hitachi seiki 21L, CS20 Maintenance Manual

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
Volt age and Cycle .........................................................................................	1	- 8
1-1-7 Connection of Chip Conveyor ......................................................................	1 - 10
1-1-8 Installation and Leveling ...............................................................................	1 - 11
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 Apparatus 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 Status ..............................................................................	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 Status Display ....................................................................	4	- 4
4-1-3 Spindle Amplifier Alarm..................................................................................	4	- 5
4-1-4 Detail of Spindle Amplifier Alarm Contents ...................................................	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
4-4 Alarm Display .....................................................................................................	4 - 21
4-4-1 NC Alarm.....................................................................................................	4 - 21
4-4-2 PC Alarm.....................................................................................................	4 - 28
5. EXPENDABLE PARTS LIST...............................................................	5 - 1
5-1 Expendable 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.

1)The bearing capacity of soil should be 5 ton/m2 or larger and thickness of the foundation should 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.

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 100Ω or comply with the laws and regulations of the country.

Or the earth wire size must be not less than 6mm2.

3)Example of earth of NC machine

The earth state of NC machine and electric machines and appliances illustrated as under.

Power receiving equipment

To be separated system wiring
3 pase	3 pase
AC400V	AC400V

Powersupply

Electric machine More than 20m

NC

and appliance

Grounding:Class 3 grounding work within 5m

[Grounding resistance of 100Ω or below. Wire size of 6mm2 or above.]

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3 - 1

Dimention : metric (mm)

inch ( ” )

should be 5 ton/m2 (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° , proper angle being 60° .

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.

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Fig. 1-3 Slinging

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.

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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. Before doing this 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.

(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, don’t 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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Front view

13 - 1

Oil Lubrication of List

Supply spot

Method

Frequency

Q’ty

Nisseki

Idemitsu

Shell

Mobil

Mitsubishi

ESSO

MOK Clewbar

ISO symbol

1

Spindle cooling unit

Trochold

Replace every 6 month;

28l

Nisseki

UNI-POWER

pump

replenish occasion

Multi-

Daphne

Tetra oil

MOBIL

Diamond

MP32

purpose 32

Multi-way

32

DTE oil

Tetrat 32

2

Hydraulic unit

Piston

Replace every 6 month;

10l

32ER

light

pump

replenish occasionally

CB32

3

Hydraulic chuck

Manual

Supply oil fully every day

Molynock

Daphne

Retina

MOBIL

Diamond

R-temp Q

Multi-

BICON Q2

grease 2

grease M2

AM

grease

purpose M

NB50

special

grease 2

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 maker’s 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, enviromentand 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	*	This type is excellent
		used widely in the		in permeability
		cutting field, because		because it is small in
		it is relatively large in		particle diameter
		particle diameter ( 4		( 0.1 to 0.03 m ).
		to 7 m) and high in	*	It has been used
		lubricating property.			Do not use this type.
				mainly for grinding
	* It is the soluble			purposes, but it is
		cutting agent that was		used also for cutting
		made first.		purposes due to the
	*	It decomposes easily		development of the
				extreme pressure
		due to lack of stability.
				agent.
			*	Since it uses much
				surface-active agent,
				it is likely to affect
				coating adversely.
Form	*	Dissolving this in	*	Dissolving this in
		water, it becomes		water, it becomes
		milky. This is		semi-transparent.
		because particles		This is because
		dissolved in water are		particles dissolver in
		large, reflecting light.		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 doesn’t 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/cm2}

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