hitachi seiki CS25 Maintenance Manual
INVERTED VERTICAL TURNING CELL
CS25
INSTRUCTION MANUAL
MAINTENANCE
SEIKI - SEICOS å21L
44 Edition 1.01 11-2000
Hitachi Seiki Deutschland
Werkzeugmaschinen GmbH
2
Introduction
Thank you for your having purchased the machine, favoring our product lines for your use.
This manual contains fundamental information on the maintenace. Please read and fully understand
the contents for your safe machine operation.
In particular , the contents of the items concerning safety in this manual and the descriptions on the
“caution plates” attached to the machine are important. Please follow the instructions contained
and keep them always in mind to ensure safe operation.
The reference record papers on adjusting setting values such as a parameter list are attached to
the machine unit and enclosed in the packing. These are necessary for maintenance and
adjustment of the machine later on. Please keep them safely not to be mislaid.
The design and specifications of this machine may be changed to meet any future improvement.
As the result, there may arise some cases where explanations in this manual could become partly
inconsistent with the actual machine. Please note this point in advance.
In this manual, items on the standard and optional specifications are handled indiscriminately.
Please refer to the “delivery note” for the detailed specification of your machine confirmation.
1
2
CONTENTS
1. INSTALLATION.................................................................................... 1 - 1
1-1 Machine Installation ...........................................................................................................1 - 1
1-1-1 Environment of the Machine ...................................................................................... 1 - 1
1-1-2 Slinging Operation (Diagram 1-3)..............................................................................1 - 5
1-1-3 Forklift operation ........................................................................................................1 - 5
1-1-4 Cleaning of Machine .................................................................................................. 1 - 6
1-1-5 Power Source and Pneumatic Source ...................................................................... 1 - 7
1-1-6 Change of Electric Specification Machining Source Power Voltage and Cycle.......... 1 - 8
1-1-7 Connection of Chip Conveyor.................................................................................. 1 - 10
1-1-8 Installation and Leveling (Diagram 1-7).................................................................... 1 - 11
1-2 Lubrication and Oil Supply...............................................................................................1 - 13
1-2-1 List of Lubrication Oil ............................................................................................... 1 - 14
1-2-2 Coolant .................................................................................................................... 1 - 15
1-2-3 Check Before Trial Operation of the Machine .......................................................... 1 - 20
2. MAINTENANCE AND CHECKING ...................................................... 2 - 1
2-1 Daily Checking Items......................................................................................................... 2 - 1
2-2 Periodic Check Items ........................................................................................................2 - 5
3. MAINTENANCE AND ADJUSTMENT ................................................ 3 - 1
3-1 Adjusting Method of X and Z Axes Backlash ...................................................................... 3 - 1
3-2 Hydraulic Unit/Hydraulic Circuit Diagram........................................................................... 3 - 3
3-3 Hydraulic Chuck ................................................................................................................3 - 4
3-4 Layout of Limit Switches and Solenoid V alves................................................................... 3 - 9
3-5 Restoration of NC Torque Limiter ....................................................................................3 - 10
3-6 Returning Method from face Declination of Turret Index.................................................. 3 - 11
3-7 Alarm Diagnosis ..............................................................................................................3 - 12
3-7-1 When the Warning Lamp (Call Light) Lights ON...................................................... 3 - 12
3-7-2 Alarm Display........................................................................................................... 3 - 13
3-7-3 Display of Switch Status .......................................................................................... 3 - 14
4. REFERENCE MATERIALS ................................................................. 4 - 1
4-1 Servo Unit..........................................................................................................................4 - 1
4-1-1 Alarm Concerning Power Supply Unit (Source Power of Spindle/Servo Amplifier)....4 - 1
4-1-2 Spindle Amplifier S t atus Display................................................................................ 4 - 4
4-1-3 S pindle Amplifier Alarm ............................................................................................. 4 - 5
4-1-4 Details of S pindle Amplifier Alarm Contents ............................................................ 4 - 10
4-2 Inverter for Turret.............................................................................................................4 - 17
4-2-1 St atus Indication (on the Point Module).................................................................... 4 - 17
4-2-2 Troubleshooting ....................................................................................................... 4 - 18
i
4-3 Replacing Method of Battery........................................................................................... 4 - 20
4-4 Alarm Display .................................................................................................................. 4 - 21
4-4-1 NC Alarm ................................................................................................................. 4 - 21
4-4-2 PC Alarm ................................................................................................................. 4 - 28
5. EXPENDABLE PARTS LIST ............................................................. 5 - 1
ii
1. INSTALLATION
1-1 Machine Installation
Foundation diagram (1-1) Arrangement diagram (1-2)
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.
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.
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,
or larger and thickness of the foundation should
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
1 - 1
[3] High frequency drying machine
[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
1 - 3
Fig 1-1 Foundation and layout
Dimension :matric (mm)
inch ( ")
Note)
1. The bearing capacity of soil should be 5 ton/m
(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.
2
Dimension :matric (mm)
inch ( ")
Fig 1-2 Machine arrangement
1 - 4
1-1-2 Slinging Operation (Diagram 1-3)
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 5200kg, 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) When lifting the machine, start winding slowly then stop the winding once the wire rope
is felt tension and confirm that the sling is secure. Carry on winding until the machine
is being just floated, then stop and confirm the sling condition again before finally lifting
up the machine.
Also for landing, slowly lowering the machine, once stop just before it touches the
ground, then confirm the position of the machine installation.
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
Hoisting accessory
Fig. 1-3 Slinging
1-1-4 Cleaning of Machine
Do not move saddle and cross slide before cleaning, as the anticorrosive paint is often
contaminated with dust during transportation.
The machine ex factory is tightly secured in every movable part. Loosen these parts
before cleaning.
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 (refer to in Table 1-1) on the
finished surface thinly.
1 - 6
1-1-5 Power Source and Pneumatic Source
1. Power source and wiring
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.
[2] Grounding line connecting bolt
[3] Circuit Breaker (CB-1)
Electric wire pull-in hole 1
Electric wire pull-in hole 2
At the time of machine installation, the wiring arrangement to the primary side of the high
power circuit breaker CB-1 ([1] in above diagram) is to be taken care of by the customer.
As for power source wire and grounding wire, refer to the table below.
The grounding wire is to be connected with grounding bolt [2].
Machine Type Total capacity Wire thickness Fuse
R.S.T. Grounding (Capacity)
CS15 26 kV A
22
5.5 75 A
1 - 7
1-1-6 Change of Electric Specification Machining Source Power Voltage 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 200/220V ±10%
Source power cycle 50/60Hz
Switching over of the tap of source power transformer ([5] in above diagram) for high power
control.
Each apparatus is mounted on the high power control board.
(The relative location of the control board to the machine proper is shown on the
diagram of electric apparatus arrangement, to which please refer.
[5] Control Circut Transformer
±1Hz
[1] Circut Breaker (CB-1)
1 - 8
Open the control board door, and remove the plastic cover of the switch-over transformer
([5] in the diagram), then connect Line No.R2 and T2 to the appropriate positions on the
inflow side at the screws indicating specified voltage.
(To select the tap screws meeting the source power voltage)
Source Power Voltage Line No. T2 Line No. R2
180 V - 190 V Tap screw 0 Tap screw 180 V
191 V - 210 V Tap screw 0 Tap screw 200 V
211 V - 240 V Tap screw 0 Tap screw 220 V
1 - 9
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 of Control Board)
1 - 10
1-1-8 Installation and Leveling (Diagram 1-7)
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.1-7. Let Z fully
stroke (1235mm). 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 - 11
Fig. 1-7 Leveling Method
1 - 12
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 Fig. 1-8 and Table
1-1.
1 - 13
1 - 14
1-2-1 List of Lubrication Oil
Front view
Fig. 1-8
Supply spot
Spindle cooling unit
1
Hydraulic unit
2
Hydraulic chuck
3
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
28
10
Nisseki
Nisseki
Multipurpose
32
Molynock
grease 2
Table 1-1
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
Multi pur
pose M
grease 2
ESSO
UNIPOWER
MP32
BICON
Q2
MOK
Clewbar
R-temp
Q NB50
ISO
symbol
CB32
1-2-2 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 - 15
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.
1 - 16
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) Kinds and selection of water soluble cutting fluid
Though the cutting fluid is used for various kinds of purposes, the follwing 2 points are
basically important.
Lubrication: To diminish friction and prevent heat generation...............to smooth
(Antil adhesion)
Cooling: To cool generated heat.
Besides, stress tends to be laid on the problems of environments such as washabilly and
chip removal, and becomes necessary to take the safety factor into sufficient
consideration.
The watwe is soluble cutting fluid can be roughly classified to 3 kinds; emulsion
type,soluble type and chemical solution type.
The following is a comoarison table pf respective features.
1 - 17
Type Emulsion Type Soluble Type Chemical Solution Type
Characteristics
* This type has been
used widely in the
cutting field, because
it is relatively large in
particle diameter ( 4
to 7 µm) and high in
lubricating property.
* It is the soluble
cutting agent that was
made first.
* It decomposes easily
due to lack of stability.
* This type is excellent
in permeability
because it is small in
particle diameter
( 0.1 to 0.03 µm ).
* It has been used
mainly for grinding
purposes, but it is
used also for cutting
purposes due to the
development of the
extreme pressure
agent.
* Since it uses much
surface-active agent,
it is likely to affect
coating adversely.
Do not use this type.
Form
* Dissolving this in
water, it becomes
milky. This is
because particles
dissolved in water are
large, reflecting light.
* Dissolving this in
water, it becomes
semi-transparent.
This is because
particles dissolver in
water are very fine,
passing light.
1 - 18
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.
1 - 19
Loading...