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.
4-4-2 PC Alarm..................................................................................................... 4 - 28
5. EXPENDABLE PARTS LIST ............................................................... 5 - 1
5-1Expendable Parts List of CS20 ............................................................................. 5 - 1
ii
Page 7
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.
2
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
1 - 1
Page 8
[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
Ω 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
1 - 2
Grounding:Class 3 grounding
work within 5m
[Grounding resistance of 100Ω
or below. Wire size of 6mm
or above.]
2
Page 9
1 - 3
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.
Page 10
1 - 4
Page 11
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°.
1 - 5
Page 12
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
1 - 6
Page 13
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 typeTotal capacityWire thicknessFuse
R.S.TGrounding (Capacity)
CS2023kVA
22
5.575A
1 - 7
Page 14
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
1 - 8
Page 15
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)
1 - 9
Page 16
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.
1 - 10
Page 17
Fig. 1-4 Leveling Method
1 - 11
Page 18
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”.
1 - 12
Page 19
List of Lubrication Oil
Front view
1 - 13
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
Q’ty
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
Page 20
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.
1 - 14
Page 21
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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Page 22
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
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.
1 - 16
Page 23
TypeEmulsion TypeSoluble TypeChemical 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.
1 - 17
Page 24
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 .
1 - 18
Page 25
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/cm
2
}
1 - 19
Page 26
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.
2 - 1
Page 27
Daily check list
Checking partCheck itemDetails 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 leakage
⇒ Check for sound of fan running
⇒ Oil level check
⇒ Checks for clogging and cleaning
⇒ Check for oil leakage
⇒ Normal value: 0.5 MPa
⇒ Check for air leakage
⇒ Checks for coolant leakage and
abnormal noise
⇒ Oil level check
⇒ Checks for clogging and cleaning
⇒ Visual check
⇒ Check for oil leakage
⇒ Checks for coolant leakage,
abnormal noise and abnormal
vibration.
⇒ Visual check
⇒ Normal 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.
2 - 2
⇒ 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.
Page 28
Checking partCheck itemDetails 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 model’s maximum
rpm for 30 minutes before starting
work.
⇒ Check for abnormal noise during
spindle running
⇒ Check for abnormal noise when
operating feed unit
⇒ Visual check
⇒ Check 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 cleaning
⇒ Check for cleaning
⇒ Check that spindle does not run
when opening door.
2 - 3
Page 29
Checking partCheck itemDetails of checks
14.
Mist collectora) 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 drainage
⇒ Visual check
2 - 4
Page 30
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.
2 - 5
Page 31
Periodic check list
Checking partCheck itemChecking 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 partCheck itemChecking 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 partCheck itemChecking 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.
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.
2 - 8
Page 34
3. MAINTENANCE AND ADJUSTMENT
3-1 Adjusting Method of X and Z Axes Backlash
Procedure 1How 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.
3 - 1
Page 35
Procedure 3Setting 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 amount0.012
X-axis compensation amount = = = 24
Compensation unit0.0005
Backlash amount0.015
Z-axis compensation amount = = = 15
Compensation unit0.001
2) Switch OFF the source power once, they switch ON again.
Procedure 4Confirmation of backlash amount
1) Confirm that the setting values are correct, according to Procedure 2.
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")
3 - 4
Page 38
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.
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.
Note1)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].
3 - 6
Page 40
1Bolt
2Connecting bolt
3Master jaw
4Chuck body
5Eye bolt
6Spindle
7Draw rod
8Wrench
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].
3 - 7
Page 41
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 isn’t 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.
3 - 8
Page 42
3-4 Layout of Electric Apparatus and Pneumatic Circuit Diagram
3 - 9
Page 43
Turn equipment
180°Turn Arm up/down Air blow
LS List
JLS901Over thrust detection1METROLBP101
ILS899BArm up1CKD
HLS899AArm down1CKD
GLS898BTurn to 0°1SMC
FLS898ATurn to 180°1SMC
SinLS symbol UseQ'tyMakerRemarks
SOL List
ESOL900Air blowSMC
DSOL899BArm upSMC
CSOL899AArm downSMC
BSOL898BTurn to 0°SMC
ASOL898ATurn to 180°SMC
Sin SOL symbol Use Maker
Pneumatic unit List
5ASN2-01-SFlow valve4SMC
4VZ5-ASK420-1GS-01Elect magnetic valve2SMC
3VXD2130-02-1DS-BElect magnetic valve1SMC
2CMK2-C-TB-40-75-R05-DYB2 Cylinder1CKD
1CORA1BW80-180C-A57Rotary cylinder1SMC
No. Part numberUseQ'tyMaker
3 - 10
Page 44
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.1036NC torque limiter alarm
F409Servo 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
Page 45
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.
3 - 12
Page 46
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.
3 - 13
Page 47
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.
3 - 14
Page 48
[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.
3 - 15
Page 49
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.
4 - 1
Page 50
• 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.
4 - 2
Page 51
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).
4 - 3
Page 52
4-1-2 Spindle Amplifier Status Display
Status Display
ItemContents
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.
4 - 4
Page 53
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.
MessageContentsCountermeasure
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.
4 - 5
Page 54
MessageContentsCountermeasure
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
4 - 6
Page 55
Alarm No.MeaningsDescriptionRemedy
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.
4 - 7
Page 56
Alarm No.MeaningsDescriptionRemedy
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.
4 - 8
Page 57
Alarm No.MeaningsDescriptionRemedy
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.
4 - 9
Page 58
4-1-4 Detail of Spindle Amplifier Alarm Contents
AL-01Motor overheat
ItemCause of troubleCheck procedureRemedy
1Defective fan motorCheck if fan motor isReplace fan motor.
and how tools are worn. conditions and tools.
Check load meter for
cutting.
3Dirty motor coolingCheck motor coolingClean motor cooling
systemsystem for dirt.system with an air gun
4Disconnection orCheck signal lineConnect signal line
loose contact ofconnection status.correctly.
motor overheat
signal line
AL-02Excessive speed
deviation
ItemCause of troubleCheck procedureRemedy
1Overload operation Check with load meter.Review cutting
(overload)conditions and tools.
2Defective transistor Check if transistorReplace transistor
modulecollector-emitter is open. module.
3Fuse for protectingCheck if fuses F3A toInsert fuse4s firmly.
drive on PCBF3M (models 1S to 26S) Replace any blown fuse.
blown or notor FA to FG (models 30S
inserted correctlyand 40S) are blown or
(disconnection,removed.
loose contact, etc.)
4Speed feedbackCheck level of speedCheck motor speed
signal abnormalityfeedback signal.detector and signal
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.
4 - 10
Page 59
Test pointNormal wave form
PA-0V
PB-0VSame as above
RA-0VDC2.5V±0.2V
RB-0VSame 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-03Blown fuse in DC
link section
AL-04Input 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.
ItemCause of troubleCheck procedureRemedy
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.
4 - 11
Page 60
AL-05Control power
supply fuse blown
ItemCause of troubleCheck procedureRemedy
1
Defective PCB
2
Abnormal power
supply voltage
Check AC input voltage.
See (5) above.
Replace PCB.
AL-07Excessive speed
(Detection by
digital value)
AL-08High input voltage
AL-09Heat sink is
overheated
ItemCause of troubleCheck procedureRemedy
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.
ItemCause of troubleCheck procedureRemedy
AC power supply
1
voltage 10% higher
than rated voltage.
Incorrect setting of
2
toggle switch for
voltage switching.
ItemCause of troubleCheck procedureRemedy
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-10Input power
voltage drops
AL-11Overvoltage of DC
link circuit
(Regenerative
circuit is faulty ...
Regeneration
failure)
AL-12Overcurrent 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.
ItemCause of troubleCheck procedureRemedy
1
High power
impedance.
2
PCB is defective.
3
Defective transistor
module (TM1).
ItemCause of troubleCheck procedureRemedy
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.
4 - 12
Page 61
AL-13CPU internal data
memory alarm
Replace PCB.
AL-16RAM abnormality
AL-18Program ROM
sum check error
AL-19Excessive U
phase current
detection circuit
offset
ItemCause of troubleCheck procedureRemedy
1
External data
memory (RAM)
defective
2
PCB defective
ItemCause of troubleCheck procedureRemedy
Program memory
1
data (ROM)
defective
ItemCause of troubleCheck procedureRemedy
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-20Excessive V
phase current
detection circuit
offset
AL-24Serial transfer
data error
AL-25Serial data
transfer stopped
ItemCause of troubleCheck procedureRemedy
v-phase current
1
detector circuit
defective.
Loose contact of
2
connectors
between PCB and
power circuit
ItemCause of troubleCheck procedureRemedy
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.
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-27Position coder
signal
disconnection
AL-28Disconnection of
position
detection signal
for Cs
contouring
control
ItemCause of troubleCheck procedureRemedy
1
Position coder
signal line defective
2
Incorrect parameter
setting
ItemCause of troubleCheck procedureRemedy
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-29Short-time
overload
ItemCause of troubleCheck procedureRemedy
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.
4 - 14
Page 63
AL-30Input circuit
overcurrent
ItemCause of troubleCheck procedureRemedy
Defective of power
1
transistor used for
power
Defective of power
2
regeneration circuit
Check power transistor.
Replace power
transistor.
Replace PCB.
AL-31Speed detection
signal
disconnection
motor restraint
alarm
AL-32Abnormality in
RAM internal to
LSI for serial
data transfer
AL-33Insufficient DC
link section
charging
ItemCause of troubleCheck procedureRemedy
Motor constrained
1
Defective motor
2
speed feedback
signal
Defective motor
3
speed feedback
signal cable
ItemCause of troubleCheck procedureRemedy
Defective LSI used
1
in serial data
transmission
ItemCause of troubleCheck procedureRemedy
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-34Parameter data
setting beyond
allowable range
of values
AL-35Excessive gear
ratio data setting
ItemCause of troubleCheck procedureRemedy
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.
ItemCause of troubleCheck procedureRemedy
Parameter data of
1
gear ratio and
position gain are
too large.
Check gear ratio and
position gain data.
Change to suitable
values.
4 - 15
Page 64
AL-37Speed detector
parameter
setting error
ItemCause of troubleCheck procedureRemedy
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-39Alarm for
indicating failure
in detecting
1-rotation signal
for Cs contouring
control
AL-40Alarm for
indicating
1-rotation signal
for Cs contouring
control not
detected
AL-41Alarm for
indicating failure
in detecting
position coder
1-rotation signal
ItemCause of troubleCheck procedureRemedy
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
ItemCause of troubleCheck procedureRemedy
No occurrence of
1
1-rotation signal
among Cs
contouring control
feedback signals,
or 1-rotation signal
offset adjustment
error
ItemCause of troubleCheck procedureRemedy
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-47Position coder
signal
abnormality
ItemCause of troubleCheck procedureRemedy
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.
4 - 16
Page 65
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
0Just after turning ON (without setup operation) Non at ABS mode
1During zero-point offset automatic setup operation
2During jog operation
3During zero-point return operation
4During setup operation (confirmation seems impossible because of 15 msec)
5During stopped (setup operation completion)
6During automatic operation
7During 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 ateLED indication Description
Servo OFF condition, ready for operation. Af ter the power is turned
Stopped
Running0Servo ON condition and normal operation is continued.
OFF, the inverter carries out self-diagnosis and displays “-” if no error
is found.
4 - 17
Page 66
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 descriptionCause 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.
4 - 18
Page 67
[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
ContentsCause 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.”
No.Content
143Scaling mode error
144G511/G501 program format error
146G53 error
149Helical cutting command error
1583-dimension tool offset error
1593-dimension tool mode error
160Tool length offset error
161Tool position offset error
163Multiple M code command error
175Compound type fixed cycle error
176Single type fixed cycle error
177Angle designated straight line compensation error
178Chamfer, corner R error
179Groove width offset error
180G41, G42 command not possible
182T command error
183G128 error
184Rear face processing command error
188No option in address to write
189Incorrect parameter setting
191Option command
196Reverse move error[Warning]
201G25/G26 command error
210Oscillation command error
211Oscillation mode error
260HPCC command error
261HPCC mode error
262Previous control command error
263Previous control mode error
270Soft jaws forming error
271Soft jaws forming operation error
272Pre-machining graphics-drawing error
500Program character number exceeds permissible maximum
501Command data digit exceeds permissible maximum
502Non-existent character string variable
4 - 22
Page 71
No.Content
503Character string variable not possible to construct
504Undefined G code
505SETVN command format incorrect
506Command exceeds permissible value of system variable
507Search of variable value not possible
508Overflow of logical operation
509Improper argument assignment of a macro call
510Format of macro sentence incorrect
511Use of decimal point “.” improper
512Use of minus sign “-” improper
513Data following address non-existent
514Description of formula incorrect
515Variable No. not permitted to use
516False character
517Input of data to variable which does not accept data
518Faulty variable value
519Opening and closing parentheses do not correspond
520Mixed existence of NC sentence and Macro sentence
521Non-existence of corresponding sequence No.
522Non-existence of corresponding program
523Division with divisor “0”
524Negative square root
525Function BCD/BIN with negative number
526BIN function in the data not belonging to BCD
527Overflow during calculating formula
528DO/END recognition No. improper
529Branch destination included in the DO loop.
530DO/END loop intersects
531Non-existence of POPEN command
532Duplicate call up of subprogram-macro does not function
533Duplicate call up of macro does not function
534Multiple call up command with same program
535DO/END command in DNC program
536No designation of subprogram
538Non-existent function
4 - 23
Page 72
No.Content
539Error in writing function
540ADP function error
541Non-existence of END corresponding DO
542Non-existence of IF sentence corresponding ENDIF
543Non-existence of ENDIF corresponding block IF sentence
544Ineffective calculation
545Macro in compound type fixed cycle form
546Wrong G code in high precision contouring control
560External output open error
561External output communication error
570DNC operation start error
701No.1 axis Zero-point return deceleration signal is abnormal
~
708No.8 axis Zero-point return deceleration signal is abnormal
710W setter mode error
711W setter mode error
712Q setter mode error
713Q setter mode error
714Q setter interlock
715Measurement error
716Tool setter measurement error
721Start in automatic operation does not function[Warning]
724Q setter repeat error
729Setting of jaw end face position not completed[Warning]
730External No. search error
732External data I/O error
733External data I/O error
734External data input error
No.Content
773Y axis overload alarm
774Z axis overload alarm
775Swivel tool overload alarm
771non-load alarm[Warning]
780Damaged tool was selected[Warning]
781Lifeover tool was selected[Warning]
782Pre-processing tool check error[Warning]
783Surveillance program format error[Warning]
784Tool on demand registration error[Warning]
790System table error
791Executed data conversion error
794Battery exhaustion[Warning]
795Emergency stop[Warning]
No.Content
F000Switch off the source power
F085Communication error
F086Operation preparation signal is OFF
F087Buffer overflow
F092Zero return is not complete
F205Rigid mode DI 1s OFF
5000Illegal command code (HPCC)
5003Illegal parameter (HPCC)
5004HPCC not ready
5006Too many words in one block
5007Too large distance
5009Parameter zero (Dry run)
5010End of recode
5011Parameter zero (Cut max)
F300Request for n-axis zero return
F301APC alarm: n-axis communication
F302APC alarm: n-axis overtime
F303APC alarm: n-axis framing
F304APC alarm: n-axis parity
F305APC alarm: n-axis pulse error
F306APC alarm: n-axis battery voltage 0
4 - 25
Page 74
No.Content
F307APC alarm: n-axis battery low voltage 1
F308APC alarm: n-axis battery low voltage 2
F309APC alarm: n-axis zero return disable
F350SPC alarm: n-axis pulse coder
F351SPC alarm: n-axis communication
F400Servo alarm: n-axis overload
F401Servo alarm: n-axis V ready OFF
F404Servo alarm: n-axis V ready ON
F405Servo alarm: (Zero return abnormal)
F407Servo alarm: Excessive error
F409Servo alarm: n-axis abnormal load
F410Servo alarm: n-axis excessive error value
F411Servo alarm: n-axis excessive error value
F413Servo alarm: n-axis LSI overflow
F414servo alarm: n-axis detecting system error
F415Servo alarm: n-axis excessive move amount
F416Servo alarm: n-axis broken wire
F417Servo alarm: n-axis parameter improper
F420Servo alarm: n-axis excessive torque difference
F421Servo alarm: n-axis excessive error value
F500Over travel: +n
F501Over travel: -n
F502Over travel: +n
F503Over travel: -n
F504Over travel: +n
F505Over travel: -n
F506Over travel: +n
F507Over travel: -n
F510Over travel: +N
F511Over travel: -N
F700Over heat: Control unit
F701Over heat: Fan motor
F704Over heat: Spindle
F740Rigid tap alarm: Excessive error value
F741Rigid tap alarm: Excessive error value
F742Rigid tap alarm: LSI error
1000HYDRAULIC MOTOR OVER LOADThermal MS1 is tripped. Reset the
1001COOLANT MOTOR OVER LOADThermal MS2 is tripped. Reset the
1004SPINDLE COOLER UNIT ALARMSpindle cooler unit alarm is issued.
1007CHIP CONVEYOR ALARMThermal in chip conveyor control box is
1011TURRET DRIVE UNIT ALARMTurret drive unit alarm is issued. Check
1017TURRET INDEX CYCLE POWER OFFIndexing is suspended. Put back the
1020TURRET INDEX SET UP ERRORStation 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.
1021TURRET INDEX CONDITION FAULTThe conditions of turret are incomplete.
Put back the Q-setter arm.
1022SPINDLE ALARMCheck the spindle drive unit.
1023CIRCUIT PROTECTOR TRIPCircuit protector in control box is
tripped. CP-11024TURRET INDEX TIME OVERTurret index was not completed within
the specified time. Put back the turret
position according to the restoring
method.
1026Q-SETTER ARM ALARMPut back the Q-setter arm.
1027
1030NC ALARMNC alarm is issued.
1036NC TORQUE LIMITER ALARMCheck which axis is the cause of alarm
by referring NC alarm history and review
the processing conditions.
2043AIR PRESSURE ALARMAir pressure of the machine proper has
dropped. Check the air pressure
source.
1044MEASURING ARM OPERATIONWork measurement is abnormal.
ALARM
1046DOOR CLOSE NOT DETECTEDClose the door then start operation.
1047CHUCK CLOSE NOT DETECTEDClose the chuck then start operation.
4 - 28
Page 77
ALARM No.COMMENTDetails/Counter-measures
1050NOT OPTIONKey not usable was pressed.
1056SPINDLE ORIENTATION ALARMSpindle orientation was not completed
within the specified time.
1060
1061FEEDER PALLET SINK LIMIT (Z-Feeder side pallet is pressed to hard.
AXIS-0T)
1062FEEDER ALARMFeeder alarm is being issued. Check
the feeder.
1063SPINDLE BRAKE NOT RELEASEDRelease the spindle brake then start the
spindle operation.
1064C AXIS CONNECTION ALARMC axis connection/disconnection was
not completed within the specified time.
1065AUTO PRESETTER ARM OPERATINGAuto presetter action is not completed.
TIME OVER
1066AUTO DOOR OPERATING TIMEAuto door open/close action is
OVERabnormal.
1067
1070CHUCKING FAULTChucking is abnormal.
1073M FUNCTION CYCLE TIME OVERM function execution was not completed
within the specified time.
2075COUNTER COUNT UPCount number has reached the setting
value.
2076M31 STOP ALARMMaterial work has exhausted.
1077
1080
1081ZERO TETURN INCOMPLETEComplete all axes zero return.
1082Z-SETTER ARM RETURN NOTZ-setter arm is not returned to the
DETECTEDposition.
1084AUTO PRESETTER ARM RETURNAuto presetter is not returned to the
NOT DETECTEDposition.
1085MEASURING ARM RETURN NOTWork measuring arm is not returned to
DETECTEDthe position.
1086SPINDLE STOP UNFINISHDuring spindle rotation, action was
commanded for operating chuck,
center, etc.
1087ROTATING TOOL RUNNINGRotation tool is in motion.
1090CHIP CONVEYOR MODE NOT AUTOMake chip conveyor in auto mode on
the operating panel.
4 - 29
Page 78
ALARM No.COMMENTDetails/Counter-measures
1091ORIENTATION RELEASE UNFINISHRelease the spindle orientation.
1093C AXIS MODE CANCEL UNFINISHRelease the C axis connection.
1094
1095TOOL CLAMP NOT DETECTEDClamp the tool firm.
1100POSITION INTERLOCK AREA CThis 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.
1101ALL AXIS ZERO RETURNAt time of NC initial source power ON,
INTERLOCK AREA Done touch zero return does not work
unless each axis is within the position
area D.
1102NO SPARE TOOLThere is not spare tool.
1103POSITION INTERLOCK AREA EBecause of interference with the way
cover, intrusion is prohibited.
1105CHUCK UNCLAMP UNFINISHChuck is not unclamped.
1106SAFETY GUARD OPEN ALARMClose is not unclamped.
1110I/O BOARD FUSE TRIPStandard slave fuse has blown up.
1111I/O BOARD FUSE TRIPOption slave fuse has blown up.
1112
1 113OIL SCHEMER MOROE OVER LOADOil schemer is abnormal.
ALARM
1117PC PARAMETER SETTING ERRORThe setting of PC parameter is abnormal.
1120ROTATING TOOL CONNECTRotating tool is not connected.
UNFINISH
1121ROTATING TOOL CONNECTRotating tool is connection/disconnection
TIME OVERaction was not completed.
1122C AXIS CONNECT TIME OVERC-axis is not connected.
1123ROTATING TOOL INDEXINGR o tating tool indexing is not finished.