ge fanuc automation · 1 - 4 servo and spindle motors exposed to liquids - july 2000 gfk-1046f 1...

GE Fanuc Automation

Computer Numerical Control Products

Servo and Spindle MotorsExposed to Liquids

GFK-1046F July 2000

GFL-001

Warnings, Cautions, and Notesas Used in this Publication

WarningWarning notices are used in this publication to emphasize that hazardous voltages, currents,temperatures, or other conditions that could cause personal injury exist in this equipment or maybe associated with its use.

In situations where inattention could cause either personal injury or damage to equipment, aWarning notice is used.

CautionCaution notices are used where equipment might be damaged if care is not taken.

NoteNotes merely call attention to information that is especially significant to understanding andoperating the equipment.

This document is based on information available at the time of its publication. While effortshave been made to be accurate, the information contained herein does not purport to cover alldetails or variations in hardware or software, nor to provide for every possible contingency inconnection with installation, operation, or maintenance. Features may be described herein whichare not present in all hardware and software systems. GE Fanuc Automation assumes noobligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutorywith respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, orusefulness of the information contained herein. No warranties of merchantability or fitness forpurpose shall apply.

©Copyright 2000 GE Fanuc Automation North America, Inc.

All Rights Reserved.

Preface

GFK-1046F iii

Content of this Manual

Chapter 1. Protection Standards: Provides basic product information and how they relateto IEC standards.

Chapter 2. User Specifications: Provides a tool that end users can use to help their machinesuppliers provide machines that meet consistent standards of protection.

Chapter 3. Application Guide: Provides a foundation for the machine tool builder bypointing out the elements that can affect coolant entry, modes of motor failure, andmore extreme methods of keeping motors dry.

Chapter 4. Machine Runoff Checklist: This checklist can be used during machine designand test or after installation at the user site.

Chapter 5. Preventive Maintenance: Describes the steps that can be used to identifypotential motor failures as well as basic preventive maintenance procedures.

The following table identifies the chapters which will be most useful to each type of user.

Refer to this Chapter:

Function 1 2 3 4 5

Machine Tool Builder Yes Yes Yes Yes No

End User / Specifier No Yes Yes Yes No

User Maintenance / Service No No Yes Yes Yes

Related Publications

Publication S Series αααα and ß Series

α Servo Descriptions Manual GFZ-65002E GFZ-65142E

α Servo Maintenance Manual GFZ-65005E GFZ-65165E

α Spindle Descriptions Manual GFZ-65042E GFZ-65152E

α Spindle Maintenance Manual GFZ-65045E GFZ-65165E

ß Series Servo Motor Descriptions Manual GFZ-65232EN

Contents

GFK-1046F v

Chapter 1 Protection Standards ................................................................................................ 1-1

Oil Seals................................................................................................................................. 1-1Connectors ............................................................................................................................. 1-2IEC Protection Standards....................................................................................................... 1-3

Chapter 2 User Specifications .................................................................................................... 2-1

All Motor Applications.......................................................................................................... 2-1Motors Subjected to Liquids ................................................................................................. 2-5

Chapter 3 Application Guide ..................................................................................................... 3-1

Mold System.......................................................................................................................... 3-2Custom Cable Part Number System ...................................................................................... 3-2IEC Standards ........................................................................................................................ 3-2When Coolant Enters a Motor ............................................................................................... 3-3Drains and Pressurization ...................................................................................................... 3-3Fans and Derating .................................................................................................................. 3-3

Chapter 4 Machine Runoff Checklist........................................................................................ 4-1

Checklist ................................................................................................................................ 4-2

Chapter 5 Preventive Maintenance ........................................................................................... 5-1

Maintenance for Drives in a Normal Environment ............................................................... 5-2Maintenance for Drives in a Wet Environment..................................................................... 5-3Modification to the Motor ..................................................................................................... 5-4

GFK-1046F 1 - 1

Chapter Protection Standards

Developing and maintaining a highly efficient and productive system involves the machine toolbuilder, the drives/controls supplier, and the end user. The system design, selected components,and manner in which the equipment is installed, used, and maintained all contribute to the uptime ofthe system.

Oil Seals

Oil seals are designed to keep oil from entering the motor through the shaft end. Oil seals do not,however, prevent the entry of any liquids under pressure.

Caution

When liquid is present during the cooling period of a motor, lower airpressure in the motor may result in the motor breathing in the liquids.

1

1 - 2 Servo and Spindle Motors Exposed to Liquids - July 2000 GFK-1046F

1

The following illustration identifies the most vulnerable areas for coolant entry.

Figure 1 - 1. Coolant Entry

NoteFoot-mount style spindle motors are only supplied with shaft oil seals as anavailable option.

Connectors

Servo motor models 0S through 40S and α3 through α40 have the same type of cable connectorsystem (power, feedback, and brake). The cable connector system is designed to accept MS-typeconnectors.

SP-style, α1, and α2 motors use a D-type connector system. The D-type connector system hasconnectors that are as effective as MS-protected types.

Most Vulnerable

for Coolant Entry

a48031

GFK-1046F Chapter 1 Protection Standards 1 - 3

1

IEC Protection Standards

GE Fanuc motors are designed to meet the IEC protection standards listed in Table 1-1. Thesestandards are based on two characteristics, the first being protection from solid objects and thesecond being protection from water.

Table 1 - 1. IEC Protection Standards

Standard * Description

Protection from Solid Objects

IP4x Protected against solid objects greater than 1 mm thickness or diameter.

IP5x Protected against dust. "Ingress of dust is not totally prevented, but dust does not enter insufficient quantity to interfere with satisfactory operation of the equipment."

IP6x Dust tight. "No ingress of dust."

Protection from Water

IPx2 Protected against dripping water, rate equivalent to 3-5 mm of rain per minute.

IPx4 Protected against splashing water from any direction.

IPx5 Protected from harmful damage due to water jets, according to the following test:

• Spray from all angles of 12.5 liters/minute.

• Nozzle diameter = 6.3 mm.

• Pressure = 30 kN/m2 (0.3 bar).

• Distance = 3 m.

• Duration = 3 minutes.

IPx7

(see note below)

Protected against the effects of immersion, according to the following test:

• Surface of the water level shall be at least 150 mm above the highest point of the machine.

• Lowest point of the machine must be at least 1 meter below the surface of the water.

• Duration of the test must be at least 30 minutes.

• Water temperature must not differ from that of the machine by more than 5° C.

* Each standard listed below also satisfies the requirements of the lower rated standards beneath it.

For example, IPx5 also meets the standards for IPx4, IPx3, IPx2, and IPx1. For more information, refer to CEI/IEC 34-5; 1991.

NoteBy agreement between the manufacturer and the user, this test may be replaced bythe following procedure:

The machine should be tested with an inside air pressure of about 10 kPa (0.1bar). The duration of the test is one minute. If no air leaks out during the test, thetest is satisfactory. Air leakage may be detected either by submersion, with waterjust covering the machine, or by the application on to it of a solution of soap inwater.

GE Fanuc tests according to this alternate procedure. Using the other procedurerequires removing the end cap and checking for water in the motor. This destroysthe integrity of the seal.


1

IEC ratings provide a good indication of the expected performance of GE Fanuc motors becausethey are test-based systems. However:

• To meet the standard, the shaft end and electrical connections (connector or terminal box) mustbe appropriately protected by the customer.

• Because the second characteristic is based on water, the effect of various coolant materialscannot be accurately predicted.

• Motors built to meet IP67 go through a different manufacturing process. These protectionlevels cannot be readily added in the field.

• If a motor is modified (i.e., by rotating the connector, by removing the end cap to change theencoder, etc.), the protection rating is voided.

• Oil seals and connectors are the same in both standard motors and in those motors with higherlevels of protection.

• The oil seal is a double lip unit with lubricant between the lips. Lip material is antiwear NBR.

• An extra shield option is available that adds a shield for the seal and another pocket oflubricant between the shield and the lip of the seal.

• Compared to standard motors, IP67-rated motors have additional sealing materials applied tomating surfaces. Depending on the surfaces, these may include varnish, rubber-based gaskets,and RTVs. The motor is tested for leaks by a submersion process.

NoteTo maximize the service provided by the motors, regardless of their protectionlevel, they should be protected from continuous wetting by coolants.

Table 1 - 2. Servo Motors

Model IEC Standard

Hollow Shaft "T" Motors Not rated

5-0 Not rated

4-0S, 3-0S, 50S, 60S, 70S, α0.5 Not rated

2-0SP through 30S IP55 Standard

α1 through α150, β0.5 through β6 IP65 Standard (IP67 Optional)

40S and α40 IP55 Standard (excluding fan)

IP67 Optional (excluding fan)

α300, α400, α1000 IP54 (IP65 optional)

Table 1 - 3. Spindle Motors

Model IEC Standard

Built-in Motors Not rated

Selected 1S through 3S IP65 Optional

All Others IP54 (excluding fan and terminal box)

IP44 (fan and terminal box included)

GFK-1046F 2 - 1

Chapter User Specifications

All Motor Applications

For all motor applications, please follow this procedure:

1. Test machine runoff with all the equipment guards in place and with the same coolant nozzlesand pressures designed for production.

2. Orient the motor connectors down and/or away from the predominant source of liquids.

3. Use sealing-type connectors to keep moisture out. Where MS connectors are used, they must bewatertight versions.

α1 and α2 and β1 through β6 motors use D sub 15P A068-6050-K115 for feedback.

WT (watertight) connectors are available, in kit form, from GE Fanuc. The kit consists of aconnector, “O” ring, shell bushing, clamp, and grommet. These are listed as the"environmental type" in Table 2-1.

4. An alternate waterproof CE connector and cable termination is also available.

5. The severe duty cables, listed in Tables 2-2 and 2-3, are polyurethane jacketed cables with theconnector housing molded to the seal. The polyurethane jacket resists degrading by thecoolant.

6. Physical barriers, such as deflector plates, shrouds, and splash guards, should be used tominimize liquids falling on or hitting the motor.

7. Cables should have drip loops to prevent liquids from traveling along the cable to the motorconnector.

8. Any removable cover, door, shield, or other device, which protects the motor from liquids orother contaminants, should be clearly labeled to require the cover, door, or shield to bereplaced in its original position.

2


2

Table 2 - 1. MS Connector Kits Supplied by GE Fanuc

WTCE95 Catalog No.

44A730464-xxx

MS/WTEnvironmental

Catalog No.44A730464-xxx

Description

G25 G01 / G14 * Motor Brake or Fan, Straight Connector.

G17 G02 Motor Power 0, 5, 5/3, α3, α6, β1 through β6, StraightConnector.

G19 G03 Motor 10, 20, 30 α12, α22, α30, Straight Connector.

G21 G04 Motor Power 20/3, 30/3, 40, α22/3, α30/3. α40, StraightConnector.

G37 G05 Encoder 17P, Straight Connector.

— G06 Encoder 19P, Straight Connector.

G26 G07 / G15 * Motor Brake or Fan, 90° Elbow Connector.

G18 G08 Motor Power 0, 5, 5/3, α3, α6, β1 through β6, 90° ElbowConnector.

G20 G09 Motor Power 10, 20, 30, α12, α22, α30, 90° Elbow Connector.

G22 G10 Motor Power 20/3, 30/3, 40, α22/3, α30/3, α40, 90° ElbowConnector.

G38 G11 Encoder ENC 17P, 90° Elbow Connector.

— G12 Encoder 19P, 90° Elbow Connector.

* 44A730464-G01 and G07 connectors for the brake or fan are 2-pin connectors; G14 and G15 are 3-pin connectors.

Table 2 - 2. ββββ 0.5 Waterproof (IP67) Motor Connectors

FANUC Part No. Manufacturer’s Part No. Manufacturer

Power Connector A63L-0001-0780#4 RM15WTJA-4S Hirose Electric

Power Cable Clamp A63L-0001-0781#15-8 RM15WTP-CP8 Hirose Electric

Encoder Connector A63L-0001-0780#12 RM15WTJA-12S Hirose Electric

Encoder Cable Clamp A63L-0001-0781#15-7 RM15WTP-CP7 Hirose Electric

Brake Connector (with cable clamp) A63L-0001-0785 RM12WTJ-2S-(7) Hirose Electric

NOTE: The waterproof connectors of Beta 0.5/3000 do not have TUV approval.

GFK-1046F Chapter 2 User Specifications 2 - 3

2

Table 2 - 3. GE Fanuc Severe Duty Cables (S Series Motors)

Application/Motor Amplifier/Control Custom Cable Cable Length Comments 1

Servo Motor Power Cable0S/5S Motors

S and C Series CP3A-0MPB-0140-AAACP3A-1MPB-0140-AAA

14M14M

S, SD, PMGE, SD, PMG

Servo Motor Power Cable10S, 20S, 20S/1500 Motors


14M14M


Servo Motor Power Cable30S Motor


14M14M


Servo Motor Power Cable20-30S/3000, 30, 40,40S/2000, 7L Motors


14M14M

S, SD, 7W, PMGE, SD, 7W, PMG

Servo Motor Power Cable1 and 2-OSP Motors

S and C Series CP2A-0DPB-0140-AAA 14M SD, PMG

Servo Motor Brake Cable S and C Series CB2N-1MPM-0140-AAA 14M E, SD, PMG

Encoder FeedbackA Quad B Incremental0S – 70S Motors

Series 0 CNCSeries 15-A CNC

44C742206-00144C742206-002

14M14M

S, SDE, SD

Encoder FeedbackA Quad B – 10K0S – 70S Motors


44C742208-00144C742208-002

14M14M

S, SDE, SD

Encoder FeedbackA Quad B – Absolute0S – 70S Motors


44C742209-00144C742209-002

14M14M

S,. SD, NUE, SD, NU

Encoder FeedbackA Quad B – Absolute0-0SP – 2-OSP Motors

Series 0 CNC 44C742229-001 14M S, SD, NU

Encoder Feedback40K Serial IncrementalPulse Coder C0S – 70S Motors


44C742210-00144C742210-002

14M14M

S, SDE, SD

Encoder Feedback1 MM SerialPulse Coder A0S – 70S Motors


44C742211-00144C742211-002

14M14M

S, SDE, SD

Encoder FeedbackSerial Incremental/Absolute1 MM SerialPulse Coder A0-0SP – 2-0SP Motors

Series 0 CNCSeries 15-A CNCSeries 16/18 CNCSeries 15-B CNC

Power Mate E and FPower Mate G and H

44C742207-00144C742227-00144C741355-001

14M14M14M

S, SD, NUS, SD, RUS, SD

Notes:

1Cable Comments:E = Elbow type MS connector.NU = Feedback cable for systems not using a relay unit.PMG = Premating ground pin in connector.RU = Feedback cable for systems using a relay unit.S = Straight type MS connector.SD = Severe duty cable, resistant to alaphatic hydrocarbon and alkalai-based coolants (polyurethane jacket).7W = 7 conductors in cable.


2

Table 2 - 4. GE Fanuc Severe Duty Cables (αααα Motors)

Application / Control Motor Cable Cable Length Comments 1

Servo Motor Power Cables

α Series Servos

(SVM and SVU)

α3/3000

α6/2000

α6/3000

C3/2000

C6/2000

β1/3000

β2/3000

β3/3000

β6/2000

CP3A-0MPB-0070-AAA

CP3A-1MPB-0070-AAA

CP3A-0MPB-0140-AAA

CP3A-1MPB-0140-AAA

7M

7M

14M

14M

S, SD, PMG

E, SD, PMG

S, SD, PMG

E, SD, PMG


α Series Servos

(SVM and SVU)

α12/2000

α12/3000

α22/1500

α22/2000

CP4A-0MPB-0070-AAA

CP4A-1MPB-0070-AAA

CP4A-0MPB-0140-AAA

CP4A-1MPB-0140-AAA

7M

7M

14M

14M

S, SD, PMG

E, SD, PMG

S, SD, PMG

E, SD, PMG


α Series Servos

(SVM and SVU)

α22/3000

α30/2000

α30/3000

α40/2000

CP5A-0MPB-0070-AAA

CP5A-1MPB-0070-AAA

CP5A-0MPB-0140-AAA

CP5A-1MPB-0140-AAA

7M

7M

14M

14M

S, SD, PMG, 7W

E, SD, PMG, 7W

S, SD, PMG, 7W

E, SD, PMG, 7W

Feedback Cables

64K Serial Encoder

α Series Servos

Standard Honda Connector

Series 0 CNC

Series 15-A CNC

All α Motors exceptα0.5, α1 and α2.

CF3Z-0MPB-0070-AAA

CF3Z-0MPB-0140-AAA

CF3Z-2MPB-0070-AAA

CF3Z-2MPB-0140-AAA

7M

14M

7M

14M

S, SD

S, SD

E, SD

E, SD

α1 and α2 and β1through β6.

CF2A-0DPB-0140-AAA

CF2A-0DPB-0070-AAA

14M

7M

S, SD

S, SD

Feedback Cables

64K Serial Encoder

α Series Servos

Half-Pitch Connector

Series 15-B, 16-A, 16-B

Series 18 CNC

Power Mate D and E

All α Motors exceptα0.5, α1 and α2.

AF3A-0MPB-0070-AAA

AF3A-0MPB-0140-AAA

AF3A-2MPB-0070-AAA

AF3A-2MPB-0140-AAA

7M

14M

7M

14M

S, SD

S, SD

E, SD

E, SD

Servo Motor Brake Cable

Premating Ground PinAll α and β Motorsexcept α0.5, α1, α2,and β0.5.

AB1N-0MPM-0070-AAA

AB1N-1MPM-0070-AAA

AB1N-0MPM-0140-AAA

AB1N-1MPM-0140-AAA

7M

7M

14M

14M

S, SD, PMG

E, SD, PMG

S, SD, PMG

E, SD, PMG

Servo Motor Power Cables αSeries SVM and SVU

α1/3000

α2/3000CP2A-0DPB-0140-AAA 14M SD, PMG

Notes:

1Cable Comments:E = Elbow type MS connector.NU = Feedback cable for systems not using a relay unit.PMG = Premating ground pin in connector.RU = Feedback cable for systems using a relay unit.S = Straight type MS connector.SD = Severe duty cable, resistant to alaphatic hydrocarbon and alkalai-based coolants (polyurethane jacket).7W = 7 conductors in cable.

GFK-1046F Chapter 2 User Specifications 2 - 5

2

Motors Subjected to Liquids

The requirements described on page 2-1 also apply to motors subjected to splash, spray, or drip, aswell. To re-emphasize item 2, in no instance should a connector be oriented upward.

Commercially available, environmentally resistant components should be used. On servo motorsrated between 6 inch-pounds and 1327 inch-pounds, the motors must meet IP67 protection level, orhigher. To meet the intent of the IP67 standard, the machine design and connection system mustappropriately protect the motor shaft end and electrical connectors.

The interface between a flange-mounted motor and the machine device or member must bemachined and gasketed to prevent liquids or other contaminants from entering the motor.

Where any liquids have the potential of entering the motor from the shaft end, appropriate slingersor drains must be used.

If IP67-rated motors are not available or the appropriate measures cannot be taken to protect theshaft end, the installation must be reviewed and approved by the user. With prior approval, it maybe acceptable to use drain plugs and/or air purge systems.

Caution

Liquids present in motors are not covered under the motor supplier'swarranty. The machine tool builder is responsible for full replacement ofthe motor in case of a product failure due to liquid entry.

GFK-1046F 3 - 1

Chapter Application Guide

The best way to maximize a motor's service is to keep it dry, by design and in operation. If itcannot be kept dry, then a system of protection, maintenance, and, in some cases, relief is needed.This system may include:

• Motor orientation and location.

• Shaft exposure.

• Coolant pressures and types.

• Location of coolant nozzles and shape of the part.

• Connector types and orientation.

• Maintenance (covers left off, filters not cleaned, etc.).

• Motor protection level.

Figure 3 - 1. Four Layers of Defense for Best Reliability

3

1. Keep motor out of wet areas

2. Protect the motor

3. Use protected motors

4. Good maintenance practices

a48033


3

Mold SystemThe standard MS environmental connector termination is hard to make and is also hard to insurethat it is done right. The solution is to mold over the connection area of the connector. GE Fanucoffers a mold system to seal the cable/connector termination. The mold seals the back of theconnector, shapes the cable from the connector, provides the straight or right angle connection forthe cable, seals the cable end, and provides limited strain relief. A watertight MS connector shouldbe used to replace connectors on environmental cables already in the field and can be used on newcables if desired.

Custom Cable Part Number SystemCustom Cable Part Number

C P 5 A - 1 M P B - 0 0 7 0 - A A A - revision

no custom - reserved for future usecord grip (A = None) reserved for future use

xxx.x - length in meters, 1 to 25 in 1 meter incrementstermination (B = Both, M = Motor, A = Amplifier, N = None)

material (P = Polyurethene)connector type - (M = Molded, S = Standard, D = Shell, W = Watertight)

orientation - see Orientation table belownon-motor end connection - see Non-motor end connection table below

motor family - see Motors Families tabcable application (P = Power, B = Brake, F = Feedback)

designates cable

Example: CP3A-1MPB-0140-AAA Power cable, motor family 3, connected to alpha amplifier, 0 degree orient, molded connector, polyurethenematerial, both ends terminated, 14 meters, no cord grip, no special, revision A

Non-Motor End for Power Cables Non-Motor End for Feedback Cables Non-Motor End for BrakesA = Alpha Amplifier A = Amplifier , either Alpha or Beta N= None, wire stripped and tinnedB = Beta Amplifier Z = FS0 or FS 15A CNC (type A interface)N= None, wire stripped and tinned N= None, wire stripped and tinned

Orientation1 - 0 degree 0 degrees (power cables only) - the cable lines up with the shaft - present elbow configuration.2 - 45 degree 45 degrees (feedback cables only) – cables are rotated 45 degrees to avoid the power connector.4 - 135 degree 135 degrees (power cables only) - cables rotated 45 degrees from 180 to avoid the feedback connector.5 - 180 degree0 - straight

Description

Straight (for power or feedback cables) - Uses straight connector. Cable exits 90 degrees from plane of motor shaft.

0 degrees 180 degrees

Power Cable = 4 (135°°°°) Encoder Cable = 5 (180°°°°)Use for shaft-up vertical mounting.

Orientation

Power Cable = 1 (0°°°°) Encoder Cable = 2 (45°°°°)

0 degrees 180 degreesOrientation

180 degrees (feedback cables only) - feedback cable exits toward the encoder end. Use for shaft-up vertical mounting.

Power Cable = 0 (straight) Encoder Cable = 0 (straight)

Orientation

0 degrees 180 degrees

90 degrees

Figure 3-2. Custom Cable Part Number System

IEC StandardsIEC standards, such as IP65 and IP67 do not replicate the severity of the environments and durationfound on machine tools. While IP67-rated motors do offer additional protection, they are not theonly element in the solution.

GFK-1046F Chapter 3 Application Guide 3 - 3

3

When Coolant Enters a Motor

A variety of coolant types (see following table for list of known types), exposure duration andpressure, and maintenance practices have evolved as a result of a large installed base and a varietyof applications. While both standard servo motors (IP65) and motors with IP67 protection haveexperienced degradation or failure, some IP65 motors have operated for extended periods under acontinuous coolant bath. Better protected motors provide better service.

When coolant enters a motor,

1. Coolants can break down the insulating materials on the windings and/or those used at theconnection and junction points. This degradation occurs over time, but failures can beanticipated through changes in resistance. (For more information, see Chapter 5, “Servo andSpindle Drive Preventive Maintenance”.)

2. In brake motors, the coolant can interfere with the operation of the brake.

3. Coolants can attack electronic devices in the encoder.

4. Over time, motor fans will fail due to contamination.

5. Coolants can cause shorts between the pins of a connector.

Drains and Pressurization

Drains can extend the useful life of a motor by reducing the amount of contact time chemicals havewith the insulating materials in the motor. However, you must be concerned with correct placementof the drain hole and also with the risk of metal filings entering the motor.

Positive air pressure can help when there is a high level of contaminants or as the motor “breathes”during a cooling period, thus allowing liquids to enter the motor. In this case, you must beconcerned with the addition of another system requiring maintenance.

Drains and positive air pressure should be used only after all other preventive measures have failed.For more advice with these procedures, consult GE Fanuc Application Engineering.

Fans and Derating

The 40S and α40 servo motors and most of the spindle motors use an air-over fan. These motorsare susceptible to coolant entry, contamination, and failure. The air-over fans affect the continuousratings of these motors. The systems could be operated, at reduced ratings, without the fan. Formore advice with these procedures, consult GE Fanuc Application Engineering.


3

Table 3 – 1. Coolants in Use with GE Fanuc Cables

COOLANT MANUFACTURER

2000 Argent Ferrohone Argent, Ltd.

Alumisol Blue Chip Metalworking Fluids

Castrol 908 Castrol Industrial East

Castrol WY2-402B Castrol Industrial East

ChemTool 250BB ChemTool, Inc.

390 Safety Cool Chem Trend, Inc.

ML-48-2326 Metal Lubricants Co.

1100 Metkool Metalworking Lubricants Co.

251 Metkool Soap Metalworking Lubricants Co.


37A Metkut Oil Metalworking Lubricants Co.


F3C28A Metkut Metalworking Lubricants Co.

Metkool 1450 Metalworking Lubricants Co.

Metkool 3030-R Metalworking Lubricants Co.

Nat-Hone SC 4640 National Chem Oil Corp.

185-FB Kut Quaker Chemical

523 Cutting Fluid Van Stratten Chemical

NM5299 Van Stratten Chemical

C-104KTP Houghton Intl., Inc.

CLEAREDGE 6510 Castrol International

SYNTILO 9951 Castrol International

WS3-908E Castrol International

GFK-1046F 4 - 1

Chapter Machine Runoff Checklist

The following checklist is not a comprehensive checklist. It should be used by both the machinetool builder and the end user to supplement good engineering practices.

Observe each machine operating in a cutting mode, with all equipment guards in place, with thesame coolant nozzles and pressures as designed for production, and with parts of similar size andform factor in the work position.

Relative to the work area where coolants are used, where is the motor located?

! Inside or

! Outside.

! Above or

! Level with or

! Below.

How is the motor connected to the machine?

! Belted or

! Gearbox.

! Coupling exposed or

! Flange mounted to machine member.

! Is it machined well or gasketed?

4


4

Checklist

! Is coolant splashing, dripping, spraying, or flowing onto the motor?

! Are all the liquid “paths” to the motor identified?

! If the coupling area is exposed, is there a slinger on the shaft to expel coolant?

! Does the motor shaft get wet? Are liquids around the motor flange area, even when themotor is turned off?

! With foot-mount spindle motors, is the shaft fully protected from any contact withmoisture?

! Can guards, deflectors, or shields be applied to reduce or eliminate the coolant attack?

! Are removable maintenance covers or shields in place? Are notices and warnings postedto minimize the chances that they will be left off?

! Are motor fans protected or screened?

! Can the coolant get to the motor via the connectors?

! Are the connectors the environmental type? Is the “O” ring in place?

! If a strain relief is installed, did it strengthen or weaken the seal?

! Do any motor cables flex? Will this break down the cable insulation?

! Is there a drip loop in the cable?

! Are the connectors pointing down and/or away from the liquid source?

! Are the motors IP67?

GFK-1046F 5 - 1

Chapter Preventive Maintenance

Warning

The products described in this publication may use hazardous voltages orcreate other conditions that could, through misuse, inattention, or lack ofunderstanding, result in personal injury, or damage to the product or toother equipment. It is imperative that personnel involved in the installation,maintenance, or use of these products understand the operation of theproducts and the contents of this and related publications.

Some surfaces on the motors, servo amplifiers, and discharge resistors maybe extremely hot.

Different environments may require different maintenance procedures. Little maintenance isrequired in normal, clean, dry environments. Where the drives, and especially the motors, areexposed to coolants or other liquids, extra precautions must be taken to maintain the reliability ofthe drives.

If a motor must be disassembled, i.e. encoder end cap or connector, the IEC IPxx specification isvoided. (For more information on IEC Standards, refer to Chapter 1, "Protection Standards andProduct Information".)

5


5

Maintenance for Drives in a Normal Environment

When performing the following procedures, all motor cables that flex during operation should bechecked for damage to the insulation and for damage at the connection points.

Servo MotorsServo motors do not require any maintenance in a clean, dry environment. They should beinspected and cleaned, if necessary, every six months. Use factory air and a vacuum cleaner toclean the servo motor.

Spindle MotorsFor spindle motors, the following items should be checked and cleaned every six months, or moreoften if contamination has built up:

• Four ventilation openings on the front of the motor.

• Fan guard on the rear of the motor.

• Cooling fan.

Servo and Spindle AmplifiersFor servo and spindle amplifiers, the following items should be checked and cleaned every sixmonths, or more often if contamination has built up.

• Cooling fan for the spindle amplifier and the servo amplifier, if provided.

• Heat sink cooling fins.

Use factory air and a vacuum cleaner to clean the servo and spindle amplifiers.

GFK-1046F Chapter 5 Preventive Maintenance 5 - 3

5

Maintenance for Drives in a Wet Environment

Test EquipmentUse a 250-volt DC battery-operated insulation tester. The tester may have higher voltagesavailable, but it must be able to limit to 250 volts.

Motor Inspection and MaintenanceInitially, the following checks should be performed weekly until a pattern of change is established,and a different test period can be determined.

1. Verify that all machine guards, shields, etc., are in place to keep coolant off the motor. If theyare not in place, replace the guards and shields.

2. Inspect and clean the motor using factory air, a clean dry cloth, and/or a wet/dry vacuum.

3. Check all motor cables that flex during operation for damage to the insulation and also fordamage at the connection points.

4. Most spindle motors and some servo motors have fans. Inspect and clean the fans if necessary.Be sure they are running – if not, replace them.

5. Check and clean the four ventilation openings of the spindle motor.

Test ProcedureTest the motor insulation using the 250-volt DC tester. This test can be done without disconnectingthe motor from the amplifier. This assumes a good connection from the amplifier to the motor.

1. Servos: Turn off power to the servo amplifier.

2. Spindles: Turn off power to the spindle amplifier.

3. Connect the tester between one of the motor leads and ground at the amplifier.

4. Activate the tester to read the insulation resistance.

NoteFor spindle motors, a reading of 0.5 megohm may be normal because there maybe a relatively low resistance path to ground through the amplifier. If so,disconnect the motor leads from the amplifier, and perform the tests using themotor leads rather than the terminal.


5

Table 5 - 1. Insulation Resistance Readings

Reading Description

Infinity Excellent insulation. No effect from coolant. Inspection period may be lengthened.

< infinity but > 20 megohms Good insulation; however, the insulation has been affected, probably by coolant.Continue to monitor until a pattern is established.

< 20 megohms Insulation is deteriorating and should be monitored closely. Continue to check weekly.

_1 megohm Insulation system has failed. Determine the source by disconnecting the motor powerplug or leads and checking the motor directly. If the motor resistance is low, replace themotor. If the motor resistance is not low, check the plug or terminal box. If the plug orbox is wet, dry it out, retest, and take action to prevent liquid from entering the plug orbox.

NoteAny subsequent reduction of insulation resistance will give advance notice of apossible motor failure. The motor may function to zero ohms as long as it is theonly motor on the system with low ohms; but such operation is not recommended.

Servo or Spindle AmplifiersMost modules have cooling fans. Be sure the fans are running – if not, replace. Inspect and cleanas necessary. Check and clean these items every six months, or more often if contamination hasbuilt up. Carefully clean using factory air, a vacuum cleaner, and/or cleaning solvent and a clean,dry cloth.

• The cooling fan for the spindle amplifier and for the servo amplifier, if provided.

• The heat sink cooling fins.

If coolant is on the amplifier, check the enclosure seal for defects that are allowing coolant into theenclosure. Possible defects might include missing or deformed gaskets or missing filters. Corrector replace the missing or deformed items.

If there is coolant on the electronic boards, carefully remove the coolant. The contaminants maydamage components and/or cause shorts on the boards.

Modification to the Motor

α Series servo motors have a part number format of A06B-xxxx-xxxx#xxyy. If the last twocharacters (yy in the above format) are 75 or 76, it means the motor has a sealing rating of IP67.

IP67 servo motors, changing the encoder or encoder connector direction will disturb the materialsused to provide additional protection. In the case of the end cap, a liquid seal material equivalent toThree Bond #1215 is used. The encoder connector has a flourorubber-type gasket between it andthe encoder cover.

New materials should be applied to cleaned surfaces in order to attempt to regain the originalproduction integrity. However, this cannot be verified unless the motor is subjected to tests similarto the ones defined by IEC for the appropriate protection level.

Index

GFK-1046F Index-1

AAir-Over Fan, 3-3

CCable Connectors, 1-2Cables, Severe Duty, 2-3, 2-4Connectors, Cable, 1-2Coolant and its effect on a motor, 3-3

DDrains, 3-3

EExposure to Liquids, 2-5

FFans, 3-3

IIEC Standards, 1-3, 3-2IEC Standards for Servo Motors, 1-4IEC Standards for Spindle Motors, 1-4Insulation Resistance Readings, 5-4

LLiquids, Exposure to, 2-5

MMachine Runoff Checklist, 4-1Maintenance, Preventive, 5-1

For drives in a normal environment, 5-2For drives in a wet environment, 5-3

Mold System, 3-2Motor Modification, 5-4MS Connector Kits Supplied by GE Fanuc, 2-2

OOil Seals, 1-1

PPressurization, 3-3Preventive Maintenance, 5-1Protection Standards, 1-3

SSeals, Oil, 1-1Severe Duty Cables, 2-3, 2-4Standards, Protection, 1-3

GE Fanuc Automation North America, Inc., Charlottesville Virginia

ge fanuc automation · 1 - 4 servo and spindle motors exposed to liquids - july 2000 gfk-1046f 1...

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