Yasnac Mx-3 Fault Finding Guide

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GENERAL-CNC-INFORMATION
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General CNC Information
When a machine tool continually over travels when attempting zero return, make sure the overt ravel switch is not being made before the zero return function is finished. On most machines, when reference returning, the decel dog makes the switch, the machine decels and continues at this low feed rate until the switch drops off of the back of the decel dog. At this exact instant the control commands a one revolution of the motor. after the one rev it looks for the marker. One revolution on most machines equals about .200" of axis movement. So, if the over travel switch is closer to the back side of the decel dog than .200" it may be engaged while the control is trying to find the marker. Unless you are very confident of the travel limits of the machine you should move the decel dog a little in the negative direction rather than moving the over travel dog. But either one will have the desired effect. When working with 50 Hz inductive devices the voltage tolerance is 20% of the rated value. When 60 Hz it is 10%. Normally, double arm tool changers don't use a G30. The Z axis stays put while the arm moves up and down. Therefore the machines home position is the tool change position. Also on double arm tool changers, when the arm is in the up position the spring loaded grippers can be pushed in easily. When the arm is in the down position the locking pins go up which locks the fingers in on the tool holder. This prevents the tool from being thrown. On most cylindrical grinders the table traversing left to right is done by mechanical means. The lever in the center of the travel is connected by a shaft to a directional valve so that when the lever is moved either by hand or by contact with the travel dog it switches the valve which changes direction. Normally, there will be limit switches which are actuated by a cam on the lever. These switches have nothing to do with the table traversing. What they do is cause the wheel to move in by the selected amount each time the table reaches the end of travel in each direction. On a Leadwell MCV-1300S, the standby tool is stored in Diagnostic 382. This number can be seen to change as the tool positions are counted. They will change only during an Automatic Tool Change not when magazine is jogged. Diagnostic 387 records when tool position 1 is up. It should always be a 1. Diagnostic 380 is the ATC capacity. If the tool number becomes confused: 1. Manually move the magazine to tool position 1. 2. Set Diagnostic 382 to 1. 3. Set Diagnostic 387 to 1. 4. Make sure Diagnostic 380 reflects the correct capacity.
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5. Do a tool change in MDI to check operation. When setting the tool capacity, you must insert a whole number in BCD. In the case of the MCV-1300S, the tool capacity is 30 tools. So Diagnostic 380 must be 00110000. In true BCD, it would look like 0011 0000. Remember BCD works this way: 8421 8421 0011 0000 =3 =0 There is an instruction in the Ladder rung for M06 which checks Diagnostic 380. This instruction (LEC1) (R551.2) checks the tool number called against D380 (Tool Capacity). If the tool called is higher than D380(i.e, M06 T31), M06 will not execute. There will be no alarm, the M Code simply will not execute. If the contents of D380 is higher than the actual capacity, the result will be tool confusion. Setting D380 to a very high number will cause the magazine to continually rotate when a tool is called. Another symptom of a D380 incorrect setting is that if a number lower than the tool capacity but higher than the current tool is input, any tool number lower than the current tool or the magazine capacity can be called but nothing higher.
RS232 Pin outs: 9 Pin 1 2 Receive Data (RD) 3 Transmit Data (TD) 4 5 Signal Ground (SG) 7 8 15 Pin 1 Signal Ground (SG) 6 Transmit Data (TD) 7 Receive Data (RD) 11 Request to Send (RTS) 12 Clear to Send (CTS) 13 Data Set Ready (DSR) 14 Data Terminal Ready (DTR) 25 Pin 2 Transmit Data (TD) 3 Receive Data (RD) 4 Request to Send (RTS) 5 Clear to Send (CTS) 6 Data Set Ready (DSR) 7 Signal Ground (SG) 8 Data Carrier Detect (DCD) 20 Data Terminal Ready (DTR)
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15 Pin Male 1 oooooooo ooooooo 15 15 Pin Female 1 oooooooo ooooooo 15 25 Pin Male 1 ooooooooooooo oooooooooooo 25 25 Pin Female 1 ooooooooooooo oooooooooooo 25
9 Pin Male 1 ooooo oooo 9 9 Pin Female 1 ooooo oooo 9
50 pin Honda 18 50
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32
19 1 33 This is looking at the pins, the notch is at the top. Jumper requirements for RS232 on most controls. 9 Pin 7-8 6-1-4 15 Pin 13-14 11-12 (In some cases) 25 Pin 4-5 6-8-20 Pin 25 on Fanuc controls is 24vdc. If 440 volts is applied to a Bridgeport Series 1 CNC when it is wired for 220 volts, the most likely result is that the ACC board will be damaged. The Bridgeport Boss controls use open loop stepper motors. Mounted to the side door of the electrics cabinet are four nearly identical boards. Three are the X, Y and Z axis drives. The fourth is the ACC board. The final amp stage for the axes is mounted to the large heat sink. Their are four for each axis. Most parts for these controls are only available through Electrical South. 800-950-9550. Whenever working with a machine that is in a not ready state or the axes are inhibited or interlock for a reason that is difficult to discern, make sure that the ATC or tool turret, as the case may be, is ready. All machines require that the tool changing mechanism is ready before the machine can be ready. In the case of a machining center, be sure the tool pot is horizontal. In the case of a turning center, be sure the turret is clamped. LeBlond Makino does not use the Fanuc built in PMC, it builds it's own. In most cases the components are Fuji Electric. So if you try to access the Ladder, you may not be able to by normal Fanuc means. You will usually need to consult the Makino manual for the proper operation. On a Makino FNC74, if you have problems with the tool changer, check the solenoids on the side of the machine. Solenoids 70, 71, 74 and 75 should have the A side turned on when the tool changer is at home. If they are not, the ATC is not ready. If any of them are on B you must: 1. Electrically (by switching the coil wires at the solenoid) shift the valve to A. If solenoid 75 is on B, do it first.
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2. While keeping the valve switched (holding the wire) press the E-Stop. 3. Release the E-Stop. 4. Shift the next one. If 74 is on B, do it after 75. 5. Repeat the E-Stop procedure as above. 6. Do the remaining valves which require being careful to note the function of the valve before you switch it to prevent slamming one part of the tool changer into another. 7. Cycle power on the control. SOL 75 = Pot Horizontal SOL 71 = Arm In SOL 70 = Arm 60 Degrees SOL 74 is somehow related to the tool pot horizontal function. If a machine leaves a bump at the quadrants during circular interpolation, the control is probably overcompensating for backlash. On most EDM machines trying to discharge without polarity selected causes the generator power to shut down. In most cases, polarity is selected by pulling in a contactor. On all machines Feed Hold is disabled when in Rigid Tapping mode. To find the feed rate needed for the G84 line, divide the desired pitch into 1. If the turret on a Yam CK-2, when commanded to index, indexes then clamps then unclamps on it's own, check the turret clamp/unclamp confirmation switches. In this case one of them is normally stuck. if the machine has a Fanuc 0 control check Diagnostic bits 2.5 and 2.6. They should never both be 1 at the same time or 0 at the same time. HURCO AUTOBEND7 Amplifier Balancing Procedure for V1.10 PLC Software: 1. Press the MODE key. 2. Enter a number which is one greater than the last visible selection in the mode menu. (i.e. If the menu has 9 selections, enter 10.) 3. Press ENTER. 4. The message "Press RUN button" will be displayed. 5. Press RUN. 6. The balance menu will be displayed. Only one servo axis will be active at one time.
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7. To select different axes, pres UP or DOWN arrows. 8. The PLUS and MINUS keys are used to select the DAC output value. 9. The balance menu will display: - The axis number - Zero, positive, or negative DAC output voltage - Position change value 10. The first screen will be for ZERO DAC output voltage. Adjust the balance pot on the servo amp until the delta value displayed is zero. 11. Press the UP arrow button to change to negative DAC output voltage. Check the delta value displayed. 12. Press the UP arrow button to change to positive DAC output voltage. Check the delta value displayed. 13. Compare the negative and positive DAC output voltage. This value should be close. 14. Press the MODE key to exit the amp balance screen. To access the Hurco Autobend 7 Parameter screen: 1. Press the MODE button. 2. Press the 0 button then the ENTER ADV button. 3. Enter 14753 then the ENTER ADV button. ( The word ACCESS appears under the Hurco logo.) 4. Press 6 (Configuration Menu) then ENTER ADV button. ( Configuration Menu is now displayed.) 5. Select Axis Configuration Menu. ( Move orange cursor to selection using green arrow keys.) 6. Press ENTER ADV button. 7. Make changes to Parameters as necessary. - Move cursor left and right using (+) and (-) buttons. - Move cursor up and down using green arrow buttons. - Once cursor is over field to be changed, press ENTER ADV button. - The number moves to bottom of screen. - Change number to new value. - Press ENTER ADV button. - The number returns to original location. 8. Press BACK button. * Only after all necessary changes have been made. New menu is now displayed. 9. Select "Save and Exit" then press ENTER ADV button. (Move orange cursor with green arrow buttons.) 10. Turn off power, wait 30 seconds, turn power back on.
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On a Hurco control, every time it turns on all necessary data is loaded from the Flash Eprom to RAM. If you replace the Main board, you must take the blank eprom from the new board and replace it with the one from the old board. Before you do this you should do a Master Save to be sure everything in RAM is stored to the EPROM. A Master Clear will erase everything from RAM but will not affect the EPROM. This is sometimes helpful in solving problems. If you have some strange problems you can try doing a Master Clear then disconnect the backup battery from the Main Board with a piece of paper between the battery and the contacts for about two minutes with the power off. Then remove the paper and turn the power back on. If you have a Golden Sun Rotary Table that misindexes intermittently, remove the drive motor and check the gear pulley. The gear is a taper lock with six bolts. They can come loose allowing the table to misindex. If you remove the encoder to check it you must put it back with the coupler in the same orientation. It can go back one of two ways. Either correctly or 180 degrees out. If it is 180 degrees out, the table will zero return one degree from where it would otherwise. On a 15" Colchester lathe, the brake is a caliper type. It is: Matrix Engineering 1CD040-03 C15993 For problems with RS-232, especially in one direction only suspect pin 2 or 3 wiring problem depending on which direction the problem is in. If the problem is in both directions suspect pin 7 of the 25 pin connector or pin 5 of the 9 pin connector. A poor connection will cause a situation where data can be transferred at a slow baud rate but not at a higher one. On a Kia KIT30A you have to push the Standby button for the hydraulics to come on and make the machine ready. If the machine hits a hard limit switch, you must hold in the Standby button. With servo systems a motor running at a constant speed will have an equal number of command pulses and feedback pulses. Proximity switches: RED--------- 24vdc ---------BROWN BLACK------- GND ---------BLUE WHITE-------OUTPUT----------BLACK In most cases a three wire proximity switch can be replaced with a two wire (BROWN,BLUE). The Manual/Absolute signal determines whether or not the control adds travel performed manually to the Absolute coordinate. The cable supplied by SWI for the Haas indexer pins out this way. Pins 1 and 2 go to the pins for Cycle Start. Pins 3 and 4 go to the pins for Finish Signal. Pin outs for a Yuasa SUDX Indexer: # Wire Color Signal
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2 Black +24vdc __________ ________ Internal Relay 3 Green M-Code Start ____| 4 Red/White +24vdc 5 Orange M-Code Finish #1 6 White +24vdc 7 Blue M-Code Finish #2 8 Orange/Black Emergency Stop 9 Clear Do Not Use 10 Red/Black _____ _________ Feed Hold (N.O.) 11 White/Black _____| 12 Black/White _____ _________ Remote Home (M-Code or other circuit)(N.C.) 13 Blue/White _____| When a Yuasa indexer is connected to a SWI control, parameter i32 should be set to 1:0. This sets the indexer up for no handshake. Fanuc, GE Fanuc and General Numeric controls are basically the same in terms of parts, manuals, etc. For example, a GN0 is the same control as a Fanuc 0. The manual for this machine would be a part number GN61404E for General Numeric and B61404E for a Fanuc and GFZ61404E for a GE Fanuc. The Mori Seiki MH63 has a door switch on the NC cabinet. If this switch is not made, the NC will not turn on. If an axis of this machine has a jerky movement, it could be the scale but always first check the amount of backlash in the axis. Particularly with the Y axis which is moving a great deal of weight. The Y axis of a horizontal machining center carries not only it's own weight but the Z axis and the spindle. Excessive backlash in the system can cause a stick/slip condition especially on an older machine where the ways may be worn in the middle of the travel but like new at the ends. Mori-Seiki vertical machines typically use a Yasnac MX2 or MX3 control. To search for an address in the Diagnostic pages: 1.Press the DGN button. 2.Enter the address (i.e. 1872). As with a Fanuc control, the address you type will be displayed in the lower left corner of the screen. 3.Press the Cursor Down button. On a Mori-Seiki MV-65 it is normal after turning on the NC power to see the alarm 310:SERVO OFF. To clear this alarm, press the NC power on button again. When reading the hard copy of the ladder on a Yasnac MX2, the decimal point is omitted from the addresses. So 1872.4 would be written as #18724 The MV-65 uses NC driver boards to operate solenoids etc. These are Mori boards that have an MR connector from the control. It has two edge card connectors that contain the power to feed the loads, normally 24vdc as well as the wires going to the loads. The boards are just small relay boards. The tool clamp/unclamp for this machine is air over oil. It uses four air valves. It has two oil filled cylinders, one mounted horizontally the other mounted vertically. The one mounted vertically is a long aluminum cylinder. It has a plastic line on the outside that runs from top to bottom and indicates the oil level in the cylinder. It also has a switch in the bottom, I think is for detection of oil level. As far as the switches related to the drawbar clamp and unclamp there are three. The switch at the top of the unit indicates
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when the tool is clamped or unclamped. It is made when the tool is clamped. It is pressed in by the small inner cylinder. It is LS18, the address is #1024.2, it's name is TOOL CLAMP DETECTION. The large outer cylinder has two switches associated with it. The upper switch is LS25, the address is #1024.6 it's name is BELLVILLE SPRING FLEX. It should be made when the tool is clamped. The lower switch is LS24, the address is #1024.7, it's name is BELLVILLE SPRING RETURN. The manual clamping switch is address #1024.0, wire numbers are 180 and 24NC. The manual unclamping switch is address #1024.1, wire numbers are 181 and 24NC. This machine uses three driver boards. They are identical. They are basically small relay boards. At the top of each board there is a Honda 16 pin MR connector that appears to be connected to the NC I/O board. This connector is designated CN1. There are also two eight pin edge board connectors at the bottom of the board. One is CN2, the other is CN3. Each board also has ten LEDs from the top of the board to the bottom. These LEDs correspond to the ten relays on the board. The board farthest to the right controls 24 vdc outputs. The two boards to the left of this board control 220 vac outputs. The DC board pins out like this: CN2 1 2 3 | | | | | | | | N24 U23 4 5 6 7 8 | | | | | | | | U24 U25 N24 U30 U31
CN3 1 2 3 | | | | | | | | N24 N32 4 5 6 7 8 | | | | | | | | U33 U27 N24
N24
N24 is the 24 vdc power feed, P24 is the return. It originates from a small power supply to the right of the driver boards. The input to the power supply is 220 volts on wires R11 and S11. The output of the power supply is 24vdc on wires P24 and N24. There is a terminal strip behind the driver boards that contains a number of supply wires such as P24, N24, 24NC and 0NC. The boards to the left of this one are wired the same except that they control AC loads so that N24 is replaced with R11. There are three servo amplifiers. Each one has a seven segment LED as well as three green LEDs from the top of the drive to the bottom. The spindle amplifier is a Yasnac (Yaskawa) Varispeed 626 MTII. The NC is mounted to the left door. It has three boards. The top board is the CPU. It has a three volt Lithium battery for memory backup. The middle board is the I/O board. The bottom board is the SERVO board. This machine has a geared head. The cylinder used for shifting gears is mounted vertically. It has three switches that are activated by the rod end to indicate gear selection.
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If you have electrical problems, check the condition of all of the N24 and P24 wires. The Ladder cannot be monitored on the Yasnac MX2 control. For troubleshooting ATC problems on the MV-65 there is a manual ATC mode. To enter this mode there is a MANUAL ATC button that must be pressed. The button is behind a door on the right hand side of the Operators Panel cabinet Also behind this cover is the Over travel Release, the RS-232 port and the 110 VAC outlet. Once the Manual ATC button is pressed, the machine enters the EDIT mode and the ERROR lamp starts flashing. Press the ALM button, the ATC MANUAL screen is displayed. The screen looks like this: ATC MANUAL 1. POT UP 2. POT DOWN 3. ARM FORWARD 4. ARM REVERSE Now you can perform these four functions by pressing buttons that are redesignated for that function while in the Manual ATC mode. If you look closely at the buttons for things like Single Block Coolant On and Off, Block Skip, etc., you will find that there are small numbers in the right hand corner. When working in screens like ATC Manual, these numbers operate the function listed beside the number. For example, if while in the Manual ATC mode, you press the Single Block button which has a 1 on it, the pot will go up. Pressing the Coolant On button which has a 2 on it, the pot will go down. Pressing the Coolant Off button which has a 4 on it will make the ATC arm rotate in reverse. When you are finished with the ATC Manual mode you have to push the button again to turn it off. If you don't do this and you cycle power, the control will remember and issue an alarm. When the ATC is at home, Diagnostics 7408, 7409,7410 and 7413 will be 0. If you get alarm ALM140 TOOL DATA NOT EQUAL or ALM240 EMPTY POT NOT FOUND, take the tool out of the spindle, put it in the correct pot. Then set the spindle tool number in the Tool Registration to 0. The pot up/down on the MV-65 with a 30 tool magazine is done with a pneumatic cylinder. The cylinder is located behind the tool pot which is in the standby position. It is mounted vertically. The pot up limit switch is mounted to the left of and just above the standby pot position. The pot down limit switch is mounted directly behind the tool pot. The cylinder is controlled by a two way valve which is located in an enclosure to the left of the magazine. The A port of the valve moves the cylinder down, the B port moves it up. This valve has a manual override for each port. There is a regulator in each of the lines coming from the ports. They are located in the enclosure with the valve. The overrides are the slotted screw type. They are labeled OFF and ON. If the slot is horizontal the valve is manually ON. If the slot is vertical the valve is controlled by the electrical signal. The electrical signal for the A side of the valve is on wires P24 and U25. The B side is P24 and U24. The voltage is 24 vdc.
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The magazine is rotated by an electric gear motor. The magazine is locked with a pneumatic cylinder. The cylinder has a roller on the end of the shaft that rides on a cam plate that is mounted on the drive sprocket. There is also a proximity switch mounted two tool pots to the left of the standby pot position. It counts the tool pots by picking up on the pot itself. There is a manual switch for rotating the magazine in both directions. The switches are mounted on the cover of the enclosure mentioned above. The switch to the left is for clockwise rotation while the one to the right is for counter-clock wise rotation. The wire numbers for the CW are MGCW and 24NC. The numbers for the CCW button are MGCCW and 24NC. When troubleshooting problems where feedback seems to fail intermittently can be traced to moisture inside an encoder. In addition, the moisture can become a vapor under certain conditions causing reading problems that seem to occur only when ambient temperatures are high or may take the form of a problem which occurs and seems to go away after the machine sits for awhile. Chen Ho MCV-2300 I/O: INPUTS FUNCTION Low Gear High Gear Tool Release Tool Hold Tool Counter Arm Up Arm Down Pot Up Pot Down Manual Magazine Rotation X+OT XDEC X-OT 4th Axis Clamp Foot Switch Z+OT Z-OT ZDEC YDEC Y+OT Y-OT Chip Conveyor Optional Stop Coolant Key Switch Dry Run Man/Abs Machine Lock Override Cancel Single Block Block Delete ZNG (Z Axis Neglect) Cycle Start Feed Hold +Jog
ADDRESS X4A X4B X4C X4D X50 X51 X52 X4 X2E X48 X28 X18 X20 X53 X46 X2A X22 X1A X19 X29 X21 X42 X43 X44 X45 X3C X3D X40 X35 X38 X39 X3A X24 X25 X26
CONNECTOR CMD21-34 CMD21-2 CMD21-20 CMD21-35 CMD21-26 CMD21-42 CMD21-10 CMD12-5 CMD12-14 CMD22-1 CMD12-12 CMD12-24 CMD12-47 CMD22-27 CMD22-38 CMD12-45 CMD12-32 CMD12-7 CMD12-39 CMD12-29 CMD12-15 CMD22-22 CMD22-37 CMD22-5 CMD22-23 CMD11-2 CMD11-9 CMD22-36 CMD11-5 CMD11-14 CMD11-1 CMD11-8 CMD12-16 CMD12-49 CMD12-17
WIRE# 135 136 137 138 139 140 141 142 143 121 125 126 127 150 128 129 130 131 132 133 134 93 94 95 96 89 90 91 84 85 86 87 78 79 80
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-Jog Auto Reference Program Restart Spindle Start Spindle Stop X (Handle) Y (Handle) Z (Handle) 4 (Handle) Handle Multiplier (X1,X10,X100) Memory Mode Tape Mode MDI Mode Jog Mode Rapid Mode Handle Mode Reference Mode
X30 X33 X34 X16 X17 X1F X2C X2D X2F X1D X1E X5 X6 X7 X8 X31 X9 XB
CMD11-10 CMD11-11 CMD11-18 CMD12-28 CMD12-44 CMD12-9 CMD12-30 CMD12-46 CMD12-31 CMD12-8 CMD12-41 CMD12-23 CMD12-38 CMD12-6 CMD12-1 CMD11-17 CMD12-19 CMD12-2
81 82 83 70 71 74 75 76 77 72 73 51 52 53 54 55 56 57
OUTPUTS FUNCTION CR1 (Chip Conveyor) CR2 (Hydraulic Pump) CR3 (High Speed) CR4 (Coolant) CR5 (Sleep Switch) CR6 (Low Gear) CR7 (High Gear) CR8 (Tool Release) CR9 (Air Blow) CR10 (Taper Air Solenoid) CR11 (Magazine Rotation) CR12 (Arm 70 Degrees) CR13 (Arm Down) CR14 (Arm Up) CR15 (Arm 180 Degrees) CR16 (Z Axis Brake) CR19 (Pot Down) CR20 (Track Lube)
ADDRESS Y1A Y0 Y1 Y2 Y3 Y5 Y6 Y7 Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17 Y22 Y9
CONNECTOR CFD13-7 CFD13-36 CFD13-4 CFD13-22 CFD13-37 CFD13-23 CFD13-38 CFD13-6 CFD13-26 CFD13-42 CFD13-10 CFD13-27 CFD13-43 CFD13-11 CFD13-28 CFD13-44 CFD13-32 CFD13-19
WIRE# 1 2 3 4 5 6 7 8
13 14 15 16 50 23
The E-Stop button is in series with the Sleep Switch relay (CR5). Solenoids on MCV-2300: SOL1 SOL2 SOL3 SOL4 SOL6 SOL7 SOL8 SOL9 SOL10 Low Gear High Gear Tool Release Air Blow Magazine Rotation Arm 70 Degrees Arm Down Arm Up Arm 180 Degrees
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For machines in general if you have trouble with leaving chatter marks or other poor finishes make sure the gibs are not too loose because loose gibs WILL cause this problem. If you have a machine that the tool gets stuck in the spindle, check the temperature rise of the spindle. Thermal expansion will cause the tools to sometimes stick. On the Chevalier 2040MV with Fanuc 0-MD control, if reference return is commanded on the X axis while the dog is on the switch, the axis will move in the plus direction until it comes off of the switch then it will reference return The X axis decel switch for this machine is SQ3. The wires on the normally closed switch are +24 and 97. The cable pin out in the case of a Fanuc 0-MD control is M201 pin 38 of the I/O board. The diagnostic bit is 16.5, it should be 1 when the dog is not on the switch. For repair of Mitsubishi, Mazak and Yaskawa motors contact Driesilker in Illinois at 630-469-7510. On a Kiwa KNH-426X, if you get alarm 1300 NO PALLET SITTING CONFIRMATION when the machine tries to execute it's warm-up program, check the value of timer number 38 (No.38) in the case of an 18i control. On the TIMER page this is No.38 T72. The value is in milliseconds. The machine may come from the factory with this timer set for 1000 (1 second). This time is sometimes too short to allow the air pressure switch to be activated. The switch is PS5. It's bit is X6.6, symbol is PSPLSA. This bit is made high by relay CR28 being energized. CR28 is energized when 24vdc is applied to it's coil through PS5. The timer box is on the rung with the alarm, it is: SUB 3 TMR 38 The air supplied to this machine should normally be between .5 and .55 Mpa. Also, on this Kiwa, if the spindle will not start and coolant pumps one, two and three will not start but there are no alarms, check the door that is between the ATC and the spindle. If this door is not fully closed so that the proxomity switch is made, the spindle and the pumps will not start but no alarms will be generated.
Bridgeport Interact 412 with Heidenhain TNC 2500 control: If either the X axis or Y axis faults, it is possible that when the servos cut out and before the Z axis brake can engage, the head can drop a little causing a GROSS POSITIONING ERROR alarm instead of the X or Y DRIVE FAULT alarm. The way to prevent this is to block the head so it can not drop. Anytime one of the motors moves without being commanded to do so will generate the GROSS POSITIONING ERROR alarm. The AXIS FAULT alarm can be either the motor or the servo card. The drivers used on this machine are made by Bosch. It is a conventional system which consists of a chassis with a power supply card and three axis drive cards. The axis cards are identical and can be slid in and out of the chassis without removing connectors. These cards have the usual potentiometers such as Tach and Offset adjustments. The motors are DC with a permanent magnet field.
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They have encoders attached to the back and a tach. The motors are made by SEM. The type is MT30M4-24. The output from the drive cards go to the main board of the chassis before going to the motors. At the upper left hand corner of this board there are six wires (two for each motor) where the output of the board can be checked. From here one of the leads goes through a choke then to the motor. There are also three connectors at the bottom of the main board which correspond to the three drives. these connectors are the tach and encoder wires. These connectors can be unplugged and swapped with one another for testing. The encoders model number for X and Y are ERO 115-200. For Z it is ERO 115125. The first number (115) is the series of encoder. The second number (125 or 200) is the Line count. Machine Parameter 330.0, 330.1 and 330.2 for X,Y and Z tells the control what the line count is, that is, it works with the ball screw pitch parameter to measure correctly. If at some point you have to use a motor with the wrong encoder line count you can try changing this parameter to make it measure properly. The access code to get into the Machine Parameters is 95148. On a machine with a DC motor driven axis, roughness can be caused by either a commutator problem or grounded armature. This can cause a loud growling that sounds a lot like a thrust bearing problem. On a Heidenhain TNC2500 control you can check for an IN-POSITION problem by using the LAG display. You have to set parameter 1390 from 0 to 1 in order to see the true lag, be sure to set it back when you are done. You check the same way you would any other lag display, when moving at a fairly high programmed feed rate and look for it to level off and remain constant. Also needs to be the same in both directions of axis travel. When the axis is at rest, should be as close to zero as possible and not moving around. Another thing is for any axes that perform linear interpolation together such as X and Y to have the same lag value. On a Heidenhain TNC124 the alarm GROSS POSITIONING ERROR means that the value set in machine parameter 1720 (MP1720) has been exceeded. When setting this parameter it is recommended to use the value of the Lag for the axis during rapid multiplied by 1.4 but will often be set considerably higher by the OEM. MP1720 is a bit parameter, 1720.0 for first axis, 1720.1 for second axis, etc Some Heidenhain controls use Position Coded Reference Marks on the scales. These allow the machine to know where an axis is by moving just far enough, usually an inch or two, to find the nearest coded mark. This is the normal Reference Return procedure for some machines with Heidenhain controls. When reference return is commanded the axis will move just a little until it finds the mark then position itself based on that mark. This way no battery is required as in the case of rotary absolute encoders. Dainichi with Fanuc 10T control: When cycle start is commanded, message START REJECTED is displayed. Rapids are not available, the machine acts as though the axes have not been reference returned even though the ZRN lights turn on after homing. Also, the buzzer that should beep during boot up does not beep. Check for a break in the connection of N24. The machine will act like the command to cycle start is being sent form the PLC to the NC but the NC is not executing.
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For spindle orientation problems on machines using a magnetic sensor check the file FANUC.TXT
Mori-Seiki MH-63 It uses four I/O modules that plug into a backplane along with a controller module and a power supply. The first two modules from the left are output modules. They are Fanuc OD24A 24 vdc modules. Each has two 50 pin Honda connectors. The Fanuc designation for the ports are C21A and C21B. The Mori designations are C007 and C008 respectively. The second module is C005 and C006 on C21A and C21B. The input modules are ID24A. The first module has C003 and C004 on ports C20A and C20B. The last module has C001 and C002 on ports C20A and C20B. Next on the rack is the rack controller IF01A. It plugs into the backplane like the other modules and has only one cable COP4. This is a fibre optic cable that goes to port COP2 of the main board. COP1 of the main board goes to COP3 of the CRT/MDI. The last module on the rack is the power supply. It has no connectors but there are four terminals on the rack itself. They are from top to bottom ALC, ALC, 24NC and 0NC. If the lights on the operator's panel don't work check the cables and connectors of C003 and C004. The schematic shows a C208 but I have not been able to find it on the machine.
Mori-Seiki MV Junior with Yasnac MX2 control: If you get a 391, 392 or 393 TG/OC/OV ERROR for X, Y or Z axis respectively, check the servo amplifier for the axis. One of the LED's will be on, either OV, OC or TG. There is also an LED for FUSE and one for OL. The TG LED indicates a problem with the Tachogenerator. Normally the alarm 310 SERVO OFF will be displayed along with the other alarm. Servo tuning on these drives is done by adjusting pots on the top board. One of these pots, 16VR, sets the trip level for the above alarm. Setting this pot to the minimum (fully CCW) will cause the alarm to trip as soon as the servo power comes on. The LEDs are all red. TG LED: Check the in-position signal. On the Yasnac MX2 control this is done by going to the position screen and scrolling down to the proper screen. Also check the power supply voltages at the drive(+5,+12,+15,-15,+24). All of these voltages are supplied by a single power supply and all can be adjusted separately by potentiometers on the front of the power supply. The tachogenerator operates off of the 5 volt power. You can monitor the tacho input to the drive at TG-M. This is the TG MONITOR. The signal is referenced to ground. The output of the tach is 7 vdc per 1000 rpm +/-15%. As far as adjusting pots, you can try turning IN-ADJ(2VR) one notch counterclockwise. Also, try L-GAIN(4VR). Be careful adjusting the IN-ADJ pot since it is very sensitive, one notch too far can cause the axis to fault or to oscillate violently. Oscillation is normally associated with moving the pot CW. There is a pot to the right of this pot (FINE) which is a fine adjustment for IN-ADJ. Also, adjusting the IN-ADJ pot can cause the TG fault to be generated. It is important to note that very slight changes in just some of the potentiometers can cause what looks like serious servo problems. Another point of interest is that having the L-GAIN and/or IN-ADJ pot out of adjustment can cause the 341 (in the case of the X axis) but if the one of the pots is moved a little further, the alarm will change to 391 with the TG indicator coming on. If you suspect that the pots have been moved it may or may not help to set them back to their original positions (paint mark) but it's a good place to start. What usually works better is to set all of the pots the
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same as an axis that is working properly. This is especially true if you are working on the X or Y axis of a vertical mill because these two axes should need virtually identical settings. When setting the pots this way, pay attention to the dial marks of the pot. There are two dots on one end of the screw slot, make sure this end of the pot is in the same position as the go-by. Once you get close, you can use the IN-ADJ, FINE and L-GAIN to dial it in. The best way to do this is to set the thumbwheel switch to position 4 (TEST). When set to this position, go to the POSITION page of the CRT. Keep pressing the PAGE DOWN button until the ERROR PULSE screen is displayed. When you move the X and Y axes at the same feed rate, you should get the same value on both. If you don't, adjust IN-ADJ and/or FINE until you do. This is particularly useful when you have an axis that runs fine at 25% or 50% rapid but not at 100% rapid without generating either alarm 391 or 341 (for X axis). In most cases if you go to the ERROR PULSE screen and set it the same as a good axis, when you get finished you will usually be in good shape. Initially you may have to make the adjustments while in 25% or 50% rapid. Also, if the ERROR PULSE display of an axis is very far from zero while at rest you can bring it to zero with the ZERO pot. For vibration or oscillation of an axis at certain feed rates you can try adjusting 6VR C.FRQ-ADJ, this changes the carrier frequency to avoid noise and roughness caused by resonance. For service issues on Yasnac controls call 1-800-YASKAWA To change parameters on the Yasnac MX2 you must set the thumbwheel switch to 1. It is normally set to 0. The thumbwheel switch is just below the control in the electrics cabinet. Once the switch is set cursor to the parameter you want to change, type the value you want then press the WR button. Setting the thumbwheel switch to some of it's other positions will allow access to other screens of the control not normally seen when the switch is in position 0. If the tachometer leads are reversed the axis will runaway when servo power comes on.
The drives, motors and feedback units are all Yaskawa. The motors are DC. The feedback unit consists of an encoder and a tachogenerator. Complete loss of feedback such as the feedback unit being disconnected will cause the axis to runaway, usually in the positive direction, as soon as servo power comes on. If you replace one of the units, you have to orient it the same as the old one to keep it from over traveling at zero return. This can be done by positioning the set screw that holds the optical disk on the same as the old one. To access the leads to the tachogenerator, remove the cover on the very back of the motor by removing the two small screws. Motor: Yaskawa Hicup Motor UGHMED-06-MC13 Drive: Yaskawa Servopack CPCR-MR085K2 Feedback Unit Yaskawa
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Feedback Unit TFUE-25ZD7 Parameter 6280 sets the X Axis Rapid Feed rate, 6281 sets Y, 6282 for Z. Yasnac controls are made by Yaskawa. When working on servo problems, there is a RESET button on the Servo pack so you don't have to keep cycling power to clear faults. The following list is the potentiometers of the Yasnac Servo pack CPCR-MR085K2 servo amplifier and what I know about them: 1VR Auxiliary Input Adjustment Adjusts speed reference and motor characteristics when auxiliary input 2CN (1) 2CN(2) is used. Turning 1VR CW increases speed. If the auxiliary input is not used turn 1VR fully CCW. 2VR IN-ADJ Motor Speed Adjustment Adjusts speed reference and motor characteristics when speed reference is supplied to 1CN(7) and 1CN(13). Turning 2VR CW increases motor speed. Check this signal at terminals IN-M and TG-M. 3VR ZERO ADJ Zero Drift Adjustment Adjust this to keep the motor from turning when the speed reference is 0V. Turning the pot CW allows the motor to be finely adjusted in normal rotation and CCW in reverse rotation. Observe the rotation of the motor until it is at standstill when reference is 0V. 4VR L-GAIN Speed loop Gain Adjustment Adjusts proportional gain. Turning this pot CW increases gain. Monitor this signal at CUR-M and TG-M. 5VR C.GAIN-ADJ Current Loop Gain Adjustment Turning this pot CW increases the current loop gain. Increase the gain until the hunting of starting current stops. This signal is a square wave and can be monitored at CUR-M. 6VR C.FRQ-ADJ Carrier Frequency Adjustment Turn this pot CW to increase the carrier frequency. Adjust this pot when the motor noise and roughness is excessive due to frequency of the carrier is in resonance with the natural frequency of the mechanical axis. Observe this signal at OSC-M. 7VR C.LIM-ADJ Starting Current Adjustment Yaskawa recommends against adjusting. Turning this pot CW increases starting current. Check this by monitoring the actual motor current during ramp up. This is basically a torque setting. 8VR OS-ADJ
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Overspeed Detection Speed Adjustment Sets the speed at which overspeed detection is activated. Turning the pot CW increases the speed at which overspeed detection is activated. Normally, set the overspeed detection speed at 120 to 140% of the motor rated speed. This signal can be monitored at TG-M and OS-M. 9VR OL-ADJ Overload Detection Current Adjustment Yaskawa recommends against adjusting. Sets the operating current overload detecting circuit. Turning this pot CW increases the operating current and operating time. 10VR Overload Detection Offset Adjustment Yaskawa recommends against adjusting. Adjusts the offset of current detection circuit. Turning this pot CW increases output. Adjust this pot so that the overload detection output is 0V when the motor current is 0 amps. 11VR Current Detection Circuit Offset Adjustment Adjusts the offset of current detection circuit. Turning the pot CW increases output. Adjust so that the signal at CUR-M is 0 volts when the motor current is 0 amps.
12VR Current Detection Adjustment Yaskawa recommends against adjusting. Turning this pot CW increases output. Adjust 12VR so that the signal at I-M is 2V when the motor is operating at 100% of it's rated current. If this pot is set too high, overload detection operates prematurely, if it is set too low, the overload function does not operate. 16VR TRIP-ADJ Trip Voltage Setting Yaskawa recommends against adjusting. This pot adjusts the main circuit voltage at which an alarm is issued. An alarm should be issued when the DC voltage in the main circuit exceeds 400V. Turning the pot CW increases the voltage at which the alarm is issued. Set this pot so that the signal at TV-M is 2.85 volts. Improper adjustment of this pot can CAUSE DAMAGE TO THE SERVO UNIT! The following is a list of Test Points: SG0V Signal 0V 0 volt common terminal for waveform observation. IN-M (CH4) Input Monitor For monitoring speed reference input. TG-M (CH5)
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TG Monitor For observing the TG output waveform from transient speed. Should be 7vdc +/-15% at 1000 rpm. S.AMP-M (CH6) Speed Amplifier Monitor For observing the current reference (speed deflection amplified waveform). OSC-M Triangle Pulse OSC Monitor For observing the operation of triangle waveform pulse oscillator which determines carrier frequency. This waveform has a positive peak of +4 volts and a negative peak of -4 volts. The cycle time is 1.0 milliseconds. CUR-M (CH1) Current Monitor For determining the amount of current being drawn by the motor armature. Use this table to discern how many amps are represented per volt based on the servo model. Servo Model MR054K MR050K MR084K MR080K MR154K2 MR154K MR220K MR374K MR370K Amps per Volt 12.1 A/V 18.9 A/V 14.4 A/V 18.9 A/V 18.9 A/V 24.2 A/V 30.3 A/V 32.6 A/V 53.0 A/V
I-M I Monitor For detecting motor armature current. Output should be 2 volts when motor current is at 100%. V-M V Monitor For detecting motor speed. Should be 3.6 volts +/-15% per 1000 rpm. 1DR-M 1 Drive Monitor For observing the signal driving 1Tr. This signal is a square wave, the positive peak is +8 volts, the negative peak is -8 volts. 2DR-M 2 Drive Monitor For observing the signal driving 2Tr. Square wave +8 volts to -8 volts. 3DR-M 3 Drive Monitor For observing the signal driving 3Tr. Square wave +8 volts to -8 volts. 4DR-M 4 Drive Monitor For observing the signal driving 4Tr. Square wave +8 volts to -8 volts. OS-M
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Overspeed Monitor Sets the speed for overspeed detection. 270rpm/Volt +/-10% OL-M Overload Monitor Sets the level for detecting overload. Set at 0.343 Volts. TV-M Trip Voltage Monitor Sets the level of the trip voltage. To measure this voltage, observe the decibel 0V connected to 024. Yaskawa recommends against adjustment. The following is a list of the LEDs and what they mean: POWER Green LED Power Indicates that 200 volts is applied to the main terminals R and T. IN Green LED Speed Reference Input Indicates that the speed reference is being input. TG Green LED Motor Rotation Indicates the motor is rotating. Use output of tachogenerator. TG Red LED Indicates activation of TACHOGENERATOR failure detection circuit. If the LED comes on and stays on when control power is applied to power terminals R and T, the Servopack is probably defective. If TG comes on and stays on and the motor rotates when main circuit power is applied, check for one of the following: Tachogenerator failure Tachogenerator cable open or shorted Tachogenerator leads reversed Motor leads reversed If TG turns on when the feedrate is increased check the value of the Overspeed Setting, may be necessary to adjust 8VR (OS-ADJ). OC Red LED Indicates activation of OVERCURRENT detecting circuit. If OC comes on and stays on when control power is applied, the Servopack is probably defective. If OC comes on and stays on when main circuit power is applied, check for a short circuit of the DC Reactor, a gounded Motor or a defective power transistor in the Servopack. If OC comes on when the motor is starting and/or stopping, check the adjustment of potentiometer I.LIM-A. OV Red LED
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Indicates activation of OVERVOLTAGE detecting circuit. If OV comes on and stays on when the control power is applied, the Servopack is likely defective. If it turns on while the motor is stopping, the GD2 load is too great or the wrong type of regenerative unit is being used. OL Red LED Indicates activation of OVERLOAD detecting circuit. If this LED turns on when the control power is applied either the Servopack is defective or the Thermostat circuit has failed. If it comes on when the main circuit power is applied but the motor is not started check for a locked rotor condition. If the LED comes on while the motor is running, check for an overload condition. FUSE Red LED Indicates blown fuse. If this LED comes on replace the blown fuse. If it blows again there is likely a defective power transistor.
The Yaskawa Servopack has three green LEDs. From top to bottom they are: TG IN POWER The POWER LED should be on whenever servo power is supplied. The TG should be on when the tach signal is being received. The IN LED should be on when the axis is in motion. Both TG and IN normally come on when the axis starts and moving and more or less increase in brightness as feedrate goes up. In any case, they will both burn bright when the axis moves in rapid. On the Mori-Seiki MV Junior, the Z axis servo is a single amplifier. The X and Y axes are controlled by one dual amplifier. Power Supply LEDs POWER Green LED Indicates 200 volts is applied to control power terminals R and S or R and T. ALARM Red LED Indicates that the power supply is defective or the regenerative resistor unit is not connected. If the ALARM LED of the power supply turns on when the control power is applied, the power supply is probably bad. If the LED turns on approximately .5 to 1 second after the main circuit power is applied there is likely a problem with the either the regenerative resistor unit or the regenerative transistor. Check the resistance at terminals R1 and R2.
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Heidenhain TNC124: The alarm CONTAMINATION Z AXIS (or X Y, etc.) means that the signal from the scale is too low. Normally, this alarm can be cleared with the CE button and you can continue running. If you need to operate this control without the interference of the scale feedback such as when tackling sevo problems, you can make the control run in Open Loop by applying 24vdc from the power supply to Input 7 (Pin 8 of X42).
PWM Servo Amplifier Servo Dynamics Model: SD1-3060-162-1 P/N: 3300-0106 Potentiometers: AUXILLARY INPUT ADJUSTMENT SIGNAL INPUT ADJUSTMENT TACHOMETER INPUT ADJUSTMENT COMPENSATION ADJUSTMENT CURRENT LIMIT ADJUSTMENT BALANCE ADJUSTMENT These are all multi-turn pots accessible from the front of the amplifier without removing the cover. RMS ADJUSTMENT This is a single turn pot for adjusting the RMS output. It is located on the bottom of the board on the left side. The cover must be removed to access it. The initial setting for these pots is: AUX - Fully CCW. SIGNAL - 10 turns from fully CCW TAC - 7 turns from fully CCW COMP - 10 turns from fully CCW CURRENT LIMIT - Fully CCW BALANCE - 10 turns from fully CCW The Current Limit pot will have to be increased right off the bat since it is now set way too low for the motor to run. The motor output terminals should measure about 3.4 meg between each other. You can run the servo without using the tach by disconnecting it from the drive and shorting between pins 1 and 2 on connector J3. If there is a problem with the tach or the tach circuit this will allow the motor to run more smoothly. The motor will have very little torque(gain) due to the fact that there is no tach in the circuit to tell the drive that the motor has slowed down. You can acheive more gain by using a resistor instead of a junper, but torue will still be lacking. The resistor shoul be from 10k to 100k ohms.
LED's:
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OVERVOLTAGE/LOSS OF +15 INDICATION GROUND FAULT INDICATION OVERTEMP/EXCESSIVE RMS INDICATION TRANSISTOR SURGE INDICATION If the OVERTEMP/EXCESSIVE RMS INDICATION alarm issues causing the drive to shut off, you can try working with the RMS ADJUSTMENT potentiometer. This alarm is normally issued because the output exceeded 30 amps for a set period of time. It can also be caused by excessive temperature of the heatsinks of the output transistors. You can monitor the output current at J1-P5. This is a 0-10 vdc signal which is proportional to the output current, 10 volts equals 60 amps. The signal is referenced to chassis ground. For this alarm check the armature for a grounded condition. Excessive fault current should cause the GROUND FAULT INDICATION fault but sometimes will not. For other questions about this drive call Servo Dynamics at 818-700-8600. On any machine that uses DC servo motors, if the motor does not have as much power as it should or if the feedrate has to be reduced to keep the servo from faulting, check the armature for a grounded condition. In this case, a fault current can flow causing the lack of power or faulting. Also, when working with DC servo motors keep in mind that the voltage applied to the motor is not true DC. It is rectified or pulsating DC. This means that there is a frequency component to the voltage, also called carrier frequency. In situations where this frequency closely matches the natural vibration of the machine at certain feedrates and/or at certain locations on the machine, resonance occurs and can cause excessive noise and vibration. This can be adjusted out if you find the correct potentiometer or parameter. In the case of a Fanuc control, use the Filter Parameter, for example. This condition explains why a new machine can develop noise and vibration of a particular axis after a few days or weeks of operation or why a machine may behave this way after many years. Mechanical conditions change, floors settle, etc. Of course, the same thing can be observed on an AC servo system. YASNAC MX3 PARAMETERS 6219 Parameter Write Enable Switch 6004 D3 Programs O8000-O8999 6006 D0 Automatic Coordinate System Setting (Also refer to 6015, 6630 - 6639) 6006 D2 Dry Run 6007 D7 Reset After Editting 0 = Parameters Locked 1 = Write Enabled 0 = Can be displayed and edited 1 = Cannot be displayed or edited 0 = Disabled 1 = Enabled
0 = Jog Feed 1 = Rapid 0 = Required 1 = Not Required

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6008 D5 O Number with ALT Command 6015 D0-D4 Automatic Coordinate System Setting X=D0, Y=D1, Z=D2, 4th=D3, 5th=D4 6021 D2 Program Displayed When Power On 6021 D0 M2, M30 and M99 6021 D6 Loading RS-232 Program Already in Memory 6021 D7 Editting of Programs O9000-O9999 6022 D5 Display of Programs O9000-O9999 6022 D6 Binary Search in Edit/Memory Mode 6066 D6 Condition at Power On 6304 X Axis Grid Shift Amount 6305 Y Axis Grid Shift Amount 6306 Z Axis Grid Shift Amount 6307 4th Axis Grid Shift Amount 6308 5th Axis Grid Shift Amount 6400 X Axis Backlash Amount 6401 Y Axis Backlash Amount 6402 Z Axis Backlash Amount
0 = Not Changeable 1 = Changeable 0 = Off 1 = On 0 = Program O0 1 = Same Program at Power Off 0 = Not Seen as End of Program 1 = Seen as End of Program 0 = ALREADY IN Alarm Issues 1 = Writes Over Program 0 = Enabled 1 = Disabled 0 = Enabled 1 = Disabled 0 = Disabled 1 = Enabled 0 = M96 1 = M97
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6403 4th Axis Backlash Amount 6404 5th Axis Backlash Amount 6630 X Axis Inch Value for Automatic Coordinate System Setting 6631 Y Axis Inch Value for Automatic Coordinate System Setting 6632 Z Axis Inch Value for Automatic Coordinate System Setting 6633 4th Axis Inch Value for Automatic Coordinate System Setting 6634 5th Axis Inch Value for Automatic Coordinate System Setting 6636 X Axis Metric Value for Automatic Coordinate System Setting 6637 Y Axis Metric Value for Automatic Coordinate System Setting 6638 Z Axis Metric Value for Automatic Coordinate System Setting 6639 4th Axis Metric Value for Automatic Coordinate System Setting 6640 5th Axis Metric Value for Automatic Coordinate System Setting
On a Strippit SPM500, there is a top and bottom carousel for the punches. They are mechanically independent with seperate drive trains but driven by a common motor and common shaft. There is a plate at the motor with four positions. The motor must stop at one of these positions regardless of which of the ten tools are called up. A Yamatake Honeywell proximity witch is used for detecting this position. The plate is basically a round piece of sheet metal with four notches cut the width of the proximity switch 90 degrees apart. When the motor stops, the switch should be positioned in one of these slots. The bottom carousel has a flat piece welded to the bottom which is detected by a proximity switch. This proximity switch appears to be the home position for the carousels. Each carousel also has a shot pin which is driven by a pneumatic solenoid into an alignment hole for each position. The top shot pin drives down into the holes, the bottom one drives up into the holes. Each air cylinder has has two proximity switches, one for in and one for out. Sometimes the carousels will stop in between positions, additionally, they may not be aligned with one another. This normally occurs as a result of a punch getting hung up in the part. One condition which can make this situation worse is if the two carousels are in tension with one another. That is, if the tension and direction of tension of one of them is acting to pull the other one. Once the carousels have gotten out of position with one another you
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should take the chains loose so you can move them indepently. Push both shot pins out of the holes, you may have to turn the air off. Move the bottom carousel so that the dog is aligned with the proximity switch then move the top carousel to the position which corresponds to this. Push the shot pins into the holes. Loosen the sprocket at the top of the drive shaft. This is a taper lock sprocket. Release the taper enough to allow the sprocket to spin on the shaft. This will let the chain center itself while being tightened so as not to pull the lower chain and put the two in tension with one another. Now, with carousels aligned and shot pins in, you can tighten the chains. It may be necessary to loosen the tension on the chain from the motor to the drive shaft but it may not. The entire drive shaft and motor are mounted on a large plate bolted to the machine with four bolts. There are two jack screws, one on the top and one on the bottom. Adjust the chains to the proper tension one at a time making sure that the chain is riding in the sprocket and in the center of the idlers. Once the plate is tightened back down tighten the top sprocket. If you did everything correctly you can pull the shot pins back one at a time and the carousels will stay in alignment. If you did not do it all correctly when you pull a pin back, the carousel will spring back, being pulled by the chain tension. Last but not least make sure the plate is positioned over the proximity switch at the motor. You can loosen the four screws that hold the plate and move it into alignment. A good thing to do once you finish is to tighten all of the sprockets then use a permanent marker to put timing marks on every moving part so that if something ever slips you will know what moved relative to what. ACU-RITE MILLPOWER: Has motors like SWI, the sevo amplifier is attached to the motor. The scale plugs into this amplifier via a D subminiature connector. The servo power (120 vac) is sent from the pendant to the Y axis motor assembly, then jumps from there to the X axis, then to the Z axis. There is a connector on the Z axis motor like the rest of them for servo power out but is capped. This is a convienient place to check the servo power. If an axis seems to be losing servo power check these screw on amp connectors. The servo power in to each motor is a strain relief connector. The encoder cable on the motor is also a strain relief, the cable goes back to the pendant where it is a D subminiature conector. CHEVALIER SMART 818: Uses Syntec Baby-1 PC Controller and Mitsubishi MR Servo Amplifiers. This controller operates on 5vdc and 12vdc like other PC controllers but does not use a typical switching power supply. It has a power supply mounted against the back wall behind the controller. Sometimes a machine may start re-booting on it's own. This can be caused by the 5 volt signal being too low, it needs to be 5.1 volts. There is a potentiometer (VR1) to adjust this voltage. The power supply is accessed by removing the two philips head screws on the top of the controller about halfway back. Now the entire controller can be lifted up and pulled out of the way, the bottom screws are in keyhole slots. You will need a small screwdriver. You can monitor the voltage either at the test points on the mother board or at any of the spare connectors. These are like any other PC, a plug with a red and black (5vdc) and a yellow and black (12 vdc). On the Hyd-Mech saws with the PLC100 you can access the special function screens (status, etc.) by presssing the Start button while powering up the machine. On the PLC500 you hold the clear key while powering up.
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If a DC motor controlled axis moves with a jerking motion check the tach feedback. In addition to this a tach problem can cause a machine to have trouble finding it's position, often overshooting or undershooting. Sometimes this can be compensated for if the drive has a tach adjustment. If a tach armature has an open winding it may run fine at high rpm but very rough at low rpm. If the rpm is reduced to a very slow rate the motor may be seen to rotate normally through part of the revolution then take off at a high rate of speed, then slow back down and repeat the cycle. This is due to the drive losing the feedback signal during the time that the open winding is in contact with the brushes. This can be detected by measuring the resistance of the windings and slowly rotating the motor. In some cases the tach can be eliminated from the circuit by disconnecting the tach leads from the drive and either placing a jumper across two pins, moving a shorting pin, flipping a DIP switch, etc. to put the drive into open loop control. If the tach is the problem the motor will now run smoothly but without tach feedback the gain will be almost nothing so the motor will have very little torque. For general information on DC drives you can check file AUTO.TXT. Much of the information on Servo Dynamics can be used for servo drives in general. If you need the password for a Hyd-Mech saw, try one from this list. The number on the left is the Hyd-Mech Program Name. PROGRAM 100Lv1.0 100Lv1.1 100Lv2.0 100Lv2.1 100Lv2.2 100Lv2.3 100Lv2.4 100Lv2.5 50PEv2.1 50PEv2.2 50PEv2.3 50PEv2.4 100Ev1.1 100Ev1.2 100Ev1.3 100Ev1.5 100Ev2.0 100Ev2.1 100Ev2.2 100Ev2.3 100Ev2.4 100Ev2.5 100Ev2.6 100Ev2.7 100Ev2.7a 100Ev2.8 100Ev2.8a 100Ev2.9 100Ev1.4 100LEv2.0 100LEv2.1 500MEv1.0 500Mv2.0 500Mv2.1 PASSWORD 1197 0198 0598 0699 1099 1099 0500 (102) 0301 (102 Battery Password) 0998 0199 1299 0700 0198 0198 0598 1098 0698 1098 1198 1198 0399 0699 1199 0500 0500 0301 0301 1001 0698 0698 0199 0398 0698 1198
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500Mv2.2 500Mv2.2a 500Mv2.3 500Mv2.4 500Mv2.5 500Mv2.6 500Mv2.7 2100v1.0 2100v1.1
0399 0499 0699 1099 0300 0600 0302 0801 (Batt Low 1099) 1001 (Batt Low 1099)
For Mitsubishi PLC E200 password is 801. Mori-Seiki MH63 OVR ON (Red LED) comes on anytime the Feed rate Override is set on anything other than 100%. On this machine, if the following alarms are displayed at the same time check circuit breaker NFB4, it is likely tripped. A possible cause for this is a problem with the coolant motor. The alarms are: SV103 Y IMPROPER V READY OFF OT100 SPINDLE ALARM EX04 COOLANT PUMP OVERLOAD If this breaker is already tripped when the power is turned on you will normally see: OT100 SPINDLE ALARM SW000 PARAMETER ENABLE SWITCH ON The Johnford TC-20 with the Fanuc 0-TC control uses Baraffauldi TOE-160/12-3 twelve station turret, part number 12-4811-14. This turret has a VDI tool disk. It looks and operates much like a comparable Duplomatic turret. It has a 220 vac electric motor for indexing. It has a solenoid activated shot pin which is top mounted much like the Duplomatic. When the round plate on top of the turret is removed, there is access to the proximity switches for the shot pin and the locking. Just like the Duplomatic, when this turret indexes one contactor energizes to rotate the turret. Once in position, this contactor drops out, the other one energizes momentarily to back the turret up which allows the shot pin to go in. Before the turret indexes, the shot pin is up which means the proximity switch is clear of the flag. The associated wire number 10 is 0vdc and diagnostic bit 17.1 = 0. This proximity switch is mounted to the left horizontally and can be viewed in it's entirety. Also at this time the locking proximity switch will be made. It's associated wire number 11 will be 24vdc and it's associated diagnostic bit 17.2 will be 1. This switch is mounted to the right of the other switch and is mounted vertically. There is very little visible other than the LED on the back of the switch. The binary representation of the tool number output by the encoder is at Diagnostics 16.0, 16.1, 16.2 and 16.3. The wire numbers are 32, 33, 34 and 35. The other two outputs from the turret encoder are Strobe which is wire number 48, diagnostic 17.0 and Parity which is diagnostic 16.7, wire number 40. Another signal is Y51.6, this is the output for the brake. It's associated relay is R3. This bit should be 1 at all times except when the turret is indexing. The relays for CW and CCW of the indexing motor are R1 and R2. On the machine schematics the shot pin is called "Pre-indexing". When the turret is at rest the Parity and Strobe bits should be 1 but the turret will index if the parity bit is 0. The encoder is like the Duplomatic in that it mounts horizontally on the indexing shaft and can be adjusted by loosening the two hold down screws and turning the encoder until the diagnostics display the correct tool number and Parity and Strobe equal 1. When commanded to index, the brake (relay R3) should drop out, the appropriate contactor should energize, the motor rotates to the approximate position, the shot pin goes
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down, the motor backs up, the shot pin drops in, the brake turns back on, the shot pin comes back up. I think the shot pin is relay R4, diagnostic Y52.4 On a Mori-Seiki MH-63 with the Fanuc 11M control, the Grid Shift Parameter is 1850. Adjusting this parameter by adding 1000 to it's value will shift the axis one millimeter or .03937 inches. The value in 1850 needs to be the same as in 1816 (Reference Counter Capacity) or less. Normally on these machines, 1816 is set for 1001 on bits 0-3, this correlates to 10000.
BEFORE USING THE PROCEDURE BELOW BE SURE TO UNDERSTAND THAT THE ATC WILL DO JUST WHAT YOU TELL IT TO, TAKE CARE THAT THE DOOR IS OPEN BEFORE MOVING THE TOOL ARM, ETC!!!!!!!!!!! On the MH-63 independent operation of the ATC is possible but is not done by M-Code. Instead Counter Presets are used. The procedure is: 1. Select MDI mode. 2. Press the NC/PC button (If in PC screen). 3. Press the PROGRAM soft key to call up the Program screen. 4. Input M31; 5. Press the INSERT soft key. 6. Press the START button. (The FEED HOLD lamp will start flashing.) 7. Press the NC/PC button to call up the PC display. 8. Set the key switch to EDIT. 9. Press the PCPRM soft key. 10.Press the COUNTER soft key. 11.Enter the Preset number which corresponds to the desired operation in Counter 1 C00. If the machine has more than one magazine, C02-C04 may also be used. 12.Press the INPUT button. (The Preset value will change from zero to the value you entered). 13.Press the FEED HOLD button. (When the selected operation is completed and the limit switch associated with the operation is satisfied, the Preset value will once again become 0. 14.Once you are finished with the independent operation, resume to normal operation by executing M32. The FEED HOLD lamp will turn off. Below is a list of operations performed by entering the associated Preset value during independent operation: C00(Preset Value) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 OPERATION
No Operation Door Opens Main Arm moves toward the Spindle Tool is Unclamped Tool is Pulled Arm Rotates Clockwise Arm Rotates Counterclockwise Tool is Pushed Tool is Clamped Main Arm moves toward it's Original Position Door Closes Main Arm moves toward the Magazine Tool is Pulled Main Arm removes toward it's Original Position
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14 15 16
Tool is Pushed Magazine Pot is Locked Magazine Pot is Unlocked
Some of the operations appear to be duplicated but which value you used is dependent upon the direction of movement. Keep in mind that the arm's home (original) position is not all the way to the magazine but between the magazine and the spindle. Another method for moving the ATC is by using the +/- STEP buttons if the machine is equipped with them. The procedure is: 1.Perform reference return (ZRN) for the Y and Z axes. 2.Perform spindle orientation. 3.Select MDI mode. 4.Set Keep Relay K5.4 = 1. 5.Execute M31. 6.Execute M35. (The ATCHP and FEED HOLD lamps will start flashing). 7.Press the +STEP button to move the ATC forward, -STEP to move it backward. Once the ATC has moved completely forward with the +STEP then all the way back to it's original point with the -STEP button, pressing the +STEP button again will end the step operation and the lamps will stop flashing. If the machine does not have the STEP buttons, make Keep Relay K5.6 = 1 so you can use the +X and -X Feed buttons in this capacity. SOME MACHINES WILL PERFORM THE STEP OPERATION EVEN IF THE X AND Y AXES ARE NOT AT HOME, GET IN THE HABIT OF RETURNING ALL AXES HOME BEFORE USING THIS PROCEDURE. For Spindle +/- Step Operation make K5.4 = 1 and use M31, M35. For Magazine +/- Step Operation make K5.5 = 0 and use M31, M34. For Sub-Arm +/- Step Operation make K5.5 = 1 and use M31, M34. The Tos SN71 uses mechanical clutches. Both the forward and reverse clutches are mounted on the main shaft. This shaft is driven directly from the motor. The clutches can be located by following the shaft from the driven pulley to the left. The forward clutch is the one closest to the pulley. Both clutches can be accessed and adjusted by means of an access cover located on the BACK of the headstock. The access cover has six screws. This cover can be removed without draining the headstock but the machine cannot be run with it off due to the oil pump. When the lever is placed in either forward or reverse a shifting fork moves a slider which squeezes the plates of the corresponding clutch together. The slider is located at the center of the shaft between the two clutches. The adjustment is very simple. It is a split nut with a screw which pulls the two ends together. The nut is threaded onto the shaft next to the clutch. There is a nut for each clutch. To adjust, loosen the screw and turn the nut, then tighten the screw. To tighten the clutch turn the nut as you would to tighten on a right hand thread. If you get the clutch too tight the spindle will turn in that direction without being engaged. Also the lever may not feel right and may not stay engaged. If only one clutch is worn or out of adjustment the spindle will stall or run at reduced rpm in one direction but run fine in the other direction. The nut should turn very easily when you adjust on the clutch. On the END of the headstock there is a flange with a T-handle bolt in it's center. This is the metal oil filter. It should be turned from time to time to keep it clean. You can turn it as much as you want. When changing the oil it should be removed and the buildup removed from it. If you remove it before the oil is drained you will have a mess to clean up. The headstock oil is supposed to be Mobile DTE Medium (AW46) but AW32 is OK. When the lever is raised the machine runs
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in reverse, when it is lowered it runs in forward. The fill hole for the headstock is located on the very top of the headstock. On the KIA KIT30A with the Fanuc 0-Mate control if everything works except the spindle won't run, check the door switch. This switch will keep the spindle from starting but doesn't stop the spindle once it is running. The Diagnostic bit is 20.0, the wire number is X200. It is fed by wire +24N. This switch does not always show up in the hard copy of the ladder where it should. There is a rung which ends with the the internal relay coil R639.0 which has four instructions showing on the hard copy. The instruction for the switch should be here but is not.
Sometimes you can turn on the Ladder by changing bit 2 of parameter 60. Some of the LNS bar feeders used on the Ecocas have a limit switch on the track that it moves back and forth on. If the bar feeder is pushed back and this switch is not made, the machine is placed in E-Stop mode. If an axis mispositions by the same amount sometimes try to determine if the amount it mispositions by is approximately one revolution of the ballscrew. If it is try to determine if the axis zero returns in the same place every time. Sometimes the decel dog of an axis can be set so that occasionally the encoder will just miss the marker pulse and make a whole revolution to find it. This will cause the position to be of by one grid space. The problem is normally noticed when a position is commanded by G54 or some other work coordinate. Normally, when this occurs the axis will over travel every time it tries to reference return even after the power is cycled. It will only stop exceeding the soft limit once P+CANCEL has been performed. The long term fix is to move the decel dog away from the zero return point (normally the minus direction) a little, only .0500 or so. The Toyokoki press brake model 8025W is sold through Mitsubishi Heavy Industries. It uses a TNC-ACII control. It has both Okuma and Panasonic servo amps. For help on this machine you can try Aaron at MC Machinery 630-350-7061. If you get the alarm "UNUSUAL COMMUNICATION" first check all connections because this alarm means just what it says, there is a communication problem between the OSP and the HP1601. Also check the connections to the servo amps. Another thing to try is a RAM clear. To do this, hold the F5 and F8 keys while powering up. If the machine loses it's parameters you need a special device so someone from MC Machinery will likely have to do it. Supertec G30P-100CII The infeed of this grinder uses hydraulics to move the wheelhead during manual operation and a stepping motor for automatic operation. Once the hydraulic pump is running, pressing the retract button will cause the wheelhead to move toward the operator. The normal state of the hydraulic valve causes the wheelhead to be in it's retracted position unless the button is pressed. If the hydraulics are turned off while the wheelhead is in any position other than fully retracted, it will retract automatically when the hydraulics come on. The hydraulic valve is controlled by output Y6 of the PLC via wire number 21. If the head is fully retracted when the retract button is pressed Y6 turns and the head moves toward the operator. According to Supertec, a timer in the PLC causes the the head to traverse for 5 seconds in either direction but in observing the machine operating, output Y6 once turned on stays on
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until the retract button is pressed again, likewise for the reverse operation It appears that the movement is stopped by reaching a positive stop. In any case the head will move the same amount, about 3.5 inches regardless of where it has been positioned by the handwheel. Any problems with this operation should be treated as a hydraulic problem, sticking valve, etc. The PLC is a Mitsubishi MELSEC FX2N-16MR. The phone number for Mitsui Seiki in California is 562-948-4009. In New Jersey is 201-337-1300. Ask for John. Mitsui-Seiki VR5A with Fanuc 6M control This machine has a hydraulic ATC. It does not use a tool change macro so when you want to do a tool change you may have to command the Z axis to a second reference return point. For example, G91 G30 Z0. Depending on the machine you may have to include Y0 and X0. The standby/spindle tool is stored in parameter 4999. Parameters 4000-4020 are the tool registration table. As with other machines you cannot have the same number in more than one of the parameters. On most of these machines the tool must be commanded on a block other than the one in which the M06 is commanded. For example: T01; G91 G0 G30 X0 Y0 Z0; M06; The tool must be commanded first. If the magazine rotates, the spindle orients and the pot comes down but the ATC arm will not rotate check the spindle orientation signal. In the case of spindle amplifier with an orientation board make sure the IN-POSITION LED (LED 6)is on. If this LED is not on, the spindle orientation completion signal will not be output from the NC to the ladder. This LED should be on anytime the position of the spindle is within one degree of it's orientation position. If the spindle is in position but the LED is not on you can adjust RV7 to bring it on. The VR5A with the Fanuc 6M control does not issue machine alarms. When an alarm condition does occur there are a couple of red LEDs on the operator's panel that will either turn on or flicker. When this happens, check PC parameters 200-207 for the details of the alarm. To access the PC parameters: 1.Press the PARAM button twice. (PC PARAMETER 01 should be displayed in the upper left hand corner. 2.Page to the desired PC parameter. The screens of this control update very slowly so you have to be patient. PC PARAMETER 200.0 CYCLE ALARM .1 MACHINE ALARM 1 .2 MACHINE ALARM 2 .3 MACHINE ALARM 3 .4 MACHINE ALARM 4 .5 MACHINE ALARM 5 .6 MACHINE ALARM 6 .7 MACHINE ALARM 7 SOLID STATE RELAY TRIPPED CONTROL CIRCUIT BLOWN FUSE (TRIPPED BREAKER) HYDRAULIC PUMP MOTOR OVERLOAD LST COOLANT PUMP MOTOR OVERLOAD CHIP CONVEYOR MOTOR OVERLOAD SECOND COOLANT PUMP MOTOR OVERLOAD LUBRICATION PUMP MOTOR OVERLOAD
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201.0 MACHINE ALARM 8 SPINDLE LUBRICATION PUMP MOTOR OVERLOAD .1 MACHINE ALARM 9 ABNORMAL SPINDLE LUBRICATION AND COOLING UNIT .2 MACHINE ALARM 10 EXCESSIVE OIL TEMPERATURE IN THE HYDRAULIC OIL TANK .3 MACHINE ALARM 11 LUBE LEVEL LOW .4 MACHINE ALARM 12 ABNORMAL SPINDLE SPEED CONTROLLER .5 MACHINE ALARM 13 CHIP CONVEYOR TORQUE LIMIT .6 MACHINE ALARM 14 OVERLOAD OF HYDRAULIC PUMP FOR CLAMPING A/C AXIS .7 MACHINE ALARM 15 ABNORMAL LUBRICATION 203.0 WORK SET HOLD .1 APC HOLD .2 .3 T00L LIFE ALARM, NO SPARE FOR TOOL EXPIRING IT'S LIFE TIME .4 ABNORMAL TOOL DETECTING DEVICE .5 NEGLIGENCE OF RESETTING M30 POWER CUT-OFF .6 EXCESS OF AUTOMATIC CYCLE OF ROTARY TYPE APC .7 ABNORMAL TOOL CHANGE COMMAND 204.0 BROKEN TOOL .1 SPINDLE HOLD .2 ORIENTATION HOLD .3 MAGAZINE ALARM .4 T CODE ALARM .5 PROGRAM ERROR .6 DATA SEARCH ALARM .7 TOOL ALARM 205.0 .1 .2 ATC HOLD .3 ATC STOP 1 .4 ATC STOP 2 .5 HYDRAULIC OIL TEMPERATURE UPPER LIMIT DETECTION ALARM .6 NC EXTERNAL RESET ALARM .7 NEXT T CODE ALARM 207.0 OIL SHOT PUMP MOTOR OVERLOAD .1 INSUFFICIENT OIL SHOT COOLANT .2 DEFECT OF PC FOR ROTARY TYPE APC CONTROL .3 ROTARY TYPE APC ALARM .4 EXCESSIVE CUTTING LOAD SETTING ON ACS UNIT .5 ABNORMAL APC OPERATION CONFIRMATION SWITCH .6 All of the bits should normally be zero unless an alarm condition is present.
There is a box on the ATC side of the machine with an LED display. This box is used to move a tool pot to the tool loading position. There is a position to the left of the standby position where loading the tool is facilitated. There is a lever at this position for removing the tool from the pot. To use this box. 1.Press the + and - buttons at the same time. 2.Press either the + or - button to display the number of tool you want. 3.Press the START button. The pot will move to the loading position.
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This machine's spindle is a three stage geared head. It uses the old digital spindle drive. You can adjust the gear ranges individually by adjusting one of three gain pots on the drive. When the alarm lamps light on the operators panel check Diagnostics 200-210. Use the maintenance manual to find out what the Diagnostics indicate. Generally speaking, if a machine does not use a tool change macro for ATC operation, you will have to command the head to tool change position with a G30 command. Kiwa 426X: Uses absolute pulse coders on the X, Y and Z axes, reference return switch on the B axis. To zero return the B axis: 1.Press the ZRN button. 2.Press the 4th button. 3.Press the + button. The coolant through the tool pump (#3) has a pressure switch that must be satisfied. If for some reason it cannot be you can bypass it to prevent the low pressure alarm from being issued. This is done by changing the value of keep relay K3.4 If the pallet does not sweep in true with the spindle after reference return, adjust the grid shift parameter (1850) until it does. The manual operation of the pallet changer cannot be performed until the Z axis has been sent to it's second reference point (G91 G30 Z0). Once this has been done, select JOG mode, place the selector switch on UNCLAMP, press the START button. The pallet will unclamp. Place the selector switch in UP, press the START BUTTON, the pallets will raise up. Place the selector switch in CW, etc. For questions about Mitsubishi made press breaks, regardless of other brand name, call 212-397-6118 or 630-860-4666. If a spindle which uses a magsensor for orientation has trouble finding the orientation position check that the spindle deceleration is not too long. In this case the spindle may jerk back and forth searching for the position because it can't stop fast enough to stop in the middle of the sensor. If the mechanics of the machine will allow you can open the window of the orient position to make it easier for the spindle to find a stoping position. The Heidenhain Pilot VRZ739/779 DRO is a digital readout which can interface with an inverter to perform constant surface operation. The port on the DRO which is used to interface with the inverter is X41(EXT). This DRO is used on the Clausing VS lathes. In this case, X41 connects to CN18 of the relay board. These machines typically use the Mitsubishi Freqrol A-200 spindle inverter. If the DRO is turned off the spindle will not run at all. Pressing the RUN/RESET button will cause it to turn on (green), but when released it will turn off. On the Clausing lathes which use this DRO, you must push the green button (RUN/RESET) to make the machine ready, the green light should stay on after you release the button. If it does not, make sure that the spindle lever is in the neutral position and the chuck guard is closed. When the green button is pressed, relay K6 on the PCB should energize. K8 on the PCB should energize whenever power is supplied to the PCB through fuse F1 on the PCB. Relay K5 on the PCB energizes whenever the E-Stop button is
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pulled out. Also, when the E-Stop is pulled out, contactor K1 should energize. To use the constant surface feature, press the CSS button, move the X axis to the point where you want maximum rpm to be reached, adjust the spindle speed control to this rpm, press the RPM MAX button. Move the X axis to the point where machining will begin, adjust the spindle speed to the desired start rpm. As the X axis is moved in toward the centerline the rpm will increase up to the maximum rpm. The phone number for the Duplomatic dealer in Charlotte (Macoser) is 704-3920110. The contact is Dan Britton. On the Kiwa horizontal, if the magazine has less than 100 tools, parameter 6810 can be 100. If it has more than 100 tools, make it 1000. If the parameter is set too low, alarm 151 (Fanuc 18) will be issued. If a machine with a high/low geared head stalls in a cut, check the high/low gear confirmation switches. A temporary loss of one of these signals may cause the spindle to drop in and out. Typical parameter settings for the Yaskawa spindle inverter on the Sharp 1118H are: REFERENCE SOURCE Terminals RUN SOURCE Terminals STOPPING METHOD Ramp to Stop ACCEL TIME 1 3.0 Sec. DECEL TIME 1 3.0 Sec. REFERENCE 1 60.00 Hz 2 0.00 Hz 3 0.00 Hz 4 0.00 Hz JOG REFERENCE 6.00 Hz INPUT VOLTAGE 220.00 VAC MOTOR SELECTION Std Blower Cooled V/F SELECTION Custom V/F MAX FREQUENCY 204.00 Hz MAX VOLTAGE 220.00 VAC BASE FREQUENCY 60.00 Hz MIN FREQUENCY .5 Hz BASE VOLTAGE 220.00 VAC MOTOR RATED FLA 1.59 Hz NO-LOAD CURRENT 5.88 A On the Mori-Seiki MH-40, alarm EX49 occurs when a cycle such as ATC,SBC,ZRN, etc. does not finish. The control remembers the alarm even if the main power has been turned off, it can not be reset. When the alarm occurs, a Keep Relay will be changed by the control from 0 to 1. The relays to check are K14.5,6 and 7. If you get the alarm even though all cycles are complete, you can remove the alarm by changing the keep relay back to 0. To change a keep relay on a machine with a Fanuc 11 control: 1.Select MDI mode. 2.Press the SERVICE soft key. 3.Press the PARAMETER soft key. 4.Enter the 8900 and press the INP-NO soft key or page to parameter 8900. 5.Change bit 0 to 1.
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6.Press the NC/PC button. 7.Press the PCPRM soft key. 8.Press the KEEPRL soft key. 9.Cursor to the Keep Relay, enter desired value, press the INPUT button. The Mori-Seiki horizontals have wear pads on the bottom of the column, these can wear to the point where the column can drop down on one end. This will causing machining problems and rough movement in the Z axis. Alarm OT102 on a Mori-Seiki horizontal mill means that the spindle amplifier has alarm AL02 EXCESSIVE SPEED DEVIATION. If you look at the spindle amplifier, LED 2 will be on. On the older Yasnac controls (MX1, MX2, etc.) the motor encoders are called Feedback Units, if you pull these off the end of the motor and turn them over there are pots you can adjust. One of the pots is a sensitivity adjustment. This adjustment is useful in cases where the optical reader gets weak over time. A symptom of this is that it has trouble seeing the marker pulse so it is difficult for it to complete zero return. If you remove the cover from the newer Optical Encoders on the MX3 controls you will find pots as well but you should not adjust these. According to Yaskawa these encoders should not be adjusted, even their field service technicians are not allowed to adjust them. The encoder should be either replaced or sent in for repair. Often when an axis on a machine with a Yasnac MX3 control gets alarm 242 (in the case of the Y axis) when it is being zero returned, you can adjust parameter 6316-6320 (approach speed 2) to make the axis approach the zero point slower. Also in this case check the ZRN decel switch to make sure it's not sticking. On Heidenhain controls to access the Ladder you enter the code 807667 at the CODE NUMBER = prompt. Keep in mind that some controls will not display the ladder such as the TNC124. On these controls you must have the software on a PC to extract the binary file from the EPROM in the control. Even then you cannot see the ladder, only gated logic ( AND, OR, etc.) Communication parameters for a Yasnac LX3: The parameters for this control are grouped according to INPUT or OUTPUT and for INOUT/OUTPUT DEVICE 1 (SIO1) or INPUT/OUTPUT DEVICE 2 (SIO2). Parameter 6026 is for setting the baud rate for Input Device 1, parameter 6027 is for Input Device 2. Parameter 6028 is for setting the baud rate for Output Device 1, parameter 6029 is for Output Device 2. So, to set the baud rate the same for input and output on device 2 you would set parameters 6027 and 6027 to the same value. Only the first four bits (0-3) of the parameter are used for the baud rate setting. The table below applies in all cases. BAUD RATE BIT 3 BIT 2 BIT 1 BIT 0 50 100 110 150 200 300 600 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 0 1 1 0 0 1 0 1 0 1 0 1 0
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1200 2400 4800
0 1 1
1 0 0
1 0 0
1 0 1
Bit 4 of these parameters sets the number of stop bits, 0 = one stop bit, 1 = two stop bits. Bit 5 of these parameters is for control codes, 0 = DC1/DC4 are used, 1 = DC1/DC4 are not used. To change a parameter on a Yasnac LX3 control: 1.Press the SET button. The SETTING page will be displayed. 2.Type 6219, press the Cursor Down button. 3.Change it's value to 1. 4.Press the WR button. (This is equivalent to the PWE of a Fanuc control, if power is cycled while 6219 = 1, the alarm "SYSTEM SETTING NO.(6219):[1]" will be displayed) 5.Press the PRM button. 6.Type the number of the parameter you want to change, press the Cursor Down button or page to the parameter. 7.The cursor will be on the #, press the INSRT button. The cursor will move to the first bit (Bit 7). 8.Use the cursor button to move the bit desired. 9.Change the bit from 1 to 0 or vice versa, press the WR button. As with a Fanuc control, if you want to send or receive the parameters you must go to the parameter page. Then press either the IN or the OUT button. The CRT will flash either IN or OUT depending on the operation. Heidenhain LS500 series reading heads: The intensity of the light source can be increased by replacing the resistor, it is accessed by removing the cover on the bottom of the reader. According to Hyd-Mech the head of the S-20A can drift down as much as .080/in while in HOLD mode and be within specification. Also according to Hyd-Mech if the front vise and shuttle vise are not aligned they recommend to shim out the wear plates on the front vise. For parts on an Acer grinder call KLIM at 732-752-9100. When replacing thrust bearings, if the new ones are the same manufacturer they are probably the same thickness but you should check. If not the same manufacturer, stack the older bearings as they go in the machine and measure the overall thickness. It will normally be different from the old ones. If the new ones are thicker you will have to turn the difference off of the retention plate. If thinner you will have to make a spacer. For service support on the Fuji Frenic spindle drives call OESS at 201-2884422. On the Fuji Frenic 5000V2 the buss should normally be about 300 vdc. It it goes above 400vdc the over voltage alarm is issued. This indicated by leds 3 and 4 being on at the same time. When the DDF valve is replaced on the Hyd-Mech S20-A saw, the feed force
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valve must be adjusted: 1.Remove the cap from the hydraulic fitting at the bottom of the DDF. 2.Connect a hydraulic hose and gage. (You can use one of the pressure gages from the hydraulic compartment door and put the cap on the line. 3.Bring the head down to rest on a block of wood. Leave the selector switch in the DOWN mode. 4.Loosen the setscrew on the black knob (feed force adjustment) and remove the knob. 5.Use an allen wrench to turn the valve fully clockwise. 6.Adjust CCW until the gage reads 330 psi. 7.Put the knob back on with the pointer indicating 0%. Only adjust the feed force valve when the DOWN mode is selected. The S-20A with the Sequencer has three switches to control the movement of the shuttle vise. The top switch on the right is the confirmation switch for the forward travel, the middle switch stops the vise in it's reverse travel. This is how the work piece is measured. The part that contacts the switch is the spindle face of a micrometer. The micrometer moves with the length adjuster along the distance of the tape. Once the pointer is set to the desired length it can be fine adjusted with the micrometer. The micrometer is normally set for .250 so that the position can be adjusted a quarter inch either way. If the piece is cut too short the shuttle is not moving back far enough so move the micrometer back away from the switch. The bottom switch places the shuttle in slowdown mode. On the Yaskawa 616PC, terminals FV and FC are the 0-10vdc speed command input The W.F. Wells B-25-1 horizontal band saw works in the following manner: As the head moves down through the part the blade will under some circumstances be pushed up toward the blade guides (eight side bearings) which is undesirable, particularly because if the kerf of the blade is allowed to run within the guides for any length of time the blade will lose it's set. This will normally cause the saw to cut out of square from top to bottom. The saw is designed to prevent this by using two metering valves, one mounted on each guide arm. The valves are connected to the down feed force assembly by two hydraulic lines on each valve. These output of these valves is inversely proportional to the amount of displacement of the actuator. The input actuator of each valve is connected a tie rod which connects to a pivot arm on which the top bearing is mounted. The top bearing rides on the blade back. As the blade is pushed up by the material, the metering valves are forced closed in proportion and, in turn, decrease the rate of downfeed. If the valves are properly adjusted, the downfeed of the head will be stopped completely before the blade displacement reaches .050". To adjust this mechanism, first adjust the top bearings so that they just kiss the blade back with the sw cutting air. (It may be necessary to make this adjustment with the blade actually cutting material at a very low down feed setting, in this case, try to make the adjustment during the first moments of the cut). The adjustment is accomplished using the set screw and jam nut on the pivot arms. Next, place the saw in down feed condition, again cutting air. As the head feeds
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down, use a screwdriver to raise one of the top bearings off of the blade. You should see the head movement slow down and then eventually stop. A plunge dial indicator can be very helpful in determining if the head is being properly controlled by the valves. Adjustment is acheived by either increasin oe decreasing the length of the tie rods. As previously mentioned, the two valves work together and generally speaking both top bearings will move into the material simultaneously so if possible try to raise both bearings at the same time, you will find that the down feed will more affected this way rather than raising one at a time. Another thing to keep in mind is that not only is any adjustment of one side linked to the other side but also adjustment of the top bearings will affect the metering valve adjustment. As far as adjusting the blade guides, they should be set for .001" greater than the thickness of the blade. Most blades for this saw are normally either .042 or .050". An easy way to make this adjustment is to find a short piece of a broken blade, put it together with a .001" feeler gage, put the two of them between the blade guides, turn the movable bearings until they close on the blade and feeler to where you can just get them out, then tighten the nut. If the blade tension needs adjusting there is a metering valve located behind the blade tension solenoid valve. This valve is located beneath the electrical cabinet. It consists of a setscrew on the bottom of the valve.
On the Kiwa KNH-426X, to bypass the coolant pressure switch change the value of Keep Relay K3.4 The Cincinnati Arrow 750 uses the Control Techniques control. To access the Ladder on this control, press and hold CTRL + D. The PROGRAM PROTECT KEY can be found at Net 183. The magnescales used on some Sony DRO systems, particularly the LH51, have a green LED which indicates when the gap between the reader and the scale is the correct distance. If the reader is either too close or too far away, the LED will go out. Once the correct distance is achieved it will burn brightly. On the Yuasa UDNC-100, to use the work zero function: 1.Select manual mode with the MAN\REMOTE switch. 2.Zero return the table using the zero return switch. 3.Use either the Jog button or handwheel to move to desired work zero. 4.Press the W-Z SET button and hold until the display reads all zeros. To remove the chuck from a CNC lathe (hydraulic chuck): 1.Remove the bolts from the face of the chuck (usually six socket head cap screws). 2.Press the chuck pedal so that the chuck is pushed away from the spindle. 3.Unscrew the chuck from the draw tube. (It should turn freely and the threads are standard direction.
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To install a chuck: 1.Screw the chuck onto the draw tube until it runs out of threads. 2.Back it off until the alignment pin lines up with the NEAREST alignment hole on the back of the chuck.(This may take a few attempts) 3.Press the chuck pedal so that the chuck is pulled toward the spindle. 4.Once pin is aligned and chuck is pulled flush against the face of the spindle, insert and tighten the six bolts. 5.Check for run out. Sometimes a new chuck will come with a blank draw nut, that is, the draw nut has not been threaded. In this case you can re-order the chuck with a threaded nut, thread the nut yourself or in some cases the draw nut on the old chuck may be interchangeable with the new chuck. This is particularly true when the old chuck is a Kitigawa since many chucks are copies of these, notably the strong chucks. Be careful when removing and installing a draw nut that you do not lose the steel ball that rides in the detents of the draw nut, it is very small and easy to miss. The primary difference between AC servo motors and AC induction motors is that servo motors use permanent magnets. These magnets allow for precise positioning but the drawback is that the magnets can be demagnetized or the magnetic fields can be scrambled. This normally results in a motor that does not rotate smoothly, when the motor is turned by hand it will cog, that is, you will feel notches as it is rotated. When the motor is operated it's movement will be rough and jerked. It will also pull high current and the motor will have very little torque. In most cases you will be able to keep the motor from turning by holding it by hand. When this happens the motor can be repaired by re-magnetizing it but requires special equipment. One company that can do this is Endeavour Technologies in Chicago. It is also important to know that this condition can be caused by a bad servo amplifier so it is not uncommon to find a machine with the symptoms above and when you replace either the motor or the amplifier, you still have basically the same problem with the machine until you have replaced both of them.
To perform linear compensation on a Sony LH30 DRO: 1.With the DRO turned off, hold the RESET button while turning the unit on. 2.Press either the X or the YZ button until LC _ _ _ is displayed. 3.Enter the value from the table corresponds to the required amount. 4.Press the P button. 5.Cycle the power. The actual amount of error cannot be entered so a number from the table which most closely matches the error must be used. Use the table below: AMOUNT OF ERROR PER INCH .000002 002 .000004 004 .000006 006 .000008 008 .000010 010 .000015 015 LC
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.000020 | | | | .000600
020
600
To compensate for an axis that measures a standard as longer than it is use negative values: AMOUNT OF ERROR PER INCH .000002 -002 .000004 -004 .000008 -006 .000010 -010 .000015 -015 .000020 -020 | | | .000600 -600 LC
The newer TRL 1840 machines use a Yaskawa GPD 315/V7 inverter to control the spindle. If this inverter displays an alarm message that consists of a large upper case S, a large lower case r and a large upper case P, this indicates an emergency stop condition that is originating from a source external to the inverter. In the case of the 1840, try removing the computer module and reseating the boards into the motherboard or look for some other hardware problem. This alarm is related to parameter n005. The manual for this inverter as well as other Yaskawa inverters can be downloaded and or viewed directly from the website DRIVES.COM
Alarm 1300 NO PALLET SITTING CONFIRMATION on the Kiwa KNH-400 is issued when pressure switch PS5 detects a lack of back pressure. This switch is located in the back of the machine with the main air input and solenoids, etc. The switch is labeled AIR CATCH SENSOR. There is an air line from this sensor to the pallet. The sensor has four LEDs, two red and two green. At least one of the greed LEDs must be on to prevent the alarm from being generated. It does not matter about the two red ones unless they are the only ones on. In this case X0006.6 (PSPLSA) will be zero, making the alarm rung true. There is an adjustment on the switch that is normally sufficient to correct the problem. The output of the switch does not go directly to the I/O module, instead it turns on relay CR28, the output of which is tied to the I/O module. This relay can be hard to find, it is one of the tiny black solid state relays in the electrical cabinet. Anytime you have this alarm, make sure that the main air supply has not changed. Also raise the pallet and blow out any chips that may be keeping the pallet from seating. The Clausing Mastiff lathe with the Fanuc 20T uses a rolling column matrix for the operator's panel (A10). There are four 24 volt output transistors and eight current sink transistors (all from the Fanuc I/O board(A1) ) which together control 32 LEDs. In order for an LED to turn on, both it's correspondwww.machinetoolinfo.com/GENERAL-CNC-INFORMATION.html 41/70
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ing output transistor (Y address) and corresponding current sink transistor must be turned on. The anode of eight of the LEDs will be tied, in parallel with one of the 24vdc output transistors while four of the LED cathodes will be tied, in parallel, with one of the current sinking transistors. Each LED will have a different Output address (Y address) which, apparently, when called by the control will activate both transistors. The four outputs are from the I/O board (A1), connector CM31, pins B13 A13 B12 A12 to the relay board (A4) through the fuses on the relay board F5 F6 F7 F8 respectively. The current sinks are supplied from the I/O board connector CM31 A14 B14 A15 B15 and so on. The output addresses are Y1000.0 Y1000.1 Y1000.2 and so on. The Mori-Seiki MV Junior uses a Yasnac MX2 control. If the CRT is blank, check the 24vdc supply from the power supply. This power supply is located at the bottom of the electrical cabinet. The only input of this board is 220 VAC, the outputs are 5vdc, 12vdc, 15vdc and 24vdc. These are output on five connectors A, B, C, D and E. The output of connector C is +24vdc. All of these voltages go first to the top of the card rack and are jumpered from there to the boards. In the case of the 24vdc, when it goes to the I/O board it feeds a bridge rectifier which if it shorts will cause the power supply to shut down and the CRT will be blank. This power supply can be hard to troubleshoot because even though a short on one of the outputs will cause the power supply to shut down, disconnecting the connector to remove the short will cause the same problem since removing one of the connectors on even a healthy power supply will cause shutdown. Hyd-Mech H-14 One revolution of the length encoder equals 3.142 inches of linear travel. The encoder supply voltage should be 22-26 vdc. Encoder outputs: 0v to Channel A should be 10-13 vdc while encoder is in motion. 0v to Channel B should be 10-13 vdc while encoder is in motion. LEDs X0 and X1 correspond to encoder channel A and B outputs. The folowing parameters are with regard to length measurement and control. ACCEL DISTANCE - How far the shuttle vise moves in slow feed before engaging fast feed. DECEL DISTANCE - How far the shuttle vise moves in slow feed following a fast feed movement. TRIG.WINDOW - Allowable length tolerance.
ACTUAL POSITION - Normally set to 0. Set to 1 to display actual position.
If you program a length of cut whose length is shorter than the DECEL DISTANCE parameter, the shuttle vise will travel this entire distance in slow feed. To change the BLADE KERF setting: 1.Select AUTO mode. 2.Press and hold the KERF CLEAR/HOME button until the Kerf value is shown. 3.Type in the new value.
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You can view the I/O states at the PLC in the main electrical cabinet of the H-14. To calibrate the length measurement: Before you start make sure there is a piece of material in the saw which is longer than the maximum stroke of the shuttle vise. 1.Select MANUAL mode. 2.Place the FRONT VISE switch in the CLOSE position. 3.Press and hold the FWD and REV buttons at the same time until prompted for the password. 4.Enter the password. (The password corresponds to the version of software that the PLC uses. The version is displayed when the machine is powered on. To which password corresponds to your version of software check the list above or call Hyd-Mech). 5.Display will normally show the Height Calibration screen. Cursor to the Length Calibration screen. It will look like this: LTH.CLB. "ENTER" [0] ACT.LTH. 00.000 6.Press the ENTER button. The CYCLE START should start flashing and the [0] should change to [1]. 7.Start the blade. The saw will make a trim cut, raise the head then the shuttle vise will move fully back in slow, clamp on the material, bring it fully forward in slow and make the cut. The 1 will change back to 0. 8.Measure the cut. 9.Cursor to ACT.LTH. 10.Enter the length you measured plus the kerf of the blade. 11.Press the AUTO/MAN button. The PLC will calculate and store the calibration factor. If you find that you need to adjust the calibration factor, you must go thru the above procedure to change the ACT.LTH. parameter but you don't have to actually cut material. If length measurement error increases as measured length increases, increase the ACT.LTH. parameter. If the error decreases as the length decreases, decrease the parameter. Whenever troubleshooting length error problems, make sure the cushion period (slow approach distance) is set correctly. This will normally be set for one inch.
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Hitach-Seiki HT20S with Yasnac i80L: When the machine is turned on it is normal to have alarm 3000 SERVO OFF. This is because the NC does not energize 1K3 (large contactor) which sends three phase power to the servo unit. To turn on the servo unit, press either the STANDBY button or the NC POWER ON again depending on the PLC version. When the STANDBY button is pressed the output Y57 (#11057) should turn on and stay on while the button is held. It should also stay on for about five seconds after the button is released. This output is from the FC-860 board. This is the I/O board for the i80 control and is distinguishable from the other control components since it is not a plug in module of the chassis. It is normally mounted away from the control chassis and is connected to the control through a communication cable from CN11 of the FC-860 to CN21 of the FC-210. Some machines may use a FC-211 instead of FC-210 but in either case this is the PLC module mounted on the control chassis. The Y57 output is 24vdc from connector CN2 pin 7 on FC-860 to connector X23 pin 7 of DSB1 which feeds relay 1K1A (MACHINE READY P.B.). This relay is an ice cube relay located on the distribution board (DSB1). The distribution board is basically a central location for input and output connectors but it also has the 24vdc pc mounted relays which control most machine I/O functions. The majority of PLC controlled outputs are 24vdc signals from CN1 of FC-860 to DSB1. If the control is ready for Servo Power On, pc mount relay on DSB1 (1K3A) will be energized by 24vdc supplied from CN27 pin 10 on FC-230 through the relay to CN27 pin 17 ( /SVMX ). The normally open contact of this relay feeds 110 vac from connector X8 pin 1 of DSB1 to 1K3, the return side of the relay is tied to wire number 2. An important note about this relative to the HT20 is that X8 pin 1 on DSB1 actually is not connected to anything else on the PCB. In order for this board to work on the HT20, it needs to have a series of jumpers soldered to the back of the board to route the 110 volts to relay 1K3A. Diagnostic #3005.0 (SVON) should be a 1 while the STANDBY button is held. Diagnostic #3503.0 (SVONS) should be a 1 while the STANDBY button is held and for about five seconds after it is released. Alarm 79727 TURRET CLAMP FAULT will occur at power up if the turret is not clamped. The machine determines if the turret is clamped using a proximity switch located behind the index gear. This alarm can be cleared by manually turning the gear until the proximity switch is made (the red LED comes on). The E-Stop circuit consists of 24vdc output at address Y43 which feeds the E-Stop buttons on wires D101, D102, D103, etc. Make sure that you have 24vdc leaving FC-230 connector CN27 pins 10 and 11, going through E-Stop circuit returning to CN27 pin 19. Y43, in the ladder, is #11043 which is turned on by #14510 which in turn is turned on by a string of inputs including *ESP, NCOHT and SVALM.
The X axis brake is released when the 24vdc output at address Y44 from connector X8 pin B3 of DSB1 goes through a normally open contact of 1K3 to connector X8 pin A3 of DSB1 to ice cube relay 1K5 (BRAKE RELEASE RELAY). The rewww.machinetoolinfo.com/GENERAL-CNC-INFORMATION.html 44/70
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turn side of 1K5 is FC-230 CN27 pin 18. To access the Ladder on the i80 control: 1.Press the NC SCREEN button. 2.Press the FUNC SELECT soft key (F9). 3.Press F9 again. 4.Press the LADDER soft key. The ladder of the i80 searches from the top so that if the address you are looking for is located above the current position the CRT will display NOT FOUND. If this happens, press the FUNC. SELECT (F9) then press the BT/TOP Soft key. The first press will take the display to the bottom of the ladder, press it again to go to the top. To search for a Diagnostic address: 1.Press NC SCREEN soft key (F9). 2.Press FUNC. SELECT soft key (F9). 3.Press DIAGN soft key (F4). 4.Type the desired address (i.e. 3005) 5.Press the CURSOR DOWN button. The CRT will display 10 addresses (i.e. #3000-#3009). The diagnostics are displayed as an eight bit binary number with it's corresponding Hex value to the right.
If the machine has alarm 3000 SERVO OFF and 2190 MACHINE UNREADY at the same time, alarm 2190 will be masked because 3000 is a higher priority. Like most CNC controls, the servo unit of the i80 has control power applied at power on in order to do self-diagnostics, etc., but the three phase drive power is not applied to the machine is ready.
LNS Quick Load barfeeder: If the LCD displays EMERGENCY STOP LINE IS OPEN, check the two S8 terminals. They should be closed. If it displays other alarms about the collet, etc. make sure that the signals have not been bypassed and a jumper is loose. Often times the chuck close confirmation switches, etc will not be present on the machine tool so a number of the inputs to the barfeeder will be tied to a dry contact or 24 volt source. Some SEM servo motors have an encoder mounted to the back of the motor with two set screws. If these become loose the machine will have trouble repeating especially with regard to reference return to zero. If you are working on a Servo Dynamics drive with which the Lag value can not be adjusted close enough to zero, check the connections of J1 and J2. A bad connection here, or even a dirty connection can prevent the Lag from being decreased. A 2500 line rotary encoder connected to a 10mm ball screw should give a .0001" resolution.
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The position sensor for spindle orientation on a Kiwa KNH-426 is BZI type, Fanuc part number A860-2120-T401. On the Hyd-Mech H-12 with the Mitsubishi PLC, if the hydraulics cut off when you release the button and the number three LED is flashing, the program is probably either lost or scrambled. If the LED is on steady, their is likely a hardware problem with the PLC. If the LED is flashing you can order a memory card from Hyd-Mech and plug it into the PLC it will load the program. In this case the full the model number of the machine will be H-12 MITS. On the Rhino ST/8 lathe with the new spindle amplifier there is a row of 7 LEDs. The first LED from the left should indicate the PWM signal to the amplifier which should be seen to flash in sympathy with the speed signal to the amplifier. The second LED should come on when CW rotation is commanded and be off when CCW rotation is commanded. To transfer the parameters from one Yaskawa V7 inverter to another V7: 1.Change n177 of the source drive from 0 to 1. This will allow the parameters to be read and written. 2.Change n176 from Rdy to rEd. This will transfer the parameters from the drive to the digital operator. 3.Remove the digital operator and install on the target drive. 4.Change n177 to 1 if it is not already. 5.Change n176 to CPy. This will transfer the parameters from the digital operator to the inverter. 6.Change n176 to vFy. This will verify that the parameters in the digital operator match the parameters in the drive. 7.Change n177 back to 0 on both drives. This will prevent accidental overwriting. If a Yaskawa inverter will not run when commanded, check the digital operator to be sure that the display is on FREQ or at least some other selection with a green LED. If the display is on LO/REM or PRGM (red LEDs) the drive will not respond to a remote command. The parameter for setting the rapid rate of the Z axis on a machine with a Yasnac MX2 control is 6282. To run a cycle on the new Hyd-Mech S-20A Series II: 1.Turn the power on. 2.Release the E-Stop. 3.Hold the F1 key until the hydraulics turn on. The F1 key is on the operators interface. Switches must be in the NEUTRAL and HOLD positions. 4.Close the front vise. The display will change to another screen. 5.Press the F4 key. 6.Hold the NUM key while typing the desired length. 7.Release the NUM key, press the Enter key. 8.Cursor to R and enter the required number of parts. This number has to be greater than the value in C. 9.Press the CYCLE START button.
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These machines have a relay board where all of the inputs and outputs are connected. The relay board is connected to the PLC by two ribbon cables, CN1 and CN4. If the display will not come on check the cable that connects it to PLC. This is a PS2 type connector which if unplugged will keep the LCD screen from coming on. The Kia 21LMS turret uses a Fanuc Beta motor and drive for indexing. The turret uses an absolute pulse coder. The turret can become confused for a couple of reasons one of which is PMM parameter 11.0, this parameter has to be 1 for the turret home position. If this parameter gets set to 0 it causes a strange condition in that the turret will be able to index and go the correct tool but after the index the cycle start lamp will stay on because the TFIN is not generated. There will be no alarm and if the machine is turned off and back on the turret can be indexed again. To change this parameter you must access the Power Mate CNC Manager screen. The parameters stored here are used for Beta drives only. The parameters are stored in the drive itself so if you replace the drive the parameters go with it. 1.Press the SYSTEM button. 2.Press the Right Chapter button three times. 3.Press the PMM soft key. 4.Press the SYSTEM soft key. 5.Press the PARAM soft key. Another important PMM parameter is 11.7 because it must be 1 for the absolute pulse coder. Anytime the turret becomes confused or exhibits the condition described above the following procedure must be performed. 1.Go to the PMM parameters and make 11.0 = 0. With this parameter all eight bits must be entered so make sure you change the value of bit 0 only. 2.Set Keep Relay 5.0 to 1. 3.Unclamp the turret by pressing SPINDLE STOP, SELECT and FEED HOLD buttons simultaneously. The SELECT button in this case is the button which shows two arrows pointing in opposite directions and is located next to the SPINDLE FORWARD button. 4.Once the turret is unclamped turn it by hand until it is on tool station 1 and the two red arrows are aligned with one another. 5.Press the CALL/BZ button. The turret should clamp. Check the turret clamp confirmation switch at X0.7 to make sure it is clamped. 6.Set Keep Relay 5.0 back to 0. 7.Press the SPINDLE STOP, SELECT and FEED HOLD button simultaneously. This time the SELECT button is the button which shows an arrow pointing to the left and is located next to the MACHINE LOCK button. On some machines it may not have an arrow but may be a blank button labeled SELECT only. 8.Go to the PMM parameter 11.0 and make it a 1. The hydraulic solenoid on the Kiwa KNH-400 that sends the single arm back from the chain pot to home position is Sol 52,53 (wire numbers Y542C and
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Y543C). The way lube pump on the Kiwa KNH-400 comes every on eight minutes whether the spindle is running or not. It is controlled by counter C02. This oiler also oils the spindle bearings and is lighter than the usual 68. When looking at angular contact (thrust) bearings their direction can be determined by the arrows etched on the side of the outer race if the bearing has an arrow. Not all bearing makers place an arrow on the bearing. In this case you can find direction based on the fact that the inner race is wide (fat) on one side and narrow (skinny) on the other side. The arrow should point to the fat side. As far as how the bearings are stacked, there are different configurations for different loads such as high axial loads, etc. If a machine's control turns off at the end of a program or anytime it reads either a M02 or M30, check to see if the Auto Power Off function is turned on. On many machines this is in the form of a push button the operator's panel but in the case of a Fanuc control, particularly a 0-D control, this can be in the Software Operators Panel or take the form of a Keep Relay. On a Mitsubishi control it can be done with a Latch Parameter. If a machine with a double arm ATC hangs up at the spindle and especially if the ATC arm motor trips the overload check the tool grippers. Sometimes the plungers will get tight and have trouble pushing back far enough to be able to engage the tool. In this case you might see the magazine pot move excessively when the arm engages it. Mori-Seiki machines, the MV-55 in particular, use a number of timers for seperate events of the ATC cycle. Unlike most machines, changing things like hydraulic cylinder speed, switch positions, etc., can have great and unexpected effects. For example, on most machines if you suspect that the spindle unclamp confirmation switch is not being depressed far enough you can move the dog closer to the switch. Doing this on a Mori-Seiki may well prevent the ATC cycle from executing at all since the timing is so close. When working with cam follower bearings, most of the time they are available with either a straight screwdriver slot or an allen head. In either case they will often have a Torx head within the allen or the straight slot. If the X, Y and Z axes of a Mori MH63 will not move and the B axis will but there are no alarms check the pallet (B axis). The other axes are interlocked through the pallet down confirmation switch. On a machine with a Fanuc 6M control the signals are: ITX - G96.4 (X32.4) ITY - G97.4 (X33.4) ITZ - G98.4 (X34.4) These G signals are active low signals so they should be 0 for axis motion to be allowed. In the case of a machine with an indexer it may be necessary to lock it (M10/M11). The LeBlond Regal lathes use the Servo Shift mechanism to change spindle speeds. This mechanism is entirely hydraulic with the exception of the pulse switch located on dial A. This switched is open and closed anytime the dial is moved to another speed setting. This is done with detents on the dial. The dial has a shaft which connects it's center to the Servo Shift unit in the
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headstock. This unit sits just below the top cover and is easily accessible. Turning the dial turns the shaft which opens and closes the various ports in the Servo Shift unit but the shift does not actually occur until dial B is placed in the BRAKE position. Dial A should only be turned while dial B is in one of the two OFF positions. If dial A is turned while dial B is in the BRAKE position the Servo Shift will try to shift to the next speed range as the dial is rotated. The correct operation is: 1.Place dial B in one of the OFF positions. 2.Rotate dial A to the desired RPM. 3.Rotate dial B to the BRAKE position. The spindle will begin to oscillate back and forth. The higher RPM selected the wider the oscillation. 4.After several oscillations, rotate dial B to either the FORWARD or REVERSE run position. Dial A speeds: N 45 69 75 133 179 256 351 494 937 1282 1800 Dial B _________ | | Reverse |_________| | | Off |_________| | | Brake |_________| | | Off |_________| | | Forward |_________| Below Dial A is a plate held on by six screws. Behind this plate are two plastic half gears with detents. As the drive gears are shifted these half gears move, their detents ride on levers, the other ends of which work against a spring. If the Servo Shift is operated improperly such as turning Dial A when Dial B is in the BRAKE position it can result in a condition in which the gears shift as soon as Dial A is moved off of the current speed before it reaches the next RPM setting. When the machine is run and then Dial B is turned back to the BRAKE position, the spindle may start to oscillate in an effort to shift to the next speed. In some cases this may not occur immediately but instead it may happen as a result of the vibration of putting a part in the chuck, etc.
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On a machining center if there is a popping sound when the tool is removed from the spindle it could be that the collet is not releasing all the way but another cause is if the tool clean (air blast) is leaking through which will cause air pressure to build up behind the tool so that when it is released the air shoots it out causing the noise. On a Kiwa horizontal if you get alarms 2050 and 1030, etc. when you call a tool number over 64 on a machine that has a 120 tool magazine try running M100 to reset the tool table and then M101 to register the tools but check the Keep Relay K2.0 first. For 64 tools it should be 0, for 120 tools it should be 1. Machines that use a built-in (integrated) spindle do not have a pulse coder on the motor like other spindle motors, it uses a PLG unit. this unit consists of an inductive sensor that is sensing a plastic gear. There is a PCB between the sensor and connector CN5. This PCB has several potentiometers which are used to adjust the signal strength for PA and PB. If a machine like this exhibits a condition where the spindle oscillates and makes a high pitch noise, this PCB probably needs to be adjusted. Typically, the signals PA and PB need a signal strength of 3 Vpp. The gap between the sensor face and the gear is critical and should be about .006". The plastic gear has one tooth that is longer than the others and represents the reference marker. To check the parameters on an S-23A with a sequencer: 1.Turn the sequencer on while holding the INDEX button. 2.Release the INDEX button. 3.Use the INDEX button to scroll through the parameters. (The sequencer normally has only five parameters). After pressing the INDEX button for the fourth time, the display will default back to the normal display (current settings for INDEX and REQ. QUANTITY) so you really have to watch closely to see what the setting is for parameter 5. The typical settings for parameters 1-5 are: 1 - 75 2 - 50 3 - 320 4 - 50 5 - 50 If the Auto cycle will not execute on this machine, check that the limit switch for shuttle vise forward is made, if not the cycle will not continue. In some cases the sequencer can become confused causing the INDEX # display to reset itself to 0. This will, of course, cause the Auto cycle to stop because the saw needs to make at least one index to execute the cut. Sometimes this can be resolved by simply accessing and scrolling through the parameters. The condition may occur as a result of switching the Mode select switch directly from MANUAL to AUTO without stopping at the NEUTRAL position, according to Hyd-Mech you should always stop at NEUTRAL for a second. In Auto mode the machine should execute the cycle with or without the blade running with the exception that the head will not come down. In Auto mode CR10 should be energized and CR11 should be de-energized. In Manual mode CR11 should be energized and CR 10 should be de-energized. In Neutral mode both CR10 and CR11 should be de-energized. 3CR should be energwww.machinetoolinfo.com/GENERAL-CNC-INFORMATION.html 50/70
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ized anytime the hydraulics is on. The S-23 with a sequencer like the S-20 uses a limit switch to position the shuttle vise for the proper length, this is the top left limit switch and has a vernier dial (micrometer) for fine adjustment. The bottom left switch is the approach switch and it is placed ahead (in terms of travel) of the top switch. When the shuttle contacts this switch the feed rate slows to allow more precise positioning. The limit switch on the right is used only for confirmation of the shuttle vise fully forward. The B axis for the KNH-400 has two proximity switches that confirm the state of the axis, either clamped or unclamped. The CLAMP confirmation switch is LS36, it's symbol is LSBRCL, the I/O address is X0009.7. The UNCLAMP confirmation switch is LS37, it's symbol is LSBRUC, the I/O address is X0009.6. Both switches are two-wire devices, their source is wire HP. These switches are actuated by a piston in the base of the B axis. It is accessed by removing the eight screws and cover located on the ATC side of the B axis. The piston is held on by two bolts and is easily removed once the cover is out of the way. The piston is pushed out by hydraulic pressure when the axis is unclamped and is returned to it's original position by a spring. A dog is attached to the piston by a collar and set screw and moves over the face of the proximity switches. With the two bolts removed, the piston and spring can be removed as an assembly. It is not uncommon for the piston shaft to become worn and start to stick due to lateral motion of the shaft. Normally when this occurs the piston will move out under the hydraulic pressure but the spring is not strong enough to pull it back so the axis thinks it is unclamped all of the time. If you need a password to access the ladder of a Mori-Seiki, try entering the letter L, then input. The Yasnac 3000G control has only 100 parameters (00-99) but parameter 65 consists of 8 groups of parameters with each group consisting of 8 bits. If you replace the main board (CP03) board of a Yasnac 3000G control and it exhibits strange behavior, it may be necessary to regenerate the control. To do this: 1. Place the thumbwheel switch (located in the tape reader enclosure) to 5. 2. Turn NC off. 3. Hold Cancel, Reset and Parameter (PRM) while powering up. Clears Parameters. 4. Turn NC off. 5. Hold Cancel, Reset and Offset (OFS) while powering up. Clears Offsets. 6. Turn NC off. 7. Hold Cancel, Reset, Communication (COM) and Erase (ERS) while powering up. Clears Programs. 8. Reload parameters by hand. 9. Cycle power. 10. Reload programs. When reloading the parameters you need to be aware that N65 is for the Optional Features (option parameters). This parameter appears as a single zero (0) when viewed normally, but when viewed with the thumbwheel switch in position
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5, it appears as an eight bit binary number. The Optional Features are set in groups of 8. The groups appear as 65X,65Y,65Z,65A,65I,65J,65K,65R. These values are altered by typing the letter of the group (i.e., X, Z, J, etc.). The eight bits of each group are designated D0-D7 corresponding to bits 0-7. On some machines, the keypad may not have the letter A so you must use the number 4 to access group 65A. Also, if you press a key that does not represent a valid group (S, T, G, etc.), the parameter N65 will disappear from the machine. Pressing a valid letter such as X or J will cause N65 to reappear. Reloading the parameters is a simple matter of typing in the value that you want the parameter to be and pressing the Write (WR) button. Make sure that you select the correct letter designation first. For example, to change the value of parameter 71Y you would use the Page Up/Down and the Line Up/Down buttons to get to parameter 71, then type in the letter Y. Now the value that you enter will affect 71Y but not 71X, 71Z, etc. Parameter 65 is different. Since these are option parameters, there is an additional step. Once you have paged to parameter 65 and selected X, Y, etc. you must press the Insert (INS) button. this will place an asterisk under the first bit (D7). Now type in the eight bits from left to right (7-0) then press the write (WR) button. Now you MUST press the RESET button for the parameter to become effective. After performing this procedure, cycle the power all the way back to the breaker. In some cases you may need to clear the program storage area again in order to load the programs. The Strong model N212 chuck like the ones used on the Ecoca SJ-25, etc. has a jaw stroke of .417" on the diameter, the plunger stroke is .905". The actuators used on these machines have a piston stroke of .915". The electrical boxes of the LNS bar feeders are wired for the lathe they are to be installed on and LNS keeps a copy of the wiring diagram that can be referenced by the drawing number. Yasnac MX3: To access the RUN TIME, CYCLE TIME, etc, press the ALM button, then page down until TIMER is displayed at the top of the screen. You should see: 1. POWER ON 2. CYCLE START 3. CUTTING FEED 4. OPTIONAL To clear a timer value, press the desired number (1,2,3 or 4) along with the origin (ORG) button. On the Kia SKT21 with a parts catcher, catcher up confirmation is X3.0, down is X3.1. In the case of the Kia SKT15 with a Fanuc 0i control, the main spindle parts catcher up confirmation signal is X8.2, X8.3 is parts catcher down. On the SKT15 the output coils for parts catcher up/down are Y8.2 and Y8.3 respectively. The relays are 2KA11 and 2KA12. The M-code for parts catcher up is M63, down is M64. These are configured to finish with a hardware signal. The parts catcher function for the SKT15 is enabled and disabled by way of a G.DATA bit. This bit is D0009.6 and must be set to a value of 1 in order for the parts catcher to be valid. Typically the value displayed will be in decimal so you must convert the 8 bit binary number to decimal then input. If the value in D0009 is currently 0 you must enter a value of 64 (01000000). Normally on this machine the value of D0009 will be set at 32 from the factory so you would add the two and enter 96. The Krras Bend 70.30 with PGP601 back gage controller uses only 12 parameters in the controller. They are:
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Parameter 1 2 3 4 5 6 7 8 9 10 11 12
Definition
Setting
Index Quote Programming Overrun Distance 0.000 Slowing Down 0.400 Inertia Quote (PGP calculates every 2 positions) 0.004 Position Tolerance 0.004 Retraction 0.200 Time Before Retraction 0.004 Negative Limit Switch 0.450 Positive Limit Switch 23.200 Encoder Multiplier (1, 2, 4) 4 Encoder Divide Factor 9.8625 Programmable Point Decimals (0, 1, 2, 3) 0.003
The above settings are typical and may be different for other machines. The Index Quote Programming value is defined by the customer and varies depending on how far the fingers, etc. are from the die. For a twelve lead AC motor there are six windings with two leads for each set. The numbering for the sets is typically: U1-X1 U2-X2 V1-Y1 V2-Y2 W1-Z1 W2-Z2 The resistance of each winding is normally in the range of 1 ohm. When the motor is wired for DELTA (low voltage) operation there are essentially three sets of two windings with the two windings of each set in series. Using the numbering above, this is accomplished by connecting the leads as follows: U1 to Z2 X1 to U2 X2 to V1 Y1 to V2 Y2 to W1 Z1 to W2 The three phase voltage would be connected this way: L1 to U1, Z2 L2 to X2, V1 L3 to Y2, W1 For WYE operation, connect the leads as follows: X1 to U2 Y1 to V2 Z1 to W2 X2 to Y2 to Z2 The three phase voltage for WYE operation is connected: L1 to U1 L2 to V1 L3 to W1
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This connection places four windings in series with respect to any two phases. Regardless of how the windings are numbered, you can wire the motor by ringing out the leads to find individual windings and wiring accordingly. Another thing to be aware of is that the wire numbering using alpha numeric such as U1, V1, W1, X, Y and Z is IEC nomenclature while numbering that uses numbers only such as 1,2,3,4 etc., is NEMA nomenclature. 9 Lead Motor (Wye): Low Voltage 4, 5 and 6 together, 1 to 7, 2 to 8 and 3 to 9, line voltage to 1/7, 2/8 and 3/9. High Voltage 4 to 7, 5 to 8 and 6 to 9, line voltage to 1, 2 and 3. 9 Lead Motor (Delta): Low Voltage 1, 6 and 7 together, 2, 4 and 8 together, 3, 5 and 9 together. One phase of voltage to each set. High Voltage Same as for Wye connection.
KIWA KNH-400 B axis clamp/unclamp information: 24vdc is supplied by wire HP at terminal block TB5 to Unclamp limit switch LS37 and Clamp limit switch LS36. Both switches are normally open. Closure of LS37 sends 24vdc through TM2-16 to wire X096 then to Fanuc I/O Module CB151 pin 16 turning on input X9.6. Closure of LS36 sends 24vdc through TM2-17 to wire X097 then to I/O Module CB151 pin 17 turning on input X9.7. On the output side Y3.7 (B AXIS CLAMP) sends 24vdc from Fanuc I/O module CB151 pin 9 to wire Y037 through TM2-9 connecting to CR18 coil. The return is wire HN. CR18 contact closure sends 110 vac from L1-9 to wire Y37C through connector CN1-L to B Axis Clamp solenoid SOL27. The return is L2-9. The solenoid valve is Daikin KS)-G02-3BA-30-E 100 vac. Stankoservis VTL: If the table will run at some speeds but not others check the glass fuses that feed the clutches. Each fuse feeds a different set of clutches. So if, for example, the 7th fuse from the left blows speeds 1.25-6.3 will not work. In this case the table brake also will not work. When the table is started and the arm feed engaged after a set time the table speed is locked and cannot be changed. If the feed is stopped, the table speed can then be changed and feed resumed. This function may be tied to the V=C switch. *** Model A163-2000 100 *** When replacing old faceplate with adapter cable must be ordered from Anilam and rewired according to drawing number AOC 1 in Anilam file. Also, on this model readout, if an axis direction indication is backward the wire harness from the scale can be reversed on the PCB to give proper indication. Series 1100 To run in Auto, make sure the AUTO/MAN switch is in AUTO. If no program is selected, won't go into Auto. There are four LEDs on the Motion Board, if the second one from the top is off the machine is in E-Stop condition. There is a small power supply to the left of the relay board which supplies
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the 24 vdc for most things. The 110 volt supply for this unit comes from the relay board, from the connector on the lower right corner of the board. It is a four pin connector, the other two pins are the 24vdc from the power supply. K4 on the relay board has to energize first. The +24vdc for the coil of the relay is supplied directly to the coil, the -24vdc (common) is routed through the motion board. The common is a yellow wire on the power supply. The common signal from the motion board is at P1-1. It goes to P3-3 on the relay board. Having all of this in place will cause K4 to energize. To energize the other relays and make the machine ready you have to press the SERVO ENABLE soft key. On the 1100 control you change the direction of the motors by accessing the Setup Utilities. Direction +/- is shown as inverting/non-inverting. To access the CMOS setup you need a keyboard. There is a port on the control to plug an AT keyboard but if you have a PS2 keyboard you have to plug it into the CPU board. You have to press either F2 or DEL to enter setup. If the keypad and VGA ports are both on the same board (CPU), use F2. Sometimes a control will default to a drive other than the one where the startup files are stored. This may be caused when the CMOS battery dies. If you go to the setup utility and change this but it does not hold, the battery is probably dead. The CMOS battery is Rayovac BR2335 or BR2330. Some of the CPUs use a battery inside the chip, these cannot be replaced. The board has to be upgraded at a cost of about $1000. The password to access the setup utility is Y10. The Anilam 3300 has a MANUAL/AUTO switch on the back of the pendant. If this switch is in the MANUAL position, the servos will not power up. In this case the control will act as a DRO only. If the control is powered up in MANUAL then switched to AUTO, it will still not be able to operate servos, the switch must be in AUTO during power up. There is an I.D. key installed on the back of the pendant which identifies which options are available to the control. If the key is missing or damaged the options will not be available. Miscellaneous functions such as spindle operation are options on this control so if the key is missing or damaged the spindle will not turn on. In this case the serial number (SER.NO.) of the I.D. key which is normally displayed in the upper right hand corner of the CRT display will read all zeros. The key is like a gender changer so other cables can be plugged into the back of it. Certain cables such as a RS-232 plugged into the key will prevent it from working. The Motion I/O board has a row of LED indicators from top to bottom which indicate several things such as the status of the E-Stop, overtravel switches and if the servo on signal has been turned on. When the SERVO ON/ RESET button is pressed the corresponding LED should come on and the K1 relay (ice cube) should turn on energizing the solid state relay K2 which is mounted to the backplane of the cabinet with connection to the board via screws through the board. This relay sends the 115 vac to the drives. If there is no display of position change when an axis is moved check the external power supply which provides the 5vdc to the motor encoders via connectors on the Motion I/O board. FANUC CONTROLS COMMUNICATION CABLE The following cable configuration is required for communication between a Fanuc control and a PC. Pinouts for two 25 pin connectors.
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25 pin connector Pin 7 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 ---------------------------------------------____ | | ____|
25 pin connector Pin 7 Pin 3 Pin 2 Pin 4 Pin 5 Pin 6 Pin 8 Pin 20
____ |____ ____ |____ |____
____ | | Pin 8 ____| | | Pin 20 ____|
Pinouts for one 25 pin connector and one 9 pin connector.
---------------------------------------------____ | | ____| ____ | | ____| | | ____|
____ |____ ____ |____ |____
In both cases, pins not shown are not used. A ordinary parallel cable will not work and if attempted could cause damage to the PC or the control since Pin 25 of ALL Fanuc controls is a 24 vdc supply for use with specific Fanuc devices. NULL MODEM CABLES 9 Pin Null Modem Cable Pin 1 Pin 2 ------------------------------Pin 4 Pin 3
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Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9
-------------------------------------------------------------------------------------------
Pin 2 Pin 1 and 6 Pin 5 Pin 4 Pin 8 Pin 7
No Connection
25 Pin Null Modem Cable Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 ---------------------------------------------------------------------------Pin 1 Pin 3 Pin 2 Pin 5 Pin 4 Pin 20 Pin 7
-| |-------------Pin 8 -| Pin 7 ----------------
|- Pin 6 Pin 20 ---------------- | |- Pin 8 Pins not shown are not used.
Pinnouts for M5 cable on Fanuc control: 20 Pin Honda (M5) 25 Pin (RS-232)
Pin 2 ---------------------------- Pin 9 Pin 3 ---------------------------- Pin 8 Pin 4 ---------------------------- Pin 20 Pin 5 ---------------------------- Pin 19 Pin 6 ---------------------------- Pin 18 Pin 7 ---------------------------- Pin 17 Pin 8 ---------------------------- Pin 16 Pin 20 ---------------------------- Pin 5 Pin 25 ---------------------------- Pin 14 If you have a 25 pin to 9 pin molded RS-232 cable, the pin outs are probably like this:
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25 Pin
9 Pin
Pin 2 ---------------------------- Pin 3 Pin 3 ---------------------------- Pin 2 Pin 8 ---------------------------- Pin 1 Pin 20 ---------------------------- Pin 4 Pin 7 ---------------------------- Pin 5 Pin 6 ---------------------------- Pin 6 Pin 4 ---------------------------- Pin 7 Pin 5 ---------------------------- Pin 8 Pin 22 ---------------------------- Pin 9 The adapter that I use to make this cable work with controls is purchased from Radio Shack, it is configured this way: Pin 2 ---------------------------- Pin 3 Pin 3 ---------------------------- Pin 2 Pin 4 --- Pin 4 | | Pin 5 --- Pin 5 Pin 7 ---------------------------- Pin 7 Pin 6 --- Pin 6 | | Pin 8 --- Pin 8 | | Pin 20 --- Pin 20
This adapter is a RS232 SHIELDED JUMPER BOX 276-1403A. I normally use this in conjunction with a Radio Shack DOUBLE SHIELDED RS232C CABLE (6 feet). Part number is 26-269. A source for Fanuc and Mitsubishi cables is Machine Tool Services, they can make motor and feedback cables for many CNC controls. Their phone number is 480-985-1941.
Kia Turn 21 with Yasnac LX3. To enable the parts catcher you must make parameter 7005.1 equal 1. To do this: 1. Select MDI mode. 2. Press the SET button. 3. Cursor to Setting Parameter #6219 (PWE) 4. Enter 1. 5. Press the WR button. 6. Press the PRM button. 7. Cursor to parameter #7005. 8. Press the INSERT button. 9. Use the cursor down button to move to bit 1. 10. Enter 1. 11. Press the WR button.
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* Enter a value of 2 in parameter 7005.1 disables the parts catcher. If you do not change none of the M functions will work, etc. If the turret tools are confused on this machine: 1. Rotate the turret to tool station 1. 2. Set the PWE (parameter 6219) to 1. 3. Select Jog mode. 4. Press the TURRET SELECT and TURRET INDEX buttons together once.
the PWE back to 0
Hyd-Mech S-20A with Sequencer: The green light should be off until the hydraulics are started. The hydraulics will start with or without the switches in neutral, hold, etc. If the hydraulics start but shut off when the green button is released, check the blade tension switch (3LS). There is a handle on the left side of the machine. Turning the handle clockwise increases the blade tension and moves the dog toward the limit switch. When this switch is open all of the machines functions will work as long as the green button is held in except that the head will not move down. Also when the switch is open the green pilot light that is close to the blade tension adjustment will be off. The Required Quantity (Parts Count) display decrements each time the head reaches the bottom of it's stroke. Once the count reaches 000 in Auto mode, the head should go up and everything shut off including the hydraulics (the sequencer display stays on). If when the shuttle moves back, enters slowdown then wants to keep going check the stop switch. If the length adjuster is loose the switch can cause it to slide keeping it from making the switch. The Index and Required Quantity displays can not be changed unless the hydraulics are running. The circuit for the hydraulics: 110V-------{ }------|/|------|/|------|/|------|/|------| |-----( )-----N 1FU 1OL 2OL 1PB | 3LS 1M | 1M | | | | -------| |--------2PB
2PB
1FU - 5 amp fuse 1OL - Hydraulic motor overload 2OL - Blade motor overload 1PB - Stop pushbutton 3LS - Blade break limit switch 1M - Hydraulic motor holding contact and motor starter 2PB - Hydraulic start button (green button)PLC100 Error Codes:
PLC100 Error Codes: 00 01 02 05 Auto Mode Input Not Detected Hydraulics Run Input Not Detected Shuttle Vise Closed Input Not Detected Head Up Input Not Detected
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06 09 10 11 12
Head Down Input Not Detected Shuttle Home Input Not Detected PLC100 Did Not Reach Programmed Shuttle Length Shuttle Encoder Channel A and B Are Reversed No Encoder Input Has Been Detected
PLC100 Setup Parameters for H-12A S/N A0995418A: # Set Value A Machine Symbol N/A H-12A B Shuttle Length Constant 0 31478 C Pulses Per Revolution of Encoder X10 1 40000 D Shuttle Length (Inches) 2 40 E Rear Cushion 3 1 F Front Cushion 4 1 G Overshoot 5 .016 H Front Vise Dwell 6 750 I Shuttle Vise Dwell 7 750 J Wheel Constant 8 43 K Wheel Pulses Per Revolution 9 740 L Machine Characteristics A 1 When "PAUSED" is displayed the Out Of Stock Limit Switch has been activated. If the hydraulics will not stay on, try holding the button in then using the manual buttons to open the vises. If the blade break proximity switch is bad or out of adjustment the machine will start and run until it "sees" that the blade is not moving. It does this by having the prox switch look at the driven wheel. On V18APC, if the hydraulics will not start, the encoder cable may be shorted. On the V-18APC, if the length measurement is off on straight (90 degree) cuts, adjust the INCH/REV parameter. If the cut comes out too long, increase the value, if too short, decrease the value. If it is off on angle cuts, adjust the DP RADIUS parameter. The BP RADIUS parameter is normally used for when there is a measurement error when going from an angle cut to a straight cut. The S-20P Series III uses a Mitsubishi FR-S520E-2 inverter for the blade motor. If it displays alarm OV3 it normally means that the regenerative voltage was too high during deceleration. The decel time is set from the factory at .5 seconds so under certain conditions this may not be enough. You can increase the decel time by changing inverter parameter number 8. You have to change parameter number 79 from 2 to 1 to unlock the other parameters. Mazak Service 704-821-3340 Jim This office should be used whenever possible but in case of dire need you can call the Atlanta office: 770-996-1030 Most Mazaks use a main breaker which is interlocked through the door switches. If a door is opened, the main breaker will trip removing all power from the machine. *** Micro Turn *** The tool turret uses Reed switches mounted in a circular pattern to control indexing. Each position has two switches. One is for decelerating the turret motor and the other is for locating. They are mounted to a PCB which is hard
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wired to the machine. It can only be removed by de-soldering all of the wires. An arm with a magnet on one end rotates counter clockwise to activate the switches. When working properly they can be heard closing as the magnet passes each position. To orient the turret: 1. Call up a tool. 2. Once the turret locates, loosen the bolt holding the arm and move it to toward the switch which corresponds to that number. (The tool positions are printed on the PCB) 3. Listen carefully and as soon as the switch closes, stop the arm and tighten it down. If a position confirmation switch fails in the open state, the turret will index continually when that tool is called. The height of the magnet relative to the top of the switch is very important. It should be about .060". If the switches are not located correctly the turret may stop at the correct position but will unable to locate and re-clamp. If this happens and you do not know which switch is out of position or if the height is wrong, a good place to start is to: Slightly raise the first switch from CCW (Decel switch) above the board. Press the second switch (Position confirmation) flush with the board. If the turret still has trouble re-clamping, try moving the second switch a little away from the first. Remember, these are Reed switches soldered to the board so be careful not to bend the leads too far.
*** Micro Center V *** If Machine Fail light stays on, check the Head Lube Pressure switch. This switch is on the right side of the spindle in a tee in the oil line. This switch has only one wire. It is connected between the timer coil and ground. If the pressure is too low, it closes and energizes the timer. The Lube light on the side of the machine will also be on. For CHECK SUM ERROR on Mazatrol M2, press the PARAMETER key in menu, press the NEXT key in menu (F3). The bad ROM causing the check sum error will be displayed in CS20. If the first digit from the left is 0, the bad ROM is on board FX84, if it is 1, the bad ROM is on FX84-1. The next two digits from the left indicate the location of the bad ROM on the board. For M2V/B check CS24. If the first digit from the left is 0, the bad ROM is on board FX784-8, if it is 1, the bad ROM is on board FX784-9. Again, the next two digits from the left indicate the location of the bad ROM on the board. For Mazatrol T2/T3, select the DIAGNOSIS screen, select CHECK S/W VERSION, when a check sum error has occurred where the software version is normally displayed (MIL) will, instead, display the location of the bad ROM (i.e. 5K). Should look like: LAN EIA MIL 5K DNC
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YASKAWA Chicago Technical Center 847-291-2340 Technical Representative Eric Jozaitis direct line 847-291-6201 Manuals and other publications 847-509-6057 Theresa Vanover direct line. AC Inverter model 616G3: If Ov (over voltage) alarm occurs, the deceleration time is probably too short. If a braking resistor is installed, the resistor may have opened. If a braking resistor is not installed, adding one may solve the over voltage problem. This should be wired into the B1+ and B1- terminals to bleed off the excess current in the DC buss. Another thing that may prove helpful is to adjust the S curve to decrease the linearity of the ramp. In some cases the motor that the inverter is driving can overdrive the inverter on decel which causes the Ov fault. Specifically, on the 6BVS the belts can be worn or loose in which case there is not enough load or drag and if the velocity of the motor is relatively great when decel is attempted the counter EMF will exceed the limit of the DC buss. Also check Parameter N032 Motor KW to be sure it is set high enough for the size of the motor. Another thing to check for is the AC voltage parameters. If the incoming AC is 220 volts Vmtr, N003, and N011 should be 220.
On some inverter models the Fault outputs(FLT A, FLT B) are programmable. They can be made to open or close their contacts for conditions other than inverter faults (On Start-up, Up to Speed, Zero Speed, etc.) by changing parameters. In most cases, the associated parameters will be N036,N037,and N038. If changing these values does not provide the desired results then consult with Miles at Yaskawa. If constant n010 is set improperly, you will not be able to change constants 11-18. On most units it is set to F, but this pattern will not work for all applications and you will have to select another or build one yourself. Parameters for 616PC5 installed in 6BVS: Accel 5.0 Decel 5.0 Vmtr 220.0 V/F F Fgain 100 Fbias 0 FLA 19.6 PID 0 kWsav 0 PRGM n068 n001 3 n002 3 n003 220.0 n004 1 n005 1 n006 0
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n007 n008 n009 n010 n011 n012 n013 n014 n015 n016 n017 n018 n019 n020 n021 n022 n023 n024 n025 n026 n027 n028 n029 n030 n031 n032 n033 n034 n035 n036 n037 n038 n039 n040 n041 n042 n043 n044 n045 n046 n047 n048 n049 n050 n051 n052 n053 n054 n055 n056 n057 n058 n059 n060 n061 n062 n063 n064 n065
1 1 1 F 220.0 180.0 220.0 60.0 3.0 15.0 1.5 10.0 5.0 5.0 10.0 10.0 1 0 0.0 0.0 0.0 0.0 6.0 100 26 19.6 1 3 0 2 4 9 10 0 1 0 1 0 0 100 0 0 1.00 6 0 110 0.7 60 2.0 0 0 0.0 0.0 1.0 1 1 0 50 0.5
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n066 n067 n068 n069 n070 n071 n072 n073 n074 n075 n076 n077 n078 n079 n080 n081 n082 n083 n084 n085 n086 n087 n088 n089 n090 n091 n092 n093 n094 n095 n096 n097 n098 n099 n100 n101 n102 n103 n104 n105 n106 n107 n108 n109 n110 n111 n112 n113 n114 n115 n116
0.0 1.0 0.434 172 1 170 160 0.0 0 160 0.1 0.0 0.0 0 7 8 0 0.2 0 1.00 1.0 10.0 0.00 0 100 0.0 0 0 1.0 0 94.75 50 12 1 0 0.5 0.2 1 1 0 0 2 1 0.0 30 2.0 0 2.0 0 5 0
The 616PC5 has a design defect in that the control card made by Saftronics exhibits erratic behavior at frequencies between 124.5 and 160.1 Hz. This is caused by an older version of software which contains a program error.
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The software version is Ver. 1010 and has been replaced by Ver. 1015 which does not exhibit these symptoms. The software is surface mounted to the board and cannot be replaced. The memory is not EE so it cannot be changed either. The only fix is to replace the control card with a ver. 1015. The only precaution is to be sure that the replacement card is for an inverter of the same KW rating as the one being replaced. To determine the software version of a drive, look in U-10. this is where the version is stored. You must use the display key to scroll over to Montr. then use the arrow key to scroll up to U-10 then press enter. The version will be displayed. The phone number for Saftronics is 800-533-0031. Ask for Glen. The following is a current table for the 6BVS: Hz Gear Lo Motor Lo Gear Lo Motor Hi Gear Hi Motor Lo Gear Hi Motor Hi 60 80 100 120 140 160 180
11.0 7.1 11.0 7.1
6.5 4.3 6.5 4.3
4.8 3.3 4.8 3.4
3.9 2.9 3.9 3.2
3.4 2.8 3.4 3.4
3.1 2.8 3.2 3.5
2.8 3.0 2.9 4.0
Some inverters will allow access to more constants than others. To gain access to more of them on the 616PC5, change constant n001 to a value of 616. This should allow you to access up to constant n140. The newest versions of software for the 616 as of 11/97 is 2010 and 3010. Parameter Access of 616PC: When: n000=00 Constants 1-19 can be read but not written n000=01 Constants 1-19 can be read and written n000=02 Constants 1-29 can be read and written n000=03 constants 1-59 can be read and written ES3000 EDM: The ES3000 with a Heidenhain control, as with most Heidenhain controlled EDMs uses the following procedure for operation. After power-up: 1.Press CE. 2.Press the Sine Wave (Symbol) button to turn on generator power. 3.Home all axes by pressing Start once for each axis. 4.Press the PGM RUN button. (This is usually a symbol pointing to the right) 5.Press GOTO. 6.Press 0. 7.Press ENT. 8.Press START. This will take you to the beginning of the program and begin the discharge. On the ES3000 there are four contactors which select the polarity. Two of these select positive polarity and the other two select negative polarity.
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One of the polarities must be selected which means any time you are trying to burn two of these contactors must be pulled in. If not the generator power will shut off when discharge is attempted. The green LED on the DC9343 board comes on when the polarity is selected. There are six contactors at the bottom of the electrical cabinet. The four on the left are the polarity contactors. When the first and third from the left are pulled in, Reverse polarity is selected. When the second and fourth are selected, Normal polarity is selected. The fifth contactor is the Dielectric Pump, the sixth is Generator Power. If the machine will not release from the E-STOP condition and the button is not depressed, check for an axis over travel. The axis limits are tied between X21 pin 34 and X22 Pin 4. You can eliminate a machine problem by removing these connectors and connecting a jumper between the two pins. These connectors go to the Interface Board TNC3062 on connector CN6. X21 Pin 34 goes to the 14th pin from the top on the front row of pins on CN6. X22 Pin 4 goes to the 12th from the top on the same row. The E-Stop button is tied to pins 1 and 2 of CN1 on the TNC3062. The TNC306 control is for use on EDM machines. The TNC360 is for mills. If the BUFFER BATTERY alarm is issued, you need to replace the three AA batteries. They are located in a black plastic tube in the gold colored chassis. On the ES3000 this chassis is behind the Operator's Panel. Heidenhain recommends Duracell batteries because of the physical style. If you have trouble with an EDM machine that it won't move down when discharging. The generator comes on but the ram does not move. Make sure it is off of the travel limit switch. If it is off of the switch, try replacing one or both of the small PCB boards (OSC). On the 6BVS machines that I interfaced with the SWI AGE3 controls, I removed all of the power leads going to the two motor contactors (FWD/REV). I did not mess with the auxiliary contacts. I used one normally open contact from each contactor and tied them in parallel so that any time either one is pulled in the spindle inverter is enabled. When the control stops the spindle for a tool change, etc., the contactors drop out disabling the inverter. I also removed the motor leads from the overload relay. One of the two wires from the normally open contacts is tied to my forward and reverse contactors in the electrical cabinet to their common terminal. The other wire is tied to #1 in the cabinet, feeding the common. Normally when powering up the ES-3000 with the Heidenhain TNC306E and starting to run, the sequence is: 1.Turn the breaker on. 2.The first screen is POWER INTERRUPTED. 3.Press the CE button. 4.Next screen is RELAY EXT. DC VOLTAGE MISSING. 5.Press the Sine Wave button on the Remote Operator twice. You should hear the contactors energize. You should wait a second or two after the first push before pushing again. If not you may get the Emergency Stop message. 6.Next screen is TRAVERSE REFERENCE POINTS Z-AXIS Y-AXIS X-AXIS
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---------------------------------------ACTL. X nn,nnnn Y nn,nnnn Z nn,nnnn 7.Press the START button on the Remote Operator. The Z axis will reference. Press it again. The Y axis will reference. Press it again. The Z axis will reference. There are no reference switches, the axes just move a pre-determined distance in a pre-determined direction. While each axes is moving, there will be an asterisk displayed below ACTL. This indicates that the axes is not in position which is, of course, normal while moving. If after an axis stops, the asterisk does not turn off the axis has excessive offset. This is the same as the In-Position signal on other controls. In this case you must remove the asterisk. This is done by either making an adjustment on the servo driver or in some cases replacing it. The older style servo drivers only have one pot to adjust. This will normally remove the offset but you need to check the Lag. This pot has limited use in this so if the Lag is excessive you usually have to replace the driver. The newer ones have more pots to work with. Check the Lag by going to the Lag display as explained below. If an axis does not stop in-position, the asterisk is on, the control will not transition to the next screen and will not operate properly. 8.Next screen is MANUAL INTERPOLATION INTERPOLATION FACTOR: X nn,nnnn Y nn,nnnn Z nn,nnnn At this point the machine is ready to be operated in Manual Mode. The Lag value differs between axes and at different feed rates but generally should not exceed about 700. Normally, if the Lag is too high, the axis will move with a rough or jerked motion. Also you will notice that after releasing the Jog button, the axis continues to move an abnormally long time. In order to adjust Lag you need to access the Lag Display screen. This is one of the position screens. To do this: 1.Press the MOD button (For Auxiliary Mode). 2.Press either the Up Arrow or Down Arrow key until POSITION DISPLAY is shown at the top of the screen. 3.Press the ENT button until the Lag screen is displayed. 4.Press the END button to exit the Auxiliary Mode.
When troubleshooting an axis problem on a TNC 306, a useful tool is the ability to swap the allocation of the encoder inputs in the PLC. This is done with Machine Parameter MP 110. On a four axis machine the parameter is normally set this way:
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MP 110.0 MP 110.1 MP 110.2 MP 110.3
0 1 2 3
This configuration assigns the X axis to connector X1 of the Processor board, the Y axis to X2, the Z axis to X3 and the fourth axis to X4. If you swap the X axis cable from port X1 to X2 and the Y axis cable from X2 to X1, for example, you must change the parameter to: MP 110.0 MP 110.1 MP 110.2 MP 110.3 1 0 2 3
If the problem still exists on the X axis the culprit is probably the scale or encoder or their cable. All of this is aimed at troubleshooting mainly feedback of positioning problems. The idea here is to eliminate the PLC as the problem. When troubleshooting an X,Y or Z axis MEASURING SYSTEM DEFECT alarm, a good place to start is the scanning unit. You will almost certainly find that the cause of this problem to be in the scale or it's cable.
The Service Manual for the TNC 306/360 is useful in working on other Heidenhain controls because the parameter section also list parameters for other controls such as TNC2500, TNC234 and TNC355. Connector designation for the TNC306 Logic Unit are: Processor board X1 Encoder 1 X2 Encoder 2 X3 Encoder 3 X4 Encoder 4 X6 Encoder S X8 Nominal Value Output 1,2,3,4,S X9 VDU (BE or BF) X11 Hand wheel HR 130/330 X12 Touch Probe System B Signal Ground
PLC board X21 PLC Output X22 PLC Input X23 TNC Operating Panel (TE) X24 Power Supply 24V for PLC X25 Data Interface V.24/RS-232-C X26 PLC I/O board (PL 400) X27 Machine Operating Panel (MB) Power Supply X31 Power Supply 24V for LE
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Heidenhain calls the reader heads of it's scales, scanning units. In the case of the LS 603, these are optical devices. They can be replaced without the cable. Remove the four screws on the front of the unit. Inside there is an Amp connector. Unplug this connector and remove the unit from the body. When ordering a new scanning unit, you will need the ID number. This number is on the unit, it looks like: Id.Nr. 24992275 for example. Another important number is the ML number, this is the measuring length. This number is typically in millimeters (i.e., ML1740mm). When in need of Heidenhain parts you can call Heidenhain at 847-490-1191 or Machine Tool Technicians at 804-714-0700. The Com port for RS-232 is X25. For the Euro Source ES-3000 at Xaloy, the control is Heidenhain TNC 306E. The NC Software is 260030 03G. The PLC Software is 252555 13. For RS-232 operations: 1.Press the MOD button (Not the one for Graphics) 2.Press the Down Arrow button until RS-232-C INTERFACE = is displayed (Top of screen) 3.Press the Right Cursor button until EXT is displayed. 4.Press the Cursor Up or Cursor Down button until BAUD RATE is displayed. 5.Type in the desired baud rate. 6.Press the ENT button. The Transfer Protocol for RS-232 is DC1/DC3. The cable pin out for RS-232 is the same as Fanuc Standard. To output the Machine Parameters: 1.Press the MOD button. 2.Press the Cursor Up or Cursor Down button until CODE NUMBER = is displayed. 3.Enter 95148. 4.Press the ENT button. (Activates the MP code) 5.Press the EXT button then the ENT button. (Prepares the NC for data output) The 6BVS with the Dynapath control has four wires to the motor aside from the motor leads. The two yellow wires go to terminals AM and AC on the F7 inverter. These wires are for the brake, the parameter that controls this multifunction output should be set so that it monitors the output frequency. The two blue wires go to the motor fan. The parameter for this multi-function output should be set to close when the motor is running. In order for the brake to work properly on this machine, the parameter B1-03 must be set to 1 so that the motor will coast to a stop. If you try to decel the motor and use the brake, at higher RPM the brake will come on while the motor is still decelerating, cut off, then the motor will start running again until brought to a stop under normal decel. If you try to reduce the decel time enough for the brake to come on at the end of the decel curve, the drive will fault due to DC buss over voltage.
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Yasnac Mx-3 Fault Finding Guide

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Yasnac Mx-3 Fault Finding Guide

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General CNC Information

9 Pin Male 1 ooooo oooo 9 9 Pin Female 1 ooooo oooo 9

CN3 1 2 3 | | | | | | | | N24 N32 4 5 6 7 8 | | | | | | | | U33 U27 N24

0 = Jog Feed 1 = Rapid 0 = Required 1 = Not Required

500Mv2.2 500Mv2.2a 500Mv2.3 500Mv2.4 500Mv2.5 500Mv2.6 500Mv2.7 2100v1.0 2100v1.1

Tool is Pushed Magazine Pot is Locked Magazine Pot is Unlocked

1200 2400 4800

ACTUAL POSITION - Normally set to 0. Set to 1 to display actual position.

____ |____ ____ |____ |____

____ | | Pin 8 ____| | | Pin 20 ____|

Pinouts for one 25 pin connector and one 9 pin connector.

---------------------------------------------____ | | ____| ____ | | ____| | | ____|

____ |____ ____ |____ |____

Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9

Pin 2 Pin 1 and 6 Pin 5 Pin 4 Pin 8 Pin 7

-| |-------------Pin 8 -| Pin 7 ----------------

the PWE back to 0

11.0 7.1 11.0 7.1

6.5 4.3 6.5 4.3

4.8 3.3 4.8 3.4

3.9 2.9 3.9 3.2

3.4 2.8 3.4 3.4

3.1 2.8 3.2 3.5

2.8 3.0 2.9 4.0

MP 110.0 MP 110.1 MP 110.2 MP 110.3

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| | Pin 8 | | | Pin 20 |

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