Fault Finding Fanuc Alpha Spindle Amplifiers

Fault Finding Fanuc Alpha Spindle Amplifiers and how to test if they are faulty?

Firstly, the correct operation of the spindle drive is described

The Fanuc spindle unit receives power from the PSU through the bus bar at the top of the unit. The red charged led should be lit.
All 4 screws are required to be tight.

On power up the green PIL led will light, the 7 segment display will display the software revision (ie A/00/15) followed by a flashing “–”

Once the Fanuc CNC has made communication to the spindle drive through the JA7B the 7 segment will remain solid “–“.

The CNC sends a run command to the spindle drive, the 7 segment display will switch to “00”, the spindle motor will rotate.

There are 3 leds on the display

Fanuc Alpha Spindle Module Alarm Codes
The LED’s will light showing an alarm code on the Fanuc Alpha Spindle Unit

Green (PIL) : 24vdc Supply Good
Red (ALM) : Alarm – Spindle drive not operating as requested
Amber (ERR) : Error – Spindle drive not programmed correctly (drive is good)

The alarm led can light when the supplies or signals from the PSU are faulty
This can happen through the bus bar or the module interface JX1A.

Fanuc Spares and repairs

It is worth noting that when an alarm occurs on the Power Supply Unit, an alarm also appears on the Spindle.
The PSU alarm is the most likely cause of the fault paired alarms
PSU Alarm 1 : Spindle Alarm 30 : Overcurrent
PSU Alarm 2 : Spindle Alarm 59 : Cooling Fan Stopped in PSM
PSU Alarm 3 : Spindle Alarm 58 : Overload in PSM
PSU Alarm 4 : Spindle Alarm 51 : Low Bus Volts
PSU Alarm 5 : Spindle Alarm 33 : DC Link Pre Charge Failure
PSU Alarm 6 : Spindle Alarm 04 : Input Fuse Blown
PSU Alarm 7 : Spindle Alarm 11 : High Bus Volts If you have a Fanuc Spindle drive that needs a Fanuc Repair or replacing please contact us. The Fanuc Spindle Amplifier Module alarm codes are listed below:

Alarm Codes on the Fanuc  Alpha Spindle Unit
Alarm Code Fault Remedy
Not Ready Drive is Good
0 Control Ready Drive is Good
1 Motor overheat
2 Excessive Speed Error
3 Fuse on DC Link Blown Drive is faulty
4 Input Fuse/Power Fault Alpha PSU is faulty
5 Power Supply Fuse Blown
7 Overspeed
8 High Voltage Power Input
9 Overheat Main CIrcuit Drive is faulty
10 Low Voltage Input Power Check input power
11 Overvoltage in Power Circuit Alpha PSU is faulty
12 Overcurrent in Power Circuit
13 Data Memory Fault CPU  Drive is faulty
15 SP Switch Control Alarm
16 RAM Fault  Drive is faulty
18 Sumcheck Error PGM Data
19 EX Offset Current U
20 EX Offset Current V
24 Serial Transfer Error
25 Serial Transfer Stop
26 Disconnect C Velocity Detect
27 Pulsecoder Disconnected
28 Disconnect C-Pos Detect
29 Short time overload
30 Overcurrent  Alpha PSU faulty
31 Motor Lock or V-Sig Lost
32 Ram Fault Serial LSI
33 Shortage Power Charge  Alpha PSU faulty
34 Parameter Setting Error
35 Ex Setting Gear Ratio
36 Overflow Error Counter
37 Speed Detect Par. Error
39 1-Rot Cs Signal Detect
40 No 1 Rot Cs Signal Detect
41 1-Rot Position Coder Error
42 No 1 Rot. Position Coder Detect
43 Disconnect PC for Dif SP Mod
44 Control Circuit (AD) Error
46 Screw 1-Rot Position Coder Alarm
47 Position Coder Signal Abnormal
49 High Conv. Diff. Speed
50 Spindle Control Over Speed
51 Low Voltage DC Link  Alpha PSU faulty
52 ITP Signal Abnormal 1
53 ITP Signal Abnormal 2
56 Inner Cooling Fan Stop
57 Ex Deceleration Power
58 Overload in PSM  Alpha PSU faulty
59 Cooling Fan Stopped in PSM  Alpha PSU faulty
66 Communication Alarm between Spindle and  Amplifier
69 Safety Speed Exceeded
70 Abnormal Axis Data
71 Abnormal Safety Parameter
72 Motor Speed Mismatch
73 Motor Sensor Disconnected
74 CPU Test Alarm
75 CRC Test Alarm
76 Safety Function Not Executed
77 Axis Number Mismatch
78 Safety Parameter Mismatch
79 Abnormal Initial Test Operation
81 Motor Sensor one-rotation signal detection error
82 Motor Sensor one-rotation signal not detected
83 Motor Sensor Signal Error
84 Spindle Sensor Disconnected
85 Spindle Sensor one-rotation signal detection error
86 Spindle Sensor one-rotation signal not detected
87 Spindle Sensor Signal Error
88 Cooling Fan on the radiator stopped  Drive is faulty- Check Fan

Status (Amber LED)

ER-01 SFR (normal rotation command), SRV (reverse rotation command), or ORCM (orientation command) is entered when ESP (emergency stop signal, which may be a input signal or contact signal) and MRDY (machine ready signal) are not applied.
Check the sequence of *ESP and MRDY. For MRDY, check bit 0 of parameter No. 4001, specifying whether to use the MRDY signal.

ER-02 When the spindle and Fanuc AC Motor are specified separately (with bit 5 of parameter No. 4001 set to 1, and bit 6 of parameter No. 4001 set to 0) in a system employing a high–resolution magnetic pulse coder, 128 /rev must be set for the motor speed detector (bits 2, 1, and 0 of parameter No. 4011 must be set to 0, 0, and 1, respectively). However, a value other than 128 /rev is set. In such a case, the motor is not activated.
Check the parameter settings.

ER-03 The Cs contouring control command is input although bit 5 of parameter No. 4001 is set to 0 to specify that a high-resolution magnetic pulse coder is not used or although bit 4 of parameter No. 4018 is set to 0 to specify that the sensor Cs contouring control function is not used. In such a case, the motor is not activated. Check the parameter settings.

ER-04 When bit 2 of parameter No. 4001 is set to 0 to specify that a position coder signal is not used, a command for servo mode control (rigid tapping, Cs axis control, etc.) or spindle synchronization control is entered. In such a case, the motor is not activated.
Check the parameter setting enabling the use of a position coder signal.

ER-05 When the option parameter of the orientation function is not set, ORCM (orientation command) is entered. Check the parameter setting enabling the use of the orientation function.

ER-06 When the option parameter of the speed range switching control function is not set, winding for low–speed characteristics is selected (with RCH =1).
Check the setting of the parameter for using the speed range switching control function, and the power line status check signal (RCH).

ER-07 When the Cs contouring control command is entered, neither SFR (normal rotation command) nor SRV (reverse rotation command) is entered.
Check the sequence.

ER-08 When a servo mode control command (rigid tapping, Cs axis control, etc.) is entered, neither SFR (normal rotation command) nor SRV (reverse rotation command) is entered.
Check the sequence.

ER-09 When the spindle synchronization control command is entered, neither SFR (normal rotation command) nor SRV (reverse rotation command) is entered.
Check the sequence.

ER-10 When the Cs contouring control command is entered, another mode (such as the servo mode, spindle synchronous control, and orientation) is specified. When Cs contouring control is specified, do not specify another mode.
To enter another mode, first cancel the Cs contouring control command.

ER-11 When a servo mode control command (rigid tapping, Cs axis control, etc.) is entered, another mode (such as Cs contouring control, spindle synchronization control, and orientation) is specified. When a Fanuc servo mode is specified, do not specify another mode.
To enter another mode, first, cancel the servo mode command.

ER-12 When the spindle synchronization control command is entered, another mode (Cs contouring control, servo mode, or orientation) is specified. When spindle synchronization control is specified, do not specify another mode.
To enter another mode, first, cancel the spindle synchronization control command.

ER-13 When the orientation command is entered, another mode (Cs contouring control, servo mode, or spindle synchronization control) is specified. When orientation is specified, do not specify another mode.
To enter another mode, first, cancel the orientation command.

ER-14 SFR (normal rotation command) and SRV (reverse rotation command) are entered at the same time. Specify only SFR or SRV at one time.

ER-15 When bit 5 of parameter No. 4000 is set to 1 to specify the use of the differential speed control function, the Cs contouring control command is entered.
Check the parameter setting and input signal.

ER-16 When bit 5 of parameter No. 4000 is set to 0 to specify that the differential speed control function is not used, DEFMD (differential speed mode command) is entered.
Check the parameter setting and the differential speed mode command.

ER-17 The setting of bits 2, 1, and 0 of parameter No. 4011 for specifying a speed detector is incorrect. The specified speed detector cannot be found.
Check the parameter setting.

ER-18 When bit 2 of parameter No. 4001 is set to 0 to specify that a position coder signal is not used, orientation by a position coder is specified.
Check the parameter setting and input signal.

ER-19 When orientation by a magnetic sensor is specified, another mode (Cs contouring control, servo mode, or spindle synchronization control) is specified. When orientation is specified, do not specify another mode.
To enter another mode, first cancel the orientation command.

ER-20 When bit 5 of parameter No. 4014 is set to 1 to specify use of the slave operation function, bit 5 of parameter No. 4001 is set to 1 to specify use of a high resolution magnetic Fanuc encoders. The use of the slave operation function and that of a high resolution magnetic pulse coder cannot be specified at the same time. Check the parameters settings.

ER-21 In a position control mode (servo mode, orientation, etc.), SLV (slave operation command) is entered. Enter the slave operation command in normal operation mode only.

ER-22 In slave operation mode, a position control command (servo mode, orientation, etc.) is entered.
Enter a position control command in normal operation mode only.

ER-23 When bit 5 of parameter No. 4014 is set to 0 to specify that the slave operation function is not used, SLV (slave operation command) is entered.
Check the parameter setting.

ER-24 In continuous indexing with orientation by a position coder, incremental operation (INCMD = 1) is first performed, after which the absolute position command (INCMD = 0) is entered. Check INCMD (incremental command).
Before specifying absolute position commands in succession, perform absolute position command orientation.

ER-25 Bit 4 of parameter No. 4018 is set to 1 to enable the sensor Cs contouring control function although SPM TYPE 4 is not selected.
Check the parameter setting & SPM drawing number.

SPINDLE DRIVE PART NUMBERS, SPECIFICATIONS AND PCB PART NUMBERS

Fanuc Spindle Amplifier Modules Alpha Series (SPM) Type 1
New Specifications (Supporting Spindle HRV Control)
CE Marked Products

Model Drive type Main PCB Control PCB
SPM-2.2 A06B-6102-H202#H520 A16B-2202-0680 A16B-2203-0500
SPM-5.5 A06B-6102-H206#H520 A16B-2202-0681 A16B-2203-0501
SPM-11 A06B-6102-H211#H520 A20B-1006-0486
A20B-2902-0390
A16B-2203-0502
SPM-15 A06B-6102-H215#H520 A20B-1006-0486
A20B-2902-0390
A16B-2203-0502
SPM-22 A06B-6102-H222#H520 A20B-1006-0486
A20B-2902-0390
A16B-2203-0502
SPM-26 A06B-6102-H226#H520 A20B-1006-0486
A20B-2902-0390
A16B-2203-0502
SPM-30 A06B-6102-H230#H520 A20B-1006-0486
A20B-2902-0390
A16B-2203-0502
SPM-45 A06B-6102-H245#H520 A20B-1007-0591
A20B-2002-0080
A16B-2203-0502
SPM-55 A06B-6102-H255#H520 A20B-1007-0590
A20B-2002-0081
A16B-2203-0502

CE Marked Products
(Numbers in brackets are older specifications)

Model Drive type Main PCB Control PCB
 SPM-2.2  A06B-6078-H202#H500  A16B-2202-0680 A16B-2203-0330
(A16B-2202-0430)
 SPM-5.5  A06B-6078-H206#H500  A16B-2202-0681 A16B-2203-0331
(A16B-2202-0431)
 SPM-11  A06B-6078-H211#H500  A16B-2202-0682 A16B-2203-0331
(A16B-2202-0431)
 SPM-15  A06B-6088-H215#H500  A20B-1006-0486
(A20B-1006-0480)
A20B-2902-0390
A16B-2203-0332
(A16B-2202-0432)
 SPM-22  A06B-6088-H222#H500  A20B-1006-0487
(A20B-1006-0481)
A20B-2902-0390
A16B-2203-0332
(A16B-2202-0432)
 SPM-26  A06B-6088-H226#H500  A20B-1006-0488
(A20B-1006-0482)
A20B-2902-0390
A16B-2203-0332
(A16B-2202-0432)
 SPM-30 A06B-6088-H230#H500 A20B-1006-0489
(A20B-1006-0483)
A20B-2902-0390
A16B-2203-0332
(A16B-2202-0432)
 SPM-45 A06B-6088-H245#H500 A20B-1007-0591
(A20B-1006-0690)
A20B-2002-0080
A16B-2203-0332
(A16B-2202-0432)

NON-CE Marked Products
(Numbers in brackets are older specifications)

Model Drive type Main PCB Control PCB
 SPM-2.2  A06B-6078-H202#H500  A16B-2202-0470 A16B-2203-0330
(A16B-2202-0430)
 SPM-5.5  A06B-6078-H206#H500  A16B-2202-0471 A16B-2203-0331
(A16B-2202-0431)
 SPM-11  A06B-6078-H211#H500  A16B-2202-0472 A16B-2203-0331
(A16B-2202-0431)
 SPM-15  A06B-6088-H215#H500 A20B-1006-0170
A20B-2902-0280
A16B-2203-0332
(A16B-2202-0432)
 SPM-22  A06B-6088-H222#H500 A20B-1006-0171
A20B-2902-0280
A16B-2203-0332
(A16B-2202-0432)
 SPM-26  A06B-6088-H226#H500 A20B-1006-0172
A20B-2902-0280
A16B-2203-0332
(A16B-2202-0432)

NON-CE Marked Products
Old Specification

Model Drive type Main PCB Control PCB
 SPM-15  A06B-6078-H215#H500 A20B-1005-0572
A20B-2001-0010
A16B-2202-0070
A20B-2001-0150
A20B-2901-0851
 SPM-22  A06B-6078-H222#H500 A20B-1005-0571
A20B-2001-0010
A16B-2202-0070
A20B-2001-0150
A20B-2901-0851
 SPM-26  A06B-6078-H226#H500 A20B-1005-0570
A20B-2001-0010
A16B-2202-0070
A20B-2001-0150
A20B-2901-0851
 SPM-30  A06B-6078-H230#H500 A20B-1005-0575
A20B-2001-0010
A16B-2202-0070
A20B-2001-0150
A20B-2901-0851

Alpha Series Spindle Amplifier Modules (SPM) Type 2 (Cs Contour Control/BZ Sensor (separate built in sensor) Specification)
CE Marked Products
(Numbers in brackets drawing numbers of old specifications)

Model Drive type Main PCB Control PCB
 SPM-2.2  A06B-6078-H302#H500  A16B-2202-0680 A16B-2203-0433
A20B-2901-0851
 SPM-5.5  A06B-6078-H306#H500  A16B-2202-0681 A16B-2203-0331
A20B-2901-0851
 SPM-11  A06B-6078-H311#H500  A16B-2202-0682 A16B-2203-0331
A20B-2901-0851
 SPM-15  A06B-6088-H315#H500  A20B-1006-0486
(A20B-1006-0480)
A20B-2902-0390
A16B-2203-0332
A20B-2901-0851
 SPM-22  A06B-6088-H322#H500  A20B-1006-0487
(A20B-1006-0481)
A20B-2902-0390
A16B-2203-0332
A20B-2901-0851
 SPM-26  A06B-6088-H326#H500  A20B-1006-0488
(A20B-1006-0482)
A20B-2902-0390
A16B-2203-0332
A20B-2901-0851
 SPM-30 A06B-6088-H330#H500 A20B-1006-0489
(A20B-1006-0483)
A20B-2902-0390
A16B-2203-0332
A20B-2901-0851
 SPM-45 A06B-6088-H345#H500 A20B-1007-0591
(A20B-1006-0690)
A20B-2002-0080
A16B-2203-0332
A20B-2901-0851

NON-CE Marked Products

Model Drive type Main PCB Control PCB
 SPM-2.2  A06B-6078-H302#H500  A16B-2202-0470 A16B-2203-0433
A20B-2901-0851
 SPM-5.5  A06B-6078-H306#H500  A16B-2202-0471 A16B-2203-0434
A20B-2901-0851
 SPM-11  A06B-6078-H311#H500  A16B-2202-0472 A16B-2203-0435
A20B-2901-0851
 SPM-15  A06B-6088-H315#H500 A20B-1006-0170
A20B-2902-0280
A16B-2203-0435
A20B-2901-0851
 SPM-22  A06B-6088-H322#H500 A20B-1006-0171
A20B-2902-0280
A16B-2203-0435
A20B-2901-0851
 SPM-26  A06B-6088-H326#H500 A20B-1006-0172
A20B-2902-0280
A16B-2203-0435
A20B-2901-0851

NON-CE Marked Products
Old Specification

Model Drive type Main PCB Control PCB
 SPM-15  A06B-6078-H315#H500 A20B-1005-0572
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851
 SPM-22  A06B-6078-H322#H500 A20B-1005-0571
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851
 SPM-26  A06B-6078-H326#H500 A20B-1005-0570
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851
 SPM-30  A06B-6088-H330#H500 A20B-1005-0575
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851

Alpha Series Spindle Amplifier Modules (SPM), Type 3 (Spindle Switching Control/Differential Speed Control Specification)
CE Type Products

MODEL DRIVE TYPE MAIN PCB CONTROL PCB
 SPM-11 A06B-6088-H411#H500 A20B-1006-0484
A20B-2902-0390
A16B-2202-0440
A20B-2001-0700
A20B-2901-0851
 SPM-15 A06B-6088-H415#H500 A20B-1006-0486
(A20B-1006-0480)
A20B-2902-0390
A16B-2202-0440
A20B-2001-0700
A20B-2901-0851
 SPM-22 A06B-6088-H422#H500 A20B-1006-0487
(A20B-1006-0481)
A20B-2902-0390
A16B-2202-0440
A20B-2001-0700
A20B-2901-0851
 SPM-26 A06B-6088-H426#H500 A20B-1006-0488
(A20B-1006-0482)
A20B-2902-0390
A16B-2202-0440
A20B-2001-0700
A20B-2901-0851
 SPM-30 A06B-6088-H430#H500 A20B-1006-0489
(A20B-1006-0483)
A20B-2902-0390
A16B-2202-0440
A20B-2001-0700
A20B-2901-0851
 SPM-45 A06B-6088-H445#H500 A20B-1006-0591
(A20B-1006-0690)
A20B-2002-0080
A16B-2202-0440
A20B-2001-0700
A20B-2901-0851

NON-CE Type Products

MODEL DRIVE TYPE MAIN PCB CONTROL PCB
 SPM-11 A06B-6078-H411#H500 A20B-1005-0574
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851
 SPM-15 A06B-6078-H415#H500 A20B-1005-0572
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851
 SPM-22 A06B-6078-H422#H500 A20B-1005-0571
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851
 SPM-26 A06B-6078-H426#H500 A20B-1005-0570
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851
 SPM-30 A06B-6078-H430#H500 A20B-1005-0575
A20B-2001-0010
A16B-2202-0160
A20B-2001-0140
A20B-2901-0851

Alpha Series Spindle Amplifier Module (SPM), Type 4, (Alpha sensor Cs Contour Control)
New Specification (Supporting Spindle HRV Control)
CE MARKED

Model Drive type Main PCB Control PCB
SPM-2.2 A06B-6102-H102#H520 A16B-2202-0680 A16B-2203-0503
A20B-2902-0620
SPM-5.5 A06B-6102-H106#H520 A16B-2202-0681 A16B-2203-0504
A20B-2902-0620
SPM-11 A06B-6102-H111#H520 A20B-2202-0682 A16B-2203-0505
A20B-2902-0620
SPM-15 A06B-6102-H115#H520 A20B-1006-0486
A20B-2902-0390
A16B-2203-0505
A20B-2902-0620
SPM-22 A06B-6102-H122#H520 A20B-1006-0487
A20B-2902-0390
A16B-2203-0505
A20B-2902-0620
SPM-26 A06B-6102-H126#H520 A20B-1006-0488
A20B-2902-0390
A16B-2203-0505
A20B-2902-0620
SPM-30 A06B-6102-H130#H520 A20B-1006-0489
A20B-2902-0390
A16B-2203-0505
A20B-2902-0620
SPM-45 A06B-6102-H145#H520 A20B-1007-0591
A20B-2002-0080
A16B-2203-0505
A20B-2902-0620
SPM-55 A06B-6102-H155#H520 A20B-1007-0590
A20B-2002-0081
A16B-2203-0505
A20B-2902-0620

New Specification (Supporting Spindle HRV Control)
CE MARKED

Model Drive type Main PCB Control PCB
SPM-2.2 A06B-6078-H102#H500 A16B-2202-0680 A16B-2202-0433
A20B-2902-0620
(A20B-2090-0610)
SPM-5.5 A06B-6078-H106#H500 A16B-2202-0681 A16B-2202-0434
A20B-2902-0620
(A20B-2090-0610)
SPM-11 A06B-6078-H111#H500 A20B-2202-0682 A16B-2202-0434
A20B-2902-0620
(A20B-2090-0610)
SPM-15 A06B-6088-H115#H500 A20B-1006-0486
A20B-2902-0390
A16B-2202-0435
A20B-2902-0620
(A20B-2090-0610)
SPM-22 A06B-6088-H122#H500 A20B-1006-0487
A20B-2902-0390
A16B-2202-0435
A20B-2902-0620
(A20B-2090-0610)
SPM-26 A06B-6088-H126#H500 A20B-1006-0488
A20B-2902-0390
A16B-2202-0435
A20B-2902-0620
(A20B-2090-0610)
SPM-30 A06B-6088-H130#H500 A20B-1006-0489
A20B-2902-0390
A16B-2202-0435
A20B-2902-0620
(A20B-2090-0610)
SPM-45 A06B-6088-H145#H500 A20B-1007-0591
A20B-2002-0080
A16B-2202-0435
A20B-2902-0620
(A20B-2090-0610)





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