hitachi seiki 21L, CS20 Maintenance Manual

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INVERTED VERTICAL TURNING CELL
CS20
INSTRUCTION MANUAL
MAINTENANCE
SEIKI - SEICOS å21L
43 Edition 1.01 11-2000
Hitachi Seiki Deutschland Werkzeugmaschinen GmbH
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Introduction
Thank you for your having purchased the machine, favoring our product lines for your use. This manual contains fundamental information on the maintenace. Please read and fully understand the contents for your safe machine operation. In particular , the contents of the items concerning safety in this manual and the descriptions on the “caution plates” attached to the machine are important. Please follow the instructions contained and keep them always in mind to ensure safe operation. The reference record papers on adjusting setting values such as a parameter list are attached to the machine unit and enclosed in the packing. These are necessary for maintenance and adjustment of the machine later on. Please keep them safely not to be mislaid. The design and specifications of this machine may be changed to meet any future improvement. As the result, there may arise some cases where explanations in this manual could become partly inconsistent with the actual machine. Please note this point in advance. In this manual, items on the standard and optional specifications are handled indiscriminately. Please refer to the “delivery note” for the detailed specification of your machine confirmation.
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CONTENTS
1. INSTALLATION.................................................................................... 1 - 1
1-1 Machine Installation............................................................................................... 1 - 1
1-1-1 Environment of the Machine........................................................................... 1 - 1
1-1-2 Slinging Operation......................................................................................... 1 - 5
1-1-3 Forklift operation ........................................................................................... 1 - 5
1-1-4 Cleaning of Machine...................................................................................... 1 - 6
1-1-5 Power Source and Pneumatic Source ........................................................... 1 - 7
1-1-6 Change of Electric Specification Machining Source Power
V olt age and Cycle ......................................................................................... 1 - 8
1-1-7 Connection of Chip Conveyor ...................................................................... 1 - 10
1-1-8 Installation and Leveling............................................................................... 1 - 1 1
1-2 Lubrication and Oil Supply ..................................................................................1 - 13
1-3 Coolant............................................................................................................... 1 - 15
1-4 Check before trial operation of the machine ........................................................1 - 20
2. MAINTENANCE AND CHECKING ...................................................... 2 - 1
2-1 Daily Checking Items ............................................................................................2 - 1
2-2 Periodic Check Items............................................................................................2 - 5
3. MAINTENANCE AND ADJUSTMENT ................................................ 3 - 1
3-1 Adjusting Method of X and Z Axes Backlash.......................................................... 3 - 1
3-2 Hydraulic Unit/Hydraulic Circuit Diagram...............................................................3 - 3
3-3 Hydraulic Chuck....................................................................................................3 - 4
3-4 Layout of Electric App aratus and Pneumatic Circuit Diagram................................ 3 - 9
3-5 Restoration of NC Torque Limiter........................................................................ 3 - 11
3-6 Returning Method from face declination of turret index.........................................3 - 12
3-7 Alarm Diagnosis ................................................................................................. 3 - 13
3-7-1 When the Warning Lamp (Call Light) Lights ON............................................3 - 13
3-7-2 Alarm Display.............................................................................................. 3 - 14
3-7-3 Display of Switch St atus .............................................................................. 3 - 15
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4. REFERENCE MATERIALS FOR MENTENANCE
AND ADJUSTMENT....................................................... 4 - 1
4-1 Servo Unit.............................................................................................................4 - 1
4-1-1 Alarm Concerning Power Supply Unit
(Source Power of Spindle/Servo Amplifier)..................................................... 4 - 1
4-1-2 Spindle Amplifier S tatus Display .................................................................... 4 - 4
4-1-3 Spindle Amplifier Alarm.................................................................................. 4 - 5
4-1-4 Detail of S pindle Amplifier Alarm Content s................................................... 4 - 10
4-2 Inverter for Turret .................................................................................................4 - 17
4-2-1 Status Indication (on the point module)......................................................... 4 - 17
4-2-2 Troubleshooting........................................................................................... 4 - 18
4-3 Replacing Method of Battery .............................................................................. 4 - 20
4-4Alarm Display ..................................................................................................... 4 - 21
4-4-1 NC Alarm..................................................................................................... 4 - 21
4-4-2 PC Alarm..................................................................................................... 4 - 28
5. EXPENDABLE PARTS LIST ............................................................... 5 - 1
5-1Expendable Parts List of CS20 ............................................................................. 5 - 1
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1. INSTALLATION
1-1 Machine Installation
When installing NC machine, solid foundation is essential. It is also most important for maintaining the best condition of cutting accuracy of the machine. The nature of the ground condition of the factory site, for example, rock base or reclaimed land, makes a big difference. It is, therefore, difficult to give any definite rules generally applicable to the installation of this machine. It will be quite all right if you pay a reasonable attention, based on the knowledge that you have on the general foundation of machine tools. (Refer to Foundation and Layout.)
The followings are the concrete items to be carefully attended when installing this machine.
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1) The bearing capacity of soil should be 5 ton/m be 300mm or thicker.
2) The area of the foundation should be extend to at least 300mm outer circumference of the machine bed.
3) When digging vibration proof drains, they should be dug along the circumference of the foundation.
or larger and thickness of the foundation should
4) Placing separate concrete blocks underneath each machine leg instead of a real foundation is often seen, which is just not adequate. Such is no value as proper foundation,
As this machine yields large volumes of chip during machining, carts are often used for chip disposal. The traffic of carts and detaching covers in maintenance work need free space so that the operators can move around without touching other machines. This factor should be considered when selecting the installing position of the machine.
1-1-1 Environment of the Machine
Pay full attention to a room temperature, dust, vibrations, etc. in order to make use of the primary performance of the machine. High accuracy cannot be obtained in the environment where the room temperature greatly changes. Just a slight change of the room temperature partly affects the machine. Be fully careful of effects heat transfer from the direct sunshine, vent, heating unit, and so on.
Under the environment where the air is polluted so much by dust, etc., the sliding sections and electric devices of the machine are greatly effected in their service lives.
Particularly, electronic devices related to controls are susceptible to dust and humidity. Install the machine in the environment as clean as possible.
1. Installation Environment of NC Machine In case that electric machines and appliances generating high frequency noise are
installed or newly erected near by NC machines, keep to the following precautions.
1) Example of the electric machines and appliances generating high frequency noise.
[1] Arc welding machine [2] Resistance welding machine [3] High frequency drying machine
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[4] Electric discharge machine [5] Others
2) Installation form of NC machine
[1] Power supply line The power supply line (AC400V) of NC machine must be separated line with that for
electric machines and appliances. If impossible, connect the line at the point more than 20m apart from the point where
the power supply for electric machines and appliances is connected. [2] Installation place of NC machine NC machine must be installed more than 20m apart from electric machines and
appliances. [3] Earth of NC machine The earth of NC machine must be grounded within 5m from NC machine separating
from the ground of electric machines and appliances, and make a ground work with not more than 100
Or the earth wire size must be not less than 6mm
or comply with the laws and regulations of the country.
2
.
3) Example of earth of NC machine
The earth state of NC machine and electric machines and appliances illustrated as under.
Power receiving equipment
Powersupply
To be separated system wiring
AC400V
Electric machine
More than 20m
and appliance
3 pase3 pase
AC400V
NC
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Grounding:Class 3 grounding work within 5m
[Grounding resistance of 100 or below. Wire size of 6mm or above.]
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Dimention : metric (mm)
inch ( ” )
Note)
1. The bearing capacity of soil should be 5 ton/m
2
(1000lbs/ft2) or larger and thickness of the foundation should be 300mm (11.8”) or thicker.
2. The area of the foundation should be 1840x1970mm (72.4”x77.6”) or larger.
3. When digging vibration proof drains, they should be dug along the circumference of the foundation.
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1-1-2 Slinging Operation
The slinging work is one of the important operations when transporting the machine, which requires careful attention. When machine is transported, cranes or chain blocks are used for lifting, which includes slinging work. The following points should be carefully attended to for this work.
1) As the machine weighs 4900kg, the diameter of the wire used should be 14mm or thicker.
2) Draw out the coolant tank.
3) Prepare the slinging hook as illustrated in Diagram 1-3.
4) Adjust the gravity center of the machine by moving the saddle and the cross slide, so that it comes on the center line of the sling angle.
5) Sling angle should be smaller than 90
6) Do not use rusted wire ropes, those with unwound twists or with broken lines.
7) Lift the machine gradually. Stop it once when the wire rope become strained, and check a lifting conditions. When the machine is lifted up from the floor, check again that there are no abnormalities with the lifting rope, and proceed with the lifting rope. When lowering the machine, it is necessary to be careful that it is lowered down slowly. Stop lowering the machine immediately before it reaches the floor to check.
Then, lower it down completely.
1-1-3 Forklift Operation
Attention should be paid to the following points when conducting forklift operations.
1) Use a forklift capable of lifting the machine weight.
2) In order not to damage the protruding portion of the machine, a watchman should be attached to help the forklift operator to undertake cooperative work.
3) When inserting the fork, apply the fork blades to the cast iron draw grooves on the left and right sides of the base of the machine main body designed for fork blade insertion.
4) Before set to lifting work, make a trial lifting in order to ensure the best stability of the load, considering the balance of front/rear, left/right and machine gravity center.
°, proper angle being 60°.
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1-1-4 Cleaning of Machine
Do not move saddle and cross slide before cleaning, as the anticorrosive paint is often contaminated with dust during transportation.
Upon shipment from our factory, each section of the machine has been tightened. Before cleaning the machine, Loosen respective section.
For cleaning, use waste soaked with refined petroleum product (neutral) and wipe off the anticorrosive paint thoroughly.
Avoid using compressed air for cleaning, as foreign matters existing at opening portion of the fitting part may be blown into the depth of the slit by air pressure and may damage the fitting face. After cleaning, apply high quality lubricating oil specified in Lubrication and Oil Supply on the finished surface thinly.
Fig. 1-3 Slinging
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1-1-5 Power Source and Pneumatic Source
1) Main switch for source power should be installed at a place close-by the machine site so that switch opening/closing can be handled by the operator with his own responsibility. The switch should be exclusively for this machine separated from the line used for other machines. For fuse capacity, refer to the table below.
2) Wiring from source power switch to the machine
The line connection is to be arranged as shown in the following diagram.
At the time of machine installation, the wiring arrangement to the primary side of the high power circuit breaker CB-1 ([1] in above diagram) is to be taken care of by the customer.
As for power source wire and grounding wire, refer to the table below. The grounding wire is to be connected with grounding bolt [2].
Machine type Total capacity Wire thickness Fuse
R.S.T Grounding (Capacity)
CS20 23kVA
22
5.5 75A
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1-1-6 Change of Electric Specification Machining Source Power
Volt age and Cycle
Depending of the voltage and cycle of the source power, the setting of electric system has to be changed. Before the setting, confirm on these points.
Source power voltage 400V ±10% Source power cycle 50/60Hz
±1Hz
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1-1-7 Connection of Chip Conveyor
[1]In order to enable the machine running before
installing the chip conveyor, the machine ex factory attaches short circuit wire on CN2 connector. When installing the chip conveyor, pull off this wire by hand then connect CN2 wiring. make absolutely sure that the main source power of the machine be switched off.
Note) Emergency stop circuit of chip conveyor
When chip conveyor emergency stop button is pressed, the machine proper is also brought into the condition of emergency stop. Of the machine with chip conveyor attached, if the connector CN2 is disconnected (see illustration on the left), the machine will come to an emergency stop, just in the same manner as emergency stop button is pressed.
Before doing this wiring,
(Left side view of Control Board)
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1-1-8 Installation and Leveling
One of the factors deciding the machining accuracy is how to install the machine on level. Correct leveling is the most fundamental requirement in machine installation, which affects the accuracy of products as well as the service life of the machine itself.
For this reason, please follow the undermentioned steps of leveling. At first, place a block (shown in Fig.1-1) at the installing place on the floor, and install the
machine so that the leveling bolt (the jack bolt) of the machine may be placed on this block. Next, install a block around the chuck, and put on a level as shown in Fig.1-4. Let X fully stroke. Pay full attention not to interfere with the tool post.
Make adjustment so that difference of reading of the level back and forth shall be within
0.04mm/m. The sensitivity of leveling instrument recommendable is 1m long with 0.02mm graduations.
When applying the leveling instrument, the instrument should always be kept with the same end to the same direction.
The surface on which the leveling instrument is placed should be kept clean, and proper attention should be paid so that there is no dust getting in between the surface and instrument during level measurement.
When locking the leveling bolt, attention should be paid that the bolt does not to turn. For the convenience of regular maintenance of the machine level, do not solidify the bolt by mortar. When the machine generates vibration by unbalanced workpiece, fix it with an anchor bolt.
Check the machine level periodically. For 2-3 days after the initial installation, check it daily. During subsequent 6 months check it monthly, and thereafter in every 3 months.
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Fig. 1-4 Leveling Method
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1-2 Lubrication and Oil Supply
When supplying oil, sufficient care must be taken to the following:
1. Supply specified oil by the specified amount. Do not supply a different type of oil or over
the specified amount. Otherwise the machine may cause to a trouble.
2. Clean the oil inlet port etc. in advance, and pay close attention lest dust etc. should enter
inside.
3. When supplying oil, use a filter in order to prevent foreign substances such as dust from
entering into the tank. When the filter is not available, use a wire net of 150 mesh or more.
4. Whenever you supply oil, use new one. Do not mix with reproduced or old oil.
5. Even when a new oil can is opened, dont use all the oil in it, but leave some unused. This
is necessary to eliminate moisture and deposits.
* As to oil supply spots, supply frequency, oil amounts and oil types, refer List of Lubrication
Oil”.
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List of Lubrication Oil
Front view
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Supply spot
Spindle cooling unit
1
Hydraulic unit
2
3
Hydraulic chuck
Method Trochold
pump Piston
pump
Manual
Frequency
Replace every 6 month; replenish occasion
Replace every 6 month; replenish occasionally
Supply oil fully every day
Qty 28l
10l
Nisseki Nisseki
Multi­purpose 32
Molynock grease 2
Idemitsu
Daphne Multi-way 32ER
Daphne grease M2
Shell
Tetra oil 32
Retina AM
Mobil
MOBIL DTE oil light
MOBIL grease special
Mitsubishi
Diamond Tetrat 32
Diamond Multi­purpose M grease 2
ESSO
UNI-POWER MP32
BICON Q2
MOK Clewbar
R-temp Q
NB50
ISO symbol
CB32
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1-3 Coolant
1) How to control coolant fluid
The consistency of coolant fluid is changed depending upon the quality of water used, mixture of chips or foreign substances and evaporation of moisture. And unless the maintenance of the coolant fluid is made for a long time, germs may be generated, that causes to break the filters, the piping and the pump. Check the density of the fluid, and pH timely, replace the coolant fluid, and also clean the inside of the coolant tank in consideration of using conditions.
Since contaminated muddy clods may be generated when a different kind of coolant fluid is mixed up, remove completely the previous fluid through flushing the piping, the tank and the equipment sufficiently, when changing the coolant fluid.
Items to be checked periodically
It is advised to check the following items periodically.
1. Liquid color check
Observe the color eyes. When the color is changed to blown, it is presumed that rust may generate. In case of FC
and FCD, chips happen to become blown. When the coolant fluid becomes block, it is presumed that it has been corroded. When the fluid becomes block and gives out a putrid smell on Monday morning or after a long period of holidays, the color of the fluid may happen to return to the original color in the afternoon. It is phenomena that the fluid changed through extinction of bacteria (anaerobic germs) by touching the fluid with air.
When it is not returned, it is required to replace the fluid, since the fluid is too putrid. In this case, replace all the coolant fluid and make flushing sufficiently. The remaining bacteria will cause to repeat the putrid consequently.
2. Check of the putrid smell
Special care must be taken to smell. When the fluid is filled with putrid smell,
the ingredient of the cutting fluid be destroyed by breeding of bacteria or eaten by bacteria as nutritive substance, that causes the change of its density, lowering of pH and outbreak of rust.
When the putrid smell is not faded away even after half a day in the status of operation, it is required to replace the coolant fluid.
3. Check of the filthiness of the fluid
Observe the filthiness of the fluid by eyes. The filthiness of the fluid has influence on the machining accuracy, the dirt of the
machined work and the dirt of the machine.
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And the dirt of the machine makes hard to observe the state of machining from the outside.
4. Check of the quantity
Check the level of the rank periodically. Shortage of the fluid quantity causes to form bubbles or to disable the fluid to supply
sufficiently to the machining point. And also it will hasten the progress of the putrefaction.
5. Control of the density
It is the most important procedure to control the density of the fluid when soluble cutting oil is used.
It is the best way to measure the density by a refractometer. If not available, it is possible to control to some extent the density of the fluid by
calculating precisely the magnification at the time of dilution and also by calculating the magnification without fail when pouring some more fluid.
It is the most desirable method to check periodically the density by a density-meter, since there are various factors such as change of the ingredients by bacteria, decrease by taking out with the workpieces or vaporization of the fluid. When the density of the cutting fluid is low, serious problems such as bad smell by putrefaction, lowering on the pH and rust promotion will occur. Generally the density of the cutting fluid is within the extent of 20 times through 30 times, but it will be different depending on the kind of cutting fluid. Comply with the makers recommending value. Since it becomes impossible to measure the fluid when lots of rust preventive oil or lubrication oil is mixed.
6. Control of the pH
Measure the pH by using either a litmus test paper or a simple pH measuring instrument. When the pH value of the fluid is 7,
the fluid is neutral. When the value is larger than 7, the fluid is alkaline and when it is smaller than 7, the fluid is acidic.
Generally pH8.5 through 9.5 is an ideal value. When the value becomes lager than this, alkaline becomes stronger, that causes the chapping of the skin of the hands.
When it becomes smaller, the fluid is acidulate, that causes hastening of rust. Especially when the pH value of the fluid becomes less than 8, care must be taken since rust is hastened rapidly. In this case, replace the fluid.
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7. Check of the stagnant sludge
Check whether chips and/or sludge stagnate in the tank and the piping. Remove chips and/or sludge from the tank and the
piping by flushing as occasion calls. And mixture of rust preventive oil and lubrication oil
may become the nutritive elements, and the surface of the tank is covered with them, that causes the breeding of anaerobic germs. Remove the adulterated oil periodically.
It is recommendable to employ an eliminator such as skimmer.
2) Control of the waste oil
Water Pollution Control Law and Sewage Water Law are adapted to the waste oil of cutting fluid.
The substances more than 10 items of ingredients contained in the cutting fluid are designated as organic substance, and they become the object of regulation items. Therefore, appropriate disposition such as disposal by the waste oil disposing system in the factory or taking-over by the waste oil treating trader is required.
The cost for waste oil disposal at the time of replacement of the fluid is directly related to the life of fluid, and 50% of cost-down can be attained by replacing the fluid once a year instead of twice a year.
Accordingly, conclusive control of the using fluid will mean development as a whole.
3) Types and selection of water-soluble cutting agents
Though there are various purposes of cutting agents, the following two points are the most important basically.
Lubrication: The cutting agents reduces friction, prevents generation of heat, and
smoothens..............(Deposition-resistant property).
Cooling: The cutting agent cools generated heat.
In addition to the above-mentioned matters, enviroment- and safety-related metters such as washing property and swarf disposal must be taken into enough consideration. Water­soluble cutting agents are divided into an emulsion type, soluble type, and chemical solution type. Their characteristics are shown in the following table. Do not use the chemical solution type in particular, because it causes detachment of coating and affects seal materials and resin materials adversely.
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Type Emulsion Type Soluble Type Chemical Solution Type
Characteristics
* This type has been
used widely in the cutting field, because it is relatively large in particle diameter ( 4 to 7 µm) and high in lubricating property.
* It is the soluble
cutting agent that was made first.
* It decomposes easily
due to lack of stability.
* This type is excellent
in permeability because it is small in particle diameter ( 0.1 to 0.03 µm ).
* It has been used
mainly for grinding purposes, but it is used also for cutting purposes due to the development of the extreme pressure agent.
* Since it uses much
surface-active agent, it is likely to affect coating adversely.
Do not use this type.
Form
* Dissolving this in
water, it becomes milky. This is because particles dissolved in water are large, reflecting light.
* Dissolving this in
water, it becomes semi-transparent. This is because particles dissolver in water are very fine, passing light.
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Maintenance of Coolant Tank
In case of delivery of coolant from the tool post get worse,
1. Check level and fill it up if required.
2. Clean a filter in the coolant tank.
This filter can be mounted or dismounted in one touch. Pay a full attention as the coolant will easily drip down on the floor when chips in the bucket
are removed.
3. Piling up the bucket with chips may cause overflowing. Check on the bucket at least once a
day .
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1-4 Check Before Trial Operation of the Machine
Before operating the machine at first, be sure to check each item in accordance with the following order.
1. Check the voltage of the power source. The power source is different depending on the district.
Three-phase, 200V, 50Hz: Mostly in Kanto and Tohoku regions. Three-phase, 220V, 60Hz: Mostly in Kansai, Chubu, Hokuriku and Chugoku regions. Three-phase, 200V 50-60Hz: For future power supply and not available at present. When checking the power source, measure the voltage between 3 phase respectively and
the difference between each phase must be within a few voltage.
2. Turn on the breaker CB-1 in the power control cabinet and then check the phase rotation of the power source in accordance with the following.
Press the movable contact operating button in the magnetic switch (MS-1) for hydraulic motor with a driver and check that the pressure gauge for hydraulics turns up. When it doesnt turn up even pressing it for 5 to 10 seconds, turn off the barker (turn off the power on the factory side) because of different phase rotation and change the connection of either 2 of the power supply 3 lines.
3. Turn on the power source for the NC unit and check that the screen (TITLE) is displayed on the Display .
4. Set the mode selection switch to the manual (HANDLE or FEED).
5. Check of the rotating direction of every motor. Rotate every motor by respective switch and check the rotating direction in accordance with
the instruction of the rotating direction. When the rotating direction is reverse, change the connection of either 2 of the power
supply 3 lines.
[1] Cooling fan : Start/stop is operated by the breaker on the high power control
board.
[2] For hydraulic : To start by the [STANDBY] button.
To stop by the [POWER OFF] button. [3] For spindle : To jog rotation by the [SPINDLE JOG] button. [4] For cutting fluid : To start by the [COOLANT] button
To stop by pressing the button again.
6. Adjust the pressure of the hydraulic unit to the setting pressure, 3.5MPa {35kg/cm
2
}
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2. MAINTENANCE AND CHECKING
2-1 Daily Checking Items
The following are maintenance items to be checked by operators. These maintenance items are important to prevent machine trouble and to perform efficient operation. Perform maintenance according to the following daily check list.
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Daily check list
Checking part Check item Details of checks
Hydraulic unit
1.
Main cooling unit
2.
3.
Pneumatic unit
4.
Coolant unit
5.
High-pressure coolant
a) Check for normal set pressure.
b) Check hydraulic unit for faults.
c) Check hydraulic unit for sufficient
quantity of oil.
d) Check that oil temperature is
60°C or less. e) Check for oil leakage. a) Check main cooling unit for operation. b) Check cooling unit for sufficient
quantity of oil. (Checks before starting
work) c) Check that air filter is thoroughly
cleaned. d) Check for oil leakage. a) Check for normal set pressure. b) Check pneumatic unit for faults such
as air leakage. a) Check coolant unit and piping for
faults. b) Check coolant unit for sufficient
quantity of coolant. c) Check that air filter is thoroughly
cleaned. d) Check for discharge. e) Check for oil leakage. a) Check high-pressure unit and piping
for faults.
b) Check for discharge. c) Check pump for discharge pressure.
(Pressure gage)
Normal value: 3.4 MPa, 4.4 MPa
and 6.8 MPa (It depends on the model.)
Checks for abnormal noise and oil
leakage.
Oil level check
Oil temperature check: Proper
temperature is 60°C or less.Check for oil leakageCheck for sound of fan runningOil level check
Checks for clogging and cleaning
Check for oil leakageNormal value: 0.5 MPaCheck for air leakage
Checks for coolant leakage and
abnormal noise
Oil level check
Checks for clogging and cleaning
Visual checkCheck for oil leakageChecks for coolant leakage,
abnormal noise and abnormal
vibration.
Visual checkNormal value: 3.4 MPa or 6.8 MPa
(It depends on the specifications.)
6.
Operation panel and control panel
d) Check that air filter is thoroughly
cleaned.
e) Check high-pressure pump for
sufficient quantity of oil.
f) Check for high-pressure pump oil
fouling.
g) Check for sufficient quantity of
coolant.
a) Check that alarm is not displayed on
the screen. (Battery alarm, etc.)
b) Check that cooling fan is running.
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Checks for clogging and cleaning
Oil level (cap oil filling) check and
replenishment Checks for oil degradation and oil
color
Check through main tank
Visually check it to determine the
cause for corrective action. Visually check it to determine the
cause for corrective action.
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Checking part Check item Details of checks
Chuck/cylinder
7. (Turning machine)
8.
Spindle head
Feed unit
9.
10.
Tool post unit
11.
Chip conveyor
12.
Covers
13.
Interlocking device
a) Check that chuck is filled with
sufficient grease. (Once a day)
b) Check that chuck pressure can be
regulated smoothly .
c) Check that coolant recovery port at
the rear of chuck cylinder is cleaned and that chips are removed.
d) Check master jaw for actuation.
e) Check that running-in is performed.
a) Check for abnormal noise. (M/C,
NCL)
a) Check for abnormal noise.
a) Check for coolant discharge. b) Check that tool pots and tapered
portion of QCT, KV and KM are cleaned.
c) Check tool layout for imbalance.
d) Check that chips on the turret
swiveling portion are removed.
a) Check for obstructions on the
conveyor.
b) Check the quantity of chips in the
chip box and that of coolant.
c) Check that a large quantity of chips
collect on the chip conveyor. (Inclusive of screw conveyor)
d) Check for abnormal noise.
a) Check that covers are not detached.
b) Check that window is cleaned. c) Check that nameplate and caution
plate are cleaned.
a) Check door interlocking function.
Check that specified grease is filled.
Check pressure regulation for each
workpiece change.
Clean as necessary.
Check actuation by foot switch
operation.
Perform running-in by low rpm of
about 10% of the models maximum rpm for 30 minutes before starting work.
Check for abnormal noise during
spindle running
Check for abnormal noise when
operating feed unit
Visual checkCheck for removal of dust, fouling
and foreign matter such as chips (Wipe with a clean cloth.)
Check that tools are placed in
balance and that turret turns smoothly.
Check that foregin matter including
chips on the turret swiveling portion and its vicinity are removed.
Check for removal of obstructions
such as workpiece, tool and square bar
Check the quantity of chips and that
of coolant, and dispose of them as necessary .
Prevent a large quantity of chips
from collecting on the conveyor. Check that conveyor operates to discharge chips.
Check for abnormal noise when
operating chip conveyor
Check that covers are not detached.
If any cover is detached, attach it.
Check for cleaningCheck for cleaning
Check that spindle does not run
when opening door.
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Checking part Check item Details of checks
14.
Mist collector a) Check that mist does not remain in
the hose.
b) Check that filter is thoroughly
cleaned. c) Check that oil is properly drained. d) Check mist for leakage.
Visual check Provide angular hose
route.
Checks for clogging and cleaning
Visual check for proper oil drainageVisual check
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2-2 Periodic Check Items
Periodic checks by maintenance personnel are essential for assuring continued machine accuracy. Perform maintenance at regular intervals according to the following periodic check list.
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Periodic check list
Checking part Check item Checking interval(Month) Details of checks
1.
Hydraulic unit
2.
Main cooling unit
3.
Pneumatic unit
Coolant unit
4.
5.
High-pressure coolant
a) Check piping for faults.
b) Change hydraulic fluid.
c) Check that strainer is
thoroughly cleaned.
d) Check oil for
discoloration (fouling).
a) Check piping for faults.
b) Change hydraulic fluid.
a) Check piping for faults.
b) Check that filter is
thoroughly cleaned.
a) Check for conspicuously
dirty coolant unit. b) Check for foul smell. c) Check piping for faults.
a) Check piping for faults.
b) Check that filter is
thoroughly cleaned. c) Check high-pressure
pump for sufficient
quantity of oil. d) Check for high-pressure
pump oil fouling.
13612
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
Check for oil leakage, and
Clean the inside of tank
Checks for clogging and
Check oil color with oil
Check for oil leakage, and
Clean the inside of tank
Check for oil leakage, and
Checks for clogging and
Refer to Coolant section
Check for oil leakage, and
Check for oil leakage, and
Checks for clogging and
Oil level (cap oil filling)
Checks for oil degradation
tighten connector securely if necessary .
and strainer, and change hydraulic fluid as necessary.
cleaning (Shorten checking intervals depending on working environment.)
gage. When color is getting brown, change oil.
tighten connector securely if necessary .
and strainer, and change hydraulic fluid as necessary.
tighten connector securely if necessary .
cleaning (Shorten checking intervals depending on working environment.)
in the instruction manual. (NCL)
tighten connector securely if necessary .
tighten connector securely if necessary .
cleaning
check and replenishment
and oil color
2 - 6
Page 32
Checking part Check item Checking interval(Month) Details of checks
13612
High-pressure
5. coolant
6.
Operation panel and control panel
7.
Feed unit
8.
Chip conveyor
9.
Belt,Timing belt(Tool post, and X axes, )
e) Check high-pressure
pump suction and discharge valves for damage or wear.
f) Check for damaged or
dirty high-pressure pump diaphragm.
g) Check gas charging
pressure of accumulator.
a) Check for conspicuously
dirty operation panel and control panel. (Cleaning)
b) Check for foreign matter
in the control panel.
c) Check that air filter is
thoroughly cleaned.
d) Check that cooling fan is
cleaned.
e) Check power supply and
voltage.
a) Check ball screw and
guide for lubrication (oil and grease).
a) Check that chip
conveyor is oiled.
a) Check belt for
deflection.
O
O
O
O
O
O
O
O
Replace if damage or
O
O
O
wear is found.
Replace or clean if
necessary .
Recharge if charging
pressure is dropped.
(Charging pressure:4.9Mpa)
Visual check and cleaning
Removal of foreign matter
Checks for clogging and
cleaning (Shorten checking intervals depending on working environment.)
Check for dirty cooling fan
Check that secondary
voltage of main breaker is set within ±10% of the
specified value
Visually check oil film.
Apply grease to sprocket
area as necessary.
Check deflection amount
with tension meter. (Normal value:3.5 mm/kg)
.
10.
11.
Level
LS and SOL
b) Check surface for
damage and heights for deterioration.
a) Check the level of bed
and table with level vial.
a) Check that LS and SOL
are not moistened with oil.
b) Check for oil fouling.
2 - 7
O
O
O
O
Visual checks and
degreasing
Level check and
adjustment with level vial
Determine the cause to
take corrective action.
Cleaning
Page 33
Checking part Check item Checking interval(Month) Details of checks
Cover
12.
13.
Wiper and brush
a) Check mounting bolts
for looseness.
a) Check wiper and brush
for deterioration and damage.
13612
O
O
Check cover clamping
Visual checks
bolts for tightness, and tighten securely if necessary.
Interlocking
14. device
Cable
15.
OT (Over-travel)
16. Earth leakage
17. breaker
b) Check for jamming of
chips and foreign matter.
a) Check spindle speed
limiting interlocking function.
a) Check for damaged
appearance (tears, crushes, stripped conductor, etc.).
b) Check connector for
looseness.
c) Check for caught cable.
d) Check that cable is not
moistened.
a) Check LS for actuation.
a) Check breaker for
operation.
O
O
O
O
O
O
O
O
Visual checks
Check spindle speed
limiting interlocking set value (parameter) when using special chuck and jig.
Visual checks Replace if
there is something wrong.
Visual check Tighten
securely if necessary .
Visual check Return to
normal. Appearance check Replace if there is something wrong.
Visual check and cleaning
Determine the cause.
Operate the machine to
check function.
Press test button to check
breaker for operation.
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3. MAINTENANCE AND ADJUSTMENT
3-1 Adjusting Method of X and Z Axes Backlash
Procedure 1 How to cancel the compensation amount previously entered
To cancel the compensation amount entered before measuring backlash
1) Put the machine to a stop status. (This setting irrelevant to the machine status.)
2) Change the parameter according to the parameter setting method under “OPERATION MANUAL, Item 16.
3) Call up the backlash parameter 1851 and make the X and Z axes value 0.
4) Turned OFF, Turned ON again
Procedure 1 Measuring the backlash amount
1) Put the dial indicator contact to the check from the turret side.
2) Measure a backlash amount with a X-axis and Z-axis handle in the order of (a) through (c).
Turn the handle counterclockwise and set the handle and indicator to 0.
Turn the handle further counter-clockwise by another 20~30 graduations.
Turn the handle clockwise until a pointer points to 0. At this time, the difference of the indicator represents the backlash amount.
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Procedure 3 Setting of backlash amount
1) According to the parameter setting method under OPERATION MANUAL, call up the backlash parameter 1851 and set the compensation amounts of X and Z axes.
Backlash amount 0.012
X-axis compensation amount = = = 24
Compensation unit 0.0005
Backlash amount 0.015
Z-axis compensation amount = = = 15
Compensation unit 0.001
2) Switch OFF the source power once, they switch ON again.
Procedure 4 Confirmation of backlash amount
1) Confirm that the setting values are correct, according to Procedure 2.
3 - 2
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3 - 3
3-2 Hydraulic Unit/Hydraulic Circuit Diagram
Hydraulic Unit/Hydraulic Circuit Diagram
17 BLOCKING BLOCK 1 Shonan 16 19001-68-001-00 Manifold 1 Shonan 15 9001-68-002-00 Manifold 1 Shonan 14 OPG-DF-T-R1/4-6´7 13 SL-G01-E3X-GR-C Solenoid Valve 1 Fujikoshi 12 ETB69-1.8 Orifice 1 Shonan 11 SL-G01-E3X-GR-C1-11 Solenoid Valve 1 Fujikoshi 10 OCP-G01-B1-20 Pilot Check Valve 1 Fujikoshi
9 OG-G01-PC-K-5871A Reducing Module 1 Shonan 8 CT-T03-0-4044A Check Valve 1 Fujikoshi 7 VDS-0B-1A2-1249K Variable Pump 1 Fujikoshi 6 OPG-AT-R1/4-60´7MP-G Pressure Gauge 1 ASK 5 C-30-4043A Oiling Hole 1 Fujikoshi 4 KD-0A (N) Oil Level Indicator 1 Kyowa 3 VBBA-0A4A04-1156A Electric Motor w/ Cooler 1 Meidensha 2 MSN-03-150 Strainer 1 Masuda 1 TNK-10L-H Oil Tank 1 Fujikoshi
NO PART NUMBER PART NAME Q’ty MAKER
MPA
Pressure Gauge 1 ASK
Page 37
3-3 Hydraulic Chuck
This chuck is hydraulically opened and closed. With this chuck employed, a work piece setup time can be reduced, manpower can be also saved and the workpiece can be powerfully and equally gripped.
Specifications
Hydraulic chuck diameter : Hydraulic tank unit : Commonly used for the machine proper
φ210 ( 8")
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Operation
1. Select a chuck gripping direction by using the WORK GRIP INT/EXT Selector switch located on the main operation panel.
2. Open and close the jaw by the chuck open/close switch on the main operating board.
3. Adjusting the chuck pressure Adjust pressure of the hydraulic chuck by the dial on the manifold section at the left end of
the machine.
Turning the knob clockwise (direction of INC) increases the pressure.
Turning the knob counterclockwise (direction of DEC) decreases the pressure.
Adjust the chuck pressure within a range of a pressure gauge.
pressure gauge
Note 1) Due to an interlocking mechanism, the chuck cannot be opened or closed while the
spindle is rotating.
2) While the spindle is stopped, the chuck is loosened immediately by operating the chuck open/close switch. Pay attention, therefore, even on other occasions than when a workpiece is loaded or unloaded, or when gripping direction of the chuck is changed.
3) When changing the gripping directions of the chuck, be sure to unload the workpiece from the chuck without fail.
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Hydraulic Chuck and Cylinder
Solid-Chuck (made by KITAGAWA)
Hydraulic chuck HG-715-210 Hydraulic cylinder Y1230RE25
Type
With cylinder mounting adapter
Mounting of Hydraulic Cylinder
1. Mount the hydraulic cylinder to the adapter of the spindle with M12 bolt.
2. Set a measuring instrument to the rear of the cylinder. With the rear of the cylinder fixed, rotate the spindle (about 30min-1) and check the runout of the cylinder.
Note 1) Fix a part to which the measuring instrument is set.
3. Adjust the runout of the cylinder within 0.02 mm and tighten each bolt.
4. Provide piping to [A] , [B] and [D].
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1 Bolt 2 Connecting bolt 3 Master jaw 4 Chuck body 5 Eye bolt 6 Spindle 7 Draw rod 8 Wrench
1. Procedures for removing the chuck body
1) Turn off the power in the status of chuck closing.
2) Screw in eye bolt [5] and pull up the chuck [4] naturally with wire.
3) Loosen the bolt [2] connecting the draw-rod [7] by turning counter-clockwise with the attached wrench [8].
4) Loosen the bolts [1] and remove the chuck body [4].
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2. Procedures for installing the chuck body
1) Set pressure of the hydraulic chuck to 0.5MPa {5kgf/cm}, and put forward the draw rod by the chuck open/close button.
2) Thrust the wrench [8] into the bolt [1], and turn it right softly until it isnt turned.
3) Mount the chuck [4] on the spindle.
4) As the draw rod is at the forwarding end, loosen the bolt [1] by left turn until the shifter inside the chuck touches slightly the inside of the chuck front cover.
From this status, thrust it by a quarter right turn for final adjustment. (Clearance between the shifter and the front cover shall be about 0.6mm.)
Note 1) Use attached parts of the machine for the bolts to mount the chuck and jaws.
2) When preparation of these bolts newly, prepare the bolts with the following material or equivalent.
Chrome-molybdenum steel
<SCM435H> Tensile strength: 115 ~ 140Kgf/cm Hardness after heat treatment: HRC34 ~ 44 Thread class: 2nd class
2
Keep strictly a protruded length L1 and L2 of mounting bolts.
3) Regarding a bolt to mount the collect chuck and other fixture requires above item 1) and 2) as well.
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3-4 Layout of Electric Apparatus and Pneumatic Circuit Diagram
3 - 9
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Turn equipment 180°Turn Arm up/down Air blow
LS List
J LS901 Over thrust detection 1 METROL BP101
I LS899B Arm up 1 CKD
H LS899A Arm down 1 CKD
G LS898B Turn to 0° 1 SMC
F LS898A Turn to 180° 1 SMC
Sin LS symbol Use Q'ty Maker Remarks
SOL List
E SOL900 Air blow SMC D SOL899B Arm up SMC C SOL899A Arm down SMC B SOL898B Turn to 0° SMC A SOL898A Turn to 180° SMC
Sin SOL symbol Use Maker
Pneumatic unit List
5 ASN2-01-S Flow valve 4 SMC 4 VZ5-ASK420-1GS-01 Elect magnetic valve 2 SMC 3 VXD2130-02-1DS-B Elect magnetic valve 1 SMC 2 CMK2-C-TB-40-75-R05-DYB2 Cylinder 1 CKD 1 CORA1BW80-180C-A57 Rotary cylinder 1 SMC No. Part number Use Q'ty Maker
3 - 10
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3-5 Restoration of NC Torque Limiter
1. Explanation of function
This function is to detect the torque load on the feed axis and, if the detected torque is abnormally larger than the value set by the parameter, to exert an emergency stop of the spindle based on the judgement that there is an interference
2. Alarm
Alarm No. 1036 NC torque limiter alarm
F409 Servo alarm: (X, Z axes) Axis abnormal load
3. Method of restoration
The alarm status is normally restored by switching OFF the NC source power.
3 - 11
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3-6 Returning Method from face declination of turret index
This manual describes the procedures when a following alarm occurred by shut off the power or by collision, etc. while indexing. Alarm 1020 The turret face number set up is defective. [Procedure] (1) NC power [ON]. (2) Make operation preparation [ON]
(hydraulic ON). (3) Press [EMERGENCY STOP] button. (4) Every time you press the sheet key spindle
[STOP] button and the [TAPE] button
simultaneously, clamping and unclamping
of the turret are repeated alternately.
Under the clamping condition, [TURRET
INDEX] button lamp is turned off. (5) While putting the turret under unclamping
condition, turn the turret by hand and
make indexing face No.1 face ( align the
marking-off line of the turret neck section
with the line for the outer circumference
phase marking.) (6) Put the turret in clamping condition, and
confirm that the turret index button lamp is
turned off. (7) Reset [EMERGENCY STOP]. (8) Make operation preparation [ON] (9) Press following three buttons
simultaneously (No.1 face set)
[SPINDLE STOP] + [EFFECTIVE] +
[PAUSE]
for dry running and program checking
Alarm 1020 The turret face number set up is
defective. disappeared. (10) Perform turret indexing by MDI, and
confirm that NC command and indexing
face conform.
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3-7 Alarm Diagnosis
This screen display is used for trouble shooting and taking counter-measures when various alarms occur.
3-7-1 When the Warning Lamp (Call Light) Lights ON.
The call light becomes ON, in either of the following cases.
1) When the machine comes to a stop (suspension) status, by program stop or program suspension code (M00, M01, M02, M30, etc.) during executing a program.
2) When an alarm status occurs and the alarm lamp (red) on the operating panel lights ON. When the alarm lamp becomes ON, the machine is brought into the status of “Operation
stop, which indicates that some trouble has occurred with the machine.
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3-7-2 Alarm Display
1) Pressing the OPER/MAINTE key on the general
screen, maintenance relevant function keys are listed up on the display.
Pressing the F3/ALARM DIAG. key, the
2) alarm diagnosis screen is obtained and the alarm contents are displayed. Press the item which is to be processed.
3) Also, when an alarm is issued, the screen changed to the alarm screen and the contents are displayed with alarm relevant function keys.
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[1] NC unit relevant alarm (CNC Alarm)
The alarm No. and alarm message are displayed on the screen. Check the alarm cause by referring to the list of NC alarm message and remove the cause
of the trouble.
[2] Alarm relevant to machine equipment and PC control (PMC Alarm)
The alarm No. and alarm message are displayed on the screen. Check the alarm cause by referring to the list of PC alarm message and remove the cause
of the trouble.
3-7-3 Display of Switch Status
1) After getting the alarm diagnosis screen by pressing the F3/ALARM DIAG. key, press
the F2/SWITCH STATUS DISPLAY key, then the status of each switch is displayed on the screen.
2) On the switch status display screen, press the F2/ARRANGEMENT DIAGRAM key,
then the ON/OFF status of each switch is shown on the diagram. Those marked with indicate ON status and those without mark indicate OFF.
3) On the switch status display screen, press the F3/LIST key, then a list of each switch ON/OFF status. Use the page key to scroll the page, as the list extends over plural pages.
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4. REFERENCE MATERIALS FOR MENTENANCE AND ADJUSTMENT
4-1 Servo Unit
4-1-1 Alarm Concerning Power Supply Unit
(Source Power of Spindle/Servo Amplifier)
When an alarm is generated, the alarm LED (red) lights up on the status display and the alarm code is indicated in two figures on the 7-segment LED.
STATUS PIL ALM
Alarm code is displayed. (01~)
Alarm LED (red) lights up.
1) Alarm code 01
Contents
The main circuit power module (IPM) detected abnormality. (PSM-5.5, -11) Excessive current flowed at the main circuit power input part. (PSM-15~-30)
• Cause and trouble-shooting
(a) IGBT (or IPM) is defective.
Replace the IGBT (or IPM).
(b) Mismatch of AC reactor specification.
Confirm the PSM and AC reactor.
2) Alarm code 02
Contents
The cooling fan of the controlling circuit part stopped.
Cause and trouble-shooting
The cooling fan is out of order. Confirm the condition of the cooling fan rotation.
Replace the cooling fan.
3) Alarm code 03
Contents
The temperature of the main circuit radiator went up abnormally.
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• Cause and trouble-shooting
(a) The cooling fan is out of order.
Confirm the condition of the cooling fan rotation.
Replace the cooling fan.
(b) Dust contamination
Clean up the cooling system by factory air blower or by vacuum cleaner.
(c) Overload overation
Re-examine the operating conditions.
4) Alarm code 04
Contents
The voltage at the main circuit DC part (DC link) came down.
• Cause and trouble-shooting
(a) Instantaneous power down was generated.
Confirm the source power.
Replace the cooling fan.
(b) Voltage down of input source power.
Confirm the source power specification.
(c) This trouble could occur, when the main circuit source power is cut off while the
emergency stop is released.
5) Alarm code 05
Contents
Power charge to the main circuit was not made within the specified time.
• Cause and trouble-shooting
(a) The number of SVM, SPM connecting units is in excess.
Confirm the PSM specification.
(b) DC link is in short-circuit.
Confirm the connection.
(c) Charging current restricting resistance is defective.
Replace the distribution board.
6) Alarm code 06
Contents
Input source power is abnormal. (Phase defect)
• Cause and trouble-shooting
(a) Input source power phase is lacking.
Confirm the connection.
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7) Alarm code 07
Contents
The voltage at the main circuit DC part (DC link) became abnormally high.
• Cause and trouble-shooting
(a) Excessive regenerating power.
Regeneration is not possible. PSM capacity is insufficient.
Confirm the PSM specification.
(b) Impedance on the AC source power side is high.
Clean up the cooling system by factory air blower or by vacuum cleaner.
(c) Regenerating circuit is abnormal.
Check the terminal and confirm the voltage at IR, IS is normal.
Replace the distribution board and/or controlling PCB.
(d) IGBT (or IPM) is defective.
Replace IGBT (or IPM).
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4-1-2 Spindle Amplifier Status Display
Status Display
Item Contents
LED lit on is indicated by
Source power ON indicating LED “PIL” is OFF.
1. Controlling source power is not yet thrown in. Source power circuit is defective. Refer to item 4.3.2.
The last two digits of the ROM series is displayed for about
2. 1.0 second after control source power ON. Example) 00: ROM Series 9D00 ROM Version display for about 1.0 second.
3. 01, 02, 03, • • • correspond A, B, C, • • • Example) 04: ROM Version No. D
Blinking CNC source power is not yet thrown in.
4. Waiting serial communication and completion of parameter loading.
5. Parameter loading is completed. The motor is not excited.
6. The motor is excited.
Alarm status
7. SPM is not operable condition.
Alarm code display 01~
Refer to item II. 3.3.
Error status
8. Wrong parameter setting. Sequence is not proper.
Alarm code display 01~
Refer to parameter setting manual.
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4-1-3 Spindle Amplifier Alarm
When the ERR LED on the indicating window of the spindle amplifier lights up, the number indicated next right to the LED reading ER-** will tell the alarm contents. In the same way, when the “ALM” LED lights on, “AL-**” tells the alarm contents. List of alarm codes are given in the following.
NOTE
Er-xx is not displayed on CRT.
Message Contents Countermeasure
Er-01
Er-02
Er-03
Er-04
Er-05
Er-06
Er-07
Er-08
Er-09
Er-10
Er-11
Er-12
Er-13
Er-14 Er-15
*Although EPS (there are 2 types: connection signal and PMC
not input, SFR/SRV is input. However, regarding MRDY, pay attention to the setting of use/not use spindle parameter MRDY.
If spindle motor is not integrated with spindle in system with high-resolution magnetic pulse coder, speed detector of spindle motor is set to 128 p/rev. Attempt to excite motor fails if value other than 128 p/rev is set.
Parameter for high-resolution magnetic pulse coder is not set, but Cs contouring control commands is entered. In this case, motor is not excited.
Although parameter setting for using position coder was not performed, commands for servo mode and synchronous control are input. In this case, the motor will not be excited.
Although option parameter for orientation is not set, the orientation command (ORCM) is input.
Although option parameter for output switchover is not set, LOW winding is selected.
Although Cs contouring control command was entered, SFR/SRV is not entered.
Although servo mode control command was input, SFR/SRV is not input.
Although synchronous control command was input, SFR/SRV is not input.
Cs control command was entered, but another mode (servo mode, synchronous control, orientation) is specified.
Servo mode command was entered, but another mode (Cs contouring control, synchronous control, orientation) is specified.
Synchronous control command was entered, but another mode (Cs contouring control, servo mode, orientation) is specified.
Orientation command was entered, but another mode (Cs contouring control, servo mode, synchronous control) is specified.
SFR/SRV are simultaneously commanded. Cs contouring control command is entered when
differential speed control function is enabled by parameter setting (No. 6500#5=1).
CNC) and MRDY (machine ready signal) are
*Confirm the sequence of EPS and MRDY.
Set the spindle motor speed detector parameter to 128 p/rev.
Check parameter setting for high-resolution magnetic pulse coder.
Confirm the parameter setting of the position coder.
Confirm the parameter setting of orientation.
Confirm the parameter setting for output switching and power line status signal.
Confirm the sequence.
Confirm the sequence.
Confirm the sequence.
Never set another mode when Cs contouring control command is being processed. Before changing to another mode, clear Cs contouring control command.
Do not command other modes during servo mode command. When moving to other modes, perform after releasing the servo mode command.
Do not command other mode during synchronous control command. When moving to other modes, perform after releasing the synchronous control command.
Do not command other modes during orientation command. When moving to other modes, perform after releasing the orientation command.
Command one or the other. Check parameter setting and control input
signal.
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Message Contents Countermeasure
Er-16
Er-17
Er-18
Er-19
Er-20
Er-21
Er-22
Er-23
Er-24
Contact signal of *ESP
Differential mode command (DEFMDA) is entered when differential speed function is disabled by parameter setting (No. 6500#5=1).
Parameter setting (No. 6511#0, 1, 2) for speed detector is incorrect. (Specified speed detector is not present.)
Spindle orientation command of position coder type is entered when use of position code signal is disabled by parameter setting (No. 6501#2=0).
Although the command for orienting the magnetic sensor system was entered, another mode was issued.
Both the slave mode and the high-resolution magnetic pulse coder were enabled.
The slave mode command (SLV=1) was entered under position control (servo mode, orientation, etc.).
The position control command (servo mode, orientation, etc.) was entered in the slave operation mode (SLV=1).
A slave mode command was entered when the slave mode is disabled.
To perform continuous indexing in the mode for orienting the position coder system, incremental operation (INCMD=1) was first performed, then the absolute position command (INCMD=0) was entered.
Between ESP1 and ESP2 of spindle control printed circuit board
Check parameter setting and control input signal.
Check parameter setting.
Check parameter setting and control input signal.
Do not issue another mode while the orientation command is executed. Before issuing another mode, cancel the orientation command.
These two settings are incompatible. Check the parameter settings.
Enter the salve mode command in the normal operation mode.
Enter the position control command in the normal operation mode.
Enable the slave mode.
Check the control input signal (INCMD). To execute the absolute position command continuously, be sure to perform orientation with the absolute position command first.
Contact is open : emergency stop Contact is close : normal operation
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Alarm No. Meanings Description Remedy
AL-01
AL-02
AL-03
AL-04
AL-05
AL-07
AL-08
AL-09
AL-10
AL-11
AL-12
AL-13
AL-15
AL-16
AL-18
AL-19
AL-20
AL-24
AL-25
AL-26
AL-27
Motor overheat
Excessive speed deviation
DC link section fuse blown
Input fuse blown. Input power open phase.
Control power supply fuse blown
Excessive speed
High input voltage
Excessive load on main circuit section
Low input voltage
Overvoltage in DC link section
Overcurrent in DC link section
CPU internal data memory abnormality
Spindle switch/output switch alarm
RAM abnormality
Program ROM sum check error
Excessive U phase current detection circuit offset
Excessive V phase current detection circuit offset
Serial transfer data error
Serial data transfer stopped
Disconnection of position detection signal for Cs contouring control
Position coder signal disconnection
Detects internal motor temperature: exceeding specified temperature.
Detects motor speed exceeding specified speed excessively.
Detects that fuse F4 in DC link section is blown (models 30S and 40S).
Detects blown fuse (F1 to F3), open phase or momentary failure of power (models 30S and 40S).
Detects that control power supply fuse AF2 or AF3 is blown (models 30S and 40S).
Detects that motor rotation has exceeded 115% of its rated speed.
Detects that switch is set to 200 VAC when input voltage is 230 VAC or higher (models 30S and 40S).
Detects abnormal temperature rise of power transistor radiator.
Detects drop in input power supply voltage.
Detects abnormally high direct current power supply voltage in power circuit section.
Detects flow of abnormally large current in direct current section of power circuit.
Detects abnormality in CPU internal data memory. This check is made only when power is turned on.
Detects incorrect switch sequence in spindle switch/output switch operation.
Detects abnormality in RAM for external data. This check is made only when power is turned on.
Detects program ROM data error. This check is made only when power is turned on.
Detects excessive U phase current detection circuit offset. This check is made only when power is turned on.
Detects excessive V phase current detection circuit offset. This check is made only when power is turned on.
Detects serial transfer data error (such as NC power supply turned off, etc.)
Detects that serial data transfer has stopped.
Detects abnormality in speed detection signal for Cs contouring control (such as unconnected cable and adjustment error).
Detects abnormality in position coder signal (such as unconnected cable and parameter setting error).
Check load status. Cool motor, then reset alarm.
Check load status. Reset alarm.
Check power transistors, and so forth. Replace fuse.
Replace fuse. Check open phase and power supply regenerative circuit operation.
Check for control power supply short circuit. Replace fuse.
Reset alarm.
Set switch to 230 VAC.
Cool radiator, than reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then rest alarm.
Correct cause, then reset alarm.
Check sequence.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
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Alarm No. Meanings Description Remedy
AL-28
AL-29
AL-30
AL-31
AL-32
AL-33
AL-34
AL-35
AL-36 AL-37
AL-39
AL-40
AL-41
AL-42
AL-43
Disconnection of position detection signal for Cs contouring control
Short-time overload
Input circuit overcurrent
Speed detection signal disconnection motor restraint alarm
Abnormality in RAM internal to LSI for serial data transfer
Insufficient DC link section charging
Parameter data setting beyond allowable range or values
Excessive gear ratio data setting
Error counter over flow Speed detector
parameter setting error Alarm for indicating
failure in detecting 1­rotation signal for Cs contouring control
Alarm for indicating 1­rotation signal for Cs contouring control not detected
Alarm for indicating failure in detecting position coder 1­rotation signal.
Alarm for indicating position coder 1­rotation signal not detected
Alarm for indicating disconnection of position coder signal for differential speed mode
Detects abnormality in position detection signal for Cs contouring control (such as unconnected cable and adjustment error).
Detects that overload has been continuously applied for some period of time (such as restraining motor shaft in positioning).
Detects overcurrent flowing in input circuit.
Detects that motor cannot rotate at specified speed (but rotates at very slow speed or has stopped). (This includes checking of speed detection signal cable.)
Detects abnormality in RAM internal to LSI for serial data transfer. This check is made only when power is turned on.
Detects insufficient charging of direct current power supply voltage in power circuit section when magnetic contactor in amplifier is turned on (such as open phase and defective charging resistor).
Detects parameter data set beyond allowable range of values.
Detects gear ratio data set beyond allowable range of values.
Detects error counter overflow. Detects incorrect setting of parameter
for number of speed detection pulses. Detects 1-rotation signal detection
failure in Cs contouring control.
Detects that 1-rotation signal has not occurred in Cs contouring control.
Detects failure in detecting position coder 1-rotation signal.
Detects that position coder 1-rotation signal has not occurred.
Detects that main spindle position coder signal used for differential speed mode is not connected yet (or is disconnected).
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Correct cause, then reset alarm.
Set correct data.
Set correct data.
Correct cause, then reset alarm. Set correct data.
Make signal adjustment. Check cable shield status.
Make 1-rotation signal adjustment.
Make signal adjustment for signal conversion circuit. Check cable shield status.
Make 1-rotation signal adjustment for signal conversion circuit.
Check that main spindle position coder signal is connected to connector CN12.
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Alarm No. Meanings Description Remedy
AL-46
AL-47
AL-48
AL-49
AL-50
AL-51
AL-52
AL-53
AL-54
AL-55
Alarm for indicating failure in detecting position coder 1­rotation signal in thread cutting operation.
Position coder signal abnormality
Position coder 1­rotation signal abnormality
The converted differential speed is too high.
Excessive speed command calculation value in spindle synchronization control
Undervoltage at DC link section
ITP signal abnormality I
ITP signal abnormality II
Overload current alarm
Power line abnormality in spindle switching/output switching
Detects failure in detecting position coder 1-rotation signal in thread cutting operation.
Detects incorrect position coder signal count operation.
Detects that occurrence of position coder 1-rotation signal has stopped.
Detects that difference between a spindle speed and another spindle speed has exceeded allowable limit in differential speed mode.
Detects that speed command calculation value exceeded allowable range in spindle synchronization control.
Detects that DC power supply voltage of power circuit has dropped (due to momentary power failure or loose contact of magnetic contactor).
Detects abnormality in synchronization signal (ITP signal) with CNC (such as loss of ITP signal).
Detects abnormality in synchronization signal (ITP signal) with CNC (such as loss of ITP signal).
Detects that excessive current flowed in motor for long time.
Detects that switch request signal does not match power line status check signal.
Make 1-rotation signal adjustment for signal conversion circuit. Check cable shield status.
Make signal adjustment for signal conversion circuit. Check cable shield status.
Make 1-rotation signal adjustment for signal conversion circuit.
Calculate differential speed by multiplying speed of other spindle by gear ratio. Check if calculated value is not greater than maximum speed of motor.
Calculate motor speed by multiplying specified spindle speed by gear ratio. Check if calculated value is not greater than maximum speed of motor.
Correct cause, than reset alarm.
Correct cause, than reset alarm.
Correct cause, than reset alarm.
Check if overload operation or frequent acceleration/deceleration is performed.
Check operation of magnetic contractor for power line switching. Check if power line status check signal is processed normally.
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4-1-4 Detail of Spindle Amplifier Alarm Contents
AL-01 Motor overheat
Item Cause of trouble Check procedure Remedy
1 Defective fan motor Check if fan motor is Replace fan motor.
of motor rotating.
2 Overload operation Check cutting conditions Review cutting
and how tools are worn. conditions and tools. Check load meter for cutting.
3 Dirty motor cooling Check motor cooling Clean motor cooling
system system for dirt. system with an air gun
4 Disconnection or Check signal line Connect signal line
loose contact of connection status. correctly. motor overheat signal line
AL-02 Excessive speed
deviation
Item Cause of trouble Check procedure Remedy
1 Overload operation Check with load meter. Review cutting
(overload) conditions and tools.
2 Defective transistor Check if transistor Replace transistor
module collector-emitter is open. module.
3 Fuse for protecting Check if fuses F3A to Insert fuse4s firmly.
drive on PCB F3M (models 1S to 26S) Replace any blown fuse. blown or not or FA to FG (models 30S inserted correctly and 40S) are blown or (disconnection, removed. loose contact, etc.)
4 Speed feedback Check level of speed Check motor speed
signal abnormality feedback signal. detector and signal
5 Wiring failure Check that cables are
(disconnection, connected correctly. loose contact, etc.)
or vacuum cleaner.
cable connection.
NOTE
How to check the speed feedback signal Observe the speed feedback signal with an oscilloscope after turning on power and setting the rotation command off (motor stopped and drive power set off). Observe the test points indicated below, while turning the motor slowly by hand.
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Test point Normal wave form
PA-0V
PB-0V Same as above RA-0V DC2.5V±0.2V RB-0V Same as above
PAA-0V
PBA-0V
(CW rotation)
Check that the ON/OFF duty cycle is 50%. (The PAP and PBP signals are inverted in CCW direction.)
AL-03 Blown fuse in DC
link section
AL-04 Input fuse blown
Input power open phase
This alarm indicates that the fuse (F4) in the DC link section is blown. In this case, the transistor module may have failed.
Item Cause of trouble Check procedure Remedy
High impedance on
1
AC power supply side. Example:
Two transformers are connected in series, or variable autotransformer is connected.
2
Defective transistor module
3
Defective diode module or thyristor module
4
Defective surge absorber or capacitor
5
When input fuse is not blown
Alarm No. 04 is on only at time of deceleration from high speed operation. Alarm No. 04 can be on when F1 to F3 are not blown.
Disconnect diode modules DM1 to DM3 and thyristor modules SM1 to SM3, then check A-K connection with multimeter. (Defective modules are usually short-circuited.)
Check surge absorbers Z1 to Z3 and capacitors C4 to C6.
Check if Item 1 is applicable.
Change power supply to one with low impedance.There may be loose connection of input power cable Example:
Open phase due to screws not tightened firmly.
Replace transistor module and fuse.
Replace defective part.Replace blown fuse.
Replace defective part.Replace blown fuse.
When Item 1 is not applicable, replace PCB.
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AL-05 Control power
supply fuse blown
Item Cause of trouble Check procedure Remedy
1
Defective PCB
2
Abnormal power supply voltage
Check AC input voltage. See (5) above.
Replace PCB.
AL-07 Excessive speed
(Detection by digital value)
AL-08 High input voltage
AL-09 Heat sink is
overheated
Item Cause of trouble Check procedure Remedy
Incorrect setting of
1
parameter for number of speed feedback pulses (No. 6511)
Check if number of speed feedback pulses matches parameter setting.
Set correct value in parameter.
NOTE
See Chapter 6.
Item Cause of trouble Check procedure Remedy
AC power supply
1
voltage 10% higher than rated voltage.
Incorrect setting of
2
toggle switch for voltage switching.
Item Cause of trouble Check procedure Remedy
Cooling fan is
1
defective. Overload
2
operation. Dusty and dirty.
3
Check power supply voltage.
Check power supply voltage.
Check if fan is rotating. Check load by using a
load meter.
Change setting from 200V to 230V.
Replace fan.
Re-examine the cutting condition.
Clean using compressed air or vacuum cleaner.
AL-10 Input power
voltage drops
AL-11 Overvoltage of DC
link circuit (Regenerative circuit is faulty ... Regeneration failure)
AL-12 Overcurrent flows
to DC link circuit
This alarm indicates abnormally low AC power voltage (-15% or less). This alarm may be generated even during momentary power failures.
Item Cause of trouble Check procedure Remedy
1
High power impedance.
2
PCB is defective.
3
Defective transistor module (TM1).
Item Cause of trouble Check procedure Remedy
Output terminals or
1
internal circuit of motor is shorted.
Transistor module
2
is defective. PCB is defective.
3
Check connections.
Check the transistor module.
Examine AC power specification.
Replace PCB. Replace transistor
module.
Replace transistor module.
Replace PCB.
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AL-13 CPU internal data
memory alarm
Replace PCB.
AL-16 RAM abnormality
AL-18 Program ROM
sum check error
AL-19 Excessive U
phase current detection circuit offset
Item Cause of trouble Check procedure Remedy
1
External data memory (RAM) defective
2
PCB defective
Item Cause of trouble Check procedure Remedy
Program memory
1
data (ROM) defective
Item Cause of trouble Check procedure Remedy
A/D converter
1
defective U-phase current
2
detector circuit defective.
Loose contact of
3
connectors between PCB and power circuit
Compare data displayed when power is turned ON with ROM labels.
After power is turned on, check if offset voltage on check terminal IU is beyond range of about ±100mV.
Check connector connection between PCB and power circuit.
Replace memory (RAM).
Replace PCB.
Replace program memory (ROM).
Replace A/D converter.
Replace PCB.
Ensure that PCB and power circuit are securely connected with each other.
AL-20 Excessive V
phase current detection circuit offset
AL-24 Serial transfer
data error
AL-25 Serial data
transfer stopped
Item Cause of trouble Check procedure Remedy
v-phase current
1
detector circuit defective.
Loose contact of
2
connectors between PCB and power circuit
Item Cause of trouble Check procedure Remedy
1
CNC power supply is OFF.
2
Defective optical cable for serial data transmission
3
Defective data transmission/ reception elements in LSI used in serial data transmission
After power is turned on, check if offset voltage on check terminal IV is beyond range of about ±100mV.
Check connector connection between PCB and power circuit.
Check that CNC power is ON.
Check that optical cable is fitted securely to the connector. Check that the cable is not broken.Check that transmission/reception surfaces of the cable are clean.
Replace PCB.
Ensure that PCB and power circuit are securely connected with each other.
Turn CNC power ON. Connect
securely.Replace optical cable.Clean optical cable transmission/ reception surfaces.
Replace LSI.Replace PCB.
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AL-26 Disconnection of
speed detection signal for Cs contouring control
Item Cause of trouble Check procedure Remedy
Signal level of
1
spindle motor for Cs contouring control is invalid.
Signal line of
2
spindle motor for Cs contour control is defective.
Defective detector
3
circuit for Cs contour control
Incorrect parameter
4
setting
Check the signal, and if necessary adjust to the normal level using the variable resistor for signal level adjustment in the preamp.
Check that signal cable is connected securely to connector.Check that signal cable is not broken.
Check that the parameter setting does not indicate that the Cs contour control detector is used when actually it is not.
Connect signal cable securely.Replace signal cable.
Replace detector circuit.
Parameter CAXIS1=0 No.4001#5
AL-27 Position coder
signal disconnection
AL-28 Disconnection of
position detection signal for Cs contouring control
Item Cause of trouble Check procedure Remedy
1
Position coder signal line defective
2
Incorrect parameter setting
Item Cause of trouble Check procedure Remedy
Signal level of
1
spindle detector for Cs axis control is defective
Signal line of
2
spindle detector for Cs axis control is defective
Defective detector
3
circuit for Cs axis control
Check that signel cable is connected securely to connector.Check that signal cable is not broken.
Check that the parameter setting does not indicate that the position coder signal is used when actually it is not.
Check the signal level, and if necessary adjust to the normal level using the variable resistor for signal level adjustment in the preamp.
Check the signal cable is connected securely to connector.Check that signal cable is not broken.
Connect signal cable securely.Replace signal cable.
Parameter MRDY2=0 No. 4001#2
Connect signal cable securely. Replace signal cable.
Replace detector circuit.
AL-29 Short-time
overload
Item Cause of trouble Check procedure Remedy
Overload operation
1
(Overload)
Use loadmeter to check that a load close to the load resistance limit is not imposed continuously for 30 seconds or more.
Re-examine cutting conditions and tools.
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AL-30 Input circuit
overcurrent
Item Cause of trouble Check procedure Remedy
Defective of power
1
transistor used for power
Defective of power
2
regeneration circuit
Check power transistor.
Replace power transistor.
Replace PCB.
AL-31 Speed detection
signal disconnection motor restraint alarm
AL-32 Abnormality in
RAM internal to LSI for serial data transfer
AL-33 Insufficient DC
link section charging
Item Cause of trouble Check procedure Remedy
Motor constrained
1
Defective motor
2
speed feedback signal
Defective motor
3
speed feedback signal cable
Item Cause of trouble Check procedure Remedy
Defective LSI used
1
in serial data transmission
Item Cause of trouble Check procedure Remedy
Defective relay
1
used in DC link recharging. Disconnection of resistor used in limiting re-charge current
Check that nothing is preventing the motor from accelerating.
Check signal waveform. (Alarm No.2)
Check that cable is connected securely to connector.Check that cable is not broken.
Check relevant parts.
Remove cause.
Remove cause.
Connect cable securely.Replace cable.
Replace LSI. Replace PCB.
Replace amp.
AL-34 Parameter data
setting beyond allowable range of values
AL-35 Excessive gear
ratio data setting
Item Cause of trouble Check procedure Remedy
Incorrect parameter
1
setting
Check if specified parameter value is beyond allowable range of values
Specify value within allowable range.
AL-34 and F-XXX are alternately displayed in the spindle amplifier indicator section if an AL-34 alarm is raised. "XXX" indicates the data number internal to the spindle for a parameter where a value beyond the allowable range is specified.
Item Cause of trouble Check procedure Remedy
Parameter data of
1
gear ratio and position gain are too large.
Check gear ratio and position gain data.
Change to suitable values.
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AL-37 Speed detector
parameter setting error
Item Cause of trouble Check procedure Remedy
Incorrect setting of
1
parameter for number of speed feedback pulses (No. 6511)
Check if number of speed feedback pulses matches parameter setting.
Set correct value in parameter.
AL-39 Alarm for
indicating failure in detecting 1-rotation signal for Cs contouring control
AL-40 Alarm for
indicating 1-rotation signal for Cs contouring control not detected
AL-41 Alarm for
indicating failure in detecting position coder 1-rotation signal
Item Cause of trouble Check procedure Remedy
Incorrect data ROM
1
type for Cs contouring control detector circuit, or incorrect setting
Low level of Cs
2
contouring control feedback signal, or noise on same feedback signal
Item Cause of trouble Check procedure Remedy
No occurrence of
1-rotation signal among Cs contouring control feedback signals, or 1-rotation signal offset adjustment error
Item Cause of trouble Check procedure Remedy
Incorrect setting of
1
parameter for number of position coder signal pulses (No. 4003#4, 6, 7).
Incorrect amplitude
2
and offset of position coder feedback signal. or noise on same feedback signal.
Check data ROM type for Cs contouring control detector circuit and setting.
Check feedback signal level and also check if feedback signal waveform includes noise.
Check 1-rotation signal among Cs contouring control feedback signals.
Check number of position coder signal pulses and parameter setting.
Check feedback signal level and also check if feedback signal waveform includes noise.
Install correct type of ROM. Perform setting correctly.
Adjust feedback signal. Check shielding status.
Make 1-rotation signal offset adjustment.Check cables.
Set correct value in parameter.
Adjust feedback signal.Check shielding status.
AL-47 Position coder
signal abnormality
Item Cause of trouble Check procedure Remedy
Incorrect setting of
1
parameter for number of position coder signal pulses (No. 4003#4, 6, 7).
Incorrect amplitude
2
and offset of position coder feedback signal. or noise on same feedback signal.
Check number of position coder signal pulses and parameter setting.
Check feedback signal level and also check if feedback signal waveform includes noise.
Set correct value in parameter.
Adjust feedback signal.Check shielding status.
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4-2 Inverter for Turret
4-2-1 Status Indication (on the Point Module)
Status indication is also possible on the 7-segment indication on the point module board. Table 4-5 shows the contents of the status indication. This indication is continuously lit. (A flickering indication is an alarm indication.)
Table 4-1 Status Indication of Juspoint
Continuous
indication
0 Just after turning ON (without setup operation) Non at ABS mode 1 During zero-point offset automatic setup operation 2 During jog operation 3 During zero-point return operation 4 During setup operation (confirmation seems impossible because of 15 msec) 5 During stopped (setup operation completion) 6 During automatic operation 7 During manual operation 8 9 A
B C D E
F
Memory storage in ABS mode completed. (ABS.READY CLOSED being output) Just after turning ON in ABS mode (ABS.READY CLOSED being output)
Operation status
ΙΙΙ
[Status indication of inverter (Juspeed-F X3000)]
Whether or not the inverter is in the normal operating state can be monitored with the LED (7 segments) on the printed circuit board in the inverter main body (the LED is continuously lit in the normal operating state).
Table 4-6 shows the indication of the normal operating state.
Table 4-2 State Indication of Juspeed-F X3000
St ate LED indication Description
Servo OFF condition, ready for operation. Af ter the power is turned
Stopped
Running 0 Servo ON condition and normal operation is continued.
OFF, the inverter carries out self-diagnosis and displays “-” if no error is found.
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4-2-2 T roubleshooting
Cause and remedy of alarms for Juspoint III Table 4-3 is a list of alarms. The indications refer to those made on the 7-segment LED on the point module board. These indications are blinking indications (continuously lit indication indicates normal operation).
Table 4-3 Cause and remedy of alarm
Blinking
Indication
0
Driver alarm was detected (description is displayed on the driver).
1
PG fault (including poor wiring)
2
Emergency stop operation was occurred.
3
Operation was commanded without setup operation after turning ON the power (except for ABS mode 1 and 2)
4
Zero-point LS was not detected during zero­point offset automatic setup operation.
5
Zero-point LS was not detected during zero­point return operation.
6
Undefined station number was commanded.
7
Operation mode was not set correctly.
8
Zero-point offset automatic setup operation was commanded when the zero-point offset setup mode is set to parameter mode.
9
Zero-point LS position error (the zero-point LS position is too close to the Z-phase position, within ±120 pulses)
A
Zero-point offset is out of allowable range (out of the range set by parameter [C0-10].)
b
The following occurred when the backlash compensation was other than “0”.
Setup operation was commanded without zero-point return (except for ABS mode 1 and 2).
Zero-point offset automatic setup operation was commanded. The backlash compensation is larger than the unit station pulses. (Set a value smaller than the unit station pulses.)
C
Station numbers are not arranged in order in the case of the absolute position setting [C0­01=4]. Arrange the station numbers in the order of station numbers.
d
In the ABS mode, the memory storage was not completed. Reset and perform zero­point return.
Blank
Reset the alarms using the reset signal (RESET). The alarms can also be reset by the power supply (24 VDC). Reset the power supply in the case of the MCU error.
MCU error
Alarm description Cause and remedy
Check the alarm on the driver. The alarm description is displayed on the amplifier board.
PG fault, PG poor wiring, or motor locked may be the cause. Check them. Emergency stop operation was occurred to stop the motor.
Inputting OPEN for the EMG signal executes the emergency stop operation. After resetting the alarm, zero-point return or setup operation is not required.
Automatic or manual operation was performed with state “0” (without setup). Perform the setup operation and then the automatic or manual operation.
The zero-point LS was not detected after turning the motor for 40000 pulses (10 rotations) during the zero-point offset automatic setup operation. Check that the zero-point LS is correctly wired and that the signal is input to Juspoint III. Or, mount the zero-point LS at a position within 40000 pulses (10 rotations) from the zero-point.
The zero-point LS was not detected after turning the motor for all set stations during the zero-point return operation Check that the zero-point LS is correctly wired or that the signal is input to Juspoint III.
Command a station number within the range set by [C0-00: number of stations] (for setup or automatic operation).
Underfined operation mode was input. Set the correct operation mode input (MODE0-MODE2)
[C0-04=0] is set (zero-point offset setup is set to parameter mode). To perform the zero-point offset automatic setup operation, set [C0-04=1].
The Zero-point LS position and the Z-phase pulse position of PG is too close (±120 pulses). Change the LS position or Z-phase position.
The Zero-point offset detected during the zero-point offset automatic setup operation is out of the range of 120-40000. Change the zero-point LS position correctly.
A value larger than the minimum value of station interval pulses is set for the backlash compensation or zero-point return was not carried out before the setup operation. Check the two possibilities and correct the setting or sequence.
Stations are not arranged in the order of station numbers in the case of the absolute coordinate axis [C0-01=4]. Set the parameters or carry out teaching so that the stations will be in the order of station numbers.
In the case of the ABS mode [C0-09=1 or 2], the information required for the ABS operation was not stored in the nonvolatile memory before the power was turned OFF. To execute ABS operation, first change the ABS.ST signal from CLOSED to OPEN and make sure that the ABS.READY signal becomes CLOSED before turning OFF the power. This alarm is also issued when the motor shaft is forced to rotate by external force while the power is turned OFF. When the ABS mode 1 is to be used, the motor must have a brake.
Malfunction of the microcomputer (out of control). It is possible that noise has entered from the control signal line or 24 VDC power line. Take measures to prevent noise from entering these lines; shield the cables or separate the lines from the power lines carrying large currents. It is also possible that the control unit is faulty. If the error does not disappear by eliminating the noise, replace the control unit and return it to the factory.
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[Cause and remedy of alarms for the inverter (Juspeed-F X3000)]
Error indication (Errors are indicated by blinking indication.) Errors of the inverter can be monitored on the LED (7 segments) on the printed circuit
board in the inverter main body.
Table 4-4 Cause and remedy of alarms for Juspeed-F X3000
State
Overcurrent
Overvoltage
Overspeed
Under­voltage
PG error
Exceeding
temperature
CPU error I
CPU error II
CT error
Ground
Fault
Others
LED
indication
1
2
3
4
5
6
7
8
9
b
0
Contents Cause and remedy
Overcurrent or short-circuit current was detected and the inverter output was shut-off.
Regeneration overvoltage was detected and the inverter output was shut-off. DC bus voltage: 450V
The motor speed exceed 1.1 times max. speed (10% increase) was detected and the inverter output was shut­off.
A voltage drop was detected and the inverter output was shut-off. DC voltage: 213V
Encoder error was detected and the inverter output was shut-off. Note that not all the PG errors can be detected.
The temperature inside the motor has risen above the regulated value and the inverter output was shut-off.
CPU error was detected during the self-diagnosis carried out after power was supplied and the inverter output was shut­off.
CPU error (WDT) was detected during operation and the inverter output was shut­off. This error is detected for external noise.
CT (current detector) error was detected and the inverter output was shut-off.
Ground fault was detected in the output at the start of operation and the inverter output was shut-off.
An error (alarm) other than those listed above was detected and the inverter output was shut-off.
It is possible that the torque limit is too high or the output has a short­circuit. If no change can be seen after changing the torque limit to 200% or smaller, check for a short-circuit of the output.
The torque limit may be too high or the regeneration resistor may be burned out. If no change can be seen after changing the torque limit to 200% or smaller, return the regeneration resistor to the factory for investigation.
When the motor speed gets up to 1980r/min, the motor is being forced to rotate by an external force. Check for the cause and eliminate it.
The power supply voltage has dropped (180 VAC or lower) during operation or instantaneous power failure was detected. If the cause cannot be eliminated, add a sequence that will input the reset signal after the voltage drop or momentary power loss.
PG fault, PG wiring fault, or motor-lock can be considered. Check for the cause of these faults.
The temperature inside the motor has become high or the temperature detection line (inside the PG cable) is faulty. Check the motor temperature. If the temperature is normal, check the temperature detection line (PG cable).
Since the error was detected during self-diagnosis carried out after power was supplied, it is a hard ware error. Replace and return it to the factory.
Malfunction of the microcomputer (out of control). It is possible that noise has entered from the control signal line or 24 VDC power line. Take measures to prevent noise from entering these lines; shield the cables or separate the lines from power lines carrying large currents. It is also possible that the control unit is faulty. If the error does not disappear after eliminating the noise, replace the control unit and return it to the factory.
Since the CT error for current detection was detected, it is a hardware error. Replace and return it to the factory.
The ground fault was detected in output lines (U, V, W) upon servo ON. Check whether the output side being grounded. If this alarm is not reset after the grounding state was reset, replace and return it to the factory.
An error other than those listed above was detected. It is possible that it is alarm 8 above. Take the corrective action listed in the column for alarm 8, and if no improvement is made, replace and return it to the factory.
Notes: 1 When more than one alarm is detected, they are indicated cyclically.
Example: When alarms 3,4 and 7 are detected, the LED will display 3
2 The alarm state is retained unless the power supply is reset or th reset signal is used. 3 The indications blink.
4 - 19
4
7
3
4
7
3 and so on.
Page 68
4-3 Replacing Method of Battery
The CNC unit provides a battery to hold a memory which is stored programs, offset amount and parameter etc. When the battery voltage drops, a warning [794 BATTERY ALARM] is displayed on the screen. If a warning is displayed, replace the battery as soon as possible. The memory may be lost when the power source keep off for one week or more without replacing a battery.
Caution
Since the life of battery is about one year, replace it once a year periodically even if above alarm is not occurred.
(1) Replacing procedure of battery for CNC memory back up
Get a lithium battery (A02B-0200-K102) ready.
!
WARNING
A battery may be exploded unless replaced properly. Use only the specified batteries (A02B-0200-K102).
[1]Turn ON the machine (CNC) about 30 minutes, then turn it OFF. [2]Remove the battery on the top of the CNC unit.
At first, remove the connector, and remove the battery from the battery case.
[3]After replacing, connect the connector.
Note) The battery case is located,
On the middle part of the upper section of the unit as per a following
diagram, in case of with the option slot. On the right end of the upper section of the unit in case of without the optionslot.
battery case
connector
Lithium battery A02BB-0200-K102
Caution
Battery changing work [1] ~ [3] should be completed within 30 minutes. If the machine is left any longer without battery, data memory in store would be lost.
When there is a possibility of the work not being completed within 30 minutes, save the SRAM memory on the memory card in the lump. This facilitates restoration of memory even if the data is once lost. For an operating method, see APPENDIX : BOOT SYSTEM.
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4-4 Alarm Display
4-4-1 NC Alarm
No. Content 100 G10 command error 101 Zero-point return not complete 102 F command error 103 Tapping command error 106 Plane selection command error 107 Offset No. error 112 Tool No. error 113 Polar coordinates compensation command error 114 Polar coordinates compensation mode error 115 Tool diameter/Nose R offset error 117 Tool diameter/Nose R offset interference error 118 Tool diameter/Nose R offset intersection error 119 Tool diameter/Nose R offset mode error 120 Tool length measurement command error 121 Tool length measurement command error 123 Tool length measurement operating error 124 Arbitrary angle chamfer corner R error 126 Cylinder compensation command error 127 Cylinder compensation mode error 128 G68 error 130 Block command error 131 Ark radius R designation error 132 Ark compensation error 133 Fixed cycle command error 134 Boring pattern cycle command error 135 rue circle cutting command error 136 Square cutting command error 137 Pocket cutting command error 138 Direct tap command error 139 Virtual axis command error 140 Program restart error 142 Scaling command error
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No. Content 143 Scaling mode error 144 G511/G501 program format error 146 G53 error 149 Helical cutting command error 158 3-dimension tool offset error 159 3-dimension tool mode error 160 Tool length offset error 161 Tool position offset error 163 Multiple M code command error 175 Compound type fixed cycle error 176 Single type fixed cycle error 177 Angle designated straight line compensation error 178 Chamfer, corner R error 179 Groove width offset error 180 G41, G42 command not possible 182 T command error 183 G128 error 184 Rear face processing command error 188 No option in address to write 189 Incorrect parameter setting 191 Option command 196 Reverse move error [Warning] 201 G25/G26 command error 210 Oscillation command error
211 Oscillation mode error 260 HPCC command error 261 HPCC mode error 262 Previous control command error 263 Previous control mode error 270 Soft jaws forming error 271 Soft jaws forming operation error 272 Pre-machining graphics-drawing error 500 Program character number exceeds permissible maximum 501 Command data digit exceeds permissible maximum 502 Non-existent character string variable
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No. Content
503 Character string variable not possible to construct
504 Undefined G code
505 SETVN command format incorrect
506 Command exceeds permissible value of system variable
507 Search of variable value not possible
508 Overflow of logical operation
509 Improper argument assignment of a macro call
510 Format of macro sentence incorrect
511 Use of decimal point “.” improper
512 Use of minus sign “-” improper
513 Data following address non-existent
514 Description of formula incorrect
515 Variable No. not permitted to use
516 False character
517 Input of data to variable which does not accept data
518 Faulty variable value
519 Opening and closing parentheses do not correspond
520 Mixed existence of NC sentence and Macro sentence
521 Non-existence of corresponding sequence No.
522 Non-existence of corresponding program
523 Division with divisor “0”
524 Negative square root
525 Function BCD/BIN with negative number
526 BIN function in the data not belonging to BCD
527 Overflow during calculating formula
528 DO/END recognition No. improper
529 Branch destination included in the DO loop.
530 DO/END loop intersects
531 Non-existence of POPEN command
532 Duplicate call up of subprogram-macro does not function
533 Duplicate call up of macro does not function
534 Multiple call up command with same program
535 DO/END command in DNC program
536 No designation of subprogram
538 Non-existent function
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No. Content 539 Error in writing function 540 ADP function error 541 Non-existence of END corresponding DO 542 Non-existence of IF sentence corresponding ENDIF 543 Non-existence of ENDIF corresponding block IF sentence 544 Ineffective calculation 545 Macro in compound type fixed cycle form 546 Wrong G code in high precision contouring control 560 External output open error 561 External output communication error 570 DNC operation start error 701 No.1 axis Zero-point return deceleration signal is abnormal
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708 No.8 axis Zero-point return deceleration signal is abnormal 710 W setter mode error 711 W setter mode error 712 Q setter mode error 713 Q setter mode error 714 Q setter interlock 715 Measurement error 716 Tool setter measurement error 721 Start in automatic operation does not function [Warning] 724 Q setter repeat error 729 Setting of jaw end face position not completed [Warning] 730 External No. search error 732 External data I/O error 733 External data I/O error 734 External data input error
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735 External data input error 736 External data output error 738 Q setter repeat error 739 Q setter repeat error 770 Spindle overload alarm [Warning] 772 X axis overload alarm
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No. Content 773 Y axis overload alarm 774 Z axis overload alarm 775 Swivel tool overload alarm 771 non-load alarm [Warning] 780 Damaged tool was selected [Warning] 781 Lifeover tool was selected [Warning] 782 Pre-processing tool check error [Warning] 783 Surveillance program format error [Warning] 784 Tool on demand registration error [Warning] 790 System table error 791 Executed data conversion error 794 Battery exhaustion [Warning] 795 Emergency stop [Warning]
No. Content F000 Switch off the source power F085 Communication error F086 Operation preparation signal is OFF F087 Buffer overflow F092 Zero return is not complete F205 Rigid mode DI 1s OFF 5000 Illegal command code (HPCC) 5003 Illegal parameter (HPCC) 5004 HPCC not ready 5006 Too many words in one block 5007 Too large distance 5009 Parameter zero (Dry run) 5010 End of recode 5011 Parameter zero (Cut max) F300 Request for n-axis zero return F301 APC alarm: n-axis communication F302 APC alarm: n-axis overtime F303 APC alarm: n-axis framing F304 APC alarm: n-axis parity F305 APC alarm: n-axis pulse error F306 APC alarm: n-axis battery voltage 0
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No. Content F307 APC alarm: n-axis battery low voltage 1 F308 APC alarm: n-axis battery low voltage 2 F309 APC alarm: n-axis zero return disable F350 SPC alarm: n-axis pulse coder F351 SPC alarm: n-axis communication F400 Servo alarm: n-axis overload F401 Servo alarm: n-axis V ready OFF F404 Servo alarm: n-axis V ready ON F405 Servo alarm: (Zero return abnormal) F407 Servo alarm: Excessive error F409 Servo alarm: n-axis abnormal load F410 Servo alarm: n-axis excessive error value F411 Servo alarm: n-axis excessive error value F413 Servo alarm: n-axis LSI overflow F414 servo alarm: n-axis detecting system error F415 Servo alarm: n-axis excessive move amount F416 Servo alarm: n-axis broken wire F417 Servo alarm: n-axis parameter improper F420 Servo alarm: n-axis excessive torque difference F421 Servo alarm: n-axis excessive error value F500 Over travel: +n F501 Over travel: -n F502 Over travel: +n F503 Over travel: -n F504 Over travel: +n F505 Over travel: -n F506 Over travel: +n F507 Over travel: -n F510 Over travel: +N F511 Over travel: -N F700 Over heat: Control unit F701 Over heat: Fan motor F704 Over heat: Spindle F740 Rigid tap alarm: Excessive error value F741 Rigid tap alarm: Excessive error value F742 Rigid tap alarm: LSI error
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No. Content F749 S-spindle LSI error F750 Spindle serial link starting fault F751 1st spindle alarm detected F752 1st spindle mode switching abnormal F754 1st spindle abnormal load detected F761 2nd spindle alarm detected F762 2nd spindle mode switching abnormal F764 2nd spindle abnormal load detected F771 3rd spindle alarm detected F772 3rd spindle mode switching abnormal F774 3rd spindle abnormal load detected
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4-4-2 PC Alarm
ALARM No. COMMENT Details/Counter-measures
1000 HYDRAULIC MOTOR OVER LOAD Thermal MS1 is tripped. Reset the
1001 COOLANT MOTOR OVER LOAD Thermal MS2 is tripped. Reset the
1004 SPINDLE COOLER UNIT ALARM Spindle cooler unit alarm is issued.
1007 CHIP CONVEYOR ALARM Thermal in chip conveyor control box is
1011 TURRET DRIVE UNIT ALARM Turret drive unit alarm is issued. Check
1017 TURRET INDEX CYCLE POWER OFF Indexing is suspended. Put back the
1020 TURRET INDEX SET UP ERROR Station number setting is wrong. Put
thermal.
thermal.
Check the spindle cooler unit.
tripped. Reset the thermal.
the turret drive unit.
turret position according to the restoring method.
back the turret position according to the restoring method.
1021 TURRET INDEX CONDITION FAULT The conditions of turret are incomplete.
Put back the Q-setter arm. 1022 SPINDLE ALARM Check the spindle drive unit. 1023 CIRCUIT PROTECTOR TRIP Circuit protector in control box is
tripped. CP-1­1024 TURRET INDEX TIME OVER Turret index was not completed within
the specified time. Put back the turret
position according to the restoring
method. 1026 Q-SETTER ARM ALARM Put back the Q-setter arm. 1027 1030 NC ALARM NC alarm is issued. 1036 NC TORQUE LIMITER ALARM Check which axis is the cause of alarm
by referring NC alarm history and review
the processing conditions. 2043 AIR PRESSURE ALARM Air pressure of the machine proper has
dropped. Check the air pressure
source. 1044 MEASURING ARM OPERATION Work measurement is abnormal.
ALARM 1046 DOOR CLOSE NOT DETECTED Close the door then start operation. 1047 CHUCK CLOSE NOT DETECTED Close the chuck then start operation.
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ALARM No. COMMENT Details/Counter-measures
1050 NOT OPTION Key not usable was pressed. 1056 SPINDLE ORIENTATION ALARM Spindle orientation was not completed
within the specified time. 1060 1061 FEEDER PALLET SINK LIMIT (Z- Feeder side pallet is pressed to hard.
AXIS-0T)
1062 FEEDER ALARM Feeder alarm is being issued. Check
the feeder. 1063 SPINDLE BRAKE NOT RELEASED Release the spindle brake then start the
spindle operation. 1064 C AXIS CONNECTION ALARM C axis connection/disconnection was
not completed within the specified time. 1065 AUTO PRESETTER ARM OPERATING Auto presetter action is not completed.
TIME OVER
1066 AUTO DOOR OPERATING TIME Auto door open/close action is
OVER abnormal. 1067 1070 CHUCKING FAULT Chucking is abnormal. 1073 M FUNCTION CYCLE TIME OVER M function execution was not completed
within the specified time.
2075 COUNTER COUNT UP Count number has reached the setting
value. 2076 M31 STOP ALARM Material work has exhausted. 1077 1080 1081 ZERO TETURN INCOMPLETE Complete all axes zero return. 1082 Z-SETTER ARM RETURN NOT Z-setter arm is not returned to the
DETECTED position.
1084 AUTO PRESETTER ARM RETURN Auto presetter is not returned to the
NOT DETECTED position.
1085 MEASURING ARM RETURN NOT Work measuring arm is not returned to
DETECTED the position.
1086 SPINDLE STOP UNFINISH During spindle rotation, action was
commanded for operating chuck,
center, etc. 1087 ROTATING TOOL RUNNING Rotation tool is in motion. 1090 CHIP CONVEYOR MODE NOT AUTO Make chip conveyor in auto mode on
the operating panel.
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ALARM No. COMMENT Details/Counter-measures
1091 ORIENTATION RELEASE UNFINISH Release the spindle orientation. 1093 C AXIS MODE CANCEL UNFINISH Release the C axis connection. 1094 1095 TOOL CLAMP NOT DETECTED Clamp the tool firm. 1100 POSITION INTERLOCK AREA C This is the interlock in case of instrusion
into the feeder area. During program operation, when the safety guard on the feeder side is opened and there is an instrusion into the feeder area, alarm stop takes place. Also, when the spindle is rotated within the feeder area, an alarm is issued.
1101 ALL AXIS ZERO RETURN At time of NC initial source power ON,
INTERLOCK AREA D one touch zero return does not work
unless each axis is within the position
area D. 1102 NO SPARE TOOL There is not spare tool. 1103 POSITION INTERLOCK AREA E Because of interference with the way
cover, intrusion is prohibited. 1105 CHUCK UNCLAMP UNFINISH Chuck is not unclamped. 1106 SAFETY GUARD OPEN ALARM Close is not unclamped. 1110 I/O BOARD FUSE TRIP Standard slave fuse has blown up.
1111 I/O BOARD FUSE TRIP Option slave fuse has blown up. 1112 1 113 OIL SCHEMER MOROE OVER LOAD Oil schemer is abnormal.
ALARM 1117 PC PARAMETER SETTING ERROR The setting of PC parameter is abnormal. 1120 ROTATING TOOL CONNECT Rotating tool is not connected.
UNFINISH 1121 ROTATING TOOL CONNECT Rotating tool is connection/disconnection
TIME OVER action was not completed. 1122 C AXIS CONNECT TIME OVER C-axis is not connected. 1123 ROTATING TOOL INDEXING R o tating tool indexing is not finished.
UNIFINISH 1124
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5. EXPENDABLE PARTS LIST
5-1 Expendable Parts List of CS20
No. CODE NO. PRODUCT NAME MODEL (Type of VOLUME REMARKS
machines applied) SADDLE.ROSS SLIDE & Z FEED 1 03999006026 Angular ball bearing 25TAC62BSUC10PN7B 2 NSK 2 02341201450 Limit switch SL1-A 2 YAMATAKE HEADSTOCK 1 06-16LZ50 O-ring 16L250 2
2 04999097874 O-ring GS270 (φ3.1) 1 3 06315100600 O-ring 15L6 2
4 06-16LZ20 O-ring 16L220 1 BED & X FEED 1 02341201450 Limit switch SL1-A 2 YAMATAKE
1/2
2 03999006026 Angular ball bearing 25TAC62BSU C10 PN7B 4 NSK 3 05141000330 STS belt 250S8M800 1 BANDO TOOL POST 1 04999105618 X-ring R-60 2 NIHON BULKER 2 06-16L80 O-ring 16L80 1 3 06-15L16 O-ring 15L16 2 4 06-15L12 O-ring 15L12 12 5 17450041700 Seal ring OVO-240*250*5 (Fluorine) 1 SHORITSU 6 05999062529 Timing belt 250KPS8M1032 1 BANDO 7 02341201470 Limit switch SL1-H 1 YAMATAKE POWER SOURCE 1 04999001239 Solenoid valve SL-G01-E3X-GR-C1-9560B 2 FUJIKOSHI COOLANT 1 02172200500 Coolant pump VKP073A (180kW) 1 FUJI Electric SPLASH GUARD 1 02712100920 Limit switch D4D-2120 1 OM R O N 2 02921111400 Fluorescent lamp PM1115S-G10W 1 Hitachi, Ltd. 3 02921220900 Fluorescent lamp FL-10D 1 Hitachi, Ltd.
4 05902200010 Bearing NBM-6 6×24×12 2 Ochiai Shoten 5 1682-75-368-00 Wiper (WP-34-20S) 1 NITTA
6 1682-75-367-00 Wiper (WP-34-20S) 1 NITTA
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No. CODE NO. PRODUCT NAME MODEL (Type of VOLUME REMARKS
machines applied) SPLASH GUARD 7 1682-75-452-00 Wiper (WP-34-20S) 1 NITTA 8 1682-75-451-01 Wiper (WP-34-20S) 1 NITTA 9 1682-75-440-01 Wiper (WP-34-20S) 1 NITTA 10 1682-75-441-00 Wiper (WP-34-20S) 1 NITTA 11 1682-75-316-21 Wiper (WP-34-20S) 1 NITTA 12 1682-75-376-00 Wiper (WP-34-20S) 1 NITTA 13 1682-75-353-00 Wiper (WP-34-20S) 1 NITTA 14 1682-75-384-00 Wiper (WP-34-20S) 1 NITTA 15 1682-99-368-00 Wiper (WP-34-20S) 1 NITTA Q SETTER 1 02999074574 Proximity switch FL7M-7J6HD-EL05 1 YAMATAKE
2 04849000040 Seal GD40×25×5 1 NTN 3 9100-00-006-00 Probe L4P01 1 AZUMA
2/2
4 06315101200 O-ring 15L12 1 5 06316203000 O-ring 16L30 1 6 06326045000 Seal 26L45 1 TURN EQUIPMENT 1 03660064000 Deep grove 6006ZZ 2 NTN
ball bearing 2 03913112100 Drymet bush 70B-1210 2 OILES 3 03999029014 Cam follower KRV13XLLH 8 NTN 4 03999029090 Cam follower KRVU16XLLH 9 NTN 5 05999067337 Geared belt 150KPS8M848 1 BANDO
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TURNING CENTER
SUPER HiCELL250
INSTRUCTION MANUAL
MAINTENANCE
SEIKI-SEICOS S18T
Version 1.01
8-2000
First Edition6-1998
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