General CNC Information

When a machine tool continually over travels when attempting zero return, make
sure the overt ravel switch is not being made before the zero return function
is finished. On most machines, when reference returning, the decel dog makes
the switch, the machine decels and continues at this low feed rate until the
switch drops off of the back of the decel dog. At this exact instant the
control commands a one revolution of the motor. after the one rev it looks
for the marker. One revolution on most machines equals about .!!" of axis
movement. #o, if the over travel switch is closer to the back side of the
decel dog than .!!" it may be engaged while the control is trying to find
the marker. $nless you are very confident of the travel limits of the machine
you should move the decel dog a little in the negative direction rather than
moving the over travel dog. %ut either one will have the desired effect.
When working with &! 'z inductive devices the voltage tolerance is !( of
the rated value. When )! 'z it is *!(.
+ormally, double arm tool changers don,t use a -.!. /he 0 axis stays put
while the arm moves up and down. /herefore the machines home position is
the tool change position. Also on double arm tool changers, when the arm is
in the up position the spring loaded grippers can be pushed in easily. When
the arm is in the down position the locking pins go up which locks the
fingers in on the tool holder. /his prevents the tool from being thrown.
On most cylindrical grinders the table traversing left to right is done by
mechanical means. /he lever in the center of the travel is connected by a
shaft to a directional valve so that when the lever is moved either by hand
or by contact with the travel dog it switches the valve which changes
direction. +ormally, there will be limit switches which are actuated by a
cam on the lever. /hese switches have nothing to do with the table
traversing. What they do is cause the wheel to move in by the selected amount
each time the table reaches the end of travel in each direction.
On a 1eadwell 2345*.!!#, the standby tool is stored in 6iagnostic .7. /his
number can be seen to change as the tool positions are counted. /hey will
change only during an Automatic /ool 3hange not when magazine is 8ogged.
6iagnostic .79 records when tool position * is up. :t should always be a *.
6iagnostic .7! is the A/3 capacity. :f the tool number becomes confused;
*. 2anually move the magazine to tool position *.
. #et 6iagnostic .7 to *.
.. #et 6iagnostic .79 to *.
<. 2ake sure 6iagnostic .7! reflects the correct capacity.
&. 6o a tool change in 26: to check operation.
When setting the tool capacity, you must insert a whole number in %36. :n
the case of the 2345*.!!#, the tool capacity is .! tools. #o 6iagnostic .7!
must be !!**!!!!. :n true %36, it would look like !!** !!!!.
=emember %36 works this way;
7 < * 7 < *
! ! * * ! ! ! !
>. >!
/here is an instruction in the 1adder rung for 2!) which checks 6iagnostic
.7!. /his instruction ?1@3*A ?=&&*.A checks the tool number called against
6.7! ?/ool 3apacityA. :f the tool called is higher than 6.7!?i.e, 2!) /.*A,
2!) will not execute. /here will be no alarm, the 2 3ode simply will not
execute. :f the contents of 6.7! is higher than the actual capacity, the
result will be tool confusion. #etting 6.7! to a very high number will cause
the magazine to continually rotate when a tool is called. Another symptom of
a 6.7! incorrect setting is that if a number lower than the tool capacity but
higher than the current tool is input, any tool number lower than the current
tool or the magazine capacity can be called but nothing higher.
=#. Bin outs;
C Bin
*
=eceive 6ata ?=6A
. /ransmit 6ata ?/6A
<
& #ignal -round ?#-A
9
7
*& Bin
* #ignal -round ?#-A
) /ransmit 6ata ?/6A
9 =eceive 6ata ?=6A
** =equest to #end ?=/#A
* 3lear to #end ?3/#A
*. 6ata #et =eady ?6#=A
*< 6ata /erminal =eady ?6/=A
& Bin
/ransmit 6ata ?/6A
. =eceive 6ata ?=6A
< =equest to #end ?=/#A
& 3lear to #end ?3/#A
) 6ata #et =eady ?6#=A
9 #ignal -round ?#-A
7 6ata 3arrier 6etect ?636A
! 6ata /erminal =eady ?6/=A
*& Bin 2ale

*
o o o o o o o o
o o o o o o o
*&
*& Bin Demale
*
o o o o o o o o
o o o o o o o
*&
& Bin 2ale
*
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
&
& Bin Demale
*
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
&
C Bin 2ale
*
o o o o o
o o o o
C
C Bin Demale
*
o o o o o
o o o o
C
&! pin 'onda
*7 &!
.
*C
* ..
/his is looking at the pins, the notch is at the top.
Eumper requirements for =#. on most controls.
C Bin
957
)5*5<
*& Bin
*.5*<
**5* ?:n some casesA
& Bin
<5&
)575!
Bin & on Danuc controls is <vdc.
:f <<! volts is applied to a %ridgeport #eries * 3+3 when it is wired for
! volts, the most likely result is that the A33 board will be damaged.
/he %ridgeport %oss controls use open loop stepper motors. 2ounted to the
side door of the electrics cabinet are four nearly identical boards. /hree
are the F, G and 0 axis drives. /he fourth is the A33 board. /he final amp
stage for the axes is mounted to the large heat sink. /heir are four for
each axis.
2ost parts for these controls are only available through @lectrical #outh.
7!!5C&!5C&&!.
Whenever working with a machine that is in a not ready state or the axes are
inhibited or interlock for a reason that is difficult to discern, make sure
that the A/3 or tool turret, as the case may be, is ready. All machines
require that the tool changing mechanism is ready before the machine can be
ready. :n the case of a machining center, be sure the tool pot is horizontal.
:n the case of a turning center, be sure the turret is clamped.
1e%lond 2akino does not use the Danuc built in B23, it builds it,s own. :n
most cases the components are Du8i @lectric. #o if you try to access the
1adder, you may not be able to by normal Danuc means. Gou will usually need
to consult the 2akino manual for the proper operation.
On a 2akino D+39<, if you have problems with the tool changer, check the
solenoids on the side of the machine. #olenoids 9!, 9*, 9< and 9& should
have the A side turned on when the tool changer is at home. :f they are not,
the A/3 is not ready. :f any of them are on % you must;
*. @lectrically ?by switching the coil wires at the solenoidA shift the valve
to A. :f solenoid 9& is on %, do it first.
. While keeping the valve switched ?holding the wireA press the @5#top.
.. =elease the @5#top.
<. #hift the next one. :f 9< is on %, do it after 9&.
&. =epeat the @5#top procedure as above.
). 6o 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.
9. 3ycle power on the control.
#O1 9& > Bot 'orizontal
#O1 9* > Arm :n
#O1 9! > Arm )! 6egrees
#O1 9< is somehow related to the tool pot horizontal function.
:f a machine leaves a bump at the quadrants during circular interpolation,
the control is probably overcompensating for backlash.
On most @62 machines trying to discharge without polarity selected causes the
generator power to shut down. :n most cases, polarity is selected by pulling
in a contactor.
On all machines Deed 'old is disabled when in =igid /apping mode.
/o find the feed rate needed for the -7< line, divide the desired pitch into
*.
:f the turret on a Gam 3H5, when commanded to index, indexes then clamps
then unclamps on it,s own, check the turret clampIunclamp confirmation
switches. :n this case one of them is normally stuck. if the machine has a
Danuc ! control check 6iagnostic bits .& and .). /hey should never both be
* at the same time or ! at the same time.
'$=3O A$/O%@+69
Amplifier %alancing Brocedure for 4*.*! B13 #oftware;
*. Bress the 2O6@ key.
. @nter a number which is one greater than the last visible selection in the
mode menu. ?i.e. :f the menu has C selections, enter *!.A
.. Bress @+/@=.
<. /he message "Bress =$+ button" will be displayed.
&. Bress =$+.
). /he balance menu will be displayed. Only one servo axis will be active at
one time.
9. /o select different axes, pres $B or 6OW+ arrows.
7. /he B1$# and 2:+$# keys are used to select the 6A3 output value.
C. /he balance menu will display;
5 /he axis number
5 0ero, positive, or negative 6A3 output voltage
5 Bosition change value
*!. /he first screen will be for 0@=O 6A3 output voltage. Ad8ust the balance
pot on the servo amp until the delta value displayed is zero.
**. Bress the $B arrow button to change to negative 6A3 output voltage.
3heck the delta value displayed.
*. Bress the $B arrow button to change to positive 6A3 output voltage. 3heck
the delta value displayed.
*.. 3ompare the negative and positive 6A3 output voltage. /his value should
be close.
*<. Bress the 2O6@ key to exit the amp balance screen.
/o access the 'urco Autobend 9 Barameter screen;
*. Bress the 2O6@ button.
. Bress the ! button then the @+/@= A64 button.
.. @nter *<9&. then the @+/@= A64 button.
? /he word A33@## appears under the 'urco logo.A
<. Bress ) ?3onfiguration 2enuA then @+/@= A64 button.
? 3onfiguration 2enu is now displayed.A
&. #elect Axis 3onfiguration 2enu.
? 2ove orange cursor to selection using green arrow keys.A
). Bress @+/@= A64 button.
9. 2ake changes to Barameters as necessary.
5 2ove cursor left and right using ?JA and ?5A buttons.
5 2ove cursor up and down using green arrow buttons.
5 Once cursor is over field to be changed, press @+/@= A64 button.
5 /he number moves to bottom of screen.
5 3hange number to new value.
5 Bress @+/@= A64 button.
5 /he number returns to original location.
7. Bress %A3H button.
K Only after all necessary changes have been made.
+ew menu is now displayed.
C. #elect "#ave and @xit" then press @+/@= A64 button.
?2ove orange cursor with green arrow buttons.A
*!. /urn off power, wait .! seconds, turn power back on.
On a 'urco control, every time it turns on all necessary data is loaded from
the Dlash @prom to =A2. :f you replace the 2ain board, you must take the
blank eprom from the new board and replace it with the one from the old
board. %efore you do this you should do a 2aster #ave to be sure everything
in =A2 is stored to the @B=O2. A 2aster 3lear will erase everything from
=A2 but will not affect the @B=O2. /his is sometimes helpful in solving
problems. :f you have some strange problems you can try doing a 2aster 3lear
then disconnect the backup battery from the 2ain %oard with a piece of paper
between the battery and the contacts for about two minutes with the power
off. /hen remove the paper and turn the power back on.
:f you have a -olden #un =otary /able that misindexes intermittently,
remove the drive motor and check the gear pulley. /he gear is a taper lock
with six bolts. /hey can come loose allowing the table to misindex. :f
you remove the encoder to check it you must put it back with the coupler in
the same orientation. :t can go back one of two ways. @ither correctly or
*7! degrees out. :f it is *7! degrees out, the table will zero return one
degree from where it would otherwise.
On a *&" 3olchester lathe, the brake is a caliper type. :t is;
2atrix @ngineering
*36!<!5!.
3*&CC.
Dor problems with =#5., especially in one direction only suspect pin or
. wiring problem depending on which direction the problem is in. :f the
problem is in both directions suspect pin 9 of the & pin connector or pin
& of the C pin connector. A poor connection will cause a situation where
data can be transferred at a slow baud rate but not at a higher one.
On a Hia H:/.!A you have to push the #tandby button for the hydraulics to
come on and make the machine ready. :f the machine hits a hard limit switch,
you must hold in the #tandby button.
With servo systems a motor running at a constant speed will have an equal
number of command pulses and feedback pulses.
Broximity switches;
=@6555555555 <vdc 555555555%=OW+
%1A3H5555555 -+6 555555555%1$@
W':/@5555555O$/B$/5555555555%1A3H
:n most cases a three wire proximity switch can be replaced with a two wire
?%=OW+,%1$@A.
/he 2anualIAbsolute signal determines whether or not the control adds travel
performed manually to the Absolute coordinate.
/he cable supplied by #W: for the 'aas indexer pins out this way. Bins * and
go to the pins for 3ycle #tart. Bins . and < go to the pins for Dinish
#ignal.
Bin outs for a Guasa #$6F :ndexer;
L Wire 3olor #ignal
%lack J<vdc MMMMMMMMMM MMMMMMMM :nternal =elay
. -reen 253ode #tart MMMMN
< =edIWhite J<vdc
& Orange 253ode Dinish L*
) White J<vdc
9 %lue 253ode Dinish L
7 OrangeI%lack @mergency #top
C 3lear 6o +ot $se
*! =edI%lack MMMMM MMMMMMMMM Deed 'old ?+.O.A
** WhiteI%lack MMMMMN
* %lackIWhite MMMMM MMMMMMMMM =emote 'ome ?253ode or other circuitA?+.3.A
*. %lueIWhite MMMMMN
When a Guasa indexer is connected to a #W: control, parameter i. should be
set to *;!. /his sets the indexer up for no handshake.
Danuc, -@ Danuc and -eneral +umeric controls are basically the same in terms
of parts, manuals, etc. Dor example, a -+! is the same control as a Danuc !.
/he manual for this machine would be a part number -+)*<!<@ for -eneral
+umeric and %)*<!<@ for a Danuc and -D0)*<!<@ for a -@ Danuc.
/he 2ori #eiki 2'). has a door switch on the +3 cabinet. :f this switch is
not made, the +3 will not turn on. :f an axis of this machine has a 8erky
movement, it could be the scale but always first check the amount of backlash
in the axis. Barticularly with the G axis which is moving a great deal of
weight. /he G axis of a horizontal machining center carries not only it,s
own weight but the 0 axis and the spindle. @xcessive backlash in the system
can cause a stickIslip condition especially on an older machine where the
ways may be worn in the middle of the travel but like new at the ends.
2ori5#eiki vertical machines typically use a Gasnac 2F or 2F. control.
/o search for an address in the 6iagnostic pages;
*.Bress the 6-+ button.
.@nter the address ?i.e. *79A.
As with a Danuc control, the address you type will be displayed in the
lower left corner of the screen.
..Bress the 3ursor 6own button.
On a 2ori5#eiki 245)& it is normal after turning on the +3 power to see the
alarm .*!;#@=4O ODD. /o clear this alarm, press the +3 power on button again.
When reading the hard copy of the ladder on a Gasnac 2F, the decimal point
is omitted from the addresses. #o *79.< would be written as L*79<
/he 245)& uses +3 driver boards to operate solenoids etc. /hese are 2ori
boards that have an 2= connector from the control. :t has two edge card conn5
ectors that contain the power to feed the loads, normally <vdc as well as
the wires going to the loads. /he boards are 8ust small relay boards. /he
tool clampIunclamp for this machine is air over oil. :t uses four air valves.
:t has two oil filled cylinders, one mounted horizontally the other mounted
vertically. /he one mounted vertically is a long aluminum cylinder. :t has a
plastic line on the outside that runs from top to bottom and indicates the
oil level in the cylinder. :t also has a switch in the bottom, : think is for
detection of oil level. As far as the switches related to the drawbar clamp
and unclamp there are three. /he switch at the top of the unit indicates
when the tool is clamped or unclamped. :t is made when the tool is clamped.
:t is pressed in by the small inner cylinder. :t is 1#*7, the address is
L*!<., it,s name is /OO1 31A2B 6@/@3/:O+. /he large outer cylinder has two
switches associated with it. /he upper switch is 1#&, the address is L*!<.)
it,s name is %@114:11@ #B=:+- D1@F. :t should be made when the tool is clamp5
ed. /he lower switch is 1#<, the address is L*!<.9, it,s name is %@114:11@
#B=:+- =@/$=+.
/he manual clamping switch is address L*!<.!, wire numbers are *7! and <+3.
/he manual unclamping switch is address L*!<.*, wire numbers are *7* and
<+3.
/his machine uses three driver boards. /hey are identical. /hey are basically
small relay boards. At the top of each board there is a 'onda *) pin 2=
connector that appears to be connected to the +3 :IO board. /his connector is
designated 3+*. /here are also two eight pin edge board connectors at the
bottom of the board. One is 3+, the other is 3+.. @ach board also has ten
1@6s from the top of the board to the bottom. /hese 1@6s correspond to the
ten relays on the board. /he board farthest to the right controls < vdc
outputs. /he two boards to the left of this board control ! vac outputs.
/he 63 board pins out like this;
3+
* . < & ) 9 7
N N N N N N N N
N N N N N N N N
+< $. $< $& +< $.! $.*
3+.
* . < & ) 9 7
N N N N N N N N
N N N N N N N N
+< +. $.. $9 +< +<
+< is the < vdc power feed, B< is the return. :t originates from a small
power supply to the right of the driver boards. /he input to the power supply
is ! volts on wires =** and #**. /he output of the power supply is <vdc on
wires B< and +<. /here is a terminal strip behind the driver boards that
contains a number of supply wires such as B<, +<, <+3 and !+3. /he boards
to the left of this one are wired the same except that they control A3 loads
so that +< is replaced with =**.
/here are three servo amplifiers. @ach one has a seven segment 1@6 as well as
three green 1@6s from the top of the drive to the bottom.
/he spindle amplifier is a Gasnac ?GaskawaA 4arispeed )) 2/::.
/he +3 is mounted to the left door. :t has three boards. /he top board is the
3B$. :t has a three volt 1ithium battery for memory backup. /he middle board
is the :IO board. /he bottom board is the #@=4O board.
/his machine has a geared head. /he cylinder used for shifting gears is mount5
ed vertically. :t has three switches that are activated by the rod end to
indicate gear selection.
:f you have electrical problems, check the condition of all of the +< and
B< wires.
/he 1adder cannot be monitored on the Gasnac 2F control.
Dor troubleshooting A/3 problems on the 245)& there is a manual A/3 mode.
/o enter this mode there is a 2A+$A1 A/3 button that must be pressed. /he
button is behind a door on the right hand side of the Operators Banel cabinet
Also behind this cover is the Over travel =elease, the =#5. port and the
**! 4A3 outlet.
Once the 2anual A/3 button is pressed, the machine enters the @6:/ mode and
the @==O= lamp starts flashing. Bress the A12 button, the A/3 2A+$A1 screen
is displayed. /he screen looks like this;
A/3 2A+$A1
*. BO/ $B
. BO/ 6OW+
.. A=2 DO=WA=6
<. A=2 =@4@=#@
+ow you can perform these four functions by pressing buttons that are redesignated for that function
while in the 2anual A/3 mode. :f you look closely
at the buttons for things like #ingle %lock 3oolant On and Off, %lock #kip,
etc., you will find that there are small numbers in the right hand corner.
When working in screens like A/3 2anual, these numbers operate the function
listed beside the number. Dor example, if while in the 2anual A/3 mode, you
press the #ingle %lock button which has a * on it, the pot will go up. Bress5
ing the 3oolant On button which has a on it, the pot will go down. Bressing
the 3oolant Off button which has a < on it will make the A/3 arm rotate in
reverse.
When you are finished with the A/3 2anual mode you have to push the button
again to turn it off. :f you don,t do this and you cycle power, the control
will remember and issue an alarm. When the A/3 is at home, 6iagnostics 9<!7,
9<!C,9<*! and 9<*. will be !.
:f you get alarm A12*<! /OO1 6A/A +O/ @O$A1 or A12<! @2B/G BO/ +O/ DO$+6,
take the tool out of the spindle, put it in the correct pot. /hen set the
spindle tool number in the /ool =egistration to !.
/he pot upIdown on the 245)& with a .! tool magazine is done with a pneumatic
cylinder. /he cylinder is located behind the tool pot which is in the standby
position. :t is mounted vertically. /he pot up limit switch is mounted to
the left of and 8ust above the standby pot position. /he pot down limit
switch is mounted directly behind the tool pot. /he cylinder is controlled by
a two way valve which is located in an enclosure to the left of the magazine.
/he A port of the valve moves the cylinder down, the % port moves it up. /his
valve has a manual override for each port. /here is a regulator in each of
the lines coming from the ports. /hey are located in the enclosure with the
valve. /he overrides are the slotted screw type. /hey are labeled ODD and O+.
:f the slot is horizontal the valve is manually O+. :f the slot is vertical
the valve is controlled by the electrical signal.
/he electrical signal for the A side of the valve is on wires B< and $&.
/he % side is B< and $<. /he voltage is < vdc.
/he magazine is rotated by an electric gear motor. /he magazine is locked with
a pneumatic cylinder. /he cylinder has a roller on the end of the shaft that
rides on a cam plate that is mounted on the drive sprocket. /here is also a
proximity switch mounted two tool pots to the left of the standby pot posit5
ion. :t counts the tool pots by picking up on the pot itself. /here is a
manual switch for rotating the magazine in both directions. /he switches
are mounted on the cover of the enclosure mentioned above. /he switch to the
left is for clockwise rotation while the one to the right is for counter5clock
wise rotation. /he wire numbers for the 3W are 2-3W and <+3. /he numbers for
the 33W button are 2-33W and <+3.
When troubleshooting problems where feedback seems to fail intermittently
can be traced to moisture inside an encoder. :n addition, the moisture can
become a vapor under certain conditions causing reading problems that seem
to occur only when ambient temperatures are high or may take the form of a
problem which occurs and seems to go away after the machine sits for awhile.
3hen 'o 2345.!! :IO;
:+B$/#
D$+3/:O+ A66=@## 3O++@3/O= W:=@L
1ow -ear F<A 326*5.< *.&
'igh -ear F<% 326*5 *.)
/ool =elease F<3 326*5! *.9
/ool 'old F<6 326*5.& *.7
/ool 3ounter F&! 326*5) *.C
Arm $p F&* 326*5< *<!
Arm 6own F& 326*5*! *<*
Bot $p F< 326*5& *<
Bot 6own F@ 326*5*< *<.
2anual 2agazine =otation F<7 3265* **
FJO/ F7 326*5* *&
F6@3 F*7 326*5< *)
F5O/ F! 326*5<9 *9
<th Axis 3lamp F&. 32659 *&!
Doot #witch F<) 3265.7 *7
0JO/ FA 326*5<& *C
05O/ F 326*5. *.!
06@3 F*A 326*59 *.*
G6@3 F*C 326*5.C *.
GJO/ FC 326*5C *..
G5O/ F* 326*5*& *.<
3hip 3onveyor F< 3265 C.
Optional #top F<. 3265.9 C<
3oolant F<< 3265& C&
Hey #witch F<& 3265. C)
6ry =un F.3 326**5 7C
2anIAbs F.6 326**5C C!
2achine 1ock F<! 3265.) C*
Override 3ancel F.& 326**5& 7<
#ingle %lock F.7 326**5*< 7&
%lock 6elete F.C 326**5* 7)
0+- ?0 Axis +eglectA F.A 326**57 79
3ycle #tart F< 326*5*) 97
Deed 'old F& 326*5<C 9C
JEog F) 326*5*9 7!
5Eog F.! 326**5*! 7*
Auto =eference F.. 326**5** 7
Brogram =estart F.< 326**5*7 7.
#pindle #tart F*) 326*57 9!
#pindle #top F*9 326*5<< 9*
F ?'andleA F*D 326*5C 9<
G ?'andleA F3 326*5.! 9&
0 ?'andleA F6 326*5<) 9)
< ?'andleA FD 326*5.* 99
'andle 2ultiplier ?F*,F*!,F*!!A F*6 326*57 9
F*@ 326*5<* 9.
2emory 2ode F& 326*5. &*
/ape 2ode F) 326*5.7 &
26: 2ode F9 326*5) &.
Eog 2ode F7 326*5* &<
=apid 2ode F.* 326**5*9 &&
'andle 2ode FC 326*5*C &)
=eference 2ode F% 326*5 &9
O$/B$/#
D$+3/:O+ A66=@## 3O++@3/O= W:=@L
3=* ?3hip 3onveyorA G*A 3D6*.59 *
3= ?'ydraulic BumpA G! 3D6*.5.)
3=. ?'igh #peedA G* 3D6*.5< .
3=< ?3oolantA G 3D6*.5 <
3=& ?#leep #witchA G. 3D6*.5.9 &
3=) ?1ow -earA G& 3D6*.5. )
3=9 ?'igh -earA G) 3D6*.5.7 9
3=7 ?/ool =eleaseA G9 3D6*.5) 7
3=C ?Air %lowA G*! 3D6*.5)
3=*! ?/aper Air #olenoidA G** 3D6*.5<
3=** ?2agazine =otationA G* 3D6*.5*!
3=* ?Arm 9! 6egreesA G*. 3D6*.59
3=*. ?Arm 6ownA G*< 3D6*.5<. *.
3=*< ?Arm $pA G*& 3D6*.5** *<
3=*& ?Arm *7! 6egreesA G*) 3D6*.57 *&
3=*) ?0 Axis %rakeA G*9 3D6*.5<< *)
3=*C ?Bot 6ownA G 3D6*.5. &!
3=! ?/rack 1ubeA GC 3D6*.5*C .
/he @5#top button is in series with the #leep #witch relay ?3=&A.
#olenoids on 2345.!!;
#O1* 1ow -ear
#O1 'igh -ear
#O1. /ool =elease
#O1< Air %low
#O1) 2agazine =otation
#O19 Arm 9! 6egrees
#O17 Arm 6own
#O1C Arm $p
#O1*! Arm *7! 6egrees
Dor machines in general if you have trouble with leaving chatter marks or
other poor finishes make sure the gibs are not too loose because loose gibs
W:11 cause this problem.
:f you have a machine that the tool gets stuck in the spindle, check the
temperature rise of the spindle. /hermal expansion will cause the tools to
sometimes stick.
On the 3hevalier !<!24 with Danuc !526 control, if reference return is comm5
anded on the F axis while the dog is on the switch, the axis will move in the
plus direction until it comes off of the switch then it will reference return
/he F axis decel switch for this machine is #O.. /he wires on the normally
closed switch are J< and C9. /he cable pin out in the case of a Danuc !526
control is 2!* pin .7 of the :IO board. /he diagnostic bit is *).&, it
should be * when the dog is not on the switch.
Dor repair of 2itsubishi, 2azak and Gaskawa motors contact 6riesilker in
:llinois at ).!5<)C59&*!.
On a Hiwa H+'5<)F, if you get alarm *.!! +O BA11@/ #://:+- 3O+D:=2A/:O+ when
the machine tries to execute it,s warm5up program, check the value of timer
number .7 ?+o..7A in the case of an *7i control. On the /:2@= page this is
+o..7 /9. /he value is in milliseconds. /he machine may come from the
factory with this timer set for *!!! ?* secondA. /his time is sometimes too
short to allow the air pressure switch to be activated. /he switch is B#&.
:t,s bit is F).), symbol is B#B1#A. /his bit is made high by relay 3=7
being energized. 3=7 is energized when <vdc is applied to it,s coil through
B#&. /he timer box is on the rung with the alarm, it is;
#$% .
/2= .7
/he air supplied to this machine should normally be between .& and .&& 2pa.
Also, on this Hiwa, if the spindle will not start and coolant pumps one, two
and three will not start but there are no alarms, check the door that is
between the A/3 and the spindle. :f this door is not fully closed so that the
proxomity switch is made, the spindle and the pumps will not start but no
alarms will be generated.
%ridgeport :nteract <* with 'eidenhain /+3 &!! control;
:f either the F axis or G axis faults, it is possible that when the servos
cut out and before the 0 axis brake can engage, the head can drop a little
causing a -=O## BO#:/:O+:+- @==O= alarm instead of the F or G 6=:4@ DA$1/
alarm. /he 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 gener5
ate the -=O## BO#:/:O+:+- @==O= alarm.
/he AF:# DA$1/ alarm can be either the motor or the servo card. /he drivers
used on this machine are made by %osch. :t is a conventional system which
consists of a chassis with a power supply card and three axis drive cards.
/he axis cards are identical and can be slid in and out of the chassis with5
out removing connectors. /hese cards have the usual potentiometers such as
/ach and Offset ad8ustments. /he motors are 63 with a permanent magnet field.
/hey have encoders attached to the back and a tach. /he motors are made by
#@2. /he type is 2/.!2<5<. /he output from the drive cards go to the main
board of the chassis before going to the motors. At the upper left hand corn5
er of this board there are six wires ?two for each motorA where the output
of the board can be checked. Drom here one of the leads goes through a choke
then to the motor. /here are also three connectors at the bottom of the main
board which correspond to the three drives. these connectors are the tach and
encoder wires. /hese connectors can be unplugged and swapped with one another
for testing.
/he encoders model number for F and G are @=O **&5!!. Dor 0 it is @=O **&5
*&. /he first number ?**&A is the series of encoder. /he second number ?*&
or !!A is the 1ine count.
2achine Barameter ..!.!, ..!.* and ..!. for F,G and 0 tells the control
what the line count is, that is, it works with the ball screw pitch parameter
to measure correctly. :f at some point you have to use a motor with the wrong
encoder line count you can try changing this parameter to make it measure
properly.
/he access code to get into the 2achine Barameters is C&*<7.
On a machine with a 63 motor driven axis, roughness can be caused by either a
commutator problem or grounded armature. /his can cause a loud growling that
sounds a lot like a thrust bearing problem.
On a 'eidenhain /+3&!! control you can check for an :+5BO#:/:O+ problem by
using the 1A- display. Gou have to set parameter *.C! from ! to * in order to
see the true lag, be sure to set it back when you are done. Gou check the
same way you would any other lag display, when moving at a fairly high pro5
grammed feed rate and look for it to level off and remain constant. Also needs
to 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 thing
is for any axes that perform linear interpolation together such as F and G to
have the same lag value.
On a 'eidenhain /+3*< the alarm -=O## BO#:/:O+:+- @==O= means that the value
set in machine parameter *9! ?2B*9!A has been exceeded. When setting this
parameter it is recommended to use the value of the 1ag for the axis during
rapid multiplied by *.< but will often be set considerably higher by the O@2.
2B*9! is a bit parameter, *9!.! for first axis, *9!.* for second axis, etc
#ome 'eidenhain controls use Bosition 3oded =eference 2arks on the scales.
/hese allow the machine to know where an axis is by moving 8ust far enough,
usually an inch or two, to find the nearest coded mark. /his is the normal
=eference =eturn procedure for some machines with 'eidenhain controls. When
reference return is commanded the axis will move 8ust a little until it finds
the mark then position itself based on that mark. /his way no battery is
required as in the case of rotary absolute encoders.
6ainichi with Danuc *!/ control;
When cycle start is commanded, message #/A=/ =@E@3/@6 is displayed. =apids
are not available, the machine acts as though the axes have not been refer5
ence returned even though the 0=+ lights turn on after homing. Also, the
buzzer that should beep during boot up does not beep. 3heck for a break in
the connection of +<. /he machine will act like the command to cycle start
is being sent form the B13 to the +3 but the +3 is not executing.
Dor spindle orientation problems on machines using a magnetic sensor check
the file DA+$3./F/
2ori5#eiki 2'5).
:t uses four :IO modules that plug into a backplane along with a controller
module and a power supply. /he first two modules from the left are output
modules. /hey are Danuc O6<A < vdc modules. @ach has two &! pin 'onda con5
nectors. /he Danuc designation for the ports are 3*A and 3*%. /he 2ori
designations are 3!!9 and 3!!7 respectively. /he second module is 3!!& and
3!!) on 3*A and 3*%. /he input modules are :6<A. /he first module has
3!!. and 3!!< on ports 3!A and 3!%. /he last module has 3!!* and 3!! on
ports 3!A and 3!%. +ext on the rack is the rack controller :D!*A. :t plugs
into the backplane like the other modules and has only one cable 3OB<. /his
is a fibre optic cable that goes to port 3OB of the main board. 3OB* of the
main board goes to 3OB. of the 3=/I26:. /he last module on the rack is the
power supply. :t has no connectors but there are four terminals on the rack
itself. /hey are from top to bottom A13, A13, <+3 and !+3. :f the lights on
the operator,s panel don,t work check the cables and connectors of 3!!. and
3!!<. /he schematic shows a 3!7 but : have not been able to find it on the
machine.
2ori5#eiki 24 Eunior with Gasnac 2F control; :f you get a .C*, .C or .C.
/-IO3IO4 @==O= for F, G or 0 axis respectively, check the servo amplifier for
the axis. One of the 1@6,s will be on, either O4, O3 or /-. /here is also an
1@6 for D$#@ and one for O1. /he /- 1@6 indicates a problem with the /acho5
generator. +ormally the alarm .*! #@=4O ODD will be displayed along with the
other alarm. #ervo tuning on these drives is done by ad8usting pots on the
top board. One of these pots, *)4=, sets the trip level for the above alarm.
#etting this pot to the minimum ?fully 33WA will cause the alarm to trip as
soon as the servo power comes on. /he 1@6s are all red.
/- 1@6; 3heck the in5position signal. On the Gasnac 2F control this is done
by going to the position screen and scrolling down to the proper screen.
Also check the power supply voltages at the drive?J&,J*,J*&,5*&,J<A.
All of these voltages are supplied by a single power supply and all can be
ad8usted separately by potentiometers on the front of the power supply.
/he tachogenerator operates off of the & volt power. Gou can monitor the
tacho input to the drive at /-52. /his is the /- 2O+:/O=. /he signal is ref5
erenced to ground. /he output of the tach is 9 vdc per *!!! rpm JI5*&(.
As far as ad8usting pots, you can try turning :+5A6E?4=A one notch counter5
clockwise. Also, try 15-A:+?<4=A. %e careful ad8usting the :+5A6E pot since
it is very sensitive, one notch too far can cause the axis to fault or to
oscillate violently. Oscillation is normally associated with moving the pot
3W. /here is a pot to the right of this pot ?D:+@A which is a fine ad8ustment
for :+5A6E. Also, ad8usting the :+5A6E pot can cause the /- fault to be gener5
ated. :t is important to note that very slight changes in 8ust some of the
potentiometers can cause what looks like serious servo problems. Another
point of interest is that having the 15-A:+ andIor :+5A6E pot out of ad8ust5
ment can cause the .<* ?in the case of the F axisA but if the one of the pots
is moved a little further, the alarm will change to .C* with the /- indicator
coming on. :f you suspect that the pots have been moved it may or may not
help to set them back to their original positions ?paint markA but it,s a
good place to start. What usually works better is to set all of the pots the
same as an axis that is working properly. /his is especially true if you are
working on the F or G axis of a vertical mill because these two axes should
need virtually identical settings. When setting the pots this way, pay atten5
tion to the dial marks of the pot. /here are two dots on one end of the screw
slot, make sure this end of the pot is in the same position as the go5by.
Once you get close, you can use the :+5A6E, D:+@ and 15-A:+ to dial it in.
/he best way to do this is to set the thumbwheel switch to position < ?/@#/A.
When set to this position, go to the BO#:/:O+ page of the 3=/. Heep pressing
the BA-@ 6OW+ button until the @==O= B$1#@ screen is displayed. When you
move the F and G axes at the same feed rate, you should get the same value on
both. :f you don,t, ad8ust :+5A6E andIor D:+@ until you do. /his is partic5
ularly useful when you have an axis that runs fine at &( or &!( rapid but
not at *!!( rapid without generating either alarm .C* or .<* ?for F axisA.
:n most cases if you go to the @==O= B$1#@ screen and set it the same as a
good axis, when you get finished you will usually be in good shape. :nitially
you may have to make the ad8ustments while in &( or &!( rapid. Also, if the
@==O= B$1#@ display of an axis is very far from zero while at rest you can
bring it to zero with the 0@=O pot. Dor vibration or oscillation of an axis
at certain feed rates you can try ad8usting )4= 3.D=O5A6E, this changes the
carrier frequency to avoid noise and roughness caused by resonance.
Dor service issues on Gasnac controls call *57!!5GA#HAWA
/o change parameters on the Gasnac 2F you must set the thumbwheel switch to
*. :t is normally set to !. /he thumbwheel switch is 8ust below the control
in the electrics cabinet. Once the switch is set cursor to the parameter you
want to change, type the value you want then press the W= button. #etting the
thumbwheel switch to some of it,s other positions will allow access to other
screens of the control not normally seen when the switch is in position !.
:f the tachometer leads are reversed the axis will runaway when servo power
comes on.
/he drives, motors and feedback units are all Gaskawa. /he motors are 63.
/he feedback unit consists of an encoder and a tachogenerator. 3omplete loss
of feedback such as the feedback unit being disconnected will cause the axis
to runaway, usually in the positive direction, as soon as servo power comes
on. :f you replace one of the units, you have to orient it the same as the
old one to keep it from over traveling at zero return. /his can be done by
positioning the set screw that holds the optical disk on the same as the old
one. /o access the leads to the tachogenerator, remove the cover on the very
back of the motor by removing the two small screws.
2otor;
Gaskawa
'icup 2otor
$-'2@65!)523*.
6rive;
Gaskawa
#ervopack
3B3=52=!7&H
Deedback $nit
Gaskawa
Deedback $nit
/D$@5&069
Barameter )7! sets the F Axis =apid Deed rate, )7* sets G, )7 for 0.
Gasnac controls are made by Gaskawa.
When working on servo problems, there is a =@#@/ button on the #ervo pack so
you don,t have to keep cycling power to clear faults.
/he following list is the potentiometers of the Gasnac #ervo pack 3B3=52=!7&H
servo amplifier and what : know about them;
*4=
Auxiliary :nput Ad8ustment
Ad8usts speed reference and motor characteristics when auxiliary input 3+
?*A 3+?A is used. /urning *4= 3W increases speed. :f the auxiliary input is
not used turn *4= fully 33W.
4= :+5A6E
2otor #peed Ad8ustment
Ad8usts speed reference and motor characteristics when speed reference is
supplied to *3+?9A and *3+?*.A. /urning 4= 3W increases motor speed. 3heck
this signal at terminals :+52 and /-52.
.4= 0@=O A6E
0ero 6rift Ad8ustment
Ad8ust this to keep the motor from turning when the speed reference is !4.
/urning the pot 3W allows the motor to be finely ad8usted in normal rotation
and 33W in reverse rotation. Observe the rotation of the motor until it is at
standstill when reference is !4.
<4= 15-A:+
#peed loop -ain Ad8ustment
Ad8usts proportional gain. /urning this pot 3W increases gain. 2onitor this
signal at 3$=52 and /-52.
&4= 3.-A:+5A6E
3urrent 1oop -ain Ad8ustment
/urning this pot 3W increases the current loop gain. :ncrease the gain until
the hunting of starting current stops. /his signal is a square wave and can
be monitored at 3$=52.
)4= 3.D=O5A6E
3arrier Drequency Ad8ustment
/urn this pot 3W to increase the carrier frequency. Ad8ust this pot when the
motor noise and roughness is excessive due to frequency of the carrier is in
resonance with the natural frequency of the mechanical axis. Observe this
signal at O#352.
94= 3.1:25A6E
#tarting 3urrent Ad8ustment
Gaskawa recommends against ad8usting.
/urning this pot 3W increases starting current. 3heck this by monitoring the
actual motor current during ramp up. /his is basically a torque setting.
74= O#5A6E
Overspeed 6etection #peed Ad8ustment
#ets the speed at which overspeed detection is activated. /urning the pot 3W
increases the speed at which overspeed detection is activated. +ormally, set
the overspeed detection speed at *! to *<!( of the motor rated speed. /his
signal can be monitored at /-52 and O#52.
C4= O15A6E
Overload 6etection 3urrent Ad8ustment
Gaskawa recommends against ad8usting.
#ets the operating current overload detecting circuit. /urning this pot 3W
increases the operating current and operating time.
*!4=
Overload 6etection Offset Ad8ustment
Gaskawa recommends against ad8usting.
Ad8usts the offset of current detection circuit. /urning this pot 3W incr5
eases output. Ad8ust this pot so that the overload detection output is !4 when
the motor current is ! amps.
**4=
3urrent 6etection 3ircuit Offset Ad8ustment
Ad8usts the offset of current detection circuit. /urning the pot 3W incr5
eases output. Ad8ust so that the signal at 3$=52 is ! volts when the motor
current is ! amps.
*4=
3urrent 6etection Ad8ustment
Gaskawa recommends against ad8usting.
/urning this pot 3W increases output. Ad8ust *4= so that the signal at :52
is 4 when the motor is operating at *!!( of it,s rated current. :f this pot
is set too high, overload detection operates prematurely, if it is set too
low, the overload function does not operate.
*)4= /=:B5A6E
/rip 4oltage #etting
Gaskawa recommends against ad8usting.
/his pot ad8usts the main circuit voltage at which an alarm is issued. An
alarm should be issued when the 63 voltage in the main circuit exceeds <!!4.
/urning the pot 3W increases the voltage at which the alarm is issued. #et
this pot so that the signal at /452 is .7& volts. :mproper ad8ustment of
this pot can 3A$#@ 6A2A-@ /O /'@ #@=4O $+:/P
/he following is a list of /est Boints;
#-!4
#ignal !4
! volt common terminal for waveform observation.
:+52 ?3'<A
:nput 2onitor
Dor monitoring speed reference input.
/-52 ?3'&A
/- 2onitor
Dor observing the /- output waveform from transient speed. #hould be 9vdc
JI5*&( at *!!! rpm.
#.A2B52 ?3')A
#peed Amplifier 2onitor
Dor observing the current reference ?speed deflection amplified waveformA.
O#352
/riangle Bulse O#3 2onitor
Dor observing the operation of triangle waveform pulse oscillator which det5
ermines carrier frequency. /his waveform has a positive peak of J< volts and
a negative peak of 5< volts. /he cycle time is *.! milliseconds.
3$=52 ?3'*A
3urrent 2onitor
Dor determining the amount of current being drawn by the motor armature.
$se this table to discern how many amps are represented per volt based on the
servo model.
#ervo 2odel Amps per 4olt
2=!&<H *.* AI4
2=!&!H *7.C AI4
2=!7<H *<.< AI4
2=!7!H *7.C AI4
2=*&<H *7.C AI4
2=*&<H <. AI4
2=!H .!.. AI4
2=.9<H ..) AI4
2=.9!H &..! AI4
:52
: 2onitor
Dor detecting motor armature current. Output should be volts when motor
current is at *!!(.
452
4 2onitor
Dor detecting motor speed.
#hould be ..) volts JI5*&( per *!!! rpm.
*6=52
* 6rive 2onitor
Dor observing the signal driving */r. /his signal is a square wave, the pos5
itive peak is J7 volts, the negative peak is 57 volts.
6=52
6rive 2onitor
Dor observing the signal driving /r. #quare wave J7 volts to 57 volts.
.6=52
. 6rive 2onitor
Dor observing the signal driving ./r. #quare wave J7 volts to 57 volts.
<6=52
< 6rive 2onitor
Dor observing the signal driving </r. #quare wave J7 volts to 57 volts.
O#52
Overspeed 2onitor
#ets the speed for overspeed detection.
9!rpmI4olt JI5*!(
O152
Overload 2onitor
#ets the level for detecting overload.
#et at !..<. 4olts.
/452
/rip 4oltage 2onitor
#ets the level of the trip voltage. /o measure this voltage, observe the dec5
ibel !4 connected to !<. Gaskawa recommends against ad8ustment.
/he following is a list of the 1@6s and what they mean;
BOW@=
-reen 1@6
Bower
:ndicates that !! volts is applied to the main terminals = and /.
:+
-reen 1@6
#peed =eference :nput
:ndicates that the speed reference is being input.
/-
-reen 1@6
2otor =otation
:ndicates the motor is rotating. $se output of tachogenerator.
/-
=ed 1@6
:ndicates activation of /A3'O-@+@=A/O= failure detection circuit.
:f the 1@6 comes on and stays on when control power is applied to power
terminals = and /, the #ervopack is probably defective. :f /- comes on and
stays on and the motor rotates when main circuit power is applied, check for
one of the following;
/achogenerator failure
/achogenerator cable open or shorted
/achogenerator leads reversed
2otor leads reversed
:f /- turns on when the feedrate is increased check the value of the Overspeed
#etting, may be necessary to ad8ust 74= ?O#5A6EA.
O3
=ed 1@6
:ndicates activation of O4@=3$==@+/ detecting circuit.
:f O3 comes on and stays on when control power is applied, the #ervopack is
probably defective. :f O3 comes on and stays on when main circuit power is
applied, check for a short circuit of the 63 =eactor, a gounded 2otor or a
defective power transistor in the #ervopack. :f O3 comes on when the motor is
starting andIor stopping, check the ad8ustment of potentiometer :.1:25A.
O4
=ed 1@6
:ndicates activation of O4@=4O1/A-@ detecting circuit.
:f O4 comes on and stays on when the control power is applied, the #ervopack
is likely defective. :f it turns on while the motor is stopping, the -6 load
is too great or the wrong type of regenerative unit is being used.
O1
=ed 1@6
:ndicates activation of O4@=1OA6 detecting circuit.
:f this 1@6 turns on when the control power is applied either the #ervopack
is defective or the /hermostat circuit has failed. :f it comes on when the
main circuit power is applied but the motor is not started check for a locked
rotor condition. :f the 1@6 comes on while the motor is running, check for an
overload condition.
D$#@
=ed 1@6
:ndicates blown fuse.
:f this 1@6 comes on replace the blown fuse. :f it blows again there is like5
ly a defective power transistor.
/he Gaskawa #ervopack has three green 1@6s. Drom top to bottom they are;
/-
:+
BOW@=
/he BOW@= 1@6 should be on whenever servo power is supplied.
/he /- should be on when the tach signal is being received.
/he :+ 1@6 should be on when the axis is in motion.
%oth /- and :+ normally come on when the axis starts and moving and more or
less increase in brightness as feedrate goes up. :n any case, they will both
burn bright when the axis moves in rapid.
On the 2ori5#eiki 24 Eunior, the 0 axis servo is a single amplifier. /he F
and G axes are controlled by one dual amplifier.
Bower #upply 1@6s
BOW@=
-reen 1@6
:ndicates !! volts is applied to control power terminals = and # or = and /.
A1A=2
=ed 1@6
:ndicates that the power supply is defective or the regenerative resistor
unit is not connected.
:f the A1A=2 1@6 of the power supply turns on when the control power is app5
lied, the power supply is probably bad. :f the 1@6 turns on approximately
.& to * second after the main circuit power is applied there is likely a pro5
blem with the either the regenerative resistor unit or the regenerative tran5
sistor. 3heck the resistance at terminals =* and =.
'eidenhain /+3*<;
/he alarm 3O+/A2:+A/:O+ 0 AF:# ?or F G, etc.A means that the signal
from the scale is too low. +ormally, this alarm can be cleared with
the 3@ button and you can continue running.
:f you need to operate this control without the interference of the scale
feedback such as when tackling sevo problems, you can make the control run in
Open 1oop by applying <vdc from the power supply to :nput 9 ?Bin 7 of F<A.
BW2 #ervo Amplifier
#ervo 6ynamics
2odel; #6*5.!)!5*)5*
BI+; ..!!5!*!)
Botentiometers;
A$F:11A=G :+B$/ A6E$#/2@+/
#:-+A1 :+B$/ A6E$#/2@+/
/A3'O2@/@= :+B$/ A6E$#/2@+/
3O2B@+#A/:O+ A6E$#/2@+/
3$==@+/ 1:2:/ A6E$#/2@+/
%A1A+3@ A6E$#/2@+/
/hese are all multi5turn pots accessible from the front of the amplifier
without removing the cover.
=2# A6E$#/2@+/
/his is a single turn pot for ad8usting the =2# output. :t is located on the
bottom of the board on the left side. /he cover must be removed to access it.
/he initial setting for these pots is;
A$F 5 Dully 33W.
#:-+A1 5 *! turns from fully 33W
/A3 5 9 turns from fully 33W
3O2B 5 *! turns from fully 33W
3$==@+/ 1:2:/ 5 Dully 33W
%A1A+3@ 5 *! turns from fully 33W
/he 3urrent 1imit pot will have to be increased right off the bat since it is
now set way too low for the motor to run.
/he motor output terminals should measure about ..< meg between each other.
Gou can run the servo without using the tach by disconnecting it from the
drive and shorting between pins * and on connector E.. :f there is a prob5
lem with the tach or the tach circuit this will allow the motor to run more
smoothly. /he motor will have very little torque?gainA due to the fact that
there is no tach in the circuit to tell the drive that the motor has slowed
down. Gou can acheive more gain by using a resistor instead of a 8unper, but
torue will still be lacking. /he resistor shoul be from *!k to *!!k ohms.
1@6,s;
O4@=4O1/A-@I1O## OD J*& :+6:3A/:O+
-=O$+6 DA$1/ :+6:3A/:O+
O4@=/@2BI@F3@##:4@ =2# :+6:3A/:O+
/=A+#:#/O= #$=-@ :+6:3A/:O+
:f the O4@=/@2BI@F3@##:4@ =2# :+6:3A/:O+ alarm issues causing the drive to
shut off, you can try working with the =2# A6E$#/2@+/ potentiometer. /his
alarm is normally issued because the output exceeded .! amps for a set period
of time. :t can also be caused by excessive temperature of the heatsinks of
the output transistors. Gou can monitor the output current at E*5B&. /his is
a !5*! vdc signal which is proportional to the output current, *! volts
equals )! amps. /he signal is referenced to chassis ground. Dor this alarm
check the armature for a grounded condition. @xcessive fault current should
cause the -=O$+6 DA$1/ :+6:3A/:O+ fault but sometimes will not.
Dor other questions about this drive call #ervo 6ynamics at 7*759!!57)!!.
On any machine that uses 63 servo motors, if the motor does not have as much
power as it should or if the feedrate has to be reduced to keep the servo
from faulting, check the armature for a grounded condition. :n this case, a
fault current can flow causing the lack of power or faulting.
Also, when working with 63 servo motors keep in mind that the voltage applied
to the motor is not true 63. :t is rectified or pulsating 63. /his means that
there is a frequency component to the voltage, also called carrier frequency.
:n situations where this frequency closely matches the natural vibration of
the machine at certain feedrates andIor at certain locations on the machine,
resonance occurs and can cause excessive noise and vibration. /his can be
ad8usted out if you find the correct potentiometer or parameter. :n the case
of a Danuc control, use the Dilter Barameter, for example. /his condition
explains why a new machine can develop noise and vibration of a particular
axis after a few days or weeks of operation or why a machine may behave this
way after many years. 2echanical conditions change, floors settle, etc.
Of course, the same thing can be observed on an A3 servo system.
GA#+A3 2F. BA=A2@/@=#
)*C
Barameter Write @nable #witch ! > Barameters 1ocked
* > Write @nabled
)!!< 6.
Brograms O7!!!5O7CCC ! > 3an be displayed and edited
* > 3annot be displayed or edited
)!!) 6!
Automatic 3oordinate #ystem #etting ! > 6isabled
* > @nabled
?Also refer to )!*&, )).! 5 )).CA

)!!) 6
6ry =un ! > Eog Deed
* > =apid
)!!9 69
=eset After @ditting ! > =equired
* > +ot =equired
)!!7 6&
O +umber with A1/ 3ommand ! > +ot 3hangeable
* > 3hangeable
)!*& 6!56<
Automatic 3oordinate #ystem #etting ! > Off
F>6!, G>6*, 0>6, <th>6., &th>6< * > On
)!* 6
Brogram 6isplayed When Bower On ! > Brogram O!
* > #ame Brogram at Bower Off
)!* 6!
2, 2.! and 2CC ! > +ot #een as @nd of Brogram
* > #een as @nd of Brogram
)!* 6)
1oading =#5. Brogram Already ! > A1=@A6G :+ Alarm :ssues
in 2emory * > Writes Over Brogram
)!* 69
@ditting of Brograms OC!!!5OCCCC ! > @nabled
* > 6isabled
)! 6&
6isplay of Brograms OC!!!5OCCCC ! > @nabled
* > 6isabled
)! 6)
%inary #earch in @ditI2emory 2ode ! > 6isabled
* > @nabled
)!)) 6)
3ondition at Bower On ! > 2C)
* > 2C9
).!<
F Axis -rid #hift Amount
).!&
G Axis -rid #hift Amount
).!)
0 Axis -rid #hift Amount
).!9
<th Axis -rid #hift Amount
).!7
&th Axis -rid #hift Amount
)<!!
F Axis %acklash Amount
)<!*
G Axis %acklash Amount
)<!
0 Axis %acklash Amount
)<!.
<th Axis %acklash Amount
)<!<
&th Axis %acklash Amount
)).!
F Axis :nch 4alue for Automatic 3oordinate #ystem #etting
)).*
G Axis :nch 4alue for Automatic 3oordinate #ystem #etting
)).
0 Axis :nch 4alue for Automatic 3oordinate #ystem #etting
))..
<th Axis :nch 4alue for Automatic 3oordinate #ystem #etting
)).<
&th Axis :nch 4alue for Automatic 3oordinate #ystem #etting
)).)
F Axis 2etric 4alue for Automatic 3oordinate #ystem #etting
)).9
G Axis 2etric 4alue for Automatic 3oordinate #ystem #etting
)).7
0 Axis 2etric 4alue for Automatic 3oordinate #ystem #etting
)).C
<th Axis 2etric 4alue for Automatic 3oordinate #ystem #etting
))<!
&th Axis 2etric 4alue for Automatic 3oordinate #ystem #etting
On a #trippit #B2&!!, there is a top and bottom carousel for the punches.
/hey are mechanically independent with seperate drive trains but driven by a
common motor and common shaft. /here is a plate at the motor with four posit5
ions. /he motor must stop at one of these positions regardless of which of
the ten tools are called up. A Gamatake 'oneywell proximity witch is used for
detecting this position. /he plate is basically a round piece of sheet metal
with four notches cut the width of the proximity switch C! degrees apart.
When the motor stops, the switch should be positioned in one of these slots.
/he bottom carousel has a flat piece welded to the bottom which is detected
by a proximity switch. /his proximity switch appears to be the home position
for the carousels. @ach carousel also has a shot pin which is driven by a
pneumatic solenoid into an alignment hole for each position. /he top shot pin
drives down into the holes, the bottom one drives up into the holes. @ach
air cylinder has has two proximity switches, one for in and one for out.
#ometimes the carousels will stop in between positions, additionally, they
may not be aligned with one another. /his normally occurs as a result of a
punch getting hung up in the part. One condition which can make this situat5
ion worse is if the two carousels are in tension with one another. /hat is,
if the tension and direction of tension of one of them is acting to pull the
other one. Once the carousels have gotten out of position with one another you
should take the chains loose so you can move them indepently. Bush both shot
pins out of the holes, you may have to turn the air off. 2ove the bottom
carousel so that the dog is aligned with the proximity switch then move the
top carousel to the position which corresponds to this. Bush the shot pins
into the holes. 1oosen the sprocket at the top of the drive shaft. /his is
a taper lock sprocket. =elease the taper enough to allow the sprocket to spin
on the shaft. /his will let the chain center itself while being tightened so
as not to pull the lower chain and put the two in tension with one another.
+ow, with carousels aligned and shot pins in, you can tighten the chains. :t
may be necessary to loosen the tension on the chain from the motor to the
drive shaft but it may not. /he entire drive shaft and motor are mounted on a
large plate bolted to the machine with four bolts. /here are two 8ack screws,
one on the top and one on the bottom. Ad8ust the chains to the proper tension
one at a time making sure that the chain is riding in the sprocket and in the
center of the idlers. Once the plate is tightened back down tighten the top
sprocket. :f you did everything correctly you can pull the shot pins back one
at a time and the carousels will stay in alignment. :f you did not do it all
correctly when you pull a pin back, the carousel will spring back, being
pulled by the chain tension. 1ast but not least make sure the plate is posit5
ioned over the proximity switch at the motor. Gou can loosen the four screws
that hold the plate and move it into alignment. A good thing to do once you
finish is to tighten all of the sprockets then use a permanent marker to put
timing marks on every moving part so that if something ever slips you will
know what moved relative to what.
A3$5=:/@ 2:11BOW@=;
'as motors like #W:, the sevo amplifier is attached to the motor. /he scale
plugs into this amplifier via a 6 subminiature connector. /he servo power
?*! vacA is sent from the pendant to the G axis motor assembly, then 8umps
from there to the F axis, then to the 0 axis. /here is a connector on the 0
axis motor like the rest of them for servo power out but is capped. /his is a
convienient place to check the servo power. :f an axis seems to be losing
servo power check these screw on amp connectors. /he servo power in to each
motor is a strain relief connector. /he encoder cable on the motor is also
a strain relief, the cable goes back to the pendant where it is a 6 submini5
ature conector.
3'@4A1:@= #2A=/ 7*7;
$ses #yntec %aby5* B3 3ontroller and 2itsubishi 2= #ervo Amplifiers. /his
controller operates on &vdc and *vdc like other B3 controllers but does not
use a typical switching power supply. :t has a power supply mounted against
the back wall behind the controller. #ometimes a machine may start re5booting
on it,s own. /his can be caused by the & volt signal being too low, it needs
to be &.* volts. /here is a potentiometer ?4=*A to ad8ust this voltage. /he
power supply is accessed by removing the two philips head screws on the top
of the controller about halfway back. +ow the entire controller can be lifted
up and pulled out of the way, the bottom screws are in keyhole slots. Gou
will need a small screwdriver. Gou can monitor the voltage either at the test
points on the mother board or at any of the spare connectors. /hese are like
any other B3, a plug with a red and black ?&vdcA and a yellow and black ?*
vdcA.
On the 'yd52ech saws with the B13*!! you can access the special function
screens ?status, etc.A by presssing the #tart button while powering up the
machine. On the B13&!! you hold the clear key while powering up.
:f a 63 motor controlled axis moves with a 8erking motion check the tach
feedback. :n addition to this a tach problem can cause a machine to have
trouble finding it,s position, often overshooting or undershooting. #ometimes
this can be compensated for if the drive has a tach ad8ustment. :f a tach
armature has an open winding it may run fine at high rpm but very rough at
low rpm. :f the rpm is reduced to a very slow rate the motor may be seen to
rotate normally through part of the revolution then take off at a high rate
of speed, then slow back down and repeat the cycle. /his is due to the drive
losing the feedback signal during the time that the open winding is in cont5
act with the brushes. /his can be detected by measuring the resistance of the
windings and slowly rotating the motor. :n some cases the tach can be elimin5
ated from the circuit by disconnecting the tach leads from the drive and
either placing a 8umper across two pins, moving a shorting pin, flipping a
6:B switch, etc. to put the drive into open loop control. :f the tach is the
problem the motor will now run smoothly but without tach feedback the gain
will be almost nothing so the motor will have very little torque. Dor general
information on 63 drives you can check file A$/O./F/. 2uch of the information
on #ervo 6ynamics can be used for servo drives in general.
:f you need the password for a 'yd52ech saw, try one from this list. /he num5
ber on the left is the 'yd52ech Brogram +ame.
B=O-=A2 BA##WO=6
*!!1v*.! **C9
*!!1v*.* !*C7
*!!1v.! !&C7
*!!1v.* !)CC
*!!1v. *!CC
*!!1v.. *!CC
*!!1v.< !&!! ?*!A
*!!1v.& !.!* ?*! %attery BasswordA
&!B@v.* !CC7
&!B@v. !*CC
&!B@v.. *CC
&!B@v.< !9!!
*!!@v*.* !*C7
*!!@v*. !*C7
*!!@v*.. !&C7
*!!@v*.& *!C7
*!!@v.! !)C7
*!!@v.* *!C7
*!!@v. **C7
*!!@v.. **C7
*!!@v.< !.CC
*!!@v.& !)CC
*!!@v.) **CC
*!!@v.9 !&!!
*!!@v.9a !&!!
*!!@v.7 !.!*
*!!@v.7a !.!*
*!!@v.C *!!*
*!!@v*.< !)C7
*!!1@v.! !)C7
*!!1@v.* !*CC
&!!2@v*.! !.C7
&!!2v.! !)C7
&!!2v.* **C7
&!!2v. !.CC
&!!2v.a !<CC
&!!2v.. !)CC
&!!2v.< *!CC
&!!2v.& !.!!
&!!2v.) !)!!
&!!2v.9 !.!
*!!v*.! !7!* ?%att 1ow *!CCA
*!!v*.* *!!* ?%att 1ow *!CCA
Dor 2itsubishi B13 @!! password is 7!*.
2ori5#eiki 2').
O4= O+ ?=ed 1@6A comes on anytime the Deed rate Override is set on anything
other than *!!(.
On this machine, if the following alarms are displayed at the same time check
circuit breaker +D%<, it is likely tripped. A possible cause for this is a
problem with the coolant motor. /he alarms are;
#4*!. G :2B=OB@= 4 =@A6G ODD
O/*!! #B:+61@ A1A=2
@F!< 3OO1A+/ B$2B O4@=1OA6
:f this breaker is already tripped when the power is turned on you will norm5
ally see;
O/*!! #B:+61@ A1A=2
#W!!! BA=A2@/@= @+A%1@ #W:/3' O+
/he Eohnford /35! with the Danuc !5/3 control uses %araffauldi /O@5*)!I*5.
twelve station turret, part number *5<7**5*<. /his turret has a 46: tool
disk. :t looks and operates much like a comparable 6uplomatic turret. :t has
a ! vac electric motor for indexing. :t has a solenoid activated shot pin
which is top mounted much like the 6uplomatic. When the round plate on top of
the turret is removed, there is access to the proximity switches for the shot
pin and the locking. Eust like the 6uplomatic, when this turret indexes one
contactor energizes to rotate the turret. Once in position, this contactor
drops out, the other one energizes momentarily to back the turret up which
allows the shot pin to go in. %efore the turret indexes, the shot pin is up
which means the proximity switch is clear of the flag. /he associated wire
number *! is !vdc and diagnostic bit *9.* > !. /his proximity switch is
mounted to the left horizontally and can be viewed in it,s entirety. Also at
this time the locking proximity switch will be made. :t,s associated wire
number ** will be <vdc and it,s associated diagnostic bit *9. will be *.
/his switch is mounted to the right of the other switch and is mounted vert5
ically. /here is very little visible other than the 1@6 on the back of the
switch. /he binary representation of the tool number output by the encoder is
at 6iagnostics *).!, *).*, *). and *)... /he wire numbers are ., .., .< and
.&. /he other two outputs from the turret encoder are #trobe which is wire
number <7, diagnostic *9.! and Barity which is diagnostic *).9, wire number
<!. Another signal is G&*.), this is the output for the brake. :t,s associat5
ed relay is =.. /his bit should be * at all times except when the turret is
indexing. /he relays for 3W and 33W of the indexing motor are =* and =.
On the machine schematics the shot pin is called "Bre5indexing". When the
turret is at rest the Barity and #trobe bits should be * but the turret will
index if the parity bit is !. /he encoder is like the 6uplomatic in that it
mounts horizontally on the indexing shaft and can be ad8usted by loosening
the two hold down screws and turning the encoder until the diagnostics disp5
lay the correct tool number and Barity and #trobe equal *. When commanded to
index, the brake ?relay =.A should drop out, the appropriate contactor should
energize, 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, the
shot pin comes back up. : think the shot pin is relay =<, diagnostic G&.<
On a 2ori5#eiki 2'5). with the Danuc **2 control, the -rid #hift Barameter is
*7&!. Ad8usting this parameter by adding *!!! to it,s value will shift the
axis one millimeter or .!.C.9 inches. /he value in *7&! needs to be the same
as in *7*) ?=eference 3ounter 3apacityA or less. +ormally on these machines,
*7*) is set for *!!* on bits !5., this correlates to *!!!!.
%@DO=@ $#:+- /'@ B=O3@6$=@ %@1OW %@ #$=@ /O $+6@=#/A+6 /'A/ /'@ A/3 W:11
6O
E$#/ W'A/ GO$ /@11 :/ /O, /AH@ 3A=@ /'A/ /'@ 6OO= :# OB@+ %@DO=@ 2O4:+- /'@
/OO1 A=2, @/3PPPPPPPPPPP
On the 2'5). independent operation of the A/3 is possible but is not done by
253ode. :nstead 3ounter Bresets are used. /he procedure is;
*. #elect 26: mode.
. Bress the +3IB3 button ?:f in B3 screenA.
.. Bress the B=O-=A2 soft key to call up the Brogram screen.
<. :nput 2.*Q
&. Bress the :+#@=/ soft key.
). Bress the #/A=/ button.
?/he D@@6 'O16 lamp will start flashing.A
9. Bress the +3IB3 button to call up the B3 display.
7. #et the key switch to @6:/.
C. Bress the B3B=2 soft key.
*!.Bress the 3O$+/@= soft key.
**.@nter the Breset number which corresponds to the desired operation in
3ounter * 3!!. :f the machine has more than one magazine, 3!53!< may also
be used.
*.Bress the :+B$/ button. ?/he Breset value will change from zero to the
value you enteredA.
*..Bress the D@@6 'O16 button. ?When the selected operation is completed and
the limit switch associated with the operation is satisfied, the Breset
value will once again become !.
*<.Once you are finished with the independent operation, resume to normal
operation by executing 2.. /he D@@6 'O16 lamp will turn off.
%elow is a list of operations performed by entering the associated Breset
value during independent operation;
3!!?Breset 4alueA OB@=A/:O+
! +o Operation
* 6oor Opens
2ain Arm moves toward the #pindle
. /ool is $nclamped
< /ool is Bulled
& Arm =otates 3lockwise
) Arm =otates 3ounterclockwise
9 /ool is Bushed
7 /ool is 3lamped
C 2ain Arm moves toward it,s Original Bosition
*! 6oor 3loses
** 2ain Arm moves toward the 2agazine
* /ool is Bulled
*. 2ain Arm removes toward it,s Original Bosition
*< /ool is Bushed
*& 2agazine Bot is 1ocked
*) 2agazine Bot is $nlocked
#ome of the operations appear to be duplicated but which value you used is
dependent upon the direction of movement. Heep in mind that the arm,s home
?originalA position is not all the way to the magazine but between the magaz5
ine and the spindle.
Another method for moving the A/3 is by using the JI5 #/@B buttons if the
machine is equipped with them. /he procedure is;
*.Berform reference return ?0=+A for the G and 0 axes.
.Berform spindle orientation.
..#elect 26: mode.
<.#et Heep =elay H&.< > *.
&.@xecute 2.*.
).@xecute 2.&.
?/he A/3'B and D@@6 'O16 lamps will start flashingA.
9.Bress the J#/@B button to move the A/3 forward, 5#/@B to move it backward.
Once the A/3 has moved completely forward with the J#/@B then all the way
back to it,s original point with the 5#/@B button, pressing the J#/@B butt5
on again will end the step operation and the lamps will stop flashing.
:f the machine does not have the #/@B buttons, make Heep =elay H&.) > * so
you can use the JF and 5F Deed buttons in this capacity. #O2@ 2A3':+@# W:11
B@=DO=2 /'@ #/@B OB@=A/:O+ @4@+ :D /'@ F A+6 G AF@# A=@ +O/ A/ 'O2@, -@/ :+
/'@ 'A%:/ OD =@/$=+:+- A11 AF@# 'O2@ %@DO=@ $#:+- /':# B=O3@6$=@.
Dor #pindle JI5 #tep Operation make H&.< > * and use 2.*, 2.&.
Dor 2agazine JI5 #tep Operation make H&.& > ! and use 2.*, 2.<.
Dor #ub5Arm JI5 #tep Operation make H&.& > * and use 2.*, 2.<.
/he /os #+9* uses mechanical clutches. %oth the forward and reverse clutches
are mounted on the main shaft. /his shaft is driven directly from the motor.
/he clutches can be located by following the shaft from the driven pulley to
the left. /he forward clutch is the one closest to the pulley. %oth clutches
can be accessed and ad8usted by means of an access cover located on the %A3H
of the headstock. /he access cover has six screws. /his cover can be removed
without draining the headstock but the machine cannot be run with it off due
to the oil pump. When the lever is placed in either forward or reverse a
shifting fork moves a slider which squeezes the plates of the corresponding
clutch together. /he slider is located at the center of the shaft between
the two clutches. /he ad8ustment is very simple. :t is a split nut with a
screw which pulls the two ends together. /he nut is threaded onto the shaft
next to the clutch. /here is a nut for each clutch. /o ad8ust, loosen the
screw and turn the nut, then tighten the screw. /o tighten the clutch turn
the nut as you would to tighten on a right hand thread. :f you get the clutch
too tight the spindle will turn in that direction without being engaged. Also
the lever may not feel right and may not stay engaged.
:f only one clutch is worn or out of ad8ustment the spindle will stall or run
at reduced rpm in one direction but run fine in the other direction.
/he nut should turn very easily when you ad8ust on the clutch. On the @+6 of
the headstock there is a flange with a /5handle bolt in it,s center. /his is
the metal oil filter. :t should be turned from time to time to keep it clean.
Gou can turn it as much as you want. When changing the oil it should be removed
and the buildup removed from it. :f you remove it before the oil is drained
you will have a mess to clean up. /he headstock oil is supposed to be 2obile
6/@ 2edium ?AW<)A but AW. is OH. When the lever is raised the machine runs
in reverse, when it is lowered it runs in forward. /he fill hole for the head5
stock is located on the very top of the headstock.
On the H:A H:/.!A with the Danuc !52ate control if everything works except
the spindle won,t run, check the door switch. /his switch will keep the
spindle from starting but doesn,t stop the spindle once it is running. /he
6iagnostic bit is !.!, the wire number is F!!. :t is fed by wire J<+.
/his switch does not always show up in the hard copy of the ladder where it
should. /here is a rung which ends with the the internal relay coil =).C.!
which has four instructions showing on the hard copy. /he instruction for the
switch should be here but is not.
#ometimes you can turn on the 1adder by changing bit of parameter )!.
#ome of the 1+# bar feeders used on the @cocas have a limit switch on the
track that it moves back and forth on. :f the bar feeder is pushed back and
this switch is not made, the machine is placed in @5#top mode.
:f an axis mispositions by the same amount sometimes try to determine if the
amount it mispositions by is approximately one revolution of the ballscrew.
:f it is try to determine if the axis zero returns in the same place every
time. #ometimes the decel dog of an axis can be set so that occasionally the
encoder will 8ust miss the marker pulse and make a whole revolution to find
it. /his will cause the position to be of by one grid space. /he problem is
normally noticed when a position is commanded by -&< or some other work coor5
dinate. +ormally, when this occurs the axis will over travel every time it
tries to reference return even after the power is cycled. :t will only stop
exceeding the soft limit once BJ3A+3@1 has been performed. /he long term fix
is to move the decel dog away from the zero return point ?normally the minus
directionA a little, only .!&!! or so.
/he /oyokoki press brake model 7!&W is sold through 2itsubishi 'eavy :ndust5
ries. :t uses a /+35A3:: control. :t has both Okuma and Banasonic servo amps.
Dor help on this machine you can try Aaron at 23 2achinery ).!5.&!59!)*.
:f you get the alarm "$+$#$A1 3O22$+:3A/:O+" first check all connections be5
cause this alarm means 8ust what it says, there is a communication problem
between the O#B and the 'B*)!*. Also check the connections to the servo amps.
Another thing to try is a =A2 clear. /o do this, hold the D& and D7 keys
while powering up. :f the machine loses it,s parameters you need a special
device so someone from 23 2achinery will likely have to do it.
#upertec -.!B5*!!3::
/he infeed of this grinder uses hydraulics to move the wheelhead during man5
ual operation and a stepping motor for automatic operation. Once the hydraul5
ic pump is running, pressing the retract button will cause the wheelhead to
move toward the operator. /he normal state of the hydraulic valve causes the
wheelhead to be in it,s retracted position unless the button is pressed. :f
the hydraulics are turned off while the wheelhead is in any position other
than fully retracted, it will retract automatically when the hydraulics come
on. /he hydraulic valve is controlled by output G) of the B13 via wire number
*. :f the head is fully retracted when the retract button is pressed G)
turns and the head moves toward the operator. According to #upertec, a timer
in the B13 causes the the head to traverse for & seconds in either direction
but in observing the machine operating, output G) once turned on stays on
until the retract button is pressed again, likewise for the reverse operation
:t appears that the movement is stopped by reaching a positive stop. :n any
case the head will move the same amount, about ..& inches regardless of where
it has been positioned by the handwheel. Any problems with this operation
should be treated as a hydraulic problem, sticking valve, etc. /he B13 is a
2itsubishi 2@1#@3 DF+5*)2=.
/he phone number for 2itsui #eiki in 3alifornia is &)5C<75<!!C. :n +ew Eer5
sey is !*5..95*.!!. Ask for Eohn.
2itsui5#eiki 4=&A with Danuc )2 control
/his machine has a hydraulic A/3. :t does not use a tool change macro so when
you want to do a tool change you may have to command the 0 axis to a second
reference return point. Dor example, -C* -.! 0!. 6epending on the machine you
may have to include G! and F!. /he standbyIspindle tool is stored in paramet5
er <CCC. Barameters <!!!5<!! are the tool registration table. As with other
machines 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 than
the one in which the 2!) is commanded. Dor example;
/!*Q
-C* -! -.! F! G! 0!Q
2!)Q
/he tool must be commanded first.
:f the magazine rotates, the spindle orients and the pot comes down but the
A/3 arm will not rotate check the spindle orientation signal. :n the case
of spindle amplifier with an orientation board make sure the :+5BO#:/:O+ 1@6
?1@6 )Ais on. :f this 1@6 is not on, the spindle orientation completion sig5
nal will not be output from the +3 to the ladder. /his 1@6 should be on any5
time the position of the spindle is within one degree of it,s orientation
position. :f the spindle is in position but the 1@6 is not on you can ad8ust
=49 to bring it on.
/he 4=&A with the Danuc )2 control does not issue machine alarms. When an
alarm condition does occur there are a couple of red 1@6s on the operator,s
panel that will either turn on or flicker. When this happens, check B3 param5
eters !!5!9 for the details of the alarm. /o access the B3 parameters;
*.Bress the BA=A2 button twice.
?B3 BA=A2@/@= !* should be displayed in the upper left hand corner.
.Bage to the desired B3 parameter.
/he screens of this control update very slowly so you have to be patient.
B3 BA=A2@/@=
!!.! 3G31@ A1A=2
.* 2A3':+@ A1A=2 * #O1:6 #/A/@ =@1AG /=:BB@6
. 2A3':+@ A1A=2 3O+/=O1 3:=3$:/ %1OW+ D$#@ ?/=:BB@6 %=@AH@=A
.. 2A3':+@ A1A=2 . 'G6=A$1:3 B$2B 2O/O= O4@=1OA6
.< 2A3':+@ A1A=2 < 1#/ 3OO1A+/ B$2B 2O/O= O4@=1OA6
.& 2A3':+@ A1A=2 & 3':B 3O+4@GO= 2O/O= O4@=1OA6
.) 2A3':+@ A1A=2 ) #@3O+6 3OO1A+/ B$2B 2O/O= O4@=1OA6
.9 2A3':+@ A1A=2 9 1$%=:3A/:O+ B$2B 2O/O= O4@=1OA6
!*.! 2A3':+@ A1A=2 7 #B:+61@ 1$%=:3A/:O+ B$2B 2O/O= O4@=1OA6
.* 2A3':+@ A1A=2 C A%+O=2A1 #B:+61@ 1$%=:3A/:O+ A+6 3OO1:+- $+:/
. 2A3':+@ A1A=2 *! @F3@##:4@ O:1 /@2B@=A/$=@ :+ /'@ 'G6=A$1:3 O:1 /A+H
.. 2A3':+@ A1A=2 ** 1$%@ 1@4@1 1OW
.< 2A3':+@ A1A=2 * A%+O=2A1 #B:+61@ #B@@6 3O+/=O11@=
.& 2A3':+@ A1A=2 *. 3':B 3O+4@GO= /O=O$@ 1:2:/
.) 2A3':+@ A1A=2 *< O4@=1OA6 OD 'G6=A$1:3 B$2B DO= 31A2B:+- AI3 AF:#
.9 2A3':+@ A1A=2 *& A%+O=2A1 1$%=:3A/:O+
!..! WO=H #@/ 'O16
.* AB3 'O16
.
.. /!!1 1:D@ A1A=2, +O #BA=@ DO= /OO1 @FB:=:+- :/,# 1:D@ /:2@
.< A%+O=2A1 /OO1 6@/@3/:+- 6@4:3@
.& +@-1:-@+3@ OD =@#@//:+- 2.! BOW@= 3$/5ODD
.) @F3@## OD A$/O2A/:3 3G31@ OD =O/A=G /GB@ AB3
.9 A%+O=2A1 /OO1 3'A+-@ 3O22A+6
!<.! %=OH@+ /OO1
.* #B:+61@ 'O16
. O=:@+/A/:O+ 'O16
.. 2A-A0:+@ A1A=2
.< / 3O6@ A1A=2
.& B=O-=A2 @==O=
.) 6A/A #@A=3' A1A=2
.9 /OO1 A1A=2
!&.!
.*
. A/3 'O16
.. A/3 #/OB *
.< A/3 #/OB
.& 'G6=A$1:3 O:1 /@2B@=A/$=@ $BB@= 1:2:/ 6@/@3/:O+ A1A=2
.) +3 @F/@=+A1 =@#@/ A1A=2
.9 +@F/ / 3O6@ A1A=2
!9.! O:1 #'O/ B$2B 2O/O= O4@=1OA6
.* :+#$DD:3:@+/ O:1 #'O/ 3OO1A+/
. 6@D@3/ OD B3 DO= =O/A=G /GB@ AB3 3O+/=O1
.. =O/A=G /GB@ AB3 A1A=2
.< @F3@##:4@ 3$//:+- 1OA6 #@//:+- O+ A3# $+:/
.& A%+O=2A1 AB3 OB@=A/:O+ 3O+D:=2A/:O+ #W:/3'
.)
All of the bits should normally be zero unless an alarm condition is present.
/here is a box on the A/3 side of the machine with an 1@6 display. /his box
is used to move a tool pot to the tool loading position. /here is a position
to the left of the standby position where loading the tool is facilitated.
/here is a lever at this position for removing the tool from the pot. /o use
this box.
*.Bress the J and 5 buttons at the same time.
.Bress either the J or 5 button to display the number of tool you want.
..Bress the #/A=/ button.
/he pot will move to the loading position.
/his machine,s spindle is a three stage geared head. :t uses the old digital
spindle drive. Gou can ad8ust the gear ranges individually by ad8usting one
of three gain pots on the drive.
When the alarm lamps light on the operators panel check 6iagnostics !!5*!.
$se the maintenance manual to find out what the 6iagnostics indicate.
-enerally speaking, if a machine does not use a tool change macro for A/3
operation, you will have to command the head to tool change position with a
-.! command.
Hiwa <)F;
$ses absolute pulse coders on the F, G and 0 axes, reference return switch on
the % axis. /o zero return the % axis;
*.Bress the 0=+ button.
.Bress the <th button.
..Bress the J button.
/he coolant through the tool pump ?L.A has a pressure switch that must be
satisfied. :f for some reason it cannot be you can bypass it to prevent the
low pressure alarm from being issued. /his is done by changing the value of
keep relay H..<
:f the pallet does not sweep in true with the spindle after reference return,
ad8ust the grid shift parameter ?*7&!A until it does.
/he manual operation of the pallet changer cannot be performed until the 0
axis has been sent to it,s second reference point ?-C* -.! 0!A. Once this has
been done, select EO- mode, place the selector switch on $+31A2B, press the
#/A=/ button. /he pallet will unclamp. Blace the selector switch in $B, press
the #/A=/ %$//O+, the pallets will raise up. Blace the selector switch in
3W, etc.
Dor questions about 2itsubishi made press breaks, regardless of other brand
name, call *5.C95)**7 or ).!57)!5<))).
:f a spindle which uses a magsensor for orientation has trouble finding the
orientation position check that the spindle deceleration is not too long. :n
this case the spindle may 8erk back and forth searching for the position
because it can,t stop fast enough to stop in the middle of the sensor. :f the
mechanics of the machine will allow you can open the window of the orient
position to make it easier for the spindle to find a stoping position.
/he 'eidenhain Bilot 4=09.CI99C 6=O is a digital readout which can interface
with an inverter to perform constant surface operation. /he port on the 6=O
which is used to interface with the inverter is F<*?@F/A. /his 6=O is used
on the 3lausing 4# lathes. :n this case, F<* connects to 3+*7 of the relay
board. /hese machines typically use the 2itsubishi Dreqrol A5!! spindle
inverter. :f the 6=O is turned off the spindle will not run at all. Bressing
the =$+I=@#@/ button will cause it to turn on ?greenA, but when released it
will turn off. On the 3lausing lathes which use this 6=O, you must push the
green button ?=$+I=@#@/A to make the machine ready, the green light should
stay on after you release the button. :f it does not, make sure that the
spindle lever is in the neutral position and the chuck guard is closed.
When the green button is pressed, relay H) on the B3% should energize. H7 on
the B3% should energize whenever power is supplied to the B3% through fuse
D* on the B3%. =elay H& on the B3% energizes whenever the @5#top button is
pulled out. Also, when the @5#top is pulled out, contactor H* should energ5
ize.
/o use the constant surface feature, press the 3## button, move the F axis to
the point where you want maximum rpm to be reached, ad8ust the spindle speed
control to this rpm, press the =B2 2AF button. 2ove the F axis to the point
where machining will begin, ad8ust the spindle speed to the desired start
rpm. As the F axis is moved in toward the centerline the rpm will increase up
to the maximum rpm.
/he phone number for the 6uplomatic dealer in 3harlotte ?2acoserA is 9!<5.C5
!**!. /he contact is 6an %ritton.
On the Hiwa horizontal, if the magazine has less than *!! tools, parameter
)7*! can be *!!. :f it has more than *!! tools, make it *!!!. :f the paramet5
er is set too low, alarm *&* ?Danuc *7A will be issued.
:f a machine with a highIlow geared head stalls in a cut, check the highIlow
gear confirmation switches. A temporary loss of one of these signals may
cause the spindle to drop in and out.
/ypical parameter settings for the Gaskawa spindle inverter on the #harp
***7' are;
=@D@=@+3@ #O$=3@ /erminals
=$+ #O$=3@ /erminals
#/OBB:+- 2@/'O6 =amp to #top
A33@1 /:2@ * ..! #ec.
6@3@1 /:2@ * ..! #ec.
=@D@=@+3@ * )!.!! 'z
!.!! 'z
. !.!! 'z
< !.!! 'z
EO- =@D@=@+3@ ).!! 'z
:+B$/ 4O1/A-@ !.!! 4A3
2O/O= #@1@3/:O+ #td %lower 3ooled
4ID #@1@3/:O+ 3ustom 4ID
2AF D=@O$@+3G !<.!! 'z
2AF 4O1/A-@ !.!! 4A3
%A#@ D=@O$@+3G )!.!! 'z
2:+ D=@O$@+3G .& 'z
%A#@ 4O1/A-@ !.!! 4A3
2O/O= =A/@6 D1A *.&C 'z
+O51OA6 3$==@+/ &.77 A
On the 2ori5#eiki 2'5<!, alarm @F<C occurs when a cycle such as A/3,#%3,0=+,
etc. does not finish. /he control remembers the alarm even if the main power
has been turned off, it can not be reset. When the alarm occurs, a Heep =elay
will be changed by the control from ! to *. /he relays to check are H*<.&,)
and 9. :f you get the alarm even though all cycles are complete, you can re5
move the alarm by changing the keep relay back to !. /o change a keep relay
on a machine with a Danuc ** control;
*.#elect 26: mode.
.Bress the #@=4:3@ soft key.
..Bress the BA=A2@/@= soft key.
<.@nter the 7C!! and press the :+B5+O soft key or page to parameter 7C!!.
&.3hange bit ! to *.
).Bress the +3IB3 button.
9.Bress the B3B=2 soft key.
7.Bress the H@@B=1 soft key.
C.3ursor to the Heep =elay, enter desired value, press the :+B$/ button.
/he 2ori5#eiki horizontals have wear pads on the bottom of the column, these
can wear to the point where the column can drop down on one end. /his will
causing machining problems and rough movement in the 0 axis.

Alarm O/*! on a 2ori5#eiki horizontal mill means that the spindle amplifier
has alarm A1! @F3@##:4@ #B@@6 6@4:A/:O+. :f you look at the spindle amplif5
ier, 1@6 will be on.
On the older Gasnac controls ?2F*, 2F, etc.A the motor encoders are called
Deedback $nits, if you pull these off the end of the motor and turn them over
there are pots you can ad8ust. One of the pots is a sensitivity ad8ustment.
/his ad8ustment is useful in cases where the optical reader gets weak over
time. A symptom of this is that it has trouble seeing the marker pulse so it
is difficult for it to complete zero return. :f you remove the cover from the
newer Optical @ncoders on the 2F. controls you will find pots as well but you
should not ad8ust these. According to Gaskawa these encoders should not be ad5
8usted, even their field service technicians are not allowed to ad8ust them.
/he encoder should be either replaced or sent in for repair.
Often when an axis on a machine with a Gasnac 2F. control gets alarm < ?in
the case of the G axisA when it is being zero returned, you can ad8ust para5
meter ).*)5).! ?approach speed A to make the axis approach the zero point
slower. Also in this case check the 0=+ decel switch to make sure it,s not
sticking.
On 'eidenhain controls to access the 1adder you enter the code 7!9))9 at the
3O6@ +$2%@= > prompt. Heep in mind that some controls will not display the
ladder such as the /+3*<. On these controls you must have the software on a
B3 to extract the binary file from the @B=O2 in the control. @ven then you
cannot see the ladder, only gated logic ? A+6, O=, etc.A
3ommunication parameters for a Gasnac 1F.;
/he parameters for this control are grouped according to :+B$/ or O$/B$/ and
for :+O$/IO$/B$/ 6@4:3@ * ?#:O*A or :+B$/IO$/B$/ 6@4:3@ ?#:OA.
Barameter )!) is for setting the baud rate for :nput 6evice *, parameter
)!9 is for :nput 6evice . Barameter )!7 is for setting the baud rate for
Output 6evice *, parameter )!C is for Output 6evice . #o, to set the baud
rate the same for input and output on device you would set parameters )!9
and )!9 to the same value. Only the first four bits ?!5.A of the parameter
are used for the baud rate setting. /he table below applies in all cases.
%A$6 =A/@ %:/ . %:/ %:/ * %:/ !
&! ! ! ! !
*!! ! ! ! *
**! ! ! * !
*&! ! ! * *
!! ! * ! !
.!! ! * ! *
)!! ! * * !
*!! ! * * *
<!! * ! ! !
<7!! * ! ! *
%it < of these parameters sets the number of stop bits, ! > one stop bit,
* > two stop bits.
%it & of these parameters is for control codes, ! > 63*I63< are used,
* > 63*I63< are not used.
/o change a parameter on a Gasnac 1F. control;
*.Bress the #@/ button. /he #@//:+- page will be displayed.
./ype )*C, press the 3ursor 6own button.
..3hange it,s value to *.
<.Bress the W= button.
?/his is equivalent to the BW@ of a Danuc control, if power is cycled
while )*C > *, the alarm "#G#/@2 #@//:+- +O.?)*CA;R*S" will be displayedA
&.Bress the B=2 button.
)./ype the number of the parameter you want to change, press the 3ursor 6own
button or page to the parameter.
9./he cursor will be on the L, press the :+#=/ button. /he cursor will move
to the first bit ?%it 9A.
7.$se the cursor button to move the bit desired.
C.3hange the bit from * to ! or vice versa, press the W= button.
As with a Danuc control, if you want to send or receive the parameters you
must go to the parameter page. /hen press either the :+ or the O$/ button.
/he 3=/ will flash either :+ or O$/ depending on the operation.
'eidenhain 1#&!! series reading heads; /he intensity of the light source can
be increased by replacing the resistor, it is accessed by removing the cover
on the bottom of the reader.
According to 'yd52ech the head of the #5!A can drift down as much as .!7!Iin
while in 'O16 mode and be within specification. Also according to 'yd52ech if
the front vise and shuttle vise are not aligned they recommend to shim out
the wear plates on the front vise.
Dor parts on an Acer grinder call H1:2 at 9.59&5C*!!.
When replacing thrust bearings, if the new ones are the same manufacturer
they are probably the same thickness but you should check. :f not the same
manufacturer, stack the older bearings as they go in the machine and measure
the overall thickness. :t will normally be different from the old ones. :f
the new ones are thicker you will have to turn the difference off of the
retention plate. :f thinner you will have to make a spacer.
Dor service support on the Du8i Drenic spindle drives call O@## at !*5775
<<.
On the Du8i Drenic &!!!4 the buss should normally be about .!! vdc. :t it
goes above <!!vdc the over voltage alarm is issued. /his indicated by leds .
and < being on at the same time.
When the 66D valve is replaced on the 'yd52ech #!5A saw, the feed force
valve must be ad8usted;
*.=emove the cap from the hydraulic fitting at the bottom of the 66D.
.3onnect a hydraulic hose and gage. ?Gou can use one of the pressure gages
from the hydraulic compartment door and put the cap on the line.
..%ring the head down to rest on a block of wood. 1eave the selector switch
in the 6OW+ mode.
<.1oosen the setscrew on the black knob ?feed force ad8ustmentA and remove
the knob.
&.$se an allen wrench to turn the valve fully clockwise.
).Ad8ust 33W until the gage reads ..! psi.
9.But the knob back on with the pointer indicating !(.
Only ad8ust the feed force valve when the 6OW+ mode is selected.
/he #5!A with the #equencer has three switches to control the movement of
the shuttle vise. /he top switch on the right is the confirmation switch for
the forward travel, the middle switch stops the vise in it,s reverse travel.
/his is how the work piece is measured. /he part that contacts the switch is
the spindle face of a micrometer. /he micrometer moves with the length ad85
uster along the distance of the tape. Once the pointer is set to the desired
length it can be fine ad8usted with the micrometer. /he micrometer is norm5
ally set for .&! so that the position can be ad8usted a quarter inch either
way. :f the piece is cut too short the shuttle is not moving back far enough
so move the micrometer back away from the switch. /he bottom switch places
the shuttle in slowdown mode.
On the Gaskawa )*)B3, terminals D4 and D3 are the !5*!vdc speed command input
/he W.D. Wells %5&5* horizontal band saw works in the following manner;
As the head moves down through the part the blade will under some circum5
stances be pushed up toward the blade guides ?eight side bearingsA which is
undesirable, particularly because if the kerf of the blade is allowed to run
within the guides for any length of time the blade will lose it,s set. /his
will normally cause the saw to cut out of square from top to bottom. /he saw
is designed to prevent this by using two metering valves, one mounted on each
guide arm. /he valves are connected to the down feed force assembly by two
hydraulic lines on each valve. /hese output of these valves is inversely
proportional to the amount of displacement of the actuator. /he input actuat5
or of each valve is connected a tie rod which connects to a pivot arm on
which the top bearing is mounted. /he top bearing rides on the blade back.
As the blade is pushed up by the material, the metering valves are forced
closed in proportion and, in turn, decrease the rate of downfeed. :f the
valves are properly ad8usted, the downfeed of the head will be stopped compl5
etely before the blade displacement reaches .!&!". /o ad8ust this mechanism,
first ad8ust the top bearings so that they 8ust kiss the blade back with the
sw cutting air. ?:t may be necessary to make this ad8ustment with the blade
actually cutting material at a very low down feed setting, in this case, try
to make the ad8ustment during the first moments of the cutA. /he ad8ustment
is accomplished using the set screw and 8am nut on the pivot arms. +ext,
place the saw in down feed condition, again cutting air. As the head feeds
down, use a screwdriver to raise one of the top bearings off of the blade.
Gou should see the head movement slow down and then eventually stop. A
plunge dial indicator can be very helpful in determining if the head is being
properly controlled by the valves. Ad8ustment is acheived by either increas5
in oe decreasing the length of the tie rods. As previously mentioned, the
two valves work together and generally speaking both top bearings will move
into the material simultaneously so if possible try to raise both bearings
at the same time, you will find that the down feed will more affected this
way rather than raising one at a time. Another thing to keep in mind is that
not only is any ad8ustment of one side linked to the other side but also
ad8ustment of the top bearings will affect the metering valve ad8ustment.
As far as ad8usting the blade guides, they should be set for .!!*" greater
than the thickness of the blade. 2ost blades for this saw are normally either
.!< or .!&!". An easy way to make this ad8ustment is to find a short piece of
a broken blade, put it together with a .!!*" feeler gage, put the two of them
between the blade guides, turn the movable bearings until they close on the
blade and feeler to where you can 8ust get them out, then tighten the nut.
:f the blade tension needs ad8usting there is a metering valve located behind
the blade tension solenoid valve. /his valve is located beneath the electri5
cal cabinet. :t consists of a setscrew on the bottom of the valve.
On the Hiwa H+'5<)F, to bypass the coolant pressure switch change the value
of Heep =elay H..<
/he 3incinnati Arrow 9&! uses the 3ontrol /echniques control. /o access the
1adder on this control, press and hold 3/=1 J 6. /he B=O-=A2 B=O/@3/ H@G can
be found at +et *7..
/he magnescales used on some #ony 6=O systems, particularly the 1'&*, have a
green 1@6 which indicates when the gap between the reader and the scale is
the correct distance. :f the reader is either too close or too far away, the
1@6 will go out. Once the correct distance is achieved it will burn brightly.
On the Guasa $6+35*!!, to use the work zero function;
*.#elect manual mode with the 2A+T=@2O/@ switch.
.0ero return the table using the zero return switch.
..$se either the Eog button or handwheel to move to desired work zero.
<.Bress the W50 #@/ button and hold until the display reads all zeros.
/o remove the chuck from a 3+3 lathe ?hydraulic chuckA;
*.=emove the bolts from the face of the chuck ?usually six socket head cap
screwsA.
.Bress the chuck pedal so that the chuck is pushed away from the spindle.
..$nscrew the chuck from the draw tube. ?:t should turn freely and the
threads are standard direction.
/o install a chuck;
*.#crew the chuck onto the draw tube until it runs out of threads.
.%ack it off until the alignment pin lines up with the +@A=@#/ alignment
hole on the back of the chuck.?/his may take a few attemptsA
..Bress the chuck pedal so that the chuck is pulled toward the spindle.
<.Once pin is aligned and chuck is pulled flush against the face of the spin5
dle, insert and tighten the six bolts.
&.3heck for run out.
#ometimes a new chuck will come with a blank draw nut, that is, the draw nut
has not been threaded. :n this case you can re5order the chuck with a thread5
ed nut, thread the nut yourself or in some cases the draw nut on the old
chuck may be interchangeable with the new chuck. /his is particularly true
when the old chuck is a Hitigawa since many chucks are copies of these,
notably the strong chucks.
%e careful when removing and installing a draw nut that you do not lose the
steel ball that rides in the detents of the draw nut, it is very small and
easy to miss.
/he primary difference between A3 servo motors and A3 induction motors is
that servo motors use permanent magnets. /hese magnets allow for precise
positioning but the drawback is that the magnets can be demagnetized or the
magnetic fields can be scrambled. /his normally results in a motor that does
not rotate smoothly, when the motor is turned by hand it will cog, that is,
you will feel notches as it is rotated. When the motor is operated it,s
movement will be rough and 8erked. :t will also pull high current and the
motor will have very little torque. :n most cases you will be able to keep
the motor from turning by holding it by hand. When this happens the motor
can be repaired by re5magnetizing it but requires special equipment. One
company that can do this is @ndeavour /echnologies in 3hicago.
:t is also important to know that this condition can be caused by a bad servo
amplifier so it is not uncommon to find a machine with the symptoms above and
when you replace either the motor or the amplifier, you still have basically
the same problem with the machine until you have replaced both of them.
/o perform linear compensation on a #ony 1'.! 6=O;
*.With the 6=O turned off, hold the =@#@/ button while turning the unit on.
.Bress either the F or the G0 button until 13 M M M is displayed.
..@nter the value from the table corresponds to the required amount.
<.Bress the B button.
&.3ycle the power.
/he actual amount of error cannot be entered so a number from the table which
most closely matches the error must be used. $se the table below;
A2O$+/ OD @==O= B@= :+3' 13
.!!!!! !!
.!!!!!< !!<
.!!!!!) !!)
.!!!!!7 !!7
.!!!!*! !*!
.!!!!*& !*&
.!!!!! !!
N
N
N
N
.!!!)!! )!!
/o compensate for an axis that measures a standard as longer than it is use
negative values;
A2O$+/ OD @==O= B@= :+3' 13
.!!!!! 5!!
.!!!!!< 5!!<
.!!!!!7 5!!)
.!!!!*! 5!*!
.!!!!*& 5!*&
.!!!!! 5!!
N
N
N
.!!!)!! 5)!!
/he newer /=1 *7<! machines use a Gaskawa -B6 .*&I49 inverter to control the
spindle. :f this inverter displays an alarm message that consists of a large
upper case #, a large lower case r and a large upper case B, this indicates
an emergency stop condition that is originating from a source external to the
inverter. :n the case of the *7<!, try removing the computer module and re5
seating the boards into the motherboard or look for some other hardware pro5
blem. /his alarm is related to parameter n!!&.
/he manual for this inverter as well as other Gaskawa inverters can be down5
loaded and or viewed directly from the website 6=:4@#.3O2
Alarm *.!! +O BA11@/ #://:+- 3O+D:=2A/:O+ on the Hiwa H+'5<!! is issued when
pressure switch B#& detects a lack of back pressure. /his switch is located
in the back of the machine with the main air input and solenoids, etc. /he
switch is labeled A:= 3A/3' #@+#O=. /here is an air line from this sensor to
the pallet. /he sensor has four 1@6s, two red and two green. At least one of
the greed 1@6s must be on to prevent the alarm from being generated. :t does
not matter about the two red ones unless they are the only ones on. :n this
case F!!!).) ?B#B1#AA will be zero, making the alarm rung true. /here is an
ad8ustment on the switch that is normally sufficient to correct the problem.
/he output of the switch does not go directly to the :IO module, instead it
turns on relay 3=7, the output of which is tied to the :IO module. /his
relay can be hard to find, it is one of the tiny black solid state relays in
the electrical cabinet. Anytime you have this alarm, make sure that the main
air supply has not changed. Also raise the pallet and blow out any chips that
may be keeping the pallet from seating.
/he 3lausing 2astiff lathe with the Danuc !/ uses a rolling column matrix
for the operator,s panel ?A*!A. /here are four < volt output transistors and
eight current sink transistors ?all from the Danuc :IO board?A*A A which to5
gether control . 1@6s. :n order for an 1@6 to turn on, both it,s correspond5
ing output transistor ?G addressA and corresponding current sink transistor
must be turned on. /he anode of eight of the 1@6s will be tied, in parallel
with one of the <vdc output transistors while four of the 1@6 cathodes will
be tied, in parallel, with one of the current sinking transistors. @ach 1@6
will have a different Output address ?G addressA which, apparently, when
called by the control will activate both transistors. /he four outputs are
from the :IO board ?A*A, connector 32.*, pins %*. A*. %* A* to the relay
board ?A<A through the fuses on the relay board D& D) D9 D7 respectively.
/he current sinks are supplied from the :IO board connector 32.* A*< %*< A*&
%*& and so on. /he output addresses are G*!!!.! G*!!!.* G*!!!. and so on.
/he 2ori5#eiki 24 Eunior uses a Gasnac 2F control. :f the 3=/ is blank,
check the <vdc supply from the power supply. /his power supply is located at
the bottom of the electrical cabinet. /he only input of this board is !
4A3, the outputs are &vdc, *vdc, *&vdc and <vdc. /hese are output on five
connectors A, %, 3, 6 and @. /he output of connector 3 is J<vdc. All of
these voltages go first to the top of the card rack and are 8umpered from
there to the boards. :n the case of the <vdc, when it goes to the :IO board
it feeds a bridge rectifier which if it shorts will cause the power supply
to shut down and the 3=/ will be blank. /his power supply can be hard to
troubleshoot because even though a short on one of the outputs will cause the
power supply to shut down, disconnecting the connector to remove the short
will cause the same problem since removing one of the connectors on even a
healthy power supply will cause shutdown.
'yd52ech '5*<
One revolution of the length encoder equals ..*< inches of linear travel.
/he encoder supply voltage should be 5) vdc.
@ncoder outputs;
!v to 3hannel A should be *!5*. vdc while encoder is in motion.
!v to 3hannel % should be *!5*. vdc while encoder is in motion.
1@6s F! and F* correspond to encoder channel A and % outputs.
/he folowing parameters are with regard to length measurement and control.
A33@1 6:#/A+3@ 5 'ow far the shuttle vise moves in slow feed before
engaging fast feed.
6@3@1 6:#/A+3@ 5 'ow far the shuttle vise moves in slow feed following a
fast feed movement.
/=:-.W:+6OW 5 Allowable length tolerance.
A3/$A1 BO#:/:O+ 5 +ormally set to !. #et to * to display actual position.
:f you program a length of cut whose length is shorter than the 6@3@1 6:#/5
A+3@ parameter, the shuttle vise will travel this entire distance in slow
feed.
/o change the %1A6@ H@=D setting;
*.#elect A$/O mode.
.Bress and hold the H@=D 31@A=I'O2@ button until the Herf value is shown.
../ype in the new value.
Gou can view the :IO states at the B13 in the main electrical cabinet of the
'5*<.
/o calibrate the length measurement;
%efore you start make sure there is a piece of material in the saw which is
longer than the maximum stroke of the shuttle vise.
*.#elect 2A+$A1 mode.
.Blace the D=O+/ 4:#@ switch in the 31O#@ position.
..Bress and hold the DW6 and =@4 buttons at the same time until prompted for
the password.
<.@nter the password. ?/he password corresponds to the version of software
that the B13 uses. /he version is displayed when the machine is powered on.
/o which password corresponds to your version of software check the list
above or call 'yd52echA.
&.6isplay will normally show the 'eight 3alibration screen. 3ursor to the
1ength 3alibration screen. :t will look like this;
1/'.31%. "@+/@=" R!S
A3/.1/'. !!.!!!
).Bress the @+/@= button. /he 3G31@ #/A=/ should start flashing and the R!S
should change to R*S.
9.#tart the blade. /he saw will make a trim cut, raise the head then the
shuttle vise will move fully back in slow, clamp on the material, bring it
fully forward in slow and make the cut. /he * will change back to !.
7.2easure the cut.
C.3ursor to A3/.1/'.
*!.@nter the length you measured plus the kerf of the blade.
**.Bress the A$/OI2A+ button. /he B13 will calculate and store the calibrat5
ion factor.
:f you find that you need to ad8ust the calibration factor, you must go thru
the above procedure to change the A3/.1/'. parameter but you don,t have to
actually cut material. :f length measurement error increases as measured
length increases, increase the A3/.1/'. parameter. :f the error decreases as
the length decreases, decrease the parameter.
Whenever troubleshooting length error problems, make sure the cushion period
?slow approach distanceA is set correctly. /his will normally be set for one
inch.
'itach5#eiki '/!# with Gasnac i7!1;
When the machine is turned on it is normal to have alarm .!!! #@=4O ODD. /his
is because the +3 does not energize *H. ?large contactorA which sends three
phase power to the servo unit. /o turn on the servo unit, press either the
#/A+6%G button or the +3 BOW@= O+ again depending on the B13 version.
When the #/A+6%G button is pressed the output G&9 ?L**!&9A should turn on and
stay on while the button is held. :t should also stay on for about five sec5
onds after the button is released. /his output is from the D357)! board. /his
is the :IO board for the i7! control and is distinguishable from the other
control components since it is not a plug in module of the chassis. :t is
normally mounted away from the control chassis and is connected to the cont5
rol through a communication cable from 3+** of the D357)! to 3+* of the
D35*!. #ome machines may use a D35** instead of D35*! but in either case
this is the B13 module mounted on the control chassis. /he G&9 output is
<vdc from connector 3+ pin 9 on D357)! to connector F. pin 9 of 6#%* which
feeds relay *H*A ?2A3':+@ =@A6G B.%.A.
/his relay is an ice cube relay located on the distribution board ?6#%*A.
/he distribution board is basically a central location for input and output
connectors but it also has the <vdc pc mounted relays which control most
machine :IO functions. /he ma8ority of B13 controlled outputs are <vdc sign5
als from 3+* of D357)! to 6#%*. :f the control is ready for #ervo Bower On,
pc mount relay on 6#%* ?*H.AA will be energized by <vdc supplied from 3+9
pin *! on D35.! through the relay to 3+9 pin *9 ? I#42F A. /he normally
open contact of this relay feeds **! vac from connector F7 pin * of 6#%* to
*H., the return side of the relay is tied to wire number . An important note
about this relative to the '/! is that F7 pin * on 6#%* actually is not con5
nected to anything else on the B3%. :n order for this board to work on the
'/!, it needs to have a series of 8umpers soldered to the back of the board
to route the **! volts to relay *H.A.
6iagnostic L.!!&.! ?#4O+A should be a * while the #/A+6%G button is held.
6iagnostic L.&!..! ?#4O+#A should be a * while the #/A+6%G button is held and
for about five seconds after it is released.
Alarm 9C99 /$==@/ 31A2B DA$1/ will occur at power up if the turret is not
clamped. /he machine determines if the turret is clamped using a proximity
switch located behind the index gear. /his alarm can be cleared by manually
turning the gear until the proximity switch is made ?the red 1@6 comes onA.
/he @5#top circuit consists of <vdc output at address G<. which feeds the
@5#top buttons on wires 6*!*, 6*!, 6*!., etc. 2ake sure that you have <vdc
leaving D35.! connector 3+9 pins *! and **, going through @5#top circuit
returning to 3+9 pin *C.
G<., in the ladder, is L**!<. which is turned on by L*<&*! which in turn is
turned on by a string of inputs including K@#B, +3O'/ and #4A12.
/he F axis brake is released when the <vdc output at address G<< from conn5
ector F7 pin %. of 6#%* goes through a normally open contact of *H. to conn5
ector F7 pin A. of 6#%* to ice cube relay *H& ?%=AH@ =@1@A#@ =@1AGA. /he re5
turn side of *H& is D35.! 3+9 pin *7.
/o access the 1adder on the i7! control;
*.Bress the +3 #3=@@+ button.
.Bress the D$+3 #@1@3/ soft key ?DCA.
..Bress DC again.
<.Bress the 1A66@= soft key.
/he ladder of the i7! searches from the top so that if the address you are
looking for is located above the current position the 3=/ will display +O/
DO$+6. :f this happens, press the D$+3. #@1@3/ ?DCA then press the %/I/OB
#oft key. /he first press will take the display to the bottom of the ladder,
press it again to go to the top.
/o search for a 6iagnostic address;
*.Bress +3 #3=@@+ soft key ?DCA.
.Bress D$+3. #@1@3/ soft key ?DCA.
..Bress 6:A-+ soft key ?D<A.
<./ype the desired address ?i.e. .!!&A
&.Bress the 3$=#O= 6OW+ button.
/he 3=/ will display *! addresses ?i.e. L.!!!5L.!!CA. /he diagnostics are
displayed as an eight bit binary number with it,s corresponding 'ex value to
the right.
:f the machine has alarm .!!! #@=4O ODD and *C! 2A3':+@ $+=@A6G at the same
time, alarm *C! will be masked because .!!! is a higher priority.
1ike most 3+3 controls, the servo unit of the i7! has control power applied
at power on in order to do self5diagnostics, etc., but the three phase drive
power is not applied to the machine is ready.
1+# Ouick 1oad barfeeder;
:f the 136 displays @2@=-@+3G #/OB 1:+@ :# OB@+, check the two #7 terminals.
/hey should be closed. :f it displays other alarms about the collet, etc.
make sure that the signals have not been bypassed and a 8umper is loose.
Often times the chuck close confirmation switches, etc will not be present on
the machine tool so a number of the inputs to the barfeeder will be tied to
a dry contact or < volt source.
#ome #@2 servo motors have an encoder mounted to the back of the motor with
two set screws. :f these become loose the machine will have trouble repeating
especially with regard to reference return to zero.
:f you are working on a #ervo 6ynamics drive with which the 1ag value can not
be ad8usted close enough to zero, check the connections of E* and E. A bad
connection here, or even a dirty connection can prevent the 1ag from being
decreased.
A &!! line rotary encoder connected to a *!mm ball screw should give a .!!!*"
resolution.
/he position sensor for spindle orientation on a Hiwa H+'5<) is %0: type,
Danuc part number A7)!5*!5/<!*.
On the 'yd52ech '5* with the 2itsubishi B13, if the hydraulics cut off when
you release the button and the number three 1@6 is flashing, the program is
probably either lost or scrambled. :f the 1@6 is on steady, their is likely
a hardware problem with the B13. :f the 1@6 is flashing you can order a mem5
ory card from 'yd52ech and plug it into the B13 it will load the program.
:n this case the full the model number of the machine will be '5* 2:/#.
On the =hino #/I7 lathe with the new spindle amplifier there is a row of 9
1@6s. /he first 1@6 from the left should indicate the BW2 signal to the
amplifier which should be seen to flash in sympathy with the speed signal to
the amplifier. /he second 1@6 should come on when 3W rotation is commanded
and be off when 33W rotation is commanded.
/o transfer the parameters from one Gaskawa 49 inverter to another 49;
*.3hange n*99 of the source drive from ! to *. /his will allow the parameters
to be read and written.
.3hange n*9) from =dy to r@d. /his will transfer the parameters from the
drive to the digital operator.
..=emove the digital operator and install on the target drive.
<.3hange n*99 to * if it is not already.
&.3hange n*9) to 3By. /his will transfer the parameters from the digital
operator to the inverter.
).3hange n*9) to vDy. /his will verify that the parameters in the digital
operator match the parameters in the drive.
9.3hange n*99 back to ! on both drives. /his will prevent accidental over5
writing.
:f a Gaskawa inverter will not run when commanded, check the digital operator
to be sure that the display is on D=@O or at least some other selection with
a green 1@6. :f the display is on 1OI=@2 or B=-2 ?red 1@6sA the drive will
not respond to a remote command.
/he parameter for setting the rapid rate of the 0 axis on a machine with a
Gasnac 2F control is )7.
/o run a cycle on the new 'yd52ech #5!A #eries ::;
*./urn the power on.
.=elease the @5#top.
..'old the D* key until the hydraulics turn on. /he D* key is on the
operators interface. #witches must be in the +@$/=A1 and 'O16 positions.
<.3lose the front vise. /he display will change to another screen.
&.Bress the D< key.
).'old the +$2 key while typing the desired length.
9.=elease the +$2 key, press the @nter key.
7.3ursor to = and enter the required number of parts. /his number has to be
greater than the value in 3.
C.Bress the 3G31@ #/A=/ button.
/hese machines have a relay board where all of the inputs and outputs are
connected. /he relay board is connected to the B13 by two ribbon cables, 3+*
and 3+<.
:f the display will not come on check the cable that connects it to B13. /his
is a B# type connector which if unplugged will keep the 136 screen from
coming on.
/he Hia *12# turret uses a Danuc %eta motor and drive for indexing. /he tur5
ret uses an absolute pulse coder. /he turret can become confused for a couple
of reasons one of which is B22 parameter **.!, this parameter has to be * for
the turret home position. :f this parameter gets set to ! it causes a strange
condition in that the turret will be able to index and go the correct tool
but after the index the cycle start lamp will stay on because the /D:+ is not
generated. /here will be no alarm and if the machine is turned off and back on
the turret can be indexed again. /o change this parameter you must access the
Bower 2ate 3+3 2anager screen. /he parameters stored here are used for %eta
drives only. /he parameters are stored in the drive itself so if you replace
the drive the parameters go with it.
*.Bress the #G#/@2 button.
.Bress the =ight 3hapter button three times.
..Bress the B22 soft key.
<.Bress the #G#/@2 soft key.
&.Bress the BA=A2 soft key.
Another important B22 parameter is **.9 because it must be * for the absol5
ute pulse coder.
Anytime the turret becomes confused or exhibits the condition described above
the following procedure must be performed.
*.-o to the B22 parameters and make **.! > !. With this parameter all eight
bits must be entered so make sure you change the value of bit ! only.
.#et Heep =elay &.! to *.
..$nclamp the turret by pressing #B:+61@ #/OB, #@1@3/ and D@@6 'O16 buttons
simultaneously. /he #@1@3/ button in this case is the button which shows
two arrows pointing in opposite directions and is located next to the
#B:+61@ DO=WA=6 button.
<.Once the turret is unclamped turn it by hand until it is on tool station *
and the two red arrows are aligned with one another.
&.Bress the 3A11I%0 button. /he turret should clamp. 3heck the turret clamp
confirmation switch at F!.9 to make sure it is clamped.
).#et Heep =elay &.! back to !.
9.Bress the #B:+61@ #/OB, #@1@3/ and D@@6 'O16 button simultaneously. /his
time the #@1@3/ button is the button which shows an arrow pointing to the
left and is located next to the 2A3':+@ 1O3H button. On some machines it
may not have an arrow but may be a blank button labeled #@1@3/ only.
7.-o to the B22 parameter **.! and make it a *.

/he hydraulic solenoid on the Hiwa H+'5<!! that sends the single arm back
from the chain pot to home position is #ol &,&. ?wire numbers G&<3 and
G&<.3A.
/he way lube pump on the Hiwa H+'5<!! comes every on eight minutes whether the
spindle is running or not. :t is controlled by counter 3!. /his oiler also
oils the spindle bearings and is lighter than the usual )7.
When looking at angular contact ?thrustA bearings their direction can be det5
ermined by the arrows etched on the side of the outer race if the bearing has
an arrow. +ot all bearing makers place an arrow on the bearing. :n this case
you can find direction based on the fact that the inner race is wide ?fatA on
one side and narrow ?skinnyA on the other side. /he arrow should point to the
fat side. As far as how the bearings are stacked, there are different config5
urations for different loads such as high axial loads, etc.
:f a machine,s control turns off at the end of a program or anytime it reads
either a 2! or 2.!, check to see if the Auto Bower Off function is turned
on. On many machines this is in the form of a push button the operator,s
panel but in the case of a Danuc control, particularly a !56 control, this
can be in the #oftware Operators Banel or take the form of a Heep =elay. On a
2itsubishi control it can be done with a 1atch Barameter.
:f a machine with a double arm A/3 hangs up at the spindle and especially
if the A/3 arm motor trips the overload check the tool grippers. #ometimes
the plungers will get tight and have trouble pushing back far enough to be
able to engage the tool. :n this case you might see the magazine pot move
excessively when the arm engages it.
2ori5#eiki machines, the 245&& in particular, use a number of timers for
seperate events of the A/3 cycle. $nlike most machines, changing things like
hydraulic cylinder speed, switch positions, etc., can have great and unexp5
ected effects. Dor example, on most machines if you suspect that the spindle
unclamp confirmation switch is not being depressed far enough you can move
the dog closer to the switch. 6oing this on a 2ori5#eiki may well prevent the
A/3 cycle from executing at all since the timing is so close.
When working with cam follower bearings, most of the time they are available
with either a straight screwdriver slot or an allen head. :n either case they
will often have a /orx head within the allen or the straight slot.
:f the F, G and 0 axes of a 2ori 2'). will not move and the % axis will but
there are no alarms check the pallet ?% axisA. /he other axes are interlocked
through the pallet down confirmation switch. On a machine with a Danuc )2
control the signals are;
:/F 5 -C).< ?F..<A
:/G 5 -C9.< ?F...<A
:/0 5 -C7.< ?F.<.<A
/hese - signals are active low signals so they should be ! for axis motion to
be allowed.
:n the case of a machine with an indexer it may be necessary to lock it
?2*!I2**A.
/he 1e%lond =egal lathes use the #ervo #hift mechanism to change spindle
speeds. /his mechanism is entirely hydraulic with the exception of the pulse
switch located on dial A. /his switched is open and closed anytime the dial is
moved to another speed setting. /his is done with detents on the dial. /he
dial has a shaft which connects it,s center to the #ervo #hift unit in the
headstock. /his unit sits 8ust below the top cover and is easily accessible.
/urning the dial turns the shaft which opens and closes the various ports in
the #ervo #hift unit but the shift does not actually occur until dial % is
placed in the %=AH@ position. 6ial A should only be turned while dial % is in
one of the two ODD positions. :f dial A is turned while dial % is in the
%=AH@ position the #ervo #hift will try to shift to the next speed range as
the dial is rotated. /he correct operation is;
*.Blace dial % in one of the ODD positions.
.=otate dial A to the desired =B2.
..=otate dial % to the %=AH@ position.
/he spindle will begin to oscillate back and forth. /he higher =B2 selected
the wider the oscillation.
<.After several oscillations, rotate dial % to either the DO=WA=6 or =@4@=#@
run position.
6ial A speeds;
+
<&
)C
9&
*..
*9C
&)
.&*
<C<
C.9
*7
*7!!
6ial %
MMMMMMMMM
N N =everse
NMMMMMMMMMN
N N Off
NMMMMMMMMMN
N N %rake
NMMMMMMMMMN
N N Off
NMMMMMMMMMN
N N Dorward
NMMMMMMMMMN
%elow 6ial A is a plate held on by six screws. %ehind this plate are two pla5
stic half gears with detents. As the drive gears are shifted these half gears
move, their detents ride on levers, the other ends of which work against a
spring.
:f the #ervo #hift is operated improperly such as turning 6ial A when 6ial %
is in the %=AH@ position it can result in a condition in which the gears
shift as soon as 6ial A is moved off of the current speed before it reaches
the next =B2 setting. When the machine is run and then 6ial % is turned back
to the %=AH@ position, the spindle may start to oscillate in an effort to
shift to the next speed. :n some cases this may not occur immediately but
instead it may happen as a result of the vibration of putting a part in the
chuck, etc.
On a machining center if there is a popping sound when the tool is removed
from the spindle it could be that the collet is not releasing all the way but
another cause is if the tool clean ?air blastA is leaking through which will
cause air pressure to build up behind the tool so that when it is released
the air shoots it out causing the noise.
On a Hiwa horizontal if you get alarms !&! and *!.!, etc. when you call a
tool number over )< on a machine that has a *! tool magazine try running
2*!! to reset the tool table and then 2*!* to register the tools but check
the Heep =elay H.! first. Dor )< tools it should be !, for *! tools it
should be *.
2achines that use a built5in ?integratedA spindle do not have a pulse coder
on the motor like other spindle motors, it uses a B1- unit. this unit cons5
ists of an inductive sensor that is sensing a plastic gear. /here is a B3%
between the sensor and connector 3+&. /his B3% has several potentiometers
which are used to ad8ust the signal strength for BA and B%. :f a machine like
this exhibits a condition where the spindle oscillates and makes a high pitch
noise, this B3% probably needs to be ad8usted. /ypically, the signals BA and
B% need a signal strength of . 4pp. /he gap between the sensor face and the
gear is critical and should be about .!!)". /he plastic gear has one tooth
that is longer than the others and represents the reference marker.
/o check the parameters on an #5.A with a sequencer;
*./urn the sequencer on while holding the :+6@F button.
.=elease the :+6@F button.
..$se the :+6@F button to scroll through the parameters. ?/he sequencer nor5
mally has only five parametersA.
After pressing the :+6@F button for the fourth time, the display will default
back to the normal display ?current settings for :+6@F and =@O. O$A+/:/GA so
you really have to watch closely to see what the setting is for parameter &.
/he typical settings for parameters *5& are;
* 5 9&
5 &!
. 5 .!
< 5 &!
& 5 &!
:f the Auto cycle will not execute on this machine, check that the limit
switch for shuttle vise forward is made, if not the cycle will not continue.
:n some cases the sequencer can become confused causing the :+6@F L display
to reset itself to !. /his will, of course, cause the Auto cycle to stop
because the saw needs to make at least one index to execute the cut. #ome5
times this can be resolved by simply accessing and scrolling through the
parameters. /he condition may occur as a result of switching the 2ode select
switch directly from 2A+$A1 to A$/O without stopping at the +@$/=A1 position,
according to 'yd52ech you should always stop at +@$/=A1 for a second.
:n Auto mode the machine should execute the cycle with or without the blade
running with the exception that the head will not come down.
:n Auto mode 3=*! should be energized and 3=** should be de5energized. :n
2anual mode 3=** should be energized and 3= *! should be de5energized. :n
+eutral mode both 3=*! and 3=** should be de5energized. .3= should be energ5
ized anytime the hydraulics is on.
/he #5. with a sequencer like the #5! uses a limit switch to position the
shuttle vise for the proper length, this is the top left limit switch and has
a vernier dial ?micrometerA for fine ad8ustment. /he bottom left switch is
the approach switch and it is placed ahead ?in terms of travelA of the top
switch. When the shuttle contacts this switch the feed rate slows to allow
more precise positioning. /he limit switch on the right is used only for
confirmation of the shuttle vise fully forward.
/he % axis for the H+'5<!! has two proximity switches that confirm the state
of the axis, either clamped or unclamped. /he 31A2B confirmation switch is
1#.), it,s symbol is 1#%=31, the :IO address is F!!!C.9. /he $+31A2B confirm5
ation switch is 1#.9, it,s symbol is 1#%=$3, the :IO address is F!!!C.).
%oth switches are two5wire devices, their source is wire 'B. /hese switches
are actuated by a piston in the base of the % axis. :t is accessed by remov5
ing the eight screws and cover located on the A/3 side of the % axis. /he
piston is held on by two bolts and is easily removed once the cover is out of
the way. /he piston is pushed out by hydraulic pressure when the axis is
unclamped and is returned to it,s original position by a spring. A dog is
attached to the piston by a collar and set screw and moves over the face of
the proximity switches. With the two bolts removed, the piston and spring can
be removed as an assembly. :t is not uncommon for the piston shaft to become
worn and start to stick due to lateral motion of the shaft. +ormally when
this occurs the piston will move out under the hydraulic pressure but the
spring is not strong enough to pull it back so the axis thinks it is unclamp5
ed all of the time.
:f you need a password to access the ladder of a 2ori5#eiki, try entering the
letter 1, then input.
/he Gasnac .!!!- control has only *!! parameters ?!!5CCA but parameter )&
consists of 7 groups of parameters with each group consisting of 7 bits.
:f you replace the main board ?3B!.A board of a Gasnac .!!!- control and it
exhibits strange behavior, it may be necessary to regenerate the control. /o
do this;
*. Blace the thumbwheel switch ?located in the tape reader enclosureA to &.
. /urn +3 off.
.. 'old 3ancel, =eset and Barameter ?B=2A while powering up.
3lears Barameters.
<. /urn +3 off.
&. 'old 3ancel, =eset and Offset ?OD#A while powering up.
3lears Offsets.
). /urn +3 off.
9. 'old 3ancel, =eset, 3ommunication ?3O2A and @rase ?@=#A while powering up.
3lears Brograms.
7. =eload parameters by hand.
C. 3ycle power.
*!. =eload programs.
When reloading the parameters you need to be aware that +)& is for the Option5
al Deatures ?option parametersA. /his parameter appears as a single zero ?!A
when viewed normally, but when viewed with the thumbwheel switch in position
&, it appears as an eight bit binary number. /he Optional Deatures are set in
groups of 7. /he groups appear as )&F,)&G,)&0,)&A,)&:,)&E,)&H,)&=. /hese
values are altered by typing the letter of the group ?i.e., F, 0, E, etc.A.
/he eight bits of each group are designated 6!569 corresponding to bits !59.
On some machines, the keypad may not have the letter A so you must use the
number < to access group )&A. Also, if you press a key that does not repres5
ent a valid group ?#, /, -, etc.A, the parameter +)& will disappear from the
machine. Bressing a valid letter such as F or E will cause +)& to reappear.
=eloading the parameters is a simple matter of typing in the value that you
want the parameter to be and pressing the Write ?W=A button. 2ake sure that
you select the correct letter designation first. Dor example, to change the
value of parameter 9*G you would use the Bage $pI6own and the 1ine $pI6own
buttons to get to parameter 9*, then type in the letter G. +ow the value that
you enter will affect 9*G but not 9*F, 9*0, etc.
Barameter )& is different. #ince these are option parameters, there is an
additional step. Once you have paged to parameter )& and selected F, G, etc.
you must press the :nsert ?:+#A button. this will place an asterisk under
the first bit ?69A. +ow type in the eight bits from left to right ?95!A then
press the write ?W=A button. +ow you 2$#/ press the =@#@/ button for the
parameter to become effective. After performing this procedure, cycle
the power all the way back to the breaker.
:n some cases you may need to clear the program storage area again in order
to load the programs.
/he #trong model +* chuck like the ones used on the @coca #E5&, etc. has
a 8aw stroke of .<*9" on the diameter, the plunger stroke is .C!&". /he act5
uators used on these machines have a piston stroke of .C*&".
/he electrical boxes of the 1+# bar feeders are wired for the lathe they are
to be installed on and 1+# keeps a copy of the wiring diagram that can be
referenced by the drawing number.
Gasnac 2F.;
/o access the =$+ /:2@, 3G31@ /:2@, etc, press the A12 button, then page down until /:2@= is
displayed at the top of the screen. Gou should see;
*. BOW@= O+
. 3G31@ #/A=/
.. 3$//:+- D@@6
<. OB/:O+A1
/o clear a timer value, press the desired number ?*,,. or <A along with the origin ?O=-A button.
On the Hia #H/* with a parts catcher, catcher up confirmation is F..!, down is F..*. :n the case of
the Hia #H/*& with a Danuc !i control, the main spindle parts catcher up confirmation signal is F7.,
F7.. is parts catcher down. On the #H/*& the output coils for parts catcher upIdown are G7. and
G7.. respectively. /he relays are HA** and HA*. /he 25code for parts catcher up is 2)., down
is 2)<. /hese are configured to finish with a hardware signal. /he parts catcher function for the
#H/*& is enabled and disabled by way of a -.6A/A bit. /his bit is 6!!!C.) and must be set to a
value of * in order for the parts catcher to be valid. /ypically the value displayed will be in decimal so
you must convert the 7 bit binary number to decimal then input. :f the value in 6!!!C is currently !
you must enter a value of )< ?!*!!!!!!A. +ormally on this machine the value of 6!!!C will be set at
. from the factory so you would add the two and enter C).
/he Hrras %end 9!..! with B-B)!* back gage controller uses only * parameters in the controller.
/hey are;
Barameter 6efinition #etting
* :ndex Ouote Brogramming
Overrun 6istance !.!!!
. #lowing 6own !.<!!
< :nertia Ouote ?B-B calculates every positionsA !.!!<
& Bosition /olerance !.!!<
) =etraction !.!!
9 /ime %efore =etraction !.!!<
7 +egative 1imit #witch !.<&!
C Bositive 1imit #witch ..!!
*! @ncoder 2ultiplier ?*, , <A <
** @ncoder 6ivide Dactor C.7)&
* Brogrammable Boint 6ecimals ?!, *, , .A !.!!.
U /he above settings are typical and may be different for other machines.
U /he :ndex Ouote Brogramming value is defined by the customer and varies depending on how
far the fingers, etc. are from the die.
Dor a twelve lead A3 motor there are six windings with two leads for each set. /he numbering for the
sets is typically;
$*5F*
$5F
4*5G*
45G
W*50*
W50
/he resistance of each winding is normally in the range of * ohm. When the motor is wired for 6@1/A
?low voltageA operation there are essentially three sets of two windings with the two windings of each
set in series. $sing the numbering above, this is accomplished by connecting the leads as follows;
$* to 0
F* to $
F to 4*
G* to 4
G to W*
0* to W
/he three phase voltage would be connected this way;
1* to $*, 0
1 to F, 4*
1. to G, W*
Dor WG@ operation, connect the leads as follows;
F* to $
G* to 4
0* to W
F to G to 0
/he three phase voltage for WG@ operation is connected;
1* to $*
1 to 4*
1. to W*
/his connection places four windings in series with respect to any two phases.
=egardless of how the windings are numbered, you can wire the motor by ringing out the leads to find
individual windings and wiring accordingly.
Another thing to be aware of is that the wire numbering using alpha numeric such as $*, 4*, W*, F,
G and 0 is :@3 nomenclature while numbering that uses numbers only such as *,,.,< etc., is +@2A
nomenclature.
C 1ead 2otor ?WyeA;
1ow 4oltage
<, & and ) together, * to 9, to 7 and . to C, line voltage to *I9, I7 and .IC.
'igh 4oltage
< to 9, & to 7 and ) to C, line voltage to *, and ..
C 1ead 2otor ?6eltaA;
1ow 4oltage
*, ) and 9 together, , < and 7 together, ., & and C together. One phase of voltage to each set.
'igh 4oltage
#ame as for Wye connection.
H:WA H+'5<!!
% axis clampIunclamp information;
<vdc is supplied by wire 'B at terminal block /%& to $nclamp limit switch 1#.9 and 3lamp limit
switch 1#.). %oth switches are normally open. 3losure of 1#.9 sends <vdc through /25*) to wire
F!C) then to Danuc :IO 2odule 3%*&* pin *) turning on input FC.). 3losure of 1#.) sends <vdc
through /25*9 to wire F!C9 then to :IO 2odule 3%*&* pin *9 turning on input FC.9. On the output
side G..9 ?% AF:# 31A2BA sends <vdc from Danuc :IO module 3%*&* pin C to wire G!.9 through
/25C connecting to 3=*7 coil. /he return is wire '+. 3=*7 contact closure sends **! vac from 1*5
C to wire G.93 through connector 3+*51 to % Axis 3lamp solenoid #O19. /he return is 15C. /he
solenoid valve is 6aikin H#A5-!5.%A5.!5@ *!! vac.
#tankoservis 4/1;
:f the table will run at some speeds but not others check the glass fuses that feed the clutches. @ach
fuse feeds a different set of clutches. #o if, for example, the 9th fuse from the left blows speeds *.&5
).. will not work. :n this case the table brake also will not work.
When the table is started and the arm feed engaged after a set time the table speed is locked and
cannot be changed. :f the feed is stopped, the table speed can then be changed and feed resumed.
/his function may be tied to the 4>3 switch.
KKK 2odel A*).5!!! *!! KKK
When replacing old faceplate with adapter cable must be ordered from Anilam
and rewired according to drawing number AO3 * in Anilam file. Also, on this
model readout, if an axis direction indication is backward the wire harness
from the scale can be reversed on the B3% to give proper indication.
#eries **!!
/o run in Auto, make sure the A$/OI2A+ switch is in A$/O.
:f no program is selected, won,t go into Auto.
/here are four 1@6s on the 2otion %oard, if the second one from the top is
off the machine is in @5#top condition.
/here is a small power supply to the left of the relay board which supplies
the < vdc for most things. /he **! volt supply for this unit comes from the
relay board, from the connector on the lower right corner of the board. :t
is a four pin connector, the other two pins are the <vdc from the power
supply. H< on the relay board has to energize first. /he J<vdc for the coil
of the relay is supplied directly to the coil, the 5<vdc ?commonA is routed
through the motion board. /he common is a yellow wire on the power supply.
/he common signal from the motion board is at B*5*. :t goes to B.5. on the
relay board. 'aving all of this in place will cause H< to energize. /o ener5
gize the other relays and make the machine ready you have to press the #@=4O
@+A%1@ soft key.
On the **!! control you change the direction of the motors by accessing the
#etup $tilities. 6irection JI5 is shown as invertingInon5inverting.
/o access the 32O# setup you need a keyboard. /here is a port on the control
to plug an A/ keyboard but if you have a B# keyboard you have to plug it
into the 3B$ board. Gou have to press either D or 6@1 to enter setup. :f the
keypad and 4-A ports are both on the same board ?3B$A, use D. #ometimes a
control will default to a drive other than the one where the startup files
are stored. /his may be caused when the 32O# battery dies. :f you go to the
setup utility and change this but it does not hold, the battery is probably
dead. /he 32O# battery is =ayovac %=..& or %=..!. #ome of the 3B$s use a
battery inside the chip, these cannot be replaced. /he board has to be upgrad5
ed at a cost of about V*!!!.
/he password to access the setup utility is G*!.
/he Anilam ..!! has a 2A+$A1IA$/O switch on the back of the pendant. :f this
switch is in the 2A+$A1 position, the servos will not power up. :n this case
the control will act as a 6=O only. :f the control is powered up in 2A+$A1
then switched to A$/O, it will still not be able to operate servos, the
switch must be in A$/O during power up. /here is an :.6. key installed on the
back of the pendant which identifies which options are available to the cont5
rol. :f the key is missing or damaged the options will not be available.
2iscellaneous functions such as spindle operation are options on this control
so if the key is missing or damaged the spindle will not turn on. :n this
case the serial number ?#@=.+O.A of the :.6. key which is normally displayed
in the upper right hand corner of the 3=/ display will read all zeros. /he
key is like a gender changer so other cables can be plugged into the back of
it. 3ertain cables such as a =#5. plugged into the key will prevent it from
working. /he 2otion :IO board has a row of 1@6 indicators from top to bottom
which indicate several things such as the status of the @5#top, overtravel
switches and if the servo on signal has been turned on. When the #@=4O O+I
=@#@/ button is pressed the corresponding 1@6 should come on and the H* relay
?ice cubeA should turn on energizing the solid state relay H which is mount5
ed to the backplane of the cabinet with connection to the board via screws
through the board. /his relay sends the **& vac to the drives. :f there is
no display of position change when an axis is moved check the external power
supply which provides the &vdc to the motor encoders via connectors on the
2otion :IO board.
DA+$3 3O+/=O1# 3O22$+:3A/:O+ 3A%1@
/he following cable configuration is required for communication between a
Danuc control and a B3.
Binouts for two & pin connectors.
& pin & pin
connector connector
Bin 9 5555555555555555 Bin 9
Bin 5555555555555555 Bin .
Bin . 5555555555555555 Bin
Bin < MMMM MMMM Bin <
N N
Bin & MMMMN NMMMM Bin &

Bin ) MMMM MMMM Bin )
N N
Bin 7 MMMMN NMMMM Bin 7
N N
Bin ! MMMMN NMMMM Bin !
Binouts for one & pin connector and one C pin connector.
C pin & pin
connector connector
Bin & 5555555555555555 Bin 9
Bin . 5555555555555555 Bin .
Bin 5555555555555555 Bin
Bin 9 MMMM MMMM Bin <
N N
Bin 7 MMMMN NMMMM Bin &
Bin ) MMMM MMMM Bin )
N N
Bin * MMMMN NMMMM Bin 7
N N
Bin < MMMMN NMMMM Bin !
:n both cases, pins not shown are not used. A ordinary parallel cable will
not work and if attempted could cause damage to the B3 or the control since
Bin & of A11 Danuc controls is a < vdc supply for use with specific Danuc
devices.
+$11 2O6@2 3A%1@#
C Bin +ull 2odem 3able
Bin * 5555555555555555 Bin <
Bin 5555555555555555 Bin .
Bin . 5555555555555555 Bin
Bin < 5555555555555555 Bin * and )
Bin & 5555555555555555 Bin &
Bin ) 5555555555555555 Bin <
Bin 9 5555555555555555 Bin 7
Bin 7 5555555555555555 Bin 9
Bin C +o 3onnection
& Bin +ull 2odem 3able
Bin * 5555555555555555 Bin *
Bin 5555555555555555 Bin .
Bin . 5555555555555555 Bin
Bin < 5555555555555555 Bin &
Bin & 5555555555555555 Bin <
Bin ) 5N
N55555555555555 Bin !
Bin 7 5N
Bin 9 5555555555555555 Bin 9

N5 Bin )
Bin ! 5555555555555555 N
N5 Bin 7
Bins not shown are not used.
Binnouts for 2& cable on Danuc control;
! Bin 'onda ?2&A & Bin ?=#5.A
Bin 5555555555555555555555555555 Bin C
Bin . 5555555555555555555555555555 Bin 7
Bin < 5555555555555555555555555555 Bin !
Bin & 5555555555555555555555555555 Bin *C
Bin ) 5555555555555555555555555555 Bin *7
Bin 9 5555555555555555555555555555 Bin *9
Bin 7 5555555555555555555555555555 Bin *)
Bin ! 5555555555555555555555555555 Bin &
Bin & 5555555555555555555555555555 Bin *<
:f you have a & pin to C pin molded =#5. cable, the pin outs are probably
like this;
& Bin C Bin

Bin 5555555555555555555555555555 Bin .
Bin . 5555555555555555555555555555 Bin
Bin 7 5555555555555555555555555555 Bin *
Bin ! 5555555555555555555555555555 Bin <
Bin 9 5555555555555555555555555555 Bin &
Bin ) 5555555555555555555555555555 Bin )
Bin < 5555555555555555555555555555 Bin 9
Bin & 5555555555555555555555555555 Bin 7
Bin 5555555555555555555555555555 Bin C
/he adapter that : use to make this cable work with controls is purchased
from =adio #hack, it is configured this way;
Bin 5555555555555555555555555555 Bin .
Bin . 5555555555555555555555555555 Bin
Bin < 55 55 Bin <
N N
Bin & 55 55 Bin &
Bin 9 5555555555555555555555555555 Bin 9
Bin ) 55 55 Bin )
N N
Bin 7 55 55 Bin 7
N N
Bin ! 55 55 Bin !
/his adapter is a =#. #':@16@6 E$2B@= %OF 9)5*<!.A. : normally use this in
con8unction with a =adio #hack 6O$%1@ #':@16@6 =#.3 3A%1@ ?) feetA. Bart
number is )5)C.
A source for Danuc and 2itsubishi cables is 2achine /ool #ervices, they can
make motor and feedback cables for many 3+3 controls. /heir phone number is
<7!5C7&5*C<*.
Hia /urn * with Gasnac 1F..
/o enable the parts catcher you must make parameter 9!!&.* equal *. /o do this;
*. #elect 26: mode.
. Bress the #@/ button.
.. 3ursor to #etting Barameter L)*C ?BW@A
<. @nter *.
&. Bress the W= button.
). Bress the B=2 button.
9. 3ursor to parameter L9!!&.
7. Bress the :+#@=/ button.
C. $se the cursor down button to move to bit *.
*!. @nter *.
**. Bress the W= button.
K @nter a value of in parameter 9!!&.* disables the parts catcher. :f you do not change the BW@
back to ! none of the 2 functions will work, etc.
:f the turret tools are confused on this machine;
*. =otate the turret to tool station *.
. #et the BW@ ?parameter )*CA to *.
.. #elect Eog mode.
<. Bress the /$==@/ #@1@3/ and /$==@/ :+6@F buttons together once.
'yd52ech #5!A with #equencer;
/he green light should be off until the hydraulics are started. /he hydraul5
ics will start with or without the switches in neutral, hold, etc. :f the
hydraulics start but shut off when the green button is released, check the
blade tension switch ?.1#A. /here is a handle on the left side of the machine.
/urning the handle clockwise increases the blade tension and moves the dog
toward the limit switch. When this switch is open all of the machines funct5
ions will work as long as the green button is held in except that the head
will not move down. Also when the switch is open the green pilot light that
is close to the blade tension ad8ustment will be off. /he =equired Ouantity
?Barts 3ountA display decrements each time the head reaches the bottom of
it,s stroke. Once the count reaches !!! in Auto mode, the head should go up
and everything shut off including the hydraulics ?the sequencer display stays
onA. :f when the shuttle moves back, enters slowdown then wants to keep going
check the stop switch. :f the length ad8uster is loose the switch can cause
it to slide keeping it from making the switch. /he :ndex and =equired Ouant5
ity displays can not be changed unless the hydraulics are running.
/he circuit for the hydraulics;
**!45555555W X555555NIN555555NIN555555NIN555555NIN555555N N55555? A55555+
*D$ *O1 O1 *B% N .1# *2 N *2
N N
N N
5555555N N555555555
B% B%
*D$ 5 & amp fuse
*O1 5 'ydraulic motor overload
O1 5 %lade motor overload
*B% 5 #top pushbutton
.1# 5 %lade break limit switch
*2 5 'ydraulic motor holding contact and motor starter
B% 5 'ydraulic start button ?green buttonAB13*!! @rror 3odes;
B13*!! @rror 3odes;
!! Auto 2ode :nput +ot 6etected
!* 'ydraulics =un :nput +ot 6etected
! #huttle 4ise 3losed :nput +ot 6etected
!& 'ead $p :nput +ot 6etected
!) 'ead 6own :nput +ot 6etected
!C #huttle 'ome :nput +ot 6etected
*! B13*!! 6id +ot =each Brogrammed #huttle 1ength
** #huttle @ncoder 3hannel A and % Are =eversed
* +o @ncoder :nput 'as %een 6etected
B13*!! #etup Barameters for '5*A #I+ A!CC&<*7A;
L #et 4alue
A 2achine #ymbol +IA '5*A
% #huttle 1ength 3onstant ! .*<97
3 Bulses Ber =evolution of @ncoder F*! * <!!!!
6 #huttle 1ength ?:nchesA <!
@ =ear 3ushion . *
D Dront 3ushion < *
- Overshoot & .!*)
' Dront 4ise 6well ) 9&!
: #huttle 4ise 6well 9 9&!
E Wheel 3onstant 7 <.
H Wheel Bulses Ber =evolution C 9<!
1 2achine 3haracteristics A *
When "BA$#@6" is displayed the Out Of #tock 1imit #witch has been activated.
:f the hydraulics will not stay on, try holding the button in then using
the manual buttons to open the vises. :f the blade break proximity switch
is bad or out of ad8ustment the machine will start and run until it "sees"
that the blade is not moving. :t does this by having the prox switch look at
the driven wheel.
On 4*7AB3, if the hydraulics will not start, the encoder cable may be
shorted.
On the 45*7AB3, if the length measurement is off on straight ?C! degreeA cuts, ad8ust the :+3'I=@4
parameter. :f the cut comes out too long, increase the value, if too short, decrease the value. :f it is off
on angle cuts, ad8ust the 6B =A6:$# parameter. /he %B =A6:$# parameter is normally used for
when there is a measurement error when going from an angle cut to a straight cut.
/he #5!B #eries ::: uses a 2itsubishi D=5#&!@5 inverter for the blade motor. :f it displays alarm
O4. it normally means that the regenerative voltage was too high during deceleration. /he decel time
is set from the factory at .& seconds so under certain conditions this may not be enough. Gou can
increase the decel time by changing inverter parameter number 7. Gou have to change parameter
number 9C from to * to unlock the other parameters.
2azak #ervice 9!<57*5..<! Eim
/his office should be used whenever possible but in case of dire need you can
call the Atlanta office;
99!5CC)5*!.!
2ost 2azaks use a main breaker which is interlocked through the door
switches. :f a door is opened, the main breaker will trip removing all power
from the machine.
KKK 2icro /urn KKK
/he tool turret uses =eed switches mounted in a circular pattern to control
indexing. @ach position has two switches. One is for decelerating the turret
motor and the other is for locating. /hey are mounted to a B3% which is hard
wired to the machine. :t can only be removed by de5soldering all of the wires.
An arm with a magnet on one end rotates counter clockwise to activate the
switches. When working properly they can be heard closing as the magnet
passes each position. /o orient the turret;
*. 3all up a tool.
. Once the turret locates, loosen the bolt holding the arm and move it to
toward the switch which corresponds to that number. ?/he tool positions
are printed on the B3%A
.. 1isten carefully and as soon as the switch closes, stop the arm and
tighten it down.
:f a position confirmation switch fails in the open state, the turret will
index continually when that tool is called. /he height of the magnet relative
to the top of the switch is very important. :t should be about .!)!". :f the
switches are not located correctly the turret may stop at the correct
position but will unable to locate and re5clamp. :f this happens and you do
not know which switch is out of position or if the height is wrong, a good
place to start is to;
#lightly raise the first switch from 33W ?6ecel switchA above the board.
Bress the second switch ?Bosition confirmationA flush with the board.
:f the turret still has trouble re5clamping, try moving the second switch a
little away from the first. =emember, these are =eed switches soldered to the
board so be careful not to bend the leads too far.
KKK 2icro 3enter 4 KKK
:f 2achine Dail light stays on, check the 'ead 1ube Bressure switch. /his
switch is on the right side of the spindle in a tee in the oil line. /his
switch has only one wire. :t is connected between the timer coil and ground.
:f the pressure is too low, it closes and energizes the timer. /he 1ube
light on the side of the machine will also be on.
Dor 3'@3H #$2 @==O= on 2azatrol 2, press the BA=A2@/@= key in menu, press the
+@F/ key in menu ?D.A. /he bad =O2 causing the check sum error will be displ5
ayed in 3#!. :f the first digit from the left is !, the bad =O2 is on board
DF7<, if it is *, the bad =O2 is on DF7<5*. /he next two digits from the left
indicate the location of the bad =O2 on the board.
Dor 24I% check 3#<. :f the first digit from the left is !, the bad =O2 is
on board DF97<57, if it is *, the bad =O2 is on board DF97<5C. Again, the
next two digits from the left indicate the location of the bad =O2 on the
board.
Dor 2azatrol /I/., select the 6:A-+O#:# screen, select 3'@3H #IW 4@=#:O+,
when a check sum error has occurred where the software version is normally
displayed ?2:1A will, instead, display the location of the bad =O2 ?i.e.
&HA. #hould look like;
1A+
@:A
2:1 &H
6+3
GA#HAWA
3hicago /echnical 3enter 7<95C*5.<!
/echnical =epresentative @ric Eozaitis direct line 7<95C*5)!*
2anuals and other publications 7<95&!C5)!&9 /heresa 4anover direct line.
A3 :nverter model )*)-.;
:f Ov ?over voltageA alarm occurs, the deceleration time is probably too
short. :f a braking resistor is installed, the resistor may have opened.
:f a braking resistor is not installed, adding one may solve the over voltage
problem. /his should be wired into the %*J and %*5 terminals to bleed off the
excess current in the 63 buss. Another thing that may prove helpful is to
ad8ust the # curve to decrease the linearity of the ramp. :n some cases the
motor that the inverter is driving can overdrive the inverter on decel which
causes the Ov fault. #pecifically, on the )%4# the belts can be worn or
loose in which case there is not enough load or drag and if the velocity of
the motor is relatively great when decel is attempted the counter @2D will
exceed the limit of the 63 buss.
Also check Barameter +!. 2otor HW to be sure it is set high enough for the
size of the motor. Another thing to check for is the A3 voltage parameters.
:f the incoming A3 is ! volts 4mtr, +!!., and +!** should be !.
On some inverter models the Dault outputs?D1/ A, D1/ %A are programmable.
/hey can be made to open or close their contacts for conditions other than
inverter faults ?On #tart5up, $p to #peed, 0ero #peed, etc.A by changing
parameters. :n most cases, the associated parameters will be +!.),+!.9,and
+!.7. :f changing these values does not provide the desired results then
consult with 2iles at Gaskawa.
:f constant n!*! is set improperly, you will not be able to change constants
**5*7. On most units it is set to D, but this pattern will not work for all
applications and you will have to select another or build one yourself.
Barameters for )*)B3& installed in )%4#;
Accel &.!
6ecel &.!
4mtr !.!
4ID D
Dgain *!!
Dbias !
D1A *C.)
B:6 !
kWsav !
B=-2 n!)7
n!!* .
n!! .
n!!. !.!
n!!< *
n!!& *
n!!) !
n!!9 *
n!!7 *
n!!C *
n!*! D
n!** !.!
n!* *7!.!
n!*. !.!
n!*< )!.!
n!*& ..!
n!*) *&.!
n!*9 *.&
n!*7 *!.!
n!*C &.!
n!! &.!
n!* *!.!
n! *!.!
n!. *
n!< !
n!& !.!
n!) !.!
n!9 !.!
n!7 !.!
n!C ).!
n!.! *!!
n!.* )
n!. *C.)
n!.. *
n!.< .
n!.& !
n!.)
n!.9 <
n!.7 C
n!.C *!
n!<! !
n!<* *
n!< !
n!<. *
n!<< !
n!<& !
n!<) *!!
n!<9 !
n!<7 !
n!<C *.!!
n!&! )
n!&* !
n!& **!
n!&. !.9
n!&< )!
n!&& .!
n!&) !
n!&9 !
n!&7 !.!
n!&C !.!
n!)! *.!
n!)* *
n!) *
n!). !
n!)< &!
n!)& !.&
n!)) !.!
n!)9 *.!
n!)7 !.<.<
n!)C *9
n!9! *
n!9* *9!
n!9 *)!
n!9. !.!
n!9< !
n!9& *)!
n!9) !.*
n!99 !.!
n!97 !.!
n!9C !
n!7! 9
n!7* 7
n!7 !
n!7. !.
n!7< !
n!7& *.!!
n!7) *.!
n!79 *!.!
n!77 !.!!
n!7C !
n!C! *!!
n!C* !.!
n!C !
n!C. !
n!C< *.!
n!C& !
n!C) C<.9&
n!C9 &!
n!C7 *
n!CC *
n*!! !
n*!* !.&
n*! !.
n*!. *
n*!< *
n*!& !
n*!) !
n*!9
n*!7 *
n*!C !.!
n**! .!
n*** .!
n** !
n**. .!
n**< !
n**& &
n**) !
/he )*)B3& has a design defect in that the control card made by #aftronics
exhibits erratic behavior at frequencies between *<.& and *)!.* 'z. /his
is caused by an older version of software which contains a program error.
/he software version is 4er. *!*! and has been replaced by 4er. *!*& which
does not exhibit these symptoms. /he software is surface mounted to the
board and cannot be replaced. /he memory is not @@ so it cannot be changed
either. /he only fix is to replace the control card with a ver. *!*&. /he
only precaution is to be sure that the replacement card is for an inverter
of the same HW rating as the one being replaced. /o determine the software
version of a drive, look in $5*!. this is where the version is stored. Gou
must use the display key to scroll over to 2ontr. then use the arrow key to
scroll up to $5*! then press enter. /he version will be displayed.
/he phone number for #aftronics is 7!!5&..5!!.*. Ask for -len.
/he following is a current table for the )%4#;
'z )! 7! *!! *! *<! *)! *7!
-ear 1o
2otor 1o **.! ).& <.7 ..C ..< ..* .7
-ear 1o
2otor 'i 9.* <.. ... .C .7 .7 ..!
-ear 'i
2otor 1o **.! ).& <.7 ..C ..< .. .C
-ear 'i
2otor 'i 9.* <.. ..< .. ..< ..& <.!
#ome inverters will allow access to more constants than others. /o gain
access to more of them on the )*)B3&, change constant n!!* to a value of
)*). /his should allow you to access up to constant n*<!. /he newest
versions of software for the )*) as of **IC9 is !*! and .!*!.
Barameter Access of )*)B3;
When;
n!!!>!! 3onstants *5*C can be read but not written
n!!!>!* 3onstants *5*C can be read and written
n!!!>! 3onstants *5C can be read and written
n!!!>!. constants *5&C can be read and written
@#.!!! @62;
/he @#.!!! with a 'eidenhain control, as with most 'eidenhain controlled @62s
uses the following procedure for operation. After power5up;
*.Bress 3@.
.Bress the #ine Wave ?#ymbolA button to turn on generator power.
..'ome all axes by pressing #tart once for each axis.
<.Bress the B-2 =$+ button. ?/his is usually a symbol pointing to the rightA
&.Bress -O/O.
).Bress !.
9.Bress @+/.
7.Bress #/A=/.
/his will take you to the beginning of the program and begin the discharge.
On the @#.!!! there are four contactors which select the polarity. /wo of
these select positive polarity and the other two select negative polarity.
One of the polarities must be selected which means any time you are trying to
burn two of these contactors must be pulled in. :f not the generator power
will shut off when discharge is attempted. /he green 1@6 on the 63C.<. board
comes on when the polarity is selected. /here are six contactors at the
bottom of the electrical cabinet. /he four on the left are the polarity
contactors. When the first and third from the left are pulled in, =everse
polarity is selected. When the second and fourth are selected, +ormal
polarity is selected. /he fifth contactor is the 6ielectric Bump, the sixth
is -enerator Bower.
:f the machine will not release from the @5#/OB condition and the button is
not depressed, check for an axis over travel. /he axis limits are tied between
F* pin .< and F Bin <. Gou can eliminate a machine problem by removing
these connectors and connecting a 8umper between the two pins. /hese
connectors go to the :nterface %oard /+3.!) on connector 3+). F* Bin .<
goes to the *<th pin from the top on the front row of pins on 3+).
F Bin < goes to the *th from the top on the same row. /he @5#top button is
tied to pins * and of 3+* on the /+3.!).
/he /+3.!) control is for use on @62 machines. /he /+3.)! is for mills.
:f the %$DD@= %A//@=G alarm is issued, you need to replace the three AA
batteries. /hey are located in a black plastic tube in the gold colored
chassis. On the @#.!!! this chassis is behind the Operator,s Banel.
'eidenhain recommends 6uracell batteries because of the physical style.
:f you have trouble with an @62 machine that it won,t move down when dis5
charging. /he generator comes on but the ram does not move. 2ake sure it is
off of the travel limit switch. :f it is off of the switch, try replacing
one or both of the small B3% boards ?O#3A.
On the )%4# machines that : interfaced with the #W: A-@. controls, : removed
all of the power leads going to the two motor contactors ?DW6I=@4A. : did not
mess with the auxiliary contacts. : used one normally open contact from each
contactor and tied them in parallel so that any time either one is pulled in
the spindle inverter is enabled. When the control stops the spindle for a
tool change, etc., the contactors drop out disabling the inverter. : also
removed the motor leads from the overload relay. One of the two wires from
the normally open contacts is tied to my forward and reverse contactors in
the electrical cabinet to their common terminal. /he other wire is tied to
L* in the cabinet, feeding the common.
+ormally when powering up the @#5.!!! with the 'eidenhain /+3.!)@ and start5
ing to run, the sequence is;
*./urn the breaker on.
./he first screen is BOW@= :+/@==$B/@6.
..Bress the 3@ button.
<.+ext screen is =@1AG @F/. 63 4O1/A-@ 2:##:+-.
&.Bress the #ine Wave button on the =emote Operator twice.
Gou should hear the contactors energize. Gou should wait a second or two
after the first push before pushing again. :f not you may get the @mergency
#top message.
).+ext screen is /=A4@=#@ =@D@=@+3@ BO:+/#
05AF:#
G5AF:#
F5AF:#
5555555555555555555555555555555555555555
A3/1. F nn,nnnn G nn,nnnn
0 nn,nnnn
9.Bress the #/A=/ button on the =emote Operator.
/he 0 axis will reference.
Bress it again.
/he G axis will reference.
Bress it again.
/he 0 axis will reference.
/here are no reference switches, the axes 8ust move a pre5determined dist5
ance in a pre5determined direction. While each axes is moving, there will
be an asterisk displayed below A3/1. /his indicates that the axes is not
in position which is, of course, normal while moving. :f after an axis
stops, the asterisk does not turn off the axis has excessive offset. /his
is the same as the :n5Bosition signal on other controls. :n this case you
must remove the asterisk. /his is done by either making an ad8ustment on
the servo driver or in some cases replacing it. /he older style servo
drivers only have one pot to ad8ust. /his will normally remove the offset
but you need to check the 1ag. /his pot has limited use in this so if the
1ag is excessive you usually have to replace the driver. /he newer ones
have more pots to work with. 3heck the 1ag by going to the 1ag display as
explained below. :f an axis does not stop in5position, the asterisk is on,
the control will not transition to the next screen and will not operate
properly.
7.+ext screen is 2A+$A1 :+/@=BO1A/:O+
:+/@=BO1A/:O+ DA3/O=;
F nn,nnnn
G nn,nnnn
0 nn,nnnn
At this point the machine is ready to be operated in 2anual 2ode.
/he 1ag value differs between axes and at different feed rates but generally
should not exceed about 9!!. +ormally, if the 1ag is too high, the axis will
move with a rough or 8erked motion. Also you will notice that after releasing
the Eog button, the axis continues to move an abnormally long time.
:n order to ad8ust 1ag you need to access the 1ag 6isplay screen. /his is one
of the position screens. /o do this;
*.Bress the 2O6 button ?Dor Auxiliary 2odeA.
.Bress either the $p Arrow or 6own Arrow key until BO#:/:O+ 6:#B1AG is
shown at the top of the screen.
..Bress the @+/ button until the 1ag screen is displayed.
<.Bress the @+6 button to exit the Auxiliary 2ode.
When troubleshooting an axis problem on a /+3 .!), a useful tool is the
ability to swap the allocation of the encoder inputs in the B13. /his is done
with 2achine Barameter 2B **!. On a four axis machine the parameter is norm5
ally set this way;
2B **!.! !
2B **!.* *
2B **!.
2B **!.. .
/his configuration assigns the F axis to connector F* of the Brocessor board,
the G axis to F, the 0 axis to F. and the fourth axis to F<. :f you swap
the F axis cable from port F* to F and the G axis cable from F to F*, for
example, you must change the parameter to;
2B **!.! *
2B **!.* !
2B **!.
2B **!.. .
:f the problem still exists on the F axis the culprit is probably the scale
or encoder or their cable. All of this is aimed at troubleshooting mainly
feedback of positioning problems. /he idea here is to eliminate the B13 as
the problem.
When troubleshooting an F,G or 0 axis 2@A#$=:+- #G#/@2 6@D@3/ alarm, a good
place to start is the scanning unit. Gou will almost certainly find that the
cause of this problem to be in the scale or it,s cable.
/he #ervice 2anual for the /+3 .!)I.)! is useful in working on other
'eidenhain controls because the parameter section also list parameters for
other controls such as /+3&!!, /+3.< and /+3.&&.
3onnector designation for the /+3.!) 1ogic $nit are;
Brocessor board
F* @ncoder *
F @ncoder
F. @ncoder .
F< @ncoder <
F) @ncoder #
F7 +ominal 4alue Output *,,.,<,#
FC 46$ ?%@ or %DA
F** 'and wheel '= *.!I..!
F* /ouch Brobe #ystem
% #ignal -round
B13 board
F* B13 Output
F B13 :nput
F. /+3 Operating Banel ?/@A
F< Bower #upply <4 for B13
F& 6ata :nterface 4.<I=#5.53
F) B13 :IO board ?B1 <!!A
F9 2achine Operating Banel ?2%A
Bower #upply
F.* Bower #upply <4 for 1@
'eidenhain calls the reader heads of it,s scales, scanning units. :n the case
of the 1# )!., these are optical devices. /hey can be replaced without the
cable. =emove the four screws on the front of the unit. :nside there is an
Amp connector. $nplug this connector and remove the unit from the body.
When ordering a new scanning unit, you will need the :6 number. /his number
is on the unit, it looks like;
:d.+r. <CC9& for example.
Another important number is the 21 number, this is the measuring length. /his
number is typically in millimeters ?i.e., 21*9<!mmA.
When in need of 'eidenhain parts you can call 'eidenhain at 7<95<C!5**C* or
2achine /ool /echnicians at 7!<59*<5!9!!.
/he 3om port for =#5. is F&.
Dor the @uro #ource @#5.!!! at Faloy, the control is 'eidenhain /+3 .!)@.
/he +3 #oftware is )!!.! !.-. /he B13 #oftware is &&&& *..
Dor =#5. operations;
*.Bress the 2O6 button ?+ot the one for -raphicsA
.Bress the 6own Arrow button until =#5.53 :+/@=DA3@ > is displayed ?/op of
screenA
..Bress the =ight 3ursor button until @F/ is displayed.
<.Bress the 3ursor $p or 3ursor 6own button until %A$6 =A/@ is displayed.
&./ype in the desired baud rate.
).Bress the @+/ button.
/he /ransfer Brotocol for =#5. is 63*I63..
/he cable pin out for =#5. is the same as Danuc #tandard.
/o output the 2achine Barameters;
*.Bress the 2O6 button.
.Bress the 3ursor $p or 3ursor 6own button until 3O6@ +$2%@= > is displayed.
..@nter C&*<7.
<.Bress the @+/ button. ?Activates the 2B codeA
&.Bress the @F/ button then the @+/ button. ?Brepares the +3 for data outputA
/he )%4# with the 6ynapath control has four wires to the motor aside from the
motor leads. /he two yellow wires go to terminals A2 and A3 on the D9 inver5
ter. /hese wires are for the brake, the parameter that controls this multi5
function output should be set so that it monitors the output frequency. /he
two blue wires go to the motor fan. /he parameter for this multi5function
output should be set to close when the motor is running.
:n order for the brake to work properly on this machine, the parameter %*5!.
must be set to * so that the motor will coast to a stop. :f you try to decel
the motor and use the brake, at higher =B2 the brake will come on while the
motor is still decelerating, cut off, then the motor will start running
again until brought to a stop under normal decel. :f you try to reduce the
decel time enough for the brake to come on at the end of the decel curve, the
drive will fault due to 63 buss over voltage.
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