Check ESC monitor and other messages to narrow down the root cause with the safety circuit
    • Replace faulty components

Error Code 364 – Unknown operation mode

  • Possible Cause
    • Faulty KPS 600 Drive
  • Remedy
    • Replace KPS 600

Error Code 420 – Local protective stop (QE)

    • Possible Cause
      • Faulty KPS600 Drive
    • Remedy
      • Replace KPS600

Error Code 1033 – ERROR ON READING, DRIVER: ** **

Error Code 1034 – ERROR ON WRITING, DRIVER: ** **

Error Code 1133 – GEAR TORQUE EXCEEDED AXIS

  • Cause
    • The calculated gear torque is larger than the maximum permissible gear torque.
  • Monitor
    • Cyclic in interpolation cycle.
  • Effect
    • Motion and program are stopped.
  • Remedy
    • Reteach points.

Error Code 1239 – ACKN. SYNCHRONISATION ERROR DRIVE

Error Code 1376 – ACTIVE COMMANDS INHIBITED

  • Cause
    • A message which causes the active commands to be inhibited has been set.
  • Monitor
    • In command processing.
  • Effect
    • Command is not executed.
  • Remedy
    • Acknowledge active messages in the message window.

Error Code 2029 – SYNTAX ERROR IN KUKA MODULE

Error Code 2135 – NAME NOT DECLARED AS SUBROUTINE

Error Code 6502 – Error during reading INI file init/iosys.ini 1

  • Remedy
    • Check iosys.ini file
    • Ensure correct DeviceNET driver is installed
    • Check data cable between robot / cabinet

Error Code 10053

  • Remedy
    • Check fan to ensure it isn’t vibrating. This could be causing the Mfc card to move into the motherboard’s slot.

To find more info about KUKA error codes, view KUKA’s manual below.

View the KUKA Manual

MRO Electric carries replacement KUKA Robotics parts such as teach pendants, drives, motors, and more. To request a quote, please call 800-691-8511 or email sales@mroelectric.com.

Troubleshooting error codes on your KUKA controller?

We can help you resolve issues with your KUKA controllers. Whether you’re looking to repair your old controller or purchase a new one, we’re dedicated to keeping your automation systems running at their best!

Learn More About Our Repair Services
Shop Replacement KUKA Controllers
KUKA teach pendant

KUKA Teach Pendants

Joe Kaminski Leave a comment

MRO Electric and Supply distributes a variety of KUKA Teach Pendants for KRC1, KRC2, and KRC3 controls. We also can supply the new KRC4 smartPAD. The smartPAD pendant  is the latest type of KUKA teach pendant, designed to allow users to perform even the most complex operating tasks with ease – even those with little experience.  It features an 8.4″ display size with a industrial touch screen.

KUKA smartPAD Teach Pendant

The ergonomic design of the KUKA smartPAD creates a pendant with reduced weight and an anatomically comfortable operation. It can be used to operate all KUKA robots that have a KR C4 controller. Its 6D mouse allows for movement and reorientation of the robot on all axes.

All smartPADs are programmed using the KRL – KUKA programming language. This easy to learn robotics language is very intuitive, and can be used to create customized robotic motions with ease. You can also synchronize your programming with up to 6 KUKA robots. The other major benefit of the smartPAD teach pendant is that  it can be hot swapped at any time from a KR C4 controller – just simply plug it in and use.

Legacy KUKA Teach Pendants

MRO Electric also distributes a number of legacy KUKA teach pendants. We recognize that there are still a variety of older KUKA controllers still in use today. Rather than having to upgrade your control system when one of your pendants fail, we can ship you a replacement pendant to minimize any downtime.

If for some reason our stock is depleted, we can usually repair your KUKA pendant in as little as 3-5 days. Visit our main KUKA product page to see all the KUKA teach pendants that we can supply or repair.

For more information or to request a quote on a replacement pendant or panel, please call 800-691-8511 or email sales@mroelectric.com.

FANUC 18i M-Codes

Joe Kaminski Leave a comment

Fanuc Motors

In the world of automation, whether we’re talking about factory or shop automation, understanding how to operate and maintain FANUC CNC parts is imperative. Several businesses and companies suffer from dreaded downtime because a team isn’t well-rounded; many team members may know how to manage machine operators, etc., but are unaware of how to operate a CNC themselves. For a manager, knowing and understanding exactly what to look for to avoid an operating issue starts with understanding the basics of CNC machining and programming.

CNCs originally started coming about in the late 1940s, not long after World War II as NCs (Numerical Controls). They were engineered to be a reliable, cost-effective way to manufacture and design an increased amount of parts for the aircraft industry. Based on already-existing modified tools equipped with motors that manipulated the controls, CNCs were quickly and abruptly built up with computers, both digital and analog. As time has gone on, CNCs have continued to evolve as technology evolves.

Early Numerical Controls initially lacked computers. They also lacked calculating ability, which is absolutely unheard of in today’s world. After the 1960s, numerical controls eventually gained calculating and computer functions. Onboard processing became feasible and, as a result, CNC machines came about. Via the initiation of CNCs, a handful of features were then attainable, fortunately, including canned cycles, tool length compensation, sub programming, radial compensation and tool diameter.

Preparatory Codes

NC and CNC G Codes are referred to as preparatory codes. By preparing the machine to perform a specific function like, for example, rapid travel G0 / G00, the preparatory process is important to understand, as all of the stages of production are.

Miscellaneous Codes

NC / CNC M codes are known as miscellaneous codes.  CNC M codes basically perform on and off functions such as:

  • stopping processing of CNC code M0 / M00
  • turning the spindle on M3 / M0 or M3 / M03
  • stopping the spindle M5 / M05
  • turning coolant on M8 / M08

MRO Electric and Supply has new and refurbished FANUC CNC parts available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

G Code and M Code

The ANSI standard for G code and M code programming is ANSI/EIA 274D-1988. The ISO standard for G code and M code programming is ISO 6983. There is a new and different standard ISO 14649 also known as the STEP-NC standard that addresses NC and CNC programming using the enhanced features of CAD and/or CAM software.

Machine tool builders are not required to adhere to standards and every so often create variations to standard G codes and M codes. Occasionally design different, unique alternatives to orthodox G codes and M codes. Typically, the majority of CNC G codes are considered modal, which means they stay active until they’re changed. Along with understanding CNC codes, feel free to view another one of our articles focused on choosing a CNC to become as well-versed with CNCs as possible.

Auxiliary Function (M Function)

When a numeral is specified following address M, code signal and a strobe signal are sent to the machine. The machine uses these signals to turn on or off its functions. Usually, only one M code can be specified in one block.

In some cases, however, up to three M codes can be specified for some types of machine tools. Which M code corresponds to which machine function is determined by the machine tool builder.

The machine processes all operations specified by M codes except those specified by M98, M99,M198 or called subprogram(Parameter No.6071 to 6079), or called custom macro (Parameter No.6080 to 6089). Refer to the machine tool builder’s instruction manual for details.

The following M codes have special meanings:
  • M02, M03 (End of Program)
    • This indicates the end of the main program Automatic operation is stopped and the CNC unit is reset.
    • This differs with the machine tool builder. After a block specifying the end of the program is executed, control returns to the start of the program. Bit 5 of parameter 3404 (M02) or bit 4 of parameter 3404 (M30) can be used to disable M02, M30 from returning control to the start of the program.
  • M00 (Program Stop)
    • Automatic operation is stopped after a block containing M00 is executed. When the program is stopped, all existing modal information remains unchanged. The automatic operation can be restarted by actuating the cycle operation. This differs with the machine tool builder.
  • M01 (Optional Stop)
    • Similarly to M00, automatic operation is stopped after a block containing M01 is executed. This code is only effective when the Optional Stop switch on the machine operator’s panel has been pressed.
  • M98 (Calling of Sub-Program)
    • This code is used to call a subprogram. The code and strobe signals are not sent.
  • M99 (End of Subprogram)
    • This code indicates the end of a subprogram. M99 execution returns control to the main program. The code and strobe signals are not sent.
  • M198 (Calling a Subprogram)
    • This code is used to call a subprogram of a file in the external input/output function. See the description of the subprogram call function (III–4.7) for details.
Multiple M Commands in a Single Block

In general, only one M code can be specified in a block. However, up to three M codes can be specified at once in a block by setting bit 7 (M3B) of parameter No. 3404 to 1. Up to three M codes specified in a block are simultaneously output to the machine. This means that compared with the conventional method of a single M command in a single block, a shorter cycle time can be realized in machining.

CNC allows up to three M codes to be specified in one block. However, some M codes cannot be specified at the same time due to mechanical operation restrictions. For detailed information about the mechanical operation restrictions on simultaneous specification of multiple M codes in one block, refer to the manual of each machine tool builder. M00, M01, M02, M30, M98, M99, or M198 must not be specified together with another M code. Some M codes other than M00, M01, M02, M30, M98, M99, and M198 cannot be specified together with other M codes; each of those M codes must be specified in a single block.

Such M codes include these which direct the CNC to perform internal operations in addition to sending the M codes themselves to the machine. To be specified, such M codes are M codes for calling program numbers 9001 to 9009 and M codes for disabling advance reading (buffering) of subsequent blocks. Meanwhile, multiple of M codes that direct the CNC only to send the M codes themselves (without performing internal operations ) can be specified in a single block.

M Code Group Check Function

The M code group check function checks if a combination of multiple M codes (up to three M codes) contained in a block is correct.

This function has two purposes. One is to detect if any of the multiple M codes specified in a block include an M code that must be specified alone. The other purpose is to detect if any of the multiple M codes specified in a block include M codes that belong to the same group. In either of these cases, P/S alarm No. 5016 is issued. For details on group data setting, refer to the manual available from the machine tool builder.

  • M Code Setting
    • Up to 500 M codes can be specified. In general, M0 to M99 are always specified. M codes from M100 and up are optional.
  • Group Numbers
    • Group numbers can be set from 0 to 127. Note, however, that 0 and 1 have special meanings. Group number 0 represents M codes that need not be checked. Group number 1 represents M codes that must be specified alone.

Choosing a FANUC CNC

Joe Kaminski 1 Comment

fanuc cnc

Choosing a CNC

Buying and building a new CNC (view FANUC CNC parts) can be challenging and often nerve-racking. Regardless of which space you’re in, downtime needs to be avoided as much as humanly (or robotically) possible.  Check out our points to avoid common CNC issues.

One of the most common reasons for CNC downtime would be low build quality. Balls screws,  linear guides, and linear boxes need to be built with high quality to avoid downtime. Often, unfortunately, CNC machines are built using several high-quality parts, and a handful of cheaper, lower-quality parts. Although a machine may consist of mainly high-quality, top-of-the-line parts, issues are still likely to occur due to the low-quality parts. A CNC machine, like most pieces of machinery, is ‘only as strong as its weakest link’.

By taking a look at the tool changer’s location, you can usually determine if its location will be an issue or not. Faulty tool changer designs are common in the CNC world. If it’s hard to get to the tool changer to, for example, change and replace the cam followers, then another design alternative may be best. Don’t be afraid to research other up-to-par designs and designs that have worked well for others in the past.

Avoid poor-quality spindles at all costs, as they’re everywhere and often result in issues. Take a good look at the spindles’ bearings. If they’re plentiful and look larger-than-average, you’re good to go. If they’re lacking in size, research instances where spindles’ bushings have been an issue to create your standard. Along with that, take a look at the horsepower of them; if their horsepower is below average, avoid at all costs. Stalling may occur with low horsepower spindles, which often results in many others with other parts on top of the spindle. Also, be sure to check out our article focused on maintaining automation machine tools. Maintenance is unavoidable and compiling maintenance with unnecessary rebuilds is unpractical and will likely result in downtime and lost profit.

Tolerance of CNCs should be tight. The tighter the tolerance, the longer the life expectancy generally is. Tighter tolerance will also result in an overall smoother operation. MRO Electric and Supply has new and refurbished FANUC CNC parts available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.