Page 1
PRO TURN 1630SX
ProtoTRAK SLX CNC
Safety, Installation, Maintenance,
Service & Parts List Manual
Document: P/N 24318
Version: 011005
Page 2
Table of Contents
1.0 Safety Specifications
1.1 Safety Publications 1
1.2 Safety Precautions 2
2.0 Installation
2.1 Floor Plan, Layout & Space Requirements 7
2.2 Uncrating 9
2.3 Shortages: Inventory Checklist 9
2.4 Installation, Instructions & Checklist 10
2.5 Machine Specifications 12
2.6 ProtoTRAK SLX Control Hardware 13
2.7 Lifting and/or Moving the Machine 13
2.8 Cleaning 15
2.9 Leveling 15
2.9.1 1630SX 16
2.9.2 1840SX 16
2.10 Electrical Connection 17
2.10.1 Phase Converters 18
2.11 Mounting the Display Pendant 18
2.12 Cable Interconnections 19
2.13 Lubrication System 22
2.13.1 Headstock 22
2.13.2 Automatic Way Lubrication Pump 23
2.13.3 Lube Pump Operation 23
2.13.4 Factory Default Values 23
2.14 Cutting the Test Part 24
2.15 Measurement of the Test Part 24
3.0 Troubleshooting by Symptom
3.1 Problems relating to Machining Results 26
3.1.1 Poor Finish 26
3.1.2 Turning Diameters out of Round 27
3.1.3 Cutting Taper 27
3.1.4 Parts have Incorrect Dimensions 27
3.1.5 Threading Problems 28
3.2 Problems regarding the Motion
of the Machine 29
3.2.1 Run Away Axis 29
3.2.2 Slow Down Axis 29
3.2.3 Axis will not Jog 30
3.2.4 Axis Motor Motion is not Smooth 30
3.2.5 Vibration in Motion 30
3.2.6 Searching Axis 31
3.3 Problems Relating to the Operation Control 31
3.3.1 Display Blanks 31
3.3.2 Bad Picture on the Display 32
3.3.3 Keyboard Lockup 32
3.3.4 Fault X or Z 32
3.3.5 Problems Reading the Floppy Disk 33
3.3.6 System Will Not Turn ON or
Boot-Up 33
3.3.7 System Reboots by Itself 34
3.3.8 System Shuts Off 34
3.3.9 Will Not Hold Calibration 34
3.3.10 E-Stop Error 34
3.4 Problems with the Measurements 35
3.4.1 X & Z Axis Measurements Do Not
Repeat 35
3.4.2 X & Z Axis Measurements are not
Accurate 36
3.4.3 The DRO is not Counting 36
3.4.4 X & Z Axis DRO Counting in the
Wrong Direction 37
3.4.5 X & Z Axis Electric Handwheels
Turn in Wrong Direction 37
3.5 Problems with the Machine Tool 37
3.5.1 Spindle Stalls or Turns Off During
Machining 37
3.5.2 Spindle Motor Hums or Will Not
Run 37
3.5.3 Spindle Runs Backwards 38
3.5.4 Excess Gearbox Noise 38
3.5.5 Headstock is Leaking Oil 38
3.5.6 Tailstock Barrel is Stiff 39
4.0 Diagnostics
4.1 The Machine Tool & Set Up 41
4.1.1 Leveling 41
4.1.2 A Special Word about the X Gib 41
4.1.3 Lubrication 41
4.1.4 Machining Set-Up 41
4.2 The Mechanical Drive Train (X, Z) 43
4.3 Computer/Pendant Diagnostics 44
4.4 Motor Diagnostics 45
4.4.1 Cable Connections 45
4.4.2 To Check the Motor Encoders 46
4.4.3 Encoder Counts to Pendant 46
4.4.4 Moving Problem from One Axis
to Another 46
4.5 Servo Drivers 46
4.6 Electrical 47
4.6.1 Checking A/C Voltage 47
4.6.2 Checking Fuses 47
4.6.3 Main Electrical Box 48
4.6.4 Cable Breakout Box Connections 54
4.6.5 Cable Connections 54
4.7 Door Interlock Switch 55
4.8 Service Codes 55
4.8.1 Software Codes 55
4.8.2 Machine Set-Up Codes 56
4.8.3 Diagnostic Codes 59
4.8.4 Operator Defaults/Options Codes 60
5.0 Procedures for Replacements &
Maintenance
5.1 Replacements 63
5.1.1 Motor Replacement 63
5.1.2 Servo Driver Replacement 63
5.1.3 Computer Module Replacement 63
5.1.4 System Flash Disk Replacement 66
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TRAK TRL 1630SX, 1840SX ProtoTRAK SLX CNC Safety, Installation, Service & Parts List Manual
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5.1.5 Cable Routing on Machine 68
5.1.6 Electronic Handwheels & Jogstick 68
5.1.7 Cable Routing in Electrics Box 68
5.1.8 Spindle Drive Belt Replacement 68
5.1.9 Spindle Motor Removal 69
5.1.10 Spindle Encoder Replacement 69
5.1.11. X-Axis Ball Screw Removal 69
5.1.12 Installing Angular Contact Bearings 75
5.1.13 Z-Axis Ball Screw Removal 76
5.1.14 Align Z-Axis Ball Screw Assembly 77
5.1.15 Headstock Taper Adjustment 82
5.1.16 Spindle Bearing Preload 83
5.1.17 Aligning Tailstock to Spindle 84
5.1.18 Spindle Motor Wiring 84
5.2 Maintenance 85
5.2.1 Gib Adjustments 85
5.2.2 Calibration & Backlash Constants 87
5.2.3 Lubrication 90
6.0 Indexer Options
6.1 Dorian Indexer Option 94
6.1.1 Field Installation Instructions 94
6.1.2 Removing the Indexer from the
Lathe 94
6.1.3 Troubleshooting the Indexer 95
6.1.4 Troubleshooting from LED’s in
Black Box 95
6.1.5 Indexer Encoder Re-Alignment 96
6.1.6 Indexer Maintenance 96
6.1.7 Warranty Issues 96
6.2 4 Tool Indexer Option 99
6.2.1 Field Installation Instructions 99
6.2.2 Removing the Indexer from the
Lathe 99
6.2.3 Troubleshooting the Indexer 100
6.2.4 Troubleshooting the Cable
Breakout Box 100
7.0 Drawings & Parts Lists
Fig. 1 1630SX Floor Plan, Layout & Space
Specifications 7
Fig. 2 1840SX Floor Plan, Layout & Space
Specifications 8
Fig. 3 Anchor Bolt Specifications 9
Fig. 4 Lifting 1630SX & 1840SX 14
Fig. 5 Leveling 16
Fig. 6 Wiring the 1630 & 1840 18
Fig. 7 Cable Connections 20
Fig. 8 Pendant Cable Connections, Left Side 21
Fig. 9 Pendant, Right Side 22
Fig. 11 Taper Test 24
Fig. 12 Electrical Box Parts 49
Fig. 13 Spindle Control Module LED’s 53
Fig. 14 Computer Module & LCD/Enclosure
Replacement 65
Fig. 15 Flash Disk Replacement 67
Fig. 16 Spindle Drive Belt/Motor Mounting 69
Fig. 17 1630 X Axis Drive Train 70
Fig. 18 1840 X Axis Drive Train 73
Fig. 19 Angular Control Bearings 76
Fig. 20 1630 Z Axis Drive Train 78
Fig. 21 1840 Z Axis Drive Train 81
Fig. 22 Headstock Alignment 83
Fig. 23 Tailstock Alignment 84
Fig. 24 X Axis Gib Adjustment 86
Fig. 25 Z Axis Gib 87
Fig. 26 Calibration Set-Up 89
Fig. 27 1630SX & 1840SX Lubrication 91
Fig. 28 Tailstock Oil 91
Fig. 29 Indexer Mounting 97
Fig. 30 Indexer Cable Routing 98
Fig. 31 Motor Drive Adjustment & PLC Inputs &
Outputs 103
Fig. 32 Indexer Mounting – 1840 104
Fig. 33 Indexer Mounting – 1630 105
Fig. 34 4 Tool Indexer Cable Routing 106
Fig. 35 1840 Bed & Chip Pan Assembly 109
Fig. 36 1840 Splash Guard & Cover Assembly 111
Fig. 37 1840 Headstock Assembly 113
Fig. 38 1840 Headstock Assembly 114
Fig. 39 1840 Tailstock Assembly 118
Fig. 40 1840 Pendant Mounting Assembly 121
Fig. 41 Lathe Apron Assembly 123
Fig. 43 1630 Machine Assembly 125
Fig. 44 1630 Machine Assembly 126
Fig. 45 1630 Machine Assembly 127
Fig. 46 1630 Headstock Assembly 130
Fig. 47 1630 Headstock Assembly 131
Fig. 48 1630 Tailstock Assembly 134
Fig. 49 1630 Tailstock Assembly 135
Fig. 50 1630 Tailstock Assembly 136
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TRAK TRL 1630SX, 1840SX ProtoTRAK SLX CNC Safety, Installation, Service & Parts List Manual
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1.0 Safety Specifications
The safe operation of the PROTURN 1630SX depends on its proper use and the precautions
taken by each operator.
• Read and study the PROTURN 1630SX CNC Safety, Programming, Operating, and Care
Manual. Be certain that every operator understands the operation and safety
requirements of this machine
• Read and study this PROTURN 1630SX Safety, Installation, Maintenance, Service & Parts
List Manual. Be certain that every operator understands the operation and safety
requirements of this machine
• Always wear safety glasses and safety shoes.
• Always stop the spindle and check to ensure the CNC control is in the stop mode before
changing or adjusting the tool or workpiece.
• Never wear gloves, rings, watches, long sleeves, neckties, jewelry, or other loose items
when operating, or around the machine.
• Use adequate point of operation safeguarding. It is the responsibility of the employer to
provide and ensure point of operation safeguarding.
before
before
1.1 Safety Publications
its use.
servicing.
Refer to and study safety publications for assistance in enhancing the safe use of this
machine.
1.2 Danger, Warning, Caution, and Note Labels and Notices
As Used In This Manual
DANGER - Immediate hazards that
Danger labels on the machine are red in color.
WARNING - Hazards or unsafe practices that
and/or damage to the equipment. Warning labels on the machine are gold in color.
CAUTION - Hazards or unsafe practices that
equipment/product damage. Caution labels on the machine are gold in color.
NOTE - Call attention to specific issues requiring special attention or understanding.
will
result in severe personal injury or death.
could
result in severe personal injury
could
result in minor personal injury or
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1.2 Safety Precautions
WARNING!
Use only chucks which are rated to the maximum RPM of the lathe.
1. Do not operate this machine before the PROTURN 1630SX ProtoTRAK SLX CNC
Programming, Operating and Care Manual have been studied and understood.
2. Read and study this PROTURN 1630SX Safety, Installation, Maintenance, Service & Parts
List Manual. Be certain that every operator understands the operation and safety
requirements of this machine
3. Do not run this machine without knowing the function of every control key, button, knob,
or handle. Ask your supervisor or a qualified instructor for help when needed.
4. Protect your eyes. Wear approved safety glasses (with side shields) at all times.
5. Don't get caught in moving parts. Before operating this machine, remove all jewelry,
including watches and rings, neckties, and any loose-fitting clothing.
6. Keep your hair away from moving parts. Wear adequate safety head gear.
7. Protect your feet. Wear safety shoes with oil-resistant, anti-skid soles, and steel toes.
8. Take off gloves before you start the machine. Gloves are easily caught in moving parts.
9. Remove all tools (wrenches, chuck keys, etc.) from the machine before you start. Loose
items can become dangerous flying projectiles.
10. Never operate any machine tool after consuming alcoholic beverages, or taking strong
medications, or while using non-prescription drugs.
11. Protect your hands. Stop the machine spindle and ensure that the CNC control is in the
STOP mode:
• Before changing tools.
• Before changing parts.
• Before you clear away the chips, oil or coolant. Always use a chip scraper or
brush.
• Before you make an adjustment to the part, chuck, coolant nozzle or take
measurements.
• Before you open safeguards (protective shields, etc.). Never reach for the part,
tool, or fixture around a safeguard.
12. Protect your eyes and the machine as well. Don't use a compressed air hose to remove
the chips or clean the machine (oil, coolant, etc.).
13. Stop and disconnect the power to the machine before you change belts, pulley, gears, etc.
14. Keep work area well lighted. Ask for additional light if needed.
15. Do not lean on the machine while it is running.
before
servicing.
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16. Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant and
obstacles of any kind around the machine.
17. Avoid getting pinched in places where the spindle, carriage, cross slide or sliding door
create "pinch points" while in motion.
18. Securely clamp and properly locate the workpiece in the chuck or in the fixture. Use
proper tool holding equipment.
19. Use correct cutting parameters (speed, feed, and depth of cut) in order to prevent tool breakage.
20. Use proper cutting tools for the job.
21. Prevent damage to the workpiece or the cutting tool. Never start the machine (including
the rotation of the spindle) if the tool is in contact with the part.
22. Don't use dull or damaged cutting tools. They break easily and may become airborne.
Inspect the sharpness of the edges, and the integrity of cutting tools and their holders.
23. Large overhangs on cutting tools when not required result in accidents and damaged parts.
24. Prevent fires. When machining certain materials (magnesium, etc.) the chips and dust
are highly flammable. Obtain special instruction from your supervisor before machining
these materials.
25. Prevent fires. Keep flammable materials and fluids away from the machine and hot,
flying chips.
26. Do not rotate the spindle by hand unless the Red Emergency Stop button is pressed.
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2.0 Installation
Read and understand this entire installation section before beginning the installation procedure.
2.1 Floor Plan, Layout & Space Requirements
Figure 1
1630SX Floor Plan, Layout & Space Requirements
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Figure 2
Anchor Bolt Specifications
2.2 Uncrating
Carefully remove the wood crate and protective packaging, paying attention not to
scratch, damage, or mar any parts of the machine.
Remove the cardboard boxes with the PENDANT DISPLAY (handle carefully). The
leveling pads and screws for the machine can be found in the toolbox.
Loosen and remove 4 screws and nuts holding the machine to the wood pallet.
ATTENTION!
Immediately report, in writing, any damages observed at this time that can be attributed to the
transportation or improper handling/moving of the machine.
2.3 Shortages: Inventory Checklist
______Machine (check model and serial number)
______Leveling pads and screws (4 for 1630)
______Pendant Display (24000-3)
______Pendant Cable Cover (24324)
______Toolbox with various tools
______1630SX Safety, Operation & Programming Manual (P/N 24494-1)
______1630SX ProtoTRAK SLX CNC Safety, Installation, Maintenance, Service & Parts List Manual
(P/N 24318-1)
In case of shortages, contact the representative from whom you purchased the machine.
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2.4 Installation Instructions & Checklist
Installer: Use this checklist to assure a complete set-up of the 1630SX.
1. Shut off power to the machine.
2. Visually inspect the 415V going into the electrical panel. Visually verify the wiring is correct per
our wiring diagram. Make sure a strain relief is being used where the wiring enters the cabinet.
Have the customer repair any wiring discrepancies. Note: Machine can only be wired for 415
VAC.
3. Clean the machine if needed and remove any remaining grease.
4. Mount the pendant on the bracket that is attached to the chip enclosure for the 1630.
5. Make and check all the proper electrical connections from the pendant to the electric box. Be
sure to mount the cable cover to the left side of the pendant.
6. Slide the doors back and forth to make sure they slide smoothly. Adjust as necessary.
7. Remove the protective plastic covers from the headstock and the windows on the sliding doors.
8. Turn on the power to the machine and to the pendant. Make sure that the 415 volt line is
plugged in.
9. Check to make sure the coolant pump is rotating in the correct direction.
10. Visually inspect the oil level through the site glass which is found under the rear spindle cover
and verify that the oil level is correct in the head stock prior to turning on the machine tool. Add
oil if necessary. Make a notation on the installation summary sheet if the oil level is incorrect.
For the 1630, oil will only be visible on the headstock site glass when the spindle is running.
11. Manually override the automatic way oiler and pump oil to lubricate all sliding surfaces. This can
be done by running service code 300 a few times.
12. Jog the saddle and cross slide back and forth until the way surfaces are well lubricated. Oil
should be visible on all the way surfaces.
13. Position the saddle and tailstock to the center of the bed for leveling.
14. Check the level of the machine. The machine should be level to within 0.02 mm longitudinally
and 0.01 mm transversely. Even though it is the responsibility of the customer, make any
adjustments if necessary (see section 2.9 Leveling).
15. Check the tailstock and the tailstock barrel locks by locking and unlocking. Run the tailstock
barrel in and out to ensure proper function.
16. Run the spindle at 500 rpm or so for 15 to 20 minutes in order to warm the head stock.
17. Run the spindle through it's various speeds.
18. Open and close the doors and verify the door switches are functional. The control should
display a message of “DOOR OPEN” in DRO mode when the doors are open and it should
disappear when the doors are closed.
19. Make sure the X and Z electronic handwheels and jogstick are functional.
20. Check to make sure that the E-Stop button on the pendant is functioning correctly. The 1630
only has an e-stop on the pendant.
21. Perform Service Code 12, Feed Forward Constant.
22. Perform Service Code 123 to calibrate the X and Z-axis using a 150mm standard.
23. Perform Service Code 127 and 128 to manually calculate the backlash for the X and Z-axis.
24. Check for positional accuracy and repeatability on the X and Z axis using programs X LATHE
REPEAT.PT4 and Z LATHE REPEAT.PT4 respectively. Positioning and repeatability values should
be less than or = to 0.01 mm. Programs can be found on the parts program disk that comes
with each pendant. It may also be found in the PT4 folder followed by the SWI TEST
PROGRAMS folder if the customer ordered the Network/Memory software option. Note: the
doors must be closed to run these programs.
25. Perform Service Code 100 in both directions for the X and Z-axis to verify that the feed rate
shown on the display is at least 4572 mm/min (180 ipm) for Z and 3048 mm/min (120 ipm) for
X.
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26. Use accessory key on pendant and make sure the coolant pump turns on. The accessory key
should be in the ON position in DRO to test.
27. Cut the test part to check for taper. Measure the test bar and make any machine adjustments.
If unacceptable taper is found, re-check the level before attempting to adjust the headstock,
(see section 2.14 Cutting the Test Part).
28. Wipe down the machine prior to leaving.
CAUTION!
If the PRO TURN 1630 has a chuck mounted to the spindle, make sure the cam locks are tight, and
the chuck jaws are engaged onto themselves or a piece of material before running the machine.
Check to make sure the chuck is rated for the maximum rpm’s of the machine. If it is not, do not run
the machine above the chuck’s maximum rated rpm.
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2.5 Machine Specifications
Capacity 1630SX
Height of Centers 203.2 mm
Distance Between Centers 762 mm
Swing Over Bed 406.4 mm
Swing Over Saddle Wings 406.4 mm
Swing Over Cross Slide 218.4 mm
Cross Slide Travel 243.8 mm
Tool Section Max. 19 mm
Coolant 41.6 liter
Oil Pump – Way Lubrication 2 liter
Oil Reservoir – Headstock 13.3 liter
Bed
Width 320 mm
Height 320 mm
Headstock
Spindle Nose D1-6
Spindle Through Hole 53.9 mm
Spindle Taper MT#6
Taper in Reduction Sleeve n/a
Spindle Diameter Front Bearing 80 mm
Number of Bearings 2
Bearing Class (Radial Runout) P5
Number of Spindle Speed Ranges 1
Spindle Speed Range (RPM) 150-2500
Tailstock
Quill Travel 127 mm
Quill Diameter 59.9 mm
Quill Taper Hole MT#4
Spindle Motor
H.P. 7.5
Voltage 415
Amps, Full Load 13
Phase, Hz 3/50
Dimensions
Net meters L x W x H kg. 2.08 x 1.02 x 1.80m, 998
Ship meters L x W x H kg. 2.21 x 1.14 x 1.70m, 1247
Other
Coolant Pump Motor, H.P. 1/8
Spindle Motor Brake Dynamic Braking
Way Surface Hardness 400-450 HB
Headstock Lubrication Oil Bath
Options
Steady Rest (Type, Diameter) Roller 12.7 – 139.7 mm
Tooling Kit 20 mm
Chuck 203 mm, D1-6
Indexer Option – 8 tool 20 mm
Indexer Option – 4 tool 20 mm
Gang Tooling n/a
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2.6 ProtoTRAK SLX Control Hardware
• 2 -axis CNC, 2-axis DRO
• 400 MHz PC-based processor
• 128 MB of RAM
• D.C. Servo Motors rated at 280 in-oz continuous torque for X, and 560 in-oz for the Z
axis.
• Precision ground ballscrews in the carriage and cross-slide to ensure smooth
accurate contours without backlash
• Feedrate override of programmed feedrate and rapid
• Speed override of programmed RPM
• Polycarbonate sealed membrane and gasket sealed control enclosure to lock out
contamination
• 266.7 mm color LCD for clear presentation of prompts, status information and part
graphics
• Modular design simplifies service and maximizes uptime
• 256 MB flash drive
• (2) USB Ports
• Single floppy disk drive for additional part program storage
2.7 Lifting and/or Moving the Machine
CAUTION!
The 1630 machine weigh approximately 1247 kg when shipped. Proper equipment of sufficient capacity
must be used when lifting and/or moving the machine.
To lift the machine, remove the chip pan. Place the forks of the forklift at least 813 mm
apart as shown in the figure 3. Be certain to lift the lathe toward the headstock.
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Figure 3
Lifting 1630SX
Do not attempt to lift this machine with a forklift having less than 2722 kg capacity for
the 1630. The shipping weight of the machines including electronics is 1247 kg.
Do not remove the skid from the machine until it is brought to its final position,
especially if the machine is to be moved on rollers.
Once the skid has been removed, place the machine in position on top of the (4) rest
pads for the 1630SX.
For proper operation, the machine should be set on a substantial floor capable of
supporting the weight safely. For the location of the bolt holes, size and recommended
mounting (see Figures 1 & 2).
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2.8 Cleaning
1. Remove rust protective coating from the machine before moving any slideways
2. The coating is best removed with clean, dry rags. Do not use a cleaning solution
that may damage the rubber way scrapers, plastic parts, or paint.
WARNING!
Do not use gasoline or other flammable cleaning agents for cleaning the machine.
3. It may be necessary to move the carriage back and forward and the cross-slide left and
right.
CAUTION!
Never move any of the above parts over ways that were not previously cleaned. Serious
damage to the TURCITE surface of slideways can occur.
4. Be certain the carriage, cross slide and spindle move freely and smoothly over their entire
length.
2.9 Leveling
The precision and durability of the lathe depends on it being leveled properly. Final
inspection can be done only when the machine has been correctly leveled.
After the machine is in position on top of the 4 rest pads, it must be leveled by the use
of the leveling bolts. It is important that the lathe be level in order to produce accurate
work. It may be necessary to lag bolt the machine in order to eliminate a small amount
of twist.
NOTE: The use of a precision level having a minimum accuracy of 0.01 mm over 254 mm will be
required.
Move the saddle and tailstock to the center of the bed. To take a reading off the level
longitudinally, place the level at each of the four (4) corners of the bedways (Figure 4,
Positions B & C). To take a reading off the level transversely, place it on top of 19 mm
parallels at each end of the bedways (Figure 4, Positions A & D).
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Figure 4
Leveling
2.9.1 1630SX
Use the four (4) leveling screws, located at both ends of the base, to adjust the level of
the machine.
For a newly installed machine, check the level once every week. Once the foundation is
rigid enough, then check it once per month.
2.10 Electrical Connection
The 1630SX can only be wired for 415 volts, 3 phase electricity.
A 110 volt power source is needed for the pendant and is provided by the transformer.
DANGER!
Be certain that 415-volt electricity is used only with a machine labeled 415 volts and at the
electric cabinet, in the back of the machine.
The incoming 415 volt power is wired to the machine through the electric cabinet located
on the back of the machine. The wire enters the cabinet through a hole, from the top of
the cabinet. The wires are to be wired into the door breaker. The main ground wire
should be fastened to the breaker mounting bracket with the screw provided.
DANGER!
The 415 VAC, 3 phase electricity should be wired only by a qualified electrician.
i00193
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Figure 5
Wiring the 1630
Ii is recommends the machine be earth grounded by driving a copper rod into the
ground. It is the responsibility of the customer to install this rod.
2.10.1 Phase Converters
For those machines that will be run with a phase converter it must be a rotary type
rather than a static phase converter. Rotary phase converters allow for varying loads in
the system. The electrical load on the machine will vary based on the type of cut taken
and the speed of the motor. Static phase converters can only be used on machines with
a non-varying load.
2.11 Mounting the Display Pendant
The 1630 pendant is fixed to a L bracket. The L bracket is attached to a 2nd bracket
that comes mounted to the top of the chip enclosure.
Make the 6 cable connections to the left side of the pendant and cover these cables with
the cable cover provided with the machine.
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2.12 Cable Interconnections
All cable interconnections are made at the factory except for those connecting to the
pendant display. There are a total of 6 cables that need to be connected to the pendant.
See Figure 6 for pendant cable connections.
With the main 415 volt power to the machine turned off plug in the connectors that are
bundled on the side of the machine. Each cable mates to only one connector on the
pendant display, on the left side of the pendant. Use the key on the pendant to match up
the connectors with the correct port. The machine ID key and option keys should be
plugged into the port labeled as such. The test port and X and Y handwheel ports will be
left empty during installation. If the customers sets this machine up on a network, this
cable will also need to be plugged in.
Make sure the machine ID key is plugged in, otherwise the machine will not run. Also
make sure there is a hardware (option) key plugged into the parallel port of the pendant.
This key activates any converters or options ordered. The key must be programmed
according to the type of machine it is on and the options ordered.
CAUTION!
Make sure the main 415 volt power switch is disconnected on the back of the electrical cabinet
before plugging in the cables.
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Figure 6
Cable Connections
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Figure 7 Figure 7
Pendant Cable Connections Pendant Cable Connections
Left Side
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Figure 8
Pendant, Right Side
2.13 Lubrication System
2.13.1 Headstock
Before turning ON the spindle, check to make sure the headstock oil reservoir is full. A
site glass is located under the spindle cover. If low, fill the site level with Mobil DTE 24
or equivalent oil through the plug located on the headstock cover.
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For the 1630, oil will only be visible on the headstock site glass when the spindle is
running. If oil is not flowing to the site glass when the spindle is on, stop running the
spindle immediately and call for service. Failure to do so may ruin the spindle bearings.
2.13.2 Automatic Way Lubrication Pump
The 1630 auto lube system provides centralized automatic lubrication for the carriage,
cross slide and ballscrews. The lube pump has a 2-liter reservoir filled with S.A.E. 30weight oil.
CAUTION!
Oil that is too heavy and viscous such as 50W or 90W oil can clog oil line tubing. Do not mix detergent
type automotive or multi-purpose oils with the S.A.E. No. 30 lubricating oil used in this application.
The lube pump has electronic memory, which acts as an internal clock to keep track of
the running time of the axis motor. Even when the axis motors are turned off, the lube
pumps internal clock will not reset. The interval between pump cycles is based on axis
motor movement time. Also, every time the control is first turned on, the lube pump
will run for 1 lube cycle as soon as the axis motors are commanded to run.
2.13.3 Lube Pump Operation
The pumping output can be regulated electronically to control the Interval Time between
pumping cycles, and the Discharge Time of each pumping cycle. The pump can also be
run manually through a key found under service codes. The following describes the
steps used to program the lube pumps Interval and Discharge times.
• Setting Interval Time: Service Code 301
Press "Mode", "Set up", "Service Codes", "E" (Lube Pump Setup), Code 301, and then
enter the desired Interval time in minutes.
• Setting Discharge Time: Service Code 302
Press "Mode", "Set up", "Service Codes", "E" (Lube Pump Setup), Code 302, and then
enter the desired Discharge time in seconds.
• To Manually Pump Oil: Service Code 300
Press "Mode", "Set up", "Service Codes", press "E", and then press Code 300
(Lubrication Pump Switch). The pump will pump oil for the amount of time
programmed in Code 302. The spindle does not need to be turned on.
2.13.4 Factory Default Values
Interval Time - 20 min
Discharge Time - 15 sec
Discharge Pressure - Approximately 690 – 1034 kPa (100-150 psi)
To adjust the amount of Discharge Pressure displayed on the lube pump gauge, loosen
the jam nut and turn the adjustment screw located on the top right side of the lube
pump while the lube pump is activated. To activate the lube pump use Service Code 300.
CAUTION!
Failure to properly lubricate the lathe will result in the premature failure of ball screws
and sliding surfaces.
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CAUTION!
Failure to manually activate the pump at the beginning of each day, or allowing the Auto Lube to
run dry may cause severe damage to the 1630 lathe way surfaces and ballscrews.
The settings for the lube pump can be viewed by doing the following: press Service
Codes, press “A” (software), press Code 313. This screen lists the values programmed
for the cycle time and discharge time.
2.14 Cutting the Test Part (See Figure 9)
Tools Required:
• Chuck
• Tool Post
• Tool Block
• Tool Holder, right-hand face and turn type
In order to accurately machine the test part, the gears and bearings in the headstock
must be properly warmed and preloaded. This is accomplished by running the spindle
for 15 to 25 minutes prior to cutting the test bar.
Load an approximately 50 mm dia. aluminum bar into the spindle chuck (refer to Figure
9). Load a standard right hand face and turning tool into a tool block. Align and lock
the tool block onto the tool post. Set the depth of cut to a maximum of .05 mm.
Set the spindle to an acceptable speed for turning the test piece. A speed range from
650 to 950 RPM is recommended.
2.15 Measurement of the Test Part
Tools Required:
• O.D. Micrometers with .002 mm graduations
Using a calibrated O.D. micrometer with .002 mm graduations, measure and record the
generated dimension at a 152 mm spacing. The acceptable measurement of
parallelism of spindle axis to carriage movement (taper of test piece) is .02 mm in 152
mm. If the taper measured is not acceptable, re-machine the test part and/or check
and adjust the level of the machine, or adjust the headstock.
Figure 9
Taper Test
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3.0 Troubleshooting by Symptom
Use this section to begin the process of resolving a service problem. Each problem type is
described in a few words and then more fully described in an explanatory paragraph. Following
this is a chart that directs in the most logical steps.
3.1 Problems Relating to Machining Results
3.1.1 Poor Finish
Poor finish can be caused by a number of variables including: speeds, feeds,
tooling, machine setup and chatter.
Do the following Service Codes:
• Code 33 Software Identification. This is needed if you call Customer Service
• Code 12 Feed Forward Constant
• Code 127 Measures backlash in the system (not used on Dual Feedback systems)
• Code 128 Enter backlash compensation
Possible Cause Check This
Inadequate or no Lubrication to
Ballscrews and Way surfaces
X & Z-axis Drive Trains are loose Check Repeatability using the Repeatability and Positional
Way surfaces are pocked, scarred, or
excessively worn
Machine set-up problem Machine’s feet are not equally supporting weight. See
Tooling problem Improper tooling, Work piece not properly supported
X gib too tight or loose See Gib Adjustment, Section 5.2.1.
Loose bearing problem Looseness in the spindle bearings. Adjust spindle preload.
Make sure all the Way surfaces are getting proper
lubrication. If not, check to make sure that the lube pump
is functioning properly. Also check for any pinched or
blocked oil lines.
Accuracy procedure. Step by step, carefully inspect the
Drive Train for any looseness. It may be necessary to
disassemble and then reassemble the Drive Train. See
Mechanical Drive Train (X, Z) Section 4.2.
Visually check the condition of all the Way surfaces. For
machines that may have excessively worn Way surfaces
you may need to adjust the Gibs in this area. This will
affect performance when using the machine outside of
this area. Check lubrication to affected areas.
,
Leveling
speeds too fast, Feeds too slow.
See Machine Tool & Setup, Section 4.1.
Ball screw misalignment,
See Mechanical Drive Train (X,Z), Section 4.2. See Spindle
Bearing Preload
Section 2.9.
,
Section 5.1.16.
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3.1.2 Turning Diameters Out of Round
Parts are not round within .015 mm TIR for 1630SX. This is best measured by using a
.002 mm dial indicator and mounting to the inside taper of the spindle. Rotate the
spindle and measure the indicator movement.
Do the following service code and procedures:
Possible Cause Check This
Tooling problem Improper tooling, workpiece not properly supported.
See Machine Tool & Setup, Section 4.1.
Loose bearing problem Looseness in the spindle bearings. See Mechanical Drive Train (X, Z),
Section 4.2. Spindle bearing not preloaded correctly. Reseat bearing and
preload. See Spindle Bearing Preload, Section 5.1.16.
3.1.3 Cutting Taper
Parts are considered to be cutting on a taper if there is a difference in diameter of more than
.02 mm over 152.4 mm. This is best measured by using a .002 mm micrometer.
Do the following service code and procedures:
• Code 12 Determines the feed forward constant for the axis motors.
Possible Cause Check This
Machine set-up problem Machine not leveled properly
See Leveling - Section 2.9.
Tooling problem Improper tooling; Work piece not properly supported. Use steady rest or
follow rest, reduce overhang from chuck headstock or tailstock.
Looseness in the gib or
misalignment of ball screw
Loose bearing problem Looseness in the spindle bearings.
Headstock and/or tailstock
not aligned
Gib adjustment.
See Gib Adjustment - Section 5.2.1.
See Z Ball screw Alignment - Section 5.1.14.
See Mechanical Drive Train (X,Z) - 4.2.
See Spindle Bearing Preload - Section 5.1.16.
See Adjust Headstock for Taper - Section 5.1.15.
To adjust tailstock from side to side, adjust gib screw. See Aligning
Tailstock to Spindle Section 5.1.17.
3.1.4 Parts Have Incorrect Dimensions
Parts are being machined with dimensions that are different than those programmed.
Typical accuracy expectations should be:
• Parts should be round within .015 mm TIR on both the 1630SX.
• The acceptable measurement of parallelism of spindle axis to carriage movement is
.02 mm over 152.4 mm.
3.1.4 1 Every Part Has the Same Error .
Possible Cause Check This
Programming Error Programmed dimensions not correct. Check
absolute and incremental values.
Machine & Setup Related See Machine Tool & Setup - 4.1.
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3.1.4 2 Errors are Random or Accumulate in Size over he Par Run . t t
Possible Cause Check This
Machining Setup See Machine Tool & Setup - 4.1.
Looseness in the Drive Train, ball nut loose in
yoke, split nut loose, yoke loose
See Mechanical Drive Train (X,Z) - 4.2.
3.1.5 Threading Problems
Threads can be cut with an unlimited number of pitches and up to 10 leads.
To reduce the relief area when threading up to a shoulder the spindle speed should be
reduced as much as possible. The slower the speed of the spindle, the cl oser the cutting tool
can come to the end of the programmed thread before it pulls out and retracts. If a nut must
be turned all the way up to a shoulder, machine a relief area behind the last thread.
NOTE: No machine can thread up to a shoulder and instantaneously pull out.
Do the following service codes and procedures:
• Code 12 Determines the feed forward constant for the axis motors
• Code 133 Spindle encoder test
3.1.5 1 Cross Threading .
Threaded parts are cross-threaded after completion of the threading event.
Possible Cause Check This
Looseness in the Gib Gib adjustment
See Gib Adjustment - Section 5.2.1.
Looseness in the drive train The drive train Diagnostics
See Mechanical Drive Train (X,Z) - Section 4.2.
Calibration See Section 5.2.2 Calibration.
Failure of the spindle encoder
Run service code 133 to check if the encoder
counts.
Replace spindle encoder
See Spindle Encoder replacement - Section
5.1.10.
3.1.5 2 Not Threading .
The machine will not cut a thread at all.
Possible Cause Check This
Spindle speed too fast Slow down spindle speed.
Failure of the spindle encoder
Run service code 133 to check if the encoder
counts.
Broken or slipping encoder coupling Check and replace as necessary
Replace spindle encoder
See Spindle Encoder replacement - Section
5.1.10.
3.2 Problems Regarding the Motion of the Machine
3.2.1 Run Away Axis
The axis makes an unwanted move at rapid speed in one direction and faults out. This is
usually caused by an encoder signal being interrupted.
Do the following Service Codes:
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• Code 33 Software Identification. This is needed if you call Customer Service.
• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
Possible Cause Check This
The home positions or tools are not set
correctly
Bad Motor Encoder See Motor Diagnostics Section 4.4.
See the Controls Programming, Operations and Care
manual.
3.2.2 Slow Down Axis
The axis slows down and moves at a feedrate that is lower than rapid or than the
programmed feedrate.
Do the following Service Codes:
• Code 33 Software Identification. This is needed if you call Customer Service.
• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
• Code 129 Set's the maximum allowable arc accuracy error. This applies to arcs only.
Possible Cause Check This
The maximum allowable Arc Accuracy is
set too low.
Incoming AC voltage is inadequate Perform Code 100. See Service Codes Section 4.8. and
Inadequate or no Lubrication to
Ballscrews and Way surfaces
X-axis Gib is not adjusted properly Check the adjustment of the X-axis Gibs using the X-axis Gib
Binding in the Drive Train Check Repeatability using the Repeatability and Positional
Servo Drive failure See Servo Drive Section 4.5.
Motor failure See Motor Section 4.4.
This value will only slow down the machine during arc moves.
The factory default is set at 0.13 mm. Perform Code 129 to
check or change this value. See Service Codes Section 4.8.
Values lower than 0.13 mm may reduce the feedrate even
more.
Electrical Section 4.6.
Make sure all the Way surfaces are getting proper lubrication.
If not, check to make sure that the lube pump is functioning
properly. Also check for any pinched or blocked oil lines. See
Lubrication Section 2.13.
adjustment procedures. See section 5.2.1.
Accuracy procedure. Check the torque reading of the Drive
Train. Step by step, carefully inspect the Drive Train for any
binding. It may be necessary to disassemble and then
reassemble the Drive Train. See Mechanical Drive Train (X, Z)
Section 4.2.
3.2.3 Axis Will Not Jog
The system powers up but will not respond to the jog command.
Do the following Service Codes and procedures:
• Code 33 Software Identification. This is needed if you call Customer Service.
• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
Possible Cause Check This
Improper Boot-up Shut down the system and wait 10 seconds before rebooting
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E-Stop is pressed in Check E-Stop. Especially if both axes will not jog
E-Stop reset button Press the E-Stop reset button on the side of the pendant.
Servo Drive failure Especially, if only one axis will not jog;
See Servo Driver Section 4.5.
Shorted motor See Motor Section 4.4.
Poor cable or wiring connections See Cable Interconnection Section 2.12.
Computer/Pendant failed See Computer/Pendant diagnostics Section 4.3.
3.2.4 Axis Motor Motion Is Not Smooth
While under motor power, the motion is not smooth. The motion appears to be "rough" or jerky”.
Do the following Service Codes and procedures:
• Code 33 Software Identification. This is needed if you call Customer Service.
• Code 12 Feed Forward Constant
• Code 127 Measure's the backlash in the system
• Code 128 Enter backlash compensation
• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting
Possible Cause Check This
X-axis Gib are not adjusted
properly
Calibration or Backlash problem Recalibrate the machine. Reset the Backlash. Check
Binding in the Drive Train Check Repeatability using the Repeatability and Positional
Check the adjustment of the X-axis Gib using the X-axis Gib
adjustment procedures, See Section 5.2.1..
Repeatability and Positional Accuracy. See Calibration &
Backlash Constants section 5.2.2.
Accuracy procedure. Check the torque reading of the Drive
Train. Step by step, carefully inspect the Drive Train for any
binding. It may be necessary to disassemble and then
reassemble the Drive Train. See Mechanical Drive Train (X, Z)
Section 4.2.
3.2.5 Vibration in Motion
While axis is moving there is vibration or noise coming from the X or Z-axis.
Do the following Service Codes and procedures:
• Code 12 Feed Forward Constant
• Code 127 Measure's the backlash in the system.
• Code 128 Enter backlash compensation
Possible Cause Check This
Too much backlash entered in Code 128. Recheck the machines backlash. See Section 5.2.2.
Inadequate or no Lubrication to
Ballscrews and Way surfaces
X Gib not making good contact. Pull gibs out and mark with a blue die to check where the gibs
Binding or looseness in the Drive Train Check Repeatability using the Repeatability and Positional
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Make sure all the Way surfaces are getting proper lubrication.
If not, check to make sure that the lube pump is functioning
properly. Also check for any pinched or blocked oil lines. See
Lubrication Section 2.13.
are making contact. It is recommended that the gibs
uniformly contact at least 80% of the surface. See Section
5.2.1 Crosslide gib adjustment.
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Accuracy procedure. Check the torque reading of the Drive
Train. Step by step, carefully inspect the Drive Train for any
binding or looseness. It may be necessary to disassemble and
then reassemble the Drive Train. See Mechanical Drive Train
(X, Z) Section 4.2.
Axis Motor belt too tight. Loosen belt.
Misalignment of ball screw See Mechanical Drive Train (X, Z) Section 4.2.
3.2.6 Searching Axis
The ballscrews are slowly turning back and forth when the servos are engaged.
Do the following Service Code and procedures:
• Code 12 Sets a feed forward power constant to drive axis motors.
• Code 128 Backlash compensation on single feedback machines.
Possible Cause Check This
Most often causes by excess backlash
compensation
High feed forward values Check ball screw torque. Typical values should be between 1.1
Excessive friction in the sliding ways Lubrication, gib adjustments, gib locks.
Looseness in the drive train The drive train of the axis that is searching, especially the
Check physical backlash in system and re-enter in code 128.
Run code 11 on single feedback machines
– 1.7 N-m.
See Machine Tool & Setup - Section 4.1.
tightness of the drive assembly.
See Mechanical Drive Train (X, Y) - Section 4.2.
3.3 Problems Relating to the Operation of the Control
3.3.1 Display Blanks
The display is completely blank.
Possible Cause Check This
Screen saver has been activated Press any key to turn back on. All LED keys on pendant will
blink when the screen saver is on. Press any key to deactivate.
Hitting this key will not activate any feature on the control.
The system has shut down Turn the power switch off, check the computer/
pendant fuses and cable connections. See Electrical Section 4.6.
Poor cable connection from Computer
Module to LCD (Liquid Crystal Display)
Fuse blown in pendant Remove fuse and check continuity
Computer/Pendant failed See Computer/Pendant Section 4.3.
3.3.2 Bad Picture on the Display
The display has strange characters, horizontal bars or other unfamiliar images, or the
display continually rolls.
Possible Cause Check This
Poor cable connection from Computer
Module to LCD (Liquid Crystal Display)
Computer/Pendant failed See Computer/Pendant Section 4.3.
Double-check the connection from the computer module to the
LCD, see Section 5.1.3.
Check the ribbon cable connection from the LCD screen
to the computer module . See Section 5.1.3.
3.3.3 Keyboard Lockup
The screen display is normal, but the system will not respond to key presses.
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Do the following Service Codes and procedures:
• Code 81 press each key on the pendant. The screen will display a keypad that
signifies if a key is working. The pendant will also beep.
Possible Cause Check This
Voltage drop/spike has occurred Shut down the system and wait 10 seconds to reboot the
system.
Remote Stop-Go (RSG) switch has a
short (if connected)
Poor cable connections from the
Computer Module to the Distribution
Board and from the Distribution Board
to the Keyboard
Computer/Pendant failed See Computer/Pendant Section 4.3.
Remove the RSG. Turn the system off and then on again.
If the problem goes away and then re-appears when the
RSG is plugged-in, replace the RSG.
Re-seat cable connectors by pulling out and pushing back
in.
3.3.4 Fault X or Z
The program run or jogging operation is interrupted with a Fault Message on the display.
Do the following Service Codes and procedures:
• Code 33 Software Identification. This is needed if you call Customer Service.
• Code 12 Feed Forward Constant.
• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
Possible Cause Check This
Servo cables at pendant switched around. Make sure during an installation the X and Z servo
cables at the pendant are in the correct ports.
X-axis Gibs are adjusted extremely tight Check the adjustment of the X-axis Gibs using the X
Gib adjustment procedures. See X-axis Gib
Adjustments Section 5.2.1.
Excessive friction in the slideways See Machine Tool & Setup Section 4.1.
Binding or looseness in the Drive Train See Mechanical Drive Train (X, Z) Section 4.2.
Incoming electrical power Incoming voltage. See Electrical Section 2.10.
Servo Drive failure See Servo Driver - Section 4.5.
Motor failure See Motor diagnostics, Section 4.4.
Computer/Pendant failure See Computer/Pendant diagnostics, Section 4.3.
3.3.5 Problems Reading the Floppy Disk; Programs Not Saved
Properly
The floppy drive will not read or write programs from a disk.
Possible Cause Check This
Improper Boot-up Shut down the system and wait 10 seconds before
rebooting.
Floppy Disk failure The Floppy Disk may be bad. See if the Floppy Disk
can be read by a Personal Computer. Does the green
light on the floppy drive come on when you access the
disk? If so, power is getting to the floppy drive. If
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not check connections of floppy drive inside the
computer module. See Computer/Pendant Section 4.3
for more information.
Floppy Disk full Put the Floppy Disk into a Personal Computer to see
how many bytes remain.
3.3.6 System Will Not Turn On
Nothing happens when the switch is turned on.
Possible Cause Check This
110 V line is not plugged in Check incoming 110 V power source to electrical cabinet
Pendant On/Off switch is Off. Check the Pendant On/Off switch
Fuse blown in pendant or electrical
cabinet
Transformer output Check 110 V Transformer output
Computer/Pendant has failed See Computer/Pendant diagnostics Section 4.3.
Remove fuses and check continuity.
3.3.7 System Will Not Boot-Up
The system does not boot-up when the switch is turned on.
Flash Drive failure When the Computer Module starts the boot-up process,
look at the 8
Board of the Computer Module is communicating with
the Flash Drive you will see "Detecting IDE Primary
Master…Scan Disk SDCFB-256". If the Mother Board of
the Computer Module is not communicating with the
Flash Drive you will see "Detecting IDE Primary Master …
None".
Also, check the wiring connection between the Flash
Drive and the Mother Board. See Computer/Pendant
diagnostics Section 4.3.
Computer/Pendant has failed See Computer/Pendant diagnostics Section 4.3.
Disk in drive A Verify that there is no disk inserted in drive A.
System Bios Verify the system bios is set correctly.
th
line on the Display Screen. If the Mother
3.3.8 System Reboots by Itself
During operation, the screen suddenly blanks and then shows that the system has begun
the boot-up sequence.
Possible Cause Check This
Incoming 415 VAC is too high, too low
or not present
Poor wiring and cable connections Check for any loose wiring.
Computer/Pendant failed See Computer/Pendant diagnostics Section 4.3.
Transformer output Check 110 V Transformer output
Using a Voltmeter, check the incoming 415 VAC to the machine.
See Electrical Section 4.6.
3.3.9 System Shuts Off
During operation, the system shuts off and will not turn back on.
Possible Cause Check This
Fuse blown in pendant Remove fuse and check continuity
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Incoming 415 VAC is too high, too low or not
present
Poor wiring and cable connections Check for any loose wiring.
Flash disk failure Remove and reseat the flash disk. The flash disk is inside of
Transformer output Check 110 V Transformer output
Computer/Pendant has failed See Computer/Pendant diagnostics Section 4.3.
Using a Voltmeter, check the incoming 415 VAC to the
machine. See Electrical Section 4.6.
the computer module. Please see section 5.1.4.
3.3.10 Will Not Hold Calibration
The control will not hold calibration. Go to the "Configuration Values" screen and write
down the calibration values for the motor encoders (Encoder) and the position feedback
encoders (Scales). Recalibrate the system and see if the values change. Turn the
system off and on and see if the values are held.
Do the following service codes and procedures:
• Code 33
• Code 313 Configuration Values
• Code 123 Calibration Mode
Software Identification. This is needed if you call Customer Service.
Possible Cause Check This
Not saving Calibration values Replace Computer/Pendant module.
See Computer/Pendant Diagnostics Section 4.3.
If calibration factors are being saved, but the measurements are not repeating or are not accurate:
• See Measurements Are Not Repeating
• See Measurements Are Not Accurate
3.3.11 E-Stop Error
The E-Stop turns the power off to the axis and spindle motors. The 1630 has an e-stop
on the front of the pendant and a green E-stop reset button on the side of the pendant.
(See figures 6 & 8)
• For the axis motors this is done by stopping 110V power from reaching the
cable breakout box through the use of a relay in the pendant. The AC E-stop
out connector on the pendant should not have 110 volts coming out of it
when the E-stop is pressed.
• The AC drive power is turned off by a contact relay (K1), located on the
power module. The contact relay (K1) is turned off by the dual channel relay
(safety relay), which is controlled by the E-stop on the pendant.
• The E-stop LED on the spindle control module will be on when the e-stop is
in the out position. The LED will turn off when the E-stop is depressed. (See
figure 11)
• Once power reaches the cable breakout box it distributes power to the axis
motors, auxiliary functions. If power does not reach the cable breakout box
then none of these functions will work.
If the E-Stop button is depressed, and no message is displayed on the screen, then
either the E-Stop button, pendant, spindle control module, cables from pendant to
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spindle control module, or cables from spindle control module to dual channel relay
(safety relay) is at fault.
Possible Cause Check This
E-Stop reset button Press the E-Stop reset button on the side of the
pendant.
Faulty E-Stop switch Check the cable connections from the computer
module to the E-Stop switch. Check the E-Stop switch
for functionality.
Bad pendant Does 110 V power come out of the cable breakout box
power cord on the pendant? If yes and the screen
has an E-stop message then replace the pendant.
Poor cable connection Check spindle control cable connection at the pendant
and spindle control box.
E-Stop jumper Verify the E-Stop jumper in the electrical box on the
spindle control module is correct.
3.4 Problem with the Measurements
3.4.1 X and Z-Axis Measurements Do Not Repeat
With a dial indicator mounted to the bottom of the spindle, touch off a fixed surface
either in the X or Z-axis direction and then set the DRO equal to 0. Crank away several
inches and then touch off again at the same place. If the reading has not returned to 0
on the DRO, zero the display and repeat the procedure. If the measurement does not
repeat, you have a repeatability problem that must be resolved.
Test for accumulative error by moving the axis a number of times to see if the error
gradually grows by a small amount. If the error abruptly changes by a large amount it may be
caused by a bad encoder.
Expected repeatability numbers should be 0.01 mm or less.
Possible Cause Check This
Machine Tool & Setup problem Check for any looseness in the setup. See Machine Tool
& Setup Section 4.1.
X and Z-axis Gibs are loose Check the adjustment of the X-axis Gib using the X-axis
Gib adjustment procedures. See section 5.2.1.
X and Z-axis Drive Trains are loose Check Repeatability using the Repeatability and Positional
Accuracy procedure. Step by step, carefully inspect the
Drive Train for any looseness. It may be necessary to
disassemble and then reassemble the Drive Train. See
Mechanical Drive Train (X, Z) Section 4.2.
Encoder Disk or Reader Head on
motor are loose
Swap the motor in question with a known good motor.
For example, swap the X-axis motor with the Z-axis
motor. If the symptom stays with the motor in question,
then replace the motor. If not, then the motor is not at
fault and something else is causing the problem.
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3.4.2 X and Z-Axis Measurements Are Not Accurate
Measurements repeat, but with a dial indicator mounted to the spindle, traversing the
length of a gage block or some other measurement standard, the measurement is not
accurate.
Note: If your part has incorrect dimensions, see Parts Have Incorrect Dimensions, Section 3.1.4.
Note: First check for repeatability of the DRO: With a dial indicator touch off a fixed surface
either in the X or Z-axis direction and set the DRO equal to 0. Crank away several inches and
touch off again at the same place. If the reading has not returned to 0 on the DRO, zero the
display and repeat the procedure. If the measurement does not repeat, yo u have a repeatability
problem that must be resolved before the accuracy problem can be resolved. See Measurements
That Do Not Repeat, Section 3.4.1.
Possible Cause Do This
The Calibration is incorrect Recalibrate the machine.
See Calibration & Backlash Constants
Incorrect backlash values If the machine does not repeat bi-directionally check the
backlash on the axis in question. See Calibration and
Backlash Constant Section 5.2.2.
3.4.3 The DRO Is Not Counting
The DRO for one axis is not counting when an axis is moved. Often times if this is the
case the axis will fault. See section on faulting.
Do the following Service Codes:
• Code 33 Software Identification. This is needed if you call Customer Service.
• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and
if the encoders are counting.
• Code 132 Electronic handwheel test.
• Code 131 Manual Encoder Test.
Possible Cause Check This
Electronic handwheel failure The Z handwheel should count 2.54 mm per revolution in both
directions in fine mode and 10.2 mm per revolution in course
mode. The X handwheel should count 0.51 mm per revolution in
both directions in fine mode and 2.54 mm per revolution in
course mode.
Servo driver failure See Servo driver Section 4.5.
Motor Encoder not counting See Motor diagnostics (not applicable with Glass Scale option)
Computer/Pendant failure See Computer/Pendant diagnostics section 4.3.
3.4.4 X and Z-Axis DRO Counting in Wrong Direction
The DRO is counting in the wrong direction.
The positive directions for each axis are:
• X-axis – cross slide moves toward the operator
• Z-axis – carriage moves toward tailstock
Do the following service code and procedures:
• Code 33 Software Identification. This is needed if you call Customer Service.
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• Code 313 Check the line that specifies the product.
If the product does not match the machine then the machine ID key will need to be replaced.
3.4.5 X and Z-Axis Electric Handwheels Turn in Wrong Direction
The Electric Handwheels turn in the wrong direction.
The positive directions for each Electric Handwheel are:
• X-axis - Electric Handwheel turns counterclockwise.
• Z-axis - Electric Handwheel turns clockwise.
Do the following service code and procedures:
• Code 308 Reverse X-axis Handwheel Direction.
• Code 310 Reverse Z-axis Handwheel Direction.
3.5 Problems with the Machine Tool
3.5.1 Spindle Stalls or Turns-Off During Machining
During machining, the spindle turns off and loses power. First check incoming voltage
and connections.
Possible Cause Check This
Machine Tool and Setup problem Check the type of material being cut, type and size of cutting tool,
RPM, and Feed rate. Also check the condition of the cutter to
verify that the cutter is not dull. See Machine Tool & Setup Section
4.1.
Motor drive Belt is slipping Check the alignment, condition, and tension of the Drive Belt.
Cut more than the machine is capable Check speeds, feeds and depth of cut
3.5.2 Spindle Motor Hums or Will Not Run
The spindle motor makes a constant humming noise during operation or will not turn on.
Possible Cause Check This
Wrong voltage
Poor wiring connections Check all the wiring connections to the electric’s box.
Defective cable connections Check all cable connections
Spindle Motor is bad Check the resistance of the Spindle Motor windings on the Spindle
Check the 415V voltage to the machine
Motor between L1 & L2, L2 & L3, and L1 & L3, using an Ohmmeter.
The resistance should range from ".7 to 1.8 Ohm". If the Ohmmeter
reads "0 Ohms" or "OL", then replace Spindle Motor. Next, check the
resistance between L1 & Ground, L2 & Ground, and L3 & Ground,
using an Ohmmeter. The resistance should read "OL". If not then
replace Spindle Motor.
3.5.3 Spindle Runs Backwards
The spindle motor runs in the opposite direction.
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Possible Cause Check This
3-Phase wires backwards Need to switch any 2 of the 3 wires either coming out of the
Spindle Drive (T1, T2, and T3) or going into the Spindle Motor (U,
V, and W). Caution: Be sure to shut off all power to the machine
before attempting to switch any wires.
3.5.4 Excess Gearbox Noise
Gearbox noise is louder than normal. Run the lathe at the gear where the noise is most
noticeable. Remove the gearbox lid and try to isolate where the noise is coming from.
Possible Cause Check This
Insufficient amount of oil in headstock Check site glass to make sure oil is at sufficient level.
Spindle bearing not being lubricated
properly, worn bearing
Spindle preload loose Tighten spindle preload on bearing. The spindle
Remove top lid and check to make sure oil is
overflowing freely to the spindle bearings.
preload should be approximately 1.1 – 1.7 N-m.
3.5.5 Headstock is Leaking Oil
A Form-A-Gasket sealant should be use to seal any leaking areas. Make sure the sealant
fills the leaking area thoroughly. Sealant must cure for 24 hours for best results.
3.5.5 1 Leaking Oil from Rear of Gearbox .
Possible Cause Check This
Leaking from behind belt drive pulley Replace shaft seal - o-rings or gaskets.
Oil leaking from behind the spindle
encoder.
Oil leaking from the rear bearing
assembly.
Remove spindle encoder and pinion shaft cover.
Check the seal.
Make sure the spindle shaft cover is mounted
correctly, if so remove the cover and check the o-ring.
3.5.5 2 Leaking Oil From Front of Gearbox .
Possible Cause Check This
Oil leaking between cover and gearbox Remove gearbox cover. Thoroughly clean cover & top
of gearbox. Replace gasket and reassemble.
3.5.6 Tailstock Barrel is Stiff
The tailstock barrel is stiff or not smooth moving through its travel. The tailstock barrel
subassembly jams inside the tailstock.
Possible Cause Check This
Misalignment of tailstock housing Realign bearing housing and tailstock screw. Loosen
screw support and realign.
Too much grease. Disassemble and remove excess grease.
Vernier Dial is binding or rubbing on
screw support.
Remove dial and machine off a couple of thousandths
or shim.
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4.0 Diagnostics
This section explains the diagnostic procedures used to isolate service problems.
4.1 The Machine Tool & Set-Up
4.1.1 Leveling
Leveling is one of the most important aspects of setting up the machine properly.
Improper leveling can lead to a variety of machining problems.
The machine should be level to within .02 mm longitudinally and .01 mm transversely.
See Leveling Procedures, Section 2.9.
4.1.2 A Special Word About The X Gib
The X gib is vital to the performance of your lathe.
Gibs should be:
• flat
• free of twist
• free of burrs
• free of blockages in the oil passages and channels
Defective or scarred gibs must be replaced. Shimming of gibs will not yield acceptable
results.
It is good machining practice to avoid the use of shop air to clean the chips off a
machine. This risks blowing chips into the sliding way surfaces and compromising the
performance of the machine.
See Gib Adjustments, Section 5.2.1.
4.1.3 Lubrication
Lubrication is one of the single, most important maintenance issues and plays a key role
in assuring the performance and durability of the lathe. At the beginning of each day
manually supply oil to the way surfaces by doing service code 300.
Lack of lubrication can lead to a variety of problems with your machine motion due to
increased friction in the sliding ways. This increased friction may lead to part inaccuracies
and decreased life expectancies of your ballscrews and way surfaces.
Lack of lubrication in the headstock can lead to increased wear of the gear train as well
as premature wearing or failure of the spindle bearings. For the 1630, oil will be flowing
only when the spindle is on.
4.1.4 Machining Set-Up
The machining set-up itself is always something that can greatly influence the
performance of the lathe. The following are some things to keep in mind.
Problems With Can Contribute To:
Feed and Speeds (spindle rpm)
See below
Poor finish
Excessive speeds and feeds can break cutting tools
or wear out too fast.
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Tooling
Using the wrong cutter for an application
Cutting too deep Part dimensions incorrect
No coolant Poor finish, decrease the life of the cutter
Poor finish
Parts incorrect
Driving and cutting forces cause deflections, since no
material is totally rigid
The following is a list of common machining problems and some possible solutions.
Problem Check or Try This
Poor surface finish Dull tool
Reduce feedrate
Increase spindle speed
Use a higher rake angle tool
Make sure tool is not dull or chipped
Use proper grade of cutting tool
Use coolant
Check to see if tools are on the centerline
Long workpieces out of round Use a follow or steady rest
Excessive chatter Tool bit improperly ground or not on center
Avoid extreme negative rake inserts
Tool overhang too great, tool deflection
Improper feeds and speeds
X gib loose. See
Work improperly supported
Machine tool out of level - See
Section 2.9.
Gib Adjus ment, Section 5.2.1
t
Leveling Procedures,
4.1.4.1 Spindle Speeds
Spindle speeds are influenced by a number of variables:
• Material
• Rigidity of the Machine Setup
• Coolant
• Insert, geometry and material of insert
• Depth of cut
4.1.4.2 Feedrates
Factors that affect feedrates:
• Depth of cut
• Design or type of insert
• Sharpness of the insert
• Workpiece material
• Type of finish or accuracy required
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4.2 The Mechanical Drive Train (X,Z)
Indications:
• Troubleshooting instructions indicate that the drive train is potentially the
problem and other, more easily checked, variables have been exhausted.
• Roughness, looseness, tightness or jamming movement in the carriage or cross slide.
• Carriage walk-up due to Z ball screw misalignment.
1. Check for machine considerations, especially X gib adjustments and leveling. See
Gib Adjustments, Section 5.2.1.
2. Do the following special service codes:
• Code 12 - this is a procedure that helps the control adjust to the friction
characteristics unique to the machine. Write down the resulting values from the
display. If your problem is control related, check to see if this procedure has
resolved the problem.
3. The torque required to manually turn the X and Z-axis ballscrews should be between
1.1 - 1.7 N-m. These values should be consistent in both directions and along all
areas of the axis travel. Values that differ from that of above may correspond to
misaligned ball screws.
The following steps take you in a logical sequence through the assemblies. If the
step doesn’t isolate or resolve the problem, it will be necessary to disassemble the
indicated item and move to the next step.
1. Ensure that the screws that hold the bearing housing in place are not loose.
2. Ensure that the Clamp Nut is secured. The following applies to the clamp nut: When
loosening, make sure to back out the 10-32 screw from the clamp nut.
3. When tightening, snug the 10-32 screw to keep the clamp nut from spreading,
tighten it again after the clamp nut is tight.
4. Take out the angular contact bearings in the X & Z-axis and inspect them. They
should roll smoothly and be lightly greased. If not, replace them. The Z-axis has 2
bearing housings. The tailstock bearing housing only contains 1 ball bearing.
NOTE: The bearing housing and spacer rings are matched sets - keep them together.
5. With the motor and drives removed, inspect the ball screw, ball nut and yoke for the
potential problems shown in the chart below.
CAUTION!
Unlike a leadscrew, do not unscrew the ball screw from its nut. This will destroy the ball screw!
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Potential Problem: Check By:
Bad ball screw
Ball nut not
tightened to the
yoke
Yoke loose in the
carriage
Oil lines sheared
Oil line blockage
Z Ball screws not
aligned properly
• Visual inspection of the ball nut - if the nylon seal is broken or deformed, if
contamination has visibly entered the ball nut or if balls are out of the ball nut,
replace the ball screw.
• Cranking the ball screw through a significant part of its travel. If it jams, feel loose or
has rough spots, replace the ball screw.
• Dial indicator movement when indicating on the end of the ballscrew indicates
backlash between the ball screw and ball nut.
• Inspection for space between the head of the bolt and the ball nut i.e. the retaining
bolt has bottomed out in its thread and is not securing the ball nut to the yoke
properly.
• Inspection for any motion of the yoke or looseness in the Yoke mounting screws.
• Visual inspection.
• Pump the oil and ensure that it flows evenly to the ways, ball screws and cross-slide.
• Manually turn the ball screw through the length of its travel. Pay particular attention
to the movement near the headstock, the middle and the tailstock.
NOTE: Ball screws are inspected throughout their entire travel for backlash and consistent torque. A ball
screw should be good for millions of mm of travel if installed properly. Do not be too quick to replace a
ball screw if there is insufficient indication that it is bad; this will just be a costly delay to resolving the
real problem.
See: Z Ball Screw Remo val, Section 5.1.13
X Ball Screw Removal, Section 5.1.11
Aligning Z Ball Screw, Section 5.1.14
4.3 Computer/Pendant Diagnostics
The pendant consists of 2 separate modules: the computer module and the pendant
enclosure minus the computer module.
In general, the pendant/computer module is best diagnosed by eliminating all other
possible alternatives. The following table lists some problems and what these problems
can lead to.
Possible problems Can lead to
Poor cable connections There are 6 cable connections to the left side of the pendant. Make
sure all cables are properly fastened.
Pendant locks up Press the E-stop button and see if lock up clears if not then do the
following:
Turn the pendant off, wait at least 30 seconds, and turn it back on and
check to see if the malfunction has been reset.
No voltage to RSG port RSG will not work – should be 5 DC volts present
Check with a voltmeter.
Low voltage to flash drive or
slave board.
Can cause the system to lock up and the flash drive to act abnormally.
Check voltage to the RSG port with a voltmeter. It should be 4.8 DC
volts and above. Lower values than this can cause problems.
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Flash disk failure If the flash disk fails, the system will not boot up or operate. It will
need to be replaced. All programs and machine configurations will be
lost. Make sure to back up your flash drive from time to time. Only
the flash disk module will need to be replaced.
Floppy disk failure Will not allow user to save or pull up programs from a floppy disk. Can
the floppy drive format a disk? See Section 4.3.
LCD backlight burns out Check all cable connections to LCD, distribution board and computer
module. Make sure the power is turned off before doing so.
Faulty E-stop switch It can be stuck open or closed (pressed). If it is stuck closed the
pendant will need to be replaced because the user will have no way to
get rid of the message. If it is open it will allow the machine to still
operate but it will be unsafe for the user. The pendant will still need to
be replaced. The E-Stop reset button may need to be pressed.
Overlay failure (keys on
pendant)
Low voltage to pendant or
current spikes
Slave board not functioning Machine will not run. If under Code 33 it says “demo,” it means the
Certain buttons on overlay do not work. Do code 81 to verify each key
beeps.
1 amp fuse in pendant blows. Pendant will not turn on.
slave board is not functioning.
4.3.1 Checking Floppy Drive by Formatting a Disk
1. Find a new disk and install in floppy drive.
2. Install keyboard into middle port.
3. Press CTRL ESC to get to start menu.
4. Press R for run.
5. Type Format a: - press enter.
6. If the format works your disk drive is working. If format does not work, reboot
control and see if it now works. If it does not work replace the computer module.
7. Press ALT ESC to get back to PT4 software.
4.4 Motor Diagnostics
The Motor subsystem is comprised of 2 parts: The Motor Encoder and the Motor. The
motors are powered by 110 VAC voltage. The servo driver is also an integral part of
servo system, which is discussed in detail in the next section.
WARNING!
Do not work with the motors unless the power is disconnected from the machine. The motors
are run by 110 VAC. There is possibility of death by electrocution!
Rarely do both the X and Z motor/servo systems fail at the same time and in the same way.
So, if your problem is occurring on both axes, its source is probably somewhere else.
4.4.1 Cable Connections
Check the motor cable connections on the cable breakout box. Verify there are no pushed in
pins on the connector.
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4.4.2 To Check the Motor Encoders
If the motor encoder inside the motor has failed or is not reading the machine will fault out
on that axis. Do the following to verify this problem:
Run Service Code 100 or 131. This will display on the DRO if the motor encoder is counting.
If this axis does not count, the encoder is not counting. This means either the encoder or the
cable is the problem. Visually check the cable for any problems. If the encoder has failed the
motor must be replaced.
4.4.3 Encoder Counts to Pendant
Before replacing the motor due to a bad motor encoder it is a good idea to check the
cables that take those signals back to the pendant. If these signals are not getting back
to the pendant then the axis will fault. Check the following cable connections.
• Umbilical #1 and #2 at the cable breakout box
• Umbilical #1 and #2 at the pendant
• Umbilical #1 carries the X-axis signals and Umbilical #2 carries the Z-axis signal.
4.4.4 Moving Problem from One Axis to Another
Another way to troubleshoot a problem with a particular axis is to swap parts from 1 axis
to another to see if the problem moves. If the problem moves then that component is
faulty. See the example below.
Symptom – X Axis will not move and faults
This particular problem can happen because of any of following reasons: bad motor,
servo driver, power cable, or computer module. In some cases it is not always obvious
which component is causing the problem. This example will help us pinpoint the
problem through a trial and error process.
Let’s assume we have narrowed it down to the servo or electrical systems and the X-axis
has no problems. Lets also assume it is not an obvious problem like a loose connection.
This particular example was done on a machine with motor encoders only.
Swap these components Results
Physically switch the X and Z
motors
Has problem moved to Z-axis? If yes, replace motor. If no,
the motor is not the problem.
4.5 Servo Drivers
The two (2) servo drivers are located in the electrical cabinet.
Indications:
• Problems moving just one axis. The axis faults out on the screen.
Servo Types:
• X is a light duty driver
• Z is a heavy duty driver
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• Isolate the problem to the particular Servo Driver
Steps:
1. Turn off and unplug the system.
2. Physically swap the servo module from the axis that is not working to one that is.
WARNING!
Do not work with the Servo Driver unless the power is disconnected from the machine. There is
possibility of death by electrocution!
Note: To avoid pulling the wires out of the connector, use the loop to pull the connector from the
Servo Driver.
If the problem moves to the other axis and clears up from the original axis, replace the
Servo Driver.
WARNING!
Do not work run each axis very long when swapping servo’s. They are not rated to run each
motor for long periods of time.
4.6 Electrical
4.6.1 Checking A/C Voltage
This procedure tests for the 115V power for the control.
•
Use a Voltmeter, reading A/C volts
•
Acceptable range is 110V to 130V
Note: systems running consistently close to the high or low values may have problems when
normal voltage fluctuations push the voltage out of the acceptable range.
The system is shipped out assuming the customers shop has 415 V power. If the transformer
secondary tap is set on 115 volts. Measure the voltage coming out of the transformer by
placing the voltmeter across the 115 V and 0 V taps. If this measurement is above 120 volts
then move the tap from 115 V to 110 V. If the reading is low, 110 V or below, then change the
tap from 115 V to 124 V. Input power to the machine that is 430 V or above will cause the 110
voltage to be high and voltage that is 405 V or below typically causes 110 voltage to be low.
4.6.2 Checking Fuses
There are 11 fuses that make up the system on the 1630. There are 2 fuses in the
pendant, 3 fuses on the spindle control module and 6 fuses on the power module.
To check fuses:
1. Use a Volt/Ohmmeter; select “OHM” or “Ω”.
2. Remove the fuse completely from the pendant display or electrical box.
3. Place a lead of the meter on each end of the fuse.
• A good fuse reads 0 (zero) or close to it.
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• A bad fuse reads Open or Infinity or OL (overload).
4.6.3 Main Electrical Box
The electrical box is made up of the following main components:
1. AC drive – used to control the spindle motor.
2. 2 braking resistors – used to brake the spindle motor. To verify the resistors are
good, measure the resistance across B1 and B2 of the AC drive. It should read 16
ohms when both resistors are good and 32 ohms if 1 resistor is bad and one in good.
Values lower or higher than this could be one or both resistors are bad.
3. Spindle Control Module – used to control spindle related functions, indexer option,
and the remote e-stop. The spindle control module has (1) 5 amp fuse, (1) 3 amp
fuse and (1) 12 amp fuse. The spindle control module also has (6) 110 V outlets that
supply power to the pendant, spindle, lube pump, indexer, lamp, and the door fan.
4. Cable breakout box – used to send encoder information to the pendant and provide
power to the motors.
5. Servo drivers – servo drivers for the X and Z axis axis motors.
6. Power Module - The purpose of the power module is to fuse and distribute 415 V 3
phase power to the drive module assembly. L1 and L2 lines from the 3 phase 415
VAC is used for the primary side of the transformer to produce 110 V single-phase
power to the spindle control module. The power module has (3) 25 amp fuses to
protect the entire system. It also has (2) 4 amp and (1) 2 amp secondary fuses. The
power module also has a ground bar where all the panels are grounded and a dual
channel relay (safety relay) that is controlled by the E-stop and E-stop reset button
on the pendant.
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Figure 10 Figure 10
Electrical Box Parts
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Electrical Box Parts List
Item P/N DESCRIPTION Qty
1 24039 SHEETMETAL-SLX-DRIVE MODULE 0
2 24042 MODULE-SPINDLE CONTROL 1
3 23050-2 CABINET ASSY-PT4 -SL-CABLE BREAKOUT BOX-AUXILARY FUNCTIONS 1
4 22287-1840SX AC DRIVE PROGRAMMED - 1830SX 1
5 20201 SERVO DRIVER ASSY 1
6 22283-2-3-30 WIREWAY- TYPE G LIGHT GRAY 1
7 22283-1-3-30 WIREWAY- TYPE G LIGHT GRAY 1
12 1/4-20X3/8 31Z SCREW-PH-PHIL-EXT SEMS-STL-ZINC 7
13 10-32X3/8 31Z SCREW-PH-PHIL-EXT SEMS-STL-ZINC 12
14 6-32X5/8 31B SCREW-PH-PHIL-EXT SEMS-STL-BO 8
15 20327-3 SERVO DRIVER ASSY - 4050D 1
16 20689 CABLE ASSY-L2 SERVO DRIVERS TO CONN PCB 1
17 24181 CABLE ASSY-LATHE CBB TO SPINDLE CONTROL 1
21 22392-1-30 COVER- WIREWAY- TYPE G 1
22 22392-2-30 COVER- WIREWAY- TYPE G 1
23 22778 LABEL-REVISION LEVEL 1
24 22779-21 LABEL- 1
26 21892-9 FUSE BLOCK- 600 VOLT 1
27 24488 CABLE ASSY-HEADSTOCK OIL PUMP 3
28 8-32X3/8 20B SCREW-RH-PHIL-STL-BO 2
29 21893-2 FUSE- 500 VOLT- SLO-BLO TYPE 3
30 24360-1630SX AC DRIVE PROGRAMMED - 1630SX 1
i01174
4.6.3.1 Spindle Control Module LED Segments
1st 10 LED Segment
1. LED labeled GEAR 4 – not used.
2. LED labeled GEAR 3 – not used.
3. LED labeled GEAR 2 –The 1630 does not have a gear switch.
4. LED labeled GEAR 1 This light should be off when it is in high gear or neutral.
This light is not on for the 1630 because it has no gears.
5. LED labeled SPD-FAULT – this light will be on whenever the AC drive is in a fault
condition, which includes an E-stop message from the pendant.
6. LED labeled SPD-RUN – this light should be on whenever the spindle is on.
7. LED labeled SPD-ENABLE – this light should be on whenever you are in DRO,
tool setup and RUN mode.
8. LED labeled LUBE PUMP – this light should be on whenever the lube pump is on
and off when it is not on.
LED’s 9 and 10 are not used.
nd
10 LED Segment
2
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1. LED labeled E-STOP OUT – this light should be on whenever the E-stop is in the
out position. When the E-stop is pressed, this light should go off.
2. LED labeled OFF RELAY – this light should be on whenever the off button on the
pendant is pressed.
3. LED labeled TAP MODE – light should be on whenever you are not tapping.
Light will be off when in the tap event.
4. LED labeled TAP REVERSE – this light will be on when the spindle changes
direction at the bottom of the hole on a tap event and back off after the spindle
changes direction once outside of the tap event.
5. LED labeled REV-RELAY – this light should be on whenever the spindle is running
in reverse.
6. LED labeled FWD-RELAY – this light should be on whenever the spindle is
running in forward.
7. LED labeled LI-BIT 1 – this LED should be on whenever the lathe indexer is at
any odd tool position.
8. LED labeled LI-BIT 2 – this LED should be on whenever the lathe indexer is at
tool positions 2, 3, 6 or 7.
LED’s 9 and 10 are not used.
rd
10 LED Segment
3
1. LED labeled LI-BIT 3 – this LED should be on whenever the lathe indexer is at
tool positions 4, 5, 6 or 7. For the 4 tool indexer, if you program tools 5, 6, 7 or
8, the indexer will physically move to tools 1, 2, 3 or 4 respectively. For
example, if you program tool 7, LED light LI BIT 3 should be on.
2. LED labeled LI-BIT 4 – this LED should be on whenever the lathe indexer is at
tool position 8.
3. LED labeled REMOTE E-STOP – this LED should be on whenever the remote estop or pendant e-stop is in the out position.
4. LED labeled OIL PRESSURE – not used.
5. LED labeled LI-PROX SWITCH – this LED should be on whenever the lathe
indexer is locked in position.
6. LED labeled LI-AIR PRESSURE – this LED should be on whenever the air
pressure for the lathe indexer is incorrect.
7. LED labeled 24VDC OK – this LED should be on whenever the 24 volts for the
lathe indexer is not present.
8. LED labeled 5VDC OK – this LED should be on whenever the 5 volts for the lathe
indexer is not present.
LED’s 9 and 10 are not used.
th
10 LED Segment
4
1. LED labeled FWD-KEY – this LED should be on whenever the FWD key on the
pendant is being pressed.
2. LED labeled OFF-KEY – this LED should be on whenever the OFF key on the
pendant is being pressed.
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3. LED labeled REV-KEY – this LED should be on whenever the REV key on the
pendant is being pressed.
4. LED labeled LI-SEL 4 – is not used and should never be on.
5. LED labeled LI-SEL 3 – this LED should be on whenever a tool position on the
Dorian indexer is commanded which would increment the tool by 4 positions or
decrement the tool by 1, 2, 3 or 4 positions. For increment, the Dorian indexer
is rotating in a CCW path when facing the turret. May not apply to the 4 tool
indexer.
6. LED labeled LI-SEL 2 – this LED should be on whenever a tool position on the
Dorian indexer is commanded which would increment the tool by 1, 2 or 4
positions or decrement the tool by 1or 4 positions. May not apply to the 4 tool
indexer.
7. LED labeled LI-SEL 1 – this LED should be on whenever a tool position on the
Dorian indexer is commanded which would increment the tool by 1, 3 or 4
positions or decrement the tool by 2 or 4 positions. May not apply to the 4 tool
indexer.
8. LED labeled CHUCK GUARD – not used
9. LED labeled FWD-REVERSE – not used
LED 10 is not used.
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Figure 11
Spindle Control Module LED’s
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4.6.4 Cable Breakout Box Connections
The list below describes what takes place through each connection. Power reaches the
cable breakout box through AC IN from the pendant. From there power is distributed
through the system.
• Umbilical #1 & Umb ilical #2 Ports (To Pendant) - The lathes have (2) motor
encoder signals which are communicated between the Encoder module and the
Pendant by use of (2) Umbilical cables. The X signal is communicated through
umbilical #1 and the Z motor signal is transferred through umbilical #2.
• Apron Port - Communication for X & Z-Handwheel and jogstick logic signals
between the Pendant and the cable breakout box.
• and Z- servos.
• X & Z - Motor Ports - are used to receive power from the servo and distribute it to
the motors.
• X & Z-Motor Encoder Ports - These ports are used to receive logic signals from
each of the X & Z-Motor Encoders.
• Spindle Encoder Port - The port is used to receive logic signals from the spindle
encoder, when it is engaged for a threading routine.
• Logic to Servo (PWM) - This port is used to keep continuous feedback between
the servos and the cable breakout box.
• 110 VAC Outlet - The outlet is for powering up the coolant pump. Beside the
outlet is an LED light signifying power is reaching the pump when it is active, and a
fuse to protect the pump.
• E-Stop and Spindle Out Port - used to disable power to the spindle motor when
the E-Stop is activate.
4.6.5 Cable Connections
The lathe machines use 7+ cables to communicate between systems. It is often the case
that what appears to be the failure of an electrical component is actually attributable to a
poor connection.
Indications:
• Control problems, chronic or intermittent.
• Motor problems.
• Measurement problems.
Explanation:
1. Turn off and
Do not plug and unplug connectors with the system power on. This may cause damage to the
2. Visually inspect the connections for excessive debris, moisture, or obvious damage.
unplug
the system from the wall.
WARNING!
connector board and harm to the technician.
3. Carefully clean any chips away from the connectors.
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4. One-by-one, take out each connector and then plug them back in. Do the same at
the computer/display.
5. Make sure the screws are tightened on each of the connectors.
4.7 Door Interlock Switch
The 1630 uses door interlock switches to verify to the control that the doors are closed in
various modes of operation. This switch is wired normally open but is forced closed
when the doors are closed during CNC run mode. The switches are wired in series to a 9
pin DB connector. There should be continuity between pins 1 and 6 when the switches
are forced closed and no continuity when the switches are in the open position.
4.8 Service Codes
Service codes are broken down into the 4 following categories: software, machine setup,
diagnostics, and user options/defaults.
All Service Codes are accessed in the SET-UP Mode by pressing the soft key for “SERV
CODES”. The service codes can be found under one of the headings listed on the main
screen. Press the heading you want to access the code in question. If you know code #
you want press the CODE # softkey and it will take you directly to the code in question.
Press CODE #, enter the number you want, press SET.
4.8.1 Software Codes
The following codes pertain to software functions in the control. To get to any of these
codes go to Service Codes, press “A” and press the code you wish to view.
Note - Write the values down for Code 33 or Code 313. These values will be valuable for
troubleshooting.
4.8.1.1 CODE 33: Software ID
Code 33 is the software identification procedure. The two types of software in the
control include:
• Software Version - the version of the system you have installed.
• Firmware Version - the version of firmware software that is responsible for control
to servo interface.
• Operating System Version – displays the version of the operating system.
4.8.1.2 CODE 37: RS232 Baud Rate
This code sets the baud rate for RS232 applications. The recommended baud rate is 9600.
The following baud rates can be chosen: 4800, 9600, 19200, 38400, 57600, 115200.
4.8.1.3 CODE 141: Load Configuration file from floppy “A” drive
This code allows you to load your configuration file from the floppy disk to your hard
drive. The configuration file consists of items such as calibration and backlash constants.
This code is used when a computer module or hard drive has been replaced.
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4.8.1.4 CODE 142: Save Configuration file to floppy “A” drive
This code allows you to save your configuration file to a floppy disk. The configuration
file consists of items such as calibration and backlash constants. This code is used when
a computer module or hard drive needs to be replaced. This stores the configuration file
from the hard drive to the floppy disk. It is a good idea to do this code after the
machine is initially setup so these values can be saved and used in the future. If the
computer or hard drive fails, then you will not have the ability to save the configuration
file and the machine will need to be re-setup when the computer or hard drive is
replaced.
Note: All machines will have a copy of the configuration file in the back of the electric’s cabinet.
4.8.1.5 CODE 313: Display Configuration File
This code displays the configuration file. This file contains pertinent information about
the machine. The file will look similar to the following. If the file becomes corrupt you
can load default values by pressing the F4 softkey.
Product = 1440S/1745S (displays machine ID key of machine)
Motor encoder calibration constants 610.0712 1143.8921
(These numbers above are typical numbers for the calibration constants)
Arc accuracy – 0.13
Code 128 X=0.13 Z=0.04
Code 12 (+) X=000005 Z=000006
(
Code 100 (+) X=352.7 Z=325.2
(
-) X=000005 Z=000006
-) X=350.1 Z=333.1
4.8.1.6 CODE 316: Update Master Software
Load upgrade disk in floppy drive and press this service code. New software will
automatically download and control will reboot. Please perform alignment routine
afterwards.
4.8.1.7 CODE 317: Update Slave Software
Load upgrade disk in floppy drive and press this service code. New software will
automatically download and control will reboot. Please perform alignment routine
afterwards.
4.8.1.8 CODE 318: Activate Converters or Options
See programming and operating manual.
4.8.2 Machine Set-up Codes
The following codes are used primarily when setting up a new machine. To get to any of
these codes go to Service Codes, press “B” and press the code you wish to view.
4.8.2.1 CODE 12: Feed Forward Constant
The Code 12 procedure helps the control “learn” the friction characteristics of the
machine by sending a graduated series of motor signals and observing the results. The
process takes less than 30 seconds to run. It is both a diagnostic routine that displays
values, and a routine that sets the parameters of the control for the particular machine.
The Code 12 is used for diagnosing and resolving:
• Problems with machine motion.
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• Machined parts come out bad – especially poor finish.
Note: Code 12 routine will set the parameters for the particular machine and its particular
situation. If the machine changes its friction characteristic, the Feed Forward Constant should
change too, or the system will not servo properly. Whenever gibs are adjusted or a heavy
workpiece has been added to the table, you should run a Code 12. When the heavy workpiece is
removed, Code 12 should be run again.
1. Position the table and addle in the center of travel. Note: You will lose your DRO
position reference.
2. Go into the Service Codes and input the Code 12.
3. Press Auto
4. The system will run the routine automatically and then display values on the position
readout.
Explanation
Typical values should be between 4.04 and 11.11 are considered normal for each axis.
Higher values indicate excessive friction in the system. Lower values indicate a loose
system and may mean a gib adjustment is necessary. Value 4.04 means the friction is a
factor of 4 in one direction, and 4 in the other direction. The values should be within 3
or 4 of each other in both directions. A value of 6.08 would still be considered normal.
On S products, do not equate Code 12 values to torque on ballscrew. Measure friction in
system with an N-m torque wrench.
The feed forward gain can be adjusted manually by pressing the manual button. Choose
the axis you would like to change and then enter values in the positive and negative
direction to adjust. Adjusting the gain can help solve circularity problems. Default
values can be set by pressing the Reset button. The manual feature should only be used
in extreme cases where the AUTO routine did not solve the problem. Manual adjusts
above 12 may lead to servo related problems.
4.8.2.2 CODE 100: Axis Open Loop Test
Code 100 procedure is used to diagnose problems with the configuration of the system,
the encoders and incoming A/C voltage.
IMPORTANT -- SAFETY NOTICE
During this procedure the designated axis will be given a command to move at maximum speed
for 1 second in the direction you choose. Avoid crashes by starting with the cross-slide and
saddle centered. MAKE SURE THAT NO ONE IS STANDING IN THE WAY OF THE CROSS-SLIDE
OR SADDLE!
Note: You will lose the DRO reference position.
This procedure is to be run for each axis that is servo-driven, and for both the plus and
minus direction for each axis.
1. Center the cross-slide and saddle.
2. On the Pendant display, go into the Service Codes and input the Code 100.
3. The conversation line will say: “SELECT AXIS”. Input the axis. Either X or Z.
4. In the conversation line it will say “WHICH DIRECTION? PLUS”.
• If you want to run in the plus direction, press INC SET.
• If you want to run in the minus direction, press +/-, then INC SET.
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5. In the conversation line it will say “PRESS GO”. Press Go after you are sure that the
machine will not crash in the direction and axis that you have specified.
6. Afterward the screen will display values next to the DRO position axes.
Your input Display Data displayed.
X + X Motor encoder reading
Z Nothing (should be 0)
Feedrate the maximum feedrate attained
Your input X Motor encoder reading
X -
Z Nothing (should be 0)
Feedrate the maximum feedrate attained
Your input X Nothing (should be 0 )
Z +
Z motor encoder reading
Feedrate the maximum feedrate attained
Your input X Nothing (should be 0 )
Z -
Z motor encoder reading
Feedrate the maximum feedrate attained
Interpretation of the resulting values displayed:
The values for the encoder displays should be in the range of 76 mm to 127 mm.
• If the motor encoder value is not within specification it may be the problem. If the
encoder is not reading then it will need to be replaced.
• The feedrate should be a minimum of 4572 mm/min (180 ipm). Shops with higher
voltages will see higher values.
• If the feedrate is less than 4572 mm/min (180 ipm) and inconsistent in both directions,
check the incoming AC voltage and mechanics of the drive train.
4.8.2.3 CODE 123: Calibration
See Section 5.22 for a further explanation of this code.
4.8.2.4 CODE 127 - Set X or Z Backlash Constant
See Section 5.22 for a further explanation of this code.
4.8.2.5 CODE 128: Input Backlash Constant
Code 128 allows you to enter the backlash values for each axis. It displays the value
after it enters. This code is only used on machines with motor encoders only.
4.8.2.7 Code 308: Reverse X Hand Wheel Direction
This service code reverses the direction of the X hand wheel.
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4.8.2.8 Code 310: Reverse Z Hand Wheel Direction
This service code reverses the direction of the Z hand wheel.
4.8.3 Diagnostic Codes
The following codes are used primarily when diagnosing a problem with the machine. To get
to any of these codes go to Service Codes, press “C” and press the code you wish to view.
4.8.3.1 Code 54: Program Continuous Run
This Code runs a program continuously without stopping for tool change commands. It
is helpful in running a long period to identify an intermittent problem.
1. Prepare a program as you normally would.
2. Press MODE, SET UP, “C”, Code 54, INC SET. The program run will start automatically.
3. Press STOP to stop, and GO to continue.
4.8.3.2 Code 81: Keyboard Test
This code is used to check if the keyboard is functioning correctly. It allows you to test
each key on the pendant individually. When you press the keys, the corresponding box
for that key will highlight on the screen. The pendant will also beep, indicating that the
key is working correctly. If one of the keys does not work the pendant assembly may
need to be replaced. If none of the keys are working chances are that the computer
module will need to be replaced.
4.8.3.3 Code 131: Manual DRO
A manual diagnostic routine to check the motor encoder and table encoders. Turn the X
hand wheel to display the encoder readings. This code will display the actual DRO
counts and the raw encoder counts before the calibration and backlash factors have
been factors into the counts.
4.8.3.4 Code 132 - Electronic Hand Wheel Test
Turn the X or Z-axis electronic hand wheel. The display should show movement as the
hand wheel is being turned. There should be no skipping and it should count smoothly
while the hand wheel is being turned. One revolution of hand wheel should read 10.2
mm for Z and 2.54 mm for X in course mode and 2.54 mm for Z and 0.51 mm for X in
fine mode.
4.8.3.5 Code 133 – Spindle Encoder Test
Turn the spindle or run the spindle at low RPM’s. The display should show the counts
from the spindle encoder. It should count to 360 on the Z display and then reset. Each
time it resets it displays the number in the X display area.
4.8.3.6 Code 314: Toggle Test Lights ‘ON’ in Status Line
This code toggles on and off 2 test lights that appear in status line. The top light
signifies if the master software is working. If functioning it should flash a green light.
The bottom light signifies if the slave firmware is functioning. It will appear orange in
run mode when it is processing information. Pressing the mode key will change this
orange box to black. The orange box will also change to black when the program you
are running reaches the 3
rd
event from the end of the program. If the firmware is locked
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up no keys will work. This code is useful for diagnosing intermittent problems with the
control locking up.
4.8.3.7 Code 319: Error Log
This code when turned on captures the commands that were sent to the servo system.
It includes items such as positioning commands, errors, stop and go commands, etc. It
may be helpful for identifying problems between programmed commands and executed
commands. To turn on the error log press the F6 softkey. The page forward and
backward keys allow you to scroll through the file one page at a time. The data forward
and data backward keys allow you to scroll through the file one line at a time. The data
bottom key takes you to the bottom of the file and then changes to data top which will
take you back to the top. The file will capture data until the file reaches a size of
approximately 600 Kb. At this time the file is saved to a backup file and the original file
is cleared and data is once again captured. Once again as the file reaches a size of 600
Kb it copies over the previous backup file. From here the user can save the file to the
floppy drive by pressing the F8 softkey. Once this in done it prompts you for which file
you want to save to disk. The F1 key saves the current file to disk and the F2 key saves
the backup file to disk. To clear the files press the F7 softkey.
4.8.3.8 Code 324: Toggle Simulation Mode
Simulation Mode allows the control to run a program without actually moving the table.
It is helpful in diagnosing Computer/display problems.
4.8.3.9 Code 326: Error Message Display
Error Message Display is used to describes error messages.
4.8.4 Operator Defaults/Options Codes
The following codes allow the user to set programming defaults or turn features on or
off. To get to any of these codes go to Service Codes, press “D” and press the code you
wish to view.
4.8.4.1 Code 66: Default Metric
This code causes the control to turn on in the metric mode.
4.8.4.2 Code 67: Default English
This code causes the control to turn on in the English mode.
4.8.4.3 Code 79: Beeper On
This turns on the beeper to the control keys.
4.8.4.4 Code 80: Beeper Off
This turns off the beeper to the control keys.
4.8.4.5 Code 129: Arc Accuracy
When the SL control operates at high feedrates it may create small part machining errors
as it goes around sharp corners. This exists on all CNC’s and is commonly called a
“following error.” The control is factory preset to allow a maximum following error of
0.13 mm. The feedrate will automatically be adjusted around sharp corners so as to not
violate this limit. This code only applies to arcs that are programmed and ones that are
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created in the tool path to generate the shape you want. This code will not make a
difference on mill moves.
You may adjust the maximum following error to a value as small as .003 mm. However,
the smaller the value, the slower the feedrate around corners.
To input a new Following Error use the following procedure:
Follow the instructions on the screen and input the Following Error value (from .003 to
.3 mm) and press INC SET.
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5.0 Procedures for Replacements & Maintenance
5.1 Replacements
5.1.1 Motor Replacement
1. Turn off power to the machine.
2. Each motor is mounted by the use of (4) ¼-20 screws. Be careful not to over
tighten these bolts and strip the threads.
5.1.2 Servo Driver Replacement
WARNING!
Do not work with the Servo Drivers unless the power is disconnected from the machine. The
servo drivers are run by 110 VAC. There is possibility of death by electrocution!
The Servo Driver for each axis is located inside the electric cabinet.
DANGER!
Always engage (push in) the Emergency Stop switch, turn the ProtoTRAK SLX Control off, and
disconnect the servo driver cable at the cable breakout box.
1. Press in the Emergency Stop.
2. Remove the servo driver from the panel, inside the electric cabinet.
3. Remove the 10 cap screws that hold the servo driver and its heat sink plate to the panel.
4. Disconnect the cable connector from the servo driver.
5. Reinstall the new servo driver with its heat sink plate.
5.1.3 Computer Module Replacement (See Figure 12)
1. Turn power off to the machine and control.
2. Unplug all the connectors on the pendant arm side of the pendant.
3. Remove 4 screws on the right side of the unit and 2 screws on the left side of the
unit. The module is now free to slide toward the right side of the pendant.
4. Slide the computer module a few centimeters and stop. Pulling the computer
module too far will damage the LCD cable.
5. Now reach from the pendant arm side of the unit inside and remove the 37-pin LCD
cable.
6. Now slide the module about ½ way out of the pendant sheet metal.
7. Remove the ground stud from the side of the computer module.
8. Next remove the 37 and 9 pin connectors from the top of the computer module.
9. Lastly slide the unit completely out of the sheet metal.
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10. Follow the instructions in reverse order when reinstalling the new computer module.
11. Make sure the connectors are fully seated before bolting the unit back in place.
Note: if the flash drive is functional, you may want to remove the flash disk and install it in the new flash
drive.
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Figure 12 (Figure shown with inner sheet metal removed)
Computer Module & LCD/Enclosure Replacement
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5.1.4 System Flash Disk Replacement
1. From the control, go to SETUP, SERV CODES, SECTION A, and then code 142 and
save your Configuration file (calibration values, etc.) on a floppy disk. There is a disk
in the electric’s cabinet for this purpose. Label this disk as “Backup Configuration”
and store it for later use.
2. Turn power off to the machine and control.
3. Unplug all the connectors on the pendant arm side of the pendant.
4. Remove the pendant from the pendant arm by removing the (4) ¼-20 x 3/4” SCHS
that secure it in place.
5. Place the pendant assembly on a clean and secured table with the display pointing
away from you.
6. Remove the (6) 10-32 x 3/8” Pan Phillips Head Screws and (4) 10-32 x 3/8” FHCS
securing the computer module to the LCD/enclosure.
7. Pull the computer module a few millimeters and stop. Pulling the computer module
too far will damage the ribbon cables.
8. Remove the defective System Flash Disk (located on the back side of the mother
board) by pushing the eject button on the flash drive.
9. Firmly insert the replacement System Flash Disk into the drive, making sure that the
label with the serial number is pointing towards the motherboard.
(See Figure 13)
10. Secure the computer module back to the LCD/enclosure by following the instructions
in reverse order.
11. Make sure that all connectors are properly seated before fastening the unit back in
place.
12. Turn power on to the machine and control.
13. When the system boots, you may get a message stating that the system cannot find
your configuration file. Press NO if asked to load defaults.
14. Update the System Software by inserting the PT4SX update disk into the floppy
drive. Go to service codes 316 and 317 found in section A. Update the master and
slave software.
15. Restore the Configuration file saved on your backup configuration disk with service
code 141 found in section A of the service code section.
CAUTION!
It is a good idea to back up your flash disk from time to time via a network or floppy disk. If
your flash disk needs to be replaced you will loose all of your programs. See your programming
manual for instruction on how to do this.
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Figure 13 (Figure shown with inner sheet metal removed) Figure 13 (Figure shown with inner sheet metal removed)
Flash Disk Replacement
67
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5.1.5 Cable Routing on Machine
Whenever you replace a cable or reroute a cable it is very important to keep the power
cables and logic cables separated from each other. The power cables consist of the (2) 110volt motor cables and (2) 110-volt power cables for the pendant, and a coolant pump or
solenoid power cable. The logic cables are used to carry encoder signals between the cable
breakout box and computer module. Mixing of the power and logic cables may cause noise
from the power cables to interrupt the signals in the logic cables. This can lead to
intermittent axis faults or repeatability problems.
5.1.6 Electronic Handwheels & Jogstick
There are 2 electronic handwheels on the lathes and 1 jogstick to move the carriage quickly
into position. Each unit is replaced as an assembly. Disconnect the handwheels and jogstick
from the apron cable. (See Figure 41, Section 7)
5.1.7 Cable Routing in Electrics Box
Whenever you replace a cable or reroute a cable it is very important to keep the power
cables and logic cables separated from each other. The power cables consist of the (2) 110
volt servo motor cables and (4) 110-volt power cables for the pendant, spindle motor fan,
coolant pump, and lube pump. The logic cables are used to carry signals between modules,
handwheels, encoders, etc. Mixing of the power and logic cables may cause noise from the
power cables to interrupt the signals in the logic cables. This can lead to intermittent axis
faults or repeatability problems.
5.1.8 Spindle Drive Belt Replacement (See Figure 14)
The spindle drive motor is located inside the base pedestal, underneath the headstock
gearbox. Access is gained by opening the upper door on the headstock and removing the
lower access panel on the pedestal. When removing the belt, loosen nut “G” and advance
nut “H” until the belt has sufficient slack to be removed from the pulleys.
When installing the belt, retract nut “H” and tighten nut “G”. Initially, tension the belt such
that there is no slippage when the lathe is started at its maximum speed.
Belt tension should be checked frequently during the first days of operation, and periodically
thereafter. Keep the pulleys and belt clean and free of any foreign material to ensure long
life and maximum traction.
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Figure 14
Spindle Drive Belt/Motor Mounting
5.1.9 Spindle Motor Removal (see Figure 14)
1. Unplug or remove all power from the lathe.
2. Remove the motor belt.
3. Mark and remove motor electrical leads.
4. Because of the weight and size of the spindle motor, and the restricted working
space, extreme caution should be used in sliding the motor from its mounting plate.
5. Loosen the belt tension. See section above.
6. The motor is secured with four screws to a flange plate.
5.1.10 Spindle Encoder Replacement
1. Unplug or remove all power from the lathe.
2. Open the rear spindle cover to gain access to the encoder.
3. Loosen setscrews on flexible coupling and the bolts that hold the encoder on.
4. Slide the encoder off.
5. The spindle encoder assembly is only available as a complete unit. Do not
disassemble.
5.1.11 X-Axis Ball Screw Removal (see Figure 15)
1. Unplug or remove all power from the lathe.
2. Access to the X-axis ball screw is gained by removing the access guard and removing
the X-axis motor cover.
3. Remove the motor.
4. Remove all items on the right end of the ball screw.
5. Unbolt the ballscrew nut from the yoke.
6. The X ball screw is removed through the exposed hole when the cross slide is
removed.
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Figure
1630 X Axi
15
s Drive Train
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1630 X Axis Drive Train Parts List
Item Parts No. Description Material Specification Q'ty
1 Hexagon Socket Screw M6x16L 6
2 24698 Wiper - Crosslide (front) Rubber 25-0 220 1
3 25-0215 Cross Slide FC25 1
4 Socket Button Head Screw M6x10L 2
5 25-0739 Front Cover Plate SS41 1
6 Socket Head Cap Screw M8x16L 1
7 O-Ring P7 1
8 Socket Head Cap Screw M8x30L 4
9 25-0212 Seat - Nut FC25 1
10 Socket Button Head Screw M6x10L 4
11 24699 Wiper - Crosslide (Rear) Rubber 25-0221 1
12 20984 Ballscrew - X Axis SCM415 25-0211 1
13 25-0218 Rear Cover Plate SS41 1
14 25-0209 Clamping Block FC20 1
15 25-0206 Bumper PU 2
16 25-0205 Cam SS41 2
17 Socket Head Cap Screw M8x35L 4
18 Cover - Bearing 7204AVH 1
19 23930 Bearing Set - Angular Contact Ball 7204BECBP 2
20 15885 Spacer S45C 1
21 16300 Bearing Housing S45C 1
22 16314 Nut - Clamp S45C j19x16UNF 1
23 24A-0216 Cone Clamping Element Brass 1
24 98481A090 Woodruff Key #3(1/8"x1/2") 1
25 16983-1 Pulley-ballscrew S45C 5Mx44T 1
26 W02 Lock Washer W02(j15) 1
27 NT02 Lock Nut N02(j15x32UNF) 1
28 Socket Head Cap Screw 10-32x3/4" 1
29 25-0219 Rear Cover Plate SS41 1
30 Socket Head Cap Screw M8x30L 4
31 450-5M-15 Belt-X Axis 5M-450-15 1
32 Set Screw M5x6L 3
33 Pulley Aluminum 5Mx16T 1
34 Lock Ring SS41 1
35 25-0208 Plate - Cover - X Axis Motor SS41 1
36 25-0207 Plate - Motor SS41 1
37 24316 Motor - X Axis Servo 1
38 24-0315 Clampiing Block (Rear) FC25 1
39 50-0325-00 Screw - Adjusting S30C 4
40 Socket Head Cap Screw M8x25L 10
41 23337-28 Gib - Z Axis FC25 24-0313 2
42 24-0314 Clamping Block (Front) FC25 1
43 25-0712 Cover - Protection SS41 1
44 24-0311 Apron FC25 1
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45 Socket Head Cap Screw M8x30L 4
46 Socket Head Cap Screw M6x30L 4
47 23337-72 Wiper - Bedway (Right, Rear) Rubber 24-0337 1
48 Crossed Recessed Head Screw M6x16L 12
49 23337-73 Wiper - Bed way (Left, Rear) Rubber 24-0336 1
50 Hexagon Socket Screw M5x6L 8
57 22446 Bearing - self aligning 2204E-2RS1TN9 1
58 N04 Lock Nut S45C N04(j20x16UNF) 1
59 W04 Lock Washer W04 1
60 16295-1 Bearing Housing FC20 1
61 Socket Head Cap Screw M12x50L 4
62 Washer - Spring M12 4
63 Socket Head Cap Screw M6x20L 2
64 25-0321 Bumper Rubber 2
65 25-0320 Cam SS41 1
66 Socket Head Cap Screw M8x70L 2
67 23337-82 Wiper - Bedway (Right, Front) Rubber 25-0335 1
68 24714 Gib - X Axis FC30 25-0217 1
69 17-0321-00 Screw - Adjusting S30C 2
70 Socket Head Cap Screw M8x25L 4
71 25-0201 Saddle FC25 1
72 Socket Head Cap Screw M12x65L 4
73 23337-81 Wiper - Bed way (Left, Front) Rubber 25-0334 1
74 24704 Ballscrew - Z Axis SCM415 25-0310 1
75 Cover - Bearing AVH7205 1
76 23940 Bearing Set - Angular Contact Ball 7205 BECBP 2
77 16302 Spacer S45C 1
78 24A-0308 Seat - Bearing S45C 1
79 Socket Head Cap Screw M8x25L 4
80 16452 Nut - Clamp S45C j19x16UNF 1
81 24A-0216 Cone Clamping Element Brass 1
82 16983-1 Pulley-ballscrew Aluminum 1
83 98481A090 Woodruff Key #3 (1/8"x 1/2") 1
84 W01 Lock Washer W01 (j12) 1
85 N01 Lock Nut N01 (j12x3 2UNF) 1
86 Set Screw M5x10L 3
87 Socket Head Cap Screw 10-32x3/4" 1
88 Socket Head Cap Screw M12x35L 4
89 400-5M-15 Belt - Z Axis 400-5M-15 1
90 Pulley Aluminum 5M-30T 1
91 Socket Head Cap Screw 1/4-20UNCx30L 4
92 Washer - Flat 1/4" 4
93 Washer -Spring 1/4" 4
94 77USDA-0304 Base - Motor - Z Axis FC30 1
95 16775-1 Motor - Z Axis Servo 1
96 25-0223 Cover Plate (Front) SS41 1
I01153.xls
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5.1.12 Installing Angular Contact Bearings
1. On the inner race of the angular contact bearings, the thin walls face each other.
2. When tightening the clamp nut, first engage a few threads. Then lightly tighten the
locking screw slowly, so that when you slowly thread the lock nut inwards you can
feel some contact between the two threads.
3. Once the clamp nut is completely threaded inwards you will need to use a torque
wrench to apply 68 N-m. of torque, properly seating the bearings.
4. Completely thread in the locking screw to prevent the lock nut from unthreading.
(See Figure 16)
Figure 16
Angular Contact Bearings
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5.1.13 Z-Axis Ball Screw Removal
1. Unplug or remove all power from the lathe.
2. The Z-axis ball screw is attached to the lathe in three places:
a. The left end where the Z-axis motor, the pulley, the clamp and the pair of
angular contact bearings are mounted.
b. Behind the apron assembly where the ball nut is attached to the yoke and the oil
line is located.
c. The right end where the floating bearing is located.
3. Access to the left end is gained by removing the sheet metal panel below the
headstock nameplate.
4. Access to the ball nut and the yoke is gained by removing the apron assembly.
5. For easy assess to the ball screw, remove the ball screw cover.
(see Figure 17)
5.1.14 Align Z-Axis Ball Screw Assembly (See Figure 17)
1. Recheck machine level. Adjust as necessary.
2. Move carriage to middle of travel.
3. Loosen headstock bearing housing and mounting bracket and loosen tailstock
bearing housing.
4. Snug but do not tighten the yoke mounting bolts.
5. Move the ball screw manually and move the carriage to the tail stock end.
6. Tighten the yoke, this will align it vertically.
7. Tighten the tailstock bearing housing.
8. Loosen the yoke and retighten to realign ball horizontally.
9. Using a socket extension, move the carriage to the headstock.
10. Tighten the Z-axis housing.
11. Tighten the bearing housing.
12. Turn the ball screw manually with the socket extension and move the carriage to
the middle of the travel.
13. Loosen the yoke mounting bolts to readjust the apron plate after the bearings have
been tightened.
14. Retighten the yoke.
15. Move the ball screw manually and move the carriage through the entire length of
the Z-axis. Pay special attention to the areas near the headstock, tailstock, and in
the middle of the travel. If there is any binding or rough spots, the alignment
procedure must be repeated. The axis should feel equally free throughout the
entire range.
16. Using a torque wrench, measure the torque to move the z-axis at each end, and in the
middle of the axis travel. The torque reading should be a maximum of 1.1 - 1.7 N-m.
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Figure 17
1630 Z Axis Drive Train
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1630 Z Axis Drive Train Parts List
Item Parts No. Description Material Specification Q'ty
1 Hexagon Socket Screw M6x16L 6
2 24698 Wiper - Crosslide (front) Rubber 25-0220 1
3 25-0215 Cross Slide FC25 1
4 Socket Button Head Screw M6x10L 2
5 25-0739 Front Cover Plate SS41 1
6 Socket Head Cap Screw M8x16L 1
7 O-Ring P7 1
8 Socket Head Cap Screw M8x30L 4
9 25-0212 Seat - Nut FC25 1
10 Socket Button Head Screw M6x10L 4
11 24699 Wiper - Crosslide (Rear) Rubber 25-0221 1
12 20984 Ballscrew - X Axis SCM415 25-0211 1
13 25-0218 Rear Cover Plate SS41 1
14 25-0209 Clamping Block FC20 1
15 25-0206 Bumper PU 2
16 25-0205 Cam SS41 2
17 Socket Head Cap Screw M8x35L 4
18 Cover - Bearing 7204AVH 1
19 23930 Bearing Set - Angular Contact Ball 7204BECBP 2
20 15885 Spacer S45C 1
21 16300 Bearing Housing S45C 1
22 16314 Nut - Clamp S45C
23 24A-0216 Cone Clamping Element Brass 1
24 98481A090 Woodruff Key #3(1/8"x1/2") 1
25 16983-1 Pulley-ballscrew S45C 5Mx44T 1
26 W02 Lock Washer
27 NT02 Lock Nut
28 Socket Head Cap Screw 10-32x3/4" 1
29 25-0219 Rear Cover Plate SS41 1
30 Socket Head Cap Screw M8x30L 4
31 450-5M-15 Belt-X Axis 5M-450-15 1
32 Set Screw M5x6L 3
33 Pulley Aluminum 5Mx16T 1
34 Lock Ring SS41 1
35 25-0208 Plate - Cover - X Axis Motor SS41 1
36 25-0207 Plate - Motor SS41 1
37 24316 Motor - X Axis Servo 1
38 24-0315 Clampiing Block (Rear) FC25 1
39 50-0325-00 Screw - Adjusting S30C 4
40 Socket Head Cap Screw M8x25L 10
41 23337-28 Gib - Z Axis FC25 24-0313 2
42 24-0314 Clamping Block (Front) FC25 1
43 25-0712 Cover - Protection SS41 1
44 24-0311 Apron FC25 1
ϕ19x16UNF
W02(ϕ15)
N02(ϕ15x32UNF)
1
1
1
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45 Socket Head Cap Screw M8x30L 4
46 Socket Head Cap Screw M6x30L 4
47 23337-72 Wiper - Bedway (Right, Rear) Rubber 24-0337 1
48 Crossed Recessed Head Screw M6x16L 12
49 23337-73 Wiper - Bedway (Left, Rear) Rubber 24-0336 1
50 Hexagon Socket Screw M5x6L 8
57 22446 Bearing - self aligning 2204E-2RS1TN9 1
58 N04 Lock Nut S45C
59 W04 Lock Washer W04 1
60 16295-1 Bearing Housing FC20 1
61 Socket Head Cap Screw M12x50L 4
62 Washer - Spring M12 4
63 Socket Head Cap Screw M6x20L 2
64 25-0321 Bumper Rubber 2
65 25-0320 Cam SS41 1
66 Socket Head Cap Screw M8x70L 2
67 23337-82 Wiper - Bedway (Right, Front) Rubber 25-0335 1
68 24714 Gib - X Axis FC30 25-0217 1
69 17-0321-00 Screw - Adjusting S30C 2
70 Socket Head Cap Screw M8x25L 4
71 25-0201 Saddle FC25 1
72 Socket Head Cap Screw M12x65L 4
73 23337-81 Wiper - Bedway (Left, Front) Rubber 25-0334 1
74 24704 Ballscrew - Z Axis SCM415 25-0310 1
75 Cover - Bearing AVH7205 1
76 23940 Bearing Set - Angular Contact Ball 7205 BECBP 2
77 16302 Spacer S45C 1
78 24A-0308 Seat - Bearing S45C 1
79 Socket Head Cap Screw M8x25L 4
80 16452 Nut - Clamp S45C
81 24A-0216 Cone Clamping Element Brass 1
82 16983-1 Pulley-ballscrew Aluminum 1
83 98481A090 Woodruff Key #3 (1/8"x1/2") 1
84 W01 Lock Washer
85 N01 Lock Nut
86 Set Screw M5x10L 3
87 Socket Head Cap Screw 10-32x3/4" 1
88 Socket Head Cap Screw M12x35L 4
89 400-5M-15 Belt - Z Axis 400-5M-15 1
90 Pulley Aluminum 5M-30T 1
91 Socket Head Cap Screw 1/4-20UNCx30L 4
92 Washer - Flat 1/4" 4
93 Washer -Spring 1/4" 4
94 77USDA-0304 Base - Motor - Z Axis FC30 1
95 16775-1 Motor - Z Axis Servo 1
96 25-0223 Cover Plate (Front) SS41 1
I01153.xls
N04(ϕ20x16UNF)
ϕ19x16UNF
W01 (ϕ12)
N01 (ϕ12x32UNF)
1
1
1
1
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5.1.15 Headstock Taper Adjustment
The headstock may be adjusted to remove turning taper if the taper is caused by a lack
of parallelism of the headstock to the bed ways. Ensure that the level of the bed is
correct prior to any headstock adjustments.
To adjust the headstock alignment, loosen the four socket head cap screws that attach
the headstock housing to the bed. Using the adjusting screw located at the rear of the
headstock, (See Figure 18) adjust the headstock position in the direction necessary to
remove the taper. Note that the headstock will pivot about a pin located between the
two front attaching screws. Tighten the attaching screws and test for taper.
Figure 18
Headstock Alignment
5.1.16 Spindle Bearing Preload
1. Run the lathe for 10 minutes to insure the bearings are lubricated and slightly
warmed. Run the lathe at 500 RPM.
2. For the 1630 you will need to remove the spindle motor belt because this machine
does not have a neutral. Using the torque wrench, measure the spindle rolling
torque. The acceptable range of rolling torque is around 1.1 – 1.7 N-m. Note that
the torque required to start (“breaking away torque”) the spindles rotation will be
higher.
3. Loosen the three setscrews on the spindle-adjusting nut. The spindle adjusting nut
on the 1630 is outside the gearbox so the headstock access cover will not need to be
removed.
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4. Torque too low: With a spanner wrench tighten the adjusting nut. Measure the
rolling torque and repeat until 1.1 – 1.7 N-m. of rolling torque is achieved. Tighten
the three setscrews to retain the adjustment.
5. Torque too high: With a spanner wrench loosen the adjusting nut two full turns.
Place an aluminum block over the end of the spindle and with a hammer drive the
spindle forward until it is loose. (Near zero rolling torque) With a spanner wrench
tighten the adjusting nut. Return the speed selection lever to the neutral position.
Measure the rolling torque and repeat until 1.1 – 1.7 N-m. of rolling torque is
achieved. Tighten the three setscrews to retain the adjustment.
5.1.17 Aligning Tailstock to Spindle (See Figure 19)
If there is taper appearing on the workpiece while machining by using the tailstock, the
tailstock will need to be realigned to the spindle. Follow these steps:
1. Insert a mandrel between the spindle and tailstock, attach a base of a dial indicator
to the saddle, apply the needle of the indicator to the surface of the bar, then move
the saddle through the longitudinal travel. Take the measurement of its maximum
difference from end to end for later adjustment.
2. Release the 2 bolts labeled “A” in the drawing.
3. Release the screw labeled “B”.
4. Adjust using the 2 opposing screws “C” until the tailstock is aligned with the spindle.
5. Tighten screw “B” first and then lock “A”.
I00515
Figure 19
Tailstock Alignment
5.1.18 Spindle Motor Wiring
The 1630SX spindle motor is wired for 415 volts in the configuration. The wiring
consists of 3 phase power for the motor and 110 V power for the spindle motor fan.
Please see the diagram found on the motor junction box cover for wiring information.
Each machine does however use a different spindle motor and pulley combination.
Each junction box contains 6 terminals. The terminals should be jumpered together as
shown in the figure. Connect the incoming 3 phase power to the terminals. Make sure
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to hook up the wires in the same terminals after the replacement motor is installed.
Failure to do so may run the motor in the wrong direction.
The spindle motor fan wires are also found in the junction box. There is 1 hot wire, 1
neutral wire and 1 ground wire. The hot and neutral wires are connected as shown for
each motor. It does not matter which wires are connected to the hot and neutral wires.
All grounds from each cable are connected to either of the screws labeled ground.
5.2 Maintenance
5.2.1 Gib Adjustments
The objective of adjusting the gibs is to eliminate as much play in the table, saddle and
ram sliding surfaces as possible without having the tightness of the gib interfere with
their free movement and cause a decrease in the accuracy and/or performance of the
machine due to excessive friction.
5.2.1.1 Cross Slide Gib Adjustment
1. Mount a dial indicator on the carriage and measure the slop in the cross
slide. The dial indicator should be mounted a few millimeters in front of the
tool post. (Note: this should be where the gibs are worn the worst.).
2. Try to move the cross slide back and forth to measure the amount of play.
The dial indicator should only move between a 0.005 mm and a 0.01 mm. If
it moves more than this then tighten the gibs.
3. Turn the X-axis ball screw with a torque wrench and measure the torque.
The torque should be less than 1.7 N-m. and consistent over the travel of
the X-axis. If the measurement is higher than this then loosen the gib.
Make sure the cross slide is aligned properly. One easy way to check for this
is to remove the yoke bolts and see if the yoke springs back into position.
Misalignment is also evident if the torque is higher when the yoke is up
against the rear bearing housing.
4. You can also check the gib by taking out the yoke screws on top of cross
slide.
5. Tighten gib screw and move cross slide back and forth. It should feel
somewhat tight, but not to the point where it is hard to move.
(See Figure 20)
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Figure 20
X Axis Gib Adjustment
5.2.1 2 Z-Axis Gib Adjustment
.
1. Mount a dial indicator on the Z-axis ways and locate on top of the carriage.
(See Figure 21)
2. Lift the carriage up to measure the amount of play. The dial indicator should
not move more than 0.025. If it moves more tighten the gibs. Make sure
not to over tighten the gibs.
3. This procedure with the dial indicator will need to be done in the front and
rear of the saddle.
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Figure 21
Z-Axis Gib
5.2.2 Calibration & Backlash Constants
Calibration and backlash constants were set as part of the installation and set-up of your
system. They should be re-set when indicated in the Troubleshooting section or after
the replacement of the computer module, or any parts of the drive train.
Calibration is used teach the machine a known distance. We typically calibrate our
machines over a 150 mm distance. There is no limit to how far you can calibrate the
machine.
5.2.2 1 Calibration .
NOTE: Calibration usually is only done after replacing a computer module or adjusting
the drive train.
1. Recheck machine level and adjust as necessary.
2. Press the “SERV CODE” soft key.
3. Input 123 on the keyboard, then press the “INC SET” key.
4. Input the “X” key to tell the control the x-axis is being calibrated.
5. Place the .002 mm indicator in the spindle and set up the metric standard on the
cross slide. Make sure the standard is parallel to the cross slide by using a
combination square. Ensure that the standard is set up so that the readings will be
taken with the cross slide extended towards the operator and moving in towards the
motor end of the x-axis.
6. When the indicator is zeroed at the beginning of the standard press the “INC SET”
key.
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7. Move the cross slide towards the motor side of the x-axis until the indicator zeros on
the end of the 150mm standard. Input 300mm when control prompts for a standard
length.
8. If the calibration was successful the screen will return to the set up screen.
9. Press the “SERV CODE” soft key.
10. Input 123 on the keyboard, then press the “INC SET” key.
11. Press the “Z” key to tell the control that the z-axis is being calibrated.
12. Set up the metric standard in a chuck in the spindle.
13. Set up the magnetic base and .002 mm indicator on the cross slide.
14. When the indicator is zeroed at the beginning of the standard press the “INC SET”
key.
15. Move the saddle away from the chuck until the indicator zeros on the end of the
standard, then press the “INC SET” key.
16. Input 150 on the keyboard.
17. If the calibration is successful the screen will change to the set up screen.
Figure 22
Calibration Set-Up
5.2.2 2 Backlash Compensation .
Code 127: Calculate X or Z Backlash Constant
Every mechanical system has at least a little backlash or lost motion. It is produced by
the small amount of play between the gibs and ways, and mostly by the accumulative
bending or elasticity of all the parts of the drive train under load. The backlash constant
is factory set, but may need to be adjusted periodically.
1. Set a .002-millimeter dial indicator in the spindle, and touch off on a block or the
vise along the direction (X or Z) you wish to check, or set the backlash constant.
2. Turn on the ProtoTRAK and at the Main Menu, follow the procedure below precisely:
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Conversation Says You Do
a. --- a. Press MODE
b. Select Mode b. Press SET UP
c. Select c. Press SERV CODES
d. Select d. Press “B”
e. Select Code 127 e. Press X or Z
f. Backlash Value = _ _ _ _ f. What is shown is the current value.
Follow the instruction on the screen
and press the appropriate soft keys.
Wait a few seconds between each
INCR VALUE or DECR VALUE
press.
g. The following is an example of what you
might see when running this code.
For example, if the up and down "Oscillation
Value" shown in the conversation line is .00278
millimeters, and the dial indicator is moving
back and forth .0012, then the true backlash
value is .00278 -.0012 = .00158 millimeters.
Input this by pressing MODE, SET UP, SERV
CODE, 128, SET and then .00158, SET,
RETURN.
3. The X backlash identified and stored in Step 2 should be less than 0.05 mm on a new
machine. If it is appreciably larger, inspect the drive train for loose bolts, brackets,
bearings, etc.
The backlash can also be found manually with a 0.002 mm indicator with the following
method.
• Load the indicator to zero from one direction and zero out the DRO.
• Move the indicator to 0.05 mm and then back to zero. Do not over shoot 0,
otherwise start over.
• Whatever number appears on the screen is the backlash value.
• Enter this value into service code 128.
• After entering this number redo the process. The DRO and indicator should
now both read 0.
CODE 128: Input Backlash Constant
Code 128 allows you to enter the backlash values for each axis. It displays the value
after it enters.
Be sure not to enter too much backlash on any given axis. Too much backlash in the
system may cause bi-directional repeatability problems or axis motor searching.
5.2.3 Lubrication
5.2.3.1 Headstock Lub ication r
The 1630 has a manual oil pump that is run off of the spindle through a gear. One
of the oil lines pumps oil to a site glass located on the headstock. Periodically
check to see that oil is flowing. For the 1630, the oil should be flowing when the
spindle is on only.
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A drain plug is found on the machine to drain the headstock. Oil can be added to the
reservoir by a plug in the top of the headstock cover or by removing the cover and
pouring it into the headstock. There is a level site glass located under the spindle cover.
The headstock reservoir holds approximately 9.5 liters for the 1630. Fill the headstock
with Mobil DTE 24 oil or an equivalent grade.
The headstock gearbox oil must be drained and flushed after the first 150 hours of
operation. A small percentage of kerosene may be added to the gearbox to flush
out dirt and sediment. Operate the machine for several minutes without load so
that the flushing oil can circulate through the reservoir and remove the dirt. The
flushing oil must then be drained and new oil added. Do not flush with solvents
that will soften the paint. Thereafter, the oil should be flushed and drained every
1500-2000 hours of operation.
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Figure 23
1630SX Lubrication
5.2.3.2 Tailstock
Three oilers located on top of the spindle housing lubricate the spindle and screw. The
bedways on which the tailstock slides should be cleaned and oiled frequently.
Figure 24
Tailstock Oil
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5.2.3 3 Miscellaneous Information .
For all oilers on the machine, use medium S.A.E. NO. 30 machine oil. Before filling
reservoirs or oil cups, always wipe off with a clean rag any accumulation of old oil,
grease or dirt that might get into a part being lubricated.
Do not mix detergent type automotive oil, or multi-purpose oils with the regular
grade of S.A.E. No. 30 lubricating oil.
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6.0 Indexer Options
6.1 Dorian Indexer Option
6.1.1 Field Installation Instructions
1. Turn power on to the machine.
2. Verify air has been hooked up to the machine. The air regulator is mounted to the
bottom left of the electrical cabinet.
3. Make sure the on/off switch on the white box on top of the chip guard is turned on.
When it is on a green light will be illuminated.
4. Go to SETUP mode under TOOL GROUPS to verify the indexer softkey is activated. Then
press the INDEXER key to activate the indexer. It will turn gray when activated.
5. Go to DRO mode and press TOOL # and enter a number from 1 to 8. The indexer
should move to this tool number. The tool number on the indexer is found right above
the tool slot. If the tool # in the control and on the indexer is in the wrong position,
enter Service Code 147 to re-initialize the indexer.
6. To verify the indexer is working properly run a program with all 8 tools. To run the
program, enter a home position in Setup Mode. Make sure you set the X and Z absolute
zero position 300 – 450 mm from the chuck. Set the home position to X = 3 and Z = 3.
Run a program and make sure the indexer moves to the correct tool stations
programmed. Verify that the indexer positions to each tool station. If there is a problem
refer to the troubleshooting section.
6.1.2 Removing the Indexer from the Lathe
1. Turn the main power off to the machine.
2. Unhook the air line from the air regulator.
3. Disconnect 2 air lines and 2 electrical lines. The 2 air lines need to be disconnected at the
white box that is mounted on the top of the chip enclosure. The fittings are the quickdisconnect type where you push in on the connector and pull the air lines loose. One electrical
cable needs to be removed from the white electrical box and one cable from the black electrical
box. All four connections to the indexer are inside a flexible black conduit. (See Figure 26) at
the end of this section for layout of cable connections.
4. Unhook the black cable from the brackets that run on top of the chip enclosure.
5. Remove the cabling that goes runs across the crosslide.
6. Remove the indexer from the cross slide. It is fastened down with 6 socket head cap screws to
the riser block. Remove the riser block from the cross slide. You may want to remove the
indexer and riser block assembled together but it may be difficult to slide the whole thing out of
the T-slots. Be careful, the indexer weighs approximately 36 kg.
7. To re-install the indexer, follow these steps in reverse order. Make sure you install the
riser block at least 57 mm from the front of the cross slide, not the front bracket. Failure
to do this will cause the indexer to hit the sliding door when the cross slide is all the way
toward the operator.
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6.1.3 Troubleshooting the Indexer
The following fault messages will appear on the screen when there is a problem with the
indexer. There are also LED's in the black box on top of the chip guard that may be helpful
when troubleshooting the indexer. Please refer to that section below.
Fault 85 – Impossible Tool Position
•
This message will appear if the indexer goes to a tool number that you did not select.
For example, the operator chose Tool 2 and the indexer went to Tool Station 6. To fix
this problem, re-initialize the system by choosing Service Code 147. If this does not
solve the problem, refer to the LED troubleshooting section.
Fault 86 – Indexer Power Problem
•
This message will appear if the power is interrupted to the indexer. It could indicate that
no power or low power is getting to the indexer. The black box on top of the chip
enclosure receives 115V power from the main electrical cabinet and sends it to the white
box. From there it is reduced to 24V by a power supply in the black box and reduced
to12V in the white box by a transformer. If there is a power problem you will need to
back track to find out where the power is being interrupted. If voltage drops outside of
the 20–28 volts range in the black box this message could also appear. To make sure
power is getting to the white box verify that the green light on the side of the box is
illuminated. If it is not, check the fuse next to the light.
Fault 87 – Indexer Air Pressure Problem
•
This message will appear if the air pressure sensor senses low air or no air pressure.
The recommended air pressure for the indexer is 552 kPa (80 psi). The air pressure
should be at least 483 kPa (70 psi) and no more than 1034 kPa (150 psi) for the indexer
to work correctly. Do not exceed 1034 kPa (150 psi). This will void the
warranty on the indexer. Check to make sure the air regulator is set to at least 552
kPa (80psi).
Fault 88 – Indexer Not Initialized
•
This message will appear if the indexer does not know its present position. An example
of this would be if the turret stops in the middle of a tool change. An interruption of
power or air may cause this fault. Pressing the E-stop button can also cause this
problem if the tool is not in a known position. Initialize with Service Code 147.
Fault 89 – Indexer Time Out
•
This message appears if the indexer does not get to position after a few seconds. This
may be caused by an internal problem inside the indexer such as a broken gear or
jammed component. Very low air pressure may also cause this fault. It should take no
longer than 2 or 3 seconds for the indexer.
6.1.4 Troubleshooting from LED's in Black Box
Inside the black box, which is mounted on top of the chip enclosure, there is an LED that
signifies indexer position. It reads numbers from 1 to 8. There are also directional LED's to
signify how far and in what direction the indexer is told to rotate by the control. Remove the
lid from the box in order to see the LED's. The number in the black box should correspond
to the tool number of the indexer. If these numbers are different, re-initialize the indexer
with Service Code 147. The directional LED's will be helpful in verifying that the command
from the control is getting to the black box and to the indexer. If the command is getting to
the black box but not the indexer, there is a problem with the indexer. For example, if you
command the indexer to move from Tool 1 to Tool 3 the LED for -90° should light up for a
second. When facing the indexer, the rotation of the turret in a CW direction signifies a
negative move and a CCW move signifies a positive move. Since the indexer takes the
shortest path between tool changes, it can only move 45, 90, 135 in the positive direction,
and 45, 90, 135 in the negative direction.
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6.1.5 Indexer Encoder Re-Alignment
This procedure is necessary only if the indexer does not return to a true home position after
initializing with Service Code 147. If the encoder is misaligned the turret will consistently be
off by some angle. In order to perform the operation it may be necessary to use two people.
One will adjust the encoder while the other watches the strobe 2 light inside the black box
on top of the chip enclosure. If the encoder is misaligned, a LED labeled strobe 2 will be lit.
1. Remove the 4 screws that hold the back cover onto the indexer. The encoder is mounted to
the far right of the indexer if you are at the front of the machine and facing it. Please refer to
the Dorian manual that is included with the machine for an illustration.
2. If initialization does not work, attempt to index the indexer until it sits in a true position.
A true position means the tool stations are parallel to the crosslide. This can be done by
reversing the air lines on the indexer. Reverse the blue and red air lines and then use a
breaker bar or piece of square stock to rotate the turret manually to a true position.
Make sure to reverse the air lines back when complete. It will be obvious when the
indexer is back to a true position. The indexer moves in approximately 15° increments.
3. Using an allen wrench, loosen the set screw holding the encoder onto the shaft.
4. Rotate the encoder with the allen wrench until the strobe 2 light turns off in the black
box. Carefully tighten down the setscrew making sure not to move the encoder. If the
encoder moves, the number in the box will disappear and it will be necessary to re-align
the encoder.
5. Reassemble the unit.
6.1.6 Indexer Maintenance
Dorian recommends that the indexer be lubricated twice a year after the first year. The
worm and worm gear should be lubricated with quality lithium based grease every 6 months
after the first year. Remove the side cover, top cover and stepper motor and grease the
gears. When re-mounting make sure the O-ring and side seal are intact so that no coolant
can enter the turret. Refer to the Dorian manual that is supplied with each machine for more
information and drawings.
6.1.7 Warranty Issues
Dorian warrants the Dorian Indexer for 1 year. If it is determined that there is a problem
with the indexer it will need to be sent back to Dorian for repair. Please refer to the Dorian
manual that was shipped with the indexer.
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Figure 25
Indexer Mounting
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Figure 26
Indexer Cable Routing
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Dorian Indexer Spare Parts List
Item P/N Title
1 22852 CABLE ASSY-DORIAN POWER INDEXER
2 22556-15 CABLE ASSY-PT4-PARALEL PORT-EB TO PENDANT
3 21615 INDEXER ASSY - MODIFIED DORIAN – 20 mm
4 21604 CABINET ASSY-DORIAN INDEXER INTERFACE
5 21630 INTERFACE BOX – DORIAN - WHITE
6.2 4 Tool Indexer Option
6.2.1 Field Installation Instructions
1. Turn power on to the machine.
2. Go to SETUP mode under TOOL GROUPS to verify the indexer softkey is activated. Then press
the INDEXER key to activate the indexer. It will turn gray when activated.
3. Run service code 147 to initialize the indexer.
4. Go to DRO mode and press TOOL # and enter a number from 1 to 8. The indexer
should move to this tool number. The tool number on the indexer is found on top of
each tool.
5. To verify the indexer is working properly run a program with all 4 tools. To run the
program, enter a home position in Setup Mode. Make sure you set the X and Z absolute
zero position 305 to 457 mm from the chuck. Set the home position to X = 3 and Z = 3.
Run a program and make sure the indexer moves to the correct tool stations
programmed. Verify that the indexer positions to each tool station. If there is a problem
refer to the troubleshooting section.
6.2.2 Removing the Indexer from the Lathe
1. Turn the main power off to the machine.
2. Disconnect 2 cables from the black box mounted on top of the lathe. See Figure 29 at the end
of this section for layout of cable connections.
3. Unhook the black cable from the brackets that run on top of the chip enclosure.
4. Remove the cabling that goes runs across the crosslide.
5. Remove the indexer together with the mounting base from the cross slide. It is fastened down
with 4 socket head cap screws to the crosslide. Be careful, the indexer weighs approximately
32 kg.
6. To re-install the indexer, follow these steps in reverse order. Make sure you install the
riser block at least 57 mm from the front of the cross slide, not the front bracket.
Failure to do this will cause the indexer to hit the sliding door when the cross slide is all
the way toward the operator.
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6.2.3 Troubleshooting the Indexer
The following fault messages will appear on the screen when there is a problem with the
indexer. There are also LED's in the black box on top of the chip guard that may be helpful
when troubleshooting the indexer. Please refer to that section below.
Fault 85 – Impossible Tool Position
This message will appear if the indexer goes to a tool number that you did not
select. For example, the operator chose Tool 2 and the indexer went to Tool Station
3. To fix this problem, re-initialize the system by choosing Service Code 147.
Fault 86 – Indexer Power Problem
This message will appear if the power is interrupted to the indexer. It could indicate that
no power or low power is getting to the indexer.
Fault 87 – Indexer Air Pressure Problem
This message will appear if the air pressure sensor jumper is faulty on the black
cable breakout box on top of the lathe.
Fault 88 – Indexer Not Initialized
This message will appear if the indexer does not know its present position. An example of
this would be if the turret stops in the middle of a tool change. An interruption of power or
air may cause this fault. Pressing the E-stop button can also cause this problem if the tool
is not in a known position. Initialize with Service Code 147.
Fault 89 – Indexer Time Out
This message appears if the indexer does not get to position after a few seconds.
This may be caused by an internal problem inside the indexer such as a broken gear
or jammed component. Very low air pressure may also cause this fault. It should
take no longer than 2 or 3 seconds for the indexer.
6.2.4 Troubleshooting the Cable Breakout Box
The following describes the inputs and outputs from the PLC used to run the 4 tool indexer.
6.2.4.1 PLC Inputs
There are 8 inputs to the PLC, 7 of which are used for the 4 tool indexer. For inputs 1
through 4, the corresponding LED light will be on depending on which tool is in position. In
other words, when the indexer is locked for tool 1, the I1 LED on the PLC will be lit. For
inputs 5, 6 and 7, the LED light for these will only be on for a second or so when a new
command is sent to the PLC from the control. A change of tool in DRO mode or within a
program will cause these lights to come on. See further below for which lights will come on
when changing tools.
I1 = Turret proximity sensor position #1
I2 = Turret proximity sensor position #2
I3 = Turret proximity sensor position #3
I4 = Turret proximity sensor position #4
I5 = Select #1
I6 = Select #2
I7 = Select #3
I8 = not used
I1 - I4 is from the 4 tool indexer - identifies turret position
I5 - I7 is from the control - identifies index command
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The 3 select lines gives us 8 possible incremental moves as follows. A few examples have
also been given.
+1 tool (select 1 and 2) For example, if you command the indexer to move 1
tool position, like from tool 2 to 3, you will see the select 1
and 2 lights come on briefly.
+2 tools (select 2)
+3 tools (select1) For example, if you command the indexer to move 3 tool
positions, like from 1 to 4, you will see the select 1 light
come on briefly.
+4 tools (select 1, 2, and 3) – tool stays where it is
-1 tool (select2 and 3)
-2 tools ( select 1 and 3) For example, if you command the indexer to move from tool
4 to tool 2,you will see the select 1 and 3 lights come on
briefly.
-3 tools ( select 3)
don’t move ( nothing active) this means no commands were sent, therefore no lights
come on.
The following table reflects the description above:
ITEM
SELECT 1 1 0 1 1 0 1 0 0
SELECT 2 1 1 0 1 1 0 0 0
SELECT 3 0 0 0 1 1 1 1 0
+ 1 Tool + 2 Tools + 3 Tools + 4 Tools - 1 Tool - 2 Tools
6.2.4.2.1
There are 6 outputs from the PLC to the 4 tool indexer.
Q1 = Motor on - fwd direction This light will be on when the indexer motor is
Q2 = Motor on - rev direction This light will be on when the indexer motor is
See the table below for the bit patterns for corresponding tools.
Q3 = Bit #1
Q4 = Bit #2
Q5 = Bit #3
Q6 = Bit #4
Q1 & Q2 goes to the motor driver PCB
Q3 - Q6 goes to the control - identifies position feedback to control
The following table reflects the meaning of the bit signals back to the control. Keep in mind
that the 4 tool indexer reports back up to 4 absolute positions to the PLC and the PLC will
output up to 8 absolute positions back to the control.
PLC Outputs
running forward
running reverse
- 3
Tools
DON’T
MOVE
ITEM TOOL 1 TOOL 2 TOOL 3 TOOL 4 TOOL 5 TOOL 6 TOOL 7 TOOL 8
BIT 1 1 0 1 0 1 0 1 0
BIT 2 0 1 1 0 0 1 1 0
BIT 3 0 0 0 1 1 1 1 0
BIT 4 0 0 0 0 0 0 0 1
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You can verify the bit pattern below by getting a voltmeter and seeing if a 5 volt signal is
present when a bit reads 1 in the above table. For example, if the indexer is physically on
tool 3, bits 1 and 2 should read 5 volts and bits 3 and 4 should read 0 volts. This procedure
is best done when checking the inputs 1 through 4 above with the outputs.
To measure a bit with your voltmeter you will need to do the following. For example, for bit
1, place you meter across Q3 on the PLC and a ground point.
6.2.4.3
Please see the following drawing for an illustration of how the pots are to be adjusted on the
motor driver board in the cable breakout box. The flat part of the pot should be in the
location shown in the figure. Customer service may require a visual inspection of these
settings. Also, please verify the position of 2 switches on the motor drive board.
Do not adjust any of these settings. This may cause the indexer to not run correctly or not run
Motor Driver Settings
at all and will void the warranty of the hardware.
CAUTION!
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Figure 27 Figure 27
Motor Driver Adjustments & PLC Inputs and Outputs
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Figure 28
Indexer Cable Breakout Box Mounting - 1630
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Figure 29
4 Tool Indexer Cable Routing
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4 Tool Indexer Spare Parts List
Item P/N Title
1 23720 CABINET ASSY-4 TOOL INDEXER
2 23719 MOTOR ASSY-4 TOOL INDEXER
3 23718-3/4 INDEXER ASSY-MODIFICATION-4 TOOL INDEXER-20 mm
4 23771-M10 T-HANDLE – 20 mm 4 TOOL INDEXER
5 23872 SQUARE HEAD SCREW M10 – 20 mm 4 TOOL INDEXER
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7.0 Drawings & Parts Lists
Figure 30
Lathe Apron Assembly
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Lathe Apron Assembly Parts List
Item P/N Title UseAs Qty
1 20082-2 ELECTRONIC HANDWHEEL-X-AXIS TRL EA 1
2 20082-3 ELECTRONIC HANDWHEEL-Z-AXIS TRL EA 1
3 20295 JOGSTICK-ASSY EA 1
4 21046 HOUSING & PANEL ASSY. HANDWHEEL (VER: II) EA 0
5 M4-0.7X16 25B SCREW-SHCS-STL-BO EA 3
6 M6-1.0X12 25B SCREW-SHCS-STL-BO EA 8
i00518
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Figure 31
1630 Machine Assembly
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Figure 32
1630 Machine Assembly
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Figure 33
1630 Machine Assembly
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1630 Machine Assembly Parts List
1630 Overall Machine Parts List
Item Parts No. Description Material Specification Q’ty
1 25-0707 Electrical Control Box Door SS41 1
2 24-0748 Seat - Switch SS41 1
3 24-0735 Cover - Protection SS41 1
4 25-0706 Electrical Control Box SS41 1
5 25-0704 Guard - Protection SS41 1
6 25-0721 Safety Door SS41 1
7 24693 Glass - safety 25-0722 1
8 21241-36 Handle - Door Rubber 2
9 25-0711 Cover Plate SS41 1
10 24694 Belt Set – Spindle Motor (3 belts) A-76” 1
11 25-0674 Left Stand Casting FC25 1
12 50-0676 Bracket - Motor FC25 1
13 50-0677 Shaft S45C 1
14 50-0678 Plate - Motor FC25 1
15 Screw - Adjusting S45C M20x2.5x220L 1
16 Hexagon Nut M20x2.5 3
17 50-0681 Spherical Washer (Concave) SS41 2
18 50-0682 Spherical Washer (Convex) SS41 2
19 25-0733 Stand En d Cover SS41 1
20 24695 Motor - Spindle 1
21 25-0731 Headstock Plate SS41 1
22 24-0716 Anti-Leaking Cover SS41 1
23 O-Ring G220 1
24 O-Ring G250 1
25 Socket Head Cap Screw M6x12L 6
26 22714-26
23341
27 25-0701 Guard - Protection SS41 1
28 24-0741 Base Rear Cover SS41 1
29 23265 Pump – Coolant 1/8HP 1
30 24-0742 Seat - Pump SS41 1
31 25-0675 Right Stand Casting FC25 1
32 25-0723 Coolant Tank SS41 1
33 25-0734 Chip Tray SS41 1
34 25-0732 Base Cover Plate (Front) SS41 1
35 25-0705 Cover SS41 1
36 25-0712 Cover – Protection - Ballscrew SS41 1
37 25-0724 Operation Box Cover SS41 1
38 24-0703 Protection Guard SS41 1
39 Socket Head Cap Screw M6x16L 6
40 77A-0615 Upper Roller Setting Base SS41 3
Tube – Lamp
Bulb - Worklight
A-W515DB 1
1
1630 Overall Machine Parts List
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