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Fuji FCP 2 Check Servo issue

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#62670

Fuji FCP 2 Check Servo issue | 11 September, 2010

Greetings:

I am having 'Check Servo' issues with an FCP 2 4000. It will zero set but given a few minutes afterwards, the check servo alarm sounds.

At times the X/Y table will 'coast' back to beginning position, like the power has been cut to the servos, the CPU light on the VM board is red. At this point the machine requires a shutdown and normally after zero set, the 'check servo' alarms. All three servo amps flash the same when the alarm sounds.

Sometimes I am able to get the machine up and running some production, but if it sits, it has a tendency to trip the check servo alarm. Those times I am able to run, if the X/Y table coasts without alarm, its like a computer freezing up .. reminds me of a conflict with software drivers with a PC.

I had blamed the servo issue on ambient air and humidity, though, lately, it has been cooler and we still have this issue.

Are there any troubleshooting tactics I can use to zero in on the culprit and/or has anyone else experienced anything like this?

Many thanks!

Steve

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#62695

Fuji FCP 2 Check Servo issue | 14 September, 2010

I would check for stuck inching keys.

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#62696

Fuji FCP 2 Check Servo issue | 14 September, 2010

Hi Steve,

I don't have any experience with CP2's. Sorry .. hazarding a guess though... if they use the analog servo amps like they do in the CP4's, they had a bunch of trimmer pots on them. There is a procedure to zero them using the mecca check mode. (have you done this before?) I've heard that if they are not zeroed properly, they can drift and end up tripping the servo alarm. Also, i'd do a servo gain test and make sure everything is tip top. Let me know what kind of amps you've got in there and i'll do some research into the drive system on the CP2's.

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#62719

Fuji FCP 2 Check Servo issue | 16 September, 2010

Thanks for the response Travis. I'd think the table would inch or move if it were stuck inching keys. The table would eventually trigger one of the overtravel sensors on this ancient machine.

Much Appreciated,

Steve

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#62720

Fuji FCP 2 Check Servo issue | 16 September, 2010

Hello Daxman,

Thanks for the input. Yes, the CP2 is closely related to the CP4 and does have the analog servo amps as you deduced. I did a wiggle test on the connectors and found that the x-y-r servo amp alarmed right away and blinked the x axis as the culprit. I took the amp apart and found no loose connections. Took a closer look at the connection from Amp to overload and thought perhaps the female connect was open too much- thus causing a fault through vibration of the machine. I did manage to make a tighter connection and thought everything was ok, then get the call that the machine is 'check servo' messaging again. Came in and this time it is the y-axis connection on the servo amp. I did a wiggle test, got it to check servo, tightened the connection and still get the check servo alarm during a dry run with the idling function. I visually checked the y-axis part of the servo amp, nothing unusual.

I've not heard of the mecca check mode. Is this something available on later models of the CPs?

Interesting about the trimmer POTs. I've never touched them.

I have at the very least narrowed the issue down to one servo amp. I'll need to investigate how to do a servo gain test.

Servo Amp is a 4CN, 3 servo drive amp. Nikki Denso Actus Power NPSA-102 MU-E9

Just found out that the amp next to it has a dummy sheet in english whereas this amp is in Japanese. Looks to be an overcurrent situation going on, according to the dummy sheet. Green and yellow lights flash continuously on the y-axis servo amp during check servo.

Many thanks for the info and ideas, hopefully you'll be able to dig something up!

Much Appreciated!

Steve

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#62760

Fuji FCP 2 Check Servo issue | 21 September, 2010

> Greetings: > > I am having 'Check Servo' issues > with an FCP 2 4000. It will zero set but given a > few minutes afterwards, the check servo alarm > sounds. > > At times the X/Y table will 'coast' > back to beginning position, like the power has > been cut to the servos, the CPU light on the VM > board is red. At this point the machine requires > a shutdown and normally after zero set, the > 'check servo' alarms. All three servo amps flash > the same when the alarm sounds. > > Sometimes I > am able to get the machine up and running some > production, but if it sits, it has a tendency to > trip the check servo alarm. Those times I am > able to run, if the X/Y table coasts without > alarm, its like a computer freezing up .. reminds > me of a conflict with software drivers with a > PC. > > I had blamed the servo issue on ambient > air and humidity, though, lately, it has been > cooler and we still have this issue. > > Are there > any troubleshooting tactics I can use to zero in > on the culprit and/or has anyone else experienced > anything like this? > > Many thanks! > > Steve

Update:

Servo amp is no longer giving check servo errors. Now enter the CPU failing after a while of running.

Anyone know of a way to access codes or troubleshoot the CPU card? I believe I read somewhere in the manuals stating that if the CPU doesn't boot, then one issue can be a power supply failing. I wonder if this is happening.

Thanks for any input!

Steve

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#62771

more info- os error, screen(hex) dump | 23 September, 2010

Have more info on the issue at hand.

OS Error: CODE 0001 TASK 0029 PARA 0000 STAT 33E5 ADRS 00EF0000 INST 33F9 STRG 2704 PC 001449BE

Hex dump on screen: 0000 FFFF F400 FFF7 BFD4 0090 BF63 FF7F FF71 FFFF DA73 FFED FFEB FFFF 6E4D FE79 FF36 FFEF 9735 DFFF 5A71 7FFF FF62 FFFF 7D22 FDFF FD22 FFFB FFA3 FFFD 7391 FFFF FFFF FFFF FF2B FFFF 0000 FFFF BFDB FF3F 0007 0004 6000 0011 0002 0000 0003 0009 F7B8 F7EE FF8D 0000 DF86 1107 F095 FEDF 0130 FFFF BF04 0001 B577 BFFD 9F8D BFFD FE4B

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#62851

more info- os error, screen(hex) dump | 5 October, 2010

Hi Steve, I don't know if there are a lot of people who can decrypt the trace data. I think the manual mentions sending it to fuji for analysis. Maybe that would be something worth checking into.

Regarding the Mecca check mode: I don't know if it will work on the CP2, but it's basically a method to check the servo system. One of the features is the gain test. It will jog a selected axis between 0 and a certain value of pulse counts. The screen will indicate the time it take for each cycle, and give the number of pulse overshoots. The manual will explain which values to acheive. Many factors can affect this ie: belt tension, bearing condition, motor & servo amps ect. Another feature is the zero test. A servo amp should be able to hold a servo lock without drifting. One of the pots on the servo amp adjust this. You really should have a manual to explain how to use mecca mode because you can cause damage easily. However, to see if it's possible, turn off the machine, hold down the numeric keypad #3 and turn on the machine. Keep the #3 key depressed and you should boot into mecca mode. email me if you can get into mecca mode and I can send you more procedures. -Dax

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