prototrak DPMSX2, SX3 Maintenance Manual

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Page 1

TRAK

DPMSX2, SX3 & SX5

Safety, Installation, Maintenance, Service & Parts List Manual

Document: P/N 24317 Version: 060311

Southwestern Industries, Inc

P. O. Box 9066 Compton, CA 90224-9066 USA T | 310.608.4422 | F | 310. 764.2668

Service Department: 800.367.3165

e-mail: sales@southwesternindustries.com | service@southwesternindustries.com |web: southwesternindustries.com

Rancho Dominguez, CA 90220-5610 USA

Plant location: 2615 Homestead Place

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Copyright

publication may be reproduced, stored in a retrieval system , or transmitted, in any form or by any means, mechanical, photocopying, record ing or otherwise, without the prior written permission of Southwestern Industries, Inc.

While every effort has been made to include all the information required for the purposes of this guide, So uthwestern Industries, Inc. assumes no responsibility f o r inac curacie s or omission and accepts no liability for damages resulting fr om the use of the information containe d in this guide.

All brand names and products are trademarks or registered trademarks of their respective holders.

Southwestern I ndustries, Inc.

2615 Homestead Place Rancho Dominguez, CA 90220-5610 Phn 310.608.4422

 Fax 310.764.2668

Service Department

Phn 800.367.3165

 Fax 310.886.8029

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1.0 Safety 1

1.1 Safety Publication s

1.2 Danger, Warning, Caution, Note Labels & Notices as Used in this Manual

1.3 Safety Precautions

2.0 Installation 6

2.1 Floor Plan, Layout & Space Requirements

2.2 Uncrating

2.3 Shortages: Inventory Checklist

2.4 Installation Instructions & Checklist

2.5 Machine Specifications

2.6 Maximum Work Capacities

2.7 ProtoTRAK SMX Control Hardware

2.8 Lifting and/or Mov in g th e M a ch ine

2.9 Releasin g the He a d Counterw e ig h t Supports

2.10 Cleaning

2.11 Leveling: Tolerance for DPMS is .0005”/10”

2.12 Electrical Connection

2.12.1 Phase Converters

2.12.2 FlangeDisconnect/Transformer – Non Spindle Con tr ol

2.1.2.3 Flange Dis c on nect/T rans f or mer – Spindle Control

2.13 Air Connection - Optional

2.14 Mounting the Display Pendant

2.15 Cable Interconnections

2.16 Lubrication

2.16.1 Way Lubrication

2.16.2 Head Lubrication TRAK Bed Mills

2.17 ProtoTRAK SMX Euclid Block Procedure

3.0 Troubleshooting by Symptom 40

3.1 Problems Relating to Machining Results

3.1.1 Poor Finish

3.1.2 Circles Out of Round

3.1.3 Taper Cut on a Programmed

Straight Line Move

3.1.4 Par ts Have Incorr e c t Di mensions

3.2 Problems Regarding Motion of Machine

3.2.1 Run Away Axis

3.2.2 Slow Down Axis

3.2.3 Axis Will Not Jog

3.2.4 Axis Motor Motion Is Not Smooth

3.2.5 Vibration in Motion

3.2.6 Searching Axis

3.3 Problems Relatin g to Operati on of Control

3.3.1 Display Blanks

3.3.2 Bad Picture on Display

3.3.3 Keyboard Lockup

3.3.4 Fault X, Y or Z

3.3.5 Proble ms Readin g Fl oppy Disk

3.3.6 System Will Not Turn on or

Boot Up

3.3.7 System Reboots by Itself

3.3.8 System Shuts Off

3.3.9 Will Not Hold Ca librati on

3.3.10 Auxiliary Functions Not Working

3.3.11 E-Stop Error

3.3.12 Limit Switch Error

3.4 Problem with the Measurements

3.4.1 X, Y & Z-Axis Measu re m ents Do Not Repeat

3.4.2 X, Y & Z-Axis Measu re m ents Are Not Accurate

3.4.3 The DRO Is Not Counting

3.4.4 X, Y & Z-Axis DRO Cou nti n g in Wrong Direction

3.4.5 X, Y, & Z-axis Elect ri c Handwhe els Turn in Wrong Direction

3.5 Problems with the Machine Tool

3.5.1 Z-Axis Noisy

3.5.2 Spindle Stal ls o r Tu rn s Off Dur in g Machining

3.5.3 Spindle Motor Hums or Will Not Run

3.5.4 Spindle Runs Backwards

3.5.5 Head Noise

4.0 Diagnostics 59

4.1 The Machine Tool & Set-Up

4.1.1 The Milling Machine Checklist

4.1.2 A Special Word About X/Y/Z Gibs

4.1.3 Lubrication

4.1.4 Machining Set-Up

4.2 The Mechanical Drive Train (X, Y)

4.2.1 DPMSX2/3 Ballscrew Alignment

4.2.2 DPMSX5 Ballscrew Alignment

4.3 Computer/Pendant Diagnostics

4.3.1 Checking Floppy Drive

4.4 Motor Diagnostics

4.4.1 Cable Connections

4.4.2 To Check the Moto r En co der s

4.4.3 Enc oder Counts to Pendant

4.4.4 Moving Problem From One Axis to Another

4.5 Servo Drivers

4.6 Glass Scales

4.6.1 Alignment of Scales

4.6.2 Measurements Do Not Repeat

4.7 TRAK Sensors

4.7.1 Faulting Axis

4.7.2 Measurements Do Not Repeat

4.8 Electrical

4.8.1 Checking A/C Voltage

4.8.2 Checking Fuses

4.8.3 Cable Breakout Box Connections

4.8.4 Cable Connections

4.8.5 Electrical Box Schematic

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TRAK DPM SX2, SX 3 & SX5 Safety, Installation, M aintenance, Service & Parts List Manual

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4.9 Service Codes

4.9.1 Software Codes

4.9.2 Machine Set-up Codes

4.9.3 Diagnostic Codes

4.9.4 Operator Defaults/Options Codes

5.0 Procedures for Replacements

& Maintenance 84

5.1 Replacements

5.1.1 Servo Motor Replacement

5.1.2 Servo Drive r Replacem en t

5.1.3 Computer Module & LED/Enclosure Replac em ent

5.1.4 System Flash Dis k Rep lacemen t

5.1.5 Cable Routi ng on M achine

5.1.6 TRAK Sensor

5.1.7 Glass Scale Replacement

5.1.8 Power Drawbar

5.1.9 Ball Screw Replacement, X-Axis (Table), DPMSX2

5.1.10 Ball Screw Replacement, Y-Axis (Saddle), DPMSX2

5.1.11 Z-Ax is S c rew Remova l & Replacement

5.1.12 Ball Screw Replacement, X-Axis (Table)-DPMSX2

5.1.13 Ball Screw Replacement, Y-Axis (Saddle), DPMSX3

5.1.14 Ball Screw Replacement, X-Axis (Table)-DPMSX5

5.1.15 DPMSX5 X-Axis Handwheel Box

5.1.16 Ball Screw Replacement, Y-Axis (Saddle)-DPMSX5

5.1.17 Z-Axis Ball Screw Removal & Replacement

5.1.18 Air Sole noid Rep lacemen t

5.1.19 Spindle Motor Wiring

5.1.20 Feed Trip Adjustment

5.1.21 Quill Clock Sprin g Rep lacemen t & Adjustment

5.1.22 Spin d le M ot o r Re m ov a l & Replacement

5.1.23 Drive Belt Replacement

5.1.24 Timing Belt Replacement

5.1.25 Brake Shoe Replacement

5.1.26 Spindle Replacement

5.2 Maintenance

5.2.1 Gib Adjustments

5.2.2 Calibration & Backlash Constants

5.2.3 Head Rotation and Tramming

5.2.4 Limit Switch Option

6.0 Figures & Parts List 150

Fig. 1 Machine Footprin ts Fig. 2 Overall Dimensions Fig. 3 DPMSX3 Component Identification Fig. 4 DPMSX Rear View Fig. 5 Lifting the Machine , Meth od 1

Fig. 6 Lifting the Ma ch ine, Meth od 2 Fig. 7 Placement of Levels Fig. 8 Leveling Screws Fig. 9 Wiring the DPMSX2 . DPM SX3 & DPMSX 5 –

Non Spindle Control

Fig. 10-1 Wiring the DPMS X 2 , DPMS X 3 or DPM SX5

-Spindle Control

Fig. 10-2 Wiring the DPMS X 2 , DPMS X 3 or DPM SX5

-Spindle Control

Fig. 11 Flange Disconnect/Transformer Option – Non

Spindle Control

Fig. 12 Transformer Option Schematic – Non Spindle

Control

Fig. 12-1 Flange Disconn ec t/Tran sfo rm er Opti on – Spindle

Control Fig. 12-2 Transformer Option Schematic – Spindle Control Fig. 13 Air Regulat or /Soleno id Ass e mb ly Fig. 14 Pendant Cable Connections, Left Side Fig. 15 Pendant, Right Side Fig. 16 Cable Connection Diagram, Non-Spindle Control Fig. 17 Cable Connection Diagram w/Spindle Control Option Fig. 18 Euclid Block Fig. 19 Electrical Box Schematic – Non Spindle

Control Fig. 20 Schematic Diagra m of Spin d le Con tr ol Option Fig. 21 LED’s on Spindle Control Boar d Fig. 22 Servo Driver Replacement Fig. 23 Computer Module & LCD/Enclosure

Replacement Fig. 24 Flash Disk Replacement Fig. 25 M5 Base Mounting Fig. 26 TRAK Sensor Mounting Fig. 27 DPMSX2 Sens or Assembly Fig. 28 DPMSX3 Sens or Assembly Fig. 29 DPMSX5 Sens or Assembly Fig. 30 Z-Glass Scale Assembly Fig. 31 Glass Scale Alignment, DPMSX3 Fig. 32 Glass Scale Alignment, DPMSX5 Fig. 33 Power Drawbar Assemb ly Fig. 34 DPMSX2 X-Axis Dr ive Assembly Fig. 35 DPMSX2/3 Y- Ax is Dr ive T ra in Fig. 36 DPMSX2 Z-Axis Drive Train Fig. 37 DPMSX3 X-Axis Drive Assembly Fig. 38 DPMSX3 Y-Axis Drive Assembly Fig. 39 DPMSX5 X-Axis Dr ive Assembly Fig. 40 X Handwheel Drive Mechanism Fig. 41 DPMSX5 Y-Axis Drive Assembly Fig. 42 Z- Axis Drive Assembly Fig. 43 Spindle Mot or Wiring Fig. 44 Feed Trip Adjustment Fig. 45 Quill Cloc k Sp ring Replacemen t & Adjustment Fig. 46 Spindle Motor Removal & Replacement Fig. 47 Drive Belt Replacement Fig. 48 Spindle Replacement Fig. 49 Table Gib Adjustment Fig. 50 Table Gib Screw

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TRAK DPM SX2, SX 3 & SX5 Safety, Installation, M aintenance, Service & Parts List Manual

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Fig. 51 DPMSX5 Table Gib & Saddle Bottom Gib Adjustment Fig. 52 Saddle Side Gib Adjustment Fig. 53 Saddle Bottom Gib Adjustment

(DPMSX3 Only) Fig. 54 Ram Back Gib Fig. 55 Ram Side Gib Adjustment Fig. 56 Calibration Set-U p Fig. 57 Tramming of Head Fig. 58 1 Input Limit Switch Fig. 59 2 Input Limit Switch

List of Figures in Section 6 Figures 100 through 114 refer to DPMSX3 and DPMSX5 Machines Fig. 100 Top Housing Assembly Fig. 101 Gear Housing Sub Assembly Fig. 102 Hi-Low Slip Clutch Sub Assembly Fig. 103 Hi-Low Shift Clutch Sub Assembly Fig. 104 Pulley Pinion Sub Assembly Fig. 105 Lower Vari-Disc Dr ive Sub Assembly Fig. 106 Upper Vari-Disc Drive Sub Assembly Fig. 107 Speed Change Handwheel Sub Assembly Fig. 108 Spindle Motor Sub Assembly Fig. 109 Bottom Housing Assembly Fig. 110 Worm Gear Cradle Sub Assembly Fig. 111 Quill Feed Sel ec t or S ub Assembly Fig. 112 Quill Pinion Shaft Sub Assembly Fig. 113 Overload Clutch Trip Sub Assembly Fig. 114 Feed Revers e Clutch Sub Assemblies Fig. 115 Quill Spindle Sub Assembly

Fig. 116 Head Top Asse mbly w/Sp indle Control Option, DPMSX2, DPMSX3

& DPMSX5 Fig. 117 Electrical Enclosure Spindle Control Options, DPMSX2, DPMSX3

DPMSX5 Figures 117 through 131 refer to DPMSX2 Machines

Fig. 118 Top Housing Assembly Fig. 119 Gear Housing Fig. 120 Hi-Low Shift Clutch Sub Assembly Fig. 121 Hi-Low Shift Fig. 122 Pulley Pinion Fig. 123 Lower Vari-Disc Dr ive Sub Assembly Fig. 124 Upper Vari-Disc Drive Sub Assembly Fig. 125 Speed Change Handwheel Fig. 126 Spindle Motor Fig. 127 Lower Head Assembly Fig. 128 Worm Gear Cradle Fig. 129 Quill Feed Sel ec t or Fig. 130 Quill Pini on S ha ft Fig. 131 Overload Clutch Trip Fig. 132 Feed Reverse Clutch Fig. 133 Spindle Assembly Fig. 134 Lubrication Drawing-Pump

& Lube - DPMSX2

Fig. 135 Lubricat ion Draw ing - X & Y

Axis DPMSX Fig. 136 Coolant Pump Moun t ing Fig. 137 Lubricat ion Draw ing –X & Y Axi s

DPMSX3 Fig. 138 Lubricat ion Draw ing –X & Y Ax i s,

DPMSX5 Fig. 139 Manual Ram Elevation

iii

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TRAK DPM SX2, SX 3 & SX5 Safety, Installation, M aintenance, Service & Parts List Manual

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1.0 Safety

The safe operation of the TRAK DPMSX2, DPMSX3 & DPMSX5 depends on its proper use and the precautions taken by each operator.

• Read and study this manual and the ProtoTRAK SMX Programming, Operating, and Care Manual. Be certain 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 per OSHA 1910.212 - Milling Machine.

1.1 Safety Publications

Refer to and study the following publications for assistance in enhancing the safe use of this machine.

Safety Re quirements for Manua l Millin g, Drilling a n d Boring Ma c h in e s with or without Automatic Control (ANSI B11.8-2001). Available from The American National

Standards Institute, 1819 L Street N.W., Washington D.C. 20036 Concepts And Techniques Of Machine Safeguarding (OSHA Publication Number 3067).

Available from The Publication Office - O.S.H.A., U.S. Department of Labor, 200 Constitution Avenue, NW, Washington, DC 0210.

1.2 Danger, Warning, Caution, and Note Labels & Notices As Used In This Manual

DANGER - Immediate hazards that will result in severe personal injury or dea th. Dan ger labels

on the machine are red in color. WARNING - Hazards or unsafe practices that

damage to the equipment. Warning labels on the machine are orange in color. CAUTION - Hazards or unsafe practices, which

equipment/product damage. Ca ution labels on the m achine are yellow in color. NOTE - Call attention to specific issues requiring special attention or understanding.

before

its use.

could

result in severe personal injury and/or

could

result in minor personal injury or

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List Manual

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Safety & Information Labels Used On The

TRAK DPMSX2 , DPMSX3 & DPM SX5 Milling Machines

It is forbidden by OSHA regulations and by law to deface, destroy or remove any

of these labels

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List Manual

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Safety & Information Labels Used On The

TRAK DPMSX2 , DPMSX3 & DPM SX5 Milling Machines

It is forbidden by OSHA regulations and by law to deface, destroy or remove any

of these labels

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List Manual

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1.3 Safety Precautions

1. Do not operate this machine before the TRAK DPMSX2, SX3 & SX5 Installation, Maintenance, Service and Parts List Manual, and ProtoTRAK SM Programming, Operating & Care Manual have been studied and understood.

2. Do not ru n this machine without knowing the function of every control key, button, knob, or handle. Ask your supervisor or a qualified instructor for h elp when needed .

3. Protect your eyes. Wear approved safety glasses (with side shields) at all times.

4. Don't get caught in moving pa rts. Before operating this machine remove all jewelry including watches and rings, neckties, and any loose-fitting clothing.

5. Keep your hair away from moving parts. Wear adequate safety headgear.

6. Protect your feet. Wear safety shoes with oil-resistant, anti-skid soles, and steel toes.

7. Take off gloves before you start the machine. Gloves are easily caught in moving parts.

8. Remove all tools (wrenches, chuck keys, etc.) from the machine before you start. Loose items can become dangerous flying projectiles.

9. Never operate a milling machine after consuming alcoholic beverages, or taking strong medication, or while using non-prescription drugs.

10. 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, fixture, coolant nozzle or take

measurements

• Before you open safeguards (protective shields, etc.). Never reach for the part, tool, or fixture around a safeguard.

11. Protect your eyes and the machine as well. Don't use compressed air to remove the chips or clean the machine.

12. Disconnect power to the machine before you change belts, pulley, and gears.

13. Keep work areas well lighted. Ask for additional light if needed.

14. Do not lean on the machine while it is running.

15. Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant and obstacles of any kind around the machine.

16. Avoid getting pinched in places where the table, saddle or spindle head create "pinch points" while in mot ion.

17. Securely clamp and properly locate the workpiece in the vise, on the table, or in the fixture. Use stop blocks to prevent objects from flying loose. Use proper holding clamping attachments and position them clear of the tool path.

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List Manual

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18. Use correct cutting parameters (speed, feed, depth, and width of cut) in order to prevent tool breakage.

19. Use proper cutting tools for the job. Pay attention to the rotation of the spindle: Left hand tool for counterclockwise rotation of spindle, and right hand tool for clockwise rotation of spindle.

20. After an emergency stop, always turn the FORWARD/REVERSE switch to "Off" (STOP) before releasing or resetting the E-Stop.

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. Check the direction (+ or -) of movement of the table, saddle and ram when using the jog or power feed.

23. Don't use dull or damaged cutting tools. They break easily and become airborne. Inspect the sharpness of the edges, and the integrity of cutting tools and their holders. Use proper length for the tool.

24. Large overhang on cutting tools when not required result in accidents and damaged parts.

25. Handwheels must have the cra nk folded inside when using CNC programmed machining or rapid feeds, power feed or jog.

26. Prevent fires. When machining certain materials (magnesium, etc.) the chips and dust are highly flammable. Obtain special instruction from you supervisor before machin ing these materials.

27. Prevent fires. Keep flammable materials and fluids away from the machine and hot, flying chips.

28. Changing the speed of rotation of the spindle must be done while the rotation is on. It is recommended to stop and start the spindle at a low rate of speed.

29. Interlocked Table Guards. Interlocked table guards may be purchased from Southwestern Industries, Inc. if deemed necessary by the user.

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List Manual

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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 – DPMSX2, DPMSX3 & DPMSX5

Figure 1

Machine Footprints

DPMSX2 DPMSX3 DPMSX5

Footprint of Machin e 23.1” x 40.5” 24” x 44” 24” x 48.4” Weight (approximate) net 3200 lbs. 4100 lb. 4400 lb. Weight (approximate) shipping 3500 lbs. 4400 lb. 4700 lb. Pallet Size 70” x 70” 6’ x 6’ 6’ x 6’

A Overall width 101” 108” 136” B Overall length w/ electric box

door open C Bed width 23.125” 24” 24” D Bed width between leveling

screws E Distance between leveling

screws F Bed length 40.5” 43.3” 48.4”

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List

72” 76” 81”

20.5” 21.7” 21.7”

32.5” 18.1” 20.5”

Southwestern Industries, Inc.

Page 12

DPMSX2 DPMSX3 DPMSX5

G Height of table from bottom of

bed

H Maximum distance from

spindle nose to table

I Maximum height of machine

from bottom of bed to top of column cover.

J Height of machine from bottom

of bed to top of spindle motor

K Width of machine including

table

L Length of machine with electric

box door closed

Figure 2

Overall Dimensions

34” 38” 41”

23.5” 23.5” 23.5” 78” 85” 87”

89” 95” 98” 70” 73” 70” 64” 66” 71”

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List Manual

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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 box

containing the TOOL BOX and Z crank. The leveling pads and screws for the machine can be found in the toolbox. The Y way covers are shipped in a separate tube. The lower Z way cover can be f o und in a box as well.

Remove two steel bars - 1.0 inch in diameter. These items are necessary for lifting and moving the machine.

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)

______ Man ual drawbar with washer

______ Leveling pads (B239) and screws (B240). Note: 4 each for DPMSX2 and 6 each

for DPMSX3 &SX5 ______ Table tray with rubber pad (assembled to machine) (DPMSX3 only) (15977) ______ Pendant Display with four 1/4-20 screws f or m ounting ______ Pendant Arm assembled to the column ______ Toolbox with various tools ______ ProtoTRAK SMX Safety, Operation & Programming Manual (P/N 24495)

______ TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & P a rts

List Manual (P/N 24317) ______ Table trays (DPMSX5 only) ______ Manual Z-axis crank (16526) (DPMS X3 & SX5 only)

______ Way c overs DPMS X2 – front (23676) and r ear (23677) of saddl e

______ Way covers DPMSX2 - bottom on column (23675), top on column (23675)

______ Way c overs DPMS X3 – front (B268) and rear (B267) of saddle

______ Way covers DPMSX5 – front (B268) and rear (B267-1) ______ Way covers DPMSX3 & SX5 - bottom on column (B202), top on column (B201)

of saddle

In case of shortages, contact the representative from whom you purchased the machine.

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List

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2.4 Installation Instructions & Checklist

Installer: Use this checklist to assure a complete set-up of the DPMSX2, SX3 or SX5.

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1. Shut off power to the machine.

2. Visually inspect the 220 or 440V -wiring 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 with Spind le C ontrol Option is only a vailable in 220V config uration.

3. Clean the machine if needed and remove any remaining grease.

4. Unlock the table, saddle, and ram gib locks.

5. Use a 10mm socket to turn the Z-axis ball screw at the top of the column in order to lower the head until the counterweight is raised off of the counterweight support rods. (DPMSX2 only)

6. Remove the 2 bottom head supports and also remove the 2 zip ties from the counterweight chain.

7. Install the manual Z-axis hand crank. (DPMSX3 & SX5 only)

8. Using the manual hand crank, lower the head until the counterweight is raised off of the counterweight support rods.

9. Remove the two (2) counterweight support rods.

10. Remove the manual Z-axis hand crank. (DPMSX3 & SX5 only)

11. Attach (2) wiper brushes to each table tray using (2) M5 X10 button head cap screws (supplied) per brush. Install (1) table tray on each end of the table (DPMSX5 only). NOTE: Make sure that the tray does not scrap the TURCITE. Check TURCITE for any damage.

12. Mount the pendant to the pendant arm using (4) 1/4-20 x 3/4" socket head cap screws.

13. Make and check all the proper electrical connections from the pendant to the electric box. See the pendant and electric box wiring diagrams.

14. If applicable, load TRAK sensors.

15. Turn on the power to the machine and to the pendant.

16. Lubricate all the way surfaces and the ball screws.

17. Jog the table, saddle, and ram back and forth until the way surfaces are well lubricated. Oil should be visible on all the way surfa ces.

18. Check the level of the machine. The machine should be level to within 0.0005" front to back and 0.0005" side to side. Even though it is the responsibility of the cust omer, make any adjustments if necessary.

19. Check to make sure that the E-Stop button is functioning correctly.

20. Perform Service Code 12, Feed Forward Constant.

21. Perform Service Code 123 to calibrate the X and Y-axis using a 150mm standard.

22. Perform Service Code 11 to automatically calculate the backlash for the X and Y-axis of dual feedback machines (i.e. TRAK sensor or glass scale with a motor encoder).

23. Perform Service Code 127 and 128 to manually calculate the backlash for the X and Y-axis of single feedback machines (i.e. motor encoder only).

24. Check for positional accuracy and repeatability on the X and Y-axis using programs XREPEAT.PT4 and YREPEAT.PT4 respectively. Positioning and repeatability values should be less than or = to 0.0005”. Programs can be found on flash drive under the PT4 folder followed by the S WI TEST PROGRA MS folder.

25. Perform Service Code 123 and press Z to calibrate the Z-axis ram using a 75mm standard.

26. Perform Service Code 127 and 128 to manually calculate the backlash for the Z-axis ram.

27. Check for positional accuracy and repeatability on the Z- axis using program ZREPEAT.PT4 Positioning and repeatability values should b e less than or = t o 0.0005”.

28. Perform Service Code 123 an d press QUILL softkey to calibrate the Z-axis quill using a 75mm

Southwestern Industries, Inc.

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List Manual

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standard.

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29. Perform Service Code 100 in both directions for the X, Y, and Z-axis to verify that the feed rate shown on the display is at least 180 ipm.

30. Run the spindle at various speeds in both high and low gear for 15 minutes. Verify head shifts from high t o low gear smoothly. Test qu ill feed and spindle brake.

31. Install the Z-axis upper way cover. Install the Z-axis lower way cover and its bracket.

32. Install the Y-axis front and rear way covers.

33. If machine has an auxiliary function option, then use accessory key on pendant and make sure the coolant pu mp or solenoid for the mist er fires. The a ccessory key should be in t he ON position to test coolant pump or solenoid. The control should be in DRO mode. Make sure air is hooked up to the machine during the test. If the machine has a separate coolant pump switch mounted on the pendant arm then turn this on and off to test.

34. If the machine has a power drawbar option, check to make sure that the tools load and unload properly.

35. Wipe down the machine p rior to leaving.

2.5 Machine Specifications

Specifications DPMSX2 DPMSX3 DPMSX5

Table Size 49” x 9” 50” x 10” 50” x 12” T-Slots (number x width x pitch) 3 x 16 mm x 64mm 3 x 16 mm x 64 mm 3 x 16 mm x 64 mm Travel (X, Y, Z axis) 31 x 16 x 23.5” 31 x 17 x 23.5" 40 x 20 x 23.5” Quill Diameter 86 mm 100 mm 100 mm Spindle Taper R8 #40 taper #40 taper Spindle Speed Range 70 – 4200 RPM 70 – 3950 RPM 70 – 3950 RPM Optional Spindle Control Speed Range Low: 40 – 600 Low: 40 – 600 Low: 40 – 600 High: 300 – 5000 High: 300 – 5000 High: 300 – 5000 Spindle Nose to Table (max part height) 23.5” 23.5” 23.5” Spindle Center to Column Face 18” 19" 20” Spindle Motor Power 3 HP 5 HP 5 HP Voltage 220/440 V 220/440 V 220/440 V Machine with Optional Speed Control 220 V 220 V 220 V Phase/Cycle 3 phase/60Hz 3 phase/60 Hz 3 phase/60 Hz Curre nt (Full load amps) Non-Spindle Control Current (Full load amps)-Spindle Control 11 FLA 17.5 FLA 17.5 FLA Machine Net Weight/Shipping Weight 3200 lbs/3500 lbs 4100 lbs/4400 lbs 4400 lbs/4600 lbs Maximum Weight of Workpiec e 1320 lbs 1320 lbs 1760 lbs

8.5/4.25 FLA 14/7 FLA 14/7 FLA

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2.6 Maximum Work Capacities

DPMSX2 DPMSX3 DPMSX5

Drilling Mild Steel 1” 1” 1” Tapping Mild Steel .75” 1” 1” Milling (metal re moval rate/mild steel)

Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer. Each one of the following will have a n impact on the above numbers: speeds, feeds, cutter, cutter sharpness, material, setup, coolant and machine adjustments. The numbers above assume all conditions are optimal and may be higher or lower depending on material composition.

2 inch3/min 5 inch3/min 5 inch3/min

2.7 ProtoTRAK SMX Control Hardware

• 3-axis CNC, 3-axis DRO

• 400 MHz PC-based processor

• 128 MB of RAM

• D.C. Servo Motors rated at 560 in-oz continuous torque for X, Y and Z-axes

• Precision ground ballscrews in the table, saddle and ram to ensure smooth accurate

contours without backlash

• Feedrate override of programmed feedrate and rapid

• Polycarbonate sealed membrane and gasket sealed control enclosure to lock out contamination

• 10 ½" color LCD for clear presentation of prompts, status information and part graphics

• Modula r design simplifies ser vice and maximizes uptime

• 256 MB flash drive

• Single floppy disk drive for additional part program storage

• Optional auxiliary function box for control of coolant pump or spray mist coolant, spindle

off and a programmable rotary table or indexer

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Figure 3 DPMSX Component Identification

Item Part Number Description

SX2 SX2

Spind le Control 1 20819-1 24162 20820-1 24163 Spindle Motor 2 24000-1 SMX Pendant 3 15616 Y-Axis Handwheel (Saddle) 4 15616 X-Axis Handwheel (Table) 5 21157-1 Lube Pump

23198 X, Y or Z Motor

TRAK DPMSX2, SX3 & SX5 Safety, Installation, Maintenance, Service & Parts List

SX3/SX5 SX3/SX5

Spind le Control

Southwestern Industries, Inc.

Page 18

Figure 4—DPMSX Rear View

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Item Part Number Description

SX2 SX2

Spind le Control

1 220V=20676

440V=20676

2 24999 24999 24999 24999 Cable Breakout 3 24999-1 24999-1 24999-1 24999-1 Cable Breakout

24060-1 220V only

SX3/SX5 SX3/SX5

Spind le Control 220V=20676-1 440V=20676

24060-2 220V only

Electrical Box

Box Box with AUX

Functions

2.8 Lifting and/or Moving the Machine

CAUTION!

The DPMSX 2, S X3 & SX 5 m ach in es weigh approximately 3200, 4100 and 4400 lbs.

respectively. Pr op er equipment of su f f icien t capacity must b e u sed when lifting and /or

moving the machine.

Method 1

1. Insert a steel bar 1.0" dia x 36" long through the rear side holes of the bed (under column).

(see Figure 5)

2. Use a steel cable (with protective sleeving) mi n . 3/4" d ia. or a 3 t on slin g.

3. Use cardboard pieces or other suitable protective sheets on both sides of the machine to prevent scratc h ing.

4. Remove the 4 nuts and screws holding the machine to the wood skid.

5. Lift the m ach in e (the front side of th e m ach ine should be lower than t h e back side).

6. Insert the 6 screws for leveling pads in their place in the bed. 4 screws for DPMSX2.

7. Place the mac hine in its location (se e floor plan and bed footprint drawing) carefully positioning each leveling pad under each leveling screw.

8. Remove the lif ting cable or sling , the steel bar and all protective cardboard.

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Figure 5

Lifting the Machine

Method 1

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Method 2

1. Insert 2 st eel bars 1" dia x 36" long t h r o ugh bot h sides in the exist ing holes in the mac h in e base (front an d back).

2. Position 4 (two each sid e) wood vee blocks under the steel bars and ov er a suitable lift truck.

3. Lift the machine up (somewhat tilted towards the front) 4-6" from the ground and move it to its floor plan position.

The lift truck must have sufficient lifting capacity (3 tons) and be equipped with

4. Insert the 6 screws for the leveling pads in their place in the bed.

5. Place th e m ac h ine in its location (see floor plan bed/footpr int) carefu lly positioning each leve lin g pad un der each leveling sc r ew .

(see Figure 6)

suitably lon g forks.

WARNING!

Figure 6

Lifting the Machine

Method 2

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2.9 Releasing the Head Counterweight Supports

In order to move (raise or lower) the spindle head/ram it is first necessary to remove the 2 steel rods (with flanges) inserted through the holes in the column. These rods support the counterweight during shipping to prevent damage to the counterweight chains and sprockets.

1. Release ram gib locks.

2. DPMSX2 – Lower the head slowly with a 10mm socket on the top end of the Z-axis ball scr ew u n t il the chain betw een t h e r am an d the counterweight is tight.

DPMSX3 & SX5 - Lower the head slowly with the ram crank until the chain between the ram and counterweight is tight.

3. Lower a little f u r t h er u n til the 2 supp o rt st eel r ods are loose. Remove the 2 steel rods and st or e t h em f or f u ture m ach in e m ov es or transportat ion.

4. Do not continue to move the ram until all ways have been cleaned.

CAUTION!

Do not remov e the steel rods u n less t h ey ar e loose.

2.10 Cleaning

1. Remove rust protective coating from the machine before moving any

slideways (tab le, saddle, ram, etc.).

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 ga solin e or other flammable cleaning ag en ts for cleaning t h e

machine.

3. It may be necessary to move back and forward, left and right, and up and down the

table, saddle and the ram. Always release the clamp levers (two in front of the table, one underneath the saddle on each side, and two on the ram on the right side of the column) before attempting to move the above parts .

CAUTION!

Never move any of t h e above parts over way s that were n o t prev iou sly clean ed .

Serious damage to the TURCITE sur f ace of slid eway s can occu r.

4. Be certain the table, saddle, ram, an d spindle mov e fr eely an d smoothly

over their ent ire len g th.

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2.11 Leveling: Leveling Tolerance for DPMSX is .0005”/10”

1. Set th e m a chine on its 6 levelin g pads on a solid, lev el floor prepared in

accordance wit h the state an d local rules for ma ch ine tool instal lation. The DPMS X 2 only uses 4 leveling sc r ews.

2. Put on e o r two precision Sp ir it Levels or Elect ronic Lev els in the center o f

the table in the position s illu strated in F igure 7.

3. Adjust the 4 corner leveling screws on their pads u n til the machine is level

to .0005 in/10 in. Snu g the 2 middle levelin g screws being caref u l t o n ot affect the level for the DPMSX3 and DPMSX5.

4. If the mach in e m u st be anch ored to the floor, follow the g en eral

instruct ion for installing machine tools and u se f o r lev elin g any well- k n o wn methods: shim s, et c.).

5. If the machine must be installed on vibration mounts/pads (rubber,

commercia lly av ailable leveling and v ibration mount s, etc.) follow th e instructions delivered with the mounts/pads, ordering them to satisfy the load of the machin e and the maximum weight of the workpiece (6,000 lb.).

6. When mach ine is correctly level, lock t h e adjusting screws in place with t h eir h ex nuts.

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Figure 7

Placement of Levels

I00138

Figure 8

Leveling Screws

B239 Leveling Pad B240 Leveling Screw & Nut

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2.12 Electri cal Connection

The DPMS X2, SX3 & SX5 Bed Mills can be c onfigured f o r 220 or 440 v o lt 3 phase electric ity. These machines also require a 110V power source to power the control.

Note: Machines with Optional Spindle Control is only available in 220V configuration.

DANGER!

Be certain that 200-v o lt electricity (t y p ical r ange 208 – 240V) is used only with a

machine labeled 220 v o lt s at the motor an d at t h e elect r ics box on the back of

the column.

Be certain that 400-v o lt electricity (t y p ical r ange 415 - 460V) is used only with a

machine labeled 440 v o lt s at the motor an d at t h e elect r ics box on the back of

the column.

DANGER!

The 220 or 440-volt lin e m u st originate from a dedicated and in dependent fused

box with a m anual shut-o f f lever. It is the r esponsibility of t he purcha ser to

supply a wired box that meets all local codes and regulations.

Incoming 220 or 440 power connects to the machine through the electrical box located on the back of the column. The power cable enters the black box through a hole on the top of the box.

DANGER!

Only a qualified electrician sh ou ld wire the 220 or 440 v o lt 3 phase electric ity.

To convert a DPMSX2 machine from 220 to 440 volt power or vice versa 3 things must happen: spindle motor must be rewired, overload relay must be set to 8 .5 amps for 220 V and 4.25 for 440 volts and the voltage stickers on the electric’s box must be replaced.

To convert a DPMSX3 & SX5 machine from 220 to 440 volt power 3 th ings must happen : spindle motor must be rewired, overload relay must be replaced and set to 14 amps for 220 V and 7 for 440 volts and the voltage stick e rs on the electric’s box m ust be replaced.

Note: Voltage conversion from 220V to 440V not applicable to machine fitted with Spin dle Control O ption.

See Section 5 for a diagram of how to rewire the spindl e motor.

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Figure 9 Wiring the DPMSX2, DPMSX3 or DPMSX5 Non-Spindle Control

Part Number Description

SX2/SX3/SX5

220V & 440V = 20676 Electrical Box

220V & 440V = 23438-3 Overload

23436 Contactor (Qt y = 2) (Rev er se or Forw ard)

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Figure 10-1 Wiring the DPMSX2, DPMSX3 or DPMSX5 – Spindle Control

Item Part Number Description

SX2 SX3/SX5

1 24060-1 24060-2 Electrical Box 5 22890-500-120 22890-500-64 Resistor (Qty = 2)

8 25105-DPMSX2 25106-DPMSX3-5 AC Drive - Mini Vector - 220V 12 22961 Relay - Power - 115V DPST 14 21824-5 Fuse - 3 AG - Slow Blow 5 AMP 15 21824-8 Fuse - 3 AG - Slow Blow 8 AMP

See Figure 117 in th e r ear of the manual for a m or e detailed breakdown of parts.

Southwestern Industries 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.

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Figure 10-2 Wiring the DPMSX2, DPMSX3 or DPMSX5 – Spindle Control

This feature became standard as of 1/1/11.

2.12.1 Phase Converters

For those machines that will be run with a phase converter it is recommended that it is a rotary type rather than a static phase converters. 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. Static phase converters can only be used on machines with a nonvarying load. The phase converter for the DPMSX mach ines must be rated at a minimum of 5 to 7 KVA for DPMSX2 and 7 to 10 KVA for DP MSX3 &SX5.

2.12.2 Flange Disconnect/Transformer (Optional) – Non Spindle Control

The Flange Disconnect/Transformer Option eliminates the need for the user to provide a power disconnect for the machine on their own, while the Transformer Option allows the user to provide one power source to the machine.

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Figure 11 Flange Disconnect/Transformer Option P/N: 23460-220/440

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Parts List – Flange Disconnect/Transformer Option

Item P/N Title Qty 1 21258 TRANSFORMER 1000VA EI 1 4 23434 SOCKET-RELAY 1 5 23435 RELAY-POWER-100-120 VAC-DPDT 1 6 23436 CONTACTOR-4 POLE 2 7 23437 MECHANICAL INTERLOCK 1 8 23438-3 OVERLOAD RELAY-220V TO 440V CONVERSION 1 11 22199-1 RECEPTACLE- PANE L MOUNT NEMA STD 15A 125V 4 13 21871 CONNECTOR-4 POSITIO N-SIZE 11 1 14 23297-1 CONNECTOR-REVERSE SEX-13-7-CPC 1 16 21820 FUSE HOLDER 2 17 21824-5 FUSE-3AG-SLOW BLOW 1 18 21830-12 FUSE-TYPE 3AB-12A-SLO BLO 1 19 22868 TERMINAL BLOCK 4 20 22869 END PLATE 1 22 21753-3 GROUND BAR- 6 HOLE 1 23 21901-150 MOV-V150LA20B 5 24 23036 FUSE HOLDER-32 AMP-690V 2 25 23153-3 FUSE-600 VAC-TIME DE LAY-CLA S S CC 2 26 22303-16G WIRE-BUSS-16 GA AWG 12" STRAIGHT 12.25 40 22557-1 TERMINAL BLOCK - 6mm BLOCK 3 41 24299-3 TERMINAL BLOCK-RAI L END STOP/ GRO UND 2 42 22571-8.125 RAIL-DIN 8.13 45 23429 SHEETMETA L- COVE R PLATE LEFT -PT4-SM TRANSFORMER OPTION 1 48 24407 NAMEPLATE - TRANSFORME R 1 i01397

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Figure 12 Transformer Option Schematic – Non Spindle Control P/N: 23440-220/440

2.12.3 Flange Disconnect/Transformer (Optional) – Spindle

Control

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Figure 12-1 Flange Disconnect/Transformer Option

P/N: 24635 (3 HP) or 24636 (5 HP)

Parts List – Flange Disconnect/Transformer Option

Item P/N Title Qty

1 23153-6 FUSE-600 VAC-TIME DELAY-CLASS CC-6 AMP 2 2 21893-2 FUSE- 500 VOLT- SLO-BLO TYPE-2 AMP 2 3 21258 TRANSFORMER 1000VA EI 1

24635 (3HP) O P TI ON-FLANGE/TRANSFORMER DPM 2P - 3 HP

5 6

24635 (5HP)

23430-MOD 24910-15 (3HP) FUSE-TIME DELAY- 600V - 15 AMP 23471-20 (5HP) FUSE-TIME DELAY- 20 AMP

OPTION-FLANGE/T RA NSFORMER DPM 3/5P - 5 HP

SAFETY SWITCH - 30A - 600VAC - MODIFIED 1

i01447

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Figure 12-2 Transformer Option Schematic – Spindle Control

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2.13 Air Connection - Optional

The DPMSX machin es h av e an air h ook u p in the rear of the mach ine if the machine has a po wer drawbar or au x iliar y f u n c tion option.

The drawbar opt ion in clu des an air regulator, air manifold and an oiler. The auxiliary op tion includes an air regulator , air m anifold and a solen o id. If both opt ions ar e in clu ded on the same machine, a r eg u lator, manifold, oiler and solenoid will be in c lu ded. The air fit ting is ¼” NPT. An additional air line port is on the manifold to be used for an optional mister. Remove the plug to gain access to this port. See Figure 13 below.

The air regulator is set to 90 PSI at the factory for the power drawbar unit and solenoid. S ee S ec tion 5.1.8 for mor e in f ormation on the power drawbar unit. The air comes in through the manifold and passes through the air regulator. The regulator branches into two components--an oiler for the power drawbar unit and an air solenoid. The solenoid is used for a misting syst em that the u ser m a y in stall later on this m a ch ine. The mister air hose can be plugged into the ¼” quick disconnect air fitting on the solenoid. See the figu r e below for an illustration.

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Item P/N Title Qty

2 22378 MANIFOLD-PT4 AIR 1 3 22607 FILTER/REGULATOR-PT4 1 8 22644-4 PLUG-1/4 NPT HEX SOCKET 3

9 22645-4 NIPPLE-1/4 NPT x 1.37 LG 1 11 22646-4 ADAPTOR-ELBOW MALE 1/4 x 1/8 NPT 1 12 22647-2 NIPPLE-1/8 NPT x 0.750" LG 1 18 4-40X3/8 31B SCREW-PH-PHIL-EXT SEMS-ST L- BO 2 19 10-32X3/8 10B SCREW-PH-PHIL-STL-BO 2 20 M6-1.0X25 25B SCREW-SHCS-STL-BO 2 24 22772 SOLENOID ASSY- AIR REULATOR 1 25 22773 OILER 1

i22380-1

Figure 13 Air Regulator/Solenoid Assembly P/N 22380-1

Item P/N Title Qty

2 22378 MANIFOLD-PT4 AIR 1 3 22607 FILTER/REGULATOR-PT4 1 8 22644-4 PLUG-1/4 NPT HEX SOCKET 3

9 22645-4 NIPPLE-1/4 NPT x 1.37 LG 1 11 22646-4 ADAPTOR-ELBOW MALE 1/4 x 1/8 NPT 1 12 22647-2 NIPPLE-1/8 NPT x 0.750" LG 1 18 4-40X3/8 31B SCREW-PH-PHIL- E XT SEMS -ST L- BO 2 19 10-32X3/8 10B SCREW-PH-PHIL-STL-BO 2 20 M6-1.0X25 25B SCREW-SHCS-STL-BO 2 24 22772 SOLENOID ASSY- AIR REGULATOR 1 25 22581-5 OILER 1

i22380-1

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2.14 Mounting the Display Pendant

The ProtoTRAK SMX display pendant mounts to the pendant arm with four 1/4-20 x ¾ SHCS that are shipped screwed into the left side of the display. There is a lo cating scr ew on the pendant ar m t o help align the pendant with the mounting holes.

CAUTION!

The locating screw in t h e ar m is u sed f o r positioning. Keep a hold of the

pendant u ntil t h e scr ews ar e f ast en ed.

If the pendant arm rotates too freely, remove the painted cap on the bracket attached to the column and tighten the hex nut to adjust it. Replace the cap.

2.15 Cable Interconnections

All cable interconnections are made at the factory except for those connecting to the pendant display. There are a total of 4 cables that need to be connected to the pendant. See Section 6 for a complete illustration of cable interconnections for all compone nts. There are 2 additional cables for the electronic handwheel option and 2 more cables for the spin dle control option (digital I/O and spindle contro l parts) .

With the main power to the machine turned off, plug in the connectors that are bundled on the pendant arm. Each cable mates to only one connector on the pendant display back panel. Use the label on the pendant to match the connectors with the correct port. The machine ID port and option key port (LPT1) will have keys plugged into them. The handwheel, spindle control and network ports will be left empty d uring installation.

Make sure there is sufficient slack in the cables for the pendant to rotate about the pendant arm. The worst case is when the pendant is all the way forward toward the operator. The following drawing describes all of the cable connections to the pendant.

Make sure that an option key is plugged into the option key port of the pendant. This key activates any converters or options ordered. The part # for this key is 22648-7. The key must be programmed according to the type of machine it is on and the options ordered .

The Machine ID port must have a key, or th e machine m ay n ot run. Note: Spindle Control mach in es u se a different machine ID k ey then n on -

spindle con trol machines.

CAUTION!

Make sure the m ain p o wer is turned off on the back of t h e electrical cabinet

before plugging in the cables.

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Figure 14 Pendant Cable Connections-Left Side P/N 24000-1

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Figure 15 Pendant Cable Connections-Right Side P/N 24000-1

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Figure 16 Cable Connections-Non Spindle Control

Parts List – Cable Connection—Non-Spindle Control

Item Part Number Description

SX2 SX3/SX5

1 2 21856 Cable Assembly

3 24999(-1) Cable Breakout Box (-1 with AUX Functions) 4 22648-7 Option Key—SMX 5 22758-DPMSX (XXX) Key—Machine ID 6 24000-1 SMX Pendant 7 22608-1 Cable Assy-AC Power

220V = 20676 440V = 20676

220V = 20676-1

440V = 20676

Electrical Box

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Figure 17 Cable Connection Diagram with Spindle Control Option

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Parts List – Cable Connection – Spindle Control

Item Part Number Description

1 24000-1 SMX Pendant Assem b ly 2 24060-1 Enclosu re A ssembly, SX2 2 24060-2 Enclosu re A ssembly, SX3 and SX5 3 24999 Cable Breakout Box no au x 3 24999-1 Cab le Br eak ou t Box with aux 4 22555 -10 Cable Assy - L ogic 5 22555 -10 Cable Assy - L ogic 6 22556 -10 Cable Assy - Parallel 7 22556 -10 Cable Assy - Parallel 8 22608 Power Cord 9 20267 Cable Assy - A C t o Co mputer

i01113

2.16 Lubrication

2.16.1 Way Lubrication – DPMSX2, DPMSX3 & DPMSX5

The auto lub e sy st em provides cen t r alized automatic lu brication for t he ways and ballscrews. Th e lu be pumps 2- lit er r eser voir is serv ic ed with Mob il Vactra Oil No. 2 or equivalent. The pump is fac t o r y set to pump oil for 15 seconds for every 60 min u tes of spindle tim e. Th ere is an in ternal memory on the pump so that the pump will n ot reset every time the spin dle is turned off .

The pump in g output can be regulated elec tronically to c ontrol the pause time between pumping cycles, and the duration of the pumping cycle. The following describes the buttons used to program the lube pump. In order to modify any of the settings the spindle must be on.

The pump h a s an alar m t h at will sou nd if any of the f o llow in g problems arise:

• Oil line breakage

• Oil filter blo c k a ge

• Bad motor

• Low oil pressure

• No oil in tank

INT (Interval) - this button programs the interval between pumping cycles. Each press of t h e button increases th e in t er v al b y one minute.

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DIS (Discharge) - this butt o n pr o g r a ms t h e amount of time t h e pum p will discharge each pu mping cycle. Each pr ess of the b u tton in creases the discharge time by one minute.

FEED - this butto n is used to manually f eed the ways and b allsc r ews.

RST - this button tells the pump to discharge for the time programmed. Factory Default Values

Interval Time - 60 min. Discharge Time - 15 sec Discharge Pressu re - A pproximately 100 - 150psi

To adjust the amou nt of Discharge Pressu re displayed on th e lu be 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.

At the beginnin g of each day, check th e oil lev el in t he Auto Lub e system . If low, fill wit h Mobil Vac tra Oil No. 2 or equ ivalent (S A E 30 or ISO 68).

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 TRAK DPMSX2,

DPMSX3 and DPMS X5 way su rfaces an d ballscrews.

2.16.2 Head Lubrication – TRAK Bed Mills Once Each Week:

1. Fill the oil cup on the fro n t of the head with SAE 30 or 30 W o il. This oil lubricates th e H i/L o ran ge shifter.

2. Fill the ball o iler locat e d in the fro n t lower right cor ner of the sp eed c h anger housing. Th is oil lubricate s the speed changer shaft.

3. Extend the quill fully and apply a c o at in g o f SAE 30 or 30W oil to the out side diameter of t h e quill.

Every Four Months:

Apply a good grade of general-purpose grease through the grease fittings on the back of the head and on the left side of the head. Th is grease lubricates t h e Low range gear set and the feed chan ge gears respectively. Als o lubricate varidisk on spind le mo t or by means of grease fitt ing on motor shaft.

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Every Four Months (DPMSX5 X Handwheel Drive Mechanism): Remove X handwheel drive cover and apply a general-purpose grease to the drive gears.

2.17 ProtoTRAK SMX Euclid Block Procedure

The test part should be machined at the completion of the installation.

The material for the Euclid block test part is found in the toolbox.

• Material Specification: Alumin u m , 6061-T6 or T4

• Blank Size: (minim um dimens io n s) 3 x 3 x 1”, prov ided in tool box

• Tool: .750 end mill, 2 flute, h igh speed steel,

sharp

• Coolant: Flood coolant, Cool-Tool or Kerosene

1. Mount vise an d indicate the back jaw parallel to the table within .0005”.

2. Clamp material in v ice with a minimum of .800” ab ov e t h e v ise jaws.

3. Load in the Euclid b lo c k program from the ProtoTRAK SM f lash drive, it is part nu m ber euclid.PT4. It is foun d under the PT4 f o lder followed by the SWI TEST PROGRAMS folder.

4. Use an edge finder to set Absolute 0 on X and Y. Absolute zero is the front left corner of the block as viewed from in front of the machine.

5. Load the .750 en d mill and set Z A bsolute 0 at the top of t h e part , an d set Z reference positions in the SET UP mode. Set Z-retract a few inches above the part .

6. Begin to run the prog r am . The part will be machined in th e following sequence:

7. After the program run, the program will locate to the following position.

• X = 1.318

• Y = 1.318

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Event(s)

1 2 3

5-12

8. Mount a dial indicator in t he quill and c h ec k t he circ les.

9. Check the ru n ou t of t h e sides of the square frame.

10. Inspect the machined sur f aces f or sm oot h n ess.

Figure 18

Description Depth of

Cut

circle pocket – cuts middle circle circle frame – cuts outer 1.830 diameter circle circle frame – cuts material from corners remaining on Euclid block roughs material in upper right-ha nd corne r cuts tria ngle on Euclid block rectangular frame – cuts outer 2.750” rectangle

-0.250”

-0.500”

-0.7500”

Euclid Block

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3.0 Troubleshooting by Symptom

Use this section to begin the process of resolving a service problem. Each symptom 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

The part finish is marred with scallops or is very rough. Do the following Service Codes and document values:

• Code 33 Software Identification. This is needed if you call SWI Customer Service

• Code 11 Mea sures backlash in the system (Only used on Dual Feedback systems)

• Code 12 Feed Forward Constant

• Code 127 Measures backlash in the system (Only used on Sing le Feedback system s)

• Code 128 Enter backlash compensation

Possible Caus e Check This

Too much backlash entered for code 128 or calculated with code 11.

Machine Tool & Setup problem Check for any loos eness in the setup (Tool, Tool holder,

Table, Saddle, or Ram Locks are locked Make sure the Table, Saddle, and Ram Locks are

Inadequate or no Lubrication to Ballscrews and Way surfaces

X, Y, and Z-axis Gibs are not adjusted properly X & Y-axis Drive Trains are loose Check Repeatability using the Repeatability and Positional

Way surfaces are pocked, scarred, or excessively worn

Verify nothing is mechanically loose and the backlash values are not higher than what physically is in the system.

Part, Vise , or Fixtu re). Chec k the cond ition and type of cutter being used, type of material, RPM and Feedrate, etc. See Machine Tool & Setup Section 4.1

unlocked. Never use gib locks with a CNC machine. Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is functioning pr operly. Also check for any pinched or blocked oil line s. See Lubrication Section 4.1.3 Check the adjustment of the X, Y, and Z-axis Gibs. See X, Y, and Z-axis Gib Adjustments in Section 5.2.1.

Accuracy procedure. Step by step, carefully inspect the Drive Train for any looseness. It may be nece ssary to disassemble and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) 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.

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3.1.2 Circles Out of Round

Circles are not round within 0.002” TIR over 3.0” DIA. This is best measured by placing a dial indicator in the quill and sweeping around the par t.

Note: The typical slideway-milling machine is not capable of achieving more precise results although careful adjustments to a new milling machine have produced better results. If more precise circles are required, then it is recommended to use a precision boring head/boring bar.

Do the following Service Codes and document values:

• Code 33 Software Identification. This is needed if you call SWI Customer Service

• Code 11 Mea sures backlash in the system (Only used on Dual Feedback systems)

• Code 12 Feed Forward Constant

• Code 127 Measures backlash in the system (Only used on Sing le Feedback system s)

• Code 128 Enter backlash compensation

Possible Caus e Check This

Torque values on X and Y-axis are too high.

Machine Tool an d Setup problem Check for any looseness in the se tup ( Tool, To ol holder, Part,

Machine not level Verify that the machine is level t o specification. Head is not Trammed Verify that the Head is Trammed to specification. See Tramming

X, Y, and Z-axis Gibs are not adjusted properly Calibration or Backlash problem Recalibrate the machine. Reset the Backlash. Check

TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed correctly

X & Y-axis Drive Trains are loose Check Repeatability using the Repeatability and Positional

Head Bolts are loose Verify that all the head bolts are tight.

Make sure torque is lower than 20 in-lbs. Normal values for a machine that is aligned and adjusted properly should be between 10 and 15 in-lbs. Make sure torque is cons ist ent across axis travel.

Vise, or Fixture). See Machine Tool & Setup - Section 4.1

the Head Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

Repeatability and Positional Accuracy. See Calibration & Backlash Constants Section 5.2.2

according to the Sensor or Glass Scale Installation procedures. Check for any loose brackets or misalignment etc. Also, check to make sure the Sensor or Glass Scale assemblies are functioning correctly. See TRAK Sensors or Glass Scales Sections 4.6 & 4.7.

3.1.3 Taper Cut on a Programmed Straight Line Move

An unwanted tapered cut occurs, when the machine is programmed to move in a straight line along either the X or Y-axis. The DRO shows motion of a few thousand ths of an inch in the axis that is not supposed to be moving.

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Explanation: For straight line cuts along the X or Y-axis, the control is designed to lock the motor of the axis that is not moving. A taper is created wh en there is play in the system. The force of the tool shoves the table or saddle out of position.

The system will respond to being pushed out of position by making an adjustment at the end of the move.

An unwanted tapered cut is the result of looseness in the system. Do the following Service Codes and document values:

• Code 33 Software Identification. This is needed if you call SWI Customer Service

• Code 11 Measure's the backlash in the system. Only used on machines with Dual

Feedback systems

• Code 12 Feed Forward Constant

• Code 127 Measure's the backlash in the system. Only used on machines with Single

Feedback

• Code 128 Enter backlash compensation

Possible Caus e Check This

Machine Tool & Setup problem Check for any looseness in the setu p (Tool, Tool holder, Part,

Vise, or Fixture). See Machine Tool & Setup Section 4.1

X, Y, and Z-axis Gibs are loose Check the adjustment of the X, Y, and Z-axis Gibs using the X,

Y, and Z-axis Gib adjustment procedures. See Section 5.2.1

X and Y-axis Drive Trains are loose Check Repeatability using the Repeatability and Positional

3.1.4 Parts Have Incorrect Dimensions

Parts are being machined with dimensions that are different than th ose programmed. Typical accuracy expectations should be:

• Circles: 0.002” TIR over 3.00” DIA

• Positional Accuracy: 0.0005"

• Repeatability: 0.0005"

Note: The typical slideway-milling machine is not capable of achieving more precise results although careful adjustments to a new milling machine have produced better results.

Furthermore, the system should be expected to repeat within the resolution of the displayed DRO numbers of 0.0005”. Do the following Ser vice Code:

• Code 33 Software Identification. This is needed if you call SWI Customer Service

• Code 123 Calibration

• Code 11 Measure's the backlash in the system. Only used on machines with Dual

Feedback systems

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• Code 12 Feed Forward Constant

• Code 127 Measure's the backlash in the system. Only used on machines with Single

Feedback

• Code 128 Enter backlash compensation

3.1.4.1 Every Part Has the Same Error

Possible Caus e Che ck This

Machine Tool & Setup problem See Machine Tool & Setup Se ction 4.1 Programming Error In the program, look for common errors in programming

such as transposing numbers, tool diameters, and pressing INC SET when ABS SET is meant. This is especially suspected if the dimensional errors are larger than a few thousandths. See the Controls Programming,

Operations and Care manual. Configuration file that contains calibration file and backlash constants has been erased or corrupted. Calibration or Backlash problem Recalibrate the machine. Reset the Backlash. Check

Verify configuration file (Code 313) does not read default

values. Load saved conf iguration file from floppy disk in

electrics cabinet with Code 141.

Repeatability and Positional Accuracy. See Calibration &

Backlash Constants

3.1.4.2 The Dimensional Errors Are Random or Accumulate in Size Over the Part Program Run

Possible Caus e Che ck This

Machine Tool & Setup problem See Machine Tool & Setup Se ction 4.1 TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed

correctly according to the Sensor or Glass Scale

Installation procedures. Check for any loose brackets or

misalignment etc. Also, check to make sure the Sensor or

Glass Scale assemblies are functioning correctly. See

TRAK Sensors or Glass Scales Sections 4.6 & 4.7 X and Y-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 nece ssary to

disassemble and then reassemble the Drive Train. See

Mechanical Drive Train (X, Y) Section 4.2

3.2 Problems Regarding the Motion of the Machine

3.2.1 Run Away Axis

The axis makes an unwanted move at rap id speed in one direction and faults out. This is usually caused by an encoder signal being interrupted.

Do the following Service Codes:

• Code 33 Software Identification. This is needed if you call SWI Customer Service

• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and

if the encoders are counting properly

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Possible Caus e Check This

Sensors or glass scales are counting in opposite direction of motor encoder The home positions or tools are not set correctly The Sensor or Glass Scale is not reading. Bad Motor Encoder See Motor diagnostics Section 4.4

Reverse directions with codes 321 and 322

See the Controls Programming, Operations and Care

manual.

See TRAK Sensors or Glass Scales diag nostic Section

4.6 or 4.7

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 SWI 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 Caus e Check This

The maximum allowable Arc Accuracy is set too low.

Incoming AC voltage is inadequate Perform Code 100. See Service Codes - Section 4.9 and

Table, Saddle, or Ram Locks are locked Make sure the Table, Saddle, and Ram Locks are unlocked. Inadequate or no Lubrication to Ballscrews and Way surfaces

X, Y, and Z-axis Gibs are not adjusted properly 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 sl ow down the machine during arc moves. The factory default is set at 0.001". Perform Code 129 to check or change this value. See Service Codes section

Electrical Section 4 . 8

Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is func tioning properly. Also check for any pinched or blocked oil lines. See Lubrication Secti on 4.1.3 Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

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 , Y) 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 SWI Customer Service

• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and

if the encoders are counting

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Possible Caus e Check This

Improper Boot-up Shut down the system and wait 10 seconds before r ebooting E-Stop is pressed in Check E-Stop. Especially if both axes will not jog Servo Drive failure Especially, if only one axi s will not jog;

See Servo Driver Section 4.5 Shorted motor See Motor Section 4.4 Poor cable or wiring connections See Electrical Connection 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 smo oth. T he motion appears to be "rough" or jerky”. Do the following Service Codes and procedures:

• Code 33 Software Identification. This is needed if you call SWI Customer Service

• Code 11 Mea sure's the backlash in the system. Only used on machines with Dual

Feedback systems

• Code 12 Feed Forward Constant. High feed forwar d constants will cause an unstable servo system

• Code 127 Measure's the backlash in the system. Only used on machines with Single Feedback

• 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 Caus e Check This

X, Y, and Z-axis Gibs are not adjusted properly TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed

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, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

correctly according to the Sensor or Glass Scale Installation procedures. Check for any loose brackets or misalignment etc. Also, check to make sure the Sensor or Glass Scale assemblies are functioning correctly. See TRAK Sensors or Glass Scales Section 4.6 & 4.7

Repeatability and Positional Accuracy. See Calibration & Backlash Constants section.

3.2.5 Vibration in Motion

While axis is moving there is vibration or noise coming from the X or Y-axis. Do the following Service Codes and procedures:

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• Code 11 Mea sure's the backlash in the system. Only used on machines with Dual Feedback systems

• Code 12 Feed Forward Constant . High feed for ward consta nts w ill cause an unstable servo system

• Code 127 Measure's the backlash in the system. Only used on machines with Single Feedback

• Code 128 Enter backlash compensation

• Code 123 Calibrate

Possible Caus e Check This

Too much backlash entered in Code 128 or Code 11. Inadequate or no Lubrication to Ballscrews and Way surfaces

X, Y, and Z-axis Gibs are not adjusted properly Gibs not making good contact. Pull gibs out and mark with a blue die to check where the

Binding or looseness in the Drive Train Check Repeatability using the Repeatability and Positional

Axis Motor belt too tight. Loosen belt. Misalignment of ball screw See Mechanical Drive Train (X, Y) Section 4.2

Recheck the machines backlash.

Make sure all the Way surfaces are getting proper lubrication. If not, check to make sure that the lube pump is functioning pr operly. Also check for any pinched or blocked oil lines. See Lubrication section Check the adjustment of the X, Y, and Z-axis Gibs using the X, Y, and Z-axis Gib adjustment procedures.

gibs are making contact. It is recommended that the gibs uniformly contact at least 80% of the surface.

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, Y) Section 4.2

3.2.6 Searching Axis

The handwheels are slowly turning back and forth when the servos are engaged. Several thousandths of motion are observed on the vernier dial and the frequency is one cycle every couple of seconds.

Do the following Service Code and procedures:

• Code 11 Measures back lash in system. (Used only with glass scales and sensors.)

• Code 12 Sets a feed forward power constant to drive axis motors

•

Code 127 Measure's the backlash in the system. Only used on machines with Single Feedback

• Code 128 Backlash compensation on single feedback machines

Possible Caus e Check This

Most often causes by excess backlash compensation High feed forward values Check ball screw torque. Typical code 12 values

Excessive fric tion in t he sliding way s Lubrication, gib adjustments, gib locks. Looseness in the drive train The drive train of the axis that is searching, especially

Check physical backlash in syst em and re-enter in code 128. Run code 11 on dual feed b ack machines

should be between 10 to 15 in-lbs.

See Machine Tool & Setup - Section 4.1

the tightness of the drive assembly. See Mechanical Drive Train (X, Y) - Section 4.2

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3.3 Problems Relating to the Operation of the Control

3.3.1 Display Blanks

The display is comple tely bla nk.

Possible Caus e Check This

System flash drive loose Make sure flash drive is seated properly Screen saver has been activated Press any key to turn back on. All LED keys on

pendant will b link when the scr een 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 4.8 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 bar s or othe r unfamiliar images, or the display continually rolls.

Possible Caus e 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.

Check connections on computer module.

3.3.3 Keyboard Lockup

The screen display is normal, but the system will not respond to ke y presses. Do the following Service Codes and procedures:

• Code 81 To check if the pendant keys are working properly, press each key. If the key is

working, the corresponding key on the screen will light up. The pendant will also beep.

Possible Caus e 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 Electromagnetic interference has entered through the network cable (if connected); especially if inter mittent

Remove the RSG. Turn the system off and th en 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.

Especially suspected if the network cable is run near

any electrical conduit. If the problem is chronic,

remove the cable for a while to see if there is a

difference.

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3.3.4 Fault X, Y 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 SWI Customer Service.

• Code 11 Mea sure's the backlash in the system. Only used on machines with Dual

Feedback systems.

• 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 Caus e Check This

Cable connection problems Check umbilical 1 and 2. Check #1 for X and Y -axis

problems and #2 for the Z-axis. Table, Saddle, or Ram Locks are locked Make sure the Table, Saddle, and Ram Locks are

unlocked. High torque on any axis may cause faulting

problems during alignment routine. X, Y, and Z-axis Gibs are adjusted extremely tight

Excessive friction in the slideways See Machine Tool & Setup Sect ion 4.1 Binding or looseness in the Drive Train See Mechanical Drive Train (X, Y) Section 4.2 Incoming electrical power Incoming voltage. See Electrical Section 4.8 Measurement system not functioning properly 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

Check the adjustment of the X, Y, and Z-axis Gibs

using the X, Y, and Z-axis Gib adjustment procedures.

See X, Y, and Z-axis Gib Adjustments Section 5.2.1

See Section 4.6 or 4.7

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 Caus e 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

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. A floppy can typically hold

1.4 MB of information.

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3.3.6 System Will Not Turn On or Boot-Up

Nothing happens when the switch is turned on or t he system does not b oot-up.

Possible Caus e Check This

110 V line is not plugged in Check incoming 110 V power source to black electrical

cabinet Pendant On/Off switch is Off. Chec k the Pendant On/Off switch Fuse blown in pendant or electrical cabinet Flash Drive failure When the Computer Module starts the boot-up

Computer/Pendant has failed S ee Computer/Pen dant diagnostics Sect ion 4.3

Remove fuses and check continuity.

process, look at the 8

the Mother Board of the Computer Module is

communicating with the Flash Drive you wi ll see

"Detecting IDE Primary Master…Sc an Disk SDCFB-64".

If the Mother Board of the Computer Module is not

communicating with the Flash Drive you wi ll 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

line on the Display Screen. If

3.3.7 System Reboots by Itself

During operation, the screen suddenly blanks and then shows that the system has begun the boot-up sequence.

Possible Caus e Check This

Interruption of 110 V power to pendant Using a Voltmeter, check the incoming 110VAC to the

pendant. Poor wiring and cable connections Check for any loose wiring or cables Computer/Pendant failed See Computer/Pendant diagnostics Section 4.3

3.3.8 System Shuts Off

During operation, the system shuts off and will not turn back on.

Possible Caus e Check This

Fuse blown in pendant Remove fuse and check continuity Poor wiring and cable connections Check for any loose wiring. Also, check the 110VAC

Power Cable connection from the 110VA C Power Strip

to the Pendant. See Electrical Section 4.8 Flash disk failure Remove and reseat the flash disk Computer/Pendant has failed S ee Computer/Pen dant diagnostics Sect ion 4.3

3.3.9 Will Not Hold Calibration

The control will not hold calibration. Go to the "Config uration Values" screen and write down the calibration values for the motor encoders (Encoder) and the position feedback encoders (Scales). The calibration values are written in Hexadecimal. Recalibrate the system and see if the values change. Turn the system off and on and see if the values are held.

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Do the following service codes and procedures:

• Code 33

• Code 313 Configuration Values

• Code 123 Calibration Mode

Software Identification. This is needed if yo u call SWI Cu stomer Service.

Possible Caus e Check This

Configuration file corrupt Load default configuration by going to code 313 Not saving Calibration values Replace Computer/Pendant module.

See Computer/Pendant

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

3.3.10 Auxiliary Functions Not Working (Option on Machine)

The Auxiliary Functions will not turn on or off at the programmed times. There are 3 Auxiliary Functions:

1. Activates or deactivates a "110VAC Receptacle" typically used for a coolant pump or solenoid for mist er.

2. Sen d s an electrical signal t o rotate the turret on a "Haas Indexer".

3. Turns the "Spindle Off" at the end of a programmed event.

In order to run the above auxiliary functions in run mode the accessory key on the front of the pendant must be in the AUTO mode.

All of the auxiliary function signals are carried down to th e cable breakout box through umbilical #2. Each fu nction then has its own relay inside this box. If one of these relays fail then these features will not work.

Do the following service code and procedures:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

Possible Caus e Check This

Bad 110VAC "Coolant or solenoid" receptacle fuse

Poor cable connections Check all the cable connections on the cable

Faulty "Indexer" connector Check for continuity between pins 3 and 4, when the

Bad cable breakout box Check 110 V power coming out of the AC E-stop port

Check if the f use light indicator next to the plug is lit. Verify that the fuses are good or bad by checking the resistance of the fuses u sing an Ohmmeter.

breakout box, Coolant Pump, and Air Solenoid (Located on the Air Regulator). In particular check umbilical # 2 cable, which carries the auxil iary function signals.

output of the Haas Indexer connector is activated.

with the E-stop in the out position. This will cause the spindle to not run.

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3.3.11 E-Stop Error

The E-Stop turns the power off to the axis and spindle motors. This is done by stopping 110V power from reaching the cable breakout box throu g h the use of a relay in the pendant.

Once power reaches the cable breakout box it distributes power to the axis motors, auxiliary functions and 110V power to the spindle contactor. If power does not reach the cable breakout box then none of these functions will work for non-spindle control machines.

Spindle Control Electrical Box A 5-volt signal is sent to the spindle control board, which energizes a relay that enables the AC drive.

Non-Spindle Contro l Electrical Box 110V Power reaches the electrical box through the AC E-stop cable. It is used to energize the spindle mo tor contactor . If this contactor is not energized the spindle will not turn on.

If the E-Stop button is depressed, and no message is displayed on the screen, then either the E-Stop button or the Computer Module is at fault.

Possible Caus e Check This

Faulty E-Stop switch Check the cable connections from the computer

Bad pendant Does 110 V power come out of the cable breakout box

module to the E-Stop switch. Check the E-Stop switch for functionality.

power cord on the pendant? If yes, and the screen has an E-stop message, replace the pendant.

3.3.12 Limit Switch Error - Optional

Limit switches are installed on the table, saddle, and ram to prevent serious damage to the machine in the event of a crash. In the event a limit switch is triggered, a limit switch error will appear on the screen.

Critical Error 64: Servo Erro

X-axis Limit Switch

Correct the fault condition and continue.

To return the machine to its normal state of operation, perform the following procedure:

1. Use mechanical handwheels on X and Y to move switch off of trigger. For the Z-axis, manually lift the arm on the trigger to return the limit switch to its normal position. Then jog the ram up or down as necessary.

2. Press the "Mode" or "Return" key to reset the con trol

3. Press the "DRO" key to enable the machine to once again jog.

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Possible Caus e Check This

Limit switch jumpers in cable breakout box are making poor contact. Limit Switches are triggered Reset the Limit Switches using the procedures

Poor Limit Switch Cable connection Check for any pins that are loose, pushed in, or bent.

Limit Switch failure Try this

Switch 2 limit switch cables on the cab le breakout box.

Remove and reseat jumpers.

described above.

Verify that there is a good connection between the cables on the cable breakout box. Does the limit switch p roblem move to the other axis? If it does then the switc h is most likely the problem. If it stays with the original axis then it could be the cable breakout box.

3.4 Problem with the Measurements

3.4.1 X, Y 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 Y-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 mu st 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 so, it may be caused by a misaligned sensor or scale. If the error abruptly changes by a large amount it may be caused by a bad encoder.

Expected repeatability numbers should be 0.0005” or less. Do the following service codes and procedures:

• Code 304 Toggle X sensor/glass scale on/off

• Code 305 Toggle Y sensor/glass scale on/off

Possible Caus e Check This

Machine Tool & Setup problem Check for any looseness in the setup (Tool, Tool

holder, Part, Vise , or Fixture). Make sure there is sufficient contact between the tool holder and the spindle. See M achine Tool & Setup Section 4.1

X, Y, and Z-axis Gibs are loose Check the adjustment of the X, Y, and Z- axis Gibs

using the X, Y, and Z-axis Gib adjustment procedures.

TRAK Sensor or Glass Scale problem Make sure that the Sensor or Glass Scale is installed

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Possible Caus e Check This

X and Y-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 disassemb le and then reassemble the Drive Train. See Mechanical Drive Train (X, Y) Section

4.2 Encoder Disk or Reader Head on motor are loose

Spindle and/or Quill are loose Use a Dial Indicator and check for side-to-side

Head bolts are loose Tighten Ram bolts

Swap the motor in question with a known good motor. For example, swap the X-axis motor with the Y-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.

movement between the Spindle and the Head. Next, check for side-to-side movement between the Quill and the Head. There should be no more than 0.0003" of side-to-side movement. Make sure that there is a few thousandths gap between the Spindle Collar and the Quill after tightening.

3.4.2 X, Y, and Z-Axis Measurements are not Accurate

Measurements repeat, but with a dial indicator mounted to the bottom 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 mounted to the bottom of the spindle, touch off a fixed surface either in the X, Y, 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, you 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 Caus e Do This

The Calibration is incorrec t Reca librate 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 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 Faulting Axis Section 4.7.1

Do the following Service Codes:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

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• Code 100 Axis open loop test. Used to check the maximum feedrate of an axis and if the encoders are counting.

• Code 304 & 305 Turns off X an d Y sensor or scale.

Possible Caus e Check This

Servo dr iver failure See Servo drive r Section 4.5 Motor Encoder not counting See Motor diagnostics (not applicable with Glass Scale

option) Glass Scale or Sensor Failure Does axis now count? If so, replace scale. Computer/Pendant failure See Computer/Pendant diagnostics

3.4.4 X, Y , 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 – Table moves to the left

• Y-axis – Saddle moves toward the front of the mach ine

• Z-axis – Ram moves up

Do the following service code and procedures:

• Code 33 Software Identification. This is needed if you call SWI Customer Service.

• Code 313 Check the line that spec ifies the product.

If the product does not match the machine then the machine ID key will need to be replaced.

3.4.5 X, Y , & Z-Axis Electric Handwheels T urn in Wrong Direction

The Electric Handwheels turn in the wrong direction. The positive directions for each Electric Handwheel are:

• X-axis - Electric Handwheel turns clockwise

• Y-axis - Electric Handwheel turns counterclockwise

Do the following service code and procedures:

• Code 308 Reverse X-axis Handwheel Direction

• Code 309 Reverse Y-axis Handwheel Direction

3.5 Problems with the Machine Tool

3.5.1 Z-Axis Noisy

While jogging or cutting in the Z-axis direction, the axis makes unusual noises. See below for head noise.

Possible Caus e Check This

Machine Tool and Setup problem Check for any looseness in the setup (Tool, Tool

holder, Part, Vise, or Fixture). See Machine Tool &

Setup Section 4.1

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Ram Locks are locked Make sure the Ram Locks are unlocked. Inadequate or no Lubrication to the Ballscrew and Way surfaces

Z-axis Gibs are not adjusted properly Check the adjustment of the Z-axis Gibs using the Z-

Mechanical Drive Train Misalign ballscrew, or top and lower bearing failure. Z-axis motor failure Replace Z-axis motor

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

4.1.3

axis Gib adjustment procedure. See Z-axis Gib

Adjustments Section 5.2.1

See Motor Diagnostics Section 4.4

3.5.2 Spindle Stalls or Turns-Off During Machining

During machining, the spindle t urns off and loses power. First check inco ming v oltage and connections.

Possible Caus e 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 Drive Belt in the head is slipping Check the alignmen t, condition, and tension of the

Drive Belt. Cut more than the machine is capable Check width and depth of cut

3.5.2.1 Spindle Stalls or Turns-Off During Machinin g (for Machine with the Optional Spindle Control Drive)

During machining, the spindle t urns off and loses power. First check inco ming v oltage and connections.

Possible Caus e 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

Drive Belt in the head is slipping Check the alignmen t, condition, and tension of the

Drive Belt. Cut more than the machine is capable Check width and depth of cut Spindle Drive Thermal Overload Relay has tripped

Spindle Drive parameters are not correct Spindle run command not reaching AC Drive

IOUT - Current Out (located on the Spindle Drive)

cannot exceed 12.75A for DPM SX2 and 21A for

DPMSX3/SX5 for more than a few m inutes. When the

Overload Relay is enabled, an "oL1" error occurs

shutting off the Spindle Drive. The harder the Spindle

Motor works trying to make heavy cuts, the more

current the Spind le Motor utilize s . This can be caused

by a cut so large that it exceeds the machine

capability, or a problem with the spind le motor or AC

drive.

May need to re-download the Spindle Drive

parameters. Contact Customer Service for assistance.

Verify spindle run LED is on Spin dle Control Boar d.

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3.5.3 Spindle Moto r Hums or Will Not Run

The spindle motor makes a constant humming noise during operation or will not turn on. If the spindle does not run, you must make sure 110 V power is reaching the spindle motor contactors in the electrics box. Check your 110V power across terminals wire 3 and ground. If power is not reaching the electrical cabinet, but is reaching the cable breakout box, then m ost likely a relay has failed in the cable breakout box. The cable breakout box will need to be replaced. This relay is in series with th e 110 V power in the E-stop circuit. See Section 3.3.11. If power has reached the electrical box then use the schematic in Section 4.8 for how the power is routed.

Possible Caus e Check This

Wrong voltage

Poor wiring connections Check all the wiring connections to the electric’s box. Defective cables or poor cable connections Spindle Motor is faulty Check the resistance of the spindle motor wind ings on

Spindle will not run because 110 V power is not reaching the spindle contactor

Check the 220V/440V voltage to the machine

Check all cable connections

the spindle motor between L1 (U) and L2 (V), L2 (V)

and L3 (W), then L1 (U) and L3 (W) using a digital

ohmmeter. If the ohmmeter reads more than one (1)

ohm difference or “OL” (infinite) between any pair,

replace the motor. The next check is for resistance to

ground using a digital ohmmeter. Check L1 (U) to

ground, L2 (V) to ground, and L3 (W) to ground. The

meter reading in the display w indow should be “OL”

(infinite) with reference to ground. Any other reading

indicates a problem, and the motor should be

replaced.

Check 110 V coming out of the AC e-stop port on the

cable breakout box. Relay failure in cable breakout

box. Replace cable breakout box.

3.5.3.1 Spindle Motor Hums or Will No t Run (for Machine with th e Optional Spindle Co n t ro l Drive)

The spindle motor makes a constant humming noise during operation or will not turn on.

Note: machines can only be wired for 220 volts. 440 volts will ruin electrical components in the machine. These components will not be covered under warranty.

Possible Caus e Check This

Wrong voltage

Poor wiring connections Check all the wiring connections to the Spindle Drive

Improper wiring/jumper configuration on the Spindle Motor

Spindle Drive m ay be in "Local Mode" and can not be run from the Pendant

Check the voltage to the machine before and after the Spindle Drive with a Voltmeter. Also, check the voltage to the Spindle Drive (L1, L2, and L3).

and Spindle Motor. See Electrical Connection Check to make sure that the Spindle Motor has the correct wiring/jumper configuration for 220VAC. See Electrical wiring section. On the Spindle Drive, push the "DSPL" button until "LO/RE" lights u p. Use the "Up" and "Down " arrow

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keys to choose between "Lo"- Local (Run Spindle Motor from Spindle Drive) or "r E" - Remote Spindle Motor from the Pendant).

Spindle Motor is faulty Check the resistance of the spindle motor wind ings on

the spindle motor between L1 (U) and L2 (V), L2 (V) and L3 (W), then L1 (U) and L3 (W) using a digital ohmmeter. If the ohmmeter reads more than one (1) ohm difference or “OL” (infinite) between any pair, replace the motor. The next check is for resistance to ground using a digital ohmmeter. Check L1 (U) to ground, L2 (V) to ground, and L3 (W) to ground. The meter reading in the display w indow should be “OL” (infinite) with reference to ground. Any other reading indicates a problem, and the motor should be replaced.

Spind le Drive contains incorrect parameters and is not programmed correctly Spindle enable signal not reaching AC Drive Forward/Reverse Switch is bad or Spindle Control Boar d

Contact customer service.

Verify LED on Spindle Control Board is on. Verify Forward or Reverse LED on Spindle Control

Board is lit.

(Run

3.5.4 Spindle Runs Backwards

The spindle motor runs in the opposite direction. The spindle will run in opposite directions from high to low gear.

Possible Caus e Check This

3-Phase wires backwards Need to switch any 2 of the 3 wires ei ther coming into

the machine or motor. Note: For machine fitted with the optional Spindle Control, switch any 2 of the 3 wires either coming out of the AC Drive (T1, T2 & T3) or going into th e Spindle Motor (U, V & W). Caution: Be sure to shut off all power to the machine before attempting to switch any wires.

3.5.5 Head Noise

Head noise pertains to any unusual noises coming from the head under load and no load situations. Most often head noise will only be noticeable under load situations. It is important to try to distinguish between problems with components in the head versus problems caused by the setup or tooling being used on a particular job. Use the table below to try to pinpoint the possible cause. Also try to pinpoint the noise by seeing if it exists in high, low or neutral. For example, if the noise is evident in neut ral then this elimin ates the spindle bearings.

Possible Caus e Check This

Machine setup or tooling problem If the noise is most evident under loa d (cutting

situations) then it is important to look at setup and tooling being used. Ask the following questions. Is the cutter dull? Is the tool loose in the holder? Am I taking a bigger cut then is possible on the machine? Is the part moving in the vice? Am I using realistic speeds and feeds?

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Any one of these can have a significant impact.

Upper spindle bearing is worn out. Remove the upper bearing plate above the spindle.

This will unload the bearing. If the noise goes away

then this bearing should be replaced. Verify nosepiece is tight on bottom of spindle.

Spindle bearings are worn out This is categorized by a high pitch sound and is most

To check if the nosepiece is bottomed out try to insert

a piece of paper in between the nosepiece and the

quill. If a piece of paper does fit then this may be the

problem. Before tightening or loose ning the

nosepiece make sure to loosen the setscrew that

holds it in place.

evident at high RPM’s. It should also cause chatter

under load. Replace the spindle if this is the case.

See spindle replacement in Section 5.

3.5.5.1 Head Noise (for Mach in e with th e Opt io n al Spindle Co n t ro l Drive)

Head noise pertains to any unusual noises coming from the head under load and no load situations. Most often head noise will only be noticeable under load situations. It is important to try to distinguish between problems with components in the head versus problems caused by the setup or tooling being used on a particular job. Use the table below to try to pinpoint the possible cause. Also try to isolate the noise by seeing if it exists in high, lo w or neutral speed range. For example, if the noise is evident in ne utral then this eliminates the spindle bearings.

Possible Caus e Ch eck This

Machine setup or tooling problem If the noise is most evident under load (cutting situations)

then it is important to look at setup and tooling being used. Ask the following questions. Is the cutter dull? Is the tool loose in the holder? Am I taking a bigger cut then is possible on the machine? Is the part moving in th e vice? Am I using realistic speeds and feeds? Any one of these can have a significant impact.

Upper spindle bearing is worn out. Remove the upper bearing plate above the spindle. This

will unload the bearing. If the noise goes away then this

bearing should be replaced. Verify nosepiece is tight on bottom of spindle.

Spindle bearings are worn out This is categorized by a high pitch sound and is most

The belt is not lined up with the grooves on the pulleys.

To check if the nosepiece is bottomed out try to insert a

piece of paper in between the nosepiece and the quill. If a

piece of paper does fit then this may be the problem.

Before tightening or loosening the nosepiece make sure to

loosen the setscrew that holds it in place.

evident at high RPM’s. It should also cause chatter under

load. Replace the spindle if this is the case. See spindle

replacement in Section 5.

Make sure the 10-ribs on the belt are lined up with the 10-

grooves on the 2-pulleys. If the belt is frayed then replace

the belt.

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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 The M illing Machine Checklist

The following is a quick refer ence fo r the types of problems that may arise if problems are noticed in these areas.

Problems With: Can Contribute To: Most Suspect When (and why):

Spindle bearings See Spindle Replacement

Lubrication system

Inadequate lubrication habits Premature wear of ball screws,

Gib locks - on X and Y axis If locked can lead to axis faults. X and Y gibs loose

See Gib Adjustment - S e ction 5.2.1

Gibs too tight

Gibs floating Not getting to position, does not

Gibs defective - bowed, scarred Excess play when gib is checked

Way surfaces pocked, scarred, or excessively worn

Ram gibs loose Parts incorrect dimensions

Mach ine not level Weight not distributed eve nly on all six screws See Leveling procedures Head out of tram See Tramming Head - Section 5.2.3

Noisy head Parts incorrect Circles out of round Premature wear of ball screws, wear surfaces Poor finish

wear surfaces Poor finish

Taper on straight Y moves Poor finish Circle out of round Not getting to position, does not repeat, axis faults Poor finish

repeat, axis faults Poor finish

side to side

Poor finish Out of round circles Faulting

Head out of tram in Y direction. Parts incorrect Machine geometry off, i.e. tram.

Leaves uneven surfaces on bottom of pockets.

Older machines, machines that are pushed hard

New installations (may not be hooked up or line sheared)

New installations (more motion than the machinist is used to with a manu al mill) Lubricate machine every morning before use.

Note: when using the CNC to machine, never tighten the gib locks!

When machine hasn’t been serviced in a long while.

N/A

Contact area of gibs. May need to be scraped. Very old machines may not have any more adjustments on gib. A new gib will need to be fit on the machine. Inadequate gib contact

Inadequate lubrication

Vibration or jerky motion in Z axis

New installation or heavy crash.

Machine not level, ram gibs loose.

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4.1.2 A Special Word About X/Y/Z Gibs

The slideway surfaces are vital to the performance of the bed m ill. 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 th e sliding way surfaces and compromising the performance of the machine.

Gibs that are not adjusted correct ly will affe ct the p erforma nce of the machine. It will lead to positioning and repeatability problems. The g ibs should be adjusted at least twice a year.

See Gib Adjustments Se ction 5.2.1.

4.1.3 Lubrication

Lubrication is one of the single, most important maintenance issues and plays a key role in assurin g the performan ce and d urability of the bed mill. At the beginning of each day manua lly supply oil to t he way su rfaces.

Lack of lubrication can lead to a variety of problems with your machine motion due to increa sed friction in the sliding wa ys. This increased fr iction may lead to part inaccuracies and decreased life expectancies of your ball screws and way surfaces.

4.1.4 Machining Set-Up

The mac hining set-up can grea tly influe nce the performance of your mill. Be aware of the following:

Problems With Can Contribute To:

Feed and Speeds (spindle rpm) See below

Tooling Using the wrong cutter for an application Entering the wrong size diameter and programming with tool compensation. Cutting too deep Part dimensions incorrect

No coolant Poor finish, decrease the life of the cutter

Poor finish Machine chatter Excessive speed s and feed s can break cutting tools or wear tools p rematurely. Poor finish

Parts incorrect size

Driving and cutting forces cause deflections, since no material is totally rigid Machine chatter

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4.1.4.1 Spindle Speeds

Spindle speeds are influenced by a number of variables:

• Material

• Rigidity of the Machine Setup

• Coolant

• Cutter type, material and diameter

• Cutting Depth

As a general rule:

• Lower spindle speeds are used to machine hard or tough material or where heavy cuts are taken.

• Higher spindle speeds are used to machine softer materials in order to achieve better surface finishes. Higher speeds also apply when using small diameter cutters for light cuts on frail work pieces and delicate setups.

Note: Cutter diameter greatly affects spindle speeds. The larger the diameter, the lower the spindle speed.

4.1.4.2 Feedrates

Factors that affect feedrates:

• Depth and width of cut

• Design or type of cutter

• Sharpness of the cutter

• Workpiece material

• Type of finish or accuracy required

• Climb or conventional milling

If a fine finish is required, reduce the feed rather than increase the spindle speed. Cutters are dulled by higher spindle speeds rather than high feedrates.

4.2 The Mechanical Drive Train (X, Y)

Indications:

• Troubleshooting instructions indica te that t he drive train is potentially the problem and other (more easily checked variables) have been exhausted.

• Roughness, looseness, tightness or jam ming movement in the table or saddle.

1. Check f or machine considerations, especially gib locks and gib adjustments. See Gib Ad justments section

2. Check the torque of the axis in three places (both ends and center of ball screw) along the length of the ball screw. The torque should be within 2 or 3 in-lbs across the len gth of the ball scr ew. If it is not, chances are the ball scr ew is misalign ed. A misaligned ball screw can lead to parts being out of round and servo problems at low feedrates. A bad ball screw can also cause high torque, although this is highly unlikely. See Sections 4.2.1 and 4.2.2 for more information. The following steps ta ke you in log ical seque nce through the assemb lies for the DPMSX2, DPMSX3 and DPMSX5. For drawings of these assemblies see Figure s 29 through 37 in Section 5.

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These inst ruction s break the mach ine down from fully assembled and point out the areas to look at specifically.

3. Check that the belt is properly tightened. A loose belt can lead to excessive

backlash compensation values on motor encoder only machines.

4. Check that the nut that tightens up against the ball screw pulley is tight. If this

is loose the pulley may not run t rue on the ball screw.

5. Check that the tapered sleeve that seats the pulley has not clamped to the ball

screw prematurely. It should be seated firmly against the pulley. Tightening the nut may not have ensured this. Also make sure the pulley is keyed to the ball screw.

6. DPMSX3 X-axis only - Ensure that the screws that hold the bearing housing in

place to the bracket are not loose. This assembly should also contain an M6 flat washer and a ¼” serrated lockwasher. See Figure 38.

7. DPMSX5 X-axis, DPMSX3 and DPMSX5 Y axis bearing housings - Ensure that the

bearing housing is clamped in place by the bracket. This design uses the bracket to secure the bearing housing in place. It should not allow the bearing housing to float between the bracket and machine.

8. 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.

• When tightening, snug the 10-32 screw so the clamp goes onto the ball

screw thread with some drag. Thread it onto the ball screw and torque the clamp nut to 50 ft/lbs and then tighten the screw down.

9. Take out the angular contact bearings and inspect them . They should roll

smoothly and be lightly greased. If not, replace them. When putting the bearings back into the housing make sure to put them in correctly. Failure to do this will cause problems. The thin race of each bearing should be facing inward toward the spacer ring.

Note: the bearing housing and spacer ring are matched sets - keep them together.

10. Check the ball screw mounting to the yoke. Make sure the SHCS are tight.

11. Inspect the ball screw, ball nut and yoke for the potential problems shown in the

chart on the next page.

CAUTION!

Unlike a lead screw, do not unscrew the ball screw from its nut. This will destroy the ball sc rew!

Potential Problem: Check By:

Bad ball screw • Visually inspecting the ball nut - if the nylon seal is broken or

deform ed, if contaminat ion has visibly e ntered the ball nut or if b alls 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.

• Using the dial indicator on a vertical flat of the ball screw to check for backlash between the ball screw and ball nut.

Potential Problem: Check By:

Ball nut not tightened to • Inspection for space between the head of the bolt and the ball nut i.e.

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the yoke the retaining bolt has bottomed out in its thread and is not securing

the ball nut to the yoke properly.

Yoke loose in the saddle • Inspection for any motion of the yoke or looseness in the Yoke

mounting screws.

Oil lines sheared • Visual inspection. Oil line blockage • Pump the oil and ensure that it flows evenly to the ways and ball

screw.

Ball screws not aligned properly

• Measure from the ball screw to the back of the saddle on both sides of the yoke (the table must be removed). The measurements must be within ±.005” end-to-end. See above explanations.

Note: Ball screws are inspected throughout their entire t rave l f or back lash and consiste nt torque. A ball screw should be good for millions of inches 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 resolv i ng the real problem.

4.2.1 DPMSX2 & DPMSX3 Ballscrew Alignment

• X-axis – there are 3 components that can cause misalignment: the yoke, the left

side bearing housing bracket, and the right side bearing housing.

• Yoke – the yoke is aligned at the factory and pinned in place. It is aligned to within

0.0005” with a precise alignment tool. The yoke most likely is not causing the problem. If this were the problem you would need to remove the pins and align the X ball scr ew with the back of the saddle. Drill new holes and pin the yoke in place. The Y-a x is ball screw bore is machined perpendicula r to the X bore. If the X-axis is aligned the Y-axis will also be aligned.

• Left side table be a ring housing – this is most likely the cause of the

misalignment. To align the bracket and bearing housing, move them as close to the yoke as possible. Loosen the bracket bolts and bearing housing bolts and then retighten. This should allow the bear ing hous ing to align itself up with the yoke.

• Right side table bearing housing – once again move the bearing housing as

close to the yoke as possible. Loosen the bearing housing and retighten. This should allow the bracket to align itself. If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignme nt.

• Y-axis – the only component that can cause a misalignment problem is the motor

mounting bracket. To align this bracket, move the saddle as far to the front of the machine as possible. Loosen the bracket and then retighten it. Once again moving the saddle forward allows the yoke to be as close to the bearing housing as possible.

4.2.2 DPMSX5 Ballscrew Alignment

• X-axis – there are 3 components that can cause misalignment: the yoke, the left side

bearing housing bracket, and the right side bearing housing. This machine has 2 separate yokes for the X and Y-axis. The yoke is bolted to the table on the X-axis.

• X Axis Yoke – the yoke is aligned at the factory. If you suspect the yoke is

misaligned, the bolts for the yoke can be accessed from an opening on the bottom left side of the saddle. Break these bolts free and move the table back and forth along its travel and then retighten the bolts.

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• Left side table bearing housing – To align the bracket, move the yoke (table left) as

close to the bracket as possible. Loosen the bracket bolts and then retighten. This should allow the bearing housing to align itself up with t he yoke.

• Right side table bearing housing – once again move the yoke as close to the bearing

housing as possible (table right). Loosen the bearing housing and retighten. This should allow the bracket to align itself. If you do not move the table toward the yoke the ball screw will tend to bend down slightly and cause misalignme nt. Make sure the mechanical handwheel is not causing the misalignment.

• Y-axis – the only component that can cause a misalignment problem is the motor

4.3 Computer/Pendant Diagnostics

The pendant consists of 2 separate modules: the computer module and LCD screen/enclosure.

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. Make sure to first unplug any accessories like the Remote Stop/Go switch, external keyboard, mouse, etc. to eliminate any interference.

Possible problems Can lead to

Poor cable connections There are 4 cable connections (6 spindle control) 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 por t 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 power cable at flash drive module with voltmeter. It should be 4.8 DC volts and above. Lower values than this can cause problems.

Flash disk fa ilure If the f lash disk fails, the system w ill not boot up or

operate. It will need to be repla ced. All pr ograms and machine configu rations will be lost. Make sure to back up your flash disk from time to time.

Floppy disk failure Will not allow us er to save or pull up programs from a

floppy disk. Can the floppy drive format a disk? See Section 4.3.1.

LCD backlight burns out Check all cable c onnections to LCD, distribution board

and computer module. Make sure the power is turned off before doing so.

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Possible Problems: Can Lead to:

Faulty E-stop switch It can be stuck open or closed (pressed). If it is stuck

closed th e penda nt will need to be replaced because the user will have no wa y to get rid of the message. If it is open it will allow the machine to still operate but it will be uns afe for the use r. The pendant will still need to be replaced.

Overlay failure (keys on pendant) Certain buttons on overlay do not work. Do code 81 to

verify each key beeps. Low voltage to pendant or current spikes

1 amp fuse in pen dant blows. Pendant will not turn on.

4.3.1 Checking Floppy Drive by Formatting a Disk

1. Find a new disk and install in floppy drive.

2. Install keyboard in to 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, w hich is disc ussed 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 Y motor/servo systems fail at the same time and in the same way. So, if your problem is occur ring on bot h axes, its sour ce is probably somewhe re else.

The motors on the X, Y and Z-axis are identical. The motors are heavy-duty motors.

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.

4.4.2 To Check the Motor Encoders

If the motor encoder inside the motor has failed or is n o t reading the machine will fault out on that axis. Do the following to verify this problem:

Motor encoder only machines – run Servic e Codes 100 or 131. This will display on the DRO if the motor encoder is counting. If the 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.

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Motor encoder and secondary f eedback machines – run Service Codes 100 or 131. Both the motor encoder and sensor or glass scale encoder should count on the DRO screen. The motor value should be displayed under the Z-axis and the sensor or glass scale under the X or Y-axis dep ending on which axis you are doing.

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 c able connections.

• Umbilica l #1 and #2 a t the cable breakout b o x

• Umbilical #1 and #2 at the pendant

• Umbilica l #1 carries the X and Y-ax is signals and Umbilical #2 carries the Z sig nals.

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, or comput er module. In some cases it is not always obvious which compon ent 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 Y-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 Y motors

Has problem moved to Y-axis? If yes, replace motor. If no, the motor is not the problem.

Note: motors are always replaced with the servo driver.

4.5 Servo Driver

Note: the Servo Driver is locate d i n the bl ack box on the side of e ac h motor.

WARNING!

Do not work with the Servo Driver unless the power is disconnected from the machine. There is

possibility of death by electrocution!

Indications:

• Problems moving just one axis, including hard turning in one directio n.

Servo Types:

• X, Y and Z servos are identical

Objective:

• Isolate the problem to the particular Servo Driver

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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.

Note: To avoid pulling the wires out of the connec t or, use t he l oop t o pull t he c onne ct or from the Se rvo Driver.

If the problem moves to the other axis and clears up from the original axis, replace the Servo Driver.

4.6 Glass Scales

Glass scales are used on the X and Y-axis for secondary feedback. They are optional on the DPMSX machines. The Z glass scale comes standard with the machine.

4.6.1 Alignment of Scales

• X Axis - The X-axis scale must be aligned within 0.005” in the up and down direction over the length of the scale for proper operation. Misalignment can cause the scale to not read in the certain areas of the scale that are not aligned with the reader head. If t his happens, the axis will mostly likely fault out in this area. Also make sure the mounting hardware for the reader head is tight. Loose hardware can cause excess backlash when reversing direction.

To align the scale, place a 0.001” indicator on the bed ways and on top of th e scale extrusion. Move the table along its full travel from one end to another to verify it is aligned. If the scale is misaligned loosen the 2 screws at either end to shift the scale up or down as needed. You will also need to loosen the center support bracket to allow the scale to pivot.

• Y Axis - The Y-a x is must be aligned in the up and down direction and must be parallel to the Y-axis way surface. Both surfaces must be aligned to w ithin 0.005”. Failure to align the scale properly could cause t he same p roblems as m entioned above. Mount your 0.001” indicator on the saddle and move the Y-axis back and forth along its travel.

• Z Axis – The Z scale must be aligned parallel with the quill. Make sure the g ap on the readerhead is consistent along the length of travel. Align the scale within 0.005” up and down.

See Figu re 22 in Se ction 5 for an illustrat ion of the Z glass scales.

4.6.2 Measurements Do Not Repeat

1. Determine if the error in repeatability is random or accumulating:

• Mount a dial indicato r in the quill.

• Touch off a fixed point on the table and set the DRO to 0.

• Traverse away approximately 6 inches.

• Return the touch off again.

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• Write down the reading on the DRO.

• Do not Re-zero the DRO, traverse away and return several times.

• Write down the DRO readings

Random error will be unpredictable and give scattered readings, adding and/or subtracting the error after each traverse with no pattern. See Step 2.

Accumulating error will add roughly the same amount to the read ing after each traverse. See Step 3.

2. For random error, look for problems in the set-up of the glass scale that have resulted in a loss of rigidity. Common sources of random error include:

• Loose scale mounting hardware.

• Loose reader head.

• Very loose motion of th e table or saddle.

3. Accu mulating error is commonly the result of:

• Scale out of parallel to the axis travel.

• Dirt or chip on the glass scale.

• Broken glass.

4.7 TRAK Sensors

TRAK Sensors are used on the X and Y-axis for secondary feedback. They are optional on the DPMSX machines. The following section talks about some of the common symptoms associated with a problem sensor and how to isolate or fix the problem.

Common symptoms

• Faulting Axis

• The DRO measurements do not repeat

• The DRO measurements are not accurate

Objectives:

• To deter mine if the TRAK Sensor is bad and needs to be replaced.

• To determine if there is a problem with the sensor set-up

4.7.1 Faulting Axis

If a sensor has stopped reading and you try to move an axis, the axis will run away and fault. Our control uses the counts from the sensor and motor when reading position. If either on e of these signals is not wo rking our sy stem will fault.

1. The first thing that can be done to see if it is the sensor is to turn off the sensor on the axis in question. This will allow th e system to run only on the motor encod ers. If the fault continues then the sensor was not the problem. Turn the sensor back on. See the service code section for a codes needed to turn the sensors on and off.

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2. The next thing to do is to visually inspect the sensor and base to determine if there has been a crash. A dam aged base will usua lly have crinkles in the small, triangu lar plates on the front and back.

3. Next make sure the sensor is preloaded correctly against the running surface. There is a setscrew on the base that allows for adjustment.

4. If no outward signs of damage are present, remove the sensor from its base, and inspect the wheel for damage and wear.

If the wheel is worn smooth in the center, replace the sensor.

Note: Sensors should not wear smooth for many years of normal operation.

5. If the sensor looks normal, it is probably OK and there is a mechanical obstruction somewhere in the set-up. Look for the following possible problems:

• Broken sensor base

• Broken bracket

• Sensor tilted too much (so that the wheel is not engaging the running surface)

• Sensor chip scraper has doubled back and is pushing the wheel away from the

running surface

• Sensor chip scraper is defective or has worn and is pushing the sensor unevenly

4.7.2 Measurements Do Not Repeat

1. Determine if the error in repeatability is random or accumulating:

• Mount a dial in dicator in the quill

• Touch off a fixed point on the table and set the DRO to 0.

• Traverse away approximately 6 inches

• Return and touch off again

• Write down the reading on the DRO.

• Do not re-zero the DRO, traverse away and return several times

• Write down the DRO readings

Random error will be unpredictable and give scattered readings, adding and/or subtracting the error after each traverse with no pattern. See Step 2.

Accumulating error will add roughly the sam e amount to the reading a fter each traverse. See Step 3.

2. For random error, look for problems in the set-up of the TRAK Sensor that have resulted in a loss of rigidity. Common sources of random error include:

• broken base

• broken bracket

• loose puller screws

• loose run bar

• very loose motion of the tab le or saddle

• loose clamp screw

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3. Accumulating error is almost always the result of the wheel not traveling in a path

parallel to the motion of the axis. This causes the wheel to skip at certain regular points in its travel.

• Inspec t the base to determine if it has been damaged. A damaged base will usually have crinkles in the small, trian gle-shaped plates on the front and back.

• Use a bubble level or an indicator to adjust the puller screws so that the base is parallel to the running surface.

• Inspect that the sensor is not cocked so that the case contacts the running surface.

• Inspect the wheel for chips that are adhered or for gouges.

4.8 Electrical

4.8.1 Checking A/C Voltage

This procedure tests for the 115V power for the control.

• Use a Voltmeter, reading A/C volts.

• Acceptable range is 100V to 130V.

Note: systems running consistently close t o t he l ow values may have problems when normal voltage fluctuations push the voltage out of the acceptable range.

Test the following in the order presented:

Problems Here: May Indicate:

1. The wall outlet. • Fuse blown in the shop electrical panel.

• Incoming service from local utility is bad. Call the electric company.

2. The control power cord from the wall. Check the end that goes to the electrics box.

3. Check the top fuse on the electrical cabinet. It should be an 8-amp fuse.

3. Check the 110 power cord to the pendant. • Power cord defective

• Power cord defective.

• If this is blown then power will not reach

the 4 outlets on the electrical box.

4.8.2 Checking Fuses

There are 5 fuses to check in the system. There are 2 in the pendant and 2 in the electrical cabinet. The top fuse in the electrical cabinet is 8 amp and fuses power to the pendant. The bo ttom fuse is 5 amps and fuses power to the auxiliar y 1, auxiliary 2 and lube pump outlets. The 2 fuses in the pendant are 1 amp and 8 amp. The 8 amp fuses the cable breakout box, and the 1 amp the pendant.

If you hav e the auxiliary function option then th ere is 1 more fuse to check on the cable breakout box for the coola nt or mister option.

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To check fu ses:

1. Use a Volt/Ohmmeter; select “OHM”.

2. Remove the fuse completely from the pendant, electrics box or cable breakout box.

3. Place a lead of the meter on each end of the fuse.

• A good fuse reads 0 (zero) or close to it.

• A bad fuse reads Open or Infinity.

4.8.3 Cable Breakout Box Connections

This module is located on the ba ck side of the machine. It consists of 3 motor connections, 3 limit switch connections, 3 encoder connections and an E-stop connection.

Machines with an au xiliary func tion option have 2 more outlets. A 110 V outlet for a coolant pump or air solenoid and an indexer outlet.

The coola nt pump signal and indexer sign a l comes down from umbilica l #2.

4.8.4 Cable Connections

The DPMSX machines use 10+ 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

unplug

the system from the wall.

WARNING!

connector board and harm to the technician.

2. Visually inspect the connections for excessive de bris, moisture, or obvious damage.

3. Carefu lly clean any chips away from the connectors.

4. One-by-one, take out each connector and then plug them back in. Do the same at the computer/display.

5. Make sure to tighten up the screws on each of the connectors.

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Figure 19 Electrical Box Schematic – Non-Spindle Control P/N: 20676

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4.8.5 Spindle Control Electrical Box

The spindle contr o l electrical box is made up of the following main com ponents:

1. AC drive – used to control the spindle motor.

2. 4 outp ut 110 volt outlets – 1 outlet is used to power the pendant, 1 is used to power the lube pump and is turned on based on the spindle being on, 2 additional outlets.

3. 2 braking resistors – used to brake the spindle motor. The mechanical brake should not be used to brake the spindle. To verify the resistors are good, measure the resistance across B1 and B2 of the AC drive. For 3 HP machines it should read 60 ohms and for 5 HP machines it should read 32 ohms. Values lower or higher tha n this could be one or both resistors are bad.

4. relay – used to turn on and off the lube pump and spindle motor fan.

5. Spindle control PCB board - controls the auxiliary signa ls from the pendant to the AC drive and electrical outlets. The following explains the LED lights on the spindle control board. There are (2) 10 LED segments on the board. Not all of the LEDs are used. See figure 21 for an illustration.

10 LED Segment

4. LED labeled Gear 1 – this light should be on whenever the machine is in low gear. LEDs labeled Gear 2 thru Gear 4 are not used.

5. LED labeled SP D-FAULT – this light will be on whenever the A C drive is in a fault condition, which includes an E-stop message from the pendant.

6. LED labeled SPD -RUN – this lig ht should be on whenever t he spindle is on.

7. LED labeled SPD -ENABLE – this light should be on whenever you are in DRO, tool setup and RUN mode.

10 LED Segment

1. LED labeled E-STOP OUT – this light should be on whenever the E-stop is in t he out position. When the E-stop is pressed, this light should go off .

2. LED labeled LATCH RELAY – this light should be on when the spindle is running or if the spindle is not running and the fwd/rev switch is in the off position when in DRO, tool setup or RUN mode. Note – if spindle won’t turn on and the spindle is enabled and the e-stop is out, then either the fwd/rev switch is bad or the spindle control board is bad.

3. LED labeled TAP MODE – light should be on whenever you are not t apping. Light will be off when in th e tap event. Not applicable to knee mills or retrofits.

4. LED labeled TAP REVERSE – this light will be on when the spindle changes direction at the bottom of a tap event and back off after the spindle changes direction once outside of the tap event. Not applicable to knee mills or retrofits.

5. LED labeled REV-RELAY – when fwd/rev switch is in re verse this light will be on. Note – this does not mean necessarily that the spind le will be running this direction.

6. LED labeled FWD-RELAY – when fwd/rev sw itch is in forward this light will be on. Note – this does not mean necessarily that the spindle will be running this direction.

7. LED labeled Z-LIMIT PLUS – this light will be on on ly when the Z axis plus limit switch is triggered. This only applies to a 3

8. LED labeled Z-LIMIT MINUS – this light will be on only when the Z axis minus limit switch is triggered. This only applies to a 3

axis product.

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Figure 20 Schematic Diagram of Spindle Control Option

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Figure 21 LEDs on Spindle Control Board

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4.9 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 t o the code in question. Press CODE #, enter the number you want, press SET.

4.9.1 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: If you are working with the SWI Customer Service Group, write the values down for Code 33 or Code 313. These values will be valuable for troubleshooting.

4.9.1.1 CODE 33: Software ID

The Code 33 is the software identification procedure. The two types of software in the contr ol 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.

• Converter Version – the version of software that is responsible for converters and

options.

• Operating System Version – shows t he version of t he XP operating system.

4.9.1.2 CODE 141: Load Configuration File from an external drive

This code allows you to load your configuration file from the floppy disk or external drive to your h ard drive . The configurat ion file consists of item s such as calibration and backlash constants. This code is used when a computer module or hard drive has been replaced.

4.9.1.3 CODE 142: Save Configuration File to an external drive

This code allows you to save your configuration file to a floppy disk or external drive. 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 or external drive. It is a good idea t o do this code after the machine is initially setup so these va lues can be saved and used in the future. If the com puter or hard dr ive 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 on the included parts program floppy disk.

4.9.1.4 CODE 313: Display Configuration File

This code displays the configuration file. This file contain s pertine nt 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 = DPMSX3 (displays machine ID key of machine) Motor encoder calibration constants X=1143.9002 Y=1143.8982 Z=1143.7922

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Secondary feedback calibration constants X=3302.6122 Y=3302.6045 Z=3302.7122 (These numbers above are typical numbers for the calibration constants, the numbers for secondary feedback are default numbers, which means no calibration has been done, or the machine does not have secondary feedback) Arc accuracy – 0.001” Secondary feedback – 0, 1, 2 or 3

(0 = off, 1 = X on only, 2 = Y on only, 3 = XY both on) Code 11 values X = 0.002 Y = 0.001” Code 128 X=0.001” Y=0.0014” Z=0.0016” Code 12 (+) X=000005 Y=000006 Z=000006 (-) X=000005 Y=000005 Z=000006 Code 100 (+) X=210.5 Y=208.9 Z=200.1 (-) X=207.1 Y=208.4 Z=203.6

4.9.1.5 CODE 316: Update Master Software

Load upgrade disk in floppy drive or add software to an external drive and press this service code. New software will automatically download and control w ill reboot.

4.9.1.6 CODE 317: Update Slave Software

Load upgrade disk in floppy drive or add software to an external drive and press this service code. New software will automatically download.

4.9.1.7 CODE 318: Activate Converters or Options

See programming and operating manual. To turn software features on and off, see Service Code 334 in Section 4.9.4.6 of this service manual.

4.9.2 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.

4.9.2.1 CODE 11: Hysteresis

Note: This code is use only for systems with Sensors or Glass Scales on the table and saddle.

The Code 11 service routine checks the readings of the motor encoder against the sensor encoder. It is a measurement of how much motor motion is necessary to create table or saddle motion. This test helps us to look at two things:

• Play: How much backlash must be taken up when motion is reversed.

• Friction: How much the mechanical components must be "torqued up" in order to

break the friction and create motion.

The Code 11 procedure is ver y useful and will help in diagnosing all types of mot ion and performance problems.

1. Position the table and saddle in the center of travel. Note: You will lose your DRO

position reference.

2. Go into the Service Codes and input Code 11.

3. The system will run the c heckin g routine autom atically and then display the value s in

the position readout.

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Explanation: As an overall measure of the system hysteresis, we are looking for the X and Y values to be less than .004". A value greater than this indicates a problem with either excessive friction or play that may affect the finish or accuracy of machined parts.

4.9.2.2 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.

• 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 machi ne c hange s its fric t ion c haract eristi c , 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 au tomatically and then display v alues 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 d irection, and 4 in the other direction. The values should be within 3 or 4 of each other in both directions. A va lue of 6.08 wo uld still be c o nsidered normal.

On S products, do not equate Code 12 values to torque on ballscrew. Measure friction in system with an in-lb 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.

4.9.2.3 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.

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IMPORTANT -- SAFETY NOTIC E

During this procedure the designated axis will be given a comma nd to move at maximum speed

for 1 second in the direction you choose. Avoid crashes by makin g sure th e quill is out of the

way and by starting with the table and saddle centered. MAKE SURE THAT NO ONE IS

STANDING IN THE WAY OF THE TABLE 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 table and saddle and raise the head. Make sure the gib locks are

released.

2. On the P e ndant display, go into the Service Codes and input th e Code 100.

3. The conversat ion line will say: “SELECT AXIS”. Input the axis. Either X, Y or Z.

4. In the conversation line it will say “WHIC H 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

5. In the conversation line it will say “PRESS GO”. Press Go after you are sure that the

machine will not crash in the dir ection and axis that you have specified.

6. Afterward the screen will display values ne xt to the DRO position axes. The table

below assumes machine has secondary feedback. Machines with motor encoders only will displa y the rea ding next to the axis in question.

Your input Display Data displayed.

X + X table encoder reading

Y nothing (should be 0) Z Motor encoder reading Feedrate the maximum feedrate attained

Your input X table encoder reading

X - Y nothing (should be 0)

Z Motor encoder reading Feedrate the maximum feedrate attained

Your input X nothing (should be 0)

Y + Y table encoder reading

Z Motor encoder reading Feedrate the maximum feedrate attained

Your input X nothing (should be 0)

Y - Y table encoder reading

Z Motor encoder reading Feedrate the maximum feedrate attained

Your input X nothing (should be 0)

Z + Y nothing (should be 0)

Z motor encoder reading Feedrate the maximum feedrate attained

Your input X nothing (should be 0)

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Z - Y nothing (should be 0)

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 3.0000” to 5.0000”.

• If the motor encoder and sensor or glass scale reading is not within this value, then

the one that is out of specification may be the problem. If one of the encoders is not rea ding th en it will n eed to be replaced.

• The feedrate should be a minimum of 180 ipm.

• If the feedrate is less than 180 ipm and inconsistent in both directions, check the

incoming AC voltage and mechanics of the drive train.

4.9.2.4 CODE 123: Calibration

See Section 5.2.2 for a further explanation of this code.

4.9.2.5 CODE 127 - Set X or Y Backlash Constant

See Section 5.2.2 for a further explanation of this code.

4.9.2.6 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 m achines with motor encoders only.

4.9.2.7 Code 304: Toggles X Sensor or Glass Scale On/Off

This service code toggles the X sensor or glass scale on or off. It is used to configure the machine and also is a useful tool for troubleshooting. Code 313 (configuration file) displays whether the sensors have been turned on or off. The line labeled secondary feedback explains which sensors or glass scales are turned on. This line can read any one of the following:

0 = sensors or glass scales turne d off 1 = X sensor or g la ss scale turn ed on only 2 = Y sensor or glass scale turn ed on only 3 = both X and Y sensor or glass scale turned on

4.9.2.8 Code 305: Toggles Y Sensor or Glass Scale On/Off

This service code toggles the Y sensor or glass scale on or off. See Code 304 for fu rther explanation.

4.9.2.9 Code 312: Toggles Limit Switch On/Off

4.9.2.10 Code 321: Reverse Y Position Sensor Direction

This service code reverses the direction of the encoder. It may be needed if sensors or glass scales are mounted on different sides of the machine.

4.9.2.11 Code 322: Reverse X Position Sensor Direction

This service code reverses the direction of the encoder. It may be needed if sensors or glass scales are mounted on different sides of the machine.

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4.9.2.12 Code 325: Reverse Quill Sensor Direction

This service code reverses the direction of the encoder.

4.9.2.13 Code 337: Spindle calibration (for machines with

programmable spindle)

This service code is used to calib rate a programmable spindle. You must also use a tachometer.

4.9.2.14 Code 338: Selects 1 or 2-input type limit switch

4.9.3 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.

4.9.3.1 Code 54: Program Continuous Run

This Code runs a program continuously without stopping for SET Z or CHECK Z 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.

4.9.3.2 Code 81: Keyboard Test

This code is used to check if t he keyboard is functioning correctly. It allows you to test each key on the pendant individually. When you press the keys, th e corresponding box for tha t key will hig hlight on the screen. The pendant will also bee p, 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.

4.9.3.3 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 co de will displa y the ac tual DRO counts and the raw encoder counts before the calibration and backlash factors have been factors into the counts.

4.9.3.4 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 workin g. If functionin g it should flash a gr een light. The bott o m light sig nifies if t he slave f irmware is functioning. It will appear orange in run mode when it is processing information. Pressing the mode key will change this orange b o x to black. The orange box will also change to black when the program you are running reaches the 3 up no keys will work. This code is useful f o r diagno sing intermittent problems with the control locking up.

event from the end of the program. If the firmware is locked

Turn the X, Y, 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 0.2000”.

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4.9.3.5 Code 319: Error Log

This code when turned on captures the commands that were sent to the servo system. It includ es items such as positioning commands, errors, stop and go commands, etc. It may be helpfu l 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 t o 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 or external drive by following the instructions on the screen. Once this is 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 cle ar the files press the F7 softkey.

4.9.3.6 Code 324: Toggle Simulation Mode

Simulation Mode allows the control to run a program without actually moving the table. It is helpf ul in diagnosing Computer/display pr oblems.

4.9.4 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.

4.9.4.1 Code 66: Default Metric

This code causes the control to turn on in the metric mode.

4.9.4.2 Code 67: Default English

This code causes t he control to turn on in the English mode.

4.9.4.3 Code 79: Beeper On

This turns on the beeper to the control keys.

4.9.4.4 Code 80: Beeper Off

This turns off the beeper to the control keys.

4.9.4.5 Code 129: Arc Accuracy

When the SMX 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.” Th e control is factory preset to allow a maximum following error of

0.001 inch. The feedrate will automatically be adjusted aroun d sharp corners so as to not violate this limit. This code only applies to arcs that are programmed and ones that are created in the tool path to ge nerate the shape you want. This co de will not make a difference on mill moves.

You may adjust the maximum following error to a value as small as .0001 inch. However, the smaller the value, the slower the feedrate around corners.

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To input a new Following Error use the following procedure: Follow the instructions on the screen and input th e Following Error value (from .0001 to

.0100) and press INC SET.

4.9.4.6 Code 334: Set Control Options

This code turns software features on and off.

4.9.4.7 Code 335: Toggles spindle on/off during pause events

4.9.4.8 Code 336: Enables spindle to stay on throughout all modes

(2-axis mills ONLY)

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5.0 Procedures for Replacements & Maintenance

5.1 Replacements

5.1.1 Servo Motor Replacement

WARNING!

Do not work with the Servo Motors unless the power is disconnected f rom th e machine. The

servomotors are run by 110 VAC. There is possibility of death by electrocution!

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 f rom the machine. The

servo drivers are run by 110 VAC. There is possibility of death by electrocution!

The Servo Driver for each axis is integrated into the servo motor casting.

DANGER!

Always engage (push in) the Emergency Stop switch, turn the ProtoTRAK SM Control off, and

disconnect the servo motor/driver cable at the cable breakout box.

1. Press in the Emergency Stop.

2. Remove the servo motor/driver assembly from its mounting bracket (the Y axi s

assembly is located inside the front of the bed).

3. Remove the 10 cap screws that hold the servo driver and its heat sink plate t o th e m otor

casting.

4. Disconnect the cable connector. Do not pull on the wires.

5. Reinstall the new ser vo dri ver with i ts heat sink plate. Be certain the gasket properly

seals the assemb ly.

6. Reinstall the motor/driver assembly. Make certain the belt is tight so that there is

little play if pinched in the middle.

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Figure 22 Servo Driver Replacement

5.1. 3 Computer Module and LCD/Enclo sure Replace ment

Part # Descrip tion

24101-5 X, Y or Z Servo Driver

1. Turn power off to the mach ine and control.

2. Unplug all the conn ectors on the pendant arm side of the pendant.

3. Remove the pen d ant from the pendant arm by removing the (4) ¼-20 x 3/4” SCHS that secure it in place.

4. Place the pendant assembly on a clean and secured table with the display point ing away from you.

5. 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.

6. Pull the computer module a few inches and stop. Pulling the computer module too far will damage the ribbon cables.

7. Now reach from the top and remove the 37-pin LCD cable, 37-pin distribution cable and the 9-pin E/Stop cables. The cables are to stay with the computer module.

8. Now slide the module about ½ way out of the LCD/enclosure.

9. Remove the ground wire from the LCD/enclosure side.

10. Lastly, slide the unit completely out of the LCD/enclosure.

11. Replace computer module or LCD/enclosure.

12. Follow the instructions in reverse order when reinstalling the new computer module or LCD/enclosure.

13. Make sure that all connectors are properly seated before fastening th e unit back in place.

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Figure 23 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 sav e your Configura tion file (calibration values, etc.) on a floppy disk or USB drive. Label this disk as “Backup Configuration” and store it for later use.

2. Turn power off to the mach ine and control.

3. Unplug all the conn ectors on the pendant arm side of the pendant.

4. Remove the pen d ant 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 point ing 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 inches and stop. Pulling the computer module too far will damage the ribbon cables. If need be, remove 4 cables that connect the computer module to the enclosure. Make sure to reattach them secu rely before re-assembling the pendant.

8. Remove the defec tive System Flash Disk (located on the back side of the mo ther 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.

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 th e 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. Clear this message and continue.

14. From the control, go to SETUP, SERV CODES, SECTION A, and then code 33 and verify your software and firmware versions are current.

15. To verify the current version, go to www.southwesternindustries.com and then Software for current Prototrak CNC’s, locate the download for the control.

16. If your software is an older version and does not match the one on the website, follow the instructions for updating your control using a USB thumb drive.

17. Restore the Configuration file saved on your backup configuration disk with service code 141 found in section A of the service code section.

18. If your control was networked prior to this change, you will have to reset your network settings.

, click on support

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Figure 24 Flash Disk Replacement

Flash Disk Parts List

Item P/N Description

1 24008-1 PENDANT WITHOUT COMPUTER MODULE 2 24030-1 COMPUTER MODULE

25078 FLASH DISK (used on Revision D or later pendant)

25078-1 FLA S H DISK ( used on Revision C or earlier pendant)

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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 (3) 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. See Figures 16 and 17 for a layout of the cable connections.

5.1.6 TRAK Sensor

5.1.6.1 Replacing the M5 Base

See Figures 25 and 26.

1. Remove the sensor by removing the clamp screw and then backing the load screw out a few turns. The sen sor should lift off the base easily.

2. Remove the o ld M5 Base by removing the two 1/4-20 hex head screws that are threaded into the base.

3. Assemble the new base as per Figure 25.

4. Use a bubble level to align the raised bumps on the base with the table for X axis or saddle ways for Y-axis.

5. A dial indicator may be u sed to align the bumps on the base instead of a bubble level.

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5.1.6.2 Replacing the TRAK Sensor

1. Remove the old sensor by removing the clamp screw and then backing the load

screw out a few turns. The sensor should lift off the base easily.

2. Install the new sensor on the M5 base using the clamp screw.

3. Load the sensor against the running surface (table or run bar) using the load screw.

The white lines on the side of the M5 base tell you when it is loaded correctly.

Note: You want to load the gage wheel against the running surface using the flat spring of the M5 base. Do not tighten the clamp screw fully until after loading the sensor.

Figure 25 M5 Base Mounting

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Figure 26 TRAK Sensor Mounting

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Figure 27 DPMSX2 Sensor Assembly

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Figure 28 DPMSX3 Sensor Assembly

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Figure 29 DPMS5 Sensor Assembly

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5.1.7 Glass Scale Replacement

5.1.7.1 Remove the X, Y or Z Glass Scale

1. Unplug the glass scale connector from the cable breakout box.

2. Unbolt the reader head of the glass scale from its mounting surface.

3. Unbolt the glass scale enclosure from the table on X or the mounting spar on Y.

4. Install the head alignment bracket that came with the replacement scale to this scale

to secure it for shipping back to SWI. Failure to do this may cause the glass scale to get damaged during shipment. The head alignment bracket secures the reader head so it cannot move and damage the glass in the scale.

Note: 1

align the reader head on the new scale before removing it to fasten the old scale.

CAUTION!

Once the head alignment bracket is installed, do not traverse the axis or the

reader head will break.

5.1.7.2 Install the X or Y Replacement Scale

CAUTION!

If the scale is not long enough for the table, it will break when the machine is

traversed past the scale travel.

1. Mount the scale to the back of the table or Y-axis mounting spar.

2. Align the sale so that it is within +/- 0.005" end to end.

Notes: For the Y-axis, the mounting spar should already be aligned. It must be parallel to the Yaxis travel within +/-.005" end to end both horizontally and vertically. The mounting spar can be aligned in and out by the use of the adjustment screw.

3. Line the reader head up with the mounting holes on the back of the saddle for the X-

axis or the bracket on the Y-axis.

4. Install the reader head bolts but leave them loose.

5. Use the jackscrews on the reader head to compensate for some gap between the reader

head and the reader head mounting bracket. Leave the alignment brackets attached to the reader head. This bracket assures the reader head is aligned to the glass scale.

6. Tighten each jackscrew until it touches the bracket and then back it off 0.001” or

0.002”. Use a feeler gage to set the gap.

7. Tightening the reader head mounting screws. This ensures the reader head is

aligned within a few thousandths.

8. Remove the shipping bracket that fixes the reader head to the scale for shipping.

WARNING!

After the reader head is attached to the reader head mounting bracket, do not move

the machine axis until the shipping bracket is removed. This will break the reader

head. This is not covered under warranty.

See Figure 31 and 32 for an illustration of how to align glass scales.

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prototrak DPMSX2, SX3 Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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