Beruflich Dokumente
Kultur Dokumente
If this message appears for any of the other axes (X, Y, or Z), then power off to
check the motor overload relays. Power on and if the message appears again,
call the service department, noting the error message number.
Power off the machine before checking fuses, relays, and circuit breakers. The
motor overload relays can be recognized by their white reset buttons. They are
located in both control enclosures. The white button must be pressed to reset a
relay.
This message also appears when the EMERGENCY STOP button has been
pressed. The operator must release the EMERGENCY STOP button and press
the JOG button to reset the amplifiers. (Pressing in the EMERGENCY STOP
button disconnects the axis amplifiers. This is why this message appears when
the button is pressed.)
ATC Failure
Check to see if the Z axis alignment was properly set at cold start. The
automatic tool changer has failed to respond to an M6 or the TC,1 command.
Try a power off and power on. If this does not help check the fuses.
The fuses F5, F6, F7, and F8 should be checked to see if they are burned out.
Circuit breakers 1 and 2 (if they are present) should be pressed to see if they
have been tripped.
Power off the machine before checking fuses, relays, and circuit breakers. If
this does not help, call the service department.
If this message appears with the turret in the extended position, it may be an
indication that the sensor for turret extension is faulty. Call the service
department.
The fuses F5 and F6 should be checked to see if they are burned out. Circuit
breaker 2 (if it is present) should be pressed to see if it has been tripped.
Power off the machine before checking fuses, relays, and circuit breakers.
When this message appears use the command SETCS then the command HO
which will bring the tool to the Cold Start position. It is important to visually
check the axis indicator markers to see if they are aligned; if not, jog the table
until the markers are aligned. Use the command CS, then answer Yes (Y) to the
“move to home?” question. This will bring the tool to the part’s home position
and enable the operator to begin running the program in AUTO again.
Fuses F5, F6, F7, and F8 should be checked to see if they are burned out.
Circuit breakers 1 and 2 (if present) should be pressed to see if they have been
tripped.
Power off the machine before checking fuses, relays, and circuit breakers.
Release the EMERGENCY STOP button if necessary, then press the JOG button
which will reset the machine. If the machine does not reset, call the service
department.
If the EMERGENCY STOP button is not depressed, then power off the machine
and press the reset buttons of the motor overload relays to see if they are
tripped.
The motor overload relays can be recognized by their white reset buttons. They
are located in both control enclosures. The white button must be pressed to
reset a relay.
If the machine stalls for one reason or another, the control places itself into the
Emergency Stop mode. Press the JOG button and jog the tool out of the stalled
position.
An axis fault also occurs during an emergency stop because the control
removes the power to each of the axis servo amplifiers as a safety feature. The
control then analyzes the situation and, as a part of the report, shows a servo
amplifier fault, a result of having removed power to the amplifiers.
Axis Overflow
The axis controller detected an overflow situation. Power off the machine at the
main power switch wait ten seconds, and turn the power on again. If this
problem is persistent, call the service department.
This can also indicate that the circle is programmed in absolute or incremental
and the G90 or G91 codes are incorrect.
This also occurs when no diameter value is placed in the tool table when using
Fixed subroutines L94NN, L95NN,L9601, L9701, L9801, L9901. A DIAMETER
VALUE MUST BE USED.
When the fixed subroutine for engraving (L9201) is used, the Z depth and the
R2 variable must be included in the line. See the Users Manual for the correct
format. If the R0 variable is not specified, it is assumed as R0+0. If the R1
variable is not specified, it is assumed as R1+1.
Bad R Field
This occurs during input from the keyboard or through the RS-232 port (from
an offline computer) when the R0 was typed incorrectly. Example: If RO is typed
(R with the letter O) or R with no zero (0) is typed (R-.05 is accepted but not
R.05 or R+.05).
Correct the line in the CNC; or correct the line in the text editor and send the
program again.
Bad T Word at N =
This message occurs during a SUM command. It indicates that the T word
value is larger than the tool changer capacity.
Solution:
Check to see if the program has the correct positioning mode (G90 or G91),
and check for correct signs and decimal point placement.
This message does not appear during the Auto mode. It appears when using
the SUM command (SU).
Power off the machine before checking fuses, relays, and circuit breakers. The
motor overload relays can be recognized by their white reset buttons. They are
located in both control enclosures. The white button must be pressed to reset a
relay.
Also, check the brake relay fuse (F17) to see if it is burned out. It is advised to
power off the machine when checking the fuses or motor overload relays.
Command Error
This occurs because a SET (parameter) command was typed in improperly.
Refer to the Users Manual or use the menu of the control to help with any
command format. The following is a list of available SET commands: SETH,
SETX, SETY, SETZ, SETA, SETB, SETCS, SETTO, SETP.
EXAMPLE: Format 1:
N1 G41
N2 H1 This is incorrect.
N1 H1
N2 G41 This is correct for Format 1 only.
Format 2:
N1 H1
N2 G41 This is incorrect.
N1 H1 D1 Diameter must be for Format 2 programming and
N2 G41 is acceptable for Format 1 programming.
This is a common error in one tool programs when the Z axis is set with the tool
at the gauge point. Assign an H word with no tool length offset (only a tool
diameter) in the tool table.
D or H Too Large
The control maintains a table of 99 tool diameters and 99 length offsets. The
control will only accept H words and D words up to 99.
DNC Mode
This message appears after DNC is typed at the control. The VMC is then ready
for DNC operation and is waiting for CNC code from the RS-232 port.
WARNING
All program data is deleted from memory. After the memory is reinitialized,
WARNING
! All tool diameter and length offsets are deleted from memory.
!
WARNING
All fixture offsets are deleted from memory.
Duplicate Name
No two programs in the library can be identified by the same number. When
copying an existing program assign an unused number to the new, or copied
program. Use option 2 (display program numbers) of the PR menu to
determine which numbers have been used.
If the program currently active in memory has an O word in the first line, the
program will be moved into the program library when the new program is
transferred through the RS-232 port. If the program currently active does not
have an O word in the first line, the program will be deleted when the new
program is transferred.
4) Press the JOG button which resets the amplifiers if the problem has been
resolved.
5) Type HO and press ENTER, then after the waiting message appears press
START (see note).
Note: It is not necessary to move the axes to their Cold Start position or
establish the part home again unless the message, JOG AXES TO HOME
POSITIONS, THEN ENTER THE CS COMMAND appears.
Error
This message is a program input error. It is displayed when a program block
containing an error is transmitted to the CNC via the RS-232. It appears at the
time the error is received. Therefore, list the program at the control to display
the last block of code received. The following block of code in the program,
which was not received, is in error. This normally is caused by back to back
alpha characters, which must be separated by numeric characters. Also, a 0
could be typed as an O.
7) Power off the machine’s main power, wait 15 seconds and power on the
machine.
1) Save all the programs and offset information currently in memory. Write
down the present home position.
10) Use the command RI and answer Yes (Y) to all the questions.
If the above does not work please call the Service representative in your area.
If errors are detected, list the program and look for missing line numbers to find
which lines the control did not accept. Use the IN command to insert the
missing lines where needed.
File Overflow
This message could mean that the program has too many G codes and M
codes on the same line.
It could also mean that during CRC, there were too many blocks that the control
had to look beyond for the next compensated move (comment lines, Z moves,
G code and M code lines, and dwells).
This message may also appear if a fixed cycle is in effect when attempting to
initiate cutter radius compensation.
Also, depending on the programmed feed rate, the control may or may not be
able to handle the situation. Reducing the feed rate in the program usually
helps.
I, J or K Must Be Specified at N =
This message is displayed when an X, Y, or Z is used with an R0 without a G2
or G3. Full circles must use the direction around the circle and either the I, J, or
K. See the circular interpolation section for more details.
Illegal O Word
This error occurs during program input via. the RS-232. The O word must have
a value of 1 through 9999. No other character or symbol is allowed.
12) The programmer does not cancel a fixed cycle with a G80, G28, G29, M6,
G49, or H0 before using a fixed subroutine, except for L93 (bolt hole).
13) Using L96 - L99, if R1 variable is equal to the radius of the tool. The R1
variable is used for the radius on the corner of the tool (fillet radius), not the
tool radius. For example, a 1.0 diameter end mill with a .125 corner radius,
the R1 variable will be R1+.125, and the tool diameter entered in the tool
table will be 1.0.
14) The G41 or the G42 code has not been canceled with a G40 before using a
fixed subroutine.
All the lines or program blocks must have sequence numbers. The NU
command is used to renumber the lines in the program by the increment
specified in the first parameter. For example, entering NU,5 will renumber the
lines, incremented by five. If program is large, renumber by 1.
This message also appears when the tool changer crashes and the AUTO
button is pushed or the MD command is used. However, the operator does not
have to jog to Cold Start. Use the SETCS command to reference the Cold Start
position, then enter HO to return the axes to home, and when the axes are back
at the Cold Start position, visually check, and enter the CS command.
SETP will also make this message appear. If the operator used the SETP
command at the part home, handle the situation in the same way as suggested
for a tool changer crash (see above).
M, S, T Lockout is in Effect
This message indicates the M function, Spindle, and Tool change lockout
option of the Run Time Menu has been selected. In this mode, M function,
Spindle or Tool Change commands will not be performed during Dry Run. This
option can be selected or canceled using the Run Time Menu by typing MU in
the Automatic mode.
The M30 code on the first line of the program and a subroutine heading (L100)
on the next line will also cause this error message to appear.
N1 O1 (START OF PROGRAM
N2 (ACCEPTABLE PROGRAM EXAMPLE)
N3 L100 (SUB #1)
N4 X1.
N5 *
N6 L200(SUB #2)
N7 L105
N8 M46
N9 X-5.Y-1.
N10 M47
N11 *
N12 L300 (SUB #3)
N13 G91
N14 L204
N15 L104
N16 G90
N17 *
N18 M17 ——— This ends the last subroutine.
N19 M30 ——— This separates the subsection from the main program.
N20 *
N21 (MAIN PROGRAM)
If the operator answers Yes (Y) to this question, the control may delete some of
the program in memory. Answer Yes (Y) only if the program in memory can be
replaced (if the program is stored on paper tape or on computer disk). Answer
No (N) if the program needs to be saved.
Turn the machine’s main power off. Then power on and reload the program. If
this does not work, save all the programs in the memory (PU,3) and use the RI
command, answering Yes (Y) to all the questions. After using the RI command,
load the programs back into the control.
This message will appear if the G21 or G71 code is present in the program to
verify that the Metric mode has been turned on by the operator.
Motor Overload
This is an indication that something has stalled or overheated a motor, and is
associated with an emergency stop (see EMERGENCY STOP).
When the control is executing the program, processing of the program is ahead
of the current line that is being executed. If, while processing the program, the
control detects an over travel situation, execution of the program will stop
immediately.
The setup person may have to consider moving the fixture to another location
on the table. The program may be correct but the fixture is set up incorrectly.
The programmer can provide information to the setup person, indicating how
close to the axis limits the fixture can be located.
If this message appears for the X, Y, Z, A, or B axes, power the machine’s main
power off and then on again. If this does not help, call the service department.
When the programmer is inputting a program through the RS-232 port (using
the command TA,1,0 or TA,1,1), the input will be terminated if the control
detects a bad programming word (EXAMPLE: O for 0, or double letters (XX1.5),
etc.).
The programmer will have to edit the program at the computer or Teletype
before inputting the program again.
The control will ignore all errors in the program and continue input by using the
error option 2, with the TA command (EXAMPLE: TA,1,2). An error count is
given at the end of transmission. If there were errors detected, list the program
to find missing line numbers. If the lines are numbered in sequence before
transmission of the program, look for the numbers that are out of sequence.
After the numbers have been located use the IN command to insert the
missing lines.
Orientation Failure
Visually check the air pressure, it must be between 80 and 90 PSI. If this
problem persists call the service department.
It is always best to retry the command that caused this message to appear.
After the compression, the command will often work the second time.
If unwanted programs are stored in the program library, remove them to create
more room in memory. If there is only one program in memory, try to reduce
the size of the program by removing unnecessary comments and making full
use of all modal codes. Create subroutines for repetitive portions of the
program wherever possible. The program may have to be broken up into
separate operations.
Pallet in Storage
This message occurs when there is an attempt to store a pallet where a pallet
already is stored.
Parameter Error
After a command is entered and a comma is typed, the control is expecting a
parameter. If a parameter is not typed before pressing the ENTER button, this
error message appears.
Note: If the operator is not using a parameter, for instance, the second and
third out of a possible four, the parameters can be omitted when the fourth
parameter is typed in.
Also if the DE command is used to delete a line that does not exist, or the CO
command is used to copy lines that do not exist, this message appears.
Parity Error
This message appears during input through the RS-232 port and is caused by
several factors.
17) There may be a problem with the computer that is sending the program.
A comment can be added to the line with the O word. These comments help
identify the program.
Position Limit
This message will occur when the program has instructed the tool to move out
beyond the axis limits. When the tool moves beyond the axis limit the CNC
issues an emergency stop.
The machine will stop at the line which caused the over travel.
Press Y to Keep This Position
Press N to Return to Last Position
These messages appear after jogging while in Slide Hold or Single Step
modes. See the Users Manual for the proper application of the Jog Away
feature.
The programmer may have put an O-1 or an O.1 as a program number. The
number will show up when the programs are displayed in the library but the
control will not be able to retrieve the program. If the operator uses the PU,3
command and presses the EMERGENCY STOP button when the lost program is
being displayed on the screen, that program is now active in memory and can
be edited. Delete the bad O word, from O-1 or O.1 (which appears as 1000
when it is listed in PR) to O1.
! IMPORTANT
Report this to the service department when this message appears. Do not run
the machine when this message appears.
It may also indicate line noise or the possibility of dropped characters. These
would indicate a possible problem with the RS-232 cable or the
communications port. Check the cable and communications port and retry
DNC.
A failure of the CPU may cause this error also. If the above corrections are
unsuccessful, contact the maintenance department.
Scale Error
A scale error has been detected. The LEDs in the scale interface box in the
back of the machine will indicate which axis gave the error. Call the service
department.
Single Step
This message identifies the control is in the Single Step mode. Should the
green START button be pressed when in this mode, the following program
block is executed.
At the end of each block, the operator can press the JOG button and jog away
from the current position without aborting the operation. Program execution
can be continued at the new location, or the axes can be returned to the
position at which the Jog function was initiated.
To exit single step, press the AUTO button for continuous block execution.
Slide Hold
Pressing the SLIDE HOLD button stops all axis motion. The distance to finish
the move is presented under the blinking SLIDE HOLD message.
It is possible to press the JOG button and jog away from the current position
while in the Slide Hold mode without aborting the operation. Program execution
can be continued at the new location, or the axes can be returned to the
position at which the Jog function was initiated.
To exit from the Slide Hold mode, the operator must press the START button, if
in single step, or press the AUTO button for continuous block execution.
The motor overload relays can be recognized by their white reset buttons. They
are located in both control enclosures. The white button must be pressed to
reset a relay. Call service department first.
If this message appears when not in the Emergency Stop mode, please take
these steps to help the service department analyze the problem:
1) Look at the air pressure gauge and write down the current air pressure (do
not change it at the machine!)
22) Call the service department and report this problem (while the machine is
on).
The motor overload relays can be recognized by their white reset buttons. They
are located in both control enclosures. The white button must be pressed to
reset a relay.
Stack Overflow
This message should be reported to the service department. It is caused by
excessive stacking of keyboard commands.
This message also appears if the G66 code is used on a line that does not have
a subroutine call on it.
Tape is Good
When verifying a punched tape, this message appears if the tape is accepted.
This message also appears if no errors are detected in transmission when the
TA command is used.
Temperature Fault
For any temperature fault, the operator must check the cooling fans; if they are
not operational, turn the machine’s main power off and check the fan fuses
(F23, F24, F27, and F28).
There is No Survey
(See Survey in the Axis Drive Systems Section)
If the programmer uses the fixed cycles G74, G75 or G84 and does not cancel
the cycle with any of the following codes: M6, G28, G29, G49, G80, H0, this
message will appear at the next Z move.
Use the NU (renumber) command and copy again, now that the program is
renumbered.
A solution to this is to put coding between the comment lines or put comments
on lines with program coding. This way the program can have comments on
every line.
Refer to the Users Manual, or the Menu (MU) on the control for the correct
format of each command.
1) Check the tool diameter entered in the tool table to see if it was entered
correctly.
24) If the intention was to make a rough pass using a larger tool diameter than
the finish pass tool diameter, the smallest programmed inside radius, on
the part, should be as big as the tool radius (half the tool diameter) entered
for the roughing pass.
25) Check the math work to see if it is correct, and was transferred correctly to
the program.
When debugging a program that uses cutter radius compensation use a zero
diameter in the tool table when running the program or when using the SUM
command for the first time. Then put the tool diameter in the tool table and try
it again. This will make the debugging process easier.
Waiting
In the Waiting mode, the operator has the choice of pressing either the START
or AUTO button to execute automatic motion. Or, the operator can press the
MANUAL button to exit to the Command mode.
Or just simply use the DE command and delete starting from the first block in
the program to the last.
The backlash information is retained by the battery backed memory card. If this
message appears again, after the BL command has been used, call the service
department.
If the SETZ command has been used, first use the HO command to bring all
axes home, then enter the SETCS command. Jog the Z axis to Z0 and then use
the command SETH so the X and Y home position is not lost. The TC,1
command can now be used to open the tool changer. If necessary return the Z
axis to the previous setting and use the SETZ command.
(See the error message JOG AXES TO HOME POSITIONS if the tool changer
crashes).
Emergency Error Error numbers help discern the location of the problem the axis or spindle is
Codes reporting. The error number will follow a message to call the service
department and report the error number on the screen to correct the problem.
[ 6 ] SWITCH 1 DISABLED
Currently not used.
[ 21 ] UNEXPECTED INTERRUPT
This error appears if the interrupt currently being processed is not an expected
interrupt, and therefore cannot be serviced, indicating possible failure of the
1010-4, 1030, or main CPU.
Troubleshooting
Checklist RS-232
Commmunications Use this procedure to determine which device or cable is not functioning
properly. At the end of each step check to see if communications are possible.
If no
communications
occur:
1. If a switch box is used, determine that the switch is in the proper position.
• Turn the switch handle back and forth a few times. Sometimes the con-
nections are corroded and turning the handle will TEMPORARILY correct
the problem.
3. Check to see that the phone modem cable on the inside of the control cabi-
net is disconnected from the back of the phone modem in the modem
sleeve. Some machines do not have a phone modem in the sleeve.
b. Parity - Even
• The mirror plug, found in the control cabinet of the machine, is a DB-25
plug with pins 2 and 3 crossed, and is usually shipped with the
machine. or can be ordered from our parts department.
b. Move to the cold start position and go into the diagnostics mode.
c. From the command mode type DI then press the enter button.
Then type GO 3000 (G zero, space, three thousand) then press the
enter button. A menu will appear, then select number four by
pressing the 4 button. A second selection will appear. Select the
baud rate that is desired for the test by pressing one of the num-
bers.
e. The numbers at the end of the other sentences should all be zero.
If any numbers appear at the end of these sentences an error on
the 10 port has occurred and indicates a problem with the port.
• If this test fails the S100 board is bad or the cable on the inside of the
control cabinet is faulty or it is not plugged in properly. Change the
S100 board and cable if needed. Note: It is our experience that the
S100 board and inside cable rarely need to be changed.
f. This test can be repeated with each section of cable plugged into
the machine leading up to the computer. This will test the integrity
7) After thoroughly checking the machine and the cables it can be safely
concluded that something in the computer is at fault.
b. The output voltage of the IO board across pins 7 and 12; when
transmitting a program, should be between 10 and 12 VAC.
c. The file being sent may have something wrong with it. Incorrect
syntax in a line of code may interrupt transmission.
CHART 1 DA S H ED S YM B O L S
AP PL Y TO C E N OR M
Q U IC K C H E C K O U T P R O C E D U R E EU R O P EA N M AC H IN E S
9- 2 0 -9 5 ONLY
Q U IC K C H EC K OU T
CH E C K + 5 V, +1 2 V , -1 2 V , SE T M ET ER F O R
AN D 1 1 0 V AC VA C AN D CH E C K FO R NO SE E
AC R IP P L E O N IS
AT PO W ER S U P PL Y ( 12 2 0 ) CH A R T
+5 V , + 1 2 V A N D - 1 2 V D C PO W ER O K?
(U S E O SC IL L O SC O P E NO . 1 2
(0 .01 5V AC R IP P LE M AX O N + /-12 V,
IF A VA IL A BL E ) 0.00 5V AC R IP P LE M AX O N + 5V )
1. 2 .2
1. 2 1. 2 .1 YE S 1. 2 .3
VE R IFY MA KE S U R E CH E C K D OO R S . CH E C K
YE S CH E C K CH E C K
PU L S E L E D 's FEE D R A TE (C E MA C H IN E S CI R C UI T SE E
IS IT A N A XI S EM ER G E N C Y MO T O R
O N A LL IS N O T L IM IT M O V EM E NT BR E AK ER S CH A R T
PR O B L EM ? STO P O VE R L OA D
AX IS BO AR D S AT 0 % W H EN D O O R S (C E NO . 4
BU TT O N RE L A YS
AR E BL I N KIN G AR E O P EN .) MA C H IN ES )
1. 3 NO 1. 3 .1 1. 3 .2 . 1. 3 .3 1. 3 .4 1. 3 .5 1. 3 .6 1. 3 .7
IS IT CH E C K TH AT R E LA Y S CH E C K FU S ES
YE S CH E C K
A T OOL K5 , K6 , K3 3 , K1 1 , F5 , F6 , F7 , F8 , F 19 , F2 0 SE E
CO L D ST AR T
CH A N G E R K1 2 , K 1 3 , & K 1 4 AN D C IR C U IT B RE A KE R S CH A R T
PO S ITI O N
PR O B L EM ? AR E FIR M L Y SE AT ED CB 1 & C B 2 NO . 2
OF Z AX IS
O N 1 1 0 0 -2 B O A R D O N 1 1 0 0 -2
1. 4 NO 1. 4 .1 1. 4 .2 1. 4 .3 1. 4 .4
VE R IFY
IS IT YE S PU L S E L E D 's TO O L D U L L ? SE E
A S P IN D L E O N A LL OR TO O L AR G E CH A R T
PR O B L EM ? AX IS BO AR D S A C U T? NO . 3
AR E BL I N KIN G
1. 5 NO 1. 5 .1 1. 5 .2 1. 5 .3
YE S CH E C K AD J U ST
CH E C K FO R CH E C K CH E C K FO R SE E
LE V EL N E SS PO S ITI ON L O O P
RE P EA TA BI LI TY CH I PS IN TO OL I S FIX TU R E CH A R T
OF G AI N AN D
PR O B L EM ? SP IN D L E TIG H T MO V E ME N T NO . 5
MA C H IN E FEE D R AT E C L O C K
1. 6 NO 1. 6 .1 1. 6 .2 1. 6 .3 1. 6 .4 1. 6 .5 1. 6 .7
YE S CH E C K
SE E
CO N TR O L PU L S E L E D 's
CH A R T
PR O B L EM ? ON A LL BO AR D S .
NO . 6
AR E TH E Y B L IN K IN G .
1. 7 1. 7 .1 1. 7 .2
NO
YE S SE E
KE YB O A R D
CH A R T
PR O B L EM ?
NO . 1 0
1. 8 1. 8 .1
GO T O
PA G E 2 O F
CH A R T 1
CO N T IN U E D
FROM
CH A R T 1
C H A R T 1 c o ntin u e d (p a ge 2 )
PA G E 1
Q U IC K C H E C K O U T P R O C E D U R E
9- 2 0 -9 5
CHE C K SIN/C OS
IS IT YES CHE CK S IG N A L S U S I N G SEE
A F IN IS H BA LAN CE O F S E R VIC E T O O L S T 4 8 . CHA RT
PROBLEM ? A X IS A M P L IF IE R S A D J U S T IF V A R IA N C E NO . 11
> 0.001 V
1A .1 1A .1 .1 1A .1 .2 1A .1 .3
NO
YES SEE
IS IT
CHA RT
A RO TAR Y HE AD
13, 14 . 0 R 1 5
PROBLEM ?
1A .2 1A .2 .1
NO
YE S MAKE SURE V E R IF Y
IS IT A SEE
P O S IT I O N O V E R R I D E SE R VO C OO LA N T
SE R VO C OO LA N T CHA RT
P O T IS A X IS IS S E T T O
PROBLEM ? NO . 16
CE N TE R ED C O O L A N T IN S E T P
1A .3 1A .3 .1 1A .3 .2 1A .3 .3
NO
CH E C K SIN/C O S
IS IT A YES CHE C K S IG N A L S U S I N G SEE
RO U N DN E S S BA LAN CE O F S E R V IC E T O O L S T 4 8 . CHA RT
PROBLEM ? A X IS A M P L IF IE R S A D J U S T IF V A R IA N C E NO . 17
> 0 . 00 1 V
1A .4 1A .4 .1 1A .4 .2 1A .4 .3
NO
YES SEE
ERROR
CHA RT
CO D E?
NO . 18
1A .5 1A .5 .1
NO
YES V E R IF Y
IS IT A V E R IF Y SEE
BAUD RATE AND
C O M M U N IC A T IO N CO N N EC TIO N CHA RT
C O M M U N IC A T IO N
PROBLEM ? OF R S 232 C AB LES NO . 19
PA RAM ET ER S
1A .6 1A. 6.1 1A .6 .2 1A .6 .3
NO
YES
IS IT A N YES IS IT A SEE
IN D E X E R FAD A L CHA RT
PROBLEM ? IN D EX E R ? NO . 20
1A .7 1A .7 .1
1A .7 .2
NO NO
IS IT YE S SEE
A N M -F U N C T IO N CHA RT
PROBLEM ? NO . 24
1A .8
NO 1A .8 .1
GO TO
PAGE 3 OF
CH A R T 1
CONTINUED
FROM
CHART 1 continued (page 3)
CHART 1
PAGE 2
QUICK CHECKOUT PROCEDURE
9-20-95
1B.1 1B.1.1
NO 1B.1.2
YES,
START WITH SCALE CHART
REMOVE COVER
FROM SCALE
IS IT A YES SEE
BOX ON OUTSIDE
SCALE CHART
OF CONTROL BOX
PROBLEM? NO. 22
AND CHECK FOR
ERROR LED
1B.2
1B.2.1 1B.2.2
NO
SPINDLE SOFTWARE
IS IT A YES SPINDLE INVERTER SEE
(IN 1010-S)
RIGID TAPPING MUST BE LABELED CHART
MUST BE
PROBLEM? "RIGID TAPPING" NO. 23
RIGID TAP
CH AR T 2
TOOL CH A N GE R
A UT OM A T IC T OO L CH AN G E R
10-18-95
CH E C K AI R PR E SS U R E
MA N U ALLY AC T IVA TE DO ES CH E C K AI R
DO ES NO (80P SI AN D 120P SI ) CH E C K NO
DR A W B AR SOLE N OID DR A WB AR W OR K DE LIV ERY TO
TOOL I N/OUT (M AX 3-5 PS I DR O P F20 AN D K24
AT MA C A IR W H EN M A NUA LLY DRA WB AR
W OR K ? DU R I NG TOO L ON 1100-2.
VA LVE A SS Y. OPE R AT ED ? CY LIN D E R .
CH A N GE )
CH E C K FU SE S F5 & F6 & CB 2
TU R RET FAC T OR AN D R E LAY S K5, K33,
EM ER GE NC Y ST OP SE R VO IN S ETP M U ST BE 1
DI D NO GE NE V A K11, & K 12 ON 1100-2.
MUS T B E RE LE AS ED FOR S E R VO TU RR ET .
TU R RET MOV E OR S E RVO K12 M UST BE LOW
AN D
C ORR E C TLY? TU RR ET ? C2 ON 1100-2 MU S T LE A KA GE (GREE N ).
AM PLIF IE RS R E SE T
BE B YP AS S ED . CH E C K F4 A N D
2. 4.2 SE R VO TUR R ET FUS ES .
2. 4 YE S 2. 4.1 GEN E VA 2. 4.3
2. 4.4
C H A R T 2 c o nti nu e d (p a ge 2 )
A U T OM A T IC T OO L C H A N G E R
CO N TIN U E D 1 0 -1 8 - 9 5
FR OM
PA GE 1 OF
CH A R T 2
MA N U A LL Y MO VE A T C
TO EX TE N D E D P OS ITI ON
(G R AS P A N D SW IN G
UP P ER GE N E VA A R M)
2A .1
DI D NO CL E A N, A DJ U S T, RE P L AC E
ME C H AN IS M MO VE AN D L U B R IC AT E ME C H AN IS M
SM OOTH L Y ? ME C H AN IS M IF D A MA GE D
2A .2 2A .2 .1 2A .2 .2
YE S
IS CH E C K AN D A D J US T CH E C K IF T OOL
TU R R ET FAC T OR AD J U ST
TOOL C A R R IE R NO CA R R IE R IS OU T
TU R R ET AL IG N ME N T
PR OP ER L Y A L IGN E D OF P OS ITIO N
(T U RR E T FA C TO R AN D /O R
W ITH S P IN D L E? MU S T B E 1 FO R OR S KE W E D
CO L D ST AR T PO SIT ION
SE RV O TU R RE T.) DU E TO A C R AS H
2A .3 2A .3 .1 2A .3 .2 2A .3 .3 (S E RV O TU R RE T M U S T
MA K E A M OV E BE FO R E
YE S TU RR E T A LIG N ME N T IS
AD JU ST E D.)
RE TU R N A TC T O
RE TR A C T ED PO SI TI ON .
TH EN IN MD I E N TE R (IF TO O L 2 IS IN T H E
M6 T2 SP IND LE , U SE M 6T 1.)
2A .4
AR E CH E C K AT C H OME S W IT C H .
DI D FU SE S CH E C K A TC FA U L T S W IT CH . CH E C K SL I DE M OTO R
NO YE S
ATC SL ID E F7 , F8 , & C B1 CH E C K C ON TR OL CH E C K AT C BE L T TE N SI ON
CO ME AN D R E L AY S K6 , V OL TA GE A T K 1 4 . AL IG NM E N T AN D A D JU S TM EN T
IN ? K1 3 & K 1 4 CH E C K SL I DE M OTO R O F G EN E VA S L OT
OKA Y ? & W I R IN G.
2A .5
2A .5 .1 2A .5 .2 2A .5 .3 2A .5 .4
YE S NO
RE S ET C B1 O R
RE P L AC E
F7 , F8 , K 6, K 13 , K 14
AS N EE D E D
2A .5 .1 a
CH E C K TU R R ET FA C TOR
DI D YE S TU R R ET MU S T B E
AD J U ST FOR GE N E VA .
TOOL C A R R IE R AT AN E M PTY
CO L D ST AR T PO SIT ION , CH E C K EN C OD E R A N D
CR A S H IN TO POC K ET
AN D TU R R E T A L IGN M EN T EN C OD E R W IR I NG
SP IN D L E? (A D JU S T S ET TO)
FOR S E R VO TU R R ET .
2A .6
2A .6 .1 2A .6 .2 (S E RV O TU R RE T M U S T 2A .6 .3 (T U RR E T FA C TO R M US T
NO MA K E A M OV E BE FO R E BE 1 FO R SE R VO T UR R ET .)
TU RR E T A LIG N ME N T IS
AD JU ST E D.)
GO T O
PA GE 3 OF
CH A R T 2
2A .7
C H A R T 2 continu ed (page 3)
AUTOM A TIC TOO L CHA NG E R
C O N T IN U E D 10 - 1 8 -9 5
FROM P R O P E R A IR P R E S S U R E A N D A D E Q U A T E A IR V O L U M E IS C R I T IC A L F O R T O O L C H A N G E S .
PA GE 2 OF A IR P R E S S U R E R E G U L A T O R O N M A C H IN E M U S T B E S E T A S L A B E L E D (8 0 - 9 0 P S I A N D
CH A R T 2 12 0 P S I F O R T O O L O U T R E G U L A T O R ) . A IR S U P P L Y T O M A C H IN E S H O U L D B E 1 2 0 P S I .
A IR H O S E T O M A C H IN E M U S T B E 3 /8 " A N D A S S H O R T A S P O S S IB L E .
A IR D I S T R I B U T IO N P IP E IN B U I L D IN G S H O U L D B E A M IN IM U M O F 3/ 4 " .
T H E P R E S S U R E D R O P A T T H E M A C H IN E D U R I N G A T O O L C H A N G E S H O U L D B E A
M A X I M U M O F 3 -5 P S I.
IS IS IS A IR P R E S S U R E M U S T B E
DI D NO YE S YE S YE S
TOOL STUCK DR A W B A R M A C H IN E IN 80 P S I A N D 1 2 0 P S I
Z A X IS
IN S P IN D L E ? FU SE OK A Y? A T A P -T A P (M A X 3 - 5 P S I D R O P
GO UP?
(F 2 0 ) CY C L E? DU R I NG TO O L C H AN G E)
2B .1 2B .1 .1 2B .1 .2 2B .1 .3
YE S NO NO NO 2B .1 .4
CH E C K K24
CH E C K S L I D E E X T E N D E D S W IT C H . CH E C K
RE P LAC E AN D C O N T RO L
CH E C K A T C F A U LT S W IT C H . DR A W B AR SW I TC H
FU SE VOLT AGE TO K 24
CH E C K D R A W B A R S W IT C H . (A N D A D J U S T M E N T ) ,
F20
CH E C K Z A XIS SE R VO. AN D D R A W BA R 2B .1 .5
2B .1 .1 a 2B .1 .2 a C Y L IN D E R A S S Y
2B .1 .3 a
TO O L H O L DE R S
MU S T B E CLE A N .
DI D NO GO B AC K
TURRET TO S TA RT OF
IN D E X ? 2B .1 .6
CH A R T 2
2B .2
YES 2B .2 .1
IF O V E R S H O O T /
DI D NO GO BACK
CH E C K TU R R ET UN D E R SH O OT
TURRET TO S TA RT OF
F E E D B A C K S W IT C H CH E C K/ AD J U ST
STO P? CH A R T 2
TU R R ET FAC T OR
2B .3
2B .3 .1 2B .3 .2 (T U R R E T F A C T O R 2B .3 .3
YE S MU S T B E 1 FO R
SE RV O TU R RE T.)
DI D NO CH E C K
CH E C K AT C
Z A X IS C O M E Z A X IS
SA FE TY SW ITCH
DO W N ? SE R VO
2B .4
2B .4 .1 2B .4 .2
YE S
CH E C K D R AW BA R CH E C K AIR PR E SS U R E
NO YE S CH E C K Z A XI S
DI D VA LVE FU S E F20 . (8 0 P S I ) A N D 1 2 0 P S I
DI D SL I D E FOLLOW ING
Z A X IS G O (N O T T O E X C E E D
PU LL B AC K ? ER R OR ,
UP ? C H E C K K 2 4 A N D IT S 3- 5 P S I D R O P D U R IN G
IS IT E X C E S S I V E ?
CO N TR O L V OL TA G E . TOOL CHA NGE )
2B .5 .1
2B .5
YES NO 2B .5 .2 2B .5 .3 2B .5 .4
CH E C K: SE E
CH E C K FU SE S
CH E C K AT C S L I D E E X T E N D E D S W IT C H , TOOL CHA NGE R
F7 & F8 & CB1.
A L IG N M E N T & A T C F A U LT S W IT C H , AD J U STM E NT S
CH E C K R EL A YS
BE LT TE N SION D R A W B A R S W IT C H , IN M A IN T E N A N C E
K6, K13, & K 14
SL I DE M O TO R MA N U AL
2B .5 .1 a 2B .5 .1 b 2B .5 .1 c 2B .5 .5
DI D NO CH E C K AT C CH E C K
S L ID E M O T O R S L ID E H O M E AD J U STM E NT O F
STO P? SW ITC H GEN E VA S LOT
2B .6 2B .6 .1 2B .6 .2
YE S
YE S CH E C K
MAKE SURE T OOL
D I D S P IN D L E CO L D ST AR T
HA S PR O PE R
DR O P T OO L ? P O S IT I O N .
PULL STUD.
2B .7
2B .7 .1 2B .7 .2
NO
ATC SY ST EM S OK
END
2B .8
NOT E: DIF FICUL T T O D IA GN OS E P ROB LE MS CA N OCCU R IF MAC HINE IS NOT P R OP E RL Y GROUN DED .
SPINDLE WILL NOT TH ERE MU ST B E A CONTINUOUS GROUNDIN G CON DUCTOR (AS S PE CIF IED ON T H E GROUND ING LA B EL
RUN ON A CE M ACHINE IN THE MACHINE 'S D IS CON NECT B OX) F ROM THE VMC'S GR OU ND BUS TO THE GROUND B US IN T HE
WITH THE DO ORS OPEN BUILDING'S P OWE R DIS TR IB UT ION P AN E L.
CO RRECT FAULT
AND RESET I NVERTER
3. 1
DO ES NO WILL NO SP INDLE
CHECK
SP INDLE SP INDLE TURN MA Y BE
BELTS
RUN? BY HAND? FROZE N
3. 2
3. 2.1
YES 3. 2.2 3. 2.3
YES
CHA NGE
IS YES
SPINDLE
SP INDLE POT
POT
AT 0?
SETTING
3. 2.1a NO 3. 2.1a.1
CHECK ERROR MESSAGES
ON INVERTER DISP LAY
CHECK
VERIFY LE D ON CHECK CHECK CHECK (M ITS UBI SHI INVERTE RS
AND RE SE T
SPINDLE 1010 AND RESET AIR 3-PHASE AC RE QUIRE INS TALLAT ION
CE CIRCUIT
(S LOT 14) OVERLOA D PRE SS URE POW ER T O OF P ARAM ETER UNIT )
BREAKERS
IS BLINKING RELA Y (80-90 PS I) INVERTER
A12, B12, C12
AFT ER F AULT IS CORRECTE D
3. 2.1b 3. 2.1b.1 3. 2.1b.2 3. 2.1b.3 3. 2.1b.4 PRESS RESET O N INVERTER
3. 2.1b.5
RUNS CHECK SPINDLE
3 SECONDS YE S HALL EFFECT SWIT CH ON 1100-2:
AND STOPS? AND WI RING CHECK F1 & F3.
(ERROR #8) (USE DI DS TO S EE I F
SWI TCH IS B EI NG READ) CHE CK K7, K9,
K3, & K4.
3. 3 NO 3. 3.1
3. 2.1b.6
CONTINUED
CHART 3 continued (page 2)
FROM PAGE 1
SPINDLE DRIVER SPINDLE DRIVER
(CHART 3) 10-20-95
CHECK THAT
"BAD TERMINALS ON USE ENCODER TESTER
ENCODER" ON YES GREEN CONNECTOR TO TEST AT EACH
BALDOR-SWEO ON INVERTER ARE TIGHT CONNECTOR FROM
INVERTER? AND CLAMPED ON WIRE ENCODER TO INVERTER
(NOT INSULATION)
3A.3 3A.3.1 3A.3.2
NO
REMOVE BELTS,
YES RUN SPINDLE AT DOES YES CONSULT FACTORY CONSULT FACTORY
SPINDLE
MAXIMUM SPEED SPINDLE MOTOR SERVICE DEPT. SERVICE DEPT.
MOTOR
AND CUT POWER SHAKE WHILE ABOUT BALANCING BEFORE REPLACING
SHAKES?
(MOTOR COASTS COASTING? SPINDLE MOTOR SPINDLE MOTOR
TO STOP)
3A.4 3A.4.2
3A.4.1 3A.4.3 3A.4.4
NO NO
3A.5 3A.5.1
3A.5.2 3A.5.3
YES
POSSIBILITIES: POSSIBILITIES:
BELTS, DOES NO INVERTER SOFTWARE,
PULLEY OUT OF ROUND, SHAKING/VIBRATION BENT ENCODER PIN,
MOTOR SHAFT BENT, STOP? ENCODER DISK RUNOUT,
BAD SPINDLE. BAD ENCODER,
3A.5.7
CHART 4 DA S H ED S YM B OL S
AP PL Y TO C E N OR M
AX IS C ON TR OL
A XIS C O N T R O L EU R OP EA N M AC H IN E S
10 - 2 0 -9 5 ON L Y
4. 2
4. 2 .1
NO
CH E C K VO L TAG ES :
W AS AR E +5 V , + 12 V, - 12V & IF V OL TA GE S AR E
IS IT YE S NO YE S
MOT OR AL L 3 A X ES 1 1 0V AC A T 122 0 OU T OF TOL E R AN C E ,
A RUNAWAY (A L SO C HE C K F OR A C
RE P L AC E D ? RU N N IN G CH A N GE L OGI C
PR OB LEM ? RIP PL E O N DC V OL TA G ES :
AW A Y ? 0.01 5V AC MAX O N +/-1 2V
POW ER S U PP L Y
4. 1 4. 1 .1 4. 1 .2 0.00 5V AC MAX O N +5 V)
YE S NO 4. 1 .4
NO 4. 1 .3
GO T O
DO ES YE S
CH A R T 7
TH E AX IS R U N
TO A LIM IT?
4. 1 .1 a
4. 1 .2 a
NO
SW A P TH E AX IS
CH E C K C E DI D
IS AX IS YE S CH E C K SW A P CO N TR OL L ER
CI R C UI T PR OB L EM NO
CO MP L ET EL Y MOT OR SE R VO CA RD S (1010)
BR E AK ER S FOL LOW TH E
IN OP ER A TIV E? OVE R L OA D AM PL IF IE R (R E ME MB E R TO
(A 1 0 ,B1 0, C1 0 AM PL IF IE R
RE L A Y CA R D CH A N GE J UM P ER
OR 1 4 ) CA R D ?
4. 3 BL OC K ON J 4)
4. 3.1 4. 3.2 4. 3 .3 4. 3 .4
NO YE S
4. 3 .5
DI D
RE P LAC E YE S RE P LAC E
CH E C K PR OB LEM
YE S SE R VO AX IS
IS TH ER E EM ER GE N C Y ST OP FOL L OW TH E
AM PL IF IE R CO N TR OL L ER
AN A MP L IFI ER AN D AX IS
CA R D CA R D
FAU LT? MOT OR OV ER L O AD CA R D ?
RE L A YS 4. 3 .6 4. 3 .7
4. 3 .4 a NO
4. 4
4. 4.1
NO
CH E C K C E
W AS TH E YE S
CI R C UI T RE P LAC E
PR OB L EM
BR E AK ER S RE S OL VE R
RU N A W A Y?
(A 1 0, B 1 0 , C 10
OR 1 4 )
4. 3 .6 a 4. 3 .6 a .1
NO
4. 4 .2
CO N SU L T FAC T OR Y
WAS SE R VIC E D E PT .
MOT OR W I RE S
MOT OR YE S AR E BE FOR E R EP L A C IN G
YE S AR E SH I EL D E D .
RE C E NT L Y MOT OR W I RE S SE R VO MO TOR
VE R IFY TH A T S H IE L D
RE P L AC E D OR SH OR TE D TO
IS STR I PP ED BA C K 4. 3 .6 b
RE W I RE D ? CH A S SIS ?
FR OM C ON D U C TOR .
4. 4.3 NO 4. 4 .4 4. 4 .5
NO
IF A OR B A X IS AR E
W ITH P OW ER O N W ITH P OW ER O N
YE S NO T U S ED T H EY VE R IFY TH A T
A OR B AN D D U M MY P L U G AN D D U M MY P L U G
MU S T B E IN AC T IVE DU M M Y P L U G
AX IS W H IC H A R E IN ST AL LE D , V ER IF Y IN ST AL LE D , V ER IF Y
IN P AR A ME TE R S O R SH OR TS
NO T IN U SE ? TH AT 11 0 0 -1 T B1 TH AT 1 0 6 0 J5 - 6 A N D
DU M M Y P L U G M U ST PIN S H & G
PIN 1 TO P IN 6 IS 0 V J4 - 6 AR E 0V
BE IN P L A CE .
4. 4 .3a NO 4. 4 .3 a .1 4. 4 .3 a .2 4. 4 .3 a .3 4. 4.3 a .4
YE S DO N O T M OV E Z-A X IS !
DO ES NO CO N SU L T FAC T OR Y
IS IT PR E SS EM E R GE N CY ST OP .
IT M OV E BE FOR E R E PLA C IN G
Z-A X IS?
FR EE L Y? BA L LSC R E W
TR Y TO M OV E Z-A X IS BY H A N D .
4. 4 .3 b 4. 4 .3 b .3
NO 4. 4 .3 b .1 4. 4 .3 b .2
YE S
CH E C K K1 , K2 ,K 18 ,K 2 0, JU M PE R
PR E SS J OG. NO F1 2 , & F1 4 EM ER GE N C Y CH A N GE A MP
GO T O DO A MP L IFIE R S ON 1 1 0 0-1 . STO P C I R CU I T IN D IC AT ED B Y
PA FE 2 OF STA Y ON ? CH E C K OV ER L OA D (J U MP F1 6 T O F12 FAU LT LIGH T
CH A R T 4 RE L A YS ON 1 1 00 -1 )
4. 4 .3c
4. 4 .3 c. 1 4. 4.3 c. 2 4. 4.3 c. 3
CHECK
RESOLVER NO RESOLVER
FAULTS ON CABLE.
MULTIPLE REPLACE
AXES? RESOLVER.
4A.2.4 4A.2.5
YES
CHECK
GROUNDING
4A.4
CONSULT
FACTORY
4A.5
C H A R T 4 c o n tin u e d (p a g e 3)
A X IS C O N T R O L
6-1 5 -9 5
MOTOR OVERLOADS
C O N T IN U E D
FROM
PAGE 2 OF
CHART 4
IS T H E F A U L T NO
DU R ING P R O G R A M
GO TO
EX EC U TIO N ?
PAGE 4 OF
CHART 4
4 B .1
YES
4 B .1 .1
IS T H E
PROG RAM
U S IN G M 9 0 - M 9 3 NO
P R O G R A M M A B L E G A IN
S E T T IN G S ?
M90 = U S E S E T P G A IN
M91 = N O R M A L G A IN
4 B .2 M 9 2= IN T E R M E D IA T E G A IN
M93 = H IG H G A IN
YES
IN S E R T A N M 9 1
A T B E G IN N IN G
OF PROGRAM.
R E M O V E A L L G 8 's .
4 B .3
4 B .4 .1
4 B .4
NO
PROBLEM NO IS YES
SHOULD BE T H E R E S T IL L A
RESOLVED PROBLEM ?
4 B .5
4 B .4 .1 a
IF N O T G O T O
PAGE 4 OF CHART 4
END
4 B .6
MOTOR OV ERLOA DS
CO N T IN U E D
C H A R T 4 c o nt in u e d ( p a ge 4)
FROM
PA G E 3 O F AXIS CO NTRO L
CH A R T 4 6- 1 5 -9 5
CHE C K W A YLU B E
OVE RLOA D YE S CH E C K
O C C U RS A T B A L L SC R E W
CH E C K AN D A D J US T
SLOW AL IG NM E N T
G IB S A N D S T R A P S
SP E E D ?
4C . 1
NO 4C . 1 .1 4C . 1 .2
O VE R L O A D YE S CH E C K AN D A D J US T
O C C U RS N E AR M E C H A N IC A L A XIS
P O S IT I O N LI M I T S T O P
LI M I T ?
4C . 2
NO 4C . 2 .1
LO O P G A IN P O T O N A M P L IF IE R
CU R R E N T L IM IT P O T
OCCUR YE S SH O U L D B E M O S T L Y C W .
O N A M P L IF IE R
W H IL E S T O P P E D (T U R N F U LL Y C W F O R T E S T A N D
MUS T BE FULLY CW
O R IN G 0 ? RE - AD J U ST L O O P G A IN
(E X C E P T F O R VH 6 5 )
IF T HI S CO R R E C T S P R O B LE M )
4C . 3 NO 4C . 3 .1 4C . 3 .2
M A K E A D JU S T M EN T S IN T H E
F O L L O W IN G O RD E R :
M AS T E R F E ED R A T E C L O C K ,
P O S I T IO N L O O P G A IN ,
B AL A N C E A D J US T M EN T .
4C . 4
SW I T C H T O
NO S E R V IC E P R O G R A M
PR O B L E M "P R ,5 8 1 1 "
RE S O L V E D ?
CH A N G E G 1 's T O G 0 's .
RU N PR O G R A M .
4C . 5
YE S 4C . 5 .1
W AS CH E C K BU S V O L T A G E
CH E C K SE T P
FOLLOWING YE S IS M A C H IN E YE S AT BL U E C AP A C IT O R
PA R AM ET ER :
EN D E R R O R C O RR E C T * W IR E D F O R O N A M P L IF IE R
"3 PH A S E > 5 % L O W "
THROUGHOUT 20 8 V A C ? CH A S SIS .
SH O U L D B E Y E S
4C . 6 MOVE? SH O U L D B E 1 1 5 V A C
4C . 5 .2
4C . 5 .3
NO 4C . 5 .4 4C . 5 .5
* G0 FOLLOWING ERRO R:
NO
INCH - 1840 +/-20
METRIC - X/Y 1630 + /-20
Z 1380 + /-20 DO E S
20 " M O VE NO AD J U ST M A S T ER AD J U ST PO S IT IO N
AT 1 00 IP M T AK E
F EE D R A T E C L O C K LO O P G A IN
12 . 2 -1 2 .5
SE C?
CH A N G E T H E G 0 's 4C . 5 .3 a 4C . 5 .3 a .1 4C . 5 .3 a .2
BA C K T O G 1 ' s YE S
AN D R U N P R O G R A M
AG A IN
SW A P Q U E ST I O N AB L E
AM PL IF IE R W IT H O N E O F DID YE S
4C . 5 .2 a T H E O T H E R A X E S. P R O B L EM S T A Y
W IT H A X IS?
RU N P R O G RA M AG A I N
4C . 5 .3 b 4C . 5 .3 b .1 NO , ST A YE D
W ITH A M P LI F IE R
W AS
FOLLOWING NO
E R R O R C O RR E C T *
RE P L A C E CH A N G E
THROUGHOUT
AM P L IF IE R MOT OR
MOVE?
4C . 5 .2 b
4C . 5 .3 b .3 4C . 5 .3 b .2
* G1 FO LL O W ING E R R O R : YE S
I N CH - 59 5 + / -1
M E TR IC - 30 2 + / -1
A D J U ST
P O S IT I O N
CO N SU L T
LO O P G A IN
F AC T O R Y
4C . 5 .2 b .1
4C . 5 .2 c
DI F F IC U L T T O D I A G NO S E P R O B L E M S C AN O C C UR
CHART 5 IF M A C H I NE I S N O T P R O P E R L Y G R O U N D E D.
T H E R E M U ST B E A C O N T I NU O U S G R O U N D IN G
RE P E A T A B I LI T Y
R EP EAT A B IL ITY CO N D UC T O R ( A S S P E C IF I ED O N T H E G R O U N D IN G L A B E L
9- 2 0 -9 5 IN T H E M A C H IN E 'S D IS CO N N E C T BO X ) F R O M T H E V M C 'S
G R O U N D B US T O T H E G R O UN D BU S IN T H E B U IL D IN G ' S
F O R A D D IT IO N A L P R E C I SIO N IN L E V E L IN G , POW ER DISTR IBU TION P AN E L.
V E R IF Y P E R F O R M SQ U A R E N E S S T E ST O N X & Y ,
M A C H IN E IS L EV EL T H E N S Q U A R N ES S T E S T O N C O L U M N ,
(S E E M A I NT E N A N C E T H E N S P IN D L E T R A M T E S T .
M A N U AL ) (C O N S U L T F A D A L S E R V I C E D E P T F O R P R O C E D U R E)
5. 1
RE M O VE S U B P L A T E O R F I X T U R I NG .
IS T H E R E MA C HI N E MU S T B E T ES TE D W I TH O UT FI X TU R I NG .
A S U BP LA TE YE S SU BP LA T ES O R F IXT UR IN G C A N IN D UC E P O S IT I O NIN G
PR O BL EM S TH A T A RE NO T INH E RE N T IN T H E M A CH IN E.
O R L A R G E H EA VY PO S IT IO NIN G PR O B LE MS I N DU C ED BY FI X TU R I NG
F IX T U R IN G ? MU S T B E D E AL T W IT H S EP A RA TE LY FR O M PR O BL EM S
IN TH E M AC H I NE ITS EL F.
5. 2 NO 5. 2 .1
CH E C K A N D A D J US T :
B AC K LAS H ,
B A L A N C E O N A X IS A M P S , N1 L 01 0 0
L O O P G AIN O N A M P S N2 G1 F20.
N3 X 4 .0
5. 3 N4 X - 4 .0
IN S E R T P R O G R A M N5 G 4 P 1 0 00
A T R IG H T . N6 M17
N7 M30
S E T U P IN D IC A T O R N8 L 01 9 9
N9 M2
F O R P R O B LE M A X IS
5. 4
* GO L D C O AX CO N N EC TO R (J1 , J 2 & J3 O N 101 0):
M U ST FI R M LY GR A SP C EN TE R PIN (US E SE RV IC E
RU N T O O L S T4 4 TO T ES T A N D A D JU ST ),
PR O G RA M M U ST BE SO L I DL Y C R IMP E D T O C E NT E R W IR E ,
M U ST M AK E F IRM C O NT A CT W ITH JA CK .
5. 5 RE PE A T A BIL I TY CA N BE AF FE C TE D IF CO N NE C TO R IS LO O S E.
IN S P E C T M O T O R C O U P L ER
CH E C K G O L D C O AX CH E C K A N D A D J US T
AN D B A L L S C R E W
DO ES NO CO N N EC T O RS A D J U S T G A I N A ND G IB S AN D S T R A PS
FOR LOO SE N ES S .
T H E AX IS (J 1 , J 2 O N 1 0 1 0 ) CO M P E N S A T IO N
RE P EA T ? W IT H S E R V IC E O N A XIS A M P L IF I E R CH E C K BA L L SC R E W
CH E C K F O R L O O SE
TOOL S T44 * A L IG NM E N T
5. 6 RE S O L V E R O R C O U P L IN G .
YE S 5. 6 .1 5. 6 .2 5. 6 .3 5. 6 .4
CH E C K S I NE &
CO S I NE O UT P U T
IF B A C K L A S H I S E X C E S S I VE ,
O F C L O C K C AR D
DO E S A XI S YE S CH E C K F O R
AD JU ST (1 0 2 0 ) U S IN G
HA V E A B A CK L A S H LO O S E N E S S IN M O T O R C O U P L E R ,
BA C KLA SH S E R V IC E T O O L S T 4 8
PR OB LEM ? W O R N B A L L S C R E W , A ND
BA L L S C R E W A L IG N M E N T 5. 6 .5
5. 7 5. 7.1 5. 7 .2
NO CH A N G E
RE S O L V E R
RE - IN S T A L L 5. 6 .6
S U B P L A T E AN D
F IX T U R IN G RE P EA T A B I LI T Y P R O BL E M S M A Y A L S O
BE C AU S E D BY T E M P E R AT U RE G RO W T H CH E C K
A N D R E PE AT T E S T
O F B AL L S C R E W S O R S P IN D L E . S U R V E Y T A BL E
5. 8
5. 6 .7
A X IS R E P E AT S W I T H O U T S U B P L A T E A ND F IX T U R IN G
DO ES NO CO R R EC T M E C H A N IC A L
B U T DO ES N O T R EP E A T W IT H S U B P L A T E A ND F IX T U R IN G .
T H E AX IS B IN D
T H E R E F O R E F I XT U R I NG O R S U B P L A T E IS D IS T O R T I NG T A BL E
RE P EA T O N OR C H AN G E
O R C R E A T IN G A M E C H AN I CA L B IN D .
X & Y? M A C H IN IN G P R O C E D U RE
O R A M A C H IN IN G PR O C E D U R E IS C A U S IN G N O N -R E P E A T AB IL IT Y.
5. 9 5. 9 .1 5. 9 .2
YE S
YE S IS YE S
IS IS C O O L A NT
S P IN D L E
Z A XIS O F F S E T F L O W IN G IN
CO O L ER
CH A N G IN G ? RE S E R V O IR ?
RU N N IN G ?
5. 1 0 5. 1 0 .2 5. 1 0 .3
NO NO NO
CH E C K F O R A C R IP P LE S E R V IC E T H E
EN D ON THE DC V OLTAGE S SP IN D L E CO O L E R
A L L A XE S R E P E A T (0 .01 5V AC M AX O N + / -1 2V , A S SE M B L Y
0. 00 5V AC M AX O N + 5 V) A N D P U M P A SS E M B L Y
5. 1 1
5. 1 0 .4 5. 1 0 .5
CO M P U T E R
CHART 6
COMPUTE R
PO W ER O N 9- 2 0 -9 5
(W A IT A F EW SE C O N D S
AN D P R E S S
CN C PO W ER S W IT C H )
6. 1
PRE SS A ND HOLD
A R E L ED S NO CN C PO W E R S W IT C H IS T H E R E NO
GO T O
ON B OARDS 5V O N T H E
CH A R T 1 2
F L AS H IN G ? RE S ET BO AR D S TH A T 10 6 0 ?
A R E N O T F L A S H IN G
6. 2
6. 2 .1 6. 2 .2 6. 2 .3
YE S
G O I NT O D IA G N O S T I CS
6. 3
IF M EM O R Y W A S
CA N YE S RU N DI AG NO S T IC S RE P L A C E D O R A D D ED
YO U G ET IN TO O N M EM O R Y , V ID EO , O R E PR O M M O D U L E
DI AG NO ST IC S? CL O C KS , M IL L IN T E R F A C E , W A S C H A N G ED ,
ETC . ZE R O M E M O R Y AN D
RE S E T P A R A M E T E R S
6. 4 6. 4 .1
NO 6. 4 .2
EP R O M M O DU L E ( 1 6 1 0) , CH E C K CH A N G E
EX PA N D ED M E M O RY ( 1 4 6 0 ), 5 V O LT S (5 .0 5 V ),
IS T H ER E YE S VID E O B O A R D ( 14 2 0 ) ,
AN D B U S B R ID G E ( 1 7 3 0 ) +/- 1 2 V O L T S
G AR B AG E O N T H E CO M P U T E R IN T E R F A C E ( 1 0 3 0 ),
M U S T B E F IR M L Y S E A TE D (A L SO S ET M E TE R FO R VA C
SCRE EN? CP U ( 1 4 0 0 ),
IN T H E IR C O N N E C TO R S . AN D C H EC K FO R AC RIP P LE
ON + 5V , + 12 V A ND -12 V D C ) E X P A N D ED M E M O RY ( 1 4 5 0 )
CH E C K FO R B E N T P IN S.
6. 5 .2 6. 5 .3
NO 6. 5 .1
6. 5
CH E C K VI DE O
SWITCH ON
YE S IS V ID E O CH E C K V I DE O C AB L E. IF 3 2 M P,
DI D F R O N T P A NE L YE S CH A N G E
M O N I T O R A L IV E ? CH E C K F U S E F 2 5 CH E C K
SCRE EN VID E O
(C H E CK F O R O N 1 1 0 0 -1 . CN C / DO S
G O D E AD ? CH E C K B R IG H TN E S S MONITOR
GLOW) CH E C K V I DE O C AR D . SW I T C H
A N D C O N T RA S T
P O T S O N M O N IT O R
6. 6 6. 6 .2 6. 6 .3 6. 6 .4 6. 6 .5
NO
6. 6 .1
NO PO W E R O F F
AND CHE CK
FUSE S ON
MONITOR
6. 6 .2 a
T E S T B A T T E R Y BA C KU P
IS NO O N C PU B O A R D .
CO N SU L T
M E M O RY L O S IN G RE P L A C E C PU B O A R D
F AC T O R Y
PR O G R AM S? IF B A T TE RY T ES T
FAILS.
6. 7 6. 7 .1 6. 7 .2
YE S
6. 8 6. 8 .1 6. 8 .2 6. 8 .3
NO
M E M O RY L O C A T I O N S :
RU N RA M T E S T S Z ER O M E M O R Y. O N C P U ( 1 4 0 0) 4 0 0 0 0 -5 F F F F, 80 0 0 0 - 8 F F F F
YE S IN D IA G N O S T IC S . O N R A M EX P AN S IO N ( 1 4 6 0 -2 ) 9 0 0 0 0 - EF F F F
"ME MO RY
IF T E S T F A IL S IF P R O B L EM R E CU R S
E R R O R "?
RE P L A C E C PU O R RE P L A C E C P U O R
M E M O RY E XP A N SIO N RA M E X P AN S IO N .
6. 9 6. 9 .1 6. 9 .2
CHART 7
A X IS M O T O R R U N A W A Y S
A X IS M O T O R 6- 1 5 -9 5
RU N A W A YS
W H E N R E P LA C IN G M O T O R S , C O N N E C T A L L W IR I N G A N D V E R IF Y
C O R R E C T O P E R A T IO N B E F O R E IN S T A LL I N G M O T O R IN V M C .
T H IS W IL L P R E V E N T D A M A G E T O M A C H IN E D U E T O R U N A W A Y S .
A X IS M O T O R
RUNS AW AY AFTER
R E P L A C IN G T H E
MOTOR
7.1
P O W E R D O W N M A C H IN E .
C H E C K W IR IN G A T A M P
AND
J4 J U M P E R O N C O N T RO LLER C A R D .
7.2
POW ER O N.
RELEAS E EM E RGENCY
STO P.
RES ET AM PS BY
P R E S S IN G J O G .
7.3
W AS M OTO R NO
DO ES YE S
W IR E D E X A C T L Y C O R R E C T W IR IN G
T H E A X IS
THE SAME AS OLD AND RE TE ST
RUN AW AY?
MOTOR?
7.4
7. 4 .1 7.4 .2
YES
NO
CH E C K RES OLV ER C O UP LE R .
CHECK AND A DJUST
RE SO LVE R CONNECTO R
W I T H S E R V IC E T O O L S T 4 4 .
CH E C K TA CH C ON N EC TION S.
RETEST.
7. 4 .1 a
RE V ER S E
MOT OR W IRE S
AND RE TE ST
7. 4 .1 b
T H E R E A R E 4 P O S S IB LE
M O T O R W I R E /T A C H W I R E
C O M B IN A T IO N S .
DO ES YE S RE V ER S E MOT OR W IR ES A ND R ETE S T.
GO TO
IT S T IL L IF S T IL L R U N N IN G A W A Y ,
CH A R T 4
RU N AW A Y ? R E V E R S E T A C H W IR E S A N D R E T E S T .
IF S T IL L R U N N IN G A W A Y ,
P U T W IR E S B A C K I N O R IG I N A L
7. 4 .1 c C O N F IG U R A T IO N . 7. 4 .1 c.2
NO
7. 4 .1 c.1
IS T H E PU T MOT OR W IRE S
M O T O R T U R N IN G NO B A C K A S W IR E D
RETEST
IN T H E C O R R E C T BE FORE A ND
DIR EC TION ? S W I T C H T A C H W IR E S
7. 4 .1 d 7. 4 .1 d .1 7. 4 .1 d .2
YES
END
7.5
KE YB OA RD
KEYBO ARD AP PLY TO CE NORM
EUROPEA N M ACHINES
10-18-95 ONLY
WILL NOT NO
POSS IBLE CAUSES:
CO NTINUE YE S 32M P ?
KE Y BOA RD ( 1090)
TO JOG WHEN JOG
1030
BUTT ON IS HE LD
1040 10. 1.2a YE S
DO WN?
MA KE SURE LE D ON
10. 2 10. 2.1 1030 IS BLINK ING.
DO ES YE S
NO CHANGE POSITION IF NOT , P RES S
DISP LAY
OF CNC/DOS SWIT CH EM ERGE NCY ST OP
CHA NGE ?
AND RE SE T CP U
GO TO 10.1.2a.1 (1400 B OA RD).
KE YBOARD T ES T 10. 1.2a.2 NO
IN DI AGNOS TI CS 10. 1.2a.3
10. 3 DI SCONNE CT
CHE CK CAB LE TO 1060.
SE RIAL PO RT
CHE CK 1040 BO ARD.
ARE FROM 1090
CHE CK 1030 BO ARD.
STA RT, SLIDE CHECK WIRING TO TO P C (J15)
YE S
HO LD, OR E S TOP SWITCHES. 10. 1.2a.4
BUTT ONS (NOT KE Y S) 10. 1.2a.2a
ERRA TIC? RE P LACE CONTACTS .
CHE CK ALL P OW ER
10.4 10. 4.1 NO CO NNECTI ONS TO
PROB LEM
KE YB OA RD (1090) .
NO SOLV ED?
POW ER O FF M ILL
AND RE ST ART.
POS S IBLE P ROB LE M S:
TOO LIGHT A TOUCH 10. 1.2a.2b YE S
SOM E YE S 10. 1.2a.5
KE Y PA D
KE YS DO NO T
KE Y BOA RD (1090)
WORK ? UP DA TE
CAB LE TO 1060
TO LA TE ST
1040 BO ARD
1090 SOF TWA RE
10.5 NO 10.5.1
10. 1.2a.6
10.6 NO 10.6.1
10. 1.2a.7
MA KE SURE J OG
MP G YE S CHECK CABLE RE P L ACE
WAS P RES SE D A ND RE P LACE
DO ES NOT CO NNECTI ONS TO KE YB OA RD LOGI C
JOG SW ITCHE S MP G
WORK ? MP G. (1090)
PROP ERLY S ET
10.7
10. 7.1 10. 7.2 10. 7.3 10. 7.4
NO
THE FIRST TIME JOG I S P RESSED, THE KEYBOA RD IN THE K EYBO ARD DIA GNO STI CS NO N-PRINTA BLE CHARACTE RS
LO GIC S E NDS "-J ", THE A XI S ("X ", " Y", "Z", "A" , "B " ARE DIS PLA YE D WI TH A "- ". T HE TAB LE SHO WS THE KE Y AND
OR "C"), A ND THE RES OLUTION ("H", "M ", OR "L"). THE CHA RACT ER T HAT WILL B E DIS PLA YE D.
WHEN JOG IS P RE S SE D A GAIN, THE K EY B OARD STA RT "- B"
SE NDS "-J " ONLY . AUTO "-D"
WHEN T HE M P G IS T URNE D, T HE K E YB OA RD MA NUAL NO DIS PLA Y, EX IT S T ES T
LO GIC S E NDS "-P " FOR A P OS ITIVE TURN O R SING LE S TE P "-H"
"-Q" FOR A NE GA TIV E TURN. JOG "-J "
"-J ", " -P ", A ND "-Q" ARE SI NG LE CHARACT ERS, NOT "-" SP INDLE ON/OF F "-L"
AND "J ". SHIF T-S P INDLE O N/OFF "-O "
THEY A RE DI SP LAY E D IN THE DIA GNOS TI CS W ITH SLIDE HOLD "-A "
THE "-" TO DIFFE RENTI ATE T HE M FROM THE CO OLANT 1 "-C"
LE TT ERS "J ", "P " A ND "Q". CO OLANT 2 "-E "
TOOL I N/OUT "-G "
TURRET CCW "-I"
MIS S ES YE S POSSIBLE CAUSES: TURRET CW " -M "
JOG PULS ES 1030 BA CKS PA CE "_"
FROM MP G? MP G DE LE TE "& "
10.8 ENTE R "-N"
10. 8.1 RA P ID TRAVEL SWIT CH NOT DI SP LAYABLE, SCREEN WILL SHOW " "
NO KE YLO CK S ENT WHEN ES TOP P RES S ED. ~ = LOCKE D
OPT IONA L ST OP ON = '"' O FF = " "
EM ERGE NCY ST OP GENE RALLY NOT DIS PLA YA B LE . ES TO P S E NDS
S TA TUS OF K E YLOCK A ND ES TOP , STA TUS
GO T O O F OP TIO NAL S TO P S WITCH, S TA TUS OF
PA GE 2 OF B LOCK S KIP S WIT CH, A ND STA TUS OF RAP ID
CHA RT 10 T RAV EL SWI TCH. A NY COM BINA TIO N OF
' ' OR '~" ' M AY A PP E AR.
MP G + "-P "
MP G - "-Q"
CONTINUED
FROM PAGE 1
OF CHART 10 CHART 10 continued (page 2)
KEYBOARD
10-18-95
RETURN TO
CNC MODE
10.9
10.10
NO 10.10.1
ATC
VERIFY THAT
CHANGES
YES 1090 AND 1040
DIRECTIONS WHEN
ARE LATEST
TURRETCCW IS
VERSIONS
HELD DOWN?
WITH UPDATES
10.13 10.13.1
NO
CONSULT
FACTORY
10.14
CHECK +5V,+12V,-12V.
ALSO SET METER FO R VAC
AND CHECK FOR AC RIPPLE
ON +5V, +12V AND -12V DC
(0 .015VAC RIPPLE MAX ON +/-12V,
0.00 5VAC RIPPLE MAX ON +5V)
11.0
CHECK SIN/COS
CHECK
YES CHECK SIG NALS USING CHECK FOR
WAVY FINISH CHECK SPINDLE MOTOR
BALANCE SERVICE TOOL ST48. SPINDLE
ON STRAIGHT BELTS TENSION CABLE
ON AXES ADJUST IF VARIANCE VIBRATIONS
CUTS? AND MOTO R MO UNTS
> 0.001V
CHECK
DO
YES AXIS AMPLIFIER
ANGLES HAVE
COMPENSATION
STAIR-STEP
SETTING
FINISH?
ON X & Y
11.4
11.4.1
NO
DO CO NSULT FACTORY
CUT S HAVE A YES CHECK BELTS SERVICE DEPT
CRISS-CROSS AND BEFORE
APPEARANCE? BELT TENSION REPLACING
(ESP X) SPINDLE
11.5
11.5.1 11.5.2
NO
DO ES
CO NSULT FACTORY
A BAD CUT YES CHECK SERVICE DEPT
CO RRESPOND TO
SURVEY TABLE BEFORE
A PARTICULAR PLACE
AND BACKLASH CHANGING
ON THE BALL
BALLSCREW
SCREW?
11.6.1 11.6.2
11.6
NO
CO NSULT
FACTORY
11.7
DASHED SYMBOLS
BAD POWER/ CHART 12 APPLY TO CE NORM
BAD VOLTAGE EUROPEAN MACHINES
BAD POWER/BAD VOLTAGE ONLY
6-16-95
CHECK
INCOMING VOLTAGE
AT MAIN DISCONNECT
AND AT INPUTS TO
TRANSFORMER
12.1
CONSULT
CHECK 1170
INCOMING NO CHECK FUSES ELECTRICIAN
SURGE
VOLTAGE IN MAIN POW ER FOR WIRING
SUPPRESSOR
GOOD? DISCONNECT FAULTS IN
BOARD
BUILDING
12.3
ON CE MACHINE
INPUT NO CHECK
CHECK FOR
VOLTAGE CIRCUIT BREAKERS
LOOSE TERMINALS
GOOD? ON SUPPLY TO
AXIS AMP CHASSIS
GO TO
PAGE 2 OF
CHART 12
12.8
CO N TIN U E D
FR OM
PA G E 1 O F
C H A R T 1 2 c o nti nu e d (p a ge 2)
CH A R T 1 2 B A D D C VO L T A G E
6- 1 6 -9 5
CH E C K IN PU T
VOL T AGE TO
DC POW ER S U P PL Y
(1 2 2 0 )
SH O U L D B E 1 2 0 VA C
12 A .1
US E C L AM P -ON AM ME TE R
NO CH E C K FOR
IN PU T TO C H E C K F OR E XC E SS IV E
LO OS E
VOL T AGE CU R R E N T D R A W ON
TER M IN A L S
GOO D ? 12 0 VA C L IN E S FR O M
O N 1 2 0 VA C L I NE S
12 A .2 .2 TR AN S FOR M ER
12 A .2 YE S 12 A .2 .1
TYP IC A L C U R R EN T TO 1 2 2 0 I S 1 . 5 A.
O TH E R BO AR D S (1 1 0 0 - 1 , 1 1 0 0 - 2, C H IL L E R, E TC .)
MA Y BE P UL L I N G D OW N L IN E VOL T AG E.
CH E C K D C PO W ER
SU P PL Y OU TP U TS :
+5 V & C OM , AL S O C H E CK F OR A C R IP PL E ON T H E D C VOL T AGE .
+1 2 V & C O M, SE T M ET ER F OR V AC A N D C H E C K + 5 V , + 1 2V , AN D - 1 2 V;
-1 2 V & C OM ME TE R SH O U L D SE TTL E TO L ES S TH AN 0 .0 1 V AC .
IF A C R IP PL E IS P R ES E N T R E PL A C E 1 2 2 0 P OW ER S U PP L Y .
12 A .3
CH E C K CH E C K BR OW N OU T
AL L YE S RE L A Y ( K 1 )
FU SE ON
VOL T AGE S ON 1 220
POW ER S U PP L Y
BA D ? BR O W NO U T R E LA Y M U ST
(1 2 2 0 )
BE W HIT E 1 40 2-1 (7 0Y Y2 108 4)
12 A .4 .2
12 A .4 NO 12 A .4 .1 BR O W NO U T R E LA Y (K 1) O N 1 22 0 W ILL NO T LA TC H A T L ES S TH AN 4.5 V
AN D W IL L R EL E AS E IF +5V D R O PS BE LO W 4 .5V .
DI SC ON N E C T + /- 1 2 V O U TP UT S
NO FR OM 1 2 2 0 AN D T ES T A GA IN .
+/- 1 2 V RE P L AC E 1 2 2 0
GOO D ? DC POW ER S U P PL Y
IF N O W GOO D , L OO K F OR B AD
BOA R D P U LL I N G TO O M U C H 1 2 V. 12 A .5 .2
12 A .5 .1
12 A .5
IF + / -12V I S B A D IT C A N E FF E CT CH ILL ER C O NT RO L , R S 232 , CL O CK S, S I NE /C O SIN E, A N D A XIS CO N T RO L.
YE S +/ -1 2V M AY RE A D O K ON A DC M ET ER A ND S TI LL BE BA D ; AN O SC ILL OS C O PE IS N E ED E D T O F UL LY TE S T + /-12 V,
BU T A C R IP PL E M A Y S H OW U P W HE N M ET ER IS S E T FO R VA C .
TU R N OFF MA C H IN E .
+5 V PR E SS E ME R GE N CY S TOP .
NO
GOO D ? RE M OVE A L L C A RD S
(5 .0 1 - 5 .1 0 V) FR OM C AR D C A GE.
UN P L U G J 9 -J 1 3 FR O M 1 0 6 0 .
PO W ER O N MA C H IN E .
12 A .6
YE S 12 A .6 .1
DI SC ON N E C T + 5 V
EN D IS +5 V NO O U TP UT S FR O M 1 2 2 0 . NO
+5 V
PO W ER G OO D U N D E R NO W GO OD ? ATT AC H 1 0 O H M 5 W
GOO D ?
STA TIC C O N D ITIO N S RE S IST OR B E TW E EN
12 A .7 +5 V AN D C OM.
12 A .6 .2 12 A .6 .3 12 A .6 .4
YE S SW I T CH IN G P O W E R S UP P LIE S R EQ U IR E YE S
A LO A D T O W O RK PR O P ER LY .
LO OK FO R I N D IVI D U AL C A R D
TH AT MA Y BE P U L L IN G T OO RE C ON N E C T
MU C H + 5 V +5 V O U TP U TS
(R E PL AC E CA R DS O NE A T A T IM E.) TO 1 2 2 0 .
(R E PL AC E J9-J 13 O N E AT A T IM E . )
12 A .6 .2 a (C A RD S SH O U LD NE VE R BE 12 A .6 .4 a
RE M O VE D O R R EP LA CE D
W ITH TH E P O W ER O N .)
US E C L AM P -ON
AM ME TE R
PU T AL L C A R D S RE P L AC E 1 2 2 0
TO L OO K FOR
BA C K I N C AR D C A GE DC PO W ER S U P PL Y
EX C ES SI VE
CU R R E N T D R A W
12 A .6 .4 b
12 A .6 .2 b TYP IC A L C U R R EN TS 12 A .6 .5
W ITH M A C HI N E A T R ES T:
1 0 6 0 - 5 .5 A
1 1 0 0 -1 - 0 A
1 1 0 0 -2 - 0 A
P EN D A N T - 0 .5 A
TH ES E A R E T YP I C AL VA LU ES .
AC TU A L V AL UE S M A Y V A RY .
EX CE S SIV E V A LU ES W O UL D B E 2-5A H IG H E R.
CHART 13 SO M E H E AD S HA VE T E M P ER A T U RE
RO TAR Y HE ADS
SW I T C H E S I N ST EA D O F ( O R I N
AD D IT I O N T O ) F U SE S T O PR O T E CT
RO T A RY H E A D S T H E M O T O R F R O M O V E RH E AT I NG .
A A X IS A A XIS T H ES E A U T O M A T I C AL LY RE S ET
W HE N TH E M O TO R C O O L S.
7- 4 - 95
T E M P E RA T UR E S N AP S W I TC H
W I L L S H OR T C O S SI G N AL T O G ND
GO TO
YE S CH E C K CH E C K O N R ES O LV ER B O A R D I N M O TO R
IF M O T O R O V ER H E AT S. CH A R T 4
A X IS D E A D ? OVE R LO A D RO T A RY H E A D CH E CK CO S O UT PU T T O RE S O L VE R A X IS
RE L A Y S FU SE (P I N 8 O F J 5 O N 1 06 0 ) CO N T R O L
FO R S H O RT T O G ND .
LE T C OO L .
13 . 1 NO 13 . 1 .1 13 . 1 .2 13 . 1 .4
13 . 1 .3
YE S
HE A D
O VE RH EA TS ?
13 . 3 NO
CH E C K F O R
HE A D CH E C K
YE S W AT ER IN
KE EP S FOR
FU SE HO LD E R
B L O W IN G M E C H A N IC A L
OR M OTOR
FU SE S? B IN D
HO U S IN G
13 . 4 NO 13 . 4 .1 13 . 4 .2
US E C L A M P -O N G E A R IS D A M A G E D
AM ME TE R TO CU R R E N T YE S BY A C R AS H.
YE S CH E C K F O R E X C E S S I V E IN RE T U R N H E A D
LE A K IN G RE P L A C E S E A L
EX C ES SI VE ON E SP OT? T O F A C T O RY
O IL ? T H A T IS L E A K IN G
CU R R E N T D R A W F O R R E P A IR S
13 . 4 .3 13 . 4 .4 13 . 4 .5
13 . 5 NO
NO 13 . 5 .1
BA CKLA SH YE S
AR E YE S CH E C K RE A D JU S T
AD J U ST OR GE AR ME SH
TH E GEA R S O IL L E V E L GEA R M ES H BA C KLA SH
A D J U S T M E NT
NO IS Y ? IN H E A D AN D GE A R ME S H
T O O T IG H T ?
13 . 6 NO 13 . 6 .1 13 . 6 .2 13 . 4 .4 a 13 . 4 .4 a .1
NO
DO E S
C H ECK W AS
A X IS H A V E YE S
YE S A X IS J U M P E R CA P A C IT Y
LI M I T E D M O T IO N ? DO N O T E X C E E D
ON 1010 CA RD. O F T HE H E A D
(W I L L N O T D O F U L L LO A D C A P A C IT Y
IT M U S T B E A N EX CEE D ED ?
RO T A T IO N )
A - A X IS J U M P E R.
13 . 7 .1 13 . 4 .4 b 13 . 4 .4 b .1
13 . 7 NO
NO
CH E C K R A T I O
GO TO IN S E T P IS CH A N G E
C H ART 4 YE S
DUTY CYCLE P R O G RA M
A X IS C O N T R O L
E X C E S S IV E ? T O G IV E M O T O R
13 . 7 .2 T IM E T O C O O L
13 . 9 13 . 4 .4 c
13 . 4 .4 c. 1
NO
M O T O R W I RE S
ARE
YE S AR E SH IELD E D .
M O T O R W IR E S
V E R IF Y T H A T S H IE L D
SH OR TE D TO
IS S T R I P P E D B A C K
CH A S S IS ?
FR OM COND UC TOR.
13 . 4 .4 d 13 . 4 .4 d .1
IS
S H O R T IN MOT OR RE P L A C E
MOT OR OR MOT OR
CA B L E ?
13 . 4 .4 d .2 13 . 4 .4 d .3
CA B L E
RE P A IR /
RE P L A C E
CA B L E
13 . 4 .4 d .4
C H A R T 14
FA D A L T R 65 SO M E H E AD S HA VE TE M P ER A TU RE
SW IT CH E S I N ST EA D O F (O R IN
TR 6 5 R OTA R Y H EA D S
R O TA R Y H E A D S AD D IT I O N T O ) F U SE S T O PR O TE CT
TH E M O TO R FR O M OV E RH E AT ING .
A & B A XI S A & B A XIS TH ES E A U TO M A TIC AL LY RE S ET
W HE N TH E M O TO R C OO L S.
6- 15-95
TE MP E RA T UR E S N AP S W ITC H
W ILL S H OR T C O S SIG N AL TO G ND
YE S CH E C K CH E C K ON R ES O LV ER B OA R D IN M O TO R
IF M O TO R O V ER H E AT S.
AX IS D EA D ? OVE R LOA D RO TA RY H E AD CH E CK CO S O UT PU T T O RE S OL VE R
RE LA YS FU SE (P IN 8 O F J4 0R J5 O N 10 60 )
FO R S H O RT TO G ND .
LE T C OO L .
14. 1 NO 14. 1.1 14. 1 .2
14. 1.3
FOLLOW I N G E R RO R
DO ES GO T O
YE S IMP R OP ER LY
B- AX IS CH A R T 4
AD J U STE D
FAU L T D U RI N G AX IS
RA P ID ? B A XI S SE TS FO L LO W IN G E R RO R *W HE N AD JU S TIN G B -A XIS AM P : CO N TR OL
DIF FE RE N TL Y F RO M O TH E R A XE S .* S ET PA R AM E TE R S F OR 90 : 1
D I SC O N NE C T S CA LE
14. 2 NO 14. 2.1 14. 1.4
B- AX IS
YE S YE S IN H IBI T R E LAY NO RE P L AC E R ELA Y * *A U GA T R D I R ELA Y
HE A D TR 65
TU R N S O FF A M P O R C O R R E CT IN C ON TR OL C AB IN E T
OVE R H EA TS ? B- AX IS ?
WH EN B R A KE W IR IN G
IS ON ?
14. 3 14. 3.1 14. 3.2
NO 14. 3.3
NO
YE S
BA C KLA SH YE S RE A D JU S T
YE S OR GE AR ME SH
LE A KIN G RE P LAC E S EA L BA C KLA SH
AD J U STM E NT
OIL? TH AT IS LEA K IN G AN D GE A R ME S H
TO O TIGH T?
14. 5
NO 14. 5.1 14. 4.4a 14. 4.4a.1
NO
W AS
AR E YE S CH E C K CA P AC IT Y YE S
AD J U ST DO N OT EX C EE D
TH E GEA R S OIL LE VE L OF T HE H E AD
GEA R M ES H LO AD C A P AC IT Y
NO IS Y? IN H EA D E XC E ED E D ?
14. 6 14. 4.4b
NO 14. 6.1 14. 6.2
NO 14. 4.4b.1
TR 65 IS CH A N GE
YE S BR A KE M AY B E YE S
B- AX IS D U TY C YC LE PR O G RA M
B A X IS C LUT C H DE FE C TIV E
LO SI NG EX C ES S IV E? TO G IVE M OTO R
MA Y BE LOOS E
POS ITI ON ? TIM E T O C O O L
CH E C K AI R SO LEN OI D
14. 4.4 c
14. 7 NO 14. 4.4c. 1
NO 14. 7.1 14. 7.2
MOT OR W I RE S
AR E
GO TO YE S AR E SH I ELD E D .
MO TOR W IR ES
C H AR T 4 VE R IFY TH A T S H IE L D
SH OR TE D TO
AX IS C ON TR O L IS STR I PP ED BA C K
CH A S SIS ?
FR OM C ON D U C TOR .
14. 4.4 d
14. 8 14. 4.4d.1
IS MOT OR
SH OR T IN RE P LAC E
MOT OR OR MOT OR
CA B L E?
RE P AIR /
RE P L AC E
CA B LE
14. 4.4d.4
CHART 15
TS UDAKO M A 301 SO M E H E AD S HA VE TE M P ER A TU RE
ROTAR Y HEADS
SW I T CH E S IN ST EA D O F (O R I N
AD D IT IO N T O ) F U SE S T O PR O TE CT
TSU D A KO MA 301 TH E M O TO R FR O M OV E RH E AT I NG .
A & B A XIS A & B AXIS TH ES E A U TO M A T IC AL LY RE S ET
W HE N T H E M O TO R C OO L S.
6- 1 5 -9 5
TE MP E RA T UR E S N AP S W I TC H
W ILL S H OR T C O S SI G N AL TO G ND
YE S CH E C K CH E C K ON R ES O LV ER B OA R D I N M O TO R
IF M O TO R O V ER H E AT S.
A X IS D E A D ? OVE R LOA D RO T A RY H E A D CH E CK CO S O UT PU T T O RE S OL VE R
RE L A Y S FU SE (P I N 8 O F J4 O R J 5 O N 1 06 0)
FO R S H O RT TO G ND .
15 . 1 15 . 1 .1 15 . 1 .2 L E T C OO L .
NO
15 . 1 .3
F O L L O W I N G E R RO R
DO E S GO T O
YE S IM P R O P E R L Y
B- A X IS CH A R T 4
A D J U ST E D
F A U L T D U RI N G AX IS
RA P ID ? B A XI S SE TS FO L LO W IN G E R RO R * W HE N AD JU S TIN G B -A XIS AM P : CO N T R O L
DI F FE RE N TL Y F RO M O T H E R A XE S .* S ET PA R AM E TE R S F OR 90 :1
D I SC O N NE C T S CA LE
15 . 2
NO 15 . 2 .1 15 . 1 .4
YE S
HE A D
OVE R H EA TS ?
15 . 3 NO
CH E C K F O R US E C L A M P -O N G EA R IS D A M A G E D
HE A D CH E C K YE S
YE S W AT ER I N AM ME TE R TO CU R R E N T BY A C R AS H .
KE E P S FOR
FU SE H OLD E R CH E C K F O R E X C E S S I V E IN RE T U R N H E A D
B L O W IN G M E C H A N I CA L
OR M OTOR EX C ES SIVE ON E SP OT? T O F A C T O RY
FU SE S? B IN D
HO U S IN G CU R R E N T D R A W F O R R E P A IR S
15 . 4
NO 15 . 4 .1 15 . 4 .2 15 . 4 .3 15 . 4 .4 NO 15 . 4 .5
YE S BA C KLA SH YE S
LE A K IN G RE P L A C E S E A L RE A D JU S T
OR GE AR ME SH
O IL ? T H A T IS L E A K IN G BA C KLA SH
A D J U ST M E NT
AN D GE A R ME S H
T O O T IG H T ?
15 . 5 15 . 5 .1
NO
15 . 4 .4 a 15 . 4 .4 a .1
NO
AR E YE S CH E C K W AS
AD J U ST YE S
TH E GEA R S O IL L E V E L CA P A C IT Y
G EA R M E S H DO N O T E X C E E D
NO IS Y ? IN H E A D O F T HE H E A D LO A D C A P A C IT Y
E X C EE D E D ?
15 . 6 15 . 6 .1 15 . 6 .2
NO
15 . 4 .4 b 15 . 4 .4 b .1
NO
GO TO
C H AR T 4
A X IS C O N T R O L IS CH A N G E
YE S
DU T Y C Y C L E P R O G RA M
EX C ES SIVE ? T O G IV E M O T O R
15 . 8 T IM E T O C O O L
15 . 4 .4 c NO 15 . 4 .4 c. 1
M O T O R W I RE S
AR E
YE S A R E S H I EL D E D .
M O T O R W IR E S
V E R IF Y T H A T S H IE L D
SH OR TE D TO
IS S T R I P P E D B A C K
CH A S S IS ?
FROM CONDUCTOR.
15 . 4 .4 d
15 . 4 .4 d .1
IS MOT OR
S H O R T IN RE P L AC E
MOT OR OR MOT OR
CA B L E ?
15 . 4 .4 d .2 15 . 4 .4 d .3
CA B L E
RE P AIR /
RE P L A C E
CA B L E
15 . 4 .4 d .4
CHART 16
SERVO COOLANT CONTROL
12-5-95
SERVO THE COOLANT AXIS MUST BE SET TO COOLANT IN SETP.
COOLANT
IF AXIS IS SET TO 90:1, THE MILL WILL NOT COLD START.
POSITION OVERRIDE
POT MUST BE:
COMMAND SIGNAL ENCODER MUST BE AMPLIFIER MAY BE
CENTERED,
COOLANT YES MUST BE CONNECTED UNPLUGGED OR DEAD.
PLUGGED INTO J3
NOZZLE WILL CONNECTED AT (J5 OF 1010, CHECK AMPLIFIER FUSE.
OF APPROPRIATE
NOT MOVE AMPLIFIER AND J2 & J3 OF 1890-0, AND (AMPLIFIER IS ALIVE
1010 CARD,
J1 OF 1010 9-PIN MOLEX AT MOTOR) IF GREEN LED IS LIT.)
CONNECTED TO GND
16.1 AND +12V. 16.1.4 AMPLIFIER FUSE
NO 16.1.2 16.1.3 HOLDER IS PART OF
16.1.1
POWER RECEPTACLE
ON AMPLIFIER.
16.6 16.6.1 16.6.2 * VMC MUST BE OFF WHEN WIRING IS BEING CHANGED.
NO DISCONNECT J4 FROM 1890-0 BEFORE REWIRING POT
OR 1890-0 MAY BE DAMAGED.
16.7
16.7.1 16.7.2 16.7.3
C I R C LE
CHART 17 DI F F IC U L T T O D I A G NO SE P R O B L E M S C A N O C C UR
IF M A C H I N E I S N O T P R O PE R L Y G R O U N D E D.
RO U N D N E S S C IR C L E R O U N D N ESS T H E R E M U ST BE A C O N T I NU O U S G R O U N D IN G
1 0 -3 - 9 5 CO N D UC T O R ( AS S PE C IF I ED O N T H E G R O U N D IN G L AB E L
IN T H E M A C H IN E 'S D IS C O N N E C T BO X ) F R O M T H E V M C 'S
G R O U N D B US T O T H E G R O U N D B U S IN T H E B U IL D IN G ' S
V E R IF Y F O R A D D IT IO N AL P R E C I S IO N IN L E V E L IN G , PO W E R D I S T R I BU T I O N P AN E L .
M A C H IN E IS L EV EL P E R F O R M S Q U A R E N ES S T E ST O N X & Y ,
(S E E M A I NT EN A N C E T H EN S Q U A R N E S S T E S T O N C O L U M N ,
MA NUAL) T H EN S P IN D L E T R A M T E S T .
(C O N S U L T F A D A L S E R V I C E D E P T F O R PR O C E D U R E)
17 . 1
TES T B A LAN C E OF
S IN / C O S S IG N A L S IF SI N A ND C OS A RE NO T
B A LA NC E D W I T H IN 0 . 0 0 1 V,
US IN G
B A LA NC E S I N AN D CO S
F A D A L S IN /C O S T E S T ER A N D R U N T ES T C U T A G A I N .
(S ER V IC E T O O L ST 4 8 )
17 . 2
CH E C K A N D A D J U S T PR O CE D UR E F O R A D J U ST I N G L O OP G AI N A N D B A LA N CE I S I N T H E MA I N T E NA N C E M A NU A L .
US I NG T HE F O L L O W I N G E R RO R DI S P L A Y I S MO R E AC C UR A T E T H A N A M E T E R .
P O S IT I O N L O O P G A I N ON C E T HE L O O P GA I N AN D B A L A NC E AR E A D JU ST E D, R ED U CE TH E F E ED R AT E T O F2 0 . AN D
AN D B A L A N C E F O R FI N E T UN E T H E L OO P G A I N AN D BA L A N CE A DJ US TM E N T S .
X A N D Y AX E S.
17 . 3
CH E C K
B A C KL A SH (T H E S CR E W P I T CH C O M P E NS A TI O N TA B L E S CA N AL SO A FF E C T
CI R CL E R O U ND N E S S W HE N CU T T I NG L AR G ER D I A M E TE RS . )
O F X & Y AX E S
17 . 4
CH E C K F O R
LO O S EN E S S IN
M O T O R C O U P L ER S
AND WO RN OR LOO SE
BA L L S C R E W S
17 . 5
CH E C K W A Y L U B E
AN D V ER I F Y W A Y L U B E
IS B E IN G DE L IV ER E D
T O A L L A X E S.
(L U B RI C AT E L I NE A R W A Y S .)
17 . 6
PA R T M U S T B E IN S P E C T E D O N M A C H IN E
B E F O R E A NY C L A M P IN G IS R E M O V ED .
IN SP E C T E D CL A M P I NG A ND FI X T U R I NG C A N D I S T O RT TH E P A RT .
IS PA R T
O F F M A C H IN E IF TH I S H A PP E NS , TH E P A RT W I L L B E RO U N D W H E N C U T
IN S P EC T ED O N O R
B U T W H E N P AR T IS R EL E A S ED F R O M T H E C L A M P IN G
O F F M A C H IN E ? TH E C U T W I L L BE D IS T OR T ED .
T O F I N D T H E S O UR C E O F D I S T O R TI O N, P A RT MU S T
B E I NS P EC T E D O N M AC H I NE B EF O RE I T I S R E L E AS E D.
17 . 7 IN S P EC T ED O N M A C H IN E
17 . 7 .1
N 1 (C IR C L E R O U N D N E S S T E S T
E N T E R T H E T E S T P R O G R AM
AT R I G H T T O C U T A 1 IN C H N 2 (0 .5 0 0 D I A E N D M IL L , T O O L D IA M E T E R M U S T B E IN T O O L T AB L E , T O ,1 ,.5
IN S ID E D IA H O L E 0 .2 5 D E E P N 3 (H O M E IS C EN T ER O F P A R T
IN A L U M I N U M . N 4 (S E T T O O L AT T O P O F P AR T
T E S T C IR C L E W IL L B E N 5 G 0 G 1 7 G 4 0 G 8 0 G 9 0 E0
RO U GH C U T A N D T H EN N 6 X 0 Y 0 M 3 S 1 00 0 0
F IN I SH C U T . N 7 H 1 D 1 Z 0 .1 M 8
N 8 G 1 Z - 0 .2 5 F 4 .
17 . 8 N9 G8
N 1 0 L9 4 0 2 R 0 + 1 5 . R 1 + 0 .9 8 0
N 1 1 L9 4 0 2 R 0 + 1 5 . R 1 + 1 .
PL A C E D I A L I N DI C A T O R N12 M5 M 9
IN S P IN D L E N13 G0 H 0 Z0
(A D J U S T X A N D Y
S O S P I N DL E I S AT
N14 X0 Y 0 E 0
EX AC T C E NT E R O F H O LE N15 M2
A C C OR D I NG T O I N D IC A T O R )
17 . 9
RO T A T E SP IN D L E SP EC IF IC A T IO N S F O R C IR C L E RO U N D N E S S :
MA N U ALLY TO M A XI M U M D E VIA T I O N
CH E C K R O U N D N E S S V M C 8 0 30 , VM C 6 0 3 0 < .0 0 0 6 - .0 0 1 2
O F C IR C L E V M C 5 0 20 A , 4 0 2 0 A , 4 0 2 0 , 3 01 6 , 2 2 1 6 , 1 5 < .0 0 0 4 -.0 0 0 8
17 . 1 0
CO N T IN U E D
O N P AG E 2
OF CHART 17
CONTINUED
CHART 17 continued (page 2)
FROM PAGE 1
OF CHART 17
CIRCLE ROUNDNESS
10-3-95 NOTE 1: IF A MEASUREMENT TEST FAILS, ALWAYS
MEASURE AGAIN USING A DIFFERENT TOOL OR
DIFFERENT MEASURING PROCEDURE.
THE FAULT MIGHT BE IN THE MEASURING TOOL
OR PROCEDURE INSTEAD OF THE MACHINE.
DO ANOTHER
CIRCLE TEST
CUT
17A.3
IS
CIRCLE YES
ROUND?
(SEE NOTE 1)
17A.4
NO FINISHED
IS DO IS
REINSTALL
CIRCLE YES ANOTHER CIRCLE YES
FIXTURING
ROUND? CIRCLE ROUND?
AND
(SEE NOTE 1) TEST (SEE NOTE 1)
SUBPLATE
CUT
17A.5.3
17A.5.4 17A.5.5 17A.5.6 NO
NO
FIXTURING OR SUBPLATE
IS DISTORTING MACHINE
WHICH WILL CREATE
A MECHANICAL BIND.
17A.5.7
CONSULT
FACTORY
17A.6
CHART 18 ER R OR D IA GN O S IS
ME A NI N G
ER R O R C O DE S
ERROR CODES NU M B ER
#
PR O CE D U R ES
R EP O RT E D B Y AX IS
8- 18 -95
NO M OTO R F EE D BA C K
#1 CH E C K TH AT US E FA D AL RE S OL VE R IN P U T
(E ITH E R R ES OL V ER OR CH E C K C AR D
NO M OTOR FEE D BA C K D EV IC E (S ) EN C OD E R TE ST ER AT J2 O F 1 0 10
EN C OD E R ) IN J 14
FEE D BA C K AR E PL U G GED IN TO OR S CA L E TE ST ER SH OU L D B E AB OU T
DE TE C TE D AT O F 10 6 0
10 1 0 CA R D J 2 (J 5 , J6 ) TO T ES T E N C OD ER S 1. 7 VA C
POW ER - U P
EN C O D E R US E F A D AL
#2 VE R IFY SW A P SP IN D L E
F EE D BA C K EN C O D E R TE ST ER
EN C OD E R N O T CO N N EC TI ON CO N TR OL LER C AR D
ON S PIN D L E O R S CA L E TE ST ER
RE S PON D I NG OF E N C OD ER W ITH K N OW N GOOD
FAI L ED D U R IN G T O T ES T S PI N D LE
CA B LES CA R D
RI GID T AP EN C OD E R
18. 2
18 . 2 .1 18 . 2 .2 18 . 2 .3
#3 MA C H IN E CH E C K S F O R
IN ST AL L J U MP E R AT DI SC ON N E C T
LO GIC J U MP E R RU N A W A Y AT POW ER - U P. YE S M OT OR W IR E S
A1 O N AX IS C A RD J1 O N DO ES
IN C OR R EC T O R ME SS AG E IN D IC AT ES A N OR TA C H
TO B YP A SS AX IS C AR D . AX IS R U N
SIG N AL M IS SI N G OR IN C O R R EC T MO TOR - TAC H - W IR E S A R E
FEE D BA C K TE ST AW A Y ?
MOT O R -T AC H JU M PE R C O N F I GU R AT ION RE V ER S ED
O N P O W E R -U P . POW ER O N .
IN C OR R EC T OR FA ILE D C OM PO N EN T.
18 . 3 .4
18 . 3 .1 18 . 3 .2 18 . 3 .3 NO 18 . 3 .5
18 . 3
J4 J U MP E RS O N AX IS
CA R D A R E W R ON G
OR
AX IS C AR D I S BA D
18 . 3 .4a
US E FA D AL
IN D EX ER MA R K OF
#5 VE R IFY C ON N E C T ION EN C OD E R TE ST ER
EN C OD E R OR S C AL E
NO IN D E X M A R K OF E N C OD ER OR OR S CA L E T E ST ER
NO T D E TE CT ED
DE T E C T E D SC A LE C A B LE S T O T ES T E N C OD ER
DU R I NG C OL D S T A R T
OR S CA L E
18 . 5 18 . 5 .1 18 . 5.2 18 . 5 .3
#7
EN C OD E R C OU N TS STO P S P IN D L E US E FA D AL
RI GID T AP
N OT W ITH IN AN D U S E DI D S EN C OD E R TE ST ER
PR E C YC LE
TOLE RA N C E T O C H E C K M A GN ET OR S CA L E T E ST ER
EN C OD E R C OU N T
DU R I NG R IG I D TA P (TU R N S P IN D L E T O T ES T E N C OD ER
PR O BL E M
PR E C YC L E TE ST BY H AN D ) AT AX IS C AR D (J 5 )
SP IN D L E MA GN E T W A S STO P S P IN D LE US E KN O W N GO OD
#8 IS YE S VE R IFY M AG N E T
NO T D E TE CT ED F OR AN D U S E DI D S H ALL E FF E C T SW I TC H
SP IN D L E MA GN E T SP IN D L E IS C ON N EC TE D
O VE R 3 S E CO N D S TO C H E C K M A G N ET AN D TE S T W I T H
NO T D E TE CT ED O R TU R N IN G? AN D C H E C K
W H EN S P IN D L E SH O U L D (T U R N S P IN D LE A M A GN ET
SP IN D LE N O T AD J U STM E NT
HA V E B E EN T U R NI N G BY H AN D ) US IN G D I D S
TU R N IN G 18 . 8 .2
18. 8.1 NO 18 . 8 .3 18 . 8 .4 18. 8 .5
18 . 8
OR IE NT AT IO N M A G NE T IS RE A D B Y C P U T HR O U GH 10 60 J10 PIN 8
BU T T HE SP IN DL E C A RD R EA D S IT T H RO U G H J 2.
G O TO IF W IRIN G IS B A D, C PU M AY B E A BL E T O RE AD M A GN E T,
CH A R T 3 BU T T HE SP IN DL E C A RD M AY N O T B E A BL E T O R E AD IT.
SP IN D L E
18. 8 .2a DR I VE R
SP IN D LE FAU L T L IN E CH E C K F A UL T L IN E CH E C K
#9 CH E C K
IS N OT D E T E C T ED CH E C K IN VE R T E R CA B LIN G F R O M OPE R AT ION
SP IN D L E FAU L T O VE R L OA D
OR H AS F ALL E N F OR FA U LT IN VE R TE R OF K 2
LI N E D O W N RE L A Y
BE LO W 1 0V (J 6 -6 ) ON 1 100 - 1
CO N TIN U E D
ON N EX T
PA GE
CO NTINUE D
FROM CH ART 1 8 continued (page 2)
DIA GNOS IS
ERROR
PRE VIO US
PA GE ERROR CODE S NUM B ER
#
ME A NI NG
PRO CE DURES
REPORTED BY AXIS
8-18-95
GO TO
CHA RT 3
SP INDLE
DRI VE R
18. 10.2a
#13
MOT OR CHE CK PO WER GOTO
FOLLOWI NG E RRO R CHE CK
OVE RLOA D - CHA RT 4
EX CEE DS THE OVE RLOAD FA CTOR
FOLLOWI NG E RRO R > GOTO CHART 12 AX IS
OVE RLOA D FA CTOR PA RAMET ER.
OVE RLOA D BA D PO WE R/ CO NTROL
PA RAM ET ER IS IT T OO LO W?
FACT OR BA D VO LTA GE
RUN DI AG NO ST ICS
AX IS MO VE COMMA ND CHE CK
#14 ON CPU AND A X IS:
WAS NOT PRO PE RLY +5V , + 12V, & -12V
MOV E TRA NS FE R IF O NE A XI S FAI LS, REP LACE
TRANS FE RRE D TO VOLT AGE S FROM
FAULT - MOVE SE TUP THAT AX IS CA RD AND RE TE ST .
AX IS CARD POW ER S UPP LY
INCOMP LE TE IF M ULTIP LE CARDS FA IL, RE PLA CE
(CHE CK S UM F AI LE D) SE E CHART 12A
1030 OR 1400 AND RETE ST
18. 14 18. 14.1 18. 14.2 18. 14.3
CO NTINUE D
ON NEX T
PA GE
CO NTIN UE D
FROM
CHA RT 1 8 con tin ued (pag e 3)
PRE VIO US
PA GE
ER RO R CO DE S ERROR
ME A NI NG
DIA GNOS IS
REP ORT E D BY AX IS NUM B ER PRO CE DURES
#
8-2 3-95
AX IS C ARD DO ES N OT
#18 GO T O
DE TE CT F AULT LI NE IF THE LS E CB I S LI T,
AM PLIF IE R CHE CK CAB LING CHA RT 4
OR CHE CK FOR
FAULT LINE AND A MP LIFI ER (A MP LIFI ER
SIG NAL HA S FA LLE N ME CH ANICA L B IND
DO WN FAULT)
BE L OW 1 0V
#19
STA CK
THE STA CK ON THE A XI S CA RD PROB LEM COULD B E
OVE RFL OW -
(US ED T O S TORE C P U COMM A NDS AX IS CARD (1010),
OVE RLOA DED W ITH
UNT IL TH E Y ARE S ERV ICE D) CP U CA RD (1400 ),
STE P COM MA ND
HA S OV ERFLO WE D OR 1 030
18. 1 9
18. 1 9.1 18. 19.2
#21
AN UNK NOWN CHE CK CONNECTI ONS
SP URIOUS
OR ILLE GA L RE P LACE
INTE RRUP T - NOT
INTE RRUP T FAUL TY CON NE CTIO N AX IS CARD
SE RVICE A BLE
HA S OCCURR ED CA N CA USE NOI SE
18. 2 2
18. 22.1 18. 2 2. 2 18. 2 2. 3 18. 2 2. 4
10 SE COND TI ME OUT.-
#28 STO P S P INDLE
DI D NOT ORIE NT IS VE RIFY M AGNE T
ORIE NT AT ION ORIE NT AT ION YE S AN D U S E DI DS
OR SP INDL E IS CONNECTE D
TIM EOUT OR T AP PI NG SP EE D M AY TO C HE CK M A GNET
DI D NOT ARR IV E AT 5TH TURNING? AND CHE CK
CA LIB RAT ION BE TOO LOW (TURN S P INDLE
MA GNET DURING ADJ USTM E NT
ERROR BY HAND )
CA L IB RAT ION
18 . 28 18 . 28.1 18 . 28.2 18 . 28.3 NO 18. 28.4 18. 28 .5
GO TO OR IE NT AT IO N M A G NE T IS RE A D B Y C P U T HR O U GH 10 60 J10 PIN 8
BU T T HE SP IN DL E C A RD R EA D S IT T H RO U G H J 2.
CHA RT 3 IF WIRIN G IS B A D, C PU M AY B E A BL E T O RE AD MA GN E T,
SP INDLE BU T T HE SP IN DL E C A RD M AY N O T B E A BL E T O RE AD IT.
DRI VE R
S E R IA L
CHART 19
CO M M U N IC AT IO N S S E R IA L P O R T C O M M U N I C A T IO N S
6 -1 4 - 9 5
IS
IS S IN G LE YE S
LO O K F O R IT A S Y N T A X S E N D F IL E
PROB LEM W ITH A LL F IL E F IL E M U S T B E
HID DEN ER R OR ? U S IN G T A ,1 ,1
C O M M U N IC A T IO N S O R SA VE D IN A T E X T
CH A R AC T ER S (D O E S P A R T O F F I L E SO C ON TR OL S TOP S
O N L Y A S IN G L E ONLY F ORMAT
IN T H E F I L E TRAN S MIT?) AT SYN TA X E R ROR
FILE ?
1 9 . 1 .1 1 9 . 1 .2 1 9 . 1 .3 1 9 . 1 .4
19 . 1 NO
ALL C OM M UNIC ATIO N
CHE C K BA UD R A TE LO O K F O R I L L EG A L
AN D O T H ER C O M M U N IC AT IO N CHA R AC T ERS B EFO RE
P A R A M E T E R S A T M A C H IN E A N D T H E IN IT IA L P E R C E N T
AT C OMP U TE R SIG N
19 . 2
1 9 . 1 .3 a
V E R IF Y T H A T A L L R S 2 3 2
C A B L E S A R E P L U G G E D IN
(A T 1 0 3 0 , B A C K O F C A B I N E T ,
CO MP U TE R)
19 . 3
YE S CHE C K
IS A
S W I T C H P O S I T IO N O F
NU LL M OD E M
NU LL M OD E M,
B E IN G U S E D ?
T R Y A G A IN I N O T H E R P O S I T IO N
19 . 4 NO 19 . 4 . 1
CH E C K G R O U N D IN G O F M A CH IN E.
G R O U N D M U S T B E A C O N T IN U O U S W IR E DIFF IC U LT T O D IA GN O SE P RO B LEM S C AN OC C U R
T O T H E P O W E R D IS T R IB U T IO N P A N E L
O F T H E B U IL D IN G . IF M A C H I N E I S N O T P R O P E R L Y G R O U N D E D .
G RO UN D RO DS AR E N OT A CC E P TAB LE TH E R E M U ST BE A C ON T IN U O U S G R O U N DIN G
A S T H E P R I M A R Y G R O U N D IN G M E T H O D . C O N D U C T O R ( A S S P E C I F IE D O N T H E G R O U N D IN G L A B E L
19 . 5 IN T H E M A C H I N E ' S D IS C O N N E C T B O X ) F R O M T H E V M C 'S
G R O U N D B U S T O T H E G R O U N D B U S I N T H E B U I L D I N G 'S
T H E G R O U N D W IR E O F P O W E R D IS T R IB U T IO N P A N E L .
TH E RS 232 D B 25 PLUG TH E C O M P U TE R BEIN G U S ED M U ST AL SO BE P R OP ER LY
IN T H E M A IN C A B IN E T G R O U N D ED (U N LE SS IT IS A B AT T E R Y O P E R A TE D LA P T O P ).
MUS T B E ATT AC HE D
TO T HE CA BIN ET.
P A IN T M U ST B E R E M O VE D
FOR GO OD CONTA CT.
19 . 6
IF M A C H I N E H A S A P H O N E M O D E M ,
M A K E S U R E I T IS D IS C O N N E C T E D
FROM TH E RS232 P OR T
19 . 7
19 . 8
M A C H IN E P A S S E S D I A G N O S T I C S
PL U G R S 2 3 2 C A BL E IN TO PO R T YE S
DO ES YE S DO ES AN D IS N O T A T FA U L T I N
AN D M OV E T ES T P LU G
RS 232 TE S T P AS S RS 2 32 TE S T P AS S C O M M U N IC A T IO N P R O B L E M .
TO C OM P UTER EN D O F C A BLE .
W IT H O U T W IT H O U T
RE R U N TE ST .
ER R OR S? ER RORS ? A N U L L M O D E M M IG H T B E N E E D E D .
19 . 9 19 . 9 . 1 1 9 . 9 .2 19 . 9 . 3
NO NO
EIT H ER T HE 1 0 3 0 C A R D CA B LE M A Y B E
OR TH E RS232 CA B LE D E F E C T IV E ,
FROM THE 1030 T O O LO N G ,
T O T HE D B 2 5 P LU G O R R O U T E D IN A
IS B A D N O IS Y E N V IR O N M E N T
19 . 1 0 1 9 . 9 .2 a
IF P R O B L E M S P E R S I S T , G O T O
C O M M U N IC A T IO N S T R O U B L E S H O O T IN G
S E C T IO N O F M A IN T E N A N C E M A N U A L
F O R A D D IT IO N A L I N F O R M A T I O N
19 . 1 1
CHART 20
SE R VO
IN D EX ER
FA D A L S E R V O IN D E X ER
10- 20 -95
W ITH 5V
IS
W ILL NO CH E C K FU SE MOT OR C A BLE NO NO BE TW E EN NO
PU LS E L E D
IN D EX ER ON B AC K OF DI SC ON N E C TE D , PIN 1 AN D P IN 6
ON 181 0-0
POW ER -U P? CO N TR O L B OX W ILL IN D E XE R OF J 11 ON
BLIN K IN G?
POW ER 18 10- 0?
UP ?
20 . 1 20 . 1.1 20 . 1.2 20 . 1.3 20 . 1.4
YE S YE S YE S YE S
CH E C K CH E C K FOR
CH E C K FOR S H OR T
CH E C K CO N N EC TI ON S OF 12 0V A C AT
OF 5V TO GR OU N D
CO N N EC TO R 5V R E GU L A TOR PIN S 1 & 2 OF J 1
IN C AB L E
TO D IS P LAY O N P O W E R SU P P LY ON P OW E R SU P P LY
OR E NC O D ER
(1 818-0 -2 ) (181 0-0- 2)
LI ST EN C A R EF U LL Y TO U N IT.
CH E C K
DO ES VE R IFY IF M OTO R IS TU R N IN G
W ILL NO YE S PA R AM ET ER S
DI SP LAY I ND I C ATE FEE D R A TE PO T AN D H E AD I S N OT,
HE A D MO VE ? (R A TIO AN D
MOT ION ? IS N OT S ET A T 0 A C O UP LE R IS LOOS E
EN C OD E R C OU N TS )
IN SI DE H E AD .
20 . 2.1
20 . 2 20 . 2.2 20. 2 .3 20 . 2.4
YE S NO
CH E C K VO LTAG ES
TU R N OFF AN D
CH E C K FU SE S IF A MP LIFI ER IS BLOW N , 181 0-0- 1 J3 :
UN P LU G U N IT .
ON M OTOR , LO OK FOR C A U S E. P IN 1 +5 V & P IN 2 GN D
CH E C K FOR S H OR TE D
ON 181 0-0- 1 A ND ON AR E MO TOR L E A DS P IN 5 +1 2V & PI N 6 C O M
(B LOW N )
181 0- 0-2 SH OR TE D TO C H AS S IS? 181 0-0 J11:
IGB T'S ON A M PLIF IER
P IN 1& 2 + 5V
20. 2 .1a 20. 2.1b 20 . 2.1c W IRE S T O MO T O R A R E P IN 3 +12V
SH IEL DE D . S H IEL D M U S T P IN 4 -1 2V
BE ST RIP P ED BA C K F RO M P IN 5& 6 GN D
CO N DU C TO R .
20 . 2.1 d
DO ES IF M OTO R W A S RE S ET PA R AM E TER S
DO ES YE S DI SP LAY YE S RE P LAC E D , TO F AC TO RY D E FA U L TS
HE A D R U N
IN D IC AT E MOT OR L E AD S (M IS C/ PA R AM /FA C S ET)
AW A Y ?
MOT ION ? MA Y BE R EV E R SE D AN D R E TR Y
20. 2 .1e
20 . 3 20. 3.1 20 . 3.2
NO
NO CH E C K C AB LE AN D
EN C OD E R C AB LE SOC K ET FOR D AM AG ED
CH E C K C ON N EC TO R S ON O R E N C OD E R MA Y BE B A D: PIN S OR SOC K E TS
MOT OR C A BL E A ND BOX
FOR P U SH E D IN O R CH E C K ALL E N C OD E R C ON N EC T ION S . 20. 2.1f
DA M AGE D CH E C K FOR C O NT IN U ITY OF A L L EN C OD E R
PIN S O R SO C K E TS LIN ES F RO M EN C OD E R TO U 4 ON 181 0-0 .
CH E C K FOR 5V A T E N C OD ER .
20. 3 .1a
20. 3.1b
MOT OR OV ER L O AD IF H E AD MO V E S
DO ES OR OV ER C U R R E NT BU T POS ITI ON D IS P LA Y
HE A D JO G IN BOT H NO FAU LTS I ND I C ATE DO ES N 'T C H A N GE
DI R EC TI ON S? A BL OW N IGB T TH ER E IS A N E NC O D ER
ON A MP LIFIE R FEE D BA C K PR O BLE M
20 . 4 20 . 4.1 20 . 4.2
YE S IF AM P LIF IER IS B LO W N ,
FIN D C AU S E B E FO R E R EP LA C ING .
RE SIS TA N CE A CR O SS M O TO R LE AD S S H O UL D B E 4 -6 O H M S.
RE SIS TA N CE FR O M M O TO R L EA D TO C HA S SIS S H O UL D B E IN F IN IT E.
W IRE S T O MO T O R A R E S HIE LD E D. S HIE LD M US T B E ST RIP P ED BA C K
FR O M C O N DU C TO R .
CH E C K BR A KE TR Y RU N N IN G
CH E C K C AB LE
YE S AIR LI N ES NO IN D EX ER W ITH
MOT OR DI SC ON N E C T AN D S OC K ET IS L OAD
(1 I S O U TPU T TO H EA D , NO FIX TU R IN G ,
OVE R LOA D S? AIR FOR D A MA GE D TOO HE A VY ?
2 IS IN P U T FR O M AU X ILIA R Y C H U C K ,
PIN S OR SOC K E TS
AIR SU P PL Y ) OR P AR T
RE D U C E
FEE D R AT E
GO T O
PA GE 2 OF 20A .5.6
CH A R T 20
CO N SU LT FAC T OR Y
AB OU T M OTO R TY PE
JU M PE R S ETT IN GS
20. 5 .6
CO N TIN UE D
FR OM CHART 20 conti nued (page 2)
PA GE 1 OF
CHA RT 20 FAD AL S ERV O IN DEX ER
10- 20-95
ENC ODE R C AB LE
IN DEX ER YE S TES T E N COD E R
MAY BE B AD , ENC ODE R MA Y B E
MIS POSITION S, LO SE S WITH F ADA L
VER IFY C ONTI NUI TY OF SLIP PI N G ON MOT OR
POS ITI ON ( MAY ALS O ENC ODE R TE ST ER
ENCOD E R SI GN ALS SHA FT,
MOT OR OV ER LO AD ) (E NC ODER M A Y B E B AD)
IN C AB LE
NO
CH E CK AI R SUP PLY
CHE CK CH EC K
BRA KE AND AIR LIN E TEST I N MD I
YES PA RAM ET ER S SOLI D ST ATE
DO ES N'T CO NN ECTO RS (M 60 BRA K E O N,
TO S EE I F BR AK E RE LA Y (K 1) ON
WOR K ? (A IR PR ES SUR E M61 BRA KE OF F)
IS ACTI VE 1810- 0-2)
SHOU LD B E 80 PSI)
20. 10 20.10.1
NO
IN SE RT DU M MY PLU G
IN TO R S232 DB 25 CONNEC TO R CHE C K CAB LING,
RS 232 YES DO ES YE S BA UD RAT E,
(P IN S 2 & 3 J UMP E RED )
DO ES N OT RS 232 TE ST AND P ROTOCO L
WORK ? WOR K ? (IN DEX E R IS 7 D AT A B ITS ,
RU N RS232 TE S T EV EN P ARITY, 1 S TOP B IT)
IN DIA GNOS TICS
20. 11
20. 11.1 20. 11.2 20. 11.3
INDEXE R HA S CTS, DT R , & DSR NO
JUMP E RE D INT ER NAL LY.
CHE C K VO LTAG ES
1810-0 J11:
P IN 1& 2 + 5V
P IN 3 +12V
P IN 4 -12V
P IN 5& 6 GN D
20. 11.2a
CO N T IN U E D
C H A R T 2 1 c o nti nu e d (p a ge 2 )
FR O M PA G E 1
OF C H A R T 2 1
P O S IT IO N IN G P R O B L E M S
10 - 2 0 -9 5
SU R VE Y F O R S CA L ES IS N O T
IF B AL L S C R EW SU R VE YS A RE BA LL SC R EW D E PE N DE N T. TH E S AM E AS S UR V EY FO R
HA S BE E N R EP L AC E D CH A NG IN G T H E B AL LS CR E W INV A LID AT ES TH E SU R VE Y. RE SO L VE R . F O R P O SIT ION IN G
A N E W S U R VE Y TO BE C OR R EC T , S U RV E Y F OR
M U S T B E DO N E RE SO L VE R MU S T B E E N TE RE D
W HE N SC AL E S A RE U NP LU G G ED
AN D S U RV E Y F O R S CA LE S MU S T
21 A .1 BE EN TE R ED W H EN S CA LE S AR E
RE C ON N EC T ED .
IF O VE R SH O O TIN G
IF O VE R SH O O T IN G O C C U R S
DO ES N O T O C C U R
O VE R - YE S W IT H A H E AV Y PA R T O R F IX TU R E , DO ES YE S PO W ER OF F M A C H IN E . W ITH OU T SC A L ES
SH O O T IN G BU T DO ES N O T O C C U R W I TH OU T I T : MA C H IN E HA V E DI S C O N N EC T S C A L E S.
CO N TAC T F A C TO R Y
PO S IT I ON ? US E G 5 1 R 0 - # W IT H A VA L U E >1 SC A L ES ? PO W ER ON M A C H I N E.
AB O U T S O FT W A RE
F O R X A N D Y TO L E N G T H E N F EE D R AM P S
21 A .2 .3 CH A N G E
21 A .2 21 A .2 .2
NO 21 A .2 .1 NO 21 A .2 .4
DO ES
J1 3 ON 1 0 60 MU S T
DO ES YE S DI S C O N N EC T S C A LE S, MA C H IN E YE S GO TO
BE P LU G G E D IN
M A C H IN E HA V E PO W ER D O W N MA C H I N E POS IT I O N C O R R E C T L Y CH A R T 2 2
FO R S C AL E S T O
SC A L ES ? AN D R ES T A R T W IT H O U T SC A L ES
W OR K R EL IA B L Y
SC A L ES ?
21 A .3 21 A .3 .1 21 A .3 .2 21 A .3 .3
NO TH E S C AL E E RR O R IN P UT IS O N J13 SU R VE Y F O R S CA L ES IS N O T TH E SA M E A S 21 A .3 .4
SO IT IS CR ITIC A L TO S CA LE S TH AT SU R VE Y F O R R ES O LV E R. FO R P OS ITIO N ING NO
J13 BE PL UG G E D IN . HO W V E R, TO BE C OR R EC T , S U RV E Y F OR R ES O LV ER
PO S IT IO NIN G ER R O RS CA N AL SO MU S T B E E N TE RE D W HE N SC A LE S A RE
OC C UR W ITH R ES O LV E RS IF J1 3 UN P LU GG E D AN D S U RV E Y F O R S CA LE S
IS N OT PL U GG E D IN . FO R SC A LE S MU S T B E E N TE RE D W HE N SC A LE S A RE
AN D R E SO L VE R S IT IS IM PO R TA N T RE C ON N EC T ED .
TH AT J13 BE PL U GG E D IN A ND D OO R SU R VE Y F O R S CA L ES AN D SU R VE Y F O R
IN T ER LO C KS FU N C TIO N P R OP E RL Y. RE SO L VE R CA N B E FO U ND IN M A C HIN E
RE C OR D S.
IS PA R T
EN S U RE T HA T PA R T
SL IP PI N G IN YE S AN D F I XT UR E
F IX T U R E O R
AR E AD E Q U A TE L Y
IS F IX TU R E
SE C U RE D
MO V IN G ?
21 A .4 21 A .4 .1
NO
DO ES
CO N SU L T TR Y DN C X ,
YE S TH E MA C H IN E NO
IS D NC CH A R T 1 9 SH O R T E N TH E C A BL E ,
M IS P O SI T IO N W H EN
BE IN G U S E D? SE R IAL US E A SL O W ER BA U D R AT E,
NO T U S IN G
CO MM U N IC AT IO N S TR Y AN O T HE R C O M P U T ER AN D C A BL E
DN C ?
21 A .5 21 A .5 .2 21 A .5 .3
NO 21 A .5 .1
YE S
PO W ER O F F
MA C H IN E AN D
IN SP EC T W IR I N G
21 A .6
CH E C K F OR L O O SE
OR B RO KE N W I RE S
OR B AD C R IM P S
21 A .7
T ES T A L L
GOLD COAX
CO N N EC TO RS
US IN G ST 44
SE R VIC E T O O L
21 A .8
CO N T IN U E D
O N P AG E 3
OF CHART 21
21B .1
CHE CK LEV EL
AND TRA M
21B .2
CHE CK FOR
BROK EN OR LOO SE
RE S OLVE R
CO UPLING S
21B .3
CHE CK
BA LLSCRE W
ALIG NM E NT
21B .4
US E CLAM P -ON
AM ME TE R TO CHE CK
EA CH AX IS .
AM P DRA WS M UST BE
IN S PE C A ND CONSI STE NT
21B .5
CHE CK ST RA P
ADJUSTM E NT S
(C HECK AM P DR AWS
AG AIN A FT ER
ADJUST ING S TR APS )
21B .6
IS INS PE CT PART
POS ITI ONING YE S ON M ACHINE DO ES P ART YE S OFF-MA CHINE
CLA M PING MA Y BE
ERROR RE VE A LED B Y BE FO RE REM OV I NG INSP ECT GOO D ME AS URING M A Y B E
DI ST ORTING PA RT
OFF-MA CHINE PA RT CL AMP S OR ON M ACHINE ? OUT OF CALI BRA TIO N
INS PE CTION? RE LE AS ING V IS E
21B .9
21B .11
SCALE PROBLEMS CHART 22 SCAL E PROBLEMS CAN SHOW UP AS SCALE ERRORS (AN ERROR CODE),
MISPOSITIONING, REPEATABILITY PROBLEMS, ROUNDNESS PROBL EMS
SCALE PROBLEMS OR UNEXPECTED POSITION SHIFTS.
10-20-95
22. 1
NO 22.1.1
YES, AND
ERROR IS
NO T EASILY CO NNECT
SCALE
YES WILL RECREATED SCALE ENCODER
ERROR MESSAGE?
SCALE BOARD TESTER (ST40)
(AND LED IN SCALE
RESET? BETWEEN SCALE
BOX LIT)
BOX AND AXIS CARD
NO
SWITCH
EXE BOARDS
IN SCALE BOX
22.2.1a
ERROR EXE
STAYS W ITH BOARD REPLACE
EXE BOARD OR EXE BOARD
SCALE?
22.2.1b.1
22. 2.1b SCALE
CONTINUED
ON PAGE 2
COLUMN 2
OF CHART 22
22.2.1c
22.3.4c
CO NTINUED
ON PAGE 2
CO LUMN 5
OF CHART 22
22.3.4d
CO NTINUED
FROM PAGE 1
CONTINUED
FROM PAGE 1 CHART 22 conti nued (page 2) CO NTINUED
FROM PAGE 1
CO LUMN 1
OF CHART 22
CO LUMN 2
OF CHART 22 SCALE PROBLEMS CO LUMN 5
OF CHART 22
10-20-95
22A.1 22A.2 22A.3
CO NNECT
SCALE ENCODER
PO WER DOWN TESTER (ST40)
MACHINE BETW EEN SCALE
AND DISCO NNECT BO X AND AXIS CARD
SCALES F RO M
AXIS CARDS 22A.3.1
22A.2.1 SWAP A
YES KNOW N GOOD
SCALE
CABLE BETWEEN
PUT X SCALE CABLE TESTER SHO WS
SCALE BOX
INTO Y JACK O F ERROR?
AND AXI S CARD
SCALE BO X, ETC. AND RETEST
22A.3.2 NO
PO WER ON MACHINE 22A.3.2a
22A.2.2
SWAP
AXI S CARDS
EXE 22A.3.3
ERROR BOARD REPLACE
STAYS W ITH 1580-1A BOARD
EXE BOARD OR (SCALE BOX PROBLEM YES
SCALE? MOT HERBOARD) REPLACE
STAYS W ITH
AXIS CARD
AXIS CARD?
22A.2.3
22A.2.3a 22A.3.4
SCALE 22A.3.4a
NO
22A.1.1 22A.1.1a
NO
DO ES IT
CHECK MECHANICAL
YES GO AWAY WHEN YES CHECK BACKLASH YES
CAVITATION ADJUSTMENT BACKLASH BACKLASH
SCALES ARE WIT H SCALES
OR VIBRATIO N? OF GIBS >20? MUST BE
DISCONNECTED? DISCONNECT ED.
AND STRAPS CO RRECTED.
22A.1.2
22A.1.2a 22A.1.2d
22A.1.2b 22A.1.2c 22A.1.2e
NO
NO
NO T A
SCALE
PROBLEM
CROSSOVER
YES CO NSULT GO T O
PROBLEM ?
(BUMP AT FACT ORY CHART 1
QUADRANT S)
22A.1.2a. 1
22A.1.3a
22A.1.3
R I G ID T A P
CHART 23 D I F F I C UL T T O D I A GN O S E P R O B L E M S C A N O C C U R
IF M AC H I N E I S N O T P R O P E RL Y G R O U N D ED .
R IGID TA P T H ER E MU S T B E A C O N T I N U O U S G RO U N D I N G
C O N D U C T O R ( AS SP E C I F I E D O N T H E G R OU N D I N G
10 - 2 0 -9 5 LA BE L I N T H E M A C H I N E' S D I S C O N N E C T B OX )
F R O M T H E V MC 'S G RO U N D B U S T O T H E G R O U N D
IS T H E C O R R E C T G O /N O G O BU S I N TH E BU I L D I N G 'S P OW ER D I S T R I B U T I O N P AN E L .
YE S G A G E B E IN G U S E D ?
TAP P ED H OLE
IS B A D ( NO G O )?
IS T H E P R O P E R G R A D E
O F T A P B E IN G U S E D ?
23 . 1 A C L A SS 3 H O L E I S U SU A L L Y
23 . 1 .1 TA P P E D W I T H A G H - 1 T A P.
NO
PI T C H D I A M E T E R O F T A P I N C R E A S E S
0 . 0 0 0 5 " F O R E V E R Y G H N U M B E R.
TAP M U ST BE IS C O O L A N T A N D / O R
YE S IS T H E D R I L L E D RU N R IG ID T A P T E S T
TAP 2 F L U T E S P IR A L P O IN T T A P P IN G C O M P O U N D
HO LE T H E C O R RE C T A S D E S C R IB E D I N
BR E AK S? (O R R O L L P O IN T ) TH E CO R R EC T TYP E
S IZ E F O R T H E T A P ? M A I NT E N A N C E M A N U A L
IF L E S S T H A N 5 /1 6 " A N D M IX T U R E ?
23 . 2 NO 23 . 2 .1 23 . 2 .2 23 . 2 .3 23 . 2 .4
B E F O R E D O I N G R I G ID T A P T E ST ,
Z - A XI S GA I N AN D BA C K L A S H M U S T B E
V E R I F I ED A N D / O R A D JU ST E D A S D ES C R I B E D
IN D IC A T O R YE S T H IS IS IR R E L E V A N T .
FAILS IN M A IN T EN A NC E M A N U A L .
YE S OVE R SH O OTS A T T A P IS N O T IN T H E
R I G ID T A P
T O P O F T A P P IN G HO LE A T TH E TO P O F
TES T?
CY C LE? T H E T A P P IN G C Y C L E .
23 . 3 23 . 3 .1
23 . 3 .2
NO NO
B E L T S M A Y B E S L IP P IN G
D U R I NG A CT U A L T A P P I N G .
PA SS ES
YE S CH E C K B E L T T E N S IO N IN D IC A T O R YE S
RI G ID T A P T E S T
A N D ID L E R A S S E M B L Y . OVE R SH O OTS A T AD JU ST R AM P
BU T TAP P ED
C H E C K F O R O IL O R B O T T O M O F T A P P IN G IN S E T P
HO LES A R E N O T
C O O L A N T O N B E LT S CY C LE?
GOOD?
O R E X C E S S IV E A IR IN
H Y D R A U L I C H I/L O A C T U A T O R . 23 . 3 a. 1 23 . 3 a. 2
23 . 4 NO
NO 23 . 4 .1
IS T H E C O R R E C T
G O /N O G O G A G E S P IN D L E IS T U R N IN G
B E IN G U S E D? P O S IT I V E YE S TOO FAS T,
IN D IC A T O R
23 . 4 .2 DE C R EA S E T H E
R E A D IN G W H I L E
GAIN PA RAM E TE R
IS T H E C O R R E C T G R A D E M O V IN G
IN S E T P
O F T A P B E IN G U S E D ? DO W N ?
A C L A SS 3 H O L E I S U S U A L L Y 23 . 3 b .1 NO 23 . 3 b .2
TA PP ED W I T H A G H - 1 T A P. .
P I TC H D I A M E T E R O F T A P I N CR E AS E S
0 . 0 0 0 5 " F O R EV E RY G H N U MB E R .
S P IN D L E IS T U R N IN G
23 . 4 .3 N E G A T IV E
YE S TOO SLOW ,
IN D IC A T O R
TAP M U ST BE IN C R E A S E T H E
R E A D IN G W H I L E
2 F L U T E S P IR A L P O IN T GAIN PA RAM E TE R
M O V IN G
(O R R O L L P O IN T ) IN S E T P
DO W N ?
IF L E S S T H A N 5 /1 6 "
23 . 3 c.1 NO 23 . 3 c.2
23 . 4 .4
IS T H E D RI L L T H E
C O R R E C T S IZ E ?
IN D IC A T O R R E M O V E IN D I C A T O R .
23 . 4 .5 RE A D IN G M O V IN G YE S DO A 1 0 IN C H R I G ID T A P .
UP D O E S N O T M A T C H CH E C K F OLL O W IN G E R R OR
IS C O O L A NT A N D / O R RE A D IN G M O V IN G O N Z -A X IS U P A N D D O W N .
T A P P IN G C O M P O U N D DO W N ? IS Z - A X IS B A L A N C E D ?
T H E CO R R E C T T Y P E 23 . 3 d .1
A N D M IX T U R E ? 23 . 3 d .2
23 . 4 .6
CH E C K F O L L O W IN G
HA S Z E R O O F F S E T CO N S U L T F A C T O R Y E R R O R O N C -A X I S
B E E N S E T IN A P P L IC A T I O N UP A N D D O W N .
IN V E R T E R ? E N G I NE E R IS IT T H E S A M E ?
23 . 4 .7 23 . 4 .8
23 . 3 d .3
CO N S U L T F A C T O R Y B E L T S M A Y B E S L IP P IN G .
YE S S E R V IC E D E P T . GO TO CH E C K B E L T T E N S IO N
S P IN D L E
A B O U T P O S S I B I LI T Y O F CH A R T 3 A N D ID L E R A S S E M B L Y .
MOT OR
EN C O D E R R U N O U T S P IN D L E CH E C K F O R O IL O R
SH A KE S?
A N D IN S T A L L IN G DR IVE R C O O L A N T O N B E LT S
SOLID MO TOR M OU N TS O R E X C E S S IV E A IR IN
23 . 5 NO H Y D R A U L I C H I/L O A C T U A T O R .
23 . 5 .1 23 . 5 .2
23 . 3 d .4
IS A
BU M P F ELT CH E C K + 5 V ,+ 1 2 V ,- 1 2 V .
YE S CH E C K R IG ID T A P ALS O S ET ME TE R FO R VA C
W H E N S P IN D L E
P A R A M E T E R S IN S E T P A N D C H E C K F O R A C R IP P L E
STA R TS OR
(E S P E C I A L L Y R A M P ) O N + 5V , + 1 2 V A ND -1 2 V D C
RE V ER S ES ?
(0 . 0 1 5 V AC R IP P L E M AX O N + / - 1 2 V ,
23 . 6 .1 0 . 0 0 5 V AC R IP P L E M AX O N + 5 V )
23 . 6 23 . 3 d .5
NO CO N SU LT FAC T O R Y
S E R V IC E D E P T .
23 . 7
TH I S C HA R T C O VE R S M -FU N C TI O NS C O NT RO L LE D T HR O U GH T HE 10 50 B O AR D .
M0 - 19 , M 3 0-M 4 9 , M 60 -6 9, A ND M 90 -9 9 A R E S PE C I FI C FU NC T IO N S TH AT AR E
CHART 24
CO N TR O LL ED TH R OU G H TH E 1 04 0 BO A R D O R AX IS C A RD S .
TH EY AR E NO T CO V ER E D H E RE ..
M ,- F U N C T IO N M-F U NC TI O N SE TT I N GS A ND TE R MI N A LS AR E L I ST E D I N CH A P T ER 7 O F T H E
M - F U N C T IO N MA IN TE NA N CE M AN U AL . BE SU R E Y O U A R E U S IN G TH E TA BL E F O R T HE 1 0 5 0
BO A RD YO U H AV E .
9- 1 9 -9 5
YE S CH E C K D E C A D E
M - F U N C T IO N 1 0 5 0 -3 A D E C A D E S 1050-0 D E C A D E SE LE C TION
SE L EC T I O N
DO E S N O T DE C AD E A - M 20- 2 9 DO N OT SE T 1 05 0- 0 F O R D EC A DE S 0, 1, 3 ,4 ,6 O R 9 B EC A US E T H E S E
JU M P E R S / SW I T C H E S
A C T IV A T E ? DE C AD E B - M 80- 8 9 D E CA D ES AL R E A DY H AV E S P EC I FI C FU N CT I O NS AS S IG N E D T O TH E M .
ON 1050 B OAR D 10 5 0 - 3 A HA S 2 M - F UN CT I O N S (A DO N OT SE T D E CA D E A A N D DE C AD E B T O T HE S AM E VA LU E .
O R B ) W H IC H A N Y N U M B ER I N
TH A T D EC A DE W IL L AC T IV A TE . TH E A C TI VE D EC A DE S O N TH E 1 05 0-0 AR E A S SI G N ED U SI N G D I P
24 . 1 S W I TC H ES LA B EL ED A1 , A 2 , A 3, A 4 , B 1, B 2, B3 , AN D B4 .
24 . 1 .1 2 A
3 B TO SE T D E CA D E A FO R :
4 M 20 -29 : A 1-C L OS E D, A 2-O P EN , A 4-C LO S E D, A 8 -C LO S ED .
W IT H U S E R D EV IC E A T T A CH E D 5 M 50 -59 : A 1-O P E N, A2 -CL O SE D , A 4-O P EN , A8 -CL O S E D.
NO 6
M E AS U R E V O L T A G E 7 M 70 -79 : A 1-O P E N, A2 -O P E N, A 4-O P E N , A 8-C LO S ED .
A C R O S S A P P R O P R IA T E 8 M 80 -89 : A 1-C L OS E D, A 2-C LO S ED , A4 -C LO S E D , A8 -O P E N.
9
T ER M IN A L S O F T B 1 O R T B 2 FO R D E CA D E B , US E SW I T CH E S B 1, B 2 , B4 , B 8 .
O N 1 0 6 0 W H IL E
M - F U N C T IO N IS A C T IVA T E D .
M -FU N C TIO N T E R M I N A LS
24 . 1 .2 UN ITS D E C A DE
DI G IT A B
T B1 TB 2
0 * 7+ 1 3 - 1 1+ 10 -
M - F U N C T IO N YE S 10 5 0 B O A R D 1 9 15 13 12
DO E S N O T YE S IS A C T I V A T IN G 2 2 4 19 20
DID RELA Y
R E L E A S E? M - F U N C T IO N . 3 5 6 14 1
CO N TAC T S 4 8 10 2 3
(V O LT A G E AC R O SS CH E C K C A B L IN G
CL O S E ? 5 11 16 16 15
24 . 2 TE RM I N AL S W IL L B E 0 A N D U S E R D E V IC E.
6 19 20 18 17
W HE N CO N TA C TS CL O S E )
24 . 1 .3 7 17 18 9 8
NO NO 24 . 1 .4 8 1 3 7 6
9 12 14 5 4
AR E YO U SU R E ? * FO R 1 05 0- 3 A ( P O L A R I T Y
RE LA YS P R OVID E A IM P OR T AN T F O R B O AR D S
CO N TAC T C LOS UR E , CH E C K S E T T I N G S U S IN G O PT O -I SO L A TO R S )
M - F U N C T IO N YE S
NO T A V O L T A G E . OF 1A 2A OR 1B 2B
RE L E A S E S
VO L T AG E O R C U R R E N T DIP SW ITC H ES
PR E MA TU R ELY ?
TH R OU G H R E LAY C O N TA C TS ON 1050 B OAR D
M U S T B E S U P PL IE D B Y
US E R D E V IC E . 24 . 1 .5
24 . 2 a US ER D E V I C E A ND
M-F U NC TIO N BO A R D
NO 24 . 1 .3 a MU S T B E S ET FO R
TH E S AM E PR O TO C O L .
CH E C K V O L T A G E A T
YE S CHE C K SE TTIN GS TB3-2 (M-FU N CTION R E SE T) ON 1060.
DISC ON N E C T U S ER
C N C IS OF 1A 2A OR 1B 2B S H O U L D B E 5 V W H EN R E L E A S E D ,
DE V IC E F R O M 1 0 6 0
H U N G U P? DI P S W I T C H E S 0V W HE N C L O S E D.
T B 1 / T B 2 A N D T B3
ON 1050 B OAR D RE S ET MU S T B E R ELE AS E D BE FO R E
NE X T M -F UN C T IO N O C C U R S .
24 . 2 b 24 . 2 .1 US ER D E V I C E A ND AL L M - FU N CT I ON S O N T HE 10 50 24 . 2 .3
M-F U NC TIO N BO A R D 24 . 2 .2 SH AR E TH E S A M E R E S E T LI N E .
NO
MU S T B E S ET FO R
TH E S AM E PR O TO C O L . CO N N E C T O H M M E T E R O R
SP IN D L E/ M - F U N C T IO N T E ST E R ( ST 0 3)
T O S E L E C T E D M -F U N C T I O N
T E R M IN A L S O F T B 1 O R T B 2 .
24 . 2 .4
R E L A Y A C T I O N / R E S E T C O N D IT IO N D IP S W I T C H E S
TH E R E LA Y A CT IO N A N D R ES E T C O ND I TIO N S A R E S E L E C T E D BY D IP S W ITC H ES EX E C U T E M -F U N C T IO N
L A B E LE D 1A ,2 A , 1 B ,2 B , W HE R E A AN D B A R E T HE DE C AD E S . FROM MDI.
O N TH E 1 05 0-0 A T HI R D D I G IT I N DIC A TE S T HE M -FU N CT IO N W I T HI N TH E DE C AD E .
FO R D E CA D E A , TH E S E TT IN G S A R E: RE L A Y T ER M IN A LS
1 A-O P EN 2A -O P E N = RE L A Y GI V E S A 0. 1 S E C P UL S E , SH OU LD C LOS E . *
C N C P R OC E ED S A F TE R P U LS E.
(O H M M E T E R W I LL S H O W 0 O H M
1 A-C LO S ED 2A -O P EN = R E LA Y G IV E S A 0 .1 S E C P U LS E ,
C N C P R OC E ED S A F TE R R E SE T R E LE AS E. O R S T 0 3 L ED W IL L L IG H T )
1 A-O P EN 2A -CL O SE D = R E LA Y H E L D U N TI L RE SE T C L OS E S, 24 . 2 .5 * RE LA Y T ER M I N AL S W IL L C L O S E
C N C P R OC E ED S A F TE R R E SE T R E LE AS E. OR C LO SE FO R 0. 1 S E C. A N D T HE N O P E N
1 A-C LO S ED 2A -C LO S E D = RE LA Y HE LD U NT IL R ES E T C L O S E S AN D IS R EL EA S ED , DE P E N DIN G O N T HE O PT IO N S E L EC T E D
C N C P R OC E ED S A F TE R R E SE T R E LE AS E. BY TH E D I P S W I T CH E S.
FO R D E CA D E B , TH E D I P S W I T CH E S A RE 1B A ND 2 B .
FO R M -F UN C TIO N 9 O F D EC A DE A (e. g. M 29 ) O N T HE 10 50-0 , TH E D I P S W IT CH E S S H O R T T B 3- 2 ( R E S E T ) T O T B 3 - 1 .
W OU L D B E 1 A 9 AN D 2A 9.
US U A L L Y T H E S ET TI N G S A R E F OR A 0 .1 S E C P UL S E A ND TH E CN C P R O CE E DS (O R P R E S S B U T T O N O N S T 0 3 )
A F TE R R E SE T R E LE AS E: S O TH E S E TTI N G S W OU L D B E 1 A-C L O S E D , 2A -O P E N , RE L A Y W IL L O P E N A N D
1 B -C L O S E D, 2 B- O P E N . CN C W IL L P R O C EE D
A C C O R D IN G T O T H E O P T IO N
SE L E C T E D B Y T H E D IP SW IT C H E S .
24 . 2 .6 CN C W I LL N O T P RO C E ED U NT I L
CO N DIT IO N F OR R ES E T I S S A TI S FI E D.
IF 1 0 5 0 B O A R D O P E R A T E S C O R RE C T L Y
DI SC O N N E C T E D F R O M U S E R D E V IC E ,
RE FE R TO C H AP TE R 7 O F
M A IN T E N A N C E M AN U A L A N D
MA N UAL F OR U S ER D E VIC E F OR
P R O P E R C O N F IG U R A T IO N S .
24 . 2 .7
CO N S U L T F A C T O R Y
S E R V IC E D E PT .
24 . 3
U1
(1 2 VOLT
U2 REGULATORS)
IGBT's AIR
SOLENOID
Q1 Q2 Q3 Q4
J4 K1
J2
120VAC POWER SUPPLY
1 BLACK 1
FU SE 165VDC
(A GC 10 ) WHITE 2
COM FOR 165VDC
BLACK 3
WHITE 4
1810-0-1
U4
1810-0-2
AMPLIFIER J2
(5 VOLT REGULATOR)
6 - GND (isolated)
5 - +12V (isol ated) FU SE
4 - NC (A GC 10 )
3 - NC
2 - GND
1 - +5V
1
1
1 J3 J3 J1
J1 1 1 2 3 4
WHITE
BLACK
1 3
13 15 16
MOV130LA20A
17 19
1 4
2 3
L N
W POWER
O
L L EN CORD
GREEN
YE RE CONNECTOR
BLACK
WHITE
RED
E
G U
BL
N
W
O
SHIE LD
E
BR G
1 ED AN
R R
O J11
2 J15
VI OLET
FINIS H START J3
BLACK 1 1 1
J1 J10 GRAY 1&2 - + 5V IN DEXER
1 RS -232
WHITE 3 - +12V IN TE RFACE
J1-1 P WM* ENCODER 4 - -12V
J1-2 DIR J3-3 TXD DB25-2
J10-1 T O U4 PIN 7 A- 5&6 - GND J3-5 RXD DB25- 3
J1-4 OVERCURRENT 8 - BRAK E
J1-6 OVERTEMP J10-2 T O U4 PIN 6 A+ J3-7 RTS DB25-4
J1-8 S TOP/ GO* J10-3 T O U4 PIN 1 B- J3-9 CTS DB25-5
J1-10 RES ET* J10-4 T O U4 PIN 2 B+ J3-11 DSR DB25- 6
J10-5 T O U4 PIN 14 Z - J3-13 GND DB25-7
J10-6 T O U4 PIN 15 Z + J3-14 DTR DB25- 20
J10-7&8 +5V
J10-9&10 GND CONTROL BOARD CTS IS JUMPERED TO D TR AND
DSR IS JUMPERED TO DTR.
J2
DISPLA Y 1 J6
1
J4
J5 1 1810-0
KEYPAD
RED
EMERGENCY
STOP BLACK
RED
BLACK
FEED RATE
WHITE
WHITE
START
GREEN
9-PIN CONNECTOR TO
ENCODER ON MOTO R
MOTOR 19- PIN CONNECTOR ON MOT OR CABLE
WHITE
3 GRAY
1
14 GA. SHIELDED B LACK BROWN
9 Z-
4 6 7 YELLOW
8 A+
9 RED 7
14 GA. GREEN 8 11 A-
10 12
GREEN
BLUE 6 Z+
13 15 16
ORANGE
5 B+
14 GA. SHIELDED R ED
19 VI OLET 4 B-
17
MOTOR WI RES ARE SH IELDED. BLACK
3 COM
SHIELD MUST NOT TOUCH CONDUCTOR!!!
SHIE LD 2 +5V
1 SHIE LD
8-PIN CONNECTOR TO
MOTOR 19- PIN CONNECTOR ON MOT OR CABLE ENCODER ON MOTOR
WHITE
1 +5V
3 GRAY
1 2 COM
14 GA. SHIELDED B LACK YELLOW 3 B-
4 6 7 4 B+
BROWN
5 Z-
9 RED
14 GA. GREEN 8 10 11 12
GREEN 6 Z+
BLUE 7 A-
13 15 16 8 A+
ORANGE
14 GA. SHIELDED R ED
19 VI OLET
17
MO TOR WI RES ARE SH IELDED. BLACK
WHITE 1 3
6 7
4
9
8 10 11 12
BLACK 13 15 16
17 19
N
EE
R W
G O
LL
YE U
E
BL
N
W
SHIE LD
O E
BR ED
G
R AN
R
O
2
VI OLET
BLACK
J1 0 GRAY
1
WHITE
ENCODER