Yasnac Mx-3 Fault Finding Guide

7/17/13 GENERAL-CNC-INFORMATION

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General CNC Information

When a machine tool continually over travels when attempting zero return, makesure the overt ravel switch is not being made before the zero return functionis finished. On most machines, when reference returning, the decel dog makesthe switch, the machine decels and continues at this low feed rate until theswitch drops off of the back of the decel dog. At this exact instant thecontrol commands a one revolution of the motor. after the one rev it looksfor the marker. One revolution on most machines equals about .200" of axismovement. So, if the over travel switch is closer to the back side of thedecel dog than .200" it may be engaged while the control is trying to findthe marker. Unless you are very confident of the travel limits of the machineyou should move the decel dog a little in the negative direction rather thanmoving the over travel dog. But either one will have the desired effect.

When working with 50 Hz inductive devices the voltage tolerance is 20% ofthe rated value. When 60 Hz it is 10%.

Normally, double arm tool changers don't use a G30. The Z axis stays putwhile the arm moves up and down. Therefore the machines home position isthe tool change position. Also on double arm tool changers, when the arm isin the up position the spring loaded grippers can be pushed in easily. Whenthe arm is in the down position the locking pins go up which locks thefingers in on the tool holder. This prevents the tool from being thrown.

On most cylindrical grinders the table traversing left to right is done bymechanical means. The lever in the center of the travel is connected by ashaft to a directional valve so that when the lever is moved either by handor by contact with the travel dog it switches the valve which changesdirection. Normally, there will be limit switches which are actuated by acam on the lever. These switches have nothing to do with the tabletraversing. What they do is cause the wheel to move in by the selected amounteach time the table reaches the end of travel in each direction.

On a Leadwell MCV-1300S, the standby tool is stored in Diagnostic 382. Thisnumber can be seen to change as the tool positions are counted. They willchange only during an Automatic Tool Change not when magazine is jogged.Diagnostic 387 records when tool position 1 is up. It should always be a 1.Diagnostic 380 is the ATC capacity. If the tool number becomes confused:

1. Manually move the magazine to tool position 1.2. Set Diagnostic 382 to 1.3. Set Diagnostic 387 to 1.4. Make sure Diagnostic 380 reflects the correct capacity.

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5. Do a tool change in MDI to check operation.

When setting the tool capacity, you must insert a whole number in BCD. Inthe case of the MCV-1300S, the tool capacity is 30 tools. So Diagnostic 380must be 00110000. In true BCD, it would look like 0011 0000.

Remember BCD works this way:

8 4 2 1 8 4 2 10 0 1 1 0 0 0 0=3 =0

There is an instruction in the Ladder rung for M06 which checks Diagnostic380. This instruction (LEC1) (R551.2) checks the tool number called againstD380 (Tool Capacity). If the tool called is higher than D380(i.e, M06 T31),M06 will not execute. There will be no alarm, the M Code simply will notexecute. If the contents of D380 is higher than the actual capacity, theresult will be tool confusion. Setting D380 to a very high number will causethe magazine to continually rotate when a tool is called. Another symptom ofa D380 incorrect setting is that if a number lower than the tool capacity buthigher than the current tool is input, any tool number lower than the currenttool or the magazine capacity can be called but nothing higher.

RS232 Pin outs:

9 Pin12 Receive Data (RD)3 Transmit Data (TD)45 Signal Ground (SG)78

15 Pin1 Signal Ground (SG)6 Transmit Data (TD)7 Receive Data (RD)11 Request to Send (RTS)12 Clear to Send (CTS)13 Data Set Ready (DSR)14 Data Terminal Ready (DTR)

25 Pin2 Transmit Data (TD)3 Receive Data (RD)4 Request to Send (RTS)5 Clear to Send (CTS)6 Data Set Ready (DSR)7 Signal Ground (SG)8 Data Carrier Detect (DCD)20 Data Terminal Ready (DTR)



15 Pin Male 1 o o o o o o o o o o o o o o o 15

15 Pin Female

1 o o o o o o o o o o o o o o o 15

25 Pin Male

1 o o o o o o o o o o o o o o o o o o o o o o o o o 25

25 Pin Female

1 o o o o o o o o o o o o o o o o o o o o o o o o o 25

9 Pin Male

1 o o o o o o o o o 9

9 Pin Female

1 o o o o o o o o o 9

50 pin Honda

18 50



32

191 33

This is looking at the pins, the notch is at the top.

Jumper requirements for RS232 on most controls.

9 Pin7-86-1-4

15 Pin13-1411-12 (In some cases)

25 Pin4-56-8-20

Pin 25 on Fanuc controls is 24vdc.

If 440 volts is applied to a Bridgeport Series 1 CNC when it is wired for220 volts, the most likely result is that the ACC board will be damaged.

The Bridgeport Boss controls use open loop stepper motors. Mounted to theside door of the electrics cabinet are four nearly identical boards. Threeare the X, Y and Z axis drives. The fourth is the ACC board. The final ampstage for the axes is mounted to the large heat sink. Their are four foreach axis.

Most parts for these controls are only available through Electrical South.800-950-9550.

Whenever working with a machine that is in a not ready state or the axes areinhibited or interlock for a reason that is difficult to discern, make surethat the ATC or tool turret, as the case may be, is ready. All machinesrequire that the tool changing mechanism is ready before the machine can beready. In the case of a machining center, be sure the tool pot is horizontal.In the case of a turning center, be sure the turret is clamped.

LeBlond Makino does not use the Fanuc built in PMC, it builds it's own. Inmost cases the components are Fuji Electric. So if you try to access theLadder, you may not be able to by normal Fanuc means. You will usually needto consult the Makino manual for the proper operation.

On a Makino FNC74, if you have problems with the tool changer, check thesolenoids on the side of the machine. Solenoids 70, 71, 74 and 75 shouldhave the A side turned on when the tool changer is at home. If they are not,the ATC is not ready. If any of them are on B you must:

1. Electrically (by switching the coil wires at the solenoid) shift the valve to A. If solenoid 75 is on B, do it first.



2. While keeping the valve switched (holding the wire) press the E-Stop.

3. Release the E-Stop.

4. Shift the next one. If 74 is on B, do it after 75.

5. Repeat the E-Stop procedure as above.

6. Do the remaining valves which require being careful to note the function of the valve before you switch it to prevent slamming one part of the tool changer into another.

7. Cycle power on the control.

SOL 75 = Pot HorizontalSOL 71 = Arm InSOL 70 = Arm 60 DegreesSOL 74 is somehow related to the tool pot horizontal function.

If a machine leaves a bump at the quadrants during circular interpolation,the control is probably overcompensating for backlash.

On most EDM machines trying to discharge without polarity selected causes thegenerator power to shut down. In most cases, polarity is selected by pullingin a contactor.

On all machines Feed Hold is disabled when in Rigid Tapping mode.

To find the feed rate needed for the G84 line, divide the desired pitch into1.

If the turret on a Yam CK-2, when commanded to index, indexes then clampsthen unclamps on it's own, check the turret clamp/unclamp confirmationswitches. In this case one of them is normally stuck. if the machine has aFanuc 0 control check Diagnostic bits 2.5 and 2.6. They should never both be1 at the same time or 0 at the same time.

HURCO AUTOBEND7Amplifier Balancing Procedure for V1.10 PLC Software:

1. Press the MODE key.

2. Enter a number which is one greater than the last visible selection in the mode menu. (i.e. If the menu has 9 selections, enter 10.)

3. Press ENTER.

4. The message "Press RUN button" will be displayed.

5. Press RUN.

6. The balance menu will be displayed. Only one servo axis will be active at one time.



7. To select different axes, pres UP or DOWN arrows.

8. The PLUS and MINUS keys are used to select the DAC output value.

9. The balance menu will display: - The axis number - Zero, positive, or negative DAC output voltage - Position change value

10. The first screen will be for ZERO DAC output voltage. Adjust the balance pot on the servo amp until the delta value displayed is zero.

11. Press the UP arrow button to change to negative DAC output voltage. Check the delta value displayed.

12. Press the UP arrow button to change to positive DAC output voltage. Check the delta value displayed.

13. Compare the negative and positive DAC output voltage. This value should be close.

14. Press the MODE key to exit the amp balance screen.

To access the Hurco Autobend 7 Parameter screen:

1. Press the MODE button.

2. Press the 0 button then the ENTER ADV button.

3. Enter 14753 then the ENTER ADV button. ( The word ACCESS appears under the Hurco logo.)

4. Press 6 (Configuration Menu) then ENTER ADV button. ( Configuration Menu is now displayed.)

5. Select Axis Configuration Menu. ( Move orange cursor to selection using green arrow keys.)

6. Press ENTER ADV button.

7. Make changes to Parameters as necessary. - Move cursor left and right using (+) and (-) buttons. - Move cursor up and down using green arrow buttons. - Once cursor is over field to be changed, press ENTER ADV button. - The number moves to bottom of screen. - Change number to new value. - Press ENTER ADV button. - The number returns to original location.

8. Press BACK button. * Only after all necessary changes have been made. New menu is now displayed.

9. Select "Save and Exit" then press ENTER ADV button. (Move orange cursor with green arrow buttons.)

10. Turn off power, wait 30 seconds, turn power back on.



On a Hurco control, every time it turns on all necessary data is loaded fromthe Flash Eprom to RAM. If you replace the Main board, you must take theblank eprom from the new board and replace it with the one from the oldboard. Before you do this you should do a Master Save to be sure everythingin RAM is stored to the EPROM. A Master Clear will erase everything fromRAM but will not affect the EPROM. This is sometimes helpful in solvingproblems. If you have some strange problems you can try doing a Master Clearthen disconnect the backup battery from the Main Board with a piece of paperbetween the battery and the contacts for about two minutes with the poweroff. Then remove the paper and turn the power back on.

If you have a Golden Sun Rotary Table that misindexes intermittently,remove the drive motor and check the gear pulley. The gear is a taper lockwith six bolts. They can come loose allowing the table to misindex. Ifyou remove the encoder to check it you must put it back with the coupler inthe same orientation. It can go back one of two ways. Either correctly or180 degrees out. If it is 180 degrees out, the table will zero return onedegree from where it would otherwise.

On a 15" Colchester lathe, the brake is a caliper type. It is:

Matrix Engineering1CD040-03C15993

For problems with RS-232, especially in one direction only suspect pin 2 or3 wiring problem depending on which direction the problem is in. If theproblem is in both directions suspect pin 7 of the 25 pin connector or pin5 of the 9 pin connector. A poor connection will cause a situation wheredata can be transferred at a slow baud rate but not at a higher one.

On a Kia KIT30A you have to push the Standby button for the hydraulics tocome on and make the machine ready. If the machine hits a hard limit switch,you must hold in the Standby button.

With servo systems a motor running at a constant speed will have an equalnumber of command pulses and feedback pulses.

Proximity switches:

RED--------- 24vdc ---------BROWNBLACK------- GND ---------BLUEWHITE-------OUTPUT----------BLACK

In most cases a three wire proximity switch can be replaced with a two wire(BROWN,BLUE).

The Manual/Absolute signal determines whether or not the control adds travelperformed manually to the Absolute coordinate.

The cable supplied by SWI for the Haas indexer pins out this way. Pins 1 and2 go to the pins for Cycle Start. Pins 3 and 4 go to the pins for FinishSignal.

Pin outs for a Yuasa SUDX Indexer:

# Wire Color Signal



2 Black +24vdc __________ ________ Internal Relay3 Green M-Code Start ____|4 Red/White +24vdc5 Orange M-Code Finish #16 White +24vdc7 Blue M-Code Finish #28 Orange/Black Emergency Stop9 Clear Do Not Use10 Red/Black _____ _________ Feed Hold (N.O.)11 White/Black _____|12 Black/White _____ _________ Remote Home (M-Code or other circuit)(N.C.)13 Blue/White _____|

When a Yuasa indexer is connected to a SWI control, parameter i32 should beset to 1:0. This sets the indexer up for no handshake.

Fanuc, GE Fanuc and General Numeric controls are basically the same in termsof parts, manuals, etc. For example, a GN0 is the same control as a Fanuc 0.The manual for this machine would be a part number GN61404E for GeneralNumeric and B61404E for a Fanuc and GFZ61404E for a GE Fanuc.

The Mori Seiki MH63 has a door switch on the NC cabinet. If this switch isnot made, the NC will not turn on. If an axis of this machine has a jerkymovement, it could be the scale but always first check the amount of backlashin the axis. Particularly with the Y axis which is moving a great deal ofweight. The Y axis of a horizontal machining center carries not only it'sown weight but the Z axis and the spindle. Excessive backlash in the systemcan cause a stick/slip condition especially on an older machine where theways may be worn in the middle of the travel but like new at the ends.

Mori-Seiki vertical machines typically use a Yasnac MX2 or MX3 control.To search for an address in the Diagnostic pages:

1.Press the DGN button.2.Enter the address (i.e. 1872). As with a Fanuc control, the address you type will be displayed in the lower left corner of the screen.3.Press the Cursor Down button.

On a Mori-Seiki MV-65 it is normal after turning on the NC power to see thealarm 310:SERVO OFF. To clear this alarm, press the NC power on button again.

When reading the hard copy of the ladder on a Yasnac MX2, the decimal pointis omitted from the addresses. So 1872.4 would be written as #18724

The MV-65 uses NC driver boards to operate solenoids etc. These are Moriboards that have an MR connector from the control. It has two edge card conn-ectors that contain the power to feed the loads, normally 24vdc as well asthe wires going to the loads. The boards are just small relay boards. Thetool clamp/unclamp for this machine is air over oil. It uses four air valves.It has two oil filled cylinders, one mounted horizontally the other mountedvertically. The one mounted vertically is a long aluminum cylinder. It has aplastic line on the outside that runs from top to bottom and indicates theoil level in the cylinder. It also has a switch in the bottom, I think is fordetection of oil level. As far as the switches related to the drawbar clampand unclamp there are three. The switch at the top of the unit indicates



when the tool is clamped or unclamped. It is made when the tool is clamped.It is pressed in by the small inner cylinder. It is LS18, the address is#1024.2, it's name is TOOL CLAMP DETECTION. The large outer cylinder has twoswitches associated with it. The upper switch is LS25, the address is #1024.6it's name is BELLVILLE SPRING FLEX. It should be made when the tool is clamp-ed. The lower switch is LS24, the address is #1024.7, it's name is BELLVILLESPRING RETURN.

The manual clamping switch is address #1024.0, wire numbers are 180 and 24NC.The manual unclamping switch is address #1024.1, wire numbers are 181 and24NC.

This machine uses three driver boards. They are identical. They are basicallysmall relay boards. At the top of each board there is a Honda 16 pin MRconnector that appears to be connected to the NC I/O board. This connector isdesignated CN1. There are also two eight pin edge board connectors at thebottom of the board. One is CN2, the other is CN3. Each board also has tenLEDs from the top of the board to the bottom. These LEDs correspond to theten relays on the board. The board farthest to the right controls 24 vdcoutputs. The two boards to the left of this board control 220 vac outputs. The DC board pins out like this:

CN2

1 2 3 4 5 6 7 8 | | | | | | | | | | | | | | | | N24 U23 U24 U25 N24 U30 U31

CN3

1 2 3 4 5 6 7 8 | | | | | | | | | | | | | | | |N24 N32 U33 U27 N24 N24

N24 is the 24 vdc power feed, P24 is the return. It originates from a smallpower supply to the right of the driver boards. The input to the power supplyis 220 volts on wires R11 and S11. The output of the power supply is 24vdc onwires P24 and N24. There is a terminal strip behind the driver boards thatcontains a number of supply wires such as P24, N24, 24NC and 0NC. The boardsto the left of this one are wired the same except that they control AC loadsso that N24 is replaced with R11.

There are three servo amplifiers. Each one has a seven segment LED as well asthree green LEDs from the top of the drive to the bottom.

The spindle amplifier is a Yasnac (Yaskawa) Varispeed 626 MTII.

The NC is mounted to the left door. It has three boards. The top board is theCPU. It has a three volt Lithium battery for memory backup. The middle boardis the I/O board. The bottom board is the SERVO board.

This machine has a geared head. The cylinder used for shifting gears is mount-ed vertically. It has three switches that are activated by the rod end toindicate gear selection.



If you have electrical problems, check the condition of all of the N24 andP24 wires.

The Ladder cannot be monitored on the Yasnac MX2 control.

For troubleshooting ATC problems on the MV-65 there is a manual ATC mode.To enter this mode there is a MANUAL ATC button that must be pressed. Thebutton is behind a door on the right hand side of the Operators Panel cabinetAlso behind this cover is the Over travel Release, the RS-232 port and the110 VAC outlet.

Once the Manual ATC button is pressed, the machine enters the EDIT mode andthe ERROR lamp starts flashing. Press the ALM button, the ATC MANUAL screenis displayed. The screen looks like this:

ATC MANUAL 1. POT UP 2. POT DOWN 3. ARM FORWARD 4. ARM REVERSE

Now you can perform these four functions by pressing buttons that are redesignated for that function while in theManual ATC mode. If you look closelyat the buttons for things like Single Block Coolant On and Off, Block Skip,etc., you will find that there are small numbers in the right hand corner.When working in screens like ATC Manual, these numbers operate the functionlisted beside the number. For example, if while in the Manual ATC mode, youpress the Single Block button which has a 1 on it, the pot will go up. Press-ing the Coolant On button which has a 2 on it, the pot will go down. Pressingthe Coolant Off button which has a 4 on it will make the ATC arm rotate inreverse.

When you are finished with the ATC Manual mode you have to push the buttonagain to turn it off. If you don't do this and you cycle power, the controlwill remember and issue an alarm. When the ATC is at home, Diagnostics 7408,7409,7410 and 7413 will be 0.

If you get alarm ALM140 TOOL DATA NOT EQUAL or ALM240 EMPTY POT NOT FOUND,take the tool out of the spindle, put it in the correct pot. Then set thespindle tool number in the Tool Registration to 0.

The pot up/down on the MV-65 with a 30 tool magazine is done with a pneumaticcylinder. The cylinder is located behind the tool pot which is in the standbyposition. It is mounted vertically. The pot up limit switch is mounted tothe left of and just above the standby pot position. The pot down limitswitch is mounted directly behind the tool pot. The cylinder is controlled bya two way valve which is located in an enclosure to the left of the magazine.The A port of the valve moves the cylinder down, the B port moves it up. Thisvalve has a manual override for each port. There is a regulator in each ofthe lines coming from the ports. They are located in the enclosure with thevalve. The overrides are the slotted screw type. They are labeled OFF and ON.If the slot is horizontal the valve is manually ON. If the slot is verticalthe valve is controlled by the electrical signal.

The electrical signal for the A side of the valve is on wires P24 and U25.The B side is P24 and U24. The voltage is 24 vdc.



The magazine is rotated by an electric gear motor. The magazine is locked witha pneumatic cylinder. The cylinder has a roller on the end of the shaft thatrides on a cam plate that is mounted on the drive sprocket. There is also aproximity switch mounted two tool pots to the left of the standby pot posit-ion. It counts the tool pots by picking up on the pot itself. There is amanual switch for rotating the magazine in both directions. The switchesare mounted on the cover of the enclosure mentioned above. The switch to theleft is for clockwise rotation while the one to the right is for counter-clockwise rotation. The wire numbers for the CW are MGCW and 24NC. The numbers forthe CCW button are MGCCW and 24NC.

When troubleshooting problems where feedback seems to fail intermittentlycan be traced to moisture inside an encoder. In addition, the moisture canbecome a vapor under certain conditions causing reading problems that seemto occur only when ambient temperatures are high or may take the form of aproblem which occurs and seems to go away after the machine sits for awhile.

Chen Ho MCV-2300 I/O:

INPUTSFUNCTION ADDRESS CONNECTOR WIRE#

Low Gear X4A CMD21-34 135High Gear X4B CMD21-2 136Tool Release X4C CMD21-20 137Tool Hold X4D CMD21-35 138Tool Counter X50 CMD21-26 139Arm Up X51 CMD21-42 140Arm Down X52 CMD21-10 141Pot Up X4 CMD12-5 142Pot Down X2E CMD12-14 143Manual Magazine Rotation X48 CMD22-1 121X+OT X28 CMD12-12 125XDEC X18 CMD12-24 126X-OT X20 CMD12-47 1274th Axis Clamp X53 CMD22-27 150Foot Switch X46 CMD22-38 128Z+OT X2A CMD12-45 129Z-OT X22 CMD12-32 130ZDEC X1A CMD12-7 131YDEC X19 CMD12-39 132Y+OT X29 CMD12-29 133Y-OT X21 CMD12-15 134Chip Conveyor X42 CMD22-22 93Optional Stop X43 CMD22-37 94Coolant X44 CMD22-5 95Key Switch X45 CMD22-23 96Dry Run X3C CMD11-2 89Man/Abs X3D CMD11-9 90Machine Lock X40 CMD22-36 91Override Cancel X35 CMD11-5 84Single Block X38 CMD11-14 85Block Delete X39 CMD11-1 86ZNG (Z Axis Neglect) X3A CMD11-8 87Cycle Start X24 CMD12-16 78Feed Hold X25 CMD12-49 79+Jog X26 CMD12-17 80



-Jog X30 CMD11-10 81Auto Reference X33 CMD11-11 82Program Restart X34 CMD11-18 83Spindle Start X16 CMD12-28 70Spindle Stop X17 CMD12-44 71X (Handle) X1F CMD12-9 74Y (Handle) X2C CMD12-30 75Z (Handle) X2D CMD12-46 764 (Handle) X2F CMD12-31 77Handle Multiplier (X1,X10,X100) X1D CMD12-8 72 X1E CMD12-41 73Memory Mode X5 CMD12-23 51Tape Mode X6 CMD12-38 52MDI Mode X7 CMD12-6 53Jog Mode X8 CMD12-1 54Rapid Mode X31 CMD11-17 55Handle Mode X9 CMD12-19 56Reference Mode XB CMD12-2 57

OUTPUTSFUNCTION ADDRESS CONNECTOR WIRE#

CR1 (Chip Conveyor) Y1A CFD13-7 1CR2 (Hydraulic Pump) Y0 CFD13-36 2CR3 (High Speed) Y1 CFD13-4 3CR4 (Coolant) Y2 CFD13-22 4CR5 (Sleep Switch) Y3 CFD13-37 5CR6 (Low Gear) Y5 CFD13-23 6CR7 (High Gear) Y6 CFD13-38 7CR8 (Tool Release) Y7 CFD13-6 8CR9 (Air Blow) Y10 CFD13-26CR10 (Taper Air Solenoid) Y11 CFD13-42CR11 (Magazine Rotation) Y12 CFD13-10CR12 (Arm 70 Degrees) Y13 CFD13-27CR13 (Arm Down) Y14 CFD13-43 13CR14 (Arm Up) Y15 CFD13-11 14CR15 (Arm 180 Degrees) Y16 CFD13-28 15CR16 (Z Axis Brake) Y17 CFD13-44 16CR19 (Pot Down) Y22 CFD13-32 50CR20 (Track Lube) Y9 CFD13-19 23

The E-Stop button is in series with the Sleep Switch relay (CR5).

Solenoids on MCV-2300:

SOL1 Low GearSOL2 High GearSOL3 Tool ReleaseSOL4 Air BlowSOL6 Magazine RotationSOL7 Arm 70 DegreesSOL8 Arm DownSOL9 Arm UpSOL10 Arm 180 Degrees



For machines in general if you have trouble with leaving chatter marks orother poor finishes make sure the gibs are not too loose because loose gibsWILL cause this problem.

If you have a machine that the tool gets stuck in the spindle, check thetemperature rise of the spindle. Thermal expansion will cause the tools tosometimes stick.

On the Chevalier 2040MV with Fanuc 0-MD control, if reference return is comm-anded on the X axis while the dog is on the switch, the axis will move in theplus direction until it comes off of the switch then it will reference returnThe X axis decel switch for this machine is SQ3. The wires on the normallyclosed switch are +24 and 97. The cable pin out in the case of a Fanuc 0-MDcontrol is M201 pin 38 of the I/O board. The diagnostic bit is 16.5, itshould be 1 when the dog is not on the switch.

For repair of Mitsubishi, Mazak and Yaskawa motors contact Driesilker inIllinois at 630-469-7510.

On a Kiwa KNH-426X, if you get alarm 1300 NO PALLET SITTING CONFIRMATION whenthe machine tries to execute it's warm-up program, check the value of timernumber 38 (No.38) in the case of an 18i control. On the TIMER page this isNo.38 T72. The value is in milliseconds. The machine may come from thefactory with this timer set for 1000 (1 second). This time is sometimes tooshort to allow the air pressure switch to be activated. The switch is PS5.It's bit is X6.6, symbol is PSPLSA. This bit is made high by relay CR28being energized. CR28 is energized when 24vdc is applied to it's coil throughPS5. The timer box is on the rung with the alarm, it is:

SUB 3TMR 38

The air supplied to this machine should normally be between .5 and .55 Mpa.

Also, on this Kiwa, if the spindle will not start and coolant pumps one, twoand three will not start but there are no alarms, check the door that isbetween the ATC and the spindle. If this door is not fully closed so that theproxomity switch is made, the spindle and the pumps will not start but noalarms will be generated.

Bridgeport Interact 412 with Heidenhain TNC 2500 control:If either the X axis or Y axis faults, it is possible that when the servoscut out and before the Z axis brake can engage, the head can drop a littlecausing a GROSS POSITIONING ERROR alarm instead of the X or Y DRIVE FAULTalarm. The way to prevent this is to block the head so it can not drop.Anytime one of the motors moves without being commanded to do so will gener-ate the GROSS POSITIONING ERROR alarm.

The AXIS FAULT alarm can be either the motor or the servo card. The driversused on this machine are made by Bosch. It is a conventional system whichconsists of a chassis with a power supply card and three axis drive cards.The axis cards are identical and can be slid in and out of the chassis with-out removing connectors. These cards have the usual potentiometers such asTach and Offset adjustments. The motors are DC with a permanent magnet field.



They have encoders attached to the back and a tach. The motors are made bySEM. The type is MT30M4-24. The output from the drive cards go to the mainboard of the chassis before going to the motors. At the upper left hand corn-er of this board there are six wires (two for each motor) where the outputof the board can be checked. From here one of the leads goes through a chokethen to the motor. There are also three connectors at the bottom of the mainboard which correspond to the three drives. these connectors are the tach andencoder wires. These connectors can be unplugged and swapped with one anotherfor testing.

The encoders model number for X and Y are ERO 115-200. For Z it is ERO 115-125. The first number (115) is the series of encoder. The second number (125or 200) is the Line count.

Machine Parameter 330.0, 330.1 and 330.2 for X,Y and Z tells the controlwhat the line count is, that is, it works with the ball screw pitch parameterto measure correctly. If at some point you have to use a motor with the wrongencoder line count you can try changing this parameter to make it measureproperly.

The access code to get into the Machine Parameters is 95148.

On a machine with a DC motor driven axis, roughness can be caused by either acommutator problem or grounded armature. This can cause a loud growling thatsounds a lot like a thrust bearing problem.

On a Heidenhain TNC2500 control you can check for an IN-POSITION problem byusing the LAG display. You have to set parameter 1390 from 0 to 1 in order tosee the true lag, be sure to set it back when you are done. You check thesame way you would any other lag display, when moving at a fairly high pro-grammed feed rate and look for it to level off and remain constant. Also needsto be the same in both directions of axis travel. When the axis is at rest,should be as close to zero as possible and not moving around. Another thingis for any axes that perform linear interpolation together such as X and Y tohave the same lag value.

On a Heidenhain TNC124 the alarm GROSS POSITIONING ERROR means that the valueset in machine parameter 1720 (MP1720) has been exceeded. When setting thisparameter it is recommended to use the value of the Lag for the axis duringrapid multiplied by 1.4 but will often be set considerably higher by the OEM.MP1720 is a bit parameter, 1720.0 for first axis, 1720.1 for second axis, etc

Some Heidenhain controls use Position Coded Reference Marks on the scales.These allow the machine to know where an axis is by moving just far enough,usually an inch or two, to find the nearest coded mark. This is the normalReference Return procedure for some machines with Heidenhain controls. Whenreference return is commanded the axis will move just a little until it findsthe mark then position itself based on that mark. This way no battery isrequired as in the case of rotary absolute encoders.

Dainichi with Fanuc 10T control:When cycle start is commanded, message START REJECTED is displayed. Rapidsare not available, the machine acts as though the axes have not been refer-ence returned even though the ZRN lights turn on after homing. Also, thebuzzer that should beep during boot up does not beep. Check for a break inthe connection of N24. The machine will act like the command to cycle startis being sent form the PLC to the NC but the NC is not executing.



For spindle orientation problems on machines using a magnetic sensor checkthe file FANUC.TXT

Mori-Seiki MH-63It uses four I/O modules that plug into a backplane along with a controllermodule and a power supply. The first two modules from the left are outputmodules. They are Fanuc OD24A 24 vdc modules. Each has two 50 pin Honda con-nectors. The Fanuc designation for the ports are C21A and C21B. The Moridesignations are C007 and C008 respectively. The second module is C005 andC006 on C21A and C21B. The input modules are ID24A. The first module hasC003 and C004 on ports C20A and C20B. The last module has C001 and C002 onports C20A and C20B. Next on the rack is the rack controller IF01A. It plugsinto the backplane like the other modules and has only one cable COP4. Thisis a fibre optic cable that goes to port COP2 of the main board. COP1 of themain board goes to COP3 of the CRT/MDI. The last module on the rack is thepower supply. It has no connectors but there are four terminals on the rackitself. They are from top to bottom ALC, ALC, 24NC and 0NC. If the lights onthe operator's panel don't work check the cables and connectors of C003 andC004. The schematic shows a C208 but I have not been able to find it on themachine.

Mori-Seiki MV Junior with Yasnac MX2 control: If you get a 391, 392 or 393TG/OC/OV ERROR for X, Y or Z axis respectively, check the servo amplifier forthe axis. One of the LED's will be on, either OV, OC or TG. There is also anLED for FUSE and one for OL. The TG LED indicates a problem with the Tacho-generator. Normally the alarm 310 SERVO OFF will be displayed along with theother alarm. Servo tuning on these drives is done by adjusting pots on thetop board. One of these pots, 16VR, sets the trip level for the above alarm.Setting this pot to the minimum (fully CCW) will cause the alarm to trip assoon as the servo power comes on. The LEDs are all red.

TG LED: Check the in-position signal. On the Yasnac MX2 control this is doneby going to the position screen and scrolling down to the proper screen.Also check the power supply voltages at the drive(+5,+12,+15,-15,+24).All of these voltages are supplied by a single power supply and all can beadjusted separately by potentiometers on the front of the power supply.The tachogenerator operates off of the 5 volt power. You can monitor thetacho input to the drive at TG-M. This is the TG MONITOR. The signal is ref-erenced to ground. The output of the tach is 7 vdc per 1000 rpm +/-15%.As far as adjusting pots, you can try turning IN-ADJ(2VR) one notch counter-clockwise. Also, try L-GAIN(4VR). Be careful adjusting the IN-ADJ pot sinceit is very sensitive, one notch too far can cause the axis to fault or tooscillate violently. Oscillation is normally associated with moving the potCW. There is a pot to the right of this pot (FINE) which is a fine adjustmentfor IN-ADJ. Also, adjusting the IN-ADJ pot can cause the TG fault to be gener-ated. It is important to note that very slight changes in just some of thepotentiometers can cause what looks like serious servo problems. Anotherpoint of interest is that having the L-GAIN and/or IN-ADJ pot out of adjust-ment can cause the 341 (in the case of the X axis) but if the one of the potsis moved a little further, the alarm will change to 391 with the TG indicatorcoming on. If you suspect that the pots have been moved it may or may nothelp to set them back to their original positions (paint mark) but it's agood place to start. What usually works better is to set all of the pots the



same as an axis that is working properly. This is especially true if you areworking on the X or Y axis of a vertical mill because these two axes shouldneed virtually identical settings. When setting the pots this way, pay atten-tion to the dial marks of the pot. There are two dots on one end of the screwslot, make sure this end of the pot is in the same position as the go-by.Once you get close, you can use the IN-ADJ, FINE and L-GAIN to dial it in.The best way to do this is to set the thumbwheel switch to position 4 (TEST).When set to this position, go to the POSITION page of the CRT. Keep pressingthe PAGE DOWN button until the ERROR PULSE screen is displayed. When youmove the X and Y axes at the same feed rate, you should get the same value onboth. If you don't, adjust IN-ADJ and/or FINE until you do. This is partic-ularly useful when you have an axis that runs fine at 25% or 50% rapid butnot at 100% rapid without generating either alarm 391 or 341 (for X axis).In most cases if you go to the ERROR PULSE screen and set it the same as agood axis, when you get finished you will usually be in good shape. Initiallyyou may have to make the adjustments while in 25% or 50% rapid. Also, if theERROR PULSE display of an axis is very far from zero while at rest you canbring it to zero with the ZERO pot. For vibration or oscillation of an axisat certain feed rates you can try adjusting 6VR C.FRQ-ADJ, this changes thecarrier frequency to avoid noise and roughness caused by resonance.

For service issues on Yasnac controls call 1-800-YASKAWA

To change parameters on the Yasnac MX2 you must set the thumbwheel switch to1. It is normally set to 0. The thumbwheel switch is just below the controlin the electrics cabinet. Once the switch is set cursor to the parameter youwant to change, type the value you want then press the WR button. Setting thethumbwheel switch to some of it's other positions will allow access to otherscreens of the control not normally seen when the switch is in position 0.

If the tachometer leads are reversed the axis will runaway when servo powercomes on.

The drives, motors and feedback units are all Yaskawa. The motors are DC.The feedback unit consists of an encoder and a tachogenerator. Complete lossof feedback such as the feedback unit being disconnected will cause the axisto runaway, usually in the positive direction, as soon as servo power comeson. If you replace one of the units, you have to orient it the same as theold one to keep it from over traveling at zero return. This can be done bypositioning the set screw that holds the optical disk on the same as the oldone. To access the leads to the tachogenerator, remove the cover on the veryback of the motor by removing the two small screws.

Motor:YaskawaHicup MotorUGHMED-06-MC13

Drive:YaskawaServopackCPCR-MR085K2

Feedback UnitYaskawa



Feedback UnitTFUE-25ZD7

Parameter 6280 sets the X Axis Rapid Feed rate, 6281 sets Y, 6282 for Z.

Yasnac controls are made by Yaskawa.

When working on servo problems, there is a RESET button on the Servo pack soyou don't have to keep cycling power to clear faults.

The following list is the potentiometers of the Yasnac Servo pack CPCR-MR085K2servo amplifier and what I know about them:

1VRAuxiliary Input AdjustmentAdjusts speed reference and motor characteristics when auxiliary input 2CN(1) 2CN(2) is used. Turning 1VR CW increases speed. If the auxiliary input isnot used turn 1VR fully CCW.

2VR IN-ADJMotor Speed AdjustmentAdjusts speed reference and motor characteristics when speed reference issupplied to 1CN(7) and 1CN(13). Turning 2VR CW increases motor speed. Checkthis signal at terminals IN-M and TG-M.

3VR ZERO ADJZero Drift AdjustmentAdjust this to keep the motor from turning when the speed reference is 0V.Turning the pot CW allows the motor to be finely adjusted in normal rotationand CCW in reverse rotation. Observe the rotation of the motor until it is atstandstill when reference is 0V.

4VR L-GAINSpeed loop Gain AdjustmentAdjusts proportional gain. Turning this pot CW increases gain. Monitor thissignal at CUR-M and TG-M.

5VR C.GAIN-ADJCurrent Loop Gain AdjustmentTurning this pot CW increases the current loop gain. Increase the gain untilthe hunting of starting current stops. This signal is a square wave and canbe monitored at CUR-M.

6VR C.FRQ-ADJCarrier Frequency AdjustmentTurn this pot CW to increase the carrier frequency. Adjust this pot when themotor noise and roughness is excessive due to frequency of the carrier is inresonance with the natural frequency of the mechanical axis. Observe thissignal at OSC-M.

7VR C.LIM-ADJStarting Current AdjustmentYaskawa recommends against adjusting.Turning this pot CW increases starting current. Check this by monitoring theactual motor current during ramp up. This is basically a torque setting.

8VR OS-ADJ



Overspeed Detection Speed AdjustmentSets the speed at which overspeed detection is activated. Turning the pot CWincreases the speed at which overspeed detection is activated. Normally, setthe overspeed detection speed at 120 to 140% of the motor rated speed. Thissignal can be monitored at TG-M and OS-M.

9VR OL-ADJOverload Detection Current AdjustmentYaskawa recommends against adjusting.Sets the operating current overload detecting circuit. Turning this pot CWincreases the operating current and operating time.

10VROverload Detection Offset AdjustmentYaskawa recommends against adjusting.Adjusts the offset of current detection circuit. Turning this pot CW incr-eases output. Adjust this pot so that the overload detection output is 0V whenthe motor current is 0 amps.

11VRCurrent Detection Circuit Offset AdjustmentAdjusts the offset of current detection circuit. Turning the pot CW incr-eases output. Adjust so that the signal at CUR-M is 0 volts when the motorcurrent is 0 amps.

12VRCurrent Detection AdjustmentYaskawa recommends against adjusting.Turning this pot CW increases output. Adjust 12VR so that the signal at I-Mis 2V when the motor is operating at 100% of it's rated current. If this potis set too high, overload detection operates prematurely, if it is set toolow, the overload function does not operate.

16VR TRIP-ADJTrip Voltage SettingYaskawa recommends against adjusting.This pot adjusts the main circuit voltage at which an alarm is issued. Analarm should be issued when the DC voltage in the main circuit exceeds 400V.Turning the pot CW increases the voltage at which the alarm is issued. Setthis pot so that the signal at TV-M is 2.85 volts. Improper adjustment ofthis pot can CAUSE DAMAGE TO THE SERVO UNIT!

The following is a list of Test Points:

SG0V Signal 0V0 volt common terminal for waveform observation.

IN-M (CH4)Input MonitorFor monitoring speed reference input.

TG-M (CH5)



TG MonitorFor observing the TG output waveform from transient speed. Should be 7vdc+/-15% at 1000 rpm.

S.AMP-M (CH6)Speed Amplifier MonitorFor observing the current reference (speed deflection amplified waveform).

OSC-MTriangle Pulse OSC MonitorFor observing the operation of triangle waveform pulse oscillator which det-ermines carrier frequency. This waveform has a positive peak of +4 volts anda negative peak of -4 volts. The cycle time is 1.0 milliseconds.

CUR-M (CH1)Current MonitorFor determining the amount of current being drawn by the motor armature.Use this table to discern how many amps are represented per volt based on theservo model.

Servo Model Amps per VoltMR054K 12.1 A/VMR050K 18.9 A/VMR084K 14.4 A/VMR080K 18.9 A/VMR154K2 18.9 A/VMR154K 24.2 A/VMR220K 30.3 A/VMR374K 32.6 A/VMR370K 53.0 A/V

I-MI MonitorFor detecting motor armature current. Output should be 2 volts when motorcurrent is at 100%.

V-MV MonitorFor detecting motor speed.Should be 3.6 volts +/-15% per 1000 rpm.

1DR-M1 Drive MonitorFor observing the signal driving 1Tr. This signal is a square wave, the pos-itive peak is +8 volts, the negative peak is -8 volts.

2DR-M2 Drive MonitorFor observing the signal driving 2Tr. Square wave +8 volts to -8 volts.



OS-M



Overspeed MonitorSets the speed for overspeed detection.270rpm/Volt +/-10%

OL-MOverload MonitorSets the level for detecting overload.Set at 0.343 Volts.

TV-MTrip Voltage MonitorSets the level of the trip voltage. To measure this voltage, observe the dec-ibel 0V connected to 024. Yaskawa recommends against adjustment.

The following is a list of the LEDs and what they mean:

POWERGreen LEDPowerIndicates that 200 volts is applied to the main terminals R and T.

INGreen LEDSpeed Reference InputIndicates that the speed reference is being input.

TGGreen LEDMotor RotationIndicates the motor is rotating. Use output of tachogenerator.

TGRed LEDIndicates activation of TACHOGENERATOR failure detection circuit.If the LED comes on and stays on when control power is applied to powerterminals R and T, the Servopack is probably defective. If TG comes on andstays on and the motor rotates when main circuit power is applied, check forone of the following:

Tachogenerator failureTachogenerator cable open or shortedTachogenerator leads reversedMotor leads reversedIf TG turns on when the feedrate is increased check the value of the OverspeedSetting, may be necessary to adjust 8VR (OS-ADJ).

OCRed LEDIndicates activation of OVERCURRENT detecting circuit.If OC comes on and stays on when control power is applied, the Servopack isprobably defective. If OC comes on and stays on when main circuit power isapplied, check for a short circuit of the DC Reactor, a gounded Motor or adefective power transistor in the Servopack. If OC comes on when the motor isstarting and/or stopping, check the adjustment of potentiometer I.LIM-A.

OVRed LED



Indicates activation of OVERVOLTAGE detecting circuit.If OV comes on and stays on when the control power is applied, the Servopackis likely defective. If it turns on while the motor is stopping, the GD2 loadis too great or the wrong type of regenerative unit is being used.

OLRed LEDIndicates activation of OVERLOAD detecting circuit.If this LED turns on when the control power is applied either the Servopackis defective or the Thermostat circuit has failed. If it comes on when themain circuit power is applied but the motor is not started check for a lockedrotor condition. If the LED comes on while the motor is running, check for anoverload condition.

FUSERed LEDIndicates blown fuse.If this LED comes on replace the blown fuse. If it blows again there is like-ly a defective power transistor.

The Yaskawa Servopack has three green LEDs. From top to bottom they are:

TGINPOWER

The POWER LED should be on whenever servo power is supplied.The TG should be on when the tach signal is being received.The IN LED should be on when the axis is in motion.Both TG and IN normally come on when the axis starts and moving and more orless increase in brightness as feedrate goes up. In any case, they will bothburn bright when the axis moves in rapid.

On the Mori-Seiki MV Junior, the Z axis servo is a single amplifier. The Xand Y axes are controlled by one dual amplifier.

Power Supply LEDs

POWERGreen LEDIndicates 200 volts is applied to control power terminals R and S or R and T.

ALARMRed LEDIndicates that the power supply is defective or the regenerative resistorunit is not connected.If the ALARM LED of the power supply turns on when the control power is app-lied, the power supply is probably bad. If the LED turns on approximately.5 to 1 second after the main circuit power is applied there is likely a pro-blem with the either the regenerative resistor unit or the regenerative tran-sistor. Check the resistance at terminals R1 and R2.



Heidenhain TNC124:

The alarm CONTAMINATION Z AXIS (or X Y, etc.) means that the signal from the scale is too low. Normally, this alarm can be cleared with the CE button and you can continue running.

If you need to operate this control without the interference of the scalefeedback such as when tackling sevo problems, you can make the control run inOpen Loop by applying 24vdc from the power supply to Input 7 (Pin 8 of X42).

PWM Servo AmplifierServo DynamicsModel: SD1-3060-162-1P/N: 3300-0106

Potentiometers:AUXILLARY INPUT ADJUSTMENTSIGNAL INPUT ADJUSTMENTTACHOMETER INPUT ADJUSTMENTCOMPENSATION ADJUSTMENTCURRENT LIMIT ADJUSTMENTBALANCE ADJUSTMENTThese are all multi-turn pots accessible from the front of the amplifierwithout removing the cover.

RMS ADJUSTMENTThis is a single turn pot for adjusting the RMS output. It is located on thebottom of the board on the left side. The cover must be removed to access it.

The initial setting for these pots is:

AUX - Fully CCW.SIGNAL - 10 turns from fully CCWTAC - 7 turns from fully CCWCOMP - 10 turns from fully CCWCURRENT LIMIT - Fully CCWBALANCE - 10 turns from fully CCWThe Current Limit pot will have to be increased right off the bat since it isnow set way too low for the motor to run.The motor output terminals should measure about 3.4 meg between each other.You can run the servo without using the tach by disconnecting it from thedrive and shorting between pins 1 and 2 on connector J3. If there is a prob-lem with the tach or the tach circuit this will allow the motor to run moresmoothly. The motor will have very little torque(gain) due to the fact thatthere is no tach in the circuit to tell the drive that the motor has sloweddown. You can acheive more gain by using a resistor instead of a junper, buttorue will still be lacking. The resistor shoul be from 10k to 100k ohms.

LED's:



OVERVOLTAGE/LOSS OF +15 INDICATIONGROUND FAULT INDICATIONOVERTEMP/EXCESSIVE RMS INDICATIONTRANSISTOR SURGE INDICATION

If the OVERTEMP/EXCESSIVE RMS INDICATION alarm issues causing the drive toshut off, you can try working with the RMS ADJUSTMENT potentiometer. Thisalarm is normally issued because the output exceeded 30 amps for a set periodof time. It can also be caused by excessive temperature of the heatsinks ofthe output transistors. You can monitor the output current at J1-P5. This isa 0-10 vdc signal which is proportional to the output current, 10 voltsequals 60 amps. The signal is referenced to chassis ground. For this alarmcheck the armature for a grounded condition. Excessive fault current shouldcause the GROUND FAULT INDICATION fault but sometimes will not.

For other questions about this drive call Servo Dynamics at 818-700-8600.

On any machine that uses DC servo motors, if the motor does not have as muchpower as it should or if the feedrate has to be reduced to keep the servofrom faulting, check the armature for a grounded condition. In this case, afault current can flow causing the lack of power or faulting.

Also, when working with DC servo motors keep in mind that the voltage appliedto the motor is not true DC. It is rectified or pulsating DC. This means thatthere is a frequency component to the voltage, also called carrier frequency.In situations where this frequency closely matches the natural vibration ofthe machine at certain feedrates and/or at certain locations on the machine,resonance occurs and can cause excessive noise and vibration. This can beadjusted out if you find the correct potentiometer or parameter. In the caseof a Fanuc control, use the Filter Parameter, for example. This conditionexplains why a new machine can develop noise and vibration of a particularaxis after a few days or weeks of operation or why a machine may behave thisway after many years. Mechanical conditions change, floors settle, etc.Of course, the same thing can be observed on an AC servo system.

YASNAC MX3 PARAMETERS

6219Parameter Write Enable Switch 0 = Parameters Locked 1 = Write Enabled

6004 D3Programs O8000-O8999 0 = Can be displayed and edited 1 = Cannot be displayed or edited

6006 D0Automatic Coordinate System Setting 0 = Disabled 1 = Enabled(Also refer to 6015, 6630 - 6639)

6006 D2Dry Run 0 = Jog Feed 1 = Rapid

6007 D7Reset After Editting 0 = Required 1 = Not Required



6008 D5O Number with ALT Command 0 = Not Changeable 1 = Changeable

6015 D0-D4Automatic Coordinate System Setting 0 = OffX=D0, Y=D1, Z=D2, 4th=D3, 5th=D4 1 = On

6021 D2Program Displayed When Power On 0 = Program O0 1 = Same Program at Power Off

6021 D0M2, M30 and M99 0 = Not Seen as End of Program 1 = Seen as End of Program

6021 D6Loading RS-232 Program Already 0 = ALREADY IN Alarm Issuesin Memory 1 = Writes Over Program

6021 D7Editting of Programs O9000-O9999 0 = Enabled 1 = Disabled

6022 D5Display of Programs O9000-O9999 0 = Enabled 1 = Disabled

6022 D6Binary Search in Edit/Memory Mode 0 = Disabled 1 = Enabled

6066 D6Condition at Power On 0 = M96 1 = M97

6304X Axis Grid Shift Amount

6305Y Axis Grid Shift Amount

6306Z Axis Grid Shift Amount

63074th Axis Grid Shift Amount

63085th Axis Grid Shift Amount

6400X Axis Backlash Amount

6401Y Axis Backlash Amount

6402Z Axis Backlash Amount



64034th Axis Backlash Amount

64045th Axis Backlash Amount

6630X Axis Inch Value for Automatic Coordinate System Setting

6631Y Axis Inch Value for Automatic Coordinate System Setting

6632Z Axis Inch Value for Automatic Coordinate System Setting

66334th Axis Inch Value for Automatic Coordinate System Setting

66345th Axis Inch Value for Automatic Coordinate System Setting

6636X Axis Metric Value for Automatic Coordinate System Setting

6637Y Axis Metric Value for Automatic Coordinate System Setting

6638Z Axis Metric Value for Automatic Coordinate System Setting

66394th Axis Metric Value for Automatic Coordinate System Setting

66405th Axis Metric Value for Automatic Coordinate System Setting

On a Strippit SPM500, there is a top and bottom carousel for the punches.They are mechanically independent with seperate drive trains but driven by acommon motor and common shaft. There is a plate at the motor with four posit-ions. The motor must stop at one of these positions regardless of which ofthe ten tools are called up. A Yamatake Honeywell proximity witch is used fordetecting this position. The plate is basically a round piece of sheet metalwith four notches cut the width of the proximity switch 90 degrees apart.When the motor stops, the switch should be positioned in one of these slots.The bottom carousel has a flat piece welded to the bottom which is detectedby a proximity switch. This proximity switch appears to be the home positionfor the carousels. Each carousel also has a shot pin which is driven by apneumatic solenoid into an alignment hole for each position. The top shot pindrives down into the holes, the bottom one drives up into the holes. Eachair cylinder has has two proximity switches, one for in and one for out.Sometimes the carousels will stop in between positions, additionally, theymay not be aligned with one another. This normally occurs as a result of apunch getting hung up in the part. One condition which can make this situat-ion worse is if the two carousels are in tension with one another. That is,if the tension and direction of tension of one of them is acting to pull theother one. Once the carousels have gotten out of position with one another you



should take the chains loose so you can move them indepently. Push both shotpins out of the holes, you may have to turn the air off. Move the bottomcarousel so that the dog is aligned with the proximity switch then move thetop carousel to the position which corresponds to this. Push the shot pinsinto the holes. Loosen the sprocket at the top of the drive shaft. This isa taper lock sprocket. Release the taper enough to allow the sprocket to spinon the shaft. This will let the chain center itself while being tightened soas not to pull the lower chain and put the two in tension with one another.Now, with carousels aligned and shot pins in, you can tighten the chains. Itmay be necessary to loosen the tension on the chain from the motor to thedrive shaft but it may not. The entire drive shaft and motor are mounted on alarge plate bolted to the machine with four bolts. There are two jack screws,one on the top and one on the bottom. Adjust the chains to the proper tensionone at a time making sure that the chain is riding in the sprocket and in thecenter of the idlers. Once the plate is tightened back down tighten the topsprocket. If you did everything correctly you can pull the shot pins back oneat a time and the carousels will stay in alignment. If you did not do it allcorrectly when you pull a pin back, the carousel will spring back, beingpulled by the chain tension. Last but not least make sure the plate is posit-ioned over the proximity switch at the motor. You can loosen the four screwsthat hold the plate and move it into alignment. A good thing to do once youfinish is to tighten all of the sprockets then use a permanent marker to puttiming marks on every moving part so that if something ever slips you willknow what moved relative to what.

ACU-RITE MILLPOWER:Has motors like SWI, the sevo amplifier is attached to the motor. The scaleplugs into this amplifier via a D subminiature connector. The servo power(120 vac) is sent from the pendant to the Y axis motor assembly, then jumpsfrom there to the X axis, then to the Z axis. There is a connector on the Zaxis motor like the rest of them for servo power out but is capped. This is aconvienient place to check the servo power. If an axis seems to be losingservo power check these screw on amp connectors. The servo power in to eachmotor is a strain relief connector. The encoder cable on the motor is alsoa strain relief, the cable goes back to the pendant where it is a D submini-ature conector.

CHEVALIER SMART 818:Uses Syntec Baby-1 PC Controller and Mitsubishi MR Servo Amplifiers. Thiscontroller operates on 5vdc and 12vdc like other PC controllers but does notuse a typical switching power supply. It has a power supply mounted againstthe back wall behind the controller. Sometimes a machine may start re-bootingon it's own. This can be caused by the 5 volt signal being too low, it needsto be 5.1 volts. There is a potentiometer (VR1) to adjust this voltage. Thepower supply is accessed by removing the two philips head screws on the topof the controller about halfway back. Now the entire controller can be liftedup and pulled out of the way, the bottom screws are in keyhole slots. Youwill need a small screwdriver. You can monitor the voltage either at the testpoints on the mother board or at any of the spare connectors. These are likeany other PC, a plug with a red and black (5vdc) and a yellow and black (12vdc).

On the Hyd-Mech saws with the PLC100 you can access the special functionscreens (status, etc.) by presssing the Start button while powering up themachine. On the PLC500 you hold the clear key while powering up.



If a DC motor controlled axis moves with a jerking motion check the tachfeedback. In addition to this a tach problem can cause a machine to havetrouble finding it's position, often overshooting or undershooting. Sometimesthis can be compensated for if the drive has a tach adjustment. If a tacharmature has an open winding it may run fine at high rpm but very rough atlow rpm. If the rpm is reduced to a very slow rate the motor may be seen torotate normally through part of the revolution then take off at a high rateof speed, then slow back down and repeat the cycle. This is due to the drivelosing the feedback signal during the time that the open winding is in cont-act with the brushes. This can be detected by measuring the resistance of thewindings and slowly rotating the motor. In some cases the tach can be elimin-ated from the circuit by disconnecting the tach leads from the drive andeither placing a jumper across two pins, moving a shorting pin, flipping aDIP switch, etc. to put the drive into open loop control. If the tach is theproblem the motor will now run smoothly but without tach feedback the gainwill be almost nothing so the motor will have very little torque. For generalinformation on DC drives you can check file AUTO.TXT. Much of the informationon Servo Dynamics can be used for servo drives in general.

If you need the password for a Hyd-Mech saw, try one from this list. The num-ber on the left is the Hyd-Mech Program Name.

PROGRAM PASSWORD

100Lv1.0 1197100Lv1.1 0198100Lv2.0 0598100Lv2.1 0699100Lv2.2 1099100Lv2.3 1099100Lv2.4 0500 (102)100Lv2.5 0301 (102 Battery Password)50PEv2.1 099850PEv2.2 019950PEv2.3 129950PEv2.4 0700100Ev1.1 0198100Ev1.2 0198100Ev1.3 0598100Ev1.5 1098100Ev2.0 0698100Ev2.1 1098100Ev2.2 1198100Ev2.3 1198100Ev2.4 0399100Ev2.5 0699100Ev2.6 1199100Ev2.7 0500100Ev2.7a 0500100Ev2.8 0301100Ev2.8a 0301100Ev2.9 1001100Ev1.4 0698100LEv2.0 0698100LEv2.1 0199500MEv1.0 0398500Mv2.0 0698500Mv2.1 1198



500Mv2.2 0399500Mv2.2a 0499500Mv2.3 0699500Mv2.4 1099500Mv2.5 0300500Mv2.6 0600500Mv2.7 03022100v1.0 0801 (Batt Low 1099)2100v1.1 1001 (Batt Low 1099)

For Mitsubishi PLC E200 password is 801.

Mori-Seiki MH63OVR ON (Red LED) comes on anytime the Feed rate Override is set on anythingother than 100%.On this machine, if the following alarms are displayed at the same time checkcircuit breaker NFB4, it is likely tripped. A possible cause for this is aproblem with the coolant motor. The alarms are:SV103 Y IMPROPER V READY OFFOT100 SPINDLE ALARMEX04 COOLANT PUMP OVERLOAD

If this breaker is already tripped when the power is turned on you will norm-ally see:OT100 SPINDLE ALARMSW000 PARAMETER ENABLE SWITCH ON

The Johnford TC-20 with the Fanuc 0-TC control uses Baraffauldi TOE-160/12-3twelve station turret, part number 12-4811-14. This turret has a VDI tooldisk. It looks and operates much like a comparable Duplomatic turret. It hasa 220 vac electric motor for indexing. It has a solenoid activated shot pinwhich is top mounted much like the Duplomatic. When the round plate on top ofthe turret is removed, there is access to the proximity switches for the shotpin and the locking. Just like the Duplomatic, when this turret indexes onecontactor energizes to rotate the turret. Once in position, this contactordrops out, the other one energizes momentarily to back the turret up whichallows the shot pin to go in. Before the turret indexes, the shot pin is upwhich means the proximity switch is clear of the flag. The associated wirenumber 10 is 0vdc and diagnostic bit 17.1 = 0. This proximity switch ismounted to the left horizontally and can be viewed in it's entirety. Also atthis time the locking proximity switch will be made. It's associated wirenumber 11 will be 24vdc and it's associated diagnostic bit 17.2 will be 1.This switch is mounted to the right of the other switch and is mounted vert-ically. There is very little visible other than the LED on the back of theswitch. The binary representation of the tool number output by the encoder isat Diagnostics 16.0, 16.1, 16.2 and 16.3. The wire numbers are 32, 33, 34 and35. The other two outputs from the turret encoder are Strobe which is wirenumber 48, diagnostic 17.0 and Parity which is diagnostic 16.7, wire number40. Another signal is Y51.6, this is the output for the brake. It's associat-ed relay is R3. This bit should be 1 at all times except when the turret isindexing. The relays for CW and CCW of the indexing motor are R1 and R2.On the machine schematics the shot pin is called "Pre-indexing". When theturret is at rest the Parity and Strobe bits should be 1 but the turret willindex if the parity bit is 0. The encoder is like the Duplomatic in that itmounts horizontally on the indexing shaft and can be adjusted by looseningthe two hold down screws and turning the encoder until the diagnostics disp-lay the correct tool number and Parity and Strobe equal 1. When commanded toindex, the brake (relay R3) should drop out, the appropriate contactor shouldenergize, the motor rotates to the approximate position, the shot pin goes



down, the motor backs up, the shot pin drops in, the brake turns back on, theshot pin comes back up. I think the shot pin is relay R4, diagnostic Y52.4

On a Mori-Seiki MH-63 with the Fanuc 11M control, the Grid Shift Parameter is1850. Adjusting this parameter by adding 1000 to it's value will shift theaxis one millimeter or .03937 inches. The value in 1850 needs to be the sameas in 1816 (Reference Counter Capacity) or less. Normally on these machines,1816 is set for 1001 on bits 0-3, this correlates to 10000.

BEFORE USING THE PROCEDURE BELOW BE SURE TO UNDERSTAND THAT THE ATC WILL DOJUST WHAT YOU TELL IT TO, TAKE CARE THAT THE DOOR IS OPEN BEFORE MOVING THETOOL ARM, ETC!!!!!!!!!!!

On the MH-63 independent operation of the ATC is possible but is not done byM-Code. Instead Counter Presets are used. The procedure is:

1. Select MDI mode.2. Press the NC/PC button (If in PC screen).3. Press the PROGRAM soft key to call up the Program screen.4. Input M31;5. Press the INSERT soft key.6. Press the START button. (The FEED HOLD lamp will start flashing.)7. Press the NC/PC button to call up the PC display.8. Set the key switch to EDIT.9. Press the PCPRM soft key.10.Press the COUNTER soft key.11.Enter the Preset number which corresponds to the desired operation in Counter 1 C00. If the machine has more than one magazine, C02-C04 may also be used.12.Press the INPUT button. (The Preset value will change from zero to the value you entered).13.Press the FEED HOLD button. (When the selected operation is completed and the limit switch associated with the operation is satisfied, the Preset value will once again become 0.14.Once you are finished with the independent operation, resume to normal operation by executing M32. The FEED HOLD lamp will turn off.

Below is a list of operations performed by entering the associated Presetvalue during independent operation:

C00(Preset Value) OPERATION

0 No Operation1 Door Opens2 Main Arm moves toward the Spindle3 Tool is Unclamped4 Tool is Pulled5 Arm Rotates Clockwise6 Arm Rotates Counterclockwise7 Tool is Pushed8 Tool is Clamped9 Main Arm moves toward it's Original Position10 Door Closes11 Main Arm moves toward the Magazine12 Tool is Pulled13 Main Arm removes toward it's Original Position



14 Tool is Pushed15 Magazine Pot is Locked16 Magazine Pot is Unlocked

Some of the operations appear to be duplicated but which value you used isdependent upon the direction of movement. Keep in mind that the arm's home(original) position is not all the way to the magazine but between the magaz-ine and the spindle.

Another method for moving the ATC is by using the +/- STEP buttons if themachine is equipped with them. The procedure is:

1.Perform reference return (ZRN) for the Y and Z axes.2.Perform spindle orientation.3.Select MDI mode.4.Set Keep Relay K5.4 = 1.5.Execute M31.6.Execute M35. (The ATCHP and FEED HOLD lamps will start flashing).7.Press the +STEP button to move the ATC forward, -STEP to move it backward. Once the ATC has moved completely forward with the +STEP then all the way back to it's original point with the -STEP button, pressing the +STEP button again will end the step operation and the lamps will stop flashing.

If the machine does not have the STEP buttons, make Keep Relay K5.6 = 1 soyou can use the +X and -X Feed buttons in this capacity. SOME MACHINES WILLPERFORM THE STEP OPERATION EVEN IF THE X AND Y AXES ARE NOT AT HOME, GET INTHE HABIT OF RETURNING ALL AXES HOME BEFORE USING THIS PROCEDURE.

For Spindle +/- Step Operation make K5.4 = 1 and use M31, M35.For Magazine +/- Step Operation make K5.5 = 0 and use M31, M34.For Sub-Arm +/- Step Operation make K5.5 = 1 and use M31, M34.

The Tos SN71 uses mechanical clutches. Both the forward and reverse clutchesare mounted on the main shaft. This shaft is driven directly from the motor.The clutches can be located by following the shaft from the driven pulley tothe left. The forward clutch is the one closest to the pulley. Both clutchescan be accessed and adjusted by means of an access cover located on the BACKof the headstock. The access cover has six screws. This cover can be removedwithout draining the headstock but the machine cannot be run with it off dueto the oil pump. When the lever is placed in either forward or reverse ashifting fork moves a slider which squeezes the plates of the correspondingclutch together. The slider is located at the center of the shaft betweenthe two clutches. The adjustment is very simple. It is a split nut with ascrew which pulls the two ends together. The nut is threaded onto the shaftnext to the clutch. There is a nut for each clutch. To adjust, loosen thescrew and turn the nut, then tighten the screw. To tighten the clutch turnthe nut as you would to tighten on a right hand thread. If you get the clutchtoo tight the spindle will turn in that direction without being engaged. Alsothe lever may not feel right and may not stay engaged.If only one clutch is worn or out of adjustment the spindle will stall or runat reduced rpm in one direction but run fine in the other direction. The nut should turn very easily when you adjust on the clutch. On the END ofthe headstock there is a flange with a T-handle bolt in it's center. This isthe metal oil filter. It should be turned from time to time to keep it clean.You can turn it as much as you want. When changing the oil it should be removedand the buildup removed from it. If you remove it before the oil is drainedyou will have a mess to clean up. The headstock oil is supposed to be MobileDTE Medium (AW46) but AW32 is OK. When the lever is raised the machine runs



in reverse, when it is lowered it runs in forward. The fill hole for the head-stock is located on the very top of the headstock.

On the KIA KIT30A with the Fanuc 0-Mate control if everything works exceptthe spindle won't run, check the door switch. This switch will keep thespindle from starting but doesn't stop the spindle once it is running. TheDiagnostic bit is 20.0, the wire number is X200. It is fed by wire +24N.This switch does not always show up in the hard copy of the ladder where itshould. There is a rung which ends with the the internal relay coil R639.0which has four instructions showing on the hard copy. The instruction for theswitch should be here but is not.

Sometimes you can turn on the Ladder by changing bit 2 of parameter 60.

Some of the LNS bar feeders used on the Ecocas have a limit switch on thetrack that it moves back and forth on. If the bar feeder is pushed back andthis switch is not made, the machine is placed in E-Stop mode.

If an axis mispositions by the same amount sometimes try to determine if theamount it mispositions by is approximately one revolution of the ballscrew.If it is try to determine if the axis zero returns in the same place everytime. Sometimes the decel dog of an axis can be set so that occasionally theencoder will just miss the marker pulse and make a whole revolution to findit. This will cause the position to be of by one grid space. The problem isnormally noticed when a position is commanded by G54 or some other work coor-dinate. Normally, when this occurs the axis will over travel every time ittries to reference return even after the power is cycled. It will only stopexceeding the soft limit once P+CANCEL has been performed. The long term fixis to move the decel dog away from the zero return point (normally the minusdirection) a little, only .0500 or so.

The Toyokoki press brake model 8025W is sold through Mitsubishi Heavy Indust-ries. It uses a TNC-ACII control. It has both Okuma and Panasonic servo amps.For help on this machine you can try Aaron at MC Machinery 630-350-7061.If you get the alarm "UNUSUAL COMMUNICATION" first check all connections be-cause this alarm means just what it says, there is a communication problembetween the OSP and the HP1601. Also check the connections to the servo amps.Another thing to try is a RAM clear. To do this, hold the F5 and F8 keyswhile powering up. If the machine loses it's parameters you need a specialdevice so someone from MC Machinery will likely have to do it.

Supertec G30P-100CIIThe infeed of this grinder uses hydraulics to move the wheelhead during man-ual operation and a stepping motor for automatic operation. Once the hydraul-ic pump is running, pressing the retract button will cause the wheelhead tomove toward the operator. The normal state of the hydraulic valve causes thewheelhead to be in it's retracted position unless the button is pressed. Ifthe hydraulics are turned off while the wheelhead is in any position otherthan fully retracted, it will retract automatically when the hydraulics comeon. The hydraulic valve is controlled by output Y6 of the PLC via wire number21. If the head is fully retracted when the retract button is pressed Y6turns and the head moves toward the operator. According to Supertec, a timerin the PLC causes the the head to traverse for 5 seconds in either directionbut in observing the machine operating, output Y6 once turned on stays on



until the retract button is pressed again, likewise for the reverse operationIt appears that the movement is stopped by reaching a positive stop. In anycase the head will move the same amount, about 3.5 inches regardless of whereit has been positioned by the handwheel. Any problems with this operationshould be treated as a hydraulic problem, sticking valve, etc. The PLC is aMitsubishi MELSEC FX2N-16MR.

The phone number for Mitsui Seiki in California is 562-948-4009. In New Jer-sey is 201-337-1300. Ask for John.

Mitsui-Seiki VR5A with Fanuc 6M controlThis machine has a hydraulic ATC. It does not use a tool change macro so whenyou want to do a tool change you may have to command the Z axis to a secondreference return point. For example, G91 G30 Z0. Depending on the machine youmay have to include Y0 and X0. The standby/spindle tool is stored in paramet-er 4999. Parameters 4000-4020 are the tool registration table. As with othermachines you cannot have the same number in more than one of the parameters.

On most of these machines the tool must be commanded on a block other thanthe one in which the M06 is commanded. For example:

T01;G91 G0 G30 X0 Y0 Z0;M06;

The tool must be commanded first.

If the magazine rotates, the spindle orients and the pot comes down but theATC arm will not rotate check the spindle orientation signal. In the caseof spindle amplifier with an orientation board make sure the IN-POSITION LED(LED 6)is on. If this LED is not on, the spindle orientation completion sig-nal will not be output from the NC to the ladder. This LED should be on any-time the position of the spindle is within one degree of it's orientationposition. If the spindle is in position but the LED is not on you can adjustRV7 to bring it on.

The VR5A with the Fanuc 6M control does not issue machine alarms. When analarm condition does occur there are a couple of red LEDs on the operator'spanel that will either turn on or flicker. When this happens, check PC param-eters 200-207 for the details of the alarm. To access the PC parameters:

1.Press the PARAM button twice. (PC PARAMETER 01 should be displayed in the upper left hand corner.2.Page to the desired PC parameter.

The screens of this control update very slowly so you have to be patient.

PC PARAMETER

200.0 CYCLE ALARM .1 MACHINE ALARM 1 SOLID STATE RELAY TRIPPED .2 MACHINE ALARM 2 CONTROL CIRCUIT BLOWN FUSE (TRIPPED BREAKER) .3 MACHINE ALARM 3 HYDRAULIC PUMP MOTOR OVERLOAD .4 MACHINE ALARM 4 LST COOLANT PUMP MOTOR OVERLOAD .5 MACHINE ALARM 5 CHIP CONVEYOR MOTOR OVERLOAD .6 MACHINE ALARM 6 SECOND COOLANT PUMP MOTOR OVERLOAD .7 MACHINE ALARM 7 LUBRICATION PUMP MOTOR OVERLOAD



201.0 MACHINE ALARM 8 SPINDLE LUBRICATION PUMP MOTOR OVERLOAD .1 MACHINE ALARM 9 ABNORMAL SPINDLE LUBRICATION AND COOLING UNIT .2 MACHINE ALARM 10 EXCESSIVE OIL TEMPERATURE IN THE HYDRAULIC OIL TANK .3 MACHINE ALARM 11 LUBE LEVEL LOW .4 MACHINE ALARM 12 ABNORMAL SPINDLE SPEED CONTROLLER .5 MACHINE ALARM 13 CHIP CONVEYOR TORQUE LIMIT .6 MACHINE ALARM 14 OVERLOAD OF HYDRAULIC PUMP FOR CLAMPING A/C AXIS .7 MACHINE ALARM 15 ABNORMAL LUBRICATION

203.0 WORK SET HOLD .1 APC HOLD .2 .3 T00L LIFE ALARM, NO SPARE FOR TOOL EXPIRING IT'S LIFE TIME .4 ABNORMAL TOOL DETECTING DEVICE .5 NEGLIGENCE OF RESETTING M30 POWER CUT-OFF .6 EXCESS OF AUTOMATIC CYCLE OF ROTARY TYPE APC .7 ABNORMAL TOOL CHANGE COMMAND

204.0 BROKEN TOOL .1 SPINDLE HOLD .2 ORIENTATION HOLD .3 MAGAZINE ALARM .4 T CODE ALARM .5 PROGRAM ERROR .6 DATA SEARCH ALARM .7 TOOL ALARM

205.0 .1 .2 ATC HOLD .3 ATC STOP 1 .4 ATC STOP 2 .5 HYDRAULIC OIL TEMPERATURE UPPER LIMIT DETECTION ALARM .6 NC EXTERNAL RESET ALARM .7 NEXT T CODE ALARM

207.0 OIL SHOT PUMP MOTOR OVERLOAD .1 INSUFFICIENT OIL SHOT COOLANT .2 DEFECT OF PC FOR ROTARY TYPE APC CONTROL .3 ROTARY TYPE APC ALARM .4 EXCESSIVE CUTTING LOAD SETTING ON ACS UNIT .5 ABNORMAL APC OPERATION CONFIRMATION SWITCH .6

All of the bits should normally be zero unless an alarm condition is present.

There is a box on the ATC side of the machine with an LED display. This boxis used to move a tool pot to the tool loading position. There is a positionto the left of the standby position where loading the tool is facilitated.There is a lever at this position for removing the tool from the pot. To usethis box.1.Press the + and - buttons at the same time.2.Press either the + or - button to display the number of tool you want.3.Press the START button.

The pot will move to the loading position.



This machine's spindle is a three stage geared head. It uses the old digitalspindle drive. You can adjust the gear ranges individually by adjusting oneof three gain pots on the drive.

When the alarm lamps light on the operators panel check Diagnostics 200-210.Use the maintenance manual to find out what the Diagnostics indicate.

Generally speaking, if a machine does not use a tool change macro for ATCoperation, you will have to command the head to tool change position with aG30 command.

Kiwa 426X:Uses absolute pulse coders on the X, Y and Z axes, reference return switch onthe B axis. To zero return the B axis:1.Press the ZRN button.2.Press the 4th button.3.Press the + button.

The coolant through the tool pump (#3) has a pressure switch that must besatisfied. If for some reason it cannot be you can bypass it to prevent thelow pressure alarm from being issued. This is done by changing the value ofkeep relay K3.4

If the pallet does not sweep in true with the spindle after reference return,adjust the grid shift parameter (1850) until it does.

The manual op

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Yasnac Mx-3 Fault Finding Guide