Maintenance Manual for Mitsubishi AC Servo and Spindle Controller CMDSMA1100E

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Maintenance Manual for Mitsubishi AC Servo and Spindle Controller CMDSMA1100E

Text of Maintenance Manual for Mitsubishi AC Servo and Spindle Controller CMDSMA1100E

  • Maintenance Manualfor

    MDS-A, MDS-B & MDS-C1AC Servo Amplifier & Spindle Controller

    (Mitsubishi BNP-B2046C)Publication # CMDSMA1100E

    3/2001

    CAUTION

    This Manual is published to assist experienced personnel on the operation, maintenanceand/or programming of Mazak machine tools.

    All Mazak machine tools are engineered with a number of safety devices to protectpersonnel and equipment from injury or damage. Operators should not, however, relysolely upon these safety devices, but should operate the machine only after fullyunderstanding what special precautions to take by reading the following documentationthoroughly.

    Do not attempt to operate or perform maintenance / repair on the machine without athorough understanding of the actions about to be taken. If any question exists, contactthe nearest Mazak service center for assistance.

    Certain covers, doors or safety guards may be open or removed to more clearly showmachine components. These items must be in place before operating the machine.Failure to comply with this instruction may result in serious personal injury or damage tothe machine tool.

    This manual was considered complete and accurate at the time of publication, however,due to our desire to constantly improve the quality and specification of all Mazakproducts, it is subject to change or modification.

  • Notes:

  • SAFETY PRECAUTIONSThe machine is provided with a number of safetydevices to protect personnel and equipment frominjury and damage. Operators should not,however, rely solely upon these safety devices,but should operate the machine only after fullyunderstanding what special precautions to take byreading the following documentation thoroughly.

    BASIC OPERATING PRACTICESDANGER:1) Some control panels, transformers, motors,

    junction boxes and other parts have highvoltage terminals. These should not be touchedor a severe electric shock may be sustained.

    2) Do not touch any switches with wet hands.This too, can produce an electric shock.

    WARNING:1) The emergency stop pushbutton switch

    location should be well known, so that it can beoperated at any time without having to look forit.

    2) Before replacing a fuse, turn off the mainincoming power switch to the machine.

    3) Provide sufficient working space to avoidhazardous falls.

    4) Water or oil can make floors slippery andhazardous. All floors should be clean and dryto prevent accidents

    5) Do not operated any switch without a thoroughunderstanding of the actions about to be taken.

    6) Avoid accidental operation of switches.7) Work benches near the machine must be

    strong enough to hold materials placed onthem to prevent accidents. Articles should beprevented from slipping off the bench surface.

    8) If a job is to be done by two or more persons,coordinating signals should be given at eachstep of the operation. The next step should notbe taken unless a signal is given andacknowledged.

    CAUTION:1) In the event of power failure, turn off the main

    circuit breaker immediately.2) Use the recommended hydraulic oils, lubricants

    and grease or acceptable equivalents.3) Replacement fuses should have the proper

    current ratings.4) Protect the NC unit, operating panel, electric

    control panel, etc. from shocks, since thiscould cause a failure or malfunction.

    5) Do not change parameters or electricalsettings. If changes are unavoidable, recordthe values prior to the change so that they canbe returned to their original settings, ifnecessary.

    6) Do not deface, scratch or remove any cautionplate. Should it become illegible or missing,order another caution plate from the supplier,specifying the part number shown at the lowerright corner of the plate.

    BEFORE POWERING UPDANGER:

    Cables, cords or electric wires whose insulationis damaged can produce current leaks andelectric shocks. Before using, check theircondition.

    WARNING:1) Be sure the instruction manual and the

    programming manual are fully understoodbefore operating the machine. Every functionand operating procedure should be completelyclear.

    2) Use approved oil resistant safety shoes, safetygoggles with side covers, safe clothes, andother safety protection required.

    3) Close all NC unit, operating panel, electriccontrol panel doors and covers.

    CAUTION:1) The power cable from the factory feeder switch

    to the machine main circuit breaker shouldhave a sufficient sectional area to handle theelectric power used.

    2) Cables which must be laid on the floor must beprotected from hot chips, by using rigid orother approved conduit, so that short-circuitswill not occur.

    3) Before first time operation of the machine afterunpacking it or from being idle for a long periodof time (several days or more), each slidingpart must be sufficiently lubricated. To do so,push and release the pump button severaltimes until the oil seeps out on the slidingparts. The pump button has a return spring, sodo not force it to return.

    4) Oil reservoirs should be filled to indicatedlevels. Check and add oil, if needed.

    5) For lubrication points, oil specification andappropriate levels, see the various instructionplates.

    6) Switches and levers should operate smoothly.Check that they do.

    7) When powering the machine on, turn on theswitches in the following order: first the factoryfeeder switch, then the machine main circuitbreaker, and then the control power on switchlocated on the operating panel.

    8) Check the coolant level, and add coolant, ifneeded.

    S-1

  • AFTER CONTROL POWER IS TURNED ONCAUTION:

    When the control power ON switch on theoperating panel is on, the "READY" lamp onthe operating panel should also be on (check tosee that it is).

    ROUTINE INSPECTIONSWARNING:

    When checking belt tensions, do not get yourfingers caught between the belt and pulley.

    CAUTION:1) Check pressure gages for proper readings.2) Check motors, gear boxes and other parts for

    abnormal noises.3) Check the motor lubrication, and sliding parts

    for evidence of proper lubrication.4) Check safety covers and safety devices for

    proper operation.5) Check belt tensions. Replace any set of belts

    that have become stretched with a freshmatching set.

    WARM UPCAUTION:1) Warm up the machine, especially the spindle

    and feed shaft, by running the machine for 10to 20 minutes at about one-half or one-third themaximum speed in the automatic operationmode.

    2) The automatic operation program should causeeach machine component to operate. At thesame time, check their operations.

    3) Be particularly careful to warm up the spindlewhich can turn above 4000 rpm.If the machine is used for actual machiningimmediately after being started up following along idle period, the sliding parts may be worndue to the lack of oil. Also, thermal expansionof the machine components can jeopardizemachining accuracy. To prevent this condition,always make sure that the machine is warmedup.

    PREPARATIONSWARNING:1) Tooling should conform to the machine

    specifications, dimensions and types.2) Replace all seriously worn tools with new ones

    to prevent injuries.3) The work area should be adequately lighted to

    facilitate safety checks.

    4) Tools and other items around the machine orequipment should be stored to ensure goodfooting and clear aisles.

    5) Do not place tools or any other items on theheadstock, turret, covers and similar places(For T/M).

    CAUTION:1) Tool lengths should be within specified

    tolerances to prevent interference.2) After installing a tool, make a trial run.

    OPERATIONWARNING:1) Do not work with long hair that can be caught

    by the machine. Tie it back, out of the way.2) Do not operate switches with gloves on. This

    could cause mis-operation.3) Whenever a heavy workpiece must be moved,

    if there is any risk involved, two or more peopleshould work together.

    4) Only trained, qualified workers should operateforklift trucks, cranes or similar equipment andapply slings.

    5) Whenever operating a forklift truck, crane orsimilar equipment, special care should be takento prevent collisions and damage to thesurroundings.

    6) Wire ropes or slings should be strong enoughto handle the loads to be lifted and shouldconform to the mandatory provisions.

    7) Grip workpieces securely.8) Stop the machine before adjusting the coolant

    nozzle at the tip.9) Never touch a turning workpiece in the spindle

    with bare hands, or in any other way.10) To remove a workpiece from the machine other

    than by a pallet changer, stop the tool andprovide plenty of distance between theworkpiece and the tool (for M/C).

    11) While a workpiece or tool is turning, do notwipe it off or remove chips with a cloth or byhand. Always stop the machine first and thenuse a brush and a sweeper.

    12) Do not operate the machine with the chuck andfront safety covers removed (For T/M).

    13) Use a brush to remove chips from the tool tip,do not use bare hands .

    14) Stop the machine whenever installing orremoving a tool.

    15) Whenever machining magnesium alloy parts,wear a protective mask.

    S-2

  • CAUTION:1) During automatic operation, never open the

    machine door. Machines equipped with thedoor interlock will set the program to singlestep.

    2) When performing heavy-duty machining,carefully prevent chips from being accumulatedsince hot chips from certain materials cancause a fire.

    TO INTERRUPT MACHININGWARNING:

    When leaving the machine temporarily aftercompleting a job, turn off the power switch onthe operation panel, and also the main circuitbreaker.

    COMPLETING A JOBCAUTION:1) Always clean the machine or eq

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