YASNAC LX3
CNC SYSTEM FOR TURNING APPLICATIONS
MAINTENANCE
Before initial OF
)eration read these instructions thoroughly, and retain for future reference
YASUAVVA
This manual is primarily intended to give operator’s maintenance instruc-
tions for YASK!”ICLX3.
The information contained in manual does not provide all details to be
met. concerning maintenance and troubleshooting.
If uncertainties be
encountered for particular maintenance operation, refer to the following
YASNACLX3documents for additional information:
. YASNACLX3/llX3PC SYSTEM(TOE-C843-9.1)
. YASNACLX3SPECIFICATIONS(sIE-C843-9.20)
. YASNACLX3OPERATOR’S MANUAL(TOEC843-9. 20)
. YASNACLX3CONNECTINGMANUAL(TOE-C843-9. 22)
a ---- .
YASNAC1,X3OPllRfiTOR’SSTATION
TABLEOF CONTENTS
1. OUTLINE1
1.1 COMPONENTARRANGEMENT1
1.2 CONSTRUCTION3
1.3 MAJORCOMPONENTS5
2. ROUTINEINSPECTIONSCHEDULE7
2.1 TAPEREADER8
2.2 CONTROLPANEL 8
2.3 ACSERVOMOTOR8
2.4 BATTERY9
3. MAINTENANCEINSTRUMENTS10
4. TROUBLESIIOOTING11
4.1 TROUBLEIDENTIFICATION11
4.2 TROUBLESBOOTINGBYALARMCODES 12
7. SETTINGANDADJUSTMENTFORMODULE56
7.1 MB20BOARD56
7.2 SP20 BOARD57
7.31020 BOARD57
7.4 1021 57
7.5 AREANOSETTINGAND1/0 ADDRESSPORT 5!3
8. NCDATABANDLING60
8.1 SYSTEMNO. SETTING(#6219) 60
8.2 DISPLAYINGANDWRITINGPARAMETERS60
8.3 DISPLAYINGANDWRITINGKEEPMEMORY62
8.4 TAPEINPUTOF SETTINGDATAANDPARAMETER
DATA62
8.5 PUNCBING-OUTOF SETTINGDATAAND
PARAMETERDATA63
4.3 TROUBLESHOOTINGWIT11OUTALARMCODES 28
4.4 MAINTENANCEOF ACGC 45
4.5 SUPPLYVOLTAGECIIECK 47
4.6 INPUT/OUTPUTSTATUSDISPLAYBYON-LINE
DIAGNOSTICSFUNCTION(DGN) 48
5. ADJUSTMENTSUPONINSTALLATION50
5.1 ADJUSTKIH{TPROCEiNRES50
6. MODULE/UNITREPLACEMENTPROCEDURE53
6.1 CPUUNIT 53
6.2 OPERATOR’S PANEL 54
6.3 OPTIONALMODULES55
8.6 SUMMARYOF STORINGDATAANDEDITING
OPERATIONS64
APPENDIX1 LIST OF ALARMCODE 65
APPENDIX2 LIST OF DATA 96
APPENDIX3 LIST OF SETTINGNOMBERS104
APPENDIX4 LIST OF PARAMETERNUMBERS112
APPENDIX5 STOREDLEADSCREWERROR
COMPENSATION130
APPENDIX6 LIST OF STANDAKDINPUT/
OUTPUTSIGNALS 131
INDIX
SUBJECT CHAPTER SECTION
AACSERVOMOTOR ”” S”.+.”*’ “.0” .”000””2. ”2.30 .8
ACGCALARMINDICATION*O” O* OOO*
ADJUSTMENTPROCIIDURES”+””. ”0
ADJUSTMENTSUPONINSTALLATION* “ “ “ . . “ o 0 0 “ + o 5 “ s 5.
ALARMO1OANDO1I (Parity Error)
● “ “ ● ‘ “ ● s “ ● “ “ 4 “ “ 4.2.1 “ “ 12
●o*{oco *4*04.4.20*45
●*””O”OO” 05..5.1” “50
● “ 50
ALARM075, 076, 077 (RS232C Faulty) “ . . “ “ “ . 0 “ “ 4 “ . 4.2.2 s “ 14
ALARM170, 172, 173, 174 AND175 (MemoryError) . “
ALARM179 (Temperature Alarm inside the Panel)
● “ “ ● “ 4 “ “ 4.2.4 ● “ 18
ALARM31O(Servo Power Supply Incomplete) “ . . “ “
ALARM320 (Control Not Ready)
ALARM323(ACGC2SYNC ERROR)”*”” O”
ALARM325 (Servo CPUError) .
● “ ● “ “ ● “ “ “ o “ . “ 4 “ ● 4.2.9 s “ 21
● *”. oQ”” 4.” 4.2.18 ““ 27
● ● ● ● ● ● “ . . c o “ ● 4 . “ 4.2.15 ● “ 26
ALARM329 (Built-in type PC CPUError)” + “ o “ “ “ .
ALARM330 (Emergency Stop)” “
ALARM820 (ROM/RAMCheckError) “ .
● ● “ ● . + o “ “ “ . * ● 4 ‘ “ 4.2.10 “ “ 22
● ● “ ● ● ● “ ● ● “ 4 ● o 4.2.17 ● ● 26
ALARMS231 AND232 (Zero Point Return Area Error)
● ‘ 4 . “ 4.2.3 “ . 17
● “ 4 . 0 4.2.8 ● o 21
● 4 “ o 4.2.16 . 0 26
● “ ● 4 “ “ 4.2.5 ● o 19
ALARMS241 AND242 (Reference Point Return Area Error) “ 4 “ “ 4.2.6 “ “ 20
ALARMS271 AND272 (P-SET Error)* “ “ “
ALARMS331 AND332 (Servo Fuse Blown) . .
ALARMS341 AND342 (Servo Error)
● . ● ● ● ● ● ● “ ● ● ● 4 “ ● 4.2.12 ● ● 23
● “ o “ “ ‘ “ ● 4 “ . 4.2.7 “ + 20
● ● “ ● . + ‘ 4 “ . 4.2.11 ● “ 22
PAGE
ALARMS351 AND352 (Motor Overload) “ + “ “ “ “ “
ALARMS361, 362 AND366 (PG Disconnection Error) . . “ . 4 s
● “ “ 4 ● “ 4.2.13 0 . 24
● 4.2.14 . “ 25
APPENDIXILISTOF ALARMCODE”* “*0””00”0*””.”*”0 ““””” 65
APPENDIX2LISTOFDATA” *”’” ““”””’””’”””””””” “’”””915
APPENDIx3LIsToF sETTrNGNuMBERs ““””’””’”’””””””” ““””104
APPENDIX4 LIST OF PARAMETERNUMBERS“
APPENDIX5 STOREDLEADSCREWERRORCOMPENSATION“
APPENDIX6 LIST OF STANDARDINPUT/OUTPUTSIGNALS + +
● . 0 “ . + “ “ ● “ “ o “ + o “ . ● + 112
● “ ‘ o “ “ . ● ● “ o . . . 130
● . “ ● . 0 c o “ “ “ “ lQl
AREANOSETTINGAND1/0 ADDRESSPORT” “ “ . . “ . + “ “ 7 “ o 7.5
BBATTERY”*.so”””.””.” “..””””.o”+2.”2,4
C CHECKACPOWERSUPPLYVOLTAGEo
● “ ● “ . ● + . “ ● ● ● 4 0 “ 4.5.1
CHECKDCPOWERSUPPLYVOLTAGE.“. . “ s “ “ “ “ . . “ “ 4 “ - 4.5.3
COMPON!3NTARRANGEMENT””O” “+”.””0.”*””” 1“” 1.1
CONSTRUCTIONO. “ “ “ “ “ “ “ “. + “ “ “ o 0 “ “ “ “ “ 1 “ “ 1.2
CONTROLPANEL “
● ● “ “ ‘**” ““ . 0 .* o “ “ ● “ ● 2 “ “ 2.2
II
. .
. .
. .
. .
. .
. .
. .
101
59
9
47
48
1
3
8
INI)IX
SUBJIK1’
c
DISPLAYINGANDWRITINGKEEPMEMORY
D
● ● “ “ “ ● ● “ “ ● ● 8 “ o
DISPLAYINGANDWRITINGPARAMETERSs “ o ● “ ● o + “ “ ● 8 “ o
E
EDIT DOESNOTFUNCTION”QO*”O O“”OO””OS”O 4+”
FAULTSNOTDISPLAYEDACGCALARMINDICATION”
F
● o ● ● ● “ 4 “ +
H
INDICATIONLAMPOF POWERSUPPLYUNIT” “
I
● “ ● “ o 0 0 “ 4 0 0
INITIAL DIAGNOSTICERRORDISPLAYATI’OWERAPPLICATION“ 4
INPUT/OUTPUTSTATUSDISPLAYBYON-LINEDIAGNOSTICS
FUNCTION(DGN)O****OO*” *O””
●00*0 ”” *4”*
1020 BOARD””””””””””””””” ““””””””7””
10210.”000.o”””ooc”**. 0“”0”0”*7+0
CHAPTER
SECTION
4.3.3
6.1
4.3.4
4.3.9
8.3
8.2
4.3.13
4.4.3
4.3.5
4.5.2
4.3.2
4.6
7.3
7.4
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
PAGE
29
53
30
35
62
60
40
45
30
48
29
48
57
57
MAINTENANCEINSTRUMENTS
M
● ● ● “ ● + s ● ● ● o “ ● ● ● ● 3 + ●
tlAINTENANCEOF ACGC*””” 00 O+” ● *””” 0.0”40s
MAJORCOMPONENTS””” O” DO Q”~OQ ““O OO” C”l SO
MANUALJOG MODEOPERATIONFAULTY*+ “ +
● “ ● ● ● ● ● “ 4 Q ●
MANUALRAPIDMODEOPERATIONFAULTY“ ● ● ● ● ● “ ● “ o “ 4 “ ●
MANUALZERORETURNOPERATIONFAULTY● “ o + “ “ ● ● ● ● 4 “ “
MB20BOARD””””””””””””””” ““””””””7””
MODULE/UNITREPLACEMENTPROCEDURE
● ● + ● c ● ● “ “ “ c 6 “ ●
NCDATAIIANDLING*”” BOO.”**** “*”00”0”80*
9* CRTSCREENIS DARK””””””””” ““””””””4””
OPERATINGPROCEDURETO DISPLAYINPUT/OUTPUTSIGNALS
o
● ● 4 ● ●
OPERATIONIS NOTAVAILABLEWITHGO1, G02 ORG03 “ ● o ● 4 0 ●
OPERATIONIS NOTAVAILABLEWITHG32, G76 ORG92 “ “ ● ● 4 . c
OPERATOR’SPANELO
OPTIONALMODULES*
● + . “ “ ““ “ o ● OO ● “ “ ● o ● “ 6 “ “
● ● ● “ “ ● + ● ● ● + ● ● ‘ ● s ● ● ● 6 “ o
3.
4.4
1.3
4.3.6
4.3.7
4.3.8
7.1
6.
8.
4.3.12
4.6.2
4.3.10
4.3.15
6.2
6.3
1.
4.6.1
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
10
45
5
32
33
34
56
53
60
39
49
36
42
54
55
1
48
RI
INDIX
SUBJECT
CHAPTER SECTION
PAGE
P PARAtlETERDATADISPLAY”””*” ““.”’”~””0”” 8“” 8.2.2 ““ 61
PA[{AHETERTYPES ”O” OO”. ”O ””* ““”” ”””’ 8”08.2.1*”61
POWERC8NNOTBESUPPLIED”O”. .O”” .“”””.”. 4.* 4,3.1 “O 28
PUNCHING-OUTOF SETTINGDATAANDPARAMETERDATB “ “ “ ‘ 8 “ Q 8.5 e
o 63
R RUCOGNI’rIONOF NCSYSTEM”.O.” “’””+””””~” 4“. 4.1.2 .. 11
RECOGNITIONOF TROUBLESTATUS “ . 0 . “ s . s “ o “ “ . 4 “ “ 4.1.1 “ “ 11
ROUTINEINSPECTIONSCHEDULEo . “ “ “ “ “ “ “ “ “ “ . 0 2 0 s 2. “ “ 7
Rs232C DOESNOTFUNCTIONWELL“ “ “ . “ “ “ “ “ “ “ . “ 4 “ “ 4.3.14 0 “ 41
S SETTINGANDADJUSTMINTFORMODULE.
● . “ “ “ “ “ . “ “ 7 . s 7. 0 “ 56
SKIP FUNCTION(G31) OPERATIONFAILURE o . “ . 0 “ “ . “ 4 “ “ 4.3.16 . “ 43
SOFTWAREVERSIONINDICATION. “
● . 0 0 “ “ o “ o “ “ “ 4 0 s 4.4.4 0 “ 46
SP20BOARD””O. .OS”” O”” *-O ““”” ”0”07”.7.2””57
SPINDLEDOESNOTROTATE”””. “.”””..””””” 4.” 4.3.11 .“ 37
SUMMARYOF STORINGDATAANDEDITINGOPERATIONSo
● “ “ . 8 “ “ 8.6 “ . 64
SUPPLYVOLTAGECliECK” **”””” “..00””””*~4””4.5 ‘.47
SYSTEMNO. SETTING(#6219) ”OO” O”0 ““O”OOCS 8.” 8.1 .“ 60
T TAPEINPUTOF SETTINGDATAANDPARAMETERDATA “ “ “ ~ Q 8 “ “ 8.4 “ “ 62
TAPEMODEDOESNOTFUNCTION00 ””” +. ”.”””.” 40~ 4.3.17 “* 44
TAPEREADERo
● “ . 0 + . “ o “ “ ● ● “ “ Q “ o 0 “ . “ 2 . “ 2.1 ““ 8
TROUBLEIDENTIFICATION”””” .0”00 ““00.+”” 4“” 4.1 “O 11
TROUIILESliOOTING*”. .O”””” O*O 0“.”0”.*40.4.””
TROUBLESHOOTINGBYALARMCODES“ . .
TROUBLESHOOTINGSERVICEOF ACGC
0 . “ . * . “ “ o “ 4 “ . 4.2 “ “ 12
● “ “ “ + . “ “ - “ “ ● 4 0 ● 4.4.1 “ o 45
TROUBLESHOOTINGWITHOUTALARMCODES o “ “ “ “ s “ . “ “ 4 “ “ 4.3 “ “ 28
W WI{ITINGPARAMETERDATA””’”” .-”.””’’”... 8“. 8.2.3 “- Cl
N
1. OUTLINE
The YASNACLX3provides you with an internal
self-diagnosis function (DGN). System maintenance can easily be accomplished with DGNand
other main functions as listed below;
(1) Microprocessor always monitors the machine
operations internally and can display the
status with function keys. IF any failure
occurs, NCimmediately stops with the blinking
of alarm displays. Also the same precedure
1.1 COMPONENTARRANGEMENT
MACNINE
CONTROL
STATION
1/()
9’sCRT PANEL
D’
(OpTIONAL)
v
d
2
EEJ
Ia.lz
w=
H
~g
Ucn
I
CONTROL UNITS
GENERAL PURPOSE
1/0 MODULE
be executed on machine sequence for the
can
ication of buit-in type programmable con-
apo
ler,
tro
ON/OFFSIGNALof Input to NC/Output from
(2)
NCcan be displayed with DGN
(3) Setting value of various
as accel/decel time constant
parameters such
and rapid speed.
ACCC
(OPTIONAL)
)
.
AC SERVO
DRIVE UNIT
f---
7
---
[
AC SERVO
DRIVE UNIT
—
1
X-Axis
kbtor
I
+ CONTROL CABINET I
Fig. 1.1 Component Arrangement of YASNAC-LX3
–l–
1~1 COMPONENTARRANGEMENT(Cont’ d)
YASNA(’ 1.X:1
—.
POWER SUPPLY UNIT
~-cPs.,”t4 --1
u
-.
NAIN BOARD
~-;ANCt3- kmzo -
CNA
(AVN)
0
,
CNI{
PC)
(
.
f-
CNC
(MM)
u
CNI)
(MM)
(1
1
CNI;
( OP”I”ION” )
CNl(Sl))
(’Nil
(’N12
(’N13
-J
CNl
1+
CN z
CN 4
CN5
(’N 6
1
cNII
( 1/[))
/.., *
G,. ,
!
i
L
c’N 8
-~ ,
<
+
5X
,1
ST
&
1
S1’(i
‘Ill
NS-2.i2C
111)1.c
r+I
!--L
!1
@
‘cl
@l
cl
C2
~
~
C6
\c7J j
@j
m TO
SP20. CN3
200 VAC INPUT
X-AXIS DRIVE
Fr;w$x-mlsMOTOR
~;%%y’- Z-A’IS MOTOR
k’--,-’
SPINDLE DRIVE
poWER INPUT SEQu_OpTIcM ENCODER
~.—
L-. _~
1
lto~
AC(; C
RESISTOR
FOR SPINDLE
“1
TAPE READER
TYP; :III’1{ ~
1
L _ti
]
L-_. -J
DIRECT-IN
4 POINTS
I/0 _BOARD
JANCD - 1020-
[
—-
cN51
CN52
cN53
CN54
0111”
m
OUTPUT : 40 POINTS
INPUT :
OUTPUT : 8 POINTS
INPUT : 24 POINTS
OUTPUT :
CRT PANEL
32 Fonm
8 POINTS
16 POINTS
40 POINTS
Note :
Show cable No.
Fig. 1.2 Connection Diagram
OPTICAL ENCODER
Circled “C” values.
–2–
1.2 CONSTRUCTION
(1)
(’2)
Appr(
Weigl
-176
SUPPLY
L
BOARD
BOARD
I
BOARD
MB20 MAIN BOARD
UNIT
Fig. 1.3 CPUModule
Fig. 1.4 9“CRT Unit (rear view)
Fig. 1.5 Tape Reader Unit
–3–
1, z CONSTRUL’TION(Cont’ d)
(3)
RELAY UNIT
:.-
J
/
CONTACTOR UNIT
SPINDLE
DRIVE UNIT
Fig. 1.6 Example of Un
AC SERVO PACK
J ..> /
TRANSFORMER
COOLING UNIT
t Assembly with High Voltage Units
— CPU
M,~I)lJLE
586-173
MAJORCOMPONENTS
1.3
YASNACMAJORCOMPONENTS
(1)
ComponentName
PowerSupply Unit
TapeReader
Tape Reel
tfain Board
PCBoard
tlemoryBoard
MemoryUoardfor Extension
Control Station
CRTDisplay Unit
KeyLtoardUnit
SP Board
General Purpose 1/0 Board
General Purpose 1/0 Module
Tahte 1.1 YASNACHajor Components
Type
CPS-1ON I I
MODEL2801
t10DflL1500
t10tIEL1402-1
Code
AVRKN
RED18
RLD14
RED13
I
Remarks
Option
OptIon
Option
JANCI)-MB20CDTN5270
JANCI)-PC20
JANCD-MM20
DTN4770
OTN4790
JANCI)-MM21-2DTN5170 Memorylength: [?0m,160m
JANCD-MM21-3DTN5180 Memorylength: 320 m
JANCI.-NN21-4
DTN5190 Memorylength: 640 m (option)
JANCD-MM21-5DTN5200 Memoryleneth: 1280m
JANCD-tlH21-6DTN521OMemorylength: 2560m
JZNC-OP1O1-1DUN13190Without Panel 1/0
JZNC-OP1O1-2DUN13200\With Panel 1/0
TR-9D+T,0 ,
These units are included in
the ahove control station.
JANCD-102O-OI
DTN4800
JANCD-1020-02 DTN481O
JANCO-102O-O3OTN4820
JANCD-1021
DTN5250
Separated type
–4–
(2) ACGCMajor Components
Table 1.2 ACGCMajor Components
14” CRTUnit
Keyboard Unit
Keyboard Unit BMK-2293-03
Keyboard Unit
Power Supply Unit
CPUModule
Graphic Module
MemoryModule
MemoryUnit
Battery Unit
(3) ACServo Units
Name Type
C-5470YE CRT6 Main Key
HMK-9993-02
HMK-9993-20
VST-5-522/ST AVR738
JANCD-CGOID
JANCD-CG02
JzNc-Mu::;::: - ~:;
JANCD-CG03 DTN51OO
JANCD-CG04
JANCD-CG05 DTN5120 These units are incorJANCD-CG06 DTN5130
JANCD-CG09
JZNC-BAT02 DUN13060
Code No.
SW677
Main Key
SW678 Soft Key
SW679
DTN5390
DTN4290
DTN511O
porated into memory module.
DTN551O
Remarks
Servopack
Type
CACR-SR05SB1AF
CACR-SR05SB1BF
CACR-SR05SB1DP
CACR-SR1OSB1AF
CACR-SRICISBIBF
CACR-SR1OSB1DF
CACR-SR15SB1AF
CACR-SR15SB1BF
CACR-SR15SBIDF
CACR-SR20SB1AF
CACR-SR20SB1BF
CACR-SR20SB1DF
CACR-SR30SB1AF
CACR-SR30SB1BF
CACR-SR30SB1DF
CACR-SR44SB1AF
CACR-SR44SB1BF
CACR-SR44SB1DF
Table 1.3 ACServo Units
Applied Motor
Code No.
DUA15920
DUA16020
DUA16120
DUA15940
DUA16040
DUA16140
DUA15950
Motor Type
USAFED-05FA1
USAFED-05FB1
USAPED-05FDI
usAiED-09FAl
USAFED-09FBI
USAFED-09FD1
USAFED-13FA1
DUA16050 USAFED-13FB1
DUA16150
DUA15960
DUA16060
DUA16160
DUA15970
DUA16070
DUA16170
DUA15980
DUA16080
DUA16180
USAFED-13FD1
USAFED-20FA1
USAFED-20FB1
USAFED-20FD1
USAFED-30FA1
USAFED-30FB1
_USAFED-30FD1
USAFED-44FA1
USAFED-44FB1
USAFED-44FD1
Optical Encoder
p/rev
6000
5000
4000
6000
5000
4000
6000
_
5000
4000
6000
5000
4000
6000
_
5000
4000
6000
5000
4000
–5–
1.3 MAJORCOMPONENTS(Cont‘ d)
(4) Spi nd
e Drive Units VS-626FITIR
Table 1.4 Spinal e Drive Units
Drive Unit Type Motor Type Installation
cIMR-MTm-3.7K
CIMR-MTIII-5.5K
cIMR-MTnI-7.5K
CIMR-MTIR-llK
CIMR-MTUI-15K
UAASKA-04CA1 Flange Mounted
UAASKA-04CA3 Foot Mounted
UAASKA-06CA1 Flange Mounted
UAASKA-06CA3
UAASKA-08CA1
UAASKA-08CA3 Foot Mounted
UAASKA-llCA1 Flange Mounted
UAASKA-11CA3 Foot Mounted
UAASKA-15CA1 Flange Mounted
UAASKA-15CA3 Foot Mounted
Foot Mounted
Flange Mounted
-6-
2. ROUTINEINSPECTIONSCHEDULE
The following table shows the minimumrequirements to be observed for maintenance time in
Table 2.1 Inspection Schedule
I terns
Cleaning of reading
head
Tape Cleaning of tape
Reader tumble box
Lubricating of tension
arm shaft end
Tight closing of doors Daily
Control
Panel
AC
Servo-
motor
Checking for loose fit
and gaps of side plates
and worn door gaskets
Vibration and noise
Motor contamination
and breakage
Battery
Frequency
As required o
As required o
As required o
MonthlY
Daily
Daily or
as required
Daily
order to keep the equipment in optimum condi-
tion for an extended period.
With
the
system- systemOff on
o
o
o 0
o 0
With
the
o
Remarks
Including light source
part.
Feel by hand, and do
the audible inspection.
Inspect visually.
See if alarm for BATTERY
is displayed on CRTscreen.
Except for those checks which can be made with
the NCin the energized state, such as checks
for external cleanliness, vibration, and noise, tor’s station is not sufficient, because after
be sure to turn off the power supply to the NC
before starting to undertake routine mainte-
nance service.
For this, turning off the power supply by
pushing the POWEROFF button on the NCopera-
this button is pushed, still several areas in
the housing are energized, and are potentially
dangerous.
–7–
2.1. ‘TAPEREADER
(1) [Cleaning the tape reader head (Dai
(a) Removetape rubbish and dust from the
glass with a blower brush. If the glass is
stained with oil or oily dust, wipe it using
agauze or soft cloth with absolute alcohol.
Also clean the tape guide and the tape
retainer.
(b) Remove the dust, if any, on LED (light
source) on top with a blower brush.
(2) Cleaning of tape tumble box (Weekly)
Clean the braided nylon leading tape with a
clean, soft cloth.
(3) Lubricating of tension arm shaft
Fo:r the control with 6-inch or 8-inch diameter
reels, lubricate the shaft end of tension arm,
when the tension arm does not move smoothly.
lY)
Q
LUBRICATING
o
\
/
\
(In the case of 8-inch diameter reel)
Whentrouble occurs in feeding or
winding tape with 8-inch diameter
reels, open thefront door and brush
away dust around the photo-coupler by
using a blower brush.
CONTROLPANEL
2.2
TENSION ARM
Fig. 2.1
NOTE
Keep each door tightly closed at all times.
~Tension arm shaft available as an option.
(b) After inspecting the control with dcor
open, close the door and fasten door locks (2
per door) securely using the key provided (No.
YEOOI). Whenopening or closing, insert the
key all the way into the keyhole and turn
until it clicks (approximately a quarter-turn).
The key can be removed
position.
CLOSED
POSITION—
CLOSED L
OPEN POSITION
If the optional door interlocking
switch is provided, opening the door
shuts off the main power supply and
stops all operations.
(c} Check gaskets on the rims of front and
rear doors.
(d) See if the inside of enclosure is dusty.
Clean it, if necessary.
(e) Check for any opening in the door base
with the doors shut tightly.
a
Q
t
with the door
lock on right
side of the
door (Left-hand
Hinged Door)
from an open or closed
OPEN POSITION
\
r,
d=
6
With the door
lock on left
side of the
door (Right-hand
Hinged Door)
Fig. 2.2
NOTE
CLOSED
—CLOSED
POSITION
Checks on doors for tight closing (Daily)
(1)
(a)
The control panel is constructed as a dustproof, sheet-steel enclosure with gasketed
doors so as to keep off dust and oil mists.
2.3 ACSERVO!lOTOR
(1) Vibration and noise (Daily
Vibration can be checked by resting the hand
–8–
or as required)
on the motors, and for noise, using a listen-
ing stick is recommended.
If any abnormality
is found, contact maintenance personnel imme-
diately.
(2) Motor contamination and impairment (Dai
or as required)
Check the motor exterior visually. If dirt
damage should be observed, inspect the motor
by removing the machine cover. Refer to the
machine tool builder’s manual.
2.4 BATTERY
Make sure that ‘BAT”or ‘A/B” on the right-
low position of CRTscreen is not displayed.
If it is displayed, the battery must be
replaced within a month.
(6) With the power on, remove the old battery.
(7) Put the new bat tery in the holder and set
the connector.
See Fig. 2.4. Battery connec-
tion.
Y
(8) With the power on, make sure that b] ink
display of CRTscreen or LED1goes off. IF
or
they are still illuminated, it is due to the
improper battery connection or defective
battery.
—
\
*\
,+
A -1
Whenreplacing, never remove the old battery
with power off, otherwise the data stored in
memoryare cleared.
Replacing Procedure
(1) Depress POWEROFFpushbutton to shut off
the power supply to the operator’s station.
(2) Open the frent door of the control. The
battery of the memory (printed circuit) board
can be seen on the CPUmodule which is mounted
on rear of the front door.
(3) Where the control is equipped with a door
interlock switch, pull it out by hand. The
power can be turned on, with the door open.
(4) Depress POWERONpushbutton.
(5) Check to see if lLED on memoryboard is
illuminated. Fig. 2.3 shows the arrangement
of LEDand the battery.
If illuminated,
replace the battery with new one.
A \
L
I
Fig. 2.3 Arrangement of LEDand Battery
CORRECT
Fig. 2.4 Battery Connection
CORRECT
WRONG
Battery Type: JZNC-GBAO1
–9-
(1) Measuring instruments
3. MAINTENANCEINSTRUMENTS
Name
10 to 30 VAC(at 40 to 100 Hz)
Tolerance :
Tester
or
Multi-purpose
digital meter
(2) Tools
Phillips screwdrivers; large, medium and small
Standard screwdrivers; medium and small
Several mVto 100 VDC
Tolerance :
Several Q to approx.
Tolerance :
Allowable measuring range
~~~ or less
~~~ or less
*5% or less
Purpose
To measure ACpower voltages
To measure DCpower voltages
multiple of 10MQ
(3) Chemicals
Cleaning agent for tape reader (absolute
alcohol)
To measure currents flowing
through DCmotors
–lo-
4. TROUBLESHOOTING
4.1 TROUBLE
Try to fully
which the trouble occurred. This is necessary
for identifying the trouble and/or for having
the YASNACservice personnel called in to
correct the trouble.
points will minimize
system:
4.1.1 RECOGNITIONOF
(1) What operation w
(Is other opera t ion performed normal lY?)
(2) Whendoes the trouble occur: every time
or frequently?
(3) Was there no external disturbance such as
power interruption or lightning when trouble
occurred?
(4) Did it occur during or after operation of
mode switches such as EDITor memory, or func-
tion such asm(parameter) or~(diagnose)
or key switch on CRTpanel?
(5) Ensure the fol lowing points if the trouble
occurred as related to feed and/or spindle
operation:
. Check of LEDon the drive unit
. ON/OFFcheck of fuse or MCCB
“ Time of trouble occurrence such as
power application.
at
at
acceleration.
at
deceleration.
at
steady-state running.
(6) Does it depend on part program?
If so, record also part program, offset and
coordinate system settings.
DENTIFICATION
analyze the circumstances in
Verifying the following
the down time of your
TROUBLESTATUS
11 cause the trouble?
recognize the status of
regardless of the detai
The NCunit is provided
switch. When the operator opens the door, the
NCunit power supply is tripped by MCCBand
the interlock switch is released.
Do not start the check operation until the
interlock switch is released.
(1) Nameof
(2) Time of
(3) Nameand type of machine
(4) Nameand type of NCunit and others
(Example)
NCunit
Servo drive : CACR-SR053SB
Servo motor : USAFED-05MA
Spindle drive
Spindle motor
(5) SYStem No. of NCsoftware
Check procedure
Keep depressing~button at
power application. Then, the
in Fig. 4.1 appears on the CRT.
Fig. 4.1 NCScreen at Power Application
machine manufacturer
delivery
: YASNAC-LX3(ENcM-LP332)
: VS-626MTIII
: UAASKA-08CA3
Lx 3
IrrImn Lain sy~tem No
uuuln!nnnn’
1
machine and equipment
of trouble.
with an interlock
(CIMR-MTIII7.5K)
the time of
screen as shown
\
I
Servo system No.
.
~PC system No.
4.1.2 RECOGNITIONOF NCSYSTEM
Ensure the following points so as to correctly
(6) Ensure that the parameters are the same as
those specified in the list attached to the NC
unit.
–11--
4+~ TR~U~LESj]()()’TINGBy ALAf/MCODES
This description covers the troubles displayed
by alarm codes that were recognized by diagnos-
tic function of NCunit during normal operation.
Refer to Appendix 1
“List of Alarm Codes.”
Some additional explanations are given for
especially difficult troubles.
Display Method
If an alarm condition occurs, a display “ALM”
or “A/B” (for battery alarm) blinks on the
bottom line of the CRTscreen regardless of
the mode or function.
In this case, detailed
information of the alarm condition will be
displayed by the following operations:
Depress the (ALM)key
This will cause up to 4 pairs of alarm codes
and alarm messages to appear in order of impor-
tance,
Note:
with the most serious one at the top.
In an alarm state, the alarm screen
appears taking priority over any other
display.
There is no need to operate
the (PAGE)key.
Alarm di splay
area diagnosed
by NC unit
Alarm and message
display area by
machine sequence
Fig. 4.2 Alarm Codes and Messages
Eliminate the cause of the alarm and depress
the=l key, and the alarm state and the
alarm display will be reset. Notice that the
alarm code ‘820”
is displayed regardless of
the selected function key.
The alarm codes are categorized as in Table
4.1.
AlarmNo.
000 to 099
100 to 199
200 to 299
300 to 399
400 to 499
500 to 599
600 to 699
700 to 799
800 to 899
900 to 999 I
Table 4.1
Spindle Operation Typeof Alarm
Stop at block end Tape format error alarm
Stop at block end
Decelerated to stop
Decelerated to stop
Decelerated to stop
I
I
Macro, operation, external input/output
error,
sequence error
Overtravel, reference point return,
positioning, machineready
Servo, emergency stop, overload FG,RPG
Sequence error
I
Unused
i
Sequencermessage
,
I
NCsystem stop
1
Unused
I
CPUerror, RAMerror, ROMerror
Contact YASNACService Personnel.
] Off-line error (for our maintenance)
Note:
Refer to the maintenance manual prepared by machine manufacturer for details.
Sequencer messages are the troubles concerned with machine sequence.
–12-
4.2.1 ALARMS010 ANDO1l (Parity Error)
Cause of Trouble
Alarm 010
(THerror)
Check Method
1) In case of tape operation:
The number of data holes for each
character is checked on the NC tape.
An alarm is issued when the number is:
Even: For EIA tape
Odd: For 1S0 tape
(The description that follows applies
to the EIA code.)
!Wr,ca
LSK-RR R
Ec01cNIGox123.456c hlJOCl;
II +
128
ton :
k
E(JR :
Solution
● Clean tape reader.
Check tape itself if the
feed hole is faulty and/or
the nap is raised on the
iluie.
. Failure of tape reader
itself
Tn
HII
Alarm 011
(TVerror)
Others
Alarm 010
2) In case of memoryoperation or at
time of EDIT.
3) RS232C communication error
● Framing error
. Overrun
In case of tape operation:
The tape should be capable of TVcheck
(Number of characters for one block
should be even, including llOB.)
1) Disagreement between numbers of
RS232Cbaud rates and stop bits
2) Communicantion error of RS232C
(ea. too Rioh noise level)
.
Failure of MB20board or
of expansion memory board
(MI121board)
Refer to item 4.3.14.
If the tape cannot perform
TVcheck, use it by setting
m ft6002 D6 = O (TVcheck
OFF) or make it so that it
can perform TVcheck.
● Check the specification of
RS232Cequipment
● Check parameters.
Refer to par. 4.3.14.
“ Check cable grounding.
–13-
4.2,2 ALARM075, 076, 077 (RS232CFaulty)
075: RS232C interface; disagreement between
number of bits and number of baud rates
RS232C
076: RS232C interface; transmission fi~ilure
077: RS232C interface; 10 characters or more
were read after stop code was issued.
~llkey. ~
—
Setting
data written
~No “ __!ti
correctl 9
NO
\- “-
Fig. 4.3
#6028 (OUT)
#6026 (IN)
Baud rate setting.
Stop bit setting.
Control code setting.
Check wiring.
–14-
o Settin~ of Amlicable Interface
Set the data transmission baud rate, stop bit
length and control code sending commandspecifications with parameters as shown in Tables
4.3 and 4.4.
(a) Select ion of RS232C Interface Port
Select the port of RS232C interface by setting
#6003.
1st RS232Cand 2nd RS232Ccannot be selected
simultaneously.
Table 4.2 Selection of RS232CInterface Port
Interface
1st RS232C
2nd Rs232C
Select above bits by parameter setting ‘1” .
Input
#6003D0 #6003D4
#6003f)l
Output
#6003D5
Setting of stop bit length
Setting of control code sending command
I
Common
Independentt
(c) 2nd RS232C Interface
Baud rate value setting for 2nd RS232C inter-
face is shown in Table 4.4.
input’#6026D5
output
Output #6028D5
I
=1: Does not
send control
code.
=0: Sends control
code.
(b) Ist RS232C Interface
Baud rate value setting for 1st Rs232C inter-
face is shown in Table 4.3.
Table 4.3 Baud Rate Value Setting
Common
indepen-
dentt
Baud
rate
value
Input/
output
‘nput
‘u ‘Put
Jo
110
150
200
300
600
#6026 li6026 it602E it6026
D3 D2 D1 DO
#6026 #6026 #6026 #6026
D3 D2 D1 DO
#602/?’#6028 #6028 #6028
D3 D2 D1 DO
50
0 0 0 0
o 0
0 0 1 0
0 0 1 1
0 1 0 0
0 1 0 1
0 1 1 0
0 1
Table 4.4 Baud Rate value Setting
Common
indepen-
dentt
Baud
rate
value
Input/
Output
Input
output
100
110
150
200
300
600
1200
2400
4800
9600
t1602~#602~ #602~ #6027
—
50
#&i&
iEHEk
–lrj _
4.2.2 ALARM075, 076, 077 (RS232CFaulty) (Cont’ d)
Setting of stop bit length
—
Common
lndepend- Input !16027D4 =0: One bits for
ent Out;ut
Setting of control code sending command
Function
‘Signal Status
—
_Logic
input’ #6027D4
output
#6029D4 stop bit
Table 4.5 RS232CVoltage Level
VO<-3V VO>+3V
I
OFF ON
Mark Open
I
=1: Twobits for
1 -[
stop bit
1“
Table 4.6 Connection Cable (A:
RS232C Interface
NCSide (DB-25P)
Symbol
FG Frame grounding
SD
RD Receive data
RS Request send
Cs Capable of send
DR Data set ready
SG Signal grounding
ER
I
Send data
Equipment ready
Signal
\
Connection
External
o
*
— ..—.
+
for Termina
Connection Equipment
]Pin No. Symbol
1~
I
2
3
4
5
6
7
20
—,—
0
FG
SD
RD
RS
SG
10 BUSY
ER
16
Fig. 4.4 Example of 1st RS232C Interface
1. Use 1st RS232Cinterface when the built-in
type tape reader (PTR) is used.
In this case, RS232Cinterface freely usable
by customers is 2nd RS232C interface only.
display)
“ JANCD-MB20module,
-MM20module or -MM21
module (optional) is not correctly connected.
● Failure of above modules
Contact YASREPin any of above cases,
2. Keep cable length from tape reader to main
board (JANCD-MB20Type) less than 3m. Contact
YASREPin advance if it is necessary to exceed
3m.
4.2.3 ALARM170, 172, 173, 174 AND175 (Memory
Error)
HEMERROR(OFS)
170:
Tool offset value total check error
MEtlERROR(SET)
172:
Setting area total check error
MEMERROR(PRM)
173:
Parameter area total check error
MEMERROR(KEEP)
174:
Keep memory total check error
MEMERROR(MACR)
175:
Macro total check error
These alarms indicate that tool offset value,
setting data, parameters, keep memorydata
and/or macro data were rewritten for some
reason.
The following points may be considered as
their cause.
. Failure of battery unit (battery alarm
–17-
4.2.4 flLARtl179 (Temperature Alarm inside the Panel)
Cause of Trouble
Ambient temperature of
CI)Umodule exceeded
the specified value
(70”Ct3”C) by meas-
uring at top of CPS10N as a result of fan
failure.
Failure of power
supply unit(CPS-10N)
(Temperature detector
is built inside the
power supply unit.)
_——
Ambient temperature of
NCpanel is too high.
(Applicable temperature
range is O-C to 40”C.)
Check Method
.
Open NCpanel door and ensure that the
fan runs normally.
.
Ensure that air comes out of exhaust
port at the cooling duct.
.
Ensure that air intake port of cooling
duct is not blocked,
—
“ Turn OFF power supply, open the door
of NCpanel and cool it for about
30min.
If the alarm still lights.
“ Measure the ambient temperature.
“ The temperature may rise if NCpanel
is exposed to direct rays of the sun.
Solution
o Replace the fan if
faulty.
Call our service personnel YASRllP.
● If cooling duct is
clogged, remove the
cause of clogging and
restart the operation.
The power supply unit must
be NCplaced.
Contact YASREP.
o Reduce the effects of
temperature rise by
shielding the NCunit,
etc.
–18–
4.2.5 ALARM231 AND232 (Zero Point Return Area Error)
Cause of Trouble
Zero point return
start position was at
zero point side rather
than at deceleration
LS side.
Check Method
Try zero point return again while
observing the deceleration LS:
~#1306 D4(X)
#1306 D5(Z)
As shown below an alarm results when
zero point return is made between DECLS
and zero point.
Note that this error
check can be performed only after power
supply is turned OFFand the manual
return to zero point has been completed.
SWITCH)
Solution
Return it to the decelera-
tion LS or try the zero
point return again from a
more distant point.
Final distance of zero
point return is too
short, or, approach
speed is too fast.
!%!:-L-L
SI@J& R#D
S–OT
212. ;
Perform the zero point return by jog
feed.
Try to change parameter for final
distance.
Compare the parameter for approach speed
with parameter list.
Make final distance
(parameter) longer:
. m#6304(X)
116305(Z)
● Approach speed:
#6310(X)
+16311(Z)
● If MB20,servopack and/
or servo motor are replaced, ensure position
loop gain (Kp).
–l(J._
4.2,6 ALARMS241 AND242 (Reference Point Return Area Error)
Cause of Trouble
This type of alarm
results when reference
point return performed
manually.
It also occurs by
reference point return
at low speed due to
DECLSchattering.
Observe DECLSchattering: Adjustment or replacement
DGN#1306 D4 (X-axis) of LS
#1306 D5 (Z-axis)
Observe reference point pulse: PCB
DGN#1288 D6 (X-axis) Replace ACservo.
X1289 D6 (Z-axis) Replace MB20B.
Check Method
I
● Failure of 1020 or 1021
Solution
Replace ACmotor.
PG cable failure
Occurs at high speed
by error of reference
point pulse
The alarm occurs also
In case of G28 Same as above
at automatic reference
point return.
4.2,7 ALARMS271 AND272 (P-SET Error)
In case of G27 Check the program.
(Z-axis) at the time of completing positioning
with GOO,G27, G28, G29 and G30.
[)-Set Error results when difference between Check is also required at the time of ERROR
commandposition and machine position does not DETECTON (~#1304 D5=1) and G4 (dowell).
fall within parameters #6056 (X-axis) or X6057
Cause of Trouble Check Method
Miichine runs too heavy. Measure the load current. Observe
torque motor in case of ACservo.
Servo error pulse
exceeds setting range.
Check error pulse.
Refer to par. 3.3.4.8
Display Number of Servo Lag Pulses in
Operator’s Manual.
-20–
Solution
Lighten machine load,
Adjust zero point of servo.
If it cannot be adjusted,
replace MB20or Servo Pack.
Contact YASREP.
4.2.8 ALARM310 (Servo PowerSUPPlYNot APP1ied)
Cause of Trouble
Secondary power supply
is not applied.
In caseof automatic
servo power applic-
ation 1/0 input specification is not activated by secondary
power supply.
Emergencystop input.
Secondary powersupply
was tripped by other
alarm.
Check Method
This is a normal result whendepressing
NCRESETafter initial ~r application
or resetting emergency stop alarm, etc.
Ensure that it is set to
~#1322 D7=l.
Chwk if ALht330displays, or~l!ll?lll
Dl=l.
Check for other alarm display.
Solution
Depress IWERONbutton
again.
Check wiring and sequence.
Reset emergency stop input.
Take corrective action
according to alarm code.
4.2.9 ALARM320 (Control Not Ready)
This ty~of alarm results whenposition lag
Cause of Trouble
Faulty zero point
adjustment of servo.
Machine is running.
PCsignal keeps feeding.
MIMIfailure.
Wctm!%219=4, then, ERRORPULSE
iisplay screen from~display and
wad the values of X- and Z-axes.
Check Method
does not fall within therangeofmM056
and it6057 after powr application and selfdiagnosis,
Solution
Perform zero Wint adjust-
ment of servo.
This isaproblmof the
machine side rather than
failure of NCunit.
Contact machine manufac-
turer.
Replace FCor servo.
Contact YASREP.
Replace MB20. Contact
YASREP.
–21-
4.2.10 ALARM330 (EmergencyStOP)
——
Cause of Trouble
CheckMethod
Solution
Emergencyshp button
depressed, or, machine
end L-Sis out of place
Failureof MIMI
!fter ensurinm#1281 D1=O(during
anergency stop), check continuity of
mergency stop button or nnchine end LS
shown below. For correct connection,
refer to connection diagram prepared
by math ne manufacturer.
MB20
1
ESP
Machine End LS
“ m
L--%--J
Machine End Release
Exampleof EmergencyStop Connection
This is MB2Qfailure if alarm 330 lights
even amgli%l=l.
Reset the emergency stop
button. Release itfrcrn
machine end LS according
to instruction manual
prepared by machine manu-
facturer.
I
Replace HB20.
Contact YASREP.
Drop of +24V power
Check +24 VDCpower. If thevolt.age is
below +20V, it indicates pmsible
trouble.
4.2.11 ALARMS331 AND332 (.ServoFuseBlown)
Cause of Trouble
Servopack fuse is
bl.wn or~B tripped.
I
m#1288 Dl=l X-axis alarm
#1289 D1-1 Z-axis alarm
Check Methcxl
Alarm3!%)(servoPack alarm) should also
be displayed simultaneously.
IXN#1’281D2=l
Erroneous wiring
Check if CN1-43and/or CN2-43drop to
o vi
Replace CPS-10N(power
supply unit).
Contact YASREP.
Solution
Turn off power supply to
mathine.
Check if servopack fuse is
blcm or KB tripped.
Contact YASREP.
Gm-ect wiring according
toconnection f’lanualitem
12. Servo Unit Feed Ca-mction
–22–
4.2.12 ALARMS341 AND342 (Servo Error)
Servo error results when the lag of machine
to commandvalue exceeds parameter #i6074 (X-
axis) and #7075 (Z-axis).
Trouble
Motor load is too
large and movement
commandis too small.
E.g.
“ Excessive drilling
load
● Machine requires
lubricant.
“ Program error causes
tool/work contact.
Torque is not applied.
D/A circuit failure
(output continues)
Check Method
.
Observe motor current or torque monito;
if alarm occurs during idle running
@/t3 direction atjogor rapid mode
after turning ONthe power.
.
Check oil film on slide surface of
machine and check oil level in tank.
—
● Check torque limit signal.
● Check torque monitor and motor current
Measure check terminal (IN-M) of
Servopack with servo power OFF.
It is faulty if the voltage exceeds
several 10 mVat this status.
Solution
If machine Remove, trouble
and restart operation.
● Correct torque limita-
tion.
● Replace Servopack.
“ Replace the motor.
Replace main board (MI120)
of CPUunit.
Servopack failure
(speed commandcontin-
ues. )
Wiring failure
Kp(position loop gain)
is not correctly
adjusted and it causes
excessive position lag
Whenservo power is on, the machine runs
away, causes alarm and stops.
Determine if KP value from the POS(ER)
display at the time of jog and rap’
d
feed is correct.
F=mm/min
F
‘P=16”7 x POS(ER)
(s-’)
Replace Servopack.
Refer to Connection Manual
par. 12. Connection of
Feed Servo Unit.
Adjust value by VR (LX3)
of Servopack if the va
is less than the value
ue
set
as standard by machine
manufacturer.
–23–
4.2.13 ALARMS351 AND352 (Motor Overload)
Trouble
Cutting condition is
too severe (Servopack
alarm lights and alarm
390 activates.
Ma(chineruns heavily
due to shortage of
lubricant on the guide
face of machine.
———
Disconnection or con-
tact failure of signal
between NCunit and
Servopack
!%!rvopack failure
Check Method
Did it occur during drilling and/or
threadcutt.ing?
Check if it recurs at idle running or
dry run.
Check the oil film on the guide face.
“ Ensure that alarm lamp of
Servopack does not light.
.~#1288D2=0 causes alarm.
#1289 D2=0 causes alarm.
Servopack alarm activates instantly
after power ONeven if wiring is correct
It may cause an alarm by
m#1288 D2=0
#1289 D2=0 without
causing Servopack alarm.
Solution
Wait until temperature of
servo motor cools down.
Then, restart operation by
alleviating the condition
after clearing alarm with
alarm reset button of
Servopack.
Check oil tank and oil
pipe according to instruc-
tion manual of machine.
Check wiring status
between NCunit and
Servopack according to
Connection Manual.
Replace Servopack.
Contact YASREP.
–24–
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