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    March 2003 Table of ContentsiFadalMaintenanceManualTable of ContentsTable of Contents ........................................................................................................ iactionGoToR:Specifications .................................................................................

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    ii Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:Pre-Installation Procedures actionGoToR:.......................................................................................45actionGoToR:Foundation ...................................................................................

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    March 2003 Table of ContentsiiiFadalMaintenanceManualactionGoToR:Fluids .............................................................................................. actionGoToR:85actionGoToR:Auger .............................................................................................. act...

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    iv Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:ATC Motor Replacement actionGoToR:Procedure ................................................................ actionGoToR:126actionGoToR:Replacing the Turret Motor on a Geneva actionGoToR:Wheel ATC actionGoToR:..........................

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    March 2003 Table of ContentsvFadalMaintenanceManualactionGoToR:Axis Drive Systems ..................................................................................................... actionGoToR:185actionGoToR:Axis Drive Systems actionGoToR:.........................................................

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    vi Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:Waylube Pump actionGoToR:.................................................................................. actionGoToR:214actionGoToR:Cool Power – Ballscrew actionGoToR:/ Spindle CoactionGoToR:oling System ..........................

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    March 2003 Table of ContentsviiFadalMaintenanceManualactionGoToR:Slot 10 ............................................................................................. actionGoToR:250actionGoToR:Slot 11 ............................................................................................. a...

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    viii Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:Yaskawa Drive 515 actionGoToR:(INV-0072) ............................................................ actionGoToR:282actionGoToR:Set up Instruction, Initializing and balancing actionGoToR:the drivesactionGoToR: .......................

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    March 2003 Table of ContentsixFadalMaintenanceManualactionGoToR:DRB-0024 Sticking Tools Kit, 10K LDB ................................................. actionGoToR:312actionGoToR:DRB-0025 Sticking Tools Kit, 10K LDB-CT= actionGoToR:.......................................... actionGoToR:312actionGo...

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    x Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:Dynamic Tool Load actionGoToR:CompensationactionGoToR: ................................................................. actionGoToR:344actionGoToR:Servo Coolant Assembly actionGoToR:.....................................................

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    March 2003 Table of ContentsxiFadalMaintenanceManualactionGoToR:FADAL RT-275 .................................................................................. actionGoToR:374actionGoToR:Tilting Rotary Tables, 4th actionGoToR:& 5th Axis ................actionGoToR:...............................

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    xii Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:Pre-Startup Safety InspectionactionGoToR: .............................................................. actionGoToR:468actionGoToR:Stopping the Chip Conveyor on actionGoToR:USactionGoToR: and CE MachinesactionGoToR: ..................

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    March 2003 Table of ContentsxiiiFadalMaintenanceManualactionGoToR:VMC Maintenance actionGoToR:........................................................................................ actionGoToR:490actionGoToR:Cabinet Fans actionGoToR:................................................................

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    xiv Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:TA,2 Programs actionGoToR:.............................................................................................actionGoToR: 593actionGoToR:O5801-45 Deg Test actionGoToR:.........................................................

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    March 2003 Table of ContentsxvFadalMaintenanceManualactionGoToR:TA,5 Programs actionGoToR:............................................................................................ actionGoToR:630actionGoToR:O5827-Cycle Test actionGoToR:...........................................................

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    xvi Table of ContentsMarch 2003FadalMaintenanceManualactionGoToR:SCREW ............................................................................................. actionGoToR:655actionGoToR:IPM .................................................................................................. ac...

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    March 2003Section 01: Specifications1FadalMaintenance ManualSection 01: SpecificationsIllustrations & Data for All VMC Models

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    2Section 01: SpecificationsMarch 2003FadalMaintenance Manual(This page intentionally left blank).

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    March 2003Section 01: Specifications3FadalMaintenance ManualVMC TRMFigure 1-1 VMC TRMTOP VIEWBASESIDE VIEWFRONT VIEWTOP VIEWNote: Dimensions represented in inches & [centimeters]

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    4Section 01: SpecificationsMarch 2003FadalMaintenance ManualTable 1: VMC TRM SpecificationsTRM SpecificationsTRM StandardTRM MetricTable Size35" x 12"889mm x 304.8mmFloor to Table34.5"876.3mmT-Slots (No. x Width x Span)3 x .562" x 4.375"3 x 14.3mm x 111mmCutting Feed Rate...

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    March 2003Section 01: Specifications5FadalMaintenance ManualVMC EMCFigure 1-2 VMC EMCSIDE VIEWFRONT VIEWTOP VIEWBASESCALE 2:1Note: Dimensions represented in inches & [centimeters]

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    6Section 01: SpecificationsMarch 2003FadalMaintenance ManualTable 2: VMC EMC SpecificationsEMC SpecificationsEMC StandardEMC MetricTable Size29.5" x 16"749mm x 406mm Floor to Table33.25"845mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14mm x 110mmCutting Feed Rate.01...

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    March 2003Section 01: Specifications7FadalMaintenance ManualVMC 15/15XTFigure 1-3 VMC 15, 15XT SIDE VIEWFRONT VIEWTOP VIEWTOP VIEWBASESCALE 2:1Note: Dimensions represented in inches & [centimeters]

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    8Section 01: SpecificationsMarch 2003FadalMaintenance ManualTable 1: VMC 15 Specifications15 Specifications15 Standard15 MetricTable Size29.5" x 16"749mm x 406mm Floor to Table30.5"775mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14mm x 110mmCutting Feed Rate.01-250&...

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    March 2003Section 01: Specifications9FadalMaintenance ManualTable 2: VMC 15XT Specifications15XT Specifications15XT Standard15XT MetricTable Size38" x 16 "965mm x 406mmFloor to Table30.5"775mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14mm x 110mmCutting Feed Rate.0...

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    10Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 2216Figure 1-4 VMC 2216 SIDE VIEWFRONT VIEWTOP VIEWBASE SCALE 2:1TOP VIEWNote: Dimensions represented in inches & [centimeters]

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    March 2003Section 01: Specifications11FadalMaintenance Manual* Rated Peak ValueTable 2: VMC 2216 Specifications2216 Specifications2216 Standard2216 MetricTable Size39" x 16"750mm x 406mmFloor to Table31"787mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14mm x 110mmCut...

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    12Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 3016Figure 1-5 VMC 3016SIDE VIEWTOP VIEWBASESCALE 2:1FRONT VIEWTOP VIEWNote: Dimensions represented in inches & [centimeters]

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    March 2003Section 01: Specifications13FadalMaintenance Manual* Rated Peak ValueTable 3: VMC 3016 Specifications3016 Specifications3016 Standard3016 MetricTable Size39" x 16"750mm x 406mmFloor to Table31"787mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14mm x 110mmCut...

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    14Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 2016LFigure 1-6 VMC 2016SIDE VIEWFRONT VIEWTOP VIEWBASESCALE 2:1TOP VIEWNote: Dimensions represented in inches & [centimeters]

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    March 2003Section 01: Specifications15FadalMaintenance Manual* Rated Peak ValueTable 4: VMC 2016L Specifications2016L Specifications2016L Standard2016L MetricTable Size29.5" x 16"750mm x 406mmFloor to Table30.5"775mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14mm x ...

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    16Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 3016LFigure 1-7 VMC 3016LSIDE VIEWTOP VIEWBASESCALE 2:1FRONT VIEWTOP VIEWNote: Dimensions represented in inches & [centimeters]

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    March 2003Section 01: Specifications17FadalMaintenance Manual* Rated Peak ValueTable 5: VMC 3016L Specifications3016L Specifications3016L Standard3016L MetricTable Size38" x 16"750mm x 406mmFloor to Table30.5"775mmT-Slots (No. x Width x Span)3 x .562" x 4.33"3 x 14mm x 11...

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    18Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 4020Figure 1-8 VMC 4020Optional Very High Torque Motor 30 Peak Horsepower, 32 Amps continuouscurrent in WYE mode, 56 Amps continuous current in DELTA mode, Peakcurrent may run as high as 70 AmpsNote: Dimensions represented in inches...

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    March 2003Section 01: Specifications19FadalMaintenance Manual* Rated Peak ValueTable 6: VMC 4020 Specifications4020 Specifications4020 Standard4020 MetricTable Size48" x 20"1,219mm x 508mmFloor to Table32"813mmT-Slots (No. x Width x Span)5 x .687" x 3.75"5 x 17.5mm x 95.3...

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    20Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 4020AFigure 1-9 VMC 4020ANote: Dimensions represented in inches & [centimeters]SIDE VIEWFRONT VIEWTOP VIEWBASESCALE 2:1TOP VIEW

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    March 2003Section 01: Specifications21FadalMaintenance Manual* Rated Peak ValueTable 7: VMC 4020A Specifications4020A Specifications4020A Standard4020A MetricTable Size48" x 20"1,219mm x 508mmFloor to Table35"889mmT-Slots (No. x Width x Span)5 x .687" x 3.75"5 x 17.45mm x...

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    22Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 5020AFigure 1-10 VMC 5020ANote: Dimensions represented in inches & [centimeters]SIDE VIEWTOP VIEWBASESCALE 2:1TOP VIEWFRONT VIEW

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    March 2003Section 01: Specifications23FadalMaintenance Manual* Rated Peak ValueTable 8: VMC 5020A Specifications5020A Specifications5020A Standard5020A MetricTable Size58" x 20"1,473mm x 508mmFloor to Table31"787mmT-Slots (No. x Width x Span)3 x .687" x 3.75"3 x 17.45mm x...

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    24Section 01: SpecificationsMarch 2003FadalMaintenance ManualVMC 6030Figure 1-11 VMC 6030Note: Dimensions represented in inches & [centimeters]Optional Very High Torque Motor 30 Peak Horsepower, 32 Amps continuouscurrent in WYE mode, 56 Amps continuous current in DELTA mode, Peakcurrent may r...

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    March 2003Section 01: Specifications25FadalMaintenance Manual

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    26Section 01: SpecificationsMarch 2003FadalMaintenance Manual* Rated Peak ValueTable 9: VMC 6030 Specifications6030 Specifications6030 Standard6030 MetricTable Size62.5 x 30"1,588mm x 762mmFloor to Table36"914mmT-Slots (No. x Width x Span)5 x .687" x 5.5"5 x 17.5mm x 139.7mmCu...

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    March 2003Section 01: Specifications27FadalMaintenance ManualVMC 8030Figure 1-12 VMC 8030Note: Dimensions represented in inches & [centimeters]Optional Very High Torque Motor 30 Peak Horsepower, 32 Amps continuouscurrent in WYE mode, 56 Amps continuous current in DELTA mode, Peakcurrent may r...

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    28Section 01: SpecificationsMarch 2003FadalMaintenance Manual* Rated Peak ValueTable 10: VMC 8030 Specifications8030 Specifications8030 Standard8030 MetricTable Size82.5" x 30"2,096mm x 762mmFloor to Table36"914mmT-Slots (No. x Width x Span)5 x .687" x 5.5"5 x 17.5mm x 13...

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    March 2003Section 01: Specifications29FadalMaintenance ManualVMC 3020Figure 1-13 VMC 3020Note: Dimensions represented in inches & [centimeters]Optional Very High Torque Motor 30 Peak Horsepower, 32 Amps continuouscurrent in WYE mode, 56 Amps continuous current in DELTA mode, Peakcurrent may r...

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    30Section 01: SpecificationsMarch 2003FadalMaintenance Manual* Rated Peak ValueTable 11: VMC 3020 Specifications3020 Specifications3020 Standard3020 MetricTable Size40.5" x 20"1,029mm x 508mmFloor to Table31"787mmT-Slots (No. x Width x Span)5 x .709" x 3.75"5 x 18mm x 95....

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    March 2003Section 01: Specifications31FadalMaintenance ManualVMC 4525Figure 1-14 VMC 4525Note: Dimensions represented in inches & [centimeters]SIDE VIEWFRONT VIEWTOP VIEWBASESCALE 2:1 Use to lift with

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    32Section 01: SpecificationsMarch 2003FadalMaintenance Manual* Rated Peak ValueTable 12: VMC 4525 Specifications4525 Specifications4525 Standard4525 MetricTable Size53.5" x 25"1,359mm x 635mmFloor to Table31"787mmT-Slots (No. x Width x Span)5 x .709" x 4.92"5 x 18mm x 125...

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    March 2003Section 01: Specifications33FadalMaintenance ManualVMC 6535FRONT VIEWTOP VIEWSIDE VIEWTOP VIEW BASESCALE 2:1Figure 1-15 VMC 6535Note: Dimensions represented in inches & [centimeters]

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    34Section 01: SpecificationsMarch 2003FadalMaintenance ManualTable 13: VMC 6535 Specifications6535 Specifications6535 Standard6535 MetricTable Size74.8" x 26.5"1,899mm x 673.1mmFloor to Table40.3"1024mmT-Slots (No. x Width x Span)5 x .709" x 4.92"5 x 18mm x 125mmCutting F...

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    March 2003Section 01: Specifications35FadalMaintenance ManualFadal Bolt Torque SpecificationsTable 14: Fadal Bolt Torque SpecificationsCOLUMNALLCOLUMN TO BASE5/8"-11 X X.50 HHB175FT-LBSCOLUMNALLCOUPLER SET SCREW1/4"-20 X 0.50 SHSS 70IN-LBSCOLUMNALLZ B/S MOUNT IN BACK3/8"-16 X X.XX ...

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    36Section 01: SpecificationsMarch 2003FadalMaintenance ManualTable & T-Slot DimensionsTRM TableFigure 1-16 TRM TableA = 12.00” (304.8mm) B = 35.00” (889mm) C = 35.72” (907.29)D = 1.625” (41.28mm) E = 4.375” (111mm)BDEEAC

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    March 2003Section 01: Specifications37FadalMaintenance ManualEMC, 15 & 2016LTableFigure 1-17 EMC, 15 & 2016L TableA = 16.00" (406.4mm)B = 26.00" (660.4 mm)C = 29.50" (749.3mm) D = 3.67" (93.22mm)E = 4.33" (109.98mm)2216 & 3016 TableFigure 1-18 2216 & 3016 ...

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    38Section 01: SpecificationsMarch 2003FadalMaintenance ManualEMC, 15XT & 3016LTableFigure 1-19 EMC, 15XT & 3016L TableA = 16.00" (406.4mm)B = 34.50" (876.3mm)C = 39.00" (990.6mm)D = 3.67" (93.22mm)E = 4.33" (109.98mm)EMC, 15, 15XT,2216, 3016, 2016L& 3016L T-Sl...

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    March 2003Section 01: Specifications39FadalMaintenance Manual3020, 4525 Table &T-SlotsFigure 1-21 3020, 4525 Table & SlotsA = 20.0" (508mm) B = 40.50" (1028.7mm) C = 36.00" (990.6mm)D = 2.885" (73.28mm)E = 3.750" (95.25mm) F = 2.145" (54.483mm)4020 TableFig...

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    40Section 01: SpecificationsMarch 2003FadalMaintenance Manual4020A & 5020ATableFigure 1-23 4020A & 5020A TableA = 20.00" (508mm)B = 58.00" (1473.2mm) C = 52.00" (1320.8mm)D = 2.50" (73.28mm)E = 3.75" (95.25mm)6030 TableFigure 1-24 6030 TableA = 30.00" (762mm)...

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    March 2003Section 01: Specifications41FadalMaintenance Manual8030 Table Figure 1-25 8030 TableA = 30.00" (762mm)B = 83.50" (2120.9mm) C = 78.00" (1981.2mm)D = 4.00" (101.6mm)E = 5.50" (139.7mm)6535 TableFigure 1-26 6535 TableA = 35.00" (889mm)B = 74.76" (1899mm)...

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    42Section 01: SpecificationsMarch 2003FadalMaintenance ManualTRM T-SlotsFigure 1-27 TRM T-SlotsMetric T-Slots:E = 14.28-14.33mmF = 24.6mmG = 15.9mmH = 10mm J = 25.9mmMETRICEFGHJ

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    March 2003Section 01: Specifications43FadalMaintenance Manual4020, 4020A,5020A, 6030 & 8030T-SlotsFigure 1-28 4020, 4020A, 5020A, 6030 & 8030 T-SlotsStandard T-Slots:A = .6875-.6895" (17.46-17.51mm) B = 1.250" (31.75mm)C = .70" (17.78mm) D = .485" (12.32mm)Metric T-Slo...

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    44Section 01: SpecificationsMarch 2003FadalMaintenance ManualRecommended Mainline Fuses / Circuit BreakersNote: VHT runs only on 220-240V. External transformer required for any othervoltage.Table 15: Recommended FusesSpindleType208 V3 Phase240 V3 Phase380-415 V3 Phase480 V3 Phase240 VSingle Phas...

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    March 2003Section 02: Pre-Installation Procedures45FadalMaintenance ManualSection 02: Pre-Installation ProceduresFoundationWARNINGThe VMC MUST be placed on a surface that will support the combinedweight of the VMC, options, fixtures, and tooling, etc. (refer to the VMCSpecifications section at th...

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    46Section 02: Pre-Installation ProceduresMarch 2003FadalMaintenance Manual4) Bolt the VMC directly to the pad through the .953” diameter holes that areprovided in the base casting. The dimensions for the base mounting holesof all machines are in the VMC Specifications section. Anchors are to be...

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    March 2003Section 02: Pre-Installation Procedures47FadalMaintenance ManualShipping DimensionsTable 2: VMC Shipping DimensionsVMCLENGTHWIDTHHEIGHTWEIGHTZ MTR DWN803017ft 8in8ft 8in10ft 2in19,000lbs8ft 8in653514ft 9in8ft 10in11ft 3in30,000lbs11ft 3in603013ft 2in8ft 8in10ft 2in17,000lbs8ft 8in5020A9...

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    48Section 02: Pre-Installation ProceduresMarch 2003FadalMaintenance ManualNote: VMC-TRM/15/15XT/2016L/3016L/6535 and 8030 do not get crated.They are placed on pallets and vacuum sealed.Positioning1) Place the VMC so that skylights or air vents are NOT directly overhead. Donot expose the machine t...

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    March 2003Section 02: Pre-Installation Procedures49FadalMaintenance Manual2) Ensure there is adequate room behind the VMC to fully open the rearcabinet door. Minimum clearance behind the machine is two feet (24”/60.96 cm.) (See Figure 2-3).Figure 2-3 24” Minimum Clearance Behind VMC3) Ensure ...

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    50Section 02: Pre-Installation ProceduresMarch 2003FadalMaintenance Manual1) From the main air supply line attach a 3/8” air supply line for the VMC. Thedistance from the air compressor and number of machines attached shouldbe taken into consideration when determining the size of piping for the...

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    March 2003Section 02: Pre-Installation Procedures51FadalMaintenance ManualPrimary Grounding(refer to NEC 1990 ARTICLE 250 SECTION 81)1) The grounding conductor shall be of copper. The material selected shall beresistant to any corrosive condition existing at the installation or shall besuitably p...

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    52Section 02: Pre-Installation ProceduresMarch 2003FadalMaintenance Manual3) A No. 6 (16 mm2) or larger grounding conductor shall be run in one of thefollowing:• rigid metal conduit• intermediate metal conduit• electrical metallic tubing or cable armor4) One end of the supplemental groundin...

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    March 2003Section 02: Pre-Installation Procedures53FadalMaintenance Manual3) MUST be dedicated to a single VMC. (The ground and phase conductorscannot be shared with any other equipment.)4) Ground rods and other supplemental grounding may be used in addition tothe ground specified above but not i...

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    54Section 02: Pre-Installation ProceduresMarch 2003FadalMaintenance ManualElectrical ServiceIMPORTANTElectrical installation of machine must be done by a qualified electrician.1) The total connected load should not exceed 75% of the panel rating,allowing for the VMC load. Refer to the Electrical ...

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    March 2003Section 02: Pre-Installation Procedures55FadalMaintenance ManualConduit(refer to NEC 2002 ARTICLE 300-17 and Annex C TABLE C1)1) The number and size of conductors in any raceway shall not be more thanwill permit dissipation of the heat.2) The conduit must allow ready installation or wit...

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    56Section 02: Pre-Installation ProceduresMarch 2003FadalMaintenance ManualThis page intentionally left blank.

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    March 2003Section 03: Installation Procedures57FadalMaintenance ManualSection 03: Installation ProceduresMachine Installation & Hook-UpIMPORTANTBefore beginning the Machine Installation & Hook-Up it is important toreview the entire Pre-Installation section.UnpackingTools Required Hammer, ...

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    58Section 03: Installation ProceduresMarch 2003FadalMaintenance Manual2) Release the screw.3) Turn to override door lock.Moving the VMC:Fork Lift(See Figure 3-2).Tools Required5/32” hex bit socket or Allen wrench.IMPORTANTThe head and the counterweight must be secured before lifting the VMC.Sin...

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    March 2003Section 03: Installation Procedures59FadalMaintenance ManualIMPORTANTFor the 6535 use a forklift with a 30,000 plus lifting capacity Moving the VMC:Crane(See Figure 3-2).Tools Required1/4” and 9/16” hex bit socket or Allen wrench.IMPORTANTThe head and the counterweight MUST be secur...

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    60Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualFigure 3-1 Slant Sheetmetal DetailsPlacing the VMC1) Place the leveling pads (countersink side up) under the leveling bolts. Besure leveling bolts go into countersink on leveling pads.Note: Use leveling pad (SHP-0002) (PLC-0063...

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    March 2003Section 03: Installation Procedures61FadalMaintenance Manual3) At this point the VMC is ready for power and air connections.Figure 3-2 Moving the VMCMAXIMUM FORK WIDTH IS 6.00"1" EYE BOLT2 PLACESHOLE PROVIDED FOR 1-1/4" BARMINIMUM BAR LENGTH 36"1.5” EYE BOLT 2 PLAC...

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    62Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualAir SupplyIMPORTANTAIR PRESSURE REQUIRED: 120 psi before regulator, 80 psi after regulator,15 scfm (standard cubic feet per minute) momentary.1) Connect the 3/8” air hose to the VMC. 2) Check the pressure gauge for 120 psi an...

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    March 2003Section 03: Installation Procedures63FadalMaintenance ManualVerify the MOV Surge Suppressor Board 1) Locate the MOV Surge Suppressor Board (see figure 3-4).Figure 3-4 MOV Surge Suppressor Board 2) Find the part number on the board.a. If your incoming voltage is under 250 VAC, then an 11...

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    64Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualFigure 3-5 Figure 3-6

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    March 2003Section 03: Installation Procedures65FadalMaintenance ManualFigure 3-7 Figure 3-8

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    66Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualFigure 3-9 Figure 3-10

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    March 2003Section 03: Installation Procedures67FadalMaintenance ManualFigure 3-11 Figure 3-12

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    68Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualFigure 3-13 Figure 3-14

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    March 2003Section 03: Installation Procedures69FadalMaintenance ManualFigure 3-15 Figure 3-16

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    70Section 03: Installation ProceduresMarch 2003FadalMaintenance Manual3) Subtract step (A3.2.6-7) from step (A3.2.6-2).EXAMPLE:measure voltage=240 L1-L2245 L1-L3242 L2-L3voltage setting=240 A240 B240 Cdifference=052a. If the difference is less then 10, continue.b. If the difference is greater tha...

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    March 2003Section 03: Installation Procedures71FadalMaintenance Manual4) Each phase has a group of terminals such as A3 to A8 for phase 1 and B3to B8 for phase 2. Place a jumper between the two terminals listed on thechart for each phase. Using the same example place jumper from A3 to A6for phase...

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    72Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualPhase Converter RotaryThe Normal Fadal VMC requires three phase-input power. The machines arealso configured in a single-phase power configuration when requested. Somecustomers prefer to use rotary phase converters, however Fad...

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    March 2003Section 03: Installation Procedures73FadalMaintenance ManualLevelingLeveling is an important first step in setting up the VMC. All calibration andsquareness performed on the assembly line is done with the machine leveled.It is important to follow the sequence below precisely to ensure p...

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    74Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualFigure 3-18 Leveling Box Way (6535 on right). 4) Now put the level on the left hand way (the outer left hand way on the6535) of the base with the level pointing in the same direction as on theright hand way.5) Adjust the leveli...

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    March 2003Section 03: Installation Procedures75FadalMaintenance Manual2) Drive down the four corner leveling screws to create a minimum of 1/2” gapbetween the bottom of the base and the top of the leveling pads.Figure 3-19 Drive Down Corner Leveling ScrewsNote: Verify that the leveling pads are...

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    76Section 03: Installation ProceduresMarch 2003FadalMaintenance Manual5) Place the level on the leveling tabs.500” away from the linear guide way.Situate the level so that the small level gauge is towards the column. Allleveling measurements will be taken with the level in this orientation.Figu...

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    March 2003Section 03: Installation Procedures77FadalMaintenance ManualFigure 3-22 Ways Have Same Reading When Leveled10) After the base leveling is completed, seat the two middle leveling screws onthe leveling pads.Figure 3-23 Left: Seat Middle Leveling Screws on Leveling Pads. Right: Hold Down C...

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    78Section 03: Installation ProceduresMarch 2003FadalMaintenance ManualHold Down ClampsLarger machines may vibrate, bump on reversals, and degrade floor finish.This may indicate that the base casting needs to be clamped to floor.Larger machines need to be clamped to the floor to prevent movementbe...

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    March 2003Section 04: Machine Maintenance79FadalMaintenance ManualSection 04: Machine MaintenanceScheduled MaintenanceMaintenance &LubricationScheduleDaily1) Check air pressure: Right regulator 120 PSI. max. (Tool Out Only). LeftRegulator 80-90 PSI.2) Check way lube level. Use Castrol Magna B...

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    80Section 04: Machine MaintenanceMarch 2003FadalMaintenance Manual5) Drain and clean water separator.6) Fill oiler if needed. (Not applicable to TRM)7) Activate Thru-Tool coolant system for 2-3 minutes (if machine has thisoption). (Not applicable to TRM)8) Lubricate Y axis telescoping ball screw ...

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    March 2003Section 04: Machine Maintenance81FadalMaintenance Manual2) Insert the hose of the grease gun (TLC-0285) onto the ZERK fitting.3) Pump MOBIL SHC #32 grease (CHM-0083) into each linear way truck.Pump until grease begins to come out of the linear way truck.4) Remove the grease gun.Lubricat...

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    82Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualWARNINGVerify that the air regulator is closed.6) Insert the 3/8" hose from the flush pump into a container of grade Akerosene.7) Slowly open the air regulator clockwise to start the flush pump.8) Increase the air pressure bei...

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    March 2003Section 04: Machine Maintenance83FadalMaintenance ManualIf the fan is turning slowly or not at all it may require cleaning or replacement.The fan on the bottom of the junction box has a screen that requires periodicinspection and removal for cleaning.Spindle & BallscrewCooling Syste...

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    84Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualDowfrost to a 50:50 solution, with deionized water, or sodium free distilledwater and fill to no more than 3/4 full.Figure 4-2 Tank ReservoirSource for Dowfrost:GOLDENWEST LUBRICANTS1816 POTRERO AVE.SOUTH EL MONTE, CA 91733(626) 44...

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    March 2003Section 04: Machine Maintenance85FadalMaintenance ManualFuses, Heaters, & RelaysSEE SECTION 18: Fuses, Heaters, ParametersFluidsAugerCleaning and Freeing Chips from the Auger Chip Removal SystemPrior to cleaning or removing jammed material from the Auger or its exit tube. 1) Shut do...

  • Page 102

    86Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualWARNINGDo not remove material while the machine is operating or in the EmergencyStop mode.Chip Removal from the Machine InteriorRemove the side panels, open front doors, and remove the material from theAuger. Wear heavy leather glo...

  • Page 103

    March 2003Section 04: Machine Maintenance87FadalMaintenance Manual2) Remove 6 hex bolts and washers from auger exit tube connection to thesheetmetal housing.Figure 4-5 Remove Hex Bolts and Washers from Auger Exit Tube3) Wear heavy leather gloves and use a tool such as pliers when removingjammed m...

  • Page 104

    88Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualInspectionCheck the parts of the tool falling mechanism regularly and, check for greaseon the sliding base of the tool falling mechanism and the sliding base of thepull rod. Check the parts of the tool pots and tool discs for tight...

  • Page 105

    March 2003Section 04: Machine Maintenance89FadalMaintenance ManualCalibration of VMCs using the Renishaw laser ScopeThis qualification procedure applies to all Fadal VMCs calibrated using theRenishaw Laser and software.ReferenceDocumentationRenishaw Laser Measurement System – Current Version ...

  • Page 106

    90Section 04: Machine MaintenanceMarch 2003FadalMaintenance Manuallaser methods if required. It may be used for re-calibration of a machine afterservice or re-build. It may also be used for re-calibration of a machine afterservice or re-buildThe procedure is written for a technician that has had ...

  • Page 107

    March 2003Section 04: Machine Maintenance91FadalMaintenance ManualCalibrationRequirements andLimitsVMCs over compensated via software...this is not considered calibrated. Thelimits for proper calibration are (100%pas).Maximum Target to Target Compensation < 0.0003”Maximum Range of Compensati...

  • Page 108

    92Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualNote: The laser will require 15 minutes to warm up.• Plug the RS232 cable into the RS232 serial port on the back of the sidewiring cabinet of the VMC.• Plug the laser cable into the small port on the back of the laser unit.

  • Page 109

    March 2003Section 04: Machine Maintenance93FadalMaintenance Manual• Install beam splitter into spindle. There are two arrows on the beamsplitter for calibrating the X–axis, the arrows should be pointing downthe X-axis and away from the column. The mirror “must be attached” tothe front of ...

  • Page 110

    94Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualDownload SurveyFor Fadal Control use the following survey downloading procedure:§ Run Survey Download off computer desktop [REN2FAD.EXE]§ On Fadal Control and at Enter Next Command, type CD,6 § Follow pro...

  • Page 111

    March 2003Section 04: Machine Maintenance95FadalMaintenance Manual AnalyzeSurveys – (Error Comp Table)Absolute ValueProduce Error Comp TableGraph – (Renishaw Analysis)Copies of survey and calibration placed in machine (electrical cabinet pocket)and document book or jacket. Exit Application

  • Page 112

    96Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualSample output froma laser measurementsystem.RENISHAW CALIBRATION INTERFEROMETER SYSTEMERROR COMPENSATION TABLE MACHINE VMC 3020 SERIAL No: XXXXDATE: XXXXX ...

  • Page 113

    March 2003Section 04: Machine Maintenance97FadalMaintenance ManualThis partial view of COMP_VALUES_y shows the survey values from the abovefile. Notice that there are three pointers in the brackets. Out of those three, themiddle number has the same meaning as the position No. in the file above.N5...

  • Page 114

    98Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualLaser Shut Down• When finished with entire calibration procedure for all axes Press F5and exit application, then exit to DOS.• Turn off laser and move dial one notch until target shows.• Unplug laser cable and RS232 cable.•...

  • Page 115

    March 2003Section 04: Machine Maintenance99FadalMaintenance ManualPallet Changer/Hydro Sweep™Each Part Cycle1) Make certain that HydroSweep unit is cycled before every Pallet Exchange.Use an M20 in the program to make it automatic. Frequent washing out ofchips prevents them from building up int...

  • Page 116

    100Section 04: Machine MaintenanceMarch 2003FadalMaintenance Manual3) Check Hydraulic Arm chain tension by push/pull on arm.4) Remove Head Cover, and inspect fluid lines for Hi/Lo Idler assembly,refilling, if necessary.5) Remove all tools from tool changer, and clean out any chip buildup. Whenret...

  • Page 117

    March 2003Section 04: Machine Maintenance101FadalMaintenance ManualHydroSweep™ OnlyEach Part Cycle1) Make certain that HydroSweep unit is cycled before every part change, orrun at least 20 minutes per hour run time. Use an M20 in the program tomake it automatic. Frequent washing out of chips pr...

  • Page 118

    102Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualWeekly Maintenance1) Remove Head Cover, and inspect fluid lines for Hi/Lo Idler assembly,refilling, if necessary.2) Remove all tools from tool changer, and clean out any chip buildup found.When returning tools to ATC, inspect rete...

  • Page 119

    March 2003Section 04: Machine Maintenance103FadalMaintenance ManualTests for CE Safeguards on Fadal MachinesThese tests should be done when machine is first installed and after servicingwhen any components are replaced.1) Power on machine but do not cold start. Start spindle. (Press Shift-Spindle...

  • Page 120

    104Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualDaily & Weekly Safety Tests for CE Safety CircuitsTo ensure proper functioning of safety circuits, the following tests should beperformed on a regular basis.DailyThe Door Interlock Monitor will be on the 1310-0C board if the m...

  • Page 121

    March 2003Section 04: Machine Maintenance105FadalMaintenance ManualPallet Changer (1100-3A) Daily TestNo daily test.WeeklyThe Door Interlock Monitor will be on the 1310-0C board if the machine has anauger, or on the 2000-1A board. If the machine does not have an auger and is not CE, there will be...

  • Page 122

    106Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualWeeklyDoor Interlock Monitor Weekly Test for 2000-1 B or -1 C1) Close all doors. Make sure VMC is not in emergency stop.2) Open cabinet containing Door Interlock Board (2000-1 B or -1 C) andexamine LEDs and relays on the 2000-1 B ...

  • Page 123

    March 2003Section 04: Machine Maintenance107FadalMaintenance Manual• Green "Doors Closed" LED should be off. • Yellow door LED should flash at the instants the one door is closed andwhen the other door is opened. • Spindle Enable LED and Spindle relay should go off and Spindle con...

  • Page 124

    108Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualWeekly:Front Door Lock Weekly Test for 2030-OA1) Close all doors.2) Open cabinet containing Front Door Lock Board (2030-OA) and examineLEDs and relays on the 2030-OA board. • Power LED should be on. • Green "Unlock Door&q...

  • Page 125

    March 2003Section 04: Machine Maintenance109FadalMaintenance Manual• The LED (D16) for the contactor SSR should be off.• The E-stop relay (K5) should be energized (LED on, contact indicatorshowing).• The E-stop Signal relay (K6) should be energized (LED on, contact indi-cator showing).• T...

  • Page 126

    110Section 04: Machine MaintenanceMarch 2003FadalMaintenance Manual4) Obstruct the light curtain (a towel over one of the mirrors will do this) andobserve the LEDs on the 1100-3A. • The green LEDs (D8 and D9) on the 1100-3A board will be off.• The red LED (D7) on the 1100-3A board will be on....

  • Page 127

    March 2003Section 04: Machine Maintenance111FadalMaintenance Manual• Type GOA3000 <ENTER> to display the Diagnostics Menu.• Press spacebar to get to Page 2 of the Diagnostic Menu, and select option 5 -ZERO MEMORY.• Answer "Y" (type Y) to both questions the control asks. Memo...

  • Page 128

    112Section 04: Machine MaintenanceMarch 2003FadalMaintenance ManualZero-Out MemorySettingsLast Home Position X___________ Y___________ Z____________Backlash SettingsX-axis Backlash ___________ ,___________,___________Y-axis Backlash ___________ ,___________,___________Z-axis Backlash___________A-...

  • Page 129

    March 2003Section 05: Automatic Tool Changers113FadalMaintenance ManualSection 05: Automatic Tool ChangersFadal’s EMC model comes standard with a 16 tool capacity (21 tool capacity isoptional) Geneva drive tool changer. The VMC 3020, 4525, 6535 comestandard with the Dual Arm Tool Changer. The V...

  • Page 130

    114Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualThe Turret Motor (Slide Motor) is activated when the Mill Interface PCBA (1040)pulls the line low (to Gnd), pin 16 (57), which goes though the followingconnections: 1060/J7-25 (1060/J7-24) to 1100-1/J1-25 (1100-1/J1...

  • Page 131

    March 2003Section 05: Automatic Tool Changers115FadalMaintenance ManualThe motor braking for this turret motor is provided by the gear box and the gearbox grease for the Bodine brand motors and by a wavy washer for the Bisonbrand motors. If the grease breaks down the turret will overshoot. Repack...

  • Page 132

    116Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual16) Activate the turret motor and the turret reverse (if the reverse direction isrequired) circuit(s).17) Count the turret sensor signals, with a dwell time for coasting as set by theturret factor, until the requested tool pos...

  • Page 133

    March 2003Section 05: Automatic Tool Changers117FadalMaintenance ManualATC TURRET FAILURE: The machine did not receive a signal from the ATCTurret Sensor, when the tool position change was commanded. If the turretmoved to the next position, then the sensor is not operating. This could becaused by...

  • Page 134

    118Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualWhen reverse direction is required both the reverse and motor signal have to beactivated. The turret motor reverse is activated by the Mill Interface PCBA(1040) pulls the line low on pin 5 which goes though the following conne...

  • Page 135

    March 2003Section 05: Automatic Tool Changers119FadalMaintenance ManualServo TurretController andAmplifier Boards(PCB-0108)The Servo Turret Amplifier Assembly (PCB-0108) consists of a mounting plate,Controller board 1860 and a Amplifier board 1810. The Amplifier board has an input of about 130VDC...

  • Page 136

    120Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualAdjustmentsThere are four motions that influence the automatic tool changer alignment.These motions are:• Z-axis up & down.• Spindle orientation.• Turret in & out.• Turret rotation.Z Axis Cold StartAdjustment1)...

  • Page 137

    March 2003Section 05: Automatic Tool Changers121FadalMaintenance ManualFigure 5-2 Move ATC Slide Toward Spindle5) Measure the distance from the ATC carriage to the nose of the spindle witha thickness gauge. Adjust the Z axis until the nose of the spindle is .050”[1.27mm] above the turret carria...

  • Page 138

    122Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualSpring Configuration16, 21 & 30 ToolChangersATC Turret SlideAdjustment1) Position the Z-axis to the machine zero.2) Orient the spindle using M19 from MDI mode. 3) Insert a tool holder in the spindle. 4) Manually move the s...

  • Page 139

    March 2003Section 05: Automatic Tool Changers123FadalMaintenance ManualFigure 5-5 EMC ATC Cylinder5) Give the slide a firm push toward the spindle. Retighten the 2 bolts.6) If the slide does not fully engage, loosen each of the six 3/8" hex boltsholding the tool carrier. This will allow the ...

  • Page 140

    124Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual12) Adjust the air flow. Make sure that the ATC doesn’t move too quickly or tooslowly on a tool change.13) Adjust the cushion. Make sure that during the tool change the ATC doesn’t“bang” at either end of it’s travel....

  • Page 141

    March 2003Section 05: Automatic Tool Changers125FadalMaintenance ManualATC Slide BeltReplacement &Adjustment1) Remove ATC upper cover.Figure 5-9 Remove ATC Upper Cover2) Remove tension spring.3) Loosen 4 screws holding motor.Figure 5-10 Loosen Screw that Hold Motor4) Remove belt. Install moto...

  • Page 142

    126Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual5) Install the new belt. Using a screwdriver or small pry bar, apply force tomove the motor back, then tighten the motor mount bolts.Figure 5-11 Install New BeltNote: When the belt tension is correct you should have .250” (6...

  • Page 143

    March 2003Section 05: Automatic Tool Changers127FadalMaintenance Manual9) Install Geneva gear on replacement motor at same position as on oldmotor.10) Place motor in ATC and slide it firmly toward the Head.11) Tighten motor mounting bolts.12) Connect ground wire and Molex connector. 13) Perform a...

  • Page 144

    128Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual8) Remove slide motor.9) Install replacement slide motor.10) Re-install motor mounting plate.11) Connect the Molex motor connector.12) Install belt. (see belt replacement procedure)13) Install tension spring.14) Perform alignm...

  • Page 145

    March 2003Section 05: Automatic Tool Changers129FadalMaintenance ManualThe Long and Short Lines are next to one another.• The new pulleys will also have a Third Line, which is for the Dual ArmATC.Figure 5-13 Fadal Spindle Pulleys

  • Page 146

    130Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualDual Arm Tool ChangerTool ChangerSpecificationsType of ToolCAT-40/BT-40Number of Tools24Maximum Tool DiameterAll Pockets Full100mm (4in.)Adjacent Pockets Empty180mm (7.2in.)Maximum Tool Length350mm (13.8)Tool WeightMaximum6.5k...

  • Page 147

    March 2003Section 05: Automatic Tool Changers131FadalMaintenance ManualSub-AssembliesFigure 5-14 Index MechanismNo.Part Description1Cam Base2Cylindrical Cam3Sensor Block4Proximity Switch Bracket5Motor Base6Driving Shaft7Gear8Gear Plate

  • Page 148

    132Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualFigure 5-15 Tool ArmNo.Part Description1Tool Arm2Tool Draw3Tool Holding Rod4Spring Cover5Plunger6Positioning Key7Positioning Screw8Self Lubricating Bearing9Self Lubricating Bearing10Spring Pin

  • Page 149

    March 2003Section 05: Automatic Tool Changers133FadalMaintenance ManualFigure 5-16 Tool Falling MechanismNo.Part Description1Tool Rod2Sliding Block3Sliding Block Cover Plate4Positioning Block Stand5Positioning Sliding Block (1)6Positioning Sliding Block (2)7Fixing Base of Tool Pot8Positioning Sli...

  • Page 150

    134Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualFigure 5-17 Tool TurretNo.Part Description1Tool Magazine Motor2Tool Magazine3Tool Buckets

  • Page 151

    March 2003Section 05: Automatic Tool Changers135FadalMaintenance ManualInstallation &TestingDual Arm ATC Installation and Alignment:1) Verify that all bolts are properly tightened.2) Remove the main cover surrounding the ATC arm and falling mechanism.3) Remove the oil inlet plug and fill the ...

  • Page 152

    136Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manualsmoothly. The switch is located on top and to the front of the ATC motor(the switch must be held up). See Figure 5-17, position 3.12) The ATC arm body will turn 80 degrees for the 3020, 65 degrees for the4525 and 35 degrees fo...

  • Page 153

    March 2003Section 05: Automatic Tool Changers137FadalMaintenance Manual22) If required, install the shims in groups of twos, one along the top the row ofthe ATC mount bolts and one underneath the bottom row of mount bolts.See Figure 5-18, positions 4,5, and 6. 23) With a forklift or crane still c...

  • Page 154

    138Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual30) While rotating the ATC arm, pull the motor brake switch up. This is theelectromagnetic brake that will be holding the motor back from turningsmoothly. The switch is located on top and to the front of the ATC motor(the swit...

  • Page 155

    March 2003Section 05: Automatic Tool Changers139FadalMaintenance ManualFigure 5-20 ATC Movement

  • Page 156

    140Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualFigure 5-21 Engage Gripper Key WaySoftware &Mechanical TestPerform all of the following actions at the pendant keypad. Align all of the axesto the cold start marks.1) Press the MANUAL button until ENTER NEXT COMMAND is dis...

  • Page 157

    March 2003Section 05: Automatic Tool Changers141FadalMaintenance Manual4) Type MD, and press the ENTER button. This will enter the VMC into theManual Data Input (MDI) mode.5) Type M6 T2, and press the ENTER and the START buttons.6) Verify the following:a. The proper tool number is displayed on th...

  • Page 158

    142Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualWhen installing the pulley on the spindle, use the third orientation mark toproperly line up the spindle with the tool changing arm. The third orientationmark is located approximately 100 degrees from the standard orientationm...

  • Page 159

    March 2003Section 05: Automatic Tool Changers143FadalMaintenance Manual14) Enter the Survey Table and select the ZERO OFFSET. Type the number thatwas recorded from the monitor. Press the ENTER button. Press theMANUAL button, to return to the ENTER NEXT COMMAND screen and pressthe JOG button, to e...

  • Page 160

    144Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manuala T minus (T-) command is used to pre-stage the next tool. The followingprogram is an example of the programming for this tool changer, and can beused in the Auto Mode or the Manual Data Input (MDI) Mode.Sample Program: 01M6T1...

  • Page 161

    March 2003Section 05: Automatic Tool Changers145FadalMaintenance Manual3) Pressing the “0” button will display the sensor status at the bottom of thediagnostics page. This is where the status of each sensor can be monitoredduring manual operation.Sensors Home PositionBucket UpDrawbar DownTool...

  • Page 162

    146Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual3) 3.If the Turret is mis-positioned, and the tools are NOT out of sequence,then press TURRET CW or CCW until BUCKET #1 (not TOOL #1) has beenrotated to the "Ready" position at the bottom.4) 4.Type "SETTO,1"...

  • Page 163

    March 2003Section 05: Automatic Tool Changers147FadalMaintenance Manual2) Tool Up sensor (Magnetic reed switch mounted at Bottom of Air Cylinder-normally open – “Tool Up” LED).3) Tool Down sensor (Magnetic reed switch mounted at Top of Air Cylinder-normally open -“Tool Down” LED).4) Abo...

  • Page 164

    148Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualDA-ATC Tool Change Cycle—Fadal Control1) Initiate Tool Change -- M6.2) Spindle OFF (M5). Orient Spindle (M19). Check for Orient Switch feedback.3) If feedback from Spindle Orientation Hall Effect switch, then Spindle isOrien...

  • Page 165

    March 2003Section 05: Automatic Tool Changers149FadalMaintenance Manual12) If the timer times out, and therefore the arm has not moved from the ARMHOME position, then get message #7, ATC ARM SOLENOID SENSOR/HOMESENSOR FAILURE. Halt system. Check Overload LED on 1330, Arm MotorDrive Belt, Contacto...

  • Page 166

    150Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualContactor, move Arm manually by turning top of Arm Motor shaft—checking for resistance, check for dragging brake in Arm Motor, and fusesahead of Contactor.24) Begin a new one-second timer to re-initiate “Arm Approaching Sp...

  • Page 167

    March 2003Section 05: Automatic Tool Changers151FadalMaintenance Manual35) Begin a new one-second timer to initiate “Arm Approaching ATC Home”cycle.36) As soon as the ARM STOP and ARM HOME signals are seen, stop the timer,disable 1330/K4 relay to disconnect Contactor to power OFF Arm Motor.Di...

  • Page 168

    152Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual6 Sensors - J1 and J2:• Tool Count - proximity sensor, Namur PNP, active source• Home position - proximity sensor, Namur PNP, active source• Tool Change Position - proximity sensor, Namur PNP, active source• Stopping ...

  • Page 169

    March 2003Section 05: Automatic Tool Changers153FadalMaintenance Manual• Drawbar (interlocked with E-Stop, spindle, and head position)• Tool Down (interlocked with Tool Up and E-Stop)• Tool Up (interlocked with Tool Down and E-Stop)Contactor supplying 230 V 3-phase to 1330 (interlocked with...

  • Page 170

    154Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualCurrent Sensing:There are two different values of current sensed for each motor: "overload"(current larger than allowable continuous value) and "overcurrent" (current wellbeyond allowable peak value). Overl...

  • Page 171

    March 2003Section 05: Automatic Tool Changers155FadalMaintenance Manual• SSR for Tool Up or Tool Down must be energized.• (Logic on the 1330 will disable Arm Up if Arm down is on and viceversa).For Turret Fwd or Turret Rev to be active (turret in motion):• Board must have 120V power (see ab...

  • Page 172

    156Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualScheduledMaintenanceThe maintenance schedule is based on machine usage of eight hours a day,five days a week.Daily Maintenance Perform the following daily:1) Cleaninga. Remove the chips and debris surrounding the proximity swi...

  • Page 173

    March 2003Section 05: Automatic Tool Changers157FadalMaintenance Manual50 Taper Dual Arm Tool ChangerTool ChangerSpecificationsType of ToolCAT-50/BT-50Number of Tools32Maximum Tool DiameterAll Pockets FullØ125mm (4.92in.)Adjacent Pockets EmptyØ250 (9.85in.)Maximum Tool LengthMaximum400mm (15.75...

  • Page 174

    158Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualSub-AssembliesFigure 5-22 Index MechanismNo.Part Description1Cam Base2Cylindrical Cam3Driving Spindle4Gear5Motor Base6Proximity Switch Base7Gear’s Locking Basket8Proximity Switch Block9Gear

  • Page 175

    March 2003Section 05: Automatic Tool Changers159FadalMaintenance ManualFigure 5-23 50 Taper Tool ArmNo.Part DescriptionNo.Part Description1Tool Arm Body12Counter Sunk Screw2Gripper13Female Hexagon Bolt3Tool Holding Rod14Spring(2)4Spring Cover15Spring(1)5Fixing Rod16Locking Ring6Positioning Key17H...

  • Page 176

    160Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualFigure 5-24 Tool Falling MechanismNo.Part DescriptionNo.Part Description1Tool Falling Pull Rod9Cylinder Base 2Sliding Block10Positioning Slide Block 3Sliding Block Cover Plate11Connecting Block4Positioning Block 12R-Fixing Pl...

  • Page 177

    March 2003Section 05: Automatic Tool Changers161FadalMaintenance ManualFigure 5-25 Control ElementsNo.Part Description1Tool Changing Mechanism Motor2Index Mechanism Motor3Proximity Switch 14Reed Switch 25Reed Switch 16Proximity Switch 27Proximity Switch 38Proximity Switch 49Proximity Switch 410Co...

  • Page 178

    162Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualInstallation1) Check if all the bolts and parts are affixed tightly (they might be looseduring transportation). If not; fasten them tightly.2) Check if the automatic tool changer has any interference with the column ofmachinin...

  • Page 179

    March 2003Section 05: Automatic Tool Changers163FadalMaintenance ManualInstallation Notice1) Make the necessary interlock protection programming for all the relativeconnections. The following chart is for reference.2) After the tool falling of the tool pot is completed, there must be littleprolon...

  • Page 180

    164Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualTroubleshootingSymptomPossible ReasonsSolutionTool disk is not rotating while tool selecting1. Proximity switch of toolcounting and positioning oftool disc is not sensed2. Proximity switch is out oforder3. Index mechanism moto...

  • Page 181

    March 2003Section 05: Automatic Tool Changers165FadalMaintenance ManualTool pot is shaking while tool returningor tool falling 1. Sliding base of tool falling is not lubricated enough2. Speed of cylinder is not even 1. Apply grease2. Adjust intake pressure andspeed adjusting device ofcylinderTool...

  • Page 182

    166Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualArm is not rotating after 180° toolchanging1. Inducing block of toolcatching of tool changingmechanism is not at theproper position2. Proximity switch is out oforder1. Adjust it to the properposition2. Change a new proximitys...

  • Page 183

    March 2003Section 05: Automatic Tool Changers167FadalMaintenance ManualMaintenance1) The lubricant inside the lubricant container of the tool changing mechanismshould be changed after working for 2400 hours. When the cam, rollers and the bevel gear are in use without lubricant,abnormal wear and f...

  • Page 184

    168Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual9) In the Dual Arm Tool Changer Menu, select number 4 (Move Arm Reverse)or 3 (Move Arm Forward) to bring the tool changer spindle to its homeposition. NOTE:While pressing 3 or 4, you will notice the tool changer spindle pause ...

  • Page 185

    March 2003Section 05: Automatic Tool Changers169FadalMaintenance Manual3) Snugly fasten (do not tighten!) the eight taper lock bolts at the bottom ofthe tool changer in a typical eight bolt crossing pattern.4) Lower the tool pot to the tool change position.5) Insert a tool holder into the spindle...

  • Page 186

    170Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualCAUTION!The arm of the dual arm tool changer moves suddenly and with greatforce. Make sure that while performing the following procedure you andothers are out of range of the arm. 3) In the Dual Arm Tool Changer Menu select nu...

  • Page 187

    March 2003Section 05: Automatic Tool Changers171FadalMaintenance Manual 11) Carefully slide the indicator away and Cold Start the machine.12) Slide the indicator back in, under the tool and adjust the Z axis until theindicator is Ø. Write or remember the distance traveled to reach Ø(example: -....

  • Page 188

    172Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual24) Select a flat surface on the spindle and set the indicator to Ø. (see below).25) Carefully slide the indicator out of the way.26) Type SV press ENTER.27) Select Z.28) Use the letter U or D to select [zero offset].29) Ente...

  • Page 189

    March 2003Section 05: Automatic Tool Changers173FadalMaintenance ManualPCB-0213 Dual Arm ATC Controller CardDescription andExplanation ofOperation of PCB-0213 (1330-0A)The 1330-0A is identical to the 1330-0 in terms of connections and operationwith the following exceptions: an LED indicator has b...

  • Page 190

    174Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance ManualDisables arm when doors are open. (If there is no 1310 or 2000 board, J6 pin7 must be jumpered to J6 pin 8.)Head Position Sensor - J11 (Hall sensor or magnetic reed switch) Disables armmovement (K9) if the Z-axis is not at too...

  • Page 191

    March 2003Section 05: Automatic Tool Changers175FadalMaintenance ManualCurrentsPeak current of the turret motor measures 4-6 A. Continuous current of theturret motor measures 0.8-1.2 A.Peak current of the arm motor measures at 8-13 A. Continuous current of thearm motor measures at 2-3 A. (Since t...

  • Page 192

    176Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual• Spindle must be off (Drawbar Interlock relay energized; this passes120V power to Drawbar SSR and floats Drawbar enable to AND gate).• Drawbar SSR must be energized.For Tool Up or Tool Down solenoid to be energized:• Bo...

  • Page 193

    March 2003Section 05: Automatic Tool Changers177FadalMaintenance ManualSequence of Dual Arm-ATC Operation When Used With The Fadal ControlFeedbackTool Up sensor (Magnetic reed switch mounted at Bottom of Air Cylinder-normally open – “Tool Up” LED)Tool Down sensor (Magnetic reed switch mount...

  • Page 194

    178Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual DA-ATC Tool ChangeCycle—Fadal Control1) Initiate Turret Rotate cycle Tx, where x is the Tool number to be moved toArm Ready position.2) Begin a new one second timer to initiate “Bucket UP” cycle, and verify thatthe Buck...

  • Page 195

    March 2003Section 05: Automatic Tool Changers179FadalMaintenance Manual3) Begin a new one second timer to rotate Turret.a. Enable 1330/K4 to CLOSE 3-Phase Contactor.b. Turret motor rotates and TOOL COUNT sensor mounted below TurretMotor reports that Turret is away from home position, and TOOL COU...

  • Page 196

    180Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manualb. Stop the timer as soon as the Arm moves away from its home position,and the ARM STOP and ARM HOME sensors report that Arm is away.This verifies that the ARM STOP and ARM HOME signals are workingproperly. LED’s yellow “C...

  • Page 197

    March 2003Section 05: Automatic Tool Changers181FadalMaintenance Manualb. Stop the timer as soon as the Arm moves away from its Spindle posi-tion, and the ARM STOP and ARM TOOL sensors report that Arm isaway. This verifies that the ARM STOP and ARM TOOL signals are work-ing properly. Then rotate ...

  • Page 198

    182Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manualing properly. Then rotate arm to ATC HOME position. LED’s yellow“Contactor” is lit, green “Stopping Sensor” and “Arm at Spindle” areNOT lit. Proceed to step 17.c. If the timer times out, and therefore the arm has...

  • Page 199

    March 2003Section 05: Automatic Tool Changers183FadalMaintenance ManualChanging tools on a TRMThe TRM has no automatic tool changer. Switching toolls on the TRM must bedone manually.WarningPlease take all the precautions necessary to ensure your safety and thesafety of others while switching a to...

  • Page 200

    184Section 05: Automatic Tool ChangersMarch 2003FadalMaintenance Manual50 Taper Pull Stud Specs (CAT/BT)

  • Page 201

    March 2003Section 06: Axis Drive Systems185FadalMaintenance ManualSection 06: Axis Drive SystemsAxis Drive SystemsDANGER! Hazardous voltages in this enclosure can kill. Use extreme caution when working in this area! Amplifier ChassisOperationAll of the amplifier chas...

  • Page 202

    186Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualTroubleshooting theAmplifier ChassisIf the amplifier chassis bus voltage is too low or zero, then check:1. The power voltage input.2. The control voltage input.3. The fuses on the inputs to the chassis.4. Disconnect the amplifiers ...

  • Page 203

    March 2003Section 06: Axis Drive Systems187FadalMaintenance ManualThe next three pages have the wiring diagrams for the chassis that are installedin the Fadal VMCs.

  • Page 204

    188Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualAC BrushlessChassis DiagramLocationDescriptionManufacturerMfg. Part #Fuse A,B,CFast acting, 30 A, 600 VAC Dimension (13/32” x 1 ½”)LittlefuseKLK30Fuse 1,2,3,4,5Fast acting, 20 A, 600 VACDimension (13/32”x1½”)LittlefuseKLK...

  • Page 205

    March 2003Section 06: Axis Drive Systems189FadalMaintenance Manual

  • Page 206

    190Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualAmplifiersBoth DC and AC axis drive amplifiers are Pulse Width Modulation (PWM) type. PWM is a method to output high current efficiently. For the DC drives this is achieved by turning the power transistor on to fullvoltage output a...

  • Page 207

    March 2003Section 06: Axis Drive Systems191FadalMaintenance Manualmotor operation. The motor has a temperature sensor to detect overtemperature in the motor, and information is returned in the hall effect cable.The amplifier sends a Absolute Current signal to J3 on the controller board.This sign...

  • Page 208

    192Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualAxis SoftwareVersion AC0017-5for AC Drive VMCsTo improve the floor finish using G8 command, the default Contouring Gain hasbeen changed. The Position Loop Gain #5911 program now requires differentamplifier settings than previous ax...

  • Page 209

    March 2003Section 06: Axis Drive Systems193FadalMaintenance ManualFollowing the procedure for POSITION LOOP GAIN, please note the changesbelow. The Following Error displayed will not be the same as earlier versions ofAC axis software when the AXIS DISPLAY Parameter in SETP is set to ERR.M91 can ...

  • Page 210

    194Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualSetting Cold StartPositionCold start the VMC. The axis motors are now at their index marks. The VMCcold start indicators may be misaligned. The following procedure will measurethe offset value.X-Axis1) Use a tape measure to measure...

  • Page 211

    March 2003Section 06: Axis Drive Systems195FadalMaintenance Manual3) Remove the orange connector or disconnect signal wires on the front of thefaulty card.4) Disconnect the power and motor wires. 5) Using a long phillips screw driver, loosen the two screws securing theamplifier to the chassis. S...

  • Page 212

    196Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual5) If the gain setting is not set to NORMAL select #6 from the menu and thenpress 0 to select normal gain. After selecting the gain, press selection #3 towrite the setting back to the axis controller.IMPORTANTChanges to the setting...

  • Page 213

    March 2003Section 06: Axis Drive Systems197FadalMaintenance ManualAmplifierSupply voltage. . . . . . . . . . . . . . . . . . . .230 VAC 3phaseBus voltage . . . . . . . . . . . . . . . . . . . . . .325 VDCCurrent . . . . . . . . . . . . . . . . . . . . . . . . .30A peak (3 sec.) 19A continuous....

  • Page 214

    198Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualEncoder ErrorRed (Heidenhain encoder error signal)Index MarkGreenFive Standard LEDs:Over TempRed (motor or amplifier)Over VoltageRedL.S.E.C.B.Red (low speed overcurrent)H.S.E.C.B.Red (high speed overcurrent)Run (or ON)GreenSignals ...

  • Page 215

    March 2003Section 06: Axis Drive Systems199FadalMaintenance ManualSignal Gain10 turn potCW to increase sig gainCompensation10 turn potCCW to increase amp gain6 LEDs:Top Row:FoldbackRed(OC folds back to continuous after 2 secs.)Enc. ErrorRed(solid red for encoder error;blinking if amp returns to ...

  • Page 216

    200Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual7 . . . . . . . . . . . . COM . . . . . . . . . . . . . black8 . . . . . . . . . . . . . . . . . . COM . . . . . . . . . . . . .black9 . . . . . . . . . . . . . . . . . . B+. . . . . . . . . . . . . . .brown10 . . . . . . . . . . ....

  • Page 217

    March 2003Section 06: Axis Drive Systems201FadalMaintenance Manual• SIGNAL is a 1:2 output of the differential Signal+&- input.• TACH scaling is 4V/1000 RPM.• ABS is the current output to all 3 phases. Scaling is 1V/4A.It is the peak value (but not showing all the spikes).It is an abso...

  • Page 218

    202Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual3) Adjust the balance potentiometer until the multimeter reads 1.470VDC inboth directions.4) When the above steps have been completed, the monitor will read 302 forthe following error.5) Repeat steps 1-4 for the remaining axis ampl...

  • Page 219

    March 2003Section 06: Axis Drive Systems203FadalMaintenance ManualSignal Gain1) After the balance has been adjusted, the Signal Gain must be adjusted.Change the program that was entered on the previous page to read asfollows:N2 M91 M49 G91 F25.N3 X-2.Y-2.Z-2. G1N4 X2.Y2.Z2.2) Start the program. ...

  • Page 220

    204Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualReview or ChangeSurveyTo edit any values, the user must move a cursor, defined by an asterisk (*)symbol, around the screen. This cursor may be moved up, down, left, or rightby pressing the U, ENTER, D, BACKSPACE or the L and R keys...

  • Page 221

    March 2003Section 06: Axis Drive Systems205FadalMaintenance Manualdirection, by turning the resolver, until the drill is centered between the twomarks that were made in step #1.3) The number on the monitor, in the X axis display, is the offset amount.Record the value on a sheet of paper.Y-Axis 1...

  • Page 222

    206Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualConnect the Encoder Tester to the spindle controller card for 5-volt power. ColdStart the axes, and Jog the axis until the closest green index light is seen.Insert the position value, displayed on the screen, into the SV program at...

  • Page 223

    March 2003Section 06: Axis Drive Systems207FadalMaintenance Manualprevent a user from accidentally loading in a survey, the survey may not beloaded in through the disk command in the functions menu.Axis Motors (XYZ)Motor WiringWhen installing an axis motor, it is important to wire the motor the ...

  • Page 224

    208Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualRemoval1) With the machine at the cold start position, depress the Emergency Stopbutton and power off the VMC.2) Remove the four 3/8 hex head bolts holding the axis motor in place.3) Remove the axis motor.4) For DC motors, remove t...

  • Page 225

    March 2003Section 06: Axis Drive Systems209FadalMaintenance ManualRemoval 1) With the machine at the cold start position, press the Emergency Stopbutton and power off the VMC. 2) Remove the four 3/8 hex head bolts holding the axis motor in place.3) Remove the axis motor.4) Remove the end cap of ...

  • Page 226

    210Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualEMC and TRM Way Lubrication The EMC and TRM model VMC’s must be manually lubed by the ownerevery 3-6 months depending on use:a. Remove X, Y, and Z way covers.b. Wipe off old grease and accumulated foreign objects. c. Use MOBILTEM...

  • Page 227

    March 2003Section 06: Axis Drive Systems211FadalMaintenance ManualAxis & Way SystemsWaylube SystemUSE RECOMENDED WAYLUBE TYPE Castrol Magna BD68, Shell Tonna 68V orMobil Vactra Oil #OperationNote: Frequently clogging components indicate that the wrong waylube isbeing used. The recommended wa...

  • Page 228

    212Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualThe Motor-Driven Piston Pump type operates with the 110 VAC input runninga 3 RPM motor. The motor drives some gears which move an arm up and downto pump the pump. This pump can be pumped manually by pulling up on thehandle and rele...

  • Page 229

    March 2003Section 06: Axis Drive Systems213FadalMaintenance ManualPump OperationDisconnect output oil lines from gauge, and using a short piece of 5/32 air line,close output Y fitting by inserting the tubing, one end into each side of the Y.Cycle pump until pressure builds.Does pressure now rise...

  • Page 230

    214Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manualthird port has the arrow pointing AWAY from the Choke Valve and is notconnected to anything at all.If Waylube Pump is operating OK, and system cannot develop greater than 200PSI (14 bar), then inspect system for a leak. Inspect und...

  • Page 231

    March 2003Section 06: Axis Drive Systems215FadalMaintenance Manual7) Disconnect the wiring to the motor and the float switch. (Motor) 8) Remove the four screws that attach the tank. (Both)Caution! Tank will come off.9) Remove the waylube pump assembly. (Both)10) Install a new waylube pump assemb...

  • Page 232

    216Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual5) Reconnect the air supply line to the VMC. (PDI)6) Manually activate the system. (Both)7) Check for oil and air leaks. (Both)Procedure For Flushing Way Lube SystemFlushing the way lube system is necessary when the incorrect waylu...

  • Page 233

    March 2003Section 06: Axis Drive Systems217FadalMaintenance Manual12) Remove the 3/8" hose from the kerosene and place the hose in a can ofclean fresh waylube.13) Slowly open the regulator clockwise on the flush pump. Pump oil throughthe lines, until the system is well lubricated.14) Stop t...

  • Page 234

    218Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualA double 120 VAC outlet (must have the bridge between outlets removed seenote)Chiller Unit Coolant Pump MotorNote: 120 VAC output must have the bridge between the brass screwsremoved. Bridge between silver screws is present.When th...

  • Page 235

    March 2003Section 06: Axis Drive Systems219FadalMaintenance ManualThe chiller controller board is normally in slot three in the control card cage. Itreceives the + 5 VDC and + 12 VDC from the backplane but does notcommunicate to the other boards. The controller has a heart beat LED to indicate t...

  • Page 236

    220Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualThe coolant flow path is coolant tank to pump to coolant sensor to X axisballscrew to Z axis ballscrew to spindle to Y axis ballscrew to cabinet cooler tochiller and back to coolant tank. VMC 6030 / 8030 10,000 RPM Spindle Configur...

  • Page 237

    March 2003Section 06: Axis Drive Systems221FadalMaintenance ManualMotor Couplers The motor couplers are the connection between the motor and the ballscrew.When replacing the motor or the ballscrew measure the distance from the endof the coupler and the motor or ballscrew. Install the coupler on ...

  • Page 238

    222Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual7) Operate the machine and check for Motor axis to Ballscrew axis alignment.Re-center motor under the 4 bolts to reduce Coupler Insert Disk runout, toprevent premature wear.Figure 6-3 These couplers will provide an audible “click...

  • Page 239

    March 2003Section 06: Axis Drive Systems223FadalMaintenance Manual6) Using SVT-0122 Motor Alignment Guide Rods, slide the Motor into theMount and Coupler. 7) Tighten the Coupler Bolt as above. Figure 6-4 MTR-0189 Coupler, Bellows; 7/8 Shaft. MTR-0190 Coupler, Bellows; Siemens.

  • Page 240

    224Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualGib AdjustmentIMPORTANTDO NOT rush gib adjustments—they are critical! Do not adjust any gibsunless the machine is leveled properly.Figure 6-5 Gib AdjustmentsThere are two gibs at the front of the table and from 4 to 6 Gib/Strapas...

  • Page 241

    March 2003Section 06: Axis Drive Systems225FadalMaintenance Manual1) Center the table at the X-axis cold start position. Attach a magnetic baseand an indicator just below the gib, as shown in Figure 6-7. Adjust and setat a zero reading. Figure 6-6 Attach Magnetic Base and Indicator2) Place a pry...

  • Page 242

    226Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualTable Gib/StrapAssemblyWhen adjusting gibs with shim stock, use extreme care to prevent ripping theshim and leaving pieces of it between the gib and way surfaces.There are gib/strap assemblies on the underside of the table at the f...

  • Page 243

    March 2003Section 06: Axis Drive Systems227FadalMaintenance ManualSaddle GibsThere are two gibs to the right of the center base rail and two gib/strapassemblies on the underside of the saddle. The following procedure coversadjustment of the center saddle gibs only. The following adjustments appl...

  • Page 244

    228Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual8) If the gibs need adjusting, there is a gib adjuster screw located at the endof each gib. Turning this screw clockwise will loosen the gib and counterclockwise will tighten the gib.9) Repeat the above steps, until .0003” indica...

  • Page 245

    March 2003Section 06: Axis Drive Systems229FadalMaintenance ManualHead GibsThere are two gibs that ride between the column ways, one at the top and oneat the bottom. See Figure 6-9. There is also one gib/strap assembly on theback of each column rail (the 3020 and 4525 have two gib/strap assembli...

  • Page 246

    230Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual5) Zero the indicator.6) Place the pry bar between the right side of the head and Z-axis way.7) Gently pry the head the opposite way. 8) Make adjustments according to the indicator reading. A properly adjustedZ-axis head gib is .00...

  • Page 247

    March 2003Section 06: Axis Drive Systems231FadalMaintenance Manual7) Turn both gib adjuster screws one turn counter-clockwise after the shimshave been removed from the left and right sides.Bottom Gibs8) Insert a .001" shim about 3” to 4" long between the rear of the column wayand the...

  • Page 248

    232Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual6535/4525/3020Gib & StrapAdjustmentsFigure 6-10 Base: gib & strap location. Figure 6-11 Saddle & column: strap & gib location.

  • Page 249

    March 2003Section 06: Axis Drive Systems233FadalMaintenance ManualTable GibsThere are two (2) gibs at the front of the table and four (4) GIB/STRAPassemblies on the underside of the table. The following steps describe how toadjust the front table gibs. There is one at the left and one at the rig...

  • Page 250

    234Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manualrepeat on the opposite end. Repeat the steps to .0003”. This is to avoidmaladjustment due to binding. After both gibs have been completely adjusted run the table to its extremes atthe plus and minus end and then back to center ag...

  • Page 251

    March 2003Section 06: Axis Drive Systems235FadalMaintenance Manualallow space for the gibs. It will be necessary to remove the way covers to adjustthe gibs.1) With the saddle centered at the Y axis cold start position, attach a magneticbase and indicator to the saddle and place the indicator nea...

  • Page 252

    236Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual4) Slowly turn the gib adjuster screw clockwise while pulling on the shim.5) When the shim begins to pull out, stop turning the gib adjuster screw andremove the shim completely.6) Turn the gib adjuster screw 3/4 turn counterclockwi...

  • Page 253

    March 2003Section 06: Axis Drive Systems237FadalMaintenance ManualHead GibsWARNINGShim Stock is very sharp. Handle with care.There are two (2) gibs that ride between column ways on the right side, one atthe top and on at the bottom. There is also two (2) GIB/STRAP assemblies onthe back of each c...

  • Page 254

    238Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual10) Repeat the above steps, until indicator motion is .0002” to .0003”, thenadjust the gib at the opposite side.After both gib adjustments are complete, run the head to its extremes at theplus and minus end and then back to cen...

  • Page 255

    March 2003Section 06: Axis Drive Systems239FadalMaintenance Manual11) When the shim begins to pull out, stop turning the gib adjuster screw andremove the shim completely.12) Do the same for the other side.13) Turn both gib adjuster screws one (1) turn counterclockwise after the shimshave been re...

  • Page 256

    240Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualInstalling VMCLinear Way Saddle1) Level machine ways.2) Clean way mounting pads.3) Position mounting pads for saddle.4) Position grease line couplers upward.5) Install safety stop to rail.6) Stone saddle at mounting pad areas and c...

  • Page 257

    March 2003Section 06: Axis Drive Systems241FadalMaintenance ManualProcedure for Correcting the Saddle Squareness1) Shim size is error size. Example .0007 - .0012 = .001 shim .0013 - .0017= .0015 shim2) Loosen mounting bolts.3) Loosen set ...

  • Page 258

    242Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual4) Loosen set screws.5) Loosen X axis ball screw nut at table block.6) Pry table away from mounting pad area (hard stop).7) Install shim (between pad and hard stop) and pry table to mounting pad.8) Tighten set screws, double check ...

  • Page 259

    March 2003Section 06: Axis Drive Systems243FadalMaintenance Manual2) Go to the rear of the column and locate the limit bar.Figure 6-17 Locate Limit Bar at Rear of Column3) Tighten the adjustment nut until there is no play between the Bellevillesprings, but loose enough so the springs will rotate...

  • Page 260

    244Section 06: Axis Drive SystemsMarch 2003FadalMaintenance ManualBacklash Parameter DescriptionBacklash parameter values allow the control to compensate for the physicallimitations of the ball screw when changing tool direction. Values are entered intenths (ten-thousandths of an inch). The contr...

  • Page 261

    March 2003Section 06: Axis Drive Systems245FadalMaintenance Manual2) From the command mode, clear the current backlash values for the X axisby typing BL,1,0,0,0 and pressing the ENTER button.Figure 6-19 Establish a Zero Reading3) Place a surface indicator in a tool holder and JOG the needle to Z...

  • Page 262

    246Section 06: Axis Drive SystemsMarch 2003FadalMaintenance Manual5) Run the program in the following manner:a. At line N2 the control will be in the waiting state. Adjust the dial of thesurface indicator to zero on the needle, then press the START button tocontinue.b. At line N7 the control will...

  • Page 263

    March 2003Section 07: CNC Controls247FadalMaintenance ManualSection 07: CNC ControlsFadal’s Block Diagram TempContr 1550 1400 CPU 1420 Video1030 Computer Interface XYZS P I NDL E C L OC K M I L L I N T16101470 B AM F UNC T I1100-2 1100-1 1090 Ke...

  • Page 264

    248Section 07: CNC ControlsMarch 2003FadalMaintenance ManualElectrostatic Discharge (ESD)An electrostatic field is an electrical field surrounding objects with an electricalcharge. This is a static electrical field and will vary for many reasons such asmaterial or Relative Humidity. Everyone has ...

  • Page 265

    March 2003Section 07: CNC Controls249FadalMaintenance Manualother boards. The Chiller Controller monitors a ambient temperature and one ortwo coolant temperatures and activates the chiller(s) when temperaturedifference exceeds a couple of degrees. Slot 5This is the Central Processing Unit (CPU) B...

  • Page 266

    250Section 07: CNC ControlsMarch 2003FadalMaintenance ManualExpanded Memory Boards that plug into the CPU Boards at J4 and J5 are asfollows:• 128K Expanded Memory Board (1460-21) PCB-0040• 384K Expanded Memory Board (1460-22) PCB-0041• 4MB Expanded Memory Board (1460-34) PCB-0042•...

  • Page 267

    March 2003Section 07: CNC Controls251FadalMaintenance ManualAxis ControllerBoardsThe axis controller boards receive input position, direction and speedcommands from the CPU via Computer Interface then outputs commands tothe axis amplifier. The amplifier moves the axis motor and the resolver / tac...

  • Page 268

    252Section 07: CNC ControlsMarch 2003FadalMaintenance Manual configured as A-axis and SETP parameter is set. Two pallets each with an A-axis option - both Axis Controllers in slot 12 & 13 are configured as A-axis and special software is ...

  • Page 269

    March 2003Section 07: CNC Controls253FadalMaintenance Manualhave spindle jumper configuration and the proper spindle software. TheSpindle Controller sends the spindle forward and reverses signals to the 1100-2 board and the speed command directly to the spindle drive. Encoderinformation is fed ba...

  • Page 270

    254Section 07: CNC ControlsMarch 2003FadalMaintenance ManualDC Power SupplyThe Fadal VMCs require a DC Power Supply. The power supply requires aninput voltage of 115VAC (105-125VAC @ 47-63Hz). This input is provided fromthe transformer and the Start / Brown-out circuit has a Solid State Relay (K1...

  • Page 271

    March 2003Section 07: CNC Controls255FadalMaintenance Manualpotentiometer (R48). An Emergency stop will also de-energize the spindlecontactor after the delay.J3 and J4 are for future use. J3 pin 1 is identical to J1 pin 16 (active lowoutput to generate External Slidehold). J3 pin 2 is an active...

  • Page 272

    256Section 07: CNC ControlsMarch 2003FadalMaintenance ManualK1 and K2 normally closed contacts open. One side of these contacts isconnected to ground. The other side to the fault lines (1100-1 TB1-2, TB1-3,TB-4, TB1-5, TB1-6, TB1-7), by opening the contacts the 10VDC (8 to 12 VDC)fault lines will...

  • Page 273

    March 2003Section 07: CNC Controls257FadalMaintenance ManualIf the operator hits the E-stop switch then the switch opens the 120VAC line tothe 1100-1 TB1-10 to initial the hardware E-stop and reports to the CPUthough the Keyboard Interface (1090) to the Mill Interface to the ComputerInterface to ...

  • Page 274

    258Section 07: CNC ControlsMarch 2003FadalMaintenance ManualEmergency Stop andFault Circuit

  • Page 275

    March 2003Section 07: CNC Controls259FadalMaintenance ManualEmergency StopCircuitry

  • Page 276

    260Section 07: CNC ControlsMarch 2003FadalMaintenance ManualFadal Axis BoardJumperAxis Board 1010-6 at the J4 is an access connection jumper. Jumper therequired axis as shown on the silk screen.Axis Boards 1010-1, 1010-4 and 1010-5 at the J4 Jumper Block are asfollows:Slot 9- X Axis Controller ...

  • Page 277

    March 2003Section 07: CNC Controls261FadalMaintenance Manualbut may be incorrect for the wiring connections in a given machine or rotarytable. Slot 13 –A Axis Controller – VH65, TR65, SMW 175, SMW 275 (5 to 12, 7 to10)Tri Tech Head both controller boards ...

  • Page 278

    262Section 07: CNC ControlsMarch 2003FadalMaintenance Manual1460-1 Memory Expansion BoardsExpanded Memory Board – Slot 1-4 First 128K (10 to 16, 11 to 15) 16 15 14 13 12 11 10 9 | |____________| | ...

  • Page 279

    March 2003Section 07: CNC Controls263FadalMaintenance ManualN4 X-20.N5 X20.N6 X-20.N7 X20.N8 M2_ _6) From the prompt ENTER NEXT COMMAND: Type in SETCS then home themachine with the HO command.7) Position the X axis at +10 inches if travel is less than 40 inches on X. Enterthe SETX command. 8) Pus...

  • Page 280

    264Section 07: CNC ControlsMarch 2003FadalMaintenance Manual12) Enter “X-2.0 G1 F100. M48” <ENTER>13) If the X axis does not move then it is set correctly. If the X axis moves,adjust R19, the third pot up from the bottom on the Clock board for nomovement.14) <SLIDE HOLD>15) <MA...

  • Page 281

    March 2003Section 07: CNC Controls265FadalMaintenance Manual• Select option 2-START CNC. This will take the control back to ENTERNEXT COMMAND.6) Restore PARAMETER values as needed:NOTE: The control will ask for BACKLASH values, but the PARAMETER valuesmust be checked first.• Type SETP <ENT...

  • Page 282

    266Section 07: CNC ControlsMarch 2003FadalMaintenance ManualZero-out Memory

  • Page 283

    March 2003Section 07: CNC Controls267FadalMaintenance ManualPCBA CompatibilityChartPCBANumberDescription12345Notes1400-1CPUX1400-2CPUX1400-3CPUX1400-4CPUX1400-5CPUX1460-1128K RAM ExpansionXX1460-21128K RAM ExpansionXXX1460-22384K RAM ExpansionXXX1460-344MB RAM ExpansionX1460-388MB RAM ExpansionX1...

  • Page 284

    268Section 07: CNC ControlsMarch 2003FadalMaintenance Manual1100-3Power DistributionXXXPallet Changer1170Power SurgeXXXXX240 VAC input1170-1Power SurgeXXXXX480 VAC input1550-0BTemp. ControllerXXXX1550-2Dual Temp ControllerXXXX1610-0Program ModuleX1610-1Program ModuleXXX1750-0ModemXXXX1730-0Buss B...

  • Page 285

    March 2003Section 08: Spindle Drive Systems269FadalMaintenance ManualSection 08: Spindle Drive SystemsSpindle DrivesFadal has used many spindle drives when manufacturing VMCs. The drives inthe beginning were inverters and are currently Vector Drives. The differencebetween inverters and vector dri...

  • Page 286

    270Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualInverter/Vector DriveInputs & OutputsDrive GroundThe drive is required to have a ground connection. A green and yellow 16 AWG(10 AWG for 50 taper) wire grounds the drive to the machine chassis.Input Three Phase PowerThe thre...

  • Page 287

    March 2003Section 08: Spindle Drive Systems271FadalMaintenance Manualoperated. On a standard machine a 1.3 volt DC signal will result in a speed ofabout 300 RPM in low range.On machines with rigid tapping both the K3 and K4 relays are active, enablingdrive, and a speed command of either positive ...

  • Page 288

    272Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual.Figure 8-2 1250-2 Spindle Load Meter Wiring DiagramVector Drive Encoder 9 pin Molex Connector The encoder output signals A, /A, B & /B are input through this connector.There is a +5V ground line through this connector also....

  • Page 289

    March 2003Section 08: Spindle Drive Systems273FadalMaintenance ManualVector Drive with Rigid TappingOutput the encoder signals to the spindle controller PCBA through the RigidTapping Cable.Figure 8-3 Baldor Drive ConnectionsBALDOR DRIVECONNECTIONSINVERTER ENCODER9 PIN MOLEXCONNECTORLOAD METERINVE...

  • Page 290

    274Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualAdjustmentsAdjusting the BaldorVector DrivesWhenever a Baldor Drive’s DC Power Supply or a spindle controller card isreplaced, it will need to be ZERO BALANCED to the machine. On Rigid Tappingmachines in particular, the contro...

  • Page 291

    March 2003Section 08: Spindle Drive Systems275FadalMaintenance Manual14) Press LOCAL. The display will read OFF MOTOR SPEED REMOTE 0 RPM.Baldor Spindle DriveParameter Usage forFadal VMCThe inverter replacements are INV-052 and INV-054. These two units arereplacements for inverters (Toshiba, Sweo ...

  • Page 292

    276Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualIf the “ANA CMD OFFSET” value reads any value other than 0.0%, then the“Zero Balance Offset Trim” has been set. The Factory Parameters procedure is to load or re-load the factoryparameters.Replacement Baldor Vector Drive...

  • Page 293

    March 2003Section 08: Spindle Drive Systems277FadalMaintenance ManualKeystrokes: Display shows: Off 0 0 RPM REM 0.0A 0.0 HZ PROG PRESS ENTER FOR ⇓ ⇓ LEVEL 2 BLOCKS ENTER PRESS ENTER FOR OUTPUT LIMITS ⇑ ⇑ ⇑ PRESS ENTER FOR MISCELLANEOUS ENTER RESTAR...

  • Page 294

    278Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual⇑ CMD OFFSET TRIM P: PRESS ENTER ⇑ ⇑ TEST PASSED PRESS ENTER RESET RESET RESET ⇓ PRESS ENTER FOR PROGRAMMING EXIT ENTER STOP 0 V 0 RPM LOC 0.0 A 0.0 HZ LOCAL OFF O V 0 RPM REM 0...

  • Page 295

    March 2003Section 08: Spindle Drive Systems279FadalMaintenance ManualThe Motor Tuning procedure tunes the drive to the motor. This is notnecessary to perform because the factory parameters are set up for ourmotors. This procedure can be used for troubleshooting on units that will or willnot retai...

  • Page 296

    280Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualMotor Mag Amps for INV-0070On VHT machines equipped with INV-0070, during an acceleration cycle thespindle motor will slow down and then speed up several times, appearingsimilar in symptoms to that given by a failing encoder. Ac...

  • Page 297

    March 2003Section 08: Spindle Drive Systems281FadalMaintenance ManualAfter following the Auto-Tuning procedure, and with the machine powered on:NOTE: Do not re-run the Auto-Tuning procedure without restoring value 22 inthe Motor Mag Amps parameter.Keystrokes Baldor Display ...

  • Page 298

    282Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualYaskawa Drive 515(INV-0072)Set up Instruction,Initializing andbalancing the drives1) Use this procedure for new drive installation, or replacement2) Power off Machine3) Install Yaskawa Drive with display unit.4) Power on Machine...

  • Page 299

    March 2003Section 08: Spindle Drive Systems283FadalMaintenance ManualYaskawa V7 (INV-0071) on Fadal EMCSpindle setupInstructionsBefore beginning, please note:All references to the V7 Manual are to TM 4315, dated 04/02/2001. The latestV7 manual can be downloaded from www.drives.comThis instruction...

  • Page 300

    284Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualRegenerativeResistorsIf on command of a rotating spindle to stop (M5), the Spindle Vector Drivecauses the motor to brake and coast, brake again and then coast alternatelyuntil it finally stops.If Spindle Vector Drive units are f...

  • Page 301

    March 2003Section 08: Spindle Drive Systems285FadalMaintenance ManualThe braking circuit is the circuit, internal to the drive or on an external brakeunit, that outputs the excessive power to the regen resistors. This circuitmonitors the DC buss voltage of the drive and when it exceeds approximat...

  • Page 302

    286Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualAdjusting the AMCVector DriveThe AMC VE150AD Vector drive works with all spindle controller cards. TheAMC Drive HP rating must match the motor HP rating. If they are mismatched,the motor may not run to full speed.Figure 8-5 Matc...

  • Page 303

    March 2003Section 08: Spindle Drive Systems287FadalMaintenance ManualSwitch PositionsNote: Switches are located under cover; cover must be removed for access.Switches should be preset; only switch 8 and 10 are changed. See Figure 7-6.Figure 8-6 Switches are PresetPots: (16 turn pots)• Decelerat...

  • Page 304

    288Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual•Current Limit•Loop Gain* Accel & decel pots have no effect in rigid tap mode.Adjustments Switches and pots will be preset to initial settings by AMC.Switch Settings8 On-5000 RPM Off-7500 RPM10 On-10hp motor Off-15hp mot...

  • Page 305

    March 2003Section 08: Spindle Drive Systems289FadalMaintenance Manual2) LOOP GAIN: Remove P2 connector and install jumper plug (FOR & REV toCOM). Turn the Loop Gain CW until it hums, then turn two turns CCW.Remove jumper plug and install P2 connectors.Figure 8-8 Remove Jumper Plug3) TEST/OFFS...

  • Page 306

    290Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual8) TEST/OFFSET: Turn fully CCW, then * turns CW (middle).9) FLUX: Not Adjustable.10) ACCEL/DECEL: 20k ohms for 2.2 sec Acc/Dec (11.8k for 3.5 sec) (Measurefrom P6-5 to Test points below pots. Machine must be off when setting pot...

  • Page 307

    March 2003Section 08: Spindle Drive Systems291FadalMaintenance ManualRigid Tapping (Optional Feature)Fadal Rigid TappingProcedureThis method of rigid tapping program is for Format 1.1) Place the rigid tapping test screw (SVT-0077) in the spindle.If using the test programs in the machine, use prog...

  • Page 308

    292Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualSoftware Version AC-0017 and Later-Table 2: Metric Screws7,500 RPM 7,500 RPM 7,500 RPM 7,500 RPM 7,500 RPM 10,000 RPM 15,000 RPMA ModelsL ModelsEMC6535 40T6535 50TALL1:2 ratioRPM Factor0000000Orientation Factor10152010101010Gain...

  • Page 309

    March 2003Section 08: Spindle Drive Systems293FadalMaintenance ManualBefore AC-0017Software Version -Table 4: Metric Screws7,500 RPM 7,500 RPM 7,500 RPM 7,500 RPM 7,500 RPM 10,000 RPM 15,000 RPMA ModelsL ModelsEMC6535 40T6535 50TALL1:2 ratioRPM Factor0000000Orientation Factor15151510151010Gain38...

  • Page 310

    294Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualProcedure for Setting GAIN Parameter:For Rigid Tapping with VMCs that have METRIC Ballscrews, the GAIN inSETP must be set to 80.Procedure for Setting Z TAP GAIN Parameter:For Rigid Tapping with VMCs that have METRIC Ballscrews, ...

  • Page 311

    March 2003Section 08: Spindle Drive Systems295FadalMaintenance ManualWYE / DELTA MotorsStandard motors are run in the wye mode only. Wye / Delta motors offer aflatter torque curve over the entire speed range of the motor/spindle system.Figure 8-10 WYE Delta Relay Wiring Diagram

  • Page 312

    296Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualBelt Drive SystemsPosi-Drive BeltSystemThe Posi-Drive Belt System features two belts that run on a 1-2 and 2-1reduction pulley arrangement.Spindle Belts Replacement on Auto Hi/low SystemThe spindle drive belts are Gates 315K10. ...

  • Page 313

    March 2003Section 08: Spindle Drive Systems297FadalMaintenance Manual6) Remove six each of the 1/4” hex bolts holding the Drawbar Cylinderassembly.Figure 8-12 Remove Hex Bolts Holding Drawbar Cylinder Assembly7) Remove the Drawbar Cylinder assembly. 8) Disconnect the Orientation Bridge/Drawbar ...

  • Page 314

    298Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual9) Remove three each of the 3/8” socket head cap screws holding theOrientation Bridge assembly.Figure 8-15 Remove Socket Head Cap Screws10) Remove the Orientation Bridge assembly and front belt guide.Figure 8-16 Remove Orienta...

  • Page 315

    March 2003Section 08: Spindle Drive Systems299FadalMaintenance Manual12) Remove both of the 1/2” bolts to the rear belt guide, as well as the left 1/2”Spindle motor bolt.Figure 8-17 Remove Bolts to Rear Belt GuideFigure 8-18 Remove Spindle Motor Bolt13) Swing the spindle motor forward and rem...

  • Page 316

    300Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual14) Remove the 2 spindle drive belts.15) Replace the 2 spindle drive belts. Reassemble using the previous steps inreverse order.Motor PlateTensioner CableMachines equipped with a motor plate tensioner cable system, as shown in t...

  • Page 317

    March 2003Section 08: Spindle Drive Systems301FadalMaintenance Manual3) Zero the indicator and slowly turn the 3/8” hex head bolt.Figure 8-21 Zero Indicator4) Adjust the screw until the plate moves.002 to .005 on the indicator.5) After adjusting, lock down the 3/8” jam nut with the other wren...

  • Page 318

    302Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual6) The reservoir is full when oil enters the 5/32 line on the actuator.WARNINGDO NOT allow an excessive amount of oil to flow into the separator.7) Reattach the 1/4“line to the fitting on the cylinder.8) Repeat the above steps...

  • Page 319

    March 2003Section 08: Spindle Drive Systems303FadalMaintenance Manual5) Cut all the wire ties holding the air lines and wires in place. Disconnect the1/4” assembly.Figure 8-22 Cut Wire Ties Holding Air Lines and Wires6) Remove each of the six 1/4” hex bolts to the Drawbar assembly.Figure 8-23...

  • Page 320

    304Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual8) Remove each of the four 3/8” cap bolts to the Orientation Bridge assembly.Figure 8-24 Remove Cap Bolts to Orientation Bridge Assembly9) Remove the Orientation Bridge.10) Loosen each of the two 1/2” hex bolts to the Spindl...

  • Page 321

    March 2003Section 08: Spindle Drive Systems305FadalMaintenance Manual16) Tighten two each of the 1/2” hex bolts to the Spindle motor.17) Verify that the reading has not changed.Note: If the belt tension is too tight, then vibration will appear at the tool tip,and a poor finish may result.18) Re...

  • Page 322

    306Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual* FD2 uses 1 for 10HP, 2 for 15HP 1 Cannot be used for current CE productionINV 4558-320MITS. (BRAKE+)No213INV 4551-15TOSHIBANo113INV 4558-15MITS.NoINTERNALNONEINV 4554SWEONo113INV 4554-175BALDOR-SWEONo113INV 4554Y-175BALDOR-SWE...

  • Page 323

    March 2003Section 08: Spindle Drive Systems307FadalMaintenance ManualTools Sticking in the Spindle During a Change CycleThere are many different solutions to problems leading to sticking tools, andalthough most machines experiencing a sticking tool problem will exhibit onlyone or two of these sym...

  • Page 324

    308Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual2. Drawbar CylinderHall Effects SwitchTool "Popping" can be reduced on machines equipped with Drawbar CylinderHall Effects switches, by checking the adjustment on the switch. If the switch isup too high, then the Z-axi...

  • Page 325

    March 2003Section 08: Spindle Drive Systems309FadalMaintenance Manual8. Air Leaks;Hydraulic ActuatorAssembly BoltsTwo of the 1/4-20 bolts used to mount the Hydraulic Actuator assemblypenetrate the Drawbar Cylinder housing, and may not have been sealed withteflon tape adequately. Test with soapy w...

  • Page 326

    310Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual14. Spring Pilot; BallPockets IncorrectWith the Spring Pilot removed from the spindle, carefully inspect the 4 ballpockets and insert (4) BRG-0004 1/4 steel balls into them. Remount the Spideron top of them. The balls should eas...

  • Page 327

    March 2003Section 08: Spindle Drive Systems311FadalMaintenance ManualMEASURINGDRAWBARPERFORMANCEIn order to measure the amount of push force that the Drawbar Cylinder hasupon the tool, place a tool holder into the spindle (without a tool in it) and Jogthe machine slowly downward in Z-axis onto th...

  • Page 328

    312Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualDRB-0024 StickingTools Kit, 10K LDBDRB-0025 StickingTools Kit, 10K LDB-CT=

  • Page 329

    March 2003Section 08: Spindle Drive Systems313FadalMaintenance ManualTap-Tap CycleThe purpose of the Tap-Tap Cycle is to release tools that are stuck in thespindle. When the Drawbar Cylinder is activated, the Drawbar Hall Effect switchis activated to indicate that the tool was successfully releas...

  • Page 330

    314Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manualthe air output to the drawbar cylinder from the air valve assembly to trigger avalve that supplies up to 120 PSI air to the Drawbar Cylinder to extract thestuck tool. It is simple to install and setup and should be used in conju...

  • Page 331

    March 2003Section 08: Spindle Drive Systems315FadalMaintenance Manual10) Now remove the belleville springs or the floater.11) To reinstall, reverse the above steps.Replace BellevilleSprings1) Remove drawbar (See Section A).2) Using a spring hook or a magnet remove the belleville springs (Be sure ...

  • Page 332

    316Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualSpindle Belleville Springs Quantity ChartThere have been many spindle and spring retainer combinations over theyears. To determine the number of Belleville Springs in a spindle, three factorshave to be considered: The depth of t...

  • Page 333

    March 2003Section 08: Spindle Drive Systems317FadalMaintenance ManualSpindle Pre-LoadMeasuring theSpindle Pre-Load1) Place a Pressure Gage (SVT-0066) on the table and align it with the Spindlenose. 2) Set an indicator on the Head and touch the indicator tip on the nose of theSpindle.3) Jog the he...

  • Page 334

    318Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manualevery 5 hours of continuous operation. This will allow cooling of the races andre-lubrication of the grease lubricated bearings. The actual load to the spindleis not a factor a these higher RPMs. The time period should be monito...

  • Page 335

    March 2003Section 08: Spindle Drive Systems319FadalMaintenance ManualSpindles7.5K & 10K GreasePacked SpindlesComponentsThe 7.5K and 10K grease packed spindles are self contained units. Functional DescriptionThese spindles are belt driven and require no maintenance. There is airsupplied to the...

  • Page 336

    320Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualSpindle/Lube Pump/ControlSpindleBearingsCeramic Steel HybridLubricationAir and oil pressure feed back controlOperating temp.Ambient +20°F during steady state operationMotor Power15 HPMax. Speed15,000 RPMMax. Cut3/8” Max. Dept...

  • Page 337

    March 2003Section 08: Spindle Drive Systems321FadalMaintenance Manual10) Remove the spindle drive belt.WARNINGUse heavy duty work gloves when handling the heated spindle and pulley.11) Using a propane torch, direct the flame at the spindle pulley forapproximately 6-10 minutes while slowly rotatin...

  • Page 338

    322Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualPressure Manifold MountingMount the pressure switch manifold block on the inside bottom of the cabinet,by removing the four knockouts and drilling the necessary mounting holes.Control Board MountingMount the control board on the...

  • Page 339

    March 2003Section 08: Spindle Drive Systems323FadalMaintenance ManualSpindle Tram1) Level Machine.2) Adjust TABLE GIBS, SADDLE GIBS, and HEAD GIBS. Watch for Turcite gibs:.0003" ...

  • Page 340

    324Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualAdjusting SpindleTramIf spindle is to be installed, follow this procedure. Clean all surfaces and replace O-rings. Mount spindle in head using 6 SoCap bolts. Check tram as described above. Determine which position shows the most...

  • Page 341

    March 2003Section 08: Spindle Drive Systems325FadalMaintenance Manual9) Using a propane torch, direct the flame at the spindle pulley forapproximately 5 minutes. Maintain an even amount of heat throughout thespindle pulley. WARNINGUse heavy duty work gloves when handling the heated spindle and sp...

  • Page 342

    326Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualWiring HarnessInstallation1) Using the figure below and the following clarifying instructions, install thewire harness assembly inside the control cabinet.2) The spindle lubrication pump cable runs through any available existing...

  • Page 343

    March 2003Section 08: Spindle Drive Systems327FadalMaintenance Manual5) Inspect the machine for the version of mill interface board (1040) installed.The 15K spindle system requires a 1040-2B or newer mill interface board.Update the machine to the newer card if necessary. Plumbing Spindle1) Pull f...

  • Page 344

    328Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual11) Connect the other air/oil PDI line (22) and the other pressure switch line(26) to the double end of the second Y-fitting.12) Connect the inlet line, stamped “AIR/OIL IN” (24) on the upper bearingretainer, to the single e...

  • Page 345

    March 2003Section 08: Spindle Drive Systems329FadalMaintenance ManualNote: Observe the color of the oil coming out of the oil pressure line. If the coloris DARK BROWN, there is way lube oil in the pump. Prime the line until theway lube oil is flushed out. The spindle oil color is LIGHT YELLOW, pr...

  • Page 346

    330Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualHB - blinking.OIL, AIR - illuminate.AP, LEV, OE, UAP, LAP - remain OFF.OIL - illuminates, turns OFF in 15 seconds from power ON.AIR - illuminates, turns OFF in 2 minutes from power ON.3) While the spindle is running.HB - blinkin...

  • Page 347

    March 2003Section 08: Spindle Drive Systems331FadalMaintenance Manualsolenoid can also cause this indication. If the oil pressure is still low, verify thatthe air and oil filters are clean replace elements if required.UAP LED/LAP LED - These LEDs will illuminate if the oil pressure to theupper or...

  • Page 348

    332Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual4) Remove existing Ceramic Seal retainer and Locking Drawbar Knock-outcap.5) Using Gear Puller and SVT-0073 Drawbar Removal Tool, remove LDBSpring Pilot and replace inner and outer O-rings with HDW-0155 and HDW-0158 respectively...

  • Page 349

    March 2003Section 08: Spindle Drive Systems333FadalMaintenance Manual3) With an indicator, check the level of the Ceramic Seal, this seal needs to belevel and is manufactured to a 2 Light-Bars flatness. Run out less than.0003” (.0076mm)4) Verify that the Piston assembly moves freely up and down...

  • Page 350

    334Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance ManualHydraulic ActuatorSet-up

  • Page 351

    March 2003Section 08: Spindle Drive Systems335FadalMaintenance Manual40 Taper BT & CAT Pull Studs

  • Page 352

    336Section 08: Spindle Drive SystemsMarch 2003FadalMaintenance Manual

  • Page 353

    March 2003Section 09: Attached Optional Devices337FadalMaintenance ManualSection 09: Attached Optional DevicesM-Function Board Use and SetupMiscellaneousFunctions (M-Codes)Miscellaneous functions, or M-codes, are used to control actions other than thenormal machine movement. M-functions may contr...

  • Page 354

    338Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualFadal M Functions

  • Page 355

    March 2003Section 09: Attached Optional Devices339FadalMaintenance ManualWARNING:Any wires leaving the control box must be in a grounded conduit. Pleaseobey the electrical code. In Applications where there is high current, use M-functions to activate relay.Fadal NormallySupplied M-FunctionsFadal ...

  • Page 356

    340Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualU6 (Jumper) M20 1 16 "A" M-FunctionM30 2 15 "B" M-FunctionM40 3 14M50 4 13M60 5 12M70 6 11M80 7 10M90 8 ...

  • Page 357

    March 2003Section 09: Attached Optional Devices341FadalMaintenance ManualM-Function ContactsEach M-Function has one set of normally open contacts. The contacts areavailable to the user at TB 1, TB2 and TB3 on the backplane."A" M-Function - TB 1 pins 7 & 13 "B" M-Function- ...

  • Page 358

    342Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualRemote Manual Pulse Generator

  • Page 359

    March 2003Section 09: Attached Optional Devices343FadalMaintenance ManualInstallationProcedure1) If Remote MPG is to be installed on a NEW style pendant (CNC88HS),remove tacked-on cover for adapter with hammer and punch or chisel.2) If Remote MPG is to be installed on earlier pendant that does no...

  • Page 360

    344Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualDynamic Tool Load Compensation

  • Page 361

    March 2003Section 09: Attached Optional Devices345FadalMaintenance ManualServo CoolantAssembly

  • Page 362

    346Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualServo CoolantControl

  • Page 363

    March 2003Section 09: Attached Optional Devices347FadalMaintenance ManualTroubleshootingChecklist1) Make sure all connectors are plugged in properly.2) Check dip switch settings. Switch 2=3=6=7=ON; Switch1=4=5=8=9=10=OFF.3) Check AC line fuse. AC LINE FUSE=16A, 250 VAC Slow blow (dimensions5x20 m...

  • Page 364

    348Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualCNC 88 HS Optional Diskette Drive

  • Page 365

    March 2003Section 09: Attached Optional Devices349FadalMaintenance Manual

  • Page 366

    350Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualCNC88HS Optional Diskette Drive- MiscellaneousSpecifications3.5" diskette medium. 1.44 Megabyte capacity; will read/write 720K diskettes.MS-DOS format.RequirementsSoftware version 96.1 A6-3 or later.Access from ControlT...

  • Page 367

    March 2003Section 09: Attached Optional Devices351FadalMaintenance ManualAccess from Program Using Macro Statement #DISKMacro language statement #DISK invokes a program on disk from within aprogram in the CNC memory. After processing the file from disk, control isrouted back to the line of the pr...

  • Page 368

    352Section 09: Attached Optional DevicesMarch 2003FadalMaintenance ManualRestrictions on UserDefined SubroutinesThe file executes in the CNC memory just as if it were a part of the program thatexecutes the #DISK statement, with the following restrictions on user-definedsubroutines:1) The program ...

  • Page 369

    March 2003Section 10: Rotary Tables353FadalMaintenance ManualSection 10: Rotary TablesRotary Tables, 4th AxisFigure 10-1 Rotary TablePre-installationRemove the top of the shipping crate:1) With a large screwdriver gently pry the clips from the bottom of the crate.2) Remove the crate top.Install a...

  • Page 370

    354Section 10: Rotary TablesMarch 2003FadalMaintenance ManualRemove the RotaryTable from theShipping Crate:IMPORTANTWear Safety goggles, steel toe shoes and gloves to reduce the risk of injury.The VMC table, or any surface on which the rotary table rests, must be freeof chips, or anything else th...

  • Page 371

    March 2003Section 10: Rotary Tables355FadalMaintenance Manualclean container for future use, as the machine must have either the rotarytable or the dummy plug installed in order to operate.2) Uncoil the cable by clipping only the wire ties holding the cable in a loop.The other ties are for the 1/...

  • Page 372

    356Section 10: Rotary TablesMarch 2003FadalMaintenance ManualSetting the VMCParametersWith the power on, in the COMMAND MODE type SETP then press the enterkey. There are three parameters associated with the rotary table.1) Set AXES: to X,Y,Z,A2) Set A-AXIS RATIO: to 90:13) Set M60/A-AXIS BRAKE: t...

  • Page 373

    March 2003Section 10: Rotary Tables357FadalMaintenance ManualEvaluating theFollowing ErrorTo evaluate the A-axis following error, enter the following program into theVMC. This program can also be loaded from the TA,2 programs, programnumber 5815. If you use 5815, you MUST modify the F word on lin...

  • Page 374

    358Section 10: Rotary TablesMarch 2003FadalMaintenance Manual6) Jog -.03 then +.03.The difference on the indicator is the backlash. The backlash should bebetween .0004 and .0010. If it is more, mechanical adjustment is necessary.Backlash is entered in tenths. An error of .0007 would be entered: ...

  • Page 375

    March 2003Section 10: Rotary Tables359FadalMaintenance Manual3) The bolts holding the worm pivot plate must be loose to allow setup for theadjustments.Figure 10-4 Loosen Bolts Holding Worm Pivot Plate4) The pivot adjustment screws should be set to zero (pivot plate resting onpin A) before startin...

  • Page 376

    360Section 10: Rotary TablesMarch 2003FadalMaintenance Manualprocedure is as far as the wrench will move from one side of the pocket tothe opposite side). Figure 10-6 Turn Top Pivot Adjusting Screw and Screw on Motor Side6) Set an indicator on a stand. Zero the indicator on the worm pivot plate o...

  • Page 377

    March 2003Section 10: Rotary Tables361FadalMaintenance Manual8) Keep checking that the pivot plate on the side opposite the motor stays atzero, adjust back to zero if required. Continue adjusting and checking pivotplate heights until the plates are adjusted.9) Tighten pivot plate bolts until snug...

  • Page 378

    362Section 10: Rotary TablesMarch 2003FadalMaintenance ManualN6 M17N7 M30N8 L101.1N9 A-0.0914) Listen to the operation of worm gear. Any knocking or banging indicates abad gear adjustment on the worm or motor gear. Exit the program andenter the JOG mode.15)Place an indicator on the face of the ch...

  • Page 379

    March 2003Section 10: Rotary Tables363FadalMaintenance Manual18) To correct worm gear backlash, adjust the worm gear backlash on theexposed side of the housing with adjusting bolts until indicator moves lessthan .002 (0.508mm) when the plate is pressed.Verifying Air BrakeEngagementVerify the brak...

  • Page 380

    364Section 10: Rotary TablesMarch 2003FadalMaintenance ManualMaintenanceGear OilThe gear oil is the primary concern in rotary table maintenance. The oil shouldbe changed every six to twelve months, depending on usage.1) Remove the 1/8-27 NPT plug from the cover plate opposite the motor.2) To all...

  • Page 381

    March 2003Section 10: Rotary Tables365FadalMaintenance Manual4) Unscrew the motor cable connector from the 4th axis receptacle, place aplastic bag around the connector for protection, and replace the dummyplug in the receptacle.5) Coil up the cable and wire tie it in a loop.6) Make sure there are...

  • Page 382

    366Section 10: Rotary TablesMarch 2003FadalMaintenance ManualFor all other controller cards use the following:FADAL VH-65 &VH-5C1) Set the jumpers on the 1010-5 card as follows:Figure 10-13 VH65 & VH-5C Jumper Block Note: The 5C does not use the 6-11 jumper line.2) Set the axes conf...

  • Page 383

    March 2003Section 10: Rotary Tables367FadalMaintenance ManualFADAL V-300 (V-400) Rotary TableFigure 10-14 FADALFADAL V-300 (V-400) Rotary Table1) Set the jumpers on the 1010-5 card as follows:Figure 10-15 V-300 (V-400) Jumper Block2) Set the axes configuration in the SETP to 4, which will select ...

  • Page 384

    368Section 10: Rotary TablesMarch 2003FadalMaintenance Manual10) Set backlash using the procedure in section 6.11) Square up the rotary table so it is perpendicular with the X axis. Use theprocedure in section 6.Troyke NC-101) Set the jumpers on the 1010-5 card as follows:Figure 10-16 Troyke NC-1...

  • Page 385

    March 2003Section 10: Rotary Tables369FadalMaintenance ManualTechnara MD-200R1) Set the jumpers on the 1010-5 card as follows:Figure 10-17 Technara MD-200R Jumper Block2) Set the axes configuration in the SETP to 4, which will select X,Y,Z,A.3) Once the number of axes has been set, the A axis’ ...

  • Page 386

    370Section 10: Rotary TablesMarch 2003FadalMaintenance ManualTechnara MD-300R1) Set the jumpers on the 1010-5 card as follows:Figure 10-18 Technara MD-300R2) Set the axes configuration in the SETP to 4 which, will select X,Y,Z,A. Oncethe number of axes has been set the A axis’ ratio and brake p...

  • Page 387

    March 2003Section 10: Rotary Tables371FadalMaintenance ManualTsudakoma RNCV-4011) Set the jumpers on the 1010-5 card as follows:Figure 10-19 Tsudakoma RNCV-401 Jumper Block2) Set the axes configuration in the SETP to 4, which will select X,Y,Z,A.3) Once the number of axes has been set the A ax...

  • Page 388

    372Section 10: Rotary TablesMarch 2003FadalMaintenance ManualFADAL RT-1751) Set the jumpers on the 1010-4 card as follows:Figure 10-20 RT-175 Jumper Block2) Set the axes configuration in the SETP to 4, which will select X,Y,Z,A. Oncethe number of axes has been set the A axis’ ratio and brake pa...

  • Page 389

    March 2003Section 10: Rotary Tables373FadalMaintenance ManualFADAL RT-2251) Set the jumpers on the 1010-4 card as follows:Figure 10-21 RT-225 Jumper Block2) Set the axes configuration in the SETP to 4, which will select X,Y,Z,A. Oncethe number of axes has been set the A axis’ ratio and brake pa...

  • Page 390

    374Section 10: Rotary TablesMarch 2003FadalMaintenance ManualFADAL RT-2751) Set the jumpers on the 1010-4 card as follows:Figure 10-22 RT-275 Jumper Block2) Set the axes configuration in the SETP to 4, which will select X,Y,Z,A. Oncethe number of axes has been set the A axis’ ratio and brake pa...

  • Page 391

    March 2003Section 10: Rotary Tables375FadalMaintenance ManualTilting Rotary Tables, 4th & 5th AxisFigure 10-23 Tilting Rotary TableFADAL TR-651) Set the jumpers on the 1010-5 card as follows:Figure 10-24 TR-65 Jumper Blocks2) The AB NOLIM EPROM is for the A axis. It has no limits. The 15P105N...

  • Page 392

    376Section 10: Rotary TablesMarch 2003FadalMaintenance Manual5) Set the B axis ratio to 180:1.6) Set the M60/A axis brake to YES.7) Set the M62/B axis brake to YES.8) Exit the SETP by pressing <MANUAL> and enter the CS command.9) Using service program PR,5815, set the position loop gain for...

  • Page 393

    March 2003Section 10: Rotary Tables377FadalMaintenance ManualA & B Axis PositionLoop Gain (1010-5)Note: Verify the gain setting through the SV command before continuing!The A and B axis require a different program to be entered. Enter theappropriate program for the rotary table that you have ...

  • Page 394

    378Section 10: Rotary TablesMarch 2003FadalMaintenance Manual1) Enter NEW PROGRAM NUMBER <ENTER>2) Press #6 (EXIT)3) From the prompt ENTER NEXT COMMAND type in IN <ENTER>Enter the following program (PR,5815):4) The position loop gain is adjusted by the potentiometer labeled “SIG” ...

  • Page 395

    March 2003Section 10: Rotary Tables379FadalMaintenance ManualHydraulic Brakes4th Axis BrakeInstallationFigure 10-25 4th Axis Brake Installation1) Mount the hydraulic brake unit on top of the right panel as shown.2) Drill a hole in rear wire gutter as shown.3) Install a plastic wire guard around t...

  • Page 396

    380Section 10: Rotary TablesMarch 2003FadalMaintenance Manual4th Axis BrakeCheck-Out1) Manually check the brake operation by typing the following:MD <ENTER>M60 <ENTER> <START> —- (A AXIS BRAKE SHOULD LOCK)M61 <ENTER> —- (A AXIS BRAKE SHOULD RELEASE)4th, 5th Axis BrakeI...

  • Page 397

    March 2003Section 10: Rotary Tables381FadalMaintenance Manual4th, 5th Axis BrakeCheck-Out1) Manually check the brake operation by typing the following:MD <ENTER>M60 <ENTER> <START> —- (A AXIS BRAKE SHOULD LOCK)M61 <ENTER> —- (A AXIS BRAKE SHOULD RELEASE)M62 <ENTER...

  • Page 398

    382Section 10: Rotary TablesMarch 2003FadalMaintenance ManualThis page intentionally left blank.

  • Page 399

    March 2003Section 11: Probes & Scales383FadalMaintenance ManualSection 11: Probes & ScalesProbesMP-11 ProbeThe MP-11 Probe operates by transmitting signals between the probe and themachine control via the probe cable and the interface cable. The power 12VDCis supplied from the 1060 Mother...

  • Page 400

    384Section 11: Probes & ScalesMarch 2003FadalMaintenance ManualMP-12 ProbeThis probe is used for position location of a part or home position, for accuracywhen machining multiple parts. The probe system operates by transmittingsignals between the probe and the machine control using the Optica...

  • Page 401

    March 2003Section 11: Probes & Scales385FadalMaintenance ManualScalesInstalling Scales1) Remove the front cover plate from the table and position a .001” Indicatoron the face of the table. Figure 11-1 Remove Front Cover Plate and Position Indicator2) Jog the table to the maximum negative X ...

  • Page 402

    386Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual3) Remove the telescoping way cover by removing three button head socapscrews and two 1/4-20 cap screws.Figure 11-3 Remove Telescoping Way Cover4) Jog the table to the X axis home position.Figure 11-4 Jog Table to X Axis Home Posi...

  • Page 403

    March 2003Section 11: Probes & Scales387FadalMaintenance Manual5) Measure and mark the center of the table.Figure 11-5 Measure and Mark Table Center6) Install the scale template with clamps. Center the template on the tablemarks that were made in step 5. Verify that the alignment pins are tig...

  • Page 404

    388Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual7) Drill 21/64” starting holes. [For the 6030 and 8030 drill 3/16” holes, and1/4” dowel pin holes (6 total). Skip step 8.]Figure 11-7 Drill Starting Holes8) Remove the Template.Figure 11-8 Remove Template

  • Page 405

    March 2003Section 11: Probes & Scales389FadalMaintenance Manual9) Drill the holes with 21/64” drill. Drill to a depth of 1 inch. Counter sink theholes after drilling.Figure 11-9 Counter Sink Holes(For 6030 and 8030 machines drill with a #3 drill for attachment bars and a1/4” drill for dow...

  • Page 406

    390Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual11) Clean debris from inside the holes with a air.Figure 11-11 Clean Debris from Holes12) Clean all surfaces to remove lubricant and debris.Figure 11-12 Clean Surfaces

  • Page 407

    March 2003Section 11: Probes & Scales391FadalMaintenance Manual(For 6030 and 8030 machines only: Insert 1/4” dowel pins into the mountingplates.) Figure 11-13 Insert Dowel Pins into Mounting Plates of 6030 & 803013) Attach mounting plates to the table with 1/4-20 x 1/2” socap screws (...

  • Page 408

    392Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual14) Remove the cap plate from the center line of table by removing two socapscrews with a 3/16” Allen wrench.Figure 11-15 Capscrews15) Scrape paint from all areas that the scale will cover. Stone the surfacelightly and clean the...

  • Page 409

    March 2003Section 11: Probes & Scales393FadalMaintenance Manual16) Install the X axis scale reader mounting plate with socap screws and a 3/16” Allen wrench. Using an indicator, level the plate to within .0003”.Figure 11-17 Install X Axis Scale Reader Mounting Screws17) Remove the scale f...

  • Page 410

    394Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual18) Remove the protective cover, located over the pin connector.Figure 11-19 Remove Protective Cover from Pin Connector19) Remove the packing clips from the scale assembly.Figure 11-20 Remove Packing Clips from Scale Assembly

  • Page 411

    March 2003Section 11: Probes & Scales395FadalMaintenance Manual20) Attach the scale assembly to the table with 10-32 x 3/4” button headsocap screws (HDW-797) and washers (HDW-0450) using a 1/8” Allenwrench. Do Not Tighten Securely At This Time.Figure 11-21 Attach Scale Assembly to Table21...

  • Page 412

    396Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual22) Place a .060” shim between the scale and the reader. Adjust the scale sothat a .010” shim cannot be inserted between the scale and the shim onthe reader. Continue adjusting along the length of the scale.Figure 11-23 Place ...

  • Page 413

    March 2003Section 11: Probes & Scales397FadalMaintenance Manual24) Place a straight edge against the front of the aluminum extrusion. Adjustthe reader so that it is flush with the scale. Tighten the mounting screws.Figure 11-25 Adjust Reader So it is Flush with Scale25) Attach the cable to th...

  • Page 414

    398Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual26) Route the cable through the access hole on the saddle.Figure 11-27 Route Cable Through Access Hole on Saddle27) Pull the excess cable through the saddle and tie it to the lubrication linebundle.Figure 11-28 Pull Excess Cable T...

  • Page 415

    March 2003Section 11: Probes & Scales399FadalMaintenance Manual28) Reinstall telescoping way cover.Figure 11-29 Reinstall Telescoping Way Cover29) Attach the axis position indicator to the scale cover with two 10-32 nyloknuts (HDW-0634). Attach the scale cover to the side of the table with fi...

  • Page 416

    400Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual30) Press the X-axis shield tube cap onto the end of the tube, fasten with 1/4-20 x 1/2” hex cap screw (HDW-0319) and hex nut KEPS 1/4-20 (HDW-0337).Figure 11-31 Press X Axis Shield Tube Cap onto End of Tube31) Pull the X axis c...

  • Page 417

    March 2003Section 11: Probes & Scales401FadalMaintenance Manual32) Attach the X axis shield tube to the saddle with three 5/16-18 x 1 1/4”socap screws. (HDW-0792)Figure 11-33 Attach X Axis Shield Tube to Saddle33) Clean the Y axis mounting plate.Figure 11-34 Clean Y Axis Mounting Plate

  • Page 418

    402Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual34) Remove the scale from the packaging. Remove the wire retainer and loosenthe screws holding the plastic retainer plates.Figure 11-35 Remove Wire Retainer and Loosen Screws Holding Retainer Plate35) Remove the pin connector prot...

  • Page 419

    March 2003Section 11: Probes & Scales403FadalMaintenance Manual36) Attach the cable to the scale reader with a #2.5 metric allen wrench. Thealignment pin ensures that the cable is installed correctly.Figure 11-37 Attach Cable to Scale Reader37) Remove the packing clips from the scale assembly...

  • Page 420

    404Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual38) Temporarily attach the throw rod to the scale reader. Visually align the rodwith the scale and tighten the bracket. Remove the throw rod.Figure 11-39 Attach Throw Rod to Scale Reader39) Attach the scale assembly to the mountin...

  • Page 421

    March 2003Section 11: Probes & Scales405FadalMaintenance Manual40) Attach the throw rod mounting bracket to the scale reader with two #8button head socap screws.Figure 11-41 Attach Throw Rod Mounting Bracket to Scale Reader41) Attach the cover plate to the scale using four 1/4-20 x 1/2” hex...

  • Page 422

    406Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual42) Insert two 1/4-20 x 1/2” set screws into the throw rod's saddle mountingbracket.Figure 11-43 Insert Screw into Throw Rod’s Saddle Mounting Bracket43) Insert one 3/8-16 x 2 1/2” hex cap screw (HDW-0570) with one lockwashe...

  • Page 423

    March 2003Section 11: Probes & Scales407FadalMaintenance Manual44) Insert the mounts into the machined openings at the bottom of the column.Secure to the column with the 5/16-18 cap screws.Figure 11-45 Insert Mounts into Openings at Bottom of ColumnFigure 11-46 Secure Mounts to Column

  • Page 424

    408Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual45) Insert the Y axis throw rod, flat end first, through the machined hole abovethe X axis tube.Figure 11-47 Insert Y Axis Throw Rod Through Hole Above X Axis Tube

  • Page 425

    March 2003Section 11: Probes & Scales409FadalMaintenance Manual46) Attach the Y axis throw rod bracket to the saddle with two 5/16-18 x 2"socap screws (HDW-0484). Insert the throw rod into the bracket and securethe rod with the two 1/4-20 set screws.Figure 11-48 Attach Y Axis Throw Rod B...

  • Page 426

    410Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual48) Insert the throw rod into its bracket on the scale reader and tighten the two8-32 x 3/4” socap screws (HDW-0505) using a 9/64” allen wrench. Alignthe throw rod at the side and top within .005”. Adjustments are made atthe...

  • Page 427

    March 2003Section 11: Probes & Scales411FadalMaintenance Manual50) Attach the flex shield assembly to the base with four 1/4-20 x 5/8” hex capscrews (HDW-0581) and lock washers (HDW-0279). Drill and tap four 1/4-20 holes with template.Figure 11-52 Attach Flex Shield Assembly to Base51) Feed...

  • Page 428

    412Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual52) Attach the end of the flex shield to the bracket on the X axis tube with two1/4-20 x 1/2” hex cap screws (HDW-0319) and lock washers (HDW-0279).Figure 11-54 Attach End of Flex Shield to Bracket on X Axis Tube (Side View)Figu...

  • Page 429

    March 2003Section 11: Probes & Scales413FadalMaintenance Manual53) Check the clearance between the scale reader and X axis shield tube.Adjust the clearance by applying downward pressure on the tube.Figure 11-56 Check Clearance Between Scale Reader and X Axis Shield Tube54) Route the cables to...

  • Page 430

    414Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual(For 6030/8030 Machines: Attach a support bracket between the Y scale andthe CNC junction box.) Figure 11-58 Attach Support Bracket Between Y Scale and CNC Junction Box (6030/8030)

  • Page 431

    March 2003Section 11: Probes & Scales415FadalMaintenance Manual55) Scrape the paint from the mounting bracket pad on the side of the column.Stone lightly and thoroughly clean.Figure 11-59 Scrape Paint from Mounting Bracket, Stone Lightly, Clean Thoroughly56) Attach the Z axis mounting plate t...

  • Page 432

    416Section 11: Probes & ScalesMarch 2003FadalMaintenance ManualFigure 11-60 Attach Z Axis Mounting Plate to Side of Head Assembly57) Mount a dial indicator to the column. Place the tip of the indicator on themounting plate.Figure 11-61 Mount Dial Indicator to Column

  • Page 433

    March 2003Section 11: Probes & Scales417FadalMaintenance Manual58) Zero the dial indicator and jog the Z axis through the full range of travel.Adjust the mounting plate until less than .005” deflection is achieved.Thegib/straps may require loosening to complete the adjustments.Figure 11-62 ...

  • Page 434

    418Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual59) Thoroughly clean the Z axis mounting plate.Figure 11-63 Thoroughly Clean Z Axis Mounting Plate60) Remove the scale from the packaging. Remove the wire retainer clip.Loosen the screws holding the packing clips.Figure 11-64 Remo...

  • Page 435

    March 2003Section 11: Probes & Scales419FadalMaintenance Manual61) Remove the pin connector cover plate.Figure 11-65 Remove Pin Connector Cover Plate62) Attach the cable to the scale reader with a #2.5 metric allen wrench. Thealignment pin ensures that the cable is installed correctly.Figure ...

  • Page 436

    420Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual63) Remove the packing clips from the scale assembly.Figure 11-67 Remove Packing Clips from Scale Assembly64) Attach the scale to the mounting plate with 1/4-20 x 1/2” button headsocap screws (HDW-0346).Figure 11-68 Attach Scale...

  • Page 437

    March 2003Section 11: Probes & Scales421FadalMaintenance Manual65) Set the dial indicator tip on the widest ridge on the scale. Zero the Z axisand mark the center of the scale. Adjust the scale so that it has less than.003” runout.Figure 11-69 Set Dial Indicator Tip on Scale’s Widest Ridg...

  • Page 438

    422Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual66) Attach the Z axis mounting bracket to the column with two 1/4-20 x 1 1/4”socap screws (HDW-0296), using a 3/16” Allen wrench. Figure 11-70 Attach Z Axis Mounting Bracket to Column67) Attach the scale reader to the mounting...

  • Page 439

    March 2003Section 11: Probes & Scales423FadalMaintenance Manualhousing. Adjust the length of the bracket by shaving material from the baseif required.Figure 11-71 Attach Scale Reader to Mounting Bracket68) Place the .060” shim between the scale reader and scale. Adjust the scaleat the cente...

  • Page 440

    424Section 11: Probes & ScalesMarch 2003FadalMaintenance Manualcannot be slid into this area, ream the bracket mounting holes to providethe required clearance.Figure 11-72 Adjust Scale at Center

  • Page 441

    March 2003Section 11: Probes & Scales425FadalMaintenance Manual69) Attach the scale cover to the scale with three 1/4-20 x 3/8” button headsocap screws (HDW-0347).Figure 11-73 Attach Scale Cover to Scale

  • Page 442

    426Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual1580 Board SetupFigure 11-74 X, Y Axis ScalesFigure 11-75 X, Y and Z ScalesFigure 11-76

  • Page 443

    March 2003Section 11: Probes & Scales427FadalMaintenance ManualFigure 11-77 Figure 11-78 Figure 11-79

  • Page 444

    428Section 11: Probes & ScalesMarch 2003FadalMaintenance ManualScale Box Installation / Side Mount1) Knockout the existing scale box access plate.Figure 11-80 Knockout Existing Scale Box Access Plate2) Run the ribbon cable through the opening and attach the scale junction boxto the side of th...

  • Page 445

    March 2003Section 11: Probes & Scales429FadalMaintenance Manual3) Install WIR-0506 to the terminal strip on the 1220 power supply board (#3wire to com side, #9 wire to +5VDC side).Figure 11-82 Install WIR-0506 to Terminal Strip on 1220 Power Supply Board4) Route WIR-0506 from the 1220 board t...

  • Page 446

    430Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual5) Insert WIR-0134 through the access hole. Unplug the J13 connector fromthe 1060 board and install the red wire to J13 #11 and the black wire toJ13 #10. The lower row of J13 contains the following wires: center #11right side #10....

  • Page 447

    March 2003Section 11: Probes & Scales431FadalMaintenance Manual6) Plug WIR-0506 into the J10 connector on the 1580-1A board and WIR-0134 into connector J1.Figure 11-85 Plug WIR-0506 into J-10 Connector; Plug WIR-0134 into J1 Connector7) Plug the ribbon cable from the scale box into J6 of the ...

  • Page 448

    432Section 11: Probes & ScalesMarch 2003FadalMaintenance ManualFigure 11-87 Secure Cable to Bottom of CabinetNote: Power off the machine and Lockout/Tagout the disconnect box, beforeattempting any work in the junction cabinet.8) Insert interpolation boards into slots on the 1580-1A card. Plug...

  • Page 449

    March 2003Section 11: Probes & Scales433FadalMaintenance ManualScale Box Installation / Top Mount1) Place a piece of paper in the top inside of the CNC cabinet to prevent debrisfrom falling into electronic panels while drilling holes in cabinet.Figure 11-89 Place Paper in CNC CabinetWARNINGWe...

  • Page 450

    434Section 11: Probes & ScalesMarch 2003FadalMaintenance ManualFigure 11-91 Mount Box on Top of CNC Cabinet3) Center punch the hole locations for drilling.Figure 11-92 Center Punch Hole Locations for Drilling

  • Page 451

    March 2003Section 11: Probes & Scales435FadalMaintenance Manual4) Drill a starting hole at each marked location.Figure 11-93 Drill Starting Holes5) With a step drill, open the mounting holes up to 5/16”. Open the wire holeto 1/2”. Open the B axis ribbon scale cable opening to 7/16”.Figu...

  • Page 452

    436Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual6) Use a metal punch with an RS-232 die to create the opening for the fourthaxis scale ribbon cable.Figure 11-95 Create Opening for Fourth Axis Ribbon Cable7) Attach the fourth axis scale box to the cabinet with two 1/4-20 x 1/2...

  • Page 453

    March 2003Section 11: Probes & Scales437FadalMaintenance Manual8) Plug the signal cable into J11 and the power cable into the J10 connectionon the 1580-1a board. Install a grommet and pull the cables down throughthe access hole.Figure 11-97 Plug Signal Cable into J11 and Power Cable into J10 ...

  • Page 454

    438Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual1060 board and install the red wire to J13 #11 and the black wire to J13#10 (Lower row of J13: center #11, right side #10). Secure the cable toexisting J13 wires. Plug J13 into the 1060 board.Figure 11-99 Plug J13 into 1060 Board1...

  • Page 455

    March 2003Section 11: Probes & Scales439FadalMaintenance Manualcontroller card and plug it into J6. Secure the wiring to existing wirebundles.Figure 11-101 Plug 15 Pin Connector into Scale Box ConnectorFigure 11-102 Secure Wiring to Existing Bundles

  • Page 456

    440Section 11: Probes & ScalesMarch 2003FadalMaintenance ManualHeidenhain Tester1) Remove the pin connector from the junction box and plug it into the scaletest box. Plug the power supply into a 110 VAC outlet.Figure 11-103 Plug Pin Connector Into Scale Test Box2) Program the axis to be teste...

  • Page 457

    March 2003Section 11: Probes & Scales441FadalMaintenance Manual4) The solid bar is the amplitude ratio and phase angle (TV1 And TV2). Thesolid bar must be inside the brackets during overall travel of the scale. Anarrow bar is better than a wide bar.Figure 11-105 Solid Bar Must be Inside Brack...

  • Page 458

    442Section 11: Probes & ScalesMarch 2003FadalMaintenance Manual(This page intentionally left blank).

  • Page 459

    March 2003Section 12: Pallet Changer443FadalMaintenance ManualSection 12: Pallet ChangerInstallation of Pallet Changer1) The left, front, lower edge of the base must be a minimum of 2” from thefloor. Level the machine on the 1.5” leveling pads that were shipped with the machine (see the Fadal...

  • Page 460

    444Section 12: Pallet ChangerMarch 2003FadalMaintenance Manual6) Move the VMC table to X=-20” and Y=10”.7) Open the Pallet Changer door using the UTILITIES command.a. In the ENTER NEXT COMMAND mode, type UT and press the ENTERbutton.b. Select option #5 PALLET CHANGER.c. Select option #4 SERVI...

  • Page 461

    March 2003Section 12: Pallet Changer445FadalMaintenance Manual13) Place the Alignment block on the receiver rail and the indicator on themachine rail and rotate the adjustment block to the side. The indicator willmove, indicating the side to side alignment of the rails. Move the receiverbase to b...

  • Page 462

    446Section 12: Pallet ChangerMarch 2003FadalMaintenance Manuald. Select option #1 Clamp/Unclamp.Figure 12-4 Release the Clamp21) Pull pallet A all the way on to the machine table and use the instructions instep #20 to clamp the table in place.22) Position the Pallet Changer Arm roller into the sl...

  • Page 463

    March 2003Section 12: Pallet Changer447FadalMaintenance Manualc. Slide the stop block until it rests properly over the roller.Figure 12-5 Remove Cover; Loosen Bolts; Slide Stop Block Over Roller27) Jog the table back to pallet B and load pallet B.a. In the ENTER NEXT COMMAND mode, type UT and pre...

  • Page 464

    448Section 12: Pallet ChangerMarch 2003FadalMaintenance ManualInstallation of Light Curtain1) Attach the front and rear base plates to the pallet receiver (A).2) Fasten the front and back light curtain mirror assemblies to the front andrear base plates. Verify that both mirrors are level (B).3) A...

  • Page 465

    March 2003Section 12: Pallet Changer449FadalMaintenance ManualMirror AlignmentNote: The transmitter has two lights (one red and one green) located at the topend of the unit. They represent a good alignment (green light) or a badalignment (red light). There must not be any obstructions within the ...

  • Page 466

    450Section 12: Pallet ChangerMarch 2003FadalMaintenance ManualSetting the Sensor on the 1840 BoardPurposeDuring a pallet change, the table will move to the table limits. If there isanything blocking the progress of the Y-axis, the current of the motor will be toohigh. The 1840 board senses when t...

  • Page 467

    March 2003Section 12: Pallet Changer451FadalMaintenance Manual8) Make a pallet change In the MANUAL DATA INPUT mode (do not make apallet change from the UTILITIES menu; a pallet change from the UTILITIESmenu does not utilize all of the functions of a complete pallet change).In the MANUAL DATA INP...

  • Page 468

    452Section 12: Pallet ChangerMarch 2003FadalMaintenance Manual• M33 Store and Load Pallet B - This function is used when only pallet Bis to be utilized. This exchange is performed the same as the M31 func-tion. When pallet B is on the table, it is placed in the stored position.The machine will ...

  • Page 469

    March 2003Section 12: Pallet Changer453FadalMaintenance ManualOption 1: When option 1 is selected, the following will occur:1) The pallet changer door opens.2) The machine enters the waiting state, and the message PRESS START TOMOVE PALLET appears at the bottom of the screen. If a table move isne...

  • Page 470

    454Section 12: Pallet ChangerMarch 2003FadalMaintenance ManualOption 4: When this option is selected, the following menu appears:PALLET SERVICE UTILITY1 CLAMP/UNCLAMP2 OPEN/CLOSE DOOR3 STORE PALLET4 LOAD PALLET5 MOVE TO TABLE A6 MOVE TO TABLE B7 DISPLAY SWITCHES8 JOG9 EXITENTER OPTION NUMBEROptio...

  • Page 471

    March 2003Section 12: Pallet Changer455FadalMaintenance ManualOption 5 & 6:These options will move the table to the position of either pallet Aor pallet B. If there is a pallet on the table, the machine will onlymove the table to the position of the pallet that is on the table. Afterstoring a...

  • Page 472

    456Section 12: Pallet ChangerMarch 2003FadalMaintenance ManualMaintenance ScheduleEach Part Cycle1) Use an M20 in the program to make it automatic. Frequent washing out ofchips prevents them from building up into difficult-to-remove piles.2) Blow away any chips that may lodge underneath Pallet in...

  • Page 473

    March 2003Section 12: Pallet Changer457FadalMaintenance Manual4) Remove Head Cover, and inspect fluid lines for Hi/Lo Idler assembly,refilling, if necessary.5) Remove all tools from tool changer, and clean out any chip buildup found.When returning tools to ATC, inspect retention ring tension on t...

  • Page 474

    458Section 12: Pallet ChangerMarch 2003FadalMaintenance ManualThis page intentionally left blank.

  • Page 475

    March 2003Section 13: Chip Removal Devices459FadalMaintenance ManualSection 13: Chip Removal DevicesHydroSweep™WARNINGWhen operating the HydroSweep™ make sure hands, feet and clothingare clear of all moving parts.MaintenanceScheduleEach Part Cycle1) Make certain that the HydroSweep unit is cy...

  • Page 476

    460Section 13: Chip Removal DevicesMarch 2003FadalMaintenance Manual8) Check the air pressure. Single regulators should be set for 80PSI. Dualregulators should be set at 80PSI on the left gauge, and 90-100PSImaximum on the right gauge.9) Move the X-axis to either side, and flip over the outer X-a...

  • Page 477

    March 2003Section 13: Chip Removal Devices461FadalMaintenance ManualThe above maintenance procedures may be performed by the customer'smaintenance crew.6-Month Planned MaintenanceThis should be performed by the Fadal Planned Maintenance Crew semi-annually.Auger, Chip Removal SystemWARNINGWhen ope...

  • Page 478

    462Section 13: Chip Removal DevicesMarch 2003FadalMaintenance ManualThe board requires +5V and COM (J3 pins 11 and 12). If these inputs arereversed, the diode will short out the board, preventing damage to the circuitry. 120 VAC is also required for operation (J1 pins 1 and 6).230 VAC 3-phase is ...

  • Page 479

    March 2003Section 13: Chip Removal Devices463FadalMaintenance ManualIndicators (LEDs)The LEDs on the 1310-0C are slightly different than the 1310-0A:There is only one green LED (D110) for the doors. It will be on only if all doorsare closed and all circuitry is indicating doors closed.There is a ...

  • Page 480

    464Section 13: Chip Removal DevicesMarch 2003FadalMaintenance Manualextended motor overload condition will also set this LED; however such acondition should never occur because the microcontroller will respond first.Daily and WeeklySafety Tests for DoorMonitorTo ensure proper functioning of safet...

  • Page 481

    March 2003Section 13: Chip Removal Devices465FadalMaintenance Manual4) Release the Emergency Stop switch and clear the emergency stopcondition by pressing Jog.5) Open the front door.• Heart LED should stop blinking.• Front door red LEDs should be on.• Green “Doors Closed” LED should be ...

  • Page 482

    466Section 13: Chip Removal DevicesMarch 2003FadalMaintenance Manual5) Slide the coolant tank/conveyor so that conveyor is against the left side ofthe sheet metal (Figure 13-1).Figure 13-1 6) Slide the coolant tank/conveyor so that the face of the sheet metal coolanttank is slightly in front of t...

  • Page 483

    March 2003Section 13: Chip Removal Devices467FadalMaintenance ManualFigure 13-3 8) Coolant, wash down and flood pumps are connected per normalinstallation/setup.9) A standard 55 gallon drum can be positioned underneath the conveyordischarge to collect the chips.Chip ConveyorPower and Controls1) T...

  • Page 484

    468Section 13: Chip Removal DevicesMarch 2003FadalMaintenance ManualPre-Startup SafetyInspection1) At the initial running, confirm the following before turning power on.a. Inspect for and remove any article other than material (chip, etc.) to betransported on conveyor link belt portion.WARNINGMak...

  • Page 485

    March 2003Section 13: Chip Removal Devices469FadalMaintenance ManualObservance andInspection1) Maintain oil level in the speed reducer at specified level; check at least oncea year.2) Keep correct tension of conveyor chain by adjusting take-up bearing.(Obtain equal tension on both right and left ...

  • Page 486

    470Section 13: Chip Removal DevicesMarch 2003FadalMaintenance Manual5) Lubricate conveyor chain and roller chain every 150 Hours.Cause of Trouble andCorrective Action1) Problem: Inoperative when unloadeda. Slip of torque limiter • Cause: Incorrect adjustment of torque limiter ...

  • Page 487

    March 2003Section 13: Chip Removal Devices471FadalMaintenance Manual8) Problem: Slip of torque limitera. Cause: Incorrect adjustment, of torque limiter• Solution: Adjust torque. To specified value9) Problem: Shear pin is brokena. Cause: Overloaded• Solution: Reduce to normal loadb. Cause: Wea...

  • Page 488

    472Section 13: Chip Removal DevicesMarch 2003FadalMaintenance ManualMonthly Inspection1) Change oil at 100 hours initially, every 1,500 to 2,000 hours thereafter.2) Check motor for abnormal operation, i.e. noise, heat excessive current, etc.3) Keep correct tension of conveyor chain by adjusting t...

  • Page 489

    March 2003Section 14: General Information473FadalMaintenance ManualSection 14: General InformationHelpful FormulasTemperatureDegrees Fahrenheit (F) = (9/5 x degrees C) + 32Degrees Celsius (C) = 5/9 x (degrees F-32)Conversion FactorsInch (in) = millimeter x 0.03937Inch (in) = centimeter x 0....

  • Page 490

    474Section 14: General InformationMarch 2003FadalMaintenance ManualFadal Machining Centers Serial Numbers The new serial number scheme is as follows: 99 9999 99 9999 01 – VMC 02 – Rotary 03 – Re-Man Example: 042000110020 [04 2000 11 0020] For reference...

  • Page 491

    March 2003Section 14: General Information475FadalMaintenance ManualCommunications TroubleshootingFor communication problems several factors must be examined. Review theenvironment, then check the file, the VMC, the cables, the computer, and finallythe computer's communications software. Any one o...

  • Page 492

    476Section 14: General InformationMarch 2003FadalMaintenance Manual Example: X1.23 X4.5 —- Double motion words -Y2.3 —- Incorrect placement of - (minus). 534 —- No word at all• Use the TA,1,1 command for program transmission so tha...

  • Page 493

    March 2003Section 14: General Information477FadalMaintenance Manualmodem — if it is, it will interrupt normal communications through the RS-232 port.4) Use the mirror plug to test the 1030 board. The mirror plug is stored in thebottom of the CNC control cabinet when the VMC is shipped. The plug...

  • Page 494

    478Section 14: General InformationMarch 2003FadalMaintenance ManualCables1) Verify that all connections between the communications cable and both theVMC and the computer are firmly seated, including surge suppressors,gender changers, and couplers. Pick up the cables and physically confirmthat eac...

  • Page 495

    March 2003Section 14: General Information479FadalMaintenance Manuala. If a null modem is used that was supplied from FADAL, the switch mustbe in the outward position away from the cable.8) Use the mirror plug test as described in step 4 of the VMC section above totest each section of cable from ...

  • Page 496

    480Section 14: General InformationMarch 2003FadalMaintenance Manual4) If an IBM-compatible computer has a serial mouse, is the mouse pluggedinto the proper port?a. Usually the serial mouse is used in COM1 or serial port one.• Move the mouse to COM1 and the VMC cable into COM2 and try tocommunic...

  • Page 497

    March 2003Section 14: General Information481FadalMaintenance Manual• Parity - E (Even)• Data Bits - 7 (Seven)• Stop Bits - 1 (One)• EOB (End Of Block) - CR,LF (ASCII 13,10)• Starting and ending character - % (ASCII 37)• Xon/Xoff (Software handshaking) disabled for TA ...

  • Page 498

    482Section 14: General InformationMarch 2003FadalMaintenance Manualpathname = C:\CNCDATA\ filename = PN1234.NC > = > (the > is required DOS syntax to redirect file to COM2)port = COM2• Note: Before typing these two lines, the VMC should be in the TA,1mode ready to receive the progr...

  • Page 499

    March 2003Section 14: General Information483FadalMaintenance Manualgrowth does not have a chance to come into play. For example, a typicalindustry test for linear repeatability involves only seven to ten moves away fromand back to a position.ExpansionCoefficientsThe rate of expansion of any parti...

  • Page 500

    484Section 14: General InformationMarch 2003FadalMaintenance ManualAmbientTemperatureThe general temperature of the shop environment will affect the machiningprocess, but the most significant effect will be seen when temperaturedifferences are created. Sunlight on a VMC will cause the side of the...

  • Page 501

    March 2003Section 14: General Information485FadalMaintenance Manualthermal expansion. Since the blank is going to expand locally from the heat ofcutting, the actual distance from edge to feature may change.Non-UniformExpansionMaterial DifferencesThe differing rates of expansion by unlike material...

  • Page 502

    486Section 14: General InformationMarch 2003FadalMaintenance Manualtransfers most of this heat to the head, and the thermal growth is reflected inthe head position, as mentioned above, and is independent of changes in theball screws or table.The table receives most of its heat secondhand, through...

  • Page 503

    March 2003Section 14: General Information487FadalMaintenance ManualAmbient SourcesSunlightDo not allow direct sunlight on the VMC. Window shades that diffuse sunlightcan be acceptable, but any source of warmth that only heats one side of theVMC at a time will cause uneven warming and further comp...

  • Page 504

    488Section 14: General InformationMarch 2003FadalMaintenance ManualThe other numbering systems work the same way; they just have differentbase numbers. By having a different base number, they also have a differentnumber of numerals and the columns have different weights. The Binary System or base...

  • Page 505

    March 2003Section 14: General Information489FadalMaintenance Manual10 0000 1010 0001 0000 0 A11 0000 1011 0001 0001 0 B12 0000 1100 0001 0010 ...

  • Page 506

    490Section 14: General InformationMarch 2003FadalMaintenance ManualFor example if the command 1 displayed “BD” then the binary equivalentwould be “1 0 1 1 1 1 0 1”. To decode remember that “0” is On. In thisexample, B1 the high range idler would be On and Coolant 1 would be On. VMC Ma...

  • Page 507

    March 2003Section 14: General Information491FadalMaintenance ManualRough Cut / CoolDown / Finish CutA complement to the warm up of the VMC is the use of a rough cut to removemost of the material from the part. Although the part material heats up, thematerial can then be cooled to a stable tempera...

  • Page 508

    492Section 14: General InformationMarch 2003FadalMaintenance ManualProbeA probe in the spindle can be used as a part of the program to discover whatadjustments are required to compensate for thermal expansion. The probe canbe used to pick up the new home position at the beginning of each program,...

  • Page 509

    March 2003Section 14: General Information493FadalMaintenance ManualConclusionThermal expansion is a natural occurrence in any machining operation, and,when ignored, can significantly impact accuracy and positioning. By identifyingand eliminating unwanted heat sources, by calculating or measuringe...

  • Page 510

    494Section 14: General InformationMarch 2003FadalMaintenance ManualThis page intentionally left blank.

  • Page 511

    March 2003Section 15: Diagnostics495FadalMaintenance ManualSection 15: DiagnosticsDiagnostic System CommandsTo enter the Diagnostic System, enter the DI command. The Diagnostic Systemrecognizes the following commands:The Diagnostic System may be exited by pressing “ENTER” alone withouttyping ...

  • Page 512

    496Section 15: DiagnosticsMarch 2003FadalMaintenance Manual.Table 2: Display SwitchesDISPLAYDESCRIPTIONDISPLAYDESCRIPTIONATCXTNDDSwitch closes when the ATC slide is extendedATCTURETSwitch closes momentarily when the ATC turret motion is com-plete. May not be seen because closure may occur between...

  • Page 513

    March 2003Section 15: Diagnostics497FadalMaintenance Manual COMMAND2Refer to Hex to Binary tableEach binary bit commands one solid state relay. A value of 0 turns the relay on. B0 is the rightmost bit.B0= UnusedB1= Low range idlerB2= M62/M63B3= M66/M67B4= Turret motor ONB5= Turret motor reverseB6...

  • Page 514

    498Section 15: DiagnosticsMarch 2003FadalMaintenance ManualMenu DiagnosticsWARNINGSome of these tests are intended for Fadal factory use only. Use only thosetests that the Maintenance technician has been trained to use. Call theFadal Service Department for more information.AVAILABLE IN SYSTEMS 89...

  • Page 515

    March 2003Section 15: Diagnostics499FadalMaintenance ManualThe message “MEMORY FAILURE” would appear and the data that failed isdisplayed. A failure with this test indicates the 1400 card needs to be replaced.Function 3 = RAM EXPANSION TEST (1460)Tests is the same as function 2 except it sear...

  • Page 516

    500Section 15: DiagnosticsMarch 2003FadalMaintenance ManualMenu Page 2Function 1 = KEYBOARD TESTTests the keyboard by echoing the key to the screen. Pressing the JOG keyallows the hand wheel to be tested.CAUTION!Check SETP parameters after performing this test.Function 2 = START CNCDO NOT USEFunc...

  • Page 517

    March 2003Section 15: Diagnostics501FadalMaintenance Manual0.1 seconds, and interrupt 3 interrupts after approximately 0.3 seconds.Therefore, as interrupt 1 counts to 0 interrupt 3 should count to about 6 (Notethat the counting doesn’t have to be perfect but should be in the general area).A mes...

  • Page 518

    502Section 15: DiagnosticsMarch 2003FadalMaintenance ManualFunction 3 = QUARTER DAC WITH INT6 COUNT 0FED4HINTENDED FOR FADAL USE ONLY!Function 4 = TEST ENCODERS (1010-4)Tests any encoder connected to a 1010-4 axis card. AC Machines.Function 5 = TEST ADCINTENDED FOR FADAL USE ONLY!Clamp-on Ammeter...

  • Page 519

    March 2003Section 15: Diagnostics503FadalMaintenance Manual6) Normal readings for Millimeter ballscrews range from 4 to 6. 5 amps andfor Inch ballscrews the range is from I to 2.5 amps. 6030 & 8030 4 to 6, 7amps max.7) For higher than normal readings, check the following items:a) Is the prope...

  • Page 520

    504Section 15: DiagnosticsMarch 2003FadalMaintenance Manual3) Jog the axis to the + (plus) limit.4) Enter one of the following into NMI, adjusting values to reflect the totaltravel of this axis. For example, VMC4020 has the values of X=40, Y=20,Z=20.a) GI F25. G91 X-_. M49 b) GI F25. G91 Y-_. M49...

  • Page 521

    March 2003Section 15: Diagnostics505FadalMaintenance Manual6) Jog Z up away from part.7) Turn spindle off.8) Do not move Y axis. In MDI type Y.1GO <ENTER>.9) At enter next command type SETY The Y-axis is now set.10) Turn on spindle with SHIFT-SPINDLE ON KEY.11) To set X axis, jog to right s...

  • Page 522

    506Section 15: DiagnosticsMarch 2003FadalMaintenance ManualVMC Test Cut1) Push test part towards back of fixture.2) Home position: X - as shown below Y - as shown below Z - coldstart pos...

  • Page 523

    March 2003Section 15: Diagnostics507FadalMaintenance ManualVMC Test Cut Part1) Belts2) X Motor3) Y Motor4) Belt / End Mill/Spindle Preload Spindle Motor Washer5) Comp./Bad Axis Motor

  • Page 524

    508Section 15: DiagnosticsMarch 2003FadalMaintenance Manual(This page intentionally left blank).

  • Page 525

    March 2003Section 16: Troubleshooting509FadalMaintenance ManualSection 16: TroubleshootingError MessagesAbsolute Mode Required at N =The CNC must be in the G90 (absolute) mode during all probe functions. Probefunction L9101 is programmed in the G91 (incremental) mode.Amplifier Fault on AxisThis o...

  • Page 526

    510Section 16: TroubleshootingMarch 2003FadalMaintenance ManualATC FailureCheck to see if the Z axis alignment was properly set at cold start. Theautomatic tool changer has failed to respond to an M6 or the TC,1 command.Try a power off and power on. If this does not help check the fuses.The fuses...

  • Page 527

    March 2003Section 16: Troubleshooting511FadalMaintenance ManualPower off the machine before checking fuses, relays, and circuit breakers.Attempted Division by ZeroIn a macro statement, a division by zero was attempted.Attempted SQR of a Negative NumberIn a macro statement, a square of a negative ...

  • Page 528

    512Section 16: TroubleshootingMarch 2003FadalMaintenance ManualAxis Fault(s) as FollowsThis appears when the EMERGENCY STOP button is pressed, a motor overloadrelay is tripped, or the machine places itself into the Emergency Stop mode. Ifany message or error number is presented on the screen, rec...

  • Page 529

    March 2003Section 16: Troubleshooting513FadalMaintenance ManualThis also occurs when no diameter value is placed in the tool table when usingFixed subroutines L94NN, L95NN,L9601, L9701, L9801, L9901. A DIAMETERVALUE MUST BE USED.When the fixed subroutine for engraving (L9201) is used, the Z depth...

  • Page 530

    514Section 16: TroubleshootingMarch 2003FadalMaintenance Manual2) The R plane is described to be below the final Z depth.3) The final Z depth is described to end above the I or R planes.Solution:Check to see if the program has the correct positioning mode (G90 or G91),and check for correct signs ...

  • Page 531

    March 2003Section 16: Troubleshooting515FadalMaintenance ManualAnother method to start the program in a subroutine is to use the AUTOcommand. Enter AU,# (see AUTO command in the Operators Manual), where #is a sequence number in the subroutine. The control will process the programfrom the beginnin...

  • Page 532

    516Section 16: TroubleshootingMarch 2003FadalMaintenance ManualEXAMPLE:Format 1: N1 G41N2 H1This is incorrect.N1 H1N2 G41This is correct for Format 1 only.Format 2:N1 H1N2 G41This is incorrect.N1 H1 D1Diameter must be for Format 2 programming and N2 G41 is acceptable for Format 1 programming.This...

  • Page 533

    March 2003Section 16: Troubleshooting517FadalMaintenance ManualAll program data is deleted from memory. After the memory is reinitialized,a cold start must be performed.!

  • Page 534

    518Section 16: TroubleshootingMarch 2003FadalMaintenance ManualDo You Want to Zero Tool Table?This prompt is accessed by reinitializing the memory via the RI command. A ‘Y’response zeroes the tool offset table.WARNINGAll tool diameter and length offsets are deleted from memory.Do You Want to ...

  • Page 535

    March 2003Section 16: Troubleshooting519FadalMaintenance ManualE Word May Only Be Used With G0 or G1 N =Fixture offsets cannot be on the same line with a circular move (G2, G3).Emergency Stop - Take Appropriate ActionAn emergency stop has occurred. If the emergency stop button is depressed,turn i...

  • Page 536

    520Section 16: TroubleshootingMarch 2003FadalMaintenance ManualErrorThis message is a program input error. It is displayed when a program blockcontaining an error is transmitted to the CNC via the RS-232. It appears at thetime the error is received. Therefore, list the program at the control to d...

  • Page 537

    March 2003Section 16: Troubleshooting521FadalMaintenance ManualIf errors are detected, list the program and look for missing line numbers to findwhich lines the control did not accept. Use the IN command to insert themissing lines where needed.File OverflowThis message could mean that the program...

  • Page 538

    522Section 16: TroubleshootingMarch 2003FadalMaintenance ManualG92 Must Be Only G Code in BlockThere can be no other G codes in the line with a G92. The program does notneed to be in absolute (G90) to use the G92 code.GNN is an Unsupported G Code At NThe G code displayed is not a supported code o...

  • Page 539

    March 2003Section 16: Troubleshooting523FadalMaintenance Manualtool radius. For example, a 1.0 diameter end mill with a .125 corner radius,the R1 variable will be R1+.125, and the tool diameter entered in the tooltable will be 1.0.14) The G41 or the G42 code has not been canceled with a G40 befor...

  • Page 540

    524Section 16: TroubleshootingMarch 2003FadalMaintenance ManualInput Xmodem Transmit Block Missed ErrorThis occurs when a packet has been missed or came out of order duringXModem transmission.Jog Axes to Home Positions, Then Enter the CS CommandThis message appears at power on. If the axes are at...

  • Page 541

    March 2003Section 16: Troubleshooting525FadalMaintenance ManualN1 O1 (START OF PROGRAM N2 (ACCEPTABLE PROGRAM EXAMPLE)N3 L100 (SUB #1)N4 X1.N5 *N6 L200(SUB #2)N7 L105N8 M46N9 X-5.Y-1.N10 M47N11 *N12 L300 (SUB #3)N13 G91N14 L204N15 L104N16 G90N17 *N18 M17 ——— This ends the last subroutine.N1...

  • Page 542

    526Section 16: TroubleshootingMarch 2003FadalMaintenance ManualMetric Mode Required - Operator Must SetThe control, at power on, is in the Inches mode. The Metric mode must beturned on by using the SETME command.This message will appear if the G21 or G71 code is present in the program toverify th...

  • Page 543

    March 2003Section 16: Troubleshooting527FadalMaintenance ManualNo Angle, the Points Are the SameThe calculated angle, of either function 3 or 4 of L9101, is the same as theexpected angle.No Memory Available for New ProgramWhen this occurs, the operator will have to remove (delete) as many program...

  • Page 544

    528Section 16: TroubleshootingMarch 2003FadalMaintenance ManualWhen the programmer is inputting a program through the RS-232 port (usingthe command TA,1,0 or TA,1,1), the input will be terminated if the controldetects a bad programming word (EXAMPLE: O for 0, or double letters (XX1.5),etc.).The p...

  • Page 545

    March 2003Section 16: Troubleshooting529FadalMaintenance ManualOut of File Space, a File Compression is Being TriedThis message informs the programmer that the memory of the control isalmost full. It usually is displayed when editing the active program in memory,or during program input via the RS...

  • Page 546

    530Section 16: TroubleshootingMarch 2003FadalMaintenance ManualPallet Must Be ClampedThis message occurs when both pallets are in storage and a command is giveto make a pallet change. One of the pallets must be loaded and clamped onthe table before a pallet change can occur. The feedbacks for pal...

  • Page 547

    March 2003Section 16: Troubleshooting531FadalMaintenance ManualPlease Put an O Word at the First of the Current ProgramThe Following Programs Are in MemoryTo use the PR command, the active program must have an O word and anumber in the first line. The number must be different than the other numbe...

  • Page 548

    532Section 16: TroubleshootingMarch 2003FadalMaintenance ManualProgram Does Not ExistRetry or Hit Manual to ExitThis happens when the selected program number does not exist in theprogram library. Enter a program number that does exist, or press the MANUALbutton, and then use the PR command again ...

  • Page 549

    March 2003Section 16: Troubleshooting533FadalMaintenance ManualRails Not AlignedThis message occurs when the rails for the pallet changer are not aligned orthe feedback switches need adjustment. Call service department foradjustment.Return Pallet to the Load PositionThis message occurs when a pal...

  • Page 550

    534Section 16: TroubleshootingMarch 2003FadalMaintenance ManualServo Amplifier FaultThis message appears when the EMERGENCY STOP button is pressed. Theoperator must pull the button out (for ‘85 and older models) or turn it clockwise(for ‘86 to present models) and then press the JOG button to ...

  • Page 551

    March 2003Section 16: Troubleshooting535FadalMaintenance ManualSpindle Controller or Driver FaultPlease note error number and see list of Emergency Stop Error Messages atthe end of this chapter. This message is displayed if the spindle wascommanded to turn on after an emergency stop without press...

  • Page 552

    536Section 16: TroubleshootingMarch 2003FadalMaintenance ManualSpindle Failure During ReversalThis will occur when an M3 and an M4 are in the same line. If the spindle stopswhile in G74, G75 or G84 modes, this message will appear. Problems such asa dull tap, undersized hole, poor tapping lubrican...

  • Page 553

    March 2003Section 16: Troubleshooting537FadalMaintenance ManualSubr. Nesting ErrorThis is a message that occurs when a subroutine heading (L0100) is enteredafter the M30 code. This message will also occur if a Fixed Cycle is still active(use a G80 to cancel) or G68 (rotation) is still active when...

  • Page 554

    538Section 16: TroubleshootingMarch 2003FadalMaintenance ManualThread Lead Not Specified at N =Fixed cycles G74, G75 and G84 need a Q word in the line that represents thedecimal thread lead of the tap (see the Users Manual for the proper format). Ifthe Q word is omitted this message will appear.I...

  • Page 555

    March 2003Section 16: Troubleshooting539FadalMaintenance ManualTool Breakage Detection = Failure at N =When the TS-20 touch probe is used for tool breakage detection, this errorindicates the program line that the broken tool is detected at. Replace the tooland continue the program.Tool Diameter T...

  • Page 556

    540Section 16: TroubleshootingMarch 2003FadalMaintenance Manual(See Survey command in Maintenance Manual)Trouble Reading the External Slide Hold SwitchThe feedback from the external slide hold switches is erratic or inconsistent.This is an indication that the external slide hold switch system is ...

  • Page 557

    March 2003Section 16: Troubleshooting541FadalMaintenance ManualWriting Error, Wait 2 Min. and Retry(See Survey in the Axis Drive Systems Section.)X, Y, or Z Move Must Be Specified at N =Probe function #1 (L9101) has been programmed without an axis specified forthe given plane. For example, if pro...

  • Page 558

    542Section 16: TroubleshootingMarch 2003FadalMaintenance ManualZ & M6 Lockout is in EffectThis message indicates the Z axis and Tool Change Lockout option of the RunTime Menu has been selected. In this mode, Z axis movement and tool changecommands will not be performed during Dry Run. This op...

  • Page 559

    March 2003Section 16: Troubleshooting543FadalMaintenance Manual[ 5 ] NO INDEX MARK DETECTEDThis error appears during the cold start process, if the index mark of the axisprimary feedback device, encoder or scale, is not detected.[ 6 ] SWITCH 1 DISABLEDCurrently not used.[ 7 ] RIGID TAP PRECYCLE E...

  • Page 560

    544Section 16: TroubleshootingMarch 2003FadalMaintenance Manual[ 15 ] TIME OUT ERROR — RIGID TAP PRECYCLE TESTThis error appears during the rigid tap precycle process, if the spindle rotationis interrupted or the spindle magnet is not detected within the allowable time. [ 16 ] TIME OUT ERROR ...

  • Page 561

    March 2003Section 16: Troubleshooting545FadalMaintenance Manual[ 25 ] MOTOR OVERLOAD DURING CONTOURING MODE SEE ERROR CODE 13 ABOVE[ 26 ] MOTOR OVERLOAD DURING JOG MODE SEE ERROR CODE 13 ABOVETroubleshooting Checklist RS-232 CommmunicationsUse this procedure to determine which device or cable is ...

  • Page 562

    546Section 16: TroubleshootingMarch 2003FadalMaintenance Manualc. Data Bits - Sevend. Stop Bits - Onee. EOB (End Of Byte) - CR,LF (ASCII 13,10)f. Starting and ending character - % (ASCII 37)g. Xon/Xoff (Software handshaking) - disabled for TA or PU, enabledfor DNCh. Hardware handshaking - disable...

  • Page 563

    March 2003Section 16: Troubleshooting547FadalMaintenance Manualof each section. A gender changer may be needed to plug in themirror plug in some sections.• If a switch box is used in the chain of cables, it must be checked also.Check it in the same manner that the cables were checked.7) After t...

  • Page 564

    548Section 16: TroubleshootingMarch 2003FadalMaintenance ManualTroubleshooting ChartsChart 1Quick Checkout Chart 2Automatic Tool Changer Chart 3Spindle Driver Chart 4Axis Control Chart 5Repeatability Chart 6Computer Chart 7Axis Motor Runaways Chart 8Baldor SWEO Spindle Drive Chart 9Z200/Z300 ...

  • Page 565

    March 2003Section 16: Troubleshooting549FadalMaintenance ManualFigure 16-1 Quick Checkout ProcedureCHE CK D OOR S . (CE MA C HINES LIMIT M OV EME NT WHEN DO ORS ARE OP EN.) SE E CH A R T NO . 12 NO REPEATABI LI TY PROB LEM ? IS IT A SPIN DLE PROB LEM ? IS IT A T...

  • Page 566

    550Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-2 Quick Checkout Procedure (Continued)NO NO CHA RT 1 co n t i n u e d ( p ag e 2) Q U IC K CHE CK O U T P R O C E D U R E 9 - 20 -9 5 IS IT A FIN IS H PR O B LEM ? CH E C K BA L A N C E O F A XIS A M PL I F IE R S CH E C K S...

  • Page 567

    March 2003Section 16: Troubleshooting551FadalMaintenance ManualFigure 16-3 Quick Checkout Procedure (Continued)YES IS IT A RIGID TAPPING PROBLEM? SPINDLE INVERTER MUST BE LABELED "RIGID TAPPING" SPINDLE SOFTWARE (IN 1010-S) MUST BE RIGID TAP SEE CHART NO. 23 IS IT A POSITIONING PROBLEM?...

  • Page 568

    552Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-4 Automatic Tool ChangerNO CHECK TURRET FA CTOR IN SETP . CHECK GENEV A M ECHANISM . CHECK TURRET M OTOR WIRING. SERVO CHECK FUSES F5 & F6 & CB2 AND RELAYS K5, K33, K11, & K 12 ON 1100-2. K12 M UST BE LOW L...

  • Page 569

    March 2003Section 16: Troubleshooting553FadalMaintenance ManualFigure 16-5 Automatic Tool Changer (Continued)GO T O PA GE 3 OF CH A RT 2 NO YE S YE S CHE C K AT C HOME S WIT CH. CHECK ATC FA ULT SWIT CH. CHE C K CONTROL V OLTA GE AT K14. CHE C K SLI DE M OTO R & WIRING. ARE FUSE S F7, F...

  • Page 570

    554Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-6 Automatic Tool Changer (Continued)A IR P R ES SU R E M U ST BE 80 P S I A ND 1 2 0 P S I(M A X 3- 5 P S I DR O P DU RI NG T O O L CHA NG E ) NO YE S YE S YE S YE S CO NT INUE D FR O M P A GE 2 OF CH A R T 2 GO B A C K T O...

  • Page 571

    March 2003Section 16: Troubleshooting555FadalMaintenance ManualFigure 16-7 Spindle DriverYES NO YES SP INDLE RUNS IN ONE DI RECTION ONLY?SPINDLE RUNS WITH BATTERY BOX ? SPINDLE TAKES A LONG TIME T O STO P? NO NO YES YES NO YES YE S NO CHE CK ERROR MESS AGES ON INV ERTE R DISPLAY (MITSUBISHI INVE ...

  • Page 572

    556Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-8 Spindle Driver (Continued)NO NO NO NO SPINDLE MOTOR SHAKES? REMOVE BELTS, RUN SPINDLE AT MAXIMUM SPEED AND CUT POWER (MOTOR COASTS TO STOP) DOES SPINDLE MOTOR SHAKE WHILE COASTING?CONSULT FACTORY SERVICE DEPT. ABOUT BALA...

  • Page 573

    March 2003Section 16: Troubleshooting557FadalMaintenance ManualFigure 16-9 Axis ControlYE S YE S YES NO YES YES NO NO IF VOLTAGES ARE OUT OF TOLE RANC E , CHA NGE LOGIC POW ER S UPP LY NO YE S CO NSU LT FAC T ORY SE RVIC E DE PT .BE FORE REPLA CIN G SER VO MO TOR NO NO NO YE S YE S IS AX IS CO MP...

  • Page 574

    558Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-10 Axis Control (Continued)GO TO PAGE 3 OF CHART 4 MOTOR OVERLOADS? NO NO YES YES YES CHECK AND ADJUST RESOLVER CONNECTOR AT AXIS CARD J2 WITH SERVICE TOOL ST44 * CHECK RESOLVER CHECK BUS VOLTAGE AT BLUE CAPACITOR ON AMPLIF...

  • Page 575

    March 2003Section 16: Troubleshooting559FadalMaintenance ManualFigure 16-11 Axis Control (Continued)GO TO P A GE 4 OF CH A R T 4 CO N T I N U E D FR O M P A GE 2 OF CH A R T 4 IS T H E R E ST I L L A PR O B L E M ? DO E S E R R O R S T I L L OC CU R DU R I NG P R O G R A M EX E C U T I O N ? IN S...

  • Page 576

    560Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-12 Axis Control (Continued)CO NT INUE D FR O M PA GE 3 OF CH A R T 4 NO YE S NO YE S CH E C K SE T P PA RAM ET ER: "3 PH A S E > 5% LO W " SH O U L D BE YES NO NO NO IS M A CHINE WIRE D F O R 208 VA C ? DO ES 20...

  • Page 577

    March 2003Section 16: Troubleshooting561FadalMaintenance ManualFigure 16-13 RepeatabilityNO YE S CH E C K AN D AD J UST G IB S AND S TRA PS CH E C K BA L L SC R E W AL IG NM E N T SE R VIC E TH E SP IN D L E CO O L E R AS SE MB L Y AN D P U MP ASSE MB L Y IN S PE C T M O T O R CO UP L ER AND B...

  • Page 578

    562Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-14 ComputerEP R OM MO DU LE ( 1610) , EX PA N D ED M E MO RY ( 1460), AN D B U S BR ID G E (1730) MU ST BE FIR M L Y SE ATED IN TH E IR CO NNE C TO R S . CH E C K FO R B E NT P INS. YE S NO YE S PO W ER O N (W A IT A FEW SE ...

  • Page 579

    March 2003Section 16: Troubleshooting563FadalMaintenance ManualFigure 16-15 Axis Motor RunwaysP O W E R DO W N M A CHI NE . P R E S S EMERGE NC Y S T OP . C H E C K W I RI NG A T AMP A ND J 4 J U M P E R O N CO NTR O L L E R CA RD. C H E C K R E S O LV ER C O U P LE R . C H ECK A ND A D J U ST ...

  • Page 580

    564Section 16: TroubleshootingMarch 2003FadalMaintenance ManualTable 1: Baldor SWEO Spindle Drive Error MessagesDESCRIPTIONALARM DISPLAYThis fault occurs when the main bus supply voltage has gone too low, even momentarily.DCLOThis fault occurs when the main bus supply voltage has gone too high, e...

  • Page 581

    March 2003Section 16: Troubleshooting565FadalMaintenance ManualStall preventative function was activated during constant speed opera-tion and stopped the motor.EOLTMemory in the inverter is corrupted.E PEInverter input voltage fell below the specified limit. EUVTOvercurrent due to earth fault on ...

  • Page 582

    566Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-16 KeyboardNO NO NO YES NO 32MP ? 10. 1.2a NO YES NO NO DO ES DISP LAY CHANGE ? DASHED S YMBOLS AP PLY TO CE NORM EUROPEA N MACHINES ONLY IF PROB LEM RECURS, RE PLACE KEY BO ARD LO GIC (1090) YES NO YE S YES YES POSSIBLE CAU...

  • Page 583

    March 2003Section 16: Troubleshooting567FadalMaintenance ManualFigure 16-17 Keyboard (Continued)YES NO YES YES CONSULT FACTORY MISSES KEYSTROKES OR JOG PULSES IN CNC MODE BUT NOT IN DIAGNOSTICS? DISCONNECT RS232 CABLE AND TRY AGAIN (MILL LISTENS FOR KEYBOARD AND RS232 INPUT IN MILL MODE. NOISE ...

  • Page 584

    568Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-18 Finish ProblemsYES NO YES NO YES NO CHECK SIN/COS SIGNALS USING SERVICE TOOL ST48. ADJUST IF VARIANCE > 0.001V CHECK FOR SPINDLE VIBRATIONSDO CUTS HAVE A CRISS-CROSS APPEARANCE? (ESP X) DOES A BAD CUT CORRESPOND TO A ...

  • Page 585

    March 2003Section 16: Troubleshooting569FadalMaintenance ManualFigure 16-19 Bad Power/Bad VoltageNO NO YES NO YES NO DASHED SYMBOLS APPLY TO CE NORM EUROPEAN MACHINES ONLY CHART 12 BAD POWER/BAD VOLTAGE 6-16-95 BAD POWER/ BAD VOLTAGE CHECK INCOMING VOLTAGE AT MAIN DISCONNECT AND AT INPUTS TO TRAN...

  • Page 586

    570Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-20 Bad DC Voltage (Continued)NO YE S NO YE S NO YE S NO YE S NO NO YE S USE C LAM P-ON AM ME TE R TO CH ECK F OR EXCE SS IVE CURRE N T DRA W ON 120 VA C LIN E S FR OM TR ANS FOR M ER CHE C K INPUT VOLT AGE TO DC POW ER SU PP...

  • Page 587

    March 2003Section 16: Troubleshooting571FadalMaintenance ManualFigure 16-21 Rotary Heads A AxisNO YE S YE S MO T O R YE S YE S YE S YE S YE S CHA RT 1 3 RO T A R Y HE AD S A A X IS 7- 4 - 95 AX IS D EA D ? CH E C K RO TA RY H E AD FU SE GO T O CH A R T 4 AX IS CO NTRO L HEAD KE EP S BL OW IN G F...

  • Page 588

    572Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-22 TR65 Rotary Heads A & B AxesNO YE S YES NO YES NO YE S YE S YE S YE S YE S YE S YE S TR65 ROTA RY H EA DSA & B AXIS AX IS D EA D ? CH E CK RO TA RY HE AD FUSE GO T O CHA R T 4 AX IS CO N TROL HEAD KE EPS BLOW ING...

  • Page 589

    March 2003Section 16: Troubleshooting573FadalMaintenance ManualFigure 16-23 Tsudakoma 301RotaryHeads A & B AxesYE S YE S NO YE S YE S YE S YE S YE S YE S NO YE S YE S YE S AX IS D EA D ? CH E C K RO TA RY H E AD FU SE GO T O CH A R T 4 AX IS CO N TR O L HE A D KE EP S BL OW IN G FU SE S?CH E ...

  • Page 590

    574Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-24 Servo Coolant ControlYES YES NO NO YES SERVO COOLANT COOLANT NOZZLE WILL NOT MOVE ENCODER MUST BE CONNECTED (J5 OF 1010, J2 & J3 OF 1890-0, AND 9-PIN MOLEX AT MOTOR) AMPLIFIER MAY BE UNPLUGGED OR DEAD. CHECK AMPLIFI...

  • Page 591

    March 2003Section 16: Troubleshooting575FadalMaintenance ManualFigure 16-25 Circle RoundnessIN SP EC T ED O F F M A CHINE IS PA R T IN SP EC T ED O N O R O FF M A CHINE ? PL A C E DI AL I N DI CATO R IN S PIN D L E (A DJ UST X A N D Y SO SP IN DL E IS AT EX AC T C E NT E R O F H O LEAC CORD I ...

  • Page 592

    576Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-26 Circle Roundness (Continued)NO NO NO IS THERE A SUBPLATE OR LARGE HEAVY FIXTURING? REMOVE SUBPLATE OR FIXTURING. MACHINE MUST BE TESTED WITHOUT FIXTURING. SUBPLATES OR FIXTURING CAN INDUCE POSITIONING PROBLEMS THAT ARE...

  • Page 593

    March 2003Section 16: Troubleshooting577FadalMaintenance ManualFigure 16-27 Error CodesNO SP IN DLE MA GN E T W A S NO T DE TE CT ED F OR OVER 3 SECO N D S WH EN S P IND LE SHOULD HAVE BEEN T U R NING ERROR NUM B ER # MEANING DIA GNOS IS PR O CEDU R ES #1 NO M OTOR FEE D BA CK #2 ENCODE R NOT ...

  • Page 594

    578Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-28 Error Codes (Continued)OCCURS DURING SPINDLE OPERATION IF BOTH ENCODER F EEDBACK AND SPINDLE M AG NET ARE NOT DETECTED FOR LO NGER THAN 3 SECONDS NO YES #10 ENCODER AND M AG NET NOT RESPONDING OR SPINDLE NOT TURNING IS SP...

  • Page 595

    March 2003Section 16: Troubleshooting579FadalMaintenance ManualFigure 16-29 Error Codes#18 AM PLIF IER FAULT LINE DO WN AXIS CARD DO ES NOTDE TE CT F AULT LINE OR SIG NAL HAS FA LLEN BELOW 10V CHECK CABLING AND AMPLIFIER IF THE LS ECB I S LIT, CHE CK FOR MECHANICAL B IND THE STA CK ON THE AXIS CA...

  • Page 596

    580Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-30 Serial Port CommunicationsA L L CO M M U N I CA T I O N YE S YE S NO NO SIN G LE FIL E IS PR O B L E M W I T H A L L C O M M U N IC A T IO N S O R O N L Y A SIN G L E FILE ? LO O K F O R HI D D E N CH A R A C T E R S IN T...

  • Page 597

    March 2003Section 16: Troubleshooting581FadalMaintenance ManualFigure 16-31 Servo IndexerYE S YE S YE S NO NO NO YE S YE S NO NO YE S YE S NO YE S YE S YE S NO NO NO SE R VO IND EX ER WILL IND EX ER POW ER-UP? CH E CK FU SE ON B AC K OF CO NTROL B OX WITH MOT OR CA BLE DISCONNE CTE D,WILL IN DE X...

  • Page 598

    582Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-32 Servo Indexer (Continued)YES NO YES NO NO YES NO YES NO YES YES NO YES YES NO YES HEAD MISSES START PULSES? DISCONNECT INDEXER INTERF ACE CABLE AND RUN PROGRAM USING THE START BUTTO N.DO ES PROG RAM RUN PROPERLY? ARE YOU ...

  • Page 599

    March 2003Section 16: Troubleshooting583FadalMaintenance ManualFigure 16-33 Positioning ProblemsNO YE S NO YE S YE S NO YE S YE S YE S DO ES MA C H IN E HA V E SC A LES ? J13 ON 1 060 MU S T BE P LU G GE D IN FOR SC ALES TO W OR K R ELIABLY DI S C ON NEC T S C ALE S, PO WER DOWN MA CHI NE AND RES...

  • Page 600

    584Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-34 Positioning ProblemsNO CHECK RESOLVER CO NNECTO RS AT MOTORS CHECK FOR BROKEN OR LOO SERESOLVER CO UPLING S CHE CK BA LLSCREW ALIG NMENT USE CLAMP-ON AMMETER TO CHECK EACH AXIS .AMP DRAWS MUST BE IN SPE C A ND CONSI STENT...

  • Page 601

    March 2003Section 16: Troubleshooting585FadalMaintenance ManualFigure 16-35 Scale ProblemsSCALE NO YES YES YES, AND ERROR IS NOT EASILY RECREATED EXE BOARD NO, OR ERROR REOCCURS EASILY YES YES CHART 22 SCALE PROBLEMS10-20-95 SCALE PROBLEMS CAN SHOW UP AS SCALE ERRORS (AN ERROR CODE),MISPOSITIONIN...

  • Page 602

    586Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-36 Scale Problems (Continued)NO YES YES YES YES YES YES 22A.1.2 22A.1.2a YES NO NO YES NO SCALE EXE BOARD NO CAVITATION OR VIBRATION? DOES IT GO AWAY WHEN SCALES ARE DISCONNECTED? CHECK BACKLASH WITH SCALES DISCONNECTED.BACK...

  • Page 603

    March 2003Section 16: Troubleshooting587FadalMaintenance ManualFigure 16-37 Rigid TapYE S YE S YE S YE S NO NO YE S YE S NO YE S NOYE S NO NO NO NO YE S YE S CH ART 2 3 RIG ID T A P 10 - 2 0 -9 5 RI G ID T AP TAP P ED H O LE IS BA D ( NO G O )? TAP BR E AK S? T AP M U ST BE 2 F L UT E SP IR A L P...

  • Page 604

    588Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-38 M-Function(V O LT AG E AC R O SS TE RM IN AL S W IL L B E 0 WHE N CO N TAC TS CL OS E) YE S YE S YE S NO NO YE S NO CH ART 2 4 M- F U NCTIO N9- 19-9 5 M - FUNCTIO N DO ES N O T RE L E AS E? M - FUNCTIO N DO ES N O T AC ...

  • Page 605

    March 2003Section 16: Troubleshooting589FadalMaintenance ManualFigure 16-39 Indexer Wiring DiagramSHIELDBROWNREDORANGEBLUEWHITEBLACKWHITEBLACKREDBLACKREDBLACKWHITEGREENWHITE381216191317REDWHITE111J2J3J1J31J2J4J14321J2J4111J51J6KEYPADDISPLA YJ1111J31J151810-0-221341J11IN DEXERIN TE RFACEGREENBLACK...

  • Page 606

    590Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-40 Motor Cable Wiring & Bulkhead Connector Wiring8MO TOR WI RES ARE SH IELDE D.SHIELD MUST NOT TOUCH CO NDUCTO R!!!615319171341971216VI OLETBLACKSHIE LDGRAYBLUEGREENREDBROWNORANG EWHITEYELLOW101119- PIN CONNECTOR ON MOT ...

  • Page 607

    March 2003Section 16: Troubleshooting591FadalMaintenance ManualFigure 16-41 Servo Coolant Wiring

  • Page 608

    592Section 16: TroubleshootingMarch 2003FadalMaintenance ManualFigure 16-42 Servo Turret Wiring

  • Page 609

    March 2003Section 17: Service Programs593FadalMaintenance ManualSection 17: Service ProgramsThis section has a listing of all the programs that are used during assembly ofthe machine. The programs may be helpful when servicing the machine. It isnot necessary to type in the programs, as they are s...

  • Page 610

    594Section 17: Service ProgramsMarch 2003FadalMaintenance ManualO5802-X ResolverTestN1O5802(X RESOLVER TESTN2L100N3X1.G0N4X-1.N5G4P1000N6M17N7M30N8G91(START OF THE MAIN PROGRAMN9(THE TABLE WILL MOVE TO THE LEFT IN THE X AXISN10L130O5803-Y ResolverTestN1O5803(Y RESOLVER TESTN2L100N3Y-1.G0N4Y1.N5G4...

  • Page 611

    March 2003Section 17: Service Programs595FadalMaintenance ManualN13M5M6T3N14L101N15M5M6T2N16L101N17M5M6T10N18L101N19M5M6T9N20L101N21M5M6T8N22L101N23M5M6T7N24L101N25M5M6T6N26L101/N27M5M6T21/N28L101/N29M5M6T20/N30L101/N31M5M6T19/N32L101/N33M5M6T18/N34L101/N35M5M6T17/N36L101N37M5M6T16N38L101N39M5M6T...

  • Page 612

    596Section 17: Service ProgramsMarch 2003FadalMaintenance ManualO5806-Scrape ZHeadN1O5806(SCRAPE Z HEADN2L100N3X-0.1G0N4Y8.2N5Z0.1N6Y-8.2N7Z-0.1N8M17N9M30N10G91(START OF THE MAIN PROGRAMN11(N12(N13(TOOL SHOULD BE POSITIONED TO THE FRONT LEFTN14(OF THE SPINDLE DIAMETERN15(N16(N17L178N18X7.8O5807-X...

  • Page 613

    March 2003Section 17: Service Programs597FadalMaintenance ManualO5808-Y VibrationN1O5808(Y VIBRATIONN2L100N3Y-6.G0N4Y6.N5M17N6M30N7G91(START OF THE MAIN PROGRAMN8(N9(N10(CHECK THE Y AXIS MOTOR FOR VIBRATIONN11(N12(N13L101.1O5809-Z VibrationN1O5809(Z VIBRATIONN2L100N3Z-6.G0N4Z6.N5M17N6M30N7G91(STA...

  • Page 614

    598Section 17: Service ProgramsMarch 2003FadalMaintenance ManualO5810-OrientationN1O5810(ORIENTAIONN2L100N3M49N4S300N5M3N6G4P2500N7M19N8G4P2500N9S2501M3N10G4P2500N11M19N12G4P2500N13M48N14M17N15M30N16G91(START OF THE MAIN PROGRAMN17(N18(N19(CHECK ORIENTAION IN THE LOW AND HIGH RANGEN20(N21(N22L101...

  • Page 615

    March 2003Section 17: Service Programs599FadalMaintenance ManualO5812-X Balance680N1O5812(X BALANCE 680N2L100N3M49N4X6.G1F100.N5X-6.N6M17N7M30N8M91G91(START OF THE MAIN PROGRAMN9(N10(N11(BALANCE THE X TO 680 OR 1.660 VDCN12(AT THE COM AND SIG2 LUGS OF THE AMPLIFIERN13(N14(N15L101.1O5813-Y Balance...

  • Page 616

    600Section 17: Service ProgramsMarch 2003FadalMaintenance ManualO5814-Z Balance680N1O5814(Z BALANCE 680N2L100N3M49N4Z-6.G1F100.N5Z6.N6M17N7M30N8M91G91(START OF THE MAIN PROGRAMN9(N10(N11(BALANCE THE Z TO 680 ON THE CRT OR 1.660 VDCN12(AT THE COM AND SIG2 LUGS OF THE AMPLIFIERN13(N14(N15L101.1O581...

  • Page 617

    March 2003Section 17: Service Programs601FadalMaintenance ManualO5817-Spin FwdRevN1O5817(SPIN FWD REVN2L100N3M3S1000.2N4G4P3500N5M4N6G4P3500N7M17N8M30N9G91(START OF THE MAIN PROGRAMN10(N11(N12(TEST FOR SPINDLE RUNNING FORWARD AND REVERSEN13(N14(N15L101.1O5818-Workout2216N1O5818(WORKOUT 2216N2L100...

  • Page 618

    602Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN30(MOVES BEFORE TOOL CHANGE TESTN31M3S1000N32X3.Y3.Z-3.G0N33X-3.Y-3.Z3.N34M17N35L300N36(TOOL CHANGER TURRET TEST FULL 360 DEGREE ROTATIONN37L201N38M5M6T1N39L201N40M5M6T11N41L201N42M5M6T21N43L201N44M5M6T11N45L201N46M17N47L400N48(STEP...

  • Page 619

    March 2003Section 17: Service Programs603FadalMaintenance ManualN75M19N76M3S10000N77G4P2500N78M4S10000N79G4P2500N80M3S10000N81G4P2500N82M4S10000N83G4P2500N84M17N85L500N86L101N87L301N88L401N89M17N90M30N91G91(START OF THE MAIN PROGRAMN92(N93(N94(****************************N95(********* WARNING ***...

  • Page 620

    604Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN16Z-16.N17Y10.N18X-20.N19Y-10.N20Y-10.N21X20.N22X20.N23Y10.N24Y10.N25X-20.N26Y-10.N27Z16.N28M17N29L200N30(MOVES BEFORE TOOL CHANGE TESTN31M3S1000N32X3.Y3.Z-3.G0N33X-3.Y-3.Z3.N34M17N35L300N36(TOOL CHANGER TURRET TEST FULL 360 DEGREE ...

  • Page 621

    March 2003Section 17: Service Programs605FadalMaintenance ManualN61M+R3S8000N62G4P3500N63M19N64M+R3S10000N65G4P4000N66M19N67M+R3S300N68G4P2000N69M19N70M+R3N71G4P2000N72M19N73M+R3N74G4P2000N75M19N76G4P2000N77M17N78L500N79L101N80L301N81L401R3+0.0003(SPINDLE FORWAREN82L401R3+0.0004(SPINDLE REVERSEN8...

  • Page 622

    606Section 17: Service ProgramsMarch 2003FadalMaintenance ManualO5820-Workout6030N1O5820(WORKOUT 6030N2L100N3(WORK AXIS TO LIMIT WITH Z ALL THE WAY UPN4Z4.G0N5Y10.N6X-30.N7Y-10.N8Y-10.N9X30.N10X30.N11Y10.N12Y10.N13X-30.N14Y-10.N15Z-4.N16Z-26.N17Y10.N18X-30.N19Y-10.N20Y-10.N21X30.N22X30.N23Y10.N24...

  • Page 623

    March 2003Section 17: Service Programs607FadalMaintenance ManualN46M17N47L400N48(STEP UP THE RPM AND TEST ORIENTATIONN49M+R3S1000N50G4P1500N51M19N52M+R3S2500N53G4P1500N54M19N55M+R3S2501N56G4P1500N57M19N58M+R3S5000N59G4P1500N60M19N61M+R3S8000N62G4P1500N63M19N64M+R3S10000N65G4P2000N66M19N67M+R3S300...

  • Page 624

    608Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN91(START OF THE MAIN PROGRAMN92(N93(N94(****************************N95(********* WARNING **********N96(****************************N97(N98(N99(NO TOOLS CAN BE IN THE SPINDLE AND NOTHING ON THE TABLEN100(N101(N102M0N103L501.1O5821- ...

  • Page 625

    March 2003Section 17: Service Programs609FadalMaintenance ManualO5822 -Y Calib 2216N1O5822(Y CALIB 2216N2L100N3Z0.4G1F40.N4Y0.99Z-0.4N5F2.9Y0.01N6G4P3000N7M17N8M30N9G91(START OF THE MAIN PROGRAMN10(N11(N12(VMC 2216 Y AXIS CALIBRATIONN13(N14(N15M5M19N16Z0.4G1F40.N17Y-0.2N18Y0.19Z-0.4N19F2.9Y0.01N2...

  • Page 626

    610Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN19F2.9X0.01N20M0N21(ZERO INDICATOR DIALN22L139N23F40.Z0.4N24X-39.2N25X0.19Z-0.4N26F2.9X0.01O5824 — Y Calib4020N1O5824(Y CALIB 4020N2L100N3Z0.4G1F40.N4Y0.99Z-0.4N5F2.9Y0.01N6G4P3000N7M17N8M30N9G91(START OF THE MAIN PROGRAMN10(N11(N...

  • Page 627

    March 2003Section 17: Service Programs611FadalMaintenance ManualN10(N11(N12(VMC 6030 X AXIS CALIBRATIONN13(N14(N15M5M19G1N16F40.Z0.4N17X-0.2N18X0.19Z-0.4N19F2.9X0.01N20M0N21(ZERO THE INDICATORN22L159N23F40.Z0.4N24X-59.2N25X0.19Z-0.4N26F2.9X0.01O5826-Y Calib 6030N1O5826(Y CALIB 6030N2L100N3F40.Z0....

  • Page 628

    612Section 17: Service ProgramsMarch 2003FadalMaintenance ManualO5828-Scrape 6030TableN1O5828(SCRAPE 6030 TABLEN2(N3(SET Z HOME +.010 ABOVE TABLEN4(SET X HOME +30.0N5(SET Y HOME -14.7N6(N7L100N8X-0.3Y0.3I-0.3N9X-0.3Y-0.3J-0.3N10G4P175N11L200N12X-0.3Y-0.3J-0.3N13G4P175N14X-0.3Y0.3I-0.3N15L300N16L1...

  • Page 629

    March 2003Section 17: Service Programs613FadalMaintenance ManualO5829 — Mill 6030TableN1O5829(MILL 6030 TABLEN2(N3(SET Z HOME +.010 ABOVE TABLEN4(SET X HOME +30.N5(SET Y HOME -13.75N6(N7G91M0(CHECK IF TOOL IS .01 ABOVE DESIRED DEPTH OF CUT?N8M3S200N9G1F0.1Z-0.01N10F4.X-60.N11Y5.5N12X60.N13Y5.5N...

  • Page 630

    614Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN22L266N23Z0.01N24X39.6G5N25L400N26Z-0.01F150.G1N27L112N28Z0.01N29X7.2G5N30Y0.6G5N31Z-0.01N32L212N33Z0.01N34X7.2G5N35M17N36M30N37G91M19N38M0(CHECK IF TOOL IS ORIENTED WITH LOWEST PART TO THE LEFTN39 (***TOOL TIP IS .01 ABOVE TABLE ...

  • Page 631

    March 2003Section 17: Service Programs615FadalMaintenance ManualO5831-Mill 4020TableN1O5831(MILL 4020 TABLEN2(N3 (SET Z HOME +.01N4 (SET X HOME +20.N5 (SET Y HOME -10.N6(N7M0(CHECK IF TOOL IS .01 ABOVE DESIRED DEPTH OF CUTN8G91M3S150N9G0Y9.9N10G1F2.Y0.1Z-0.01N11F3.X-40.N12Y8.25N13X40.N14Y-16.5N15...

  • Page 632

    616Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN26Z-0.01F150.G1N27L132N28Z0.01N29X19.2G5N30Y0.6G5N31Z-0.01N32L232N33Z0.01N34X19.2G5N35M17N36M30N37G91M19N38M0 (CHECK IF TOOL IS ORIENTED WITH LOWEST PART TO THE LEFTN39(*** TOOL TIP IS .01 ABOVE TABLE ***N40 (SET LEFT TOOL .01 ...

  • Page 633

    March 2003Section 17: Service Programs617FadalMaintenance ManualO5834-Scrape 20TableN1O5834(SCRAPE 20 TABLEN2(N3(SET Z HOME +.01 ABOVE TABLEN4(SET X HOME 8.25N5(SET Y HOME -7.8N6(N7L100N8X-0.3Y0.3I-0.3N9X-0.3Y-0.3J-0.3N10G4P175N11L200N12X-0.3Y-0.3J-0.3N13G4P175N14X-0.3Y0.3I-0.3N15L300N16Z-0.01N17...

  • Page 634

    618Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN46(**N47(**N48L426N49Y-15.6N50M2O5835-Test ScalesN1O5835(TEST SCALESN2L100(TEST 6030 X-TESTN3G0X-30.N4G1F50.X60.N5G0X-30.N6G4P3000M1N7L200(TEST 6030 Y-AXISN8G0Y-15.N9G1F50.Y30.N10G0Y-15.N11G4P3000M1N12L300(TEST 4020 X-AXISN13G0X-20....

  • Page 635

    March 2003Section 17: Service Programs619FadalMaintenance ManualO5836-Test CutN1O5836(TEST CUTN2(11-10-92N3L100N4M6T11(TOOL 11=.500 DIA. ROUGHING ENDMILLN5G90S7000M3N6X0.75Y4.G0N7H11Z-1.7M7N8X0F75.G1G41N9Y1.G8N10X-1.Y0I-1.G2N11X-2.9G1N12X-3.9Y1.J1.G2N13Y2.9G1N14X-2.9Y3.9I1.G2N15X-1.G1N16X0Y2.9J-1...

  • Page 636

    620Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN46X-0.6242Y0.6242I-1.3258J1.3258G2N47X0Y0G40N48G8N49G41Y0.3536G1N50X-3.5464Y3.9N51X-3.9Y3.5464N52X-0.3536Y0N53G40X0.5Y0G0N54Y2.8N55X0.2Y3.1198G41G1F50.N56X-1.7Y3.4548N57X-1.7Y2.8456N58X0.2Y2.5105N59X0.2Y3.1248N60X-1.7Y3.4598N61X-1.7...

  • Page 637

    March 2003Section 17: Service Programs621FadalMaintenance ManualN91G8N92X-0.6492Y0.6492G1G41N93X-0.6492Y0.6492I-1.3008J1.3008G2N94X0Y0G1N95G40N96G8N97Y0.3889G41N98X-3.5111Y3.9G1N99X-3.9Y3.5111N100X-0.3889Y0N101G40X0N102M5M9N103G28N104M2O5837-Probe CycleTestN1O5837(PROBE CYCLE TESTN2L100(FIND TARG...

  • Page 638

    622Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN31G31G1F50.Z-26.N32G91N33Z-0.05N34Z0.075N35G90N36G31G1F0.5Z-26.P1N37L9101R1+5.N38G10L12P87R+R1(STORE TOUCH POINT IN TOOL TABLEN39D87N40M17N41M30N42G90G1G80G40G17M49N43G10L12P75R+0(ZERO COUNTERN44L101(INITIAL POINTN45L201(ADJUST RANG...

  • Page 639

    March 2003Section 17: Service Programs623FadalMaintenance ManualN17Z-0.5N18M5N19Z-0.5N20S10000M3N21Z0.1N22M5N23Z0.1N24M3N25Z0.8N26M2O5839-PalletChangerN1O5839(PALLET CHANGER)N2(TABLE MODIFICATIONS FOR FADAL PALLET CHANGER)N3L100(3/8-16 8PLS)N4G90N5X-19.625Y1.25N6X-19.625Y-1.25N7X-16.375Y-1.25N8X-...

  • Page 640

    624Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN35X7.467N36Y3.75X7.467N37X9.779N38X12.091N39X14.403N40Y-3.75X14.403N41X12.091N42X9.779N43X7.467N44Y-7.5X7.467N45X9.779N46X12.091N47X14.403N48M17N49L300(.390 DIA HOLES 16 PLS)N50G90N51X-14.404Y5.22N52X-12.091N53X-9.779N54X-7.468N55Y-...

  • Page 641

    March 2003Section 17: Service Programs625FadalMaintenance ManualN80M6T2(.312 DRILL)N81G90G0S1400M3N82H2Z-0.9X-16.8Y7.6N83G83G98R-0.9Q0.14F6.Z-2.1N84L101N85R-2.Z-3.285N86L201N87G80N88M5M9N89G28N90M6T3(3/8-16 TAP EXTENDED)N91G90G0S200M3N92H3Z-0.9X-19.7Y1.3N93G84G98R-0.9Q0.0625F200.Z-1.8N94L101N95R-...

  • Page 642

    626Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN125X17.434G1N126Y-5.22G5N127X5.75G1N128X-5.75G5N129X-17.434G1N130M5M9N131G28N132M6T6(1.5 DIA BALL)N133G90G0S3200M3N134X-18.37Y5.32H6Z2.N135Z1.255Y5.22X-18.37N136X-5.75G1F30.N137X5.75G5N138X18.37G1N139Y-5.22G5N140X5.75G1N141X-5.75G5N...

  • Page 643

    March 2003Section 17: Service Programs627FadalMaintenance ManualN13X-39.N14Y-2.375N15X0N16M5M9N17G0G49Z0N18M2O5841-Mill PalletSlot .687-.689N1O5841(MILL PALLET SLOT .687-.689N2(HOME POSITION X=18.75 Y=0 Z=0N3(SET TOOL 1.0 ABOVE PALLET TABLEN4(.500 DIA. 2FL ENDMILLN5G0G90M3S10000N6H1Z-1.375M8N7G1G...

  • Page 644

    628Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN8(********************N9(START C. DRILLN10G0G90N11H1N12M3S2000N13G81G99Z-1.15R-0.9F15.N14X13.25Y3.N15Y7.334N16Y11.666N17Y16.N18G80N19Z0G0M5N20M6T2N21(START .390 DRILLN22G0G90N23H2N24M3S1100N25G83G99R-0.9Z-2.9F10.Q0.1X13.25Y16.N26Y11...

  • Page 645

    March 2003Section 17: Service Programs629FadalMaintenance ManualN9X-20.F3.N10Y8.N11X20.N12Y-16.N13X-20.N14Y8.1N15Z0.01N16M5N17M2O5845-Mill VMC 15N1O5845(MILL VMC 15N2(N3(HOME X+10.N4( Y+5.5N5( Z+.01N6(N7S150M3(USE VMC15 CUTTERN8Z-0.01F1.G1N9X-20.F3.N10Y11.N11X20.N12Y-11.N13Z0.01N14M5N15M2O600...

  • Page 646

    630Section 17: Service ProgramsMarch 2003FadalMaintenance ManualTA,5 ProgramsO5827-Cycle TestN1O5827(CYCLE TEST)N2L100(BEGIN XY RECIPN3G0G90N4G53X10.Y-8.N5G1N6G53X-10.Y8.N7M11N8M12N9M17N10L200(Z RECIP)N11G0G90N12Z0N13G1N14G53Z4.(MOVE FROM SETZ TO TOP STROKE)N15M13N16M17N17L300(A AXIS RECIP)N18G91...

  • Page 647

    March 2003Section 17: Service Programs631FadalMaintenance ManualN43G90X0N44G80N45M3N46G4P3000N47M5/N48T-5/N49G91/N50G74.1R+0Z-R2Q0.0714F+R1/N51G91X-0.1/N52T-4/N53X-0.1/N54T-3/N55X-0.1/N56T-2/N57X-0.1/N58T-1/N59G90X0/N60G80/N61M3/N62G4P3000/N63M5N64L600(CYCLE ORIENTATION AND TURRET)N65#V11=V11+1N6...

  • Page 648

    632Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN88G53Z4.X-10.Y-8.N89M19N90G4P5000N91X10.Y8.Z0M3(TO Z HOME)N92M19N93G4P5000N94L900(SPINDLE RUN TEST)N95T-10N96G4P20000(20 SECONDS)N97T-1N98G4P20000N99L1000(CHECK Z DISTANCE)N100(THE AZ IS CURRENT DISTANCE FROM Z HOME)N101(TEST SO Z M...

  • Page 649

    March 2003Section 17: Service Programs633FadalMaintenance ManualN133#IF V1=-1 THEN PRINT “1- 4TH AXIS”N134#IF V2=1 THEN PRINT “* 2- 5TH AXIS”N135#IF V2=-1 THEN PRINT “2- 5TH AXIS”N136#IF V3=1 THEN PRINT “* 3- RIGID TAP”N137#IF V3=-1 THEN PRINT “3- RIGID TAP”N138#IF V4=1 THEN P...

  • Page 650

    634Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN178#:NOARICPN179#IF V2=0 THEN:NOBRICPN180L401N181#:NOBRICPN182(AXES RECIPROCATING)N183(TESTS WITH XY MAYBE A,B)N184(N185L1001(MOVE TO Z+4 FROM CS AND SET R2)N186G91N187#IF R2 GT 4 THEN R2=4N188G83R+0Z-R2Q0.5F150.N189M45/N190M45/N191...

  • Page 651

    March 2003Section 17: Service Programs635FadalMaintenance ManualN223#:CALLOOPN224#R1=V10N225S+R1N226M3N227G4P2000N228G84.2N229G4P4000/N230M4/N231G4P2000/N232G74.2/N233G4P4000N234#V10=V10+V11N235#IF V10 LT 2000 THEN:CALLOOPN236#:NORIGIDN237(CYCLE ORIENTATION)N238#V11=0N239S100N240L602N241S500N242L...

  • Page 652

    636Section 17: Service ProgramsMarch 2003FadalMaintenance ManualN267T-1N268M10N269G4P10000N270G0G28N271(CYCLE GAIN SELECTION, 3 SEC PER TEST)N272#:GAINSELN273L703/N274L712N275#IF V3=0 THEN:NORIGIDCYCLEN276(RIGID TAP CYCLES:G84.1,G74.1)N277R1+750.N278L501N279R1+3000.N280L501N281#:NORIGIDCYCLEN282(...

  • Page 653

    March 2003Section 17: Service Programs637FadalMaintenance ManualN312L401N313#:NOBRICP1N314M31(CYCLE PALLET)N315G4P2000N316M31N317G4P2000N318M31N319G4P2000N320M31N321G4P2000N322M5N323M10N324G4P10000N325G0G28N326#:NOPALLETN327#GOTO:RUNLOOP6001-Ballbar TestN106001(BALLBAR XY PLANE 5.907 RADIUSN2G91N...

  • Page 654

    638Section 17: Service ProgramsMarch 2003FadalMaintenance ManualThis page intentionally left blank.

  • Page 655

    March 2003Section 18: Fuses, Heaters, Parameters639FadalMaintenance ManualSection 18: Fuses, Heaters, Parameters

  • Page 656

    640Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance Manual

  • Page 657

    March 2003Section 18: Fuses, Heaters, Parameters641FadalMaintenance Manual

  • Page 658

    642Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance Manual

  • Page 659

    March 2003Section 18: Fuses, Heaters, Parameters643FadalMaintenance ManualTable 1: Parameter SettingsOptions in SETP ModeAvailable FormatsFactory SettingCustomer PreferenceThere are two Program Formats available.Do you want 6MB/10M/11M compatibility (Format 2)?1&22Enter the default Baud rate ...

  • Page 660

    644Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualTurn the Command Menus ON or OFF?1&23Do you have a Pallet Changer?1&2Enter the Gain factor for Rigid TappingThe factor must be between 0 and 2551&2Enter the Ramp factor for Rigid TappingThe factor must be betwee...

  • Page 661

    March 2003Section 18: Fuses, Heaters, Parameters645FadalMaintenance ManualMachine ParametersThis section covers parameter settings and their purpose. To enter the parameter setting area of a Fadal VMC, type “SETP” at the“ENTER NEXT COMMAND” prompt and press the <ENTER> key.To enter ...

  • Page 662

    646Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualMachine Parameters: Page OneFORMATDO YOU WANT MAXIMUM 6MB/10M/11M CAPABILITY? 1)NO, ORIGINAL FADAL STYLE – FORMAT 1 2)YES, F...

  • Page 663

    March 2003Section 18: Fuses, Heaters, Parameters647FadalMaintenance ManualAXES: X,Y,ZENTER THE AXIS CONFIGURATION1)A2)A, B3)X,Y,Z4)X,Y,Z,A5)X,Y,Z,A,B6)X,Y,Z,B7)C onlyWhen selecting the axes, the machine must be powered off. When the power isreturned the axes selected will be active. COLD START mu...

  • Page 664

    648Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualDEFAULT: G0ENTER THE DEFAULT VALUE1)G02)G1The code selected is active at power on and when entering the MDI mode. TheG0 is rapid travel and the G1 is linear interpolation (travels at a stated feedrate).A-AXIS RATIOENTER A-A...

  • Page 665

    March 2003Section 18: Fuses, Heaters, Parameters649FadalMaintenance ManualB-AXIS RATIOENTER B-AXIS RATIONote: Displayed only when B axis selected 1) 90:12) 180:13) 360:14) 120:15) 72:16) COOLANT7) 60:18) 144:1Select the appropriate gear ratio for the rotary table bein...

  • Page 666

    650Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualIMM. FIXED CYCLESHOULD A FIXED CYCLE EXECUTE IMMEDIATELY? Note: Displayed only when Format 1 is selected. 1)YES2)NO, ONLY IF X OR Y DIMENSION WORDS ARE IN THE DEFINITION LINEA ...

  • Page 667

    March 2003Section 18: Fuses, Heaters, Parameters651FadalMaintenance ManualORIENTATIONFACTORENTER THE SPINDLE RPM ADJUSTMENTFACTOR THE FACTOR MUST BE BETWEEN 0 AND 31This parameter adjusts the speed command signal voltage from the spindle controller card to the spindle drive in small increments in...

  • Page 668

    652Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualPU FORMATSELECT PUNCH OUTPUT FORMAT1)PUNCHED TAPE FORMAT (TELETYPE STYLE)2)COMPUTER FILE FORMAT (NO NULLS)This parameter is set to file for computer use. The punch tape format is usedwhen a tape reader is used.N-WORDS ORDER...

  • Page 669

    March 2003Section 18: Fuses, Heaters, Parameters653FadalMaintenance ManualBINARY BUFFERS:255SELECT THE NUMBER OF BINARY BUFFERSLOOKAHEAD.1) 15 3) 50 5) 2552) 30 4) 100The BINARY BUFFERS parameter can be changed to increase or decrease thecontrol look ahead. The factory sets the buffer...

  • Page 670

    654Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualPALLETDO YOU HAVE A PALLET CHANGER?1)NO2)YESSelect yes if a Fadal pallet changer is installed. GAINENTER THE GAIN FACTOR FOR RIGID TAPPINGTHE FACTOR MUST BE BETWEEN 0 AND 255This parameter effects the spindle response durin...

  • Page 671

    March 2003Section 18: Fuses, Heaters, Parameters655FadalMaintenance ManualOVERLOADENTER THE MOTOR OVERLOAD FACTOR(2 IS STANDARD)THE FACTOR MUST BE BETWEEN 1 AND 8This parameter determines the allowable following distance the actual axisposition can be behind the computer commanded position. Each ...

  • Page 672

    656Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualZ TAP GAINSELECT THE Z GAIN DURING RIPID TAPPING?1)NORMAL2)MEDIUM3)HIGHThis parameter should be set to Normal for Millimeter and High for Inch ballscrews. It determines the gain of the Amplifier. VECTORDO YOU HAVE VECTOR D...

  • Page 673

    March 2003Section 18: Fuses, Heaters, Parameters657FadalMaintenance ManualA-PALLETWHICH ROTARY AXIS IS INSTALLED ONTHIS PALLET?1)NOT APPLICABLE2)A-AXIS3)B-AXIS4)A-AXIS & B-AXISSelect the appropriate option for the rotary axis being used.B-PALLETWHICH ROTARY AXIS IS INSTALLED ONTHIS PALLET?5)N...

  • Page 674

    658Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance ManualAIR VALVEFEEDBACKDO YOU HAVE AIR VALVE FEEDBACK?1)NO2)YESAnswer NO only for machines built previous to having feedback on thedrawbar.AT SPEEDWAIT UNTIL SPINDLE IS AT-SPEED BEFORE NEXT BLOCK IS EXECUTED?1)NO2)YESThis will in...

  • Page 675

    March 2003Section 18: Fuses, Heaters, Parameters659FadalMaintenance ManualTypical TRM ParametersThe following parameters in red are the typical settings for the Tool Room Millmachine:PAGE 1 OF 3*FORMAT: 1 BAUD RATE: 2400 SPINDLE AFTER M6: NO AXES: X,Y,Z ...

  • Page 676

    660Section 18: Fuses, Heaters, ParametersMarch 2003FadalMaintenance Manual

  • Page 677

    March 2003 INDEX647FadalMaintenance ManualINDEXNumericsactionGoToR:15/15XT 5actionGoToR:15K Air/Oil Spindle Installation 293actionGoToR:Install Component actionGoToR:Plumbing 297actionGoToR:Plumbing Spindle 296actionGoToR:Wiring Harness Installation 295actionGoToR:2016L 12actionGoToR:2216 8action...

  • Page 678

    648 INDEXMarch 2003FadalMaintenance ManualactionGoToR:Replacing the Turret Motor on a Servo Turret ATC 121actionGoToR:Turret Factor Setting 122actionGoToR:Attached Optional Devices 325actionGoToR:Access from Program Using Macro actionGoToR:Statement #DISK 339actionGoToR:Macro Statement actionGoTo...

  • Page 679

    March 2003 INDEX649FadalMaintenance ManualactionGoToR:Electrical Operation actionGoToR:107actionGoToR:Programming 107actionGoToR:Servo Turret Controller and Amplifier actionGoToR:Boards (PCB-0108) 113actionGoToR:Tool Change Sequence 109BactionGoToR:Ball Pockets Incorrect actionGoToR:279actionGoTo...

  • Page 680

    650 INDEXMarch 2003FadalMaintenance ManualactionGoToR:Power 312actionGoToR:Terminals 312actionGoToR:Electrostatic Discharge actionGoToR:(ESD) 306actionGoToR:Emergency Stop Circuit Overview 313actionGoToR:Axis Controller 1010-6 319Basic Hardware Operation DescriptionNormal Operation (No Fault)acti...

  • Page 681

    March 2003 INDEX651FadalMaintenance ManualDactionGoToR:Diagnostic System Commands 483actionGoToR:DS - DisplayactionGoToR: Switches 483actionGoToR:Diagnostics 483actionGoToR:Drawbar Cylinder BusactionGoToR:hing 277actionGoToR:Drawbar Cylinder Plate 277actionGoToR:Drive Control 6 actionGoToR:Pin Mo...

  • Page 682

    652 INDEXMarch 2003FadalMaintenance ManualactionGoToR:Binary Number Groupings actionGoToR:477actionGoToR:Binary Numbers 475actionGoToR:Number Systems 475actionGoToR:Communications Troubleshooting 463actionGoToR:Cables 466actionGoToR:Computer and Computer IO actionGoToR:Port 467actionGoToR:Environ...

  • Page 683

    March 2003 INDEX653FadalMaintenance ManualactionGoToR:Monitoring Position Changes 479actionGoToR:Probe 480actionGoToR:Rough Cut / Cool Down actionGoToR:/ Finish Cut 479actionGoToR:VMC Options 479actionGoToR:Warm Up 478HactionGoToR:Heidenhain Tester 428actionGoToR:HoldactionGoToR: Down Clampaction...

  • Page 684

    654 INDEXMarch 2003FadalMaintenance ManualactionGoToR:Moving the VMC-Crane actionGoToR:55actionGoToR:Moving the VMC-Fork Lift 54actionGoToR:Placing the VMC 56actionGoToR:Power Check 58actionGoToR:Unlocking Front Doors actionGoToR:with CE Door Locks 53actionGoToR:Unpacking 53actionGoToR:Installati...

  • Page 685

    March 2003 INDEX655FadalMaintenance ManualactionGoToR:Machine Parameters 632actionGoToR:3 PHASE NO 5% actionGoToR:LOW NO 638actionGoToR:5THactionGoToR: AXIS HEADactionGoToR: 644actionGoToR:A-AXIS RATIO 635actionGoToR:AIR VALVE FEEDBACK 645actionGoToR:A-PALLET 644actionGoToR:ASPECT 641actionGoToR:...

  • Page 686

    656 INDEXMarch 2003FadalMaintenance ManualactionGoToR:TRAVEL 634actionGoToR:TURRET FACTOR 640actionGoToR:VECTOR 643actionGoToR:XYZ RAMP 642actionGoToR:Z TAP GAIN 643actionGoToR:Menu Diagnostics actionGoToR:486actionGoToR:MenuactionGoToR: PageactionGoToR: 1 486actionGoToR:MenuactionGoToR: Pageacti...

  • Page 687

    March 2003 INDEX657FadalMaintenance ManualactionGoToR:Preferred Service 50actionGoToR:Pre-Installation Procedures 41actionGoToR:Primary Grounding actionGoToR:47actionGoToR:Probes 371actionGoToR:MP-11 Probe 371actionGoToR:MP-12 Probe 372actionGoToR:TS-27 372actionGoToR:Probes & ScalesactionGoT...

  • Page 688

    658 INDEXMarch 2003FadalMaintenance ManualactionGoToR:Scale Box Installation / Top Mount actionGoToR:421actionGoToR:Scales 373actionGoToR:1580 Board Setup actionGoToR:414actionGoToR:Installing Scales 373actionGoToR:Scheduled Maintenance actionGoToR:75actionGoToR:Cooling Fans 78actionGoToR:Dual Ar...

  • Page 689

    March 2003 INDEX659FadalMaintenance ManualactionGoToR:O5811-Balance InchactionGoToR: 595, Metric actionGoToR:700ipm 302 586actionGoToR:O5812-X Balance 680 actionGoToR:587actionGoToR:O5813-Y Balance 680 actionGoToR:587actionGoToR:O5814-Z Balance 680 actionGoToR:588actionGoToR:O5815-A or B 680 Bala...

  • Page 690

    660 INDEXMarch 2003FadalMaintenance ManualactionGoToR:Drawbar Removal 283actionGoToR:Remove Floater (This will rarely actionGoToR:be necessary.) actionGoToR:284actionGoToR:Replace Belleville Springs 284actionGoToR:Spindle Drive SystemactionGoToR:s 239actionGoToR:Adjustments 244actionGoToR:Adjusti...

  • Page 691

    March 2003 INDEX661FadalMaintenance ManualTactionGoToR:Table & T-Slot Dimensions 33actionGoToR:15 & 2016L TablactionGoToR:e 33actionGoToR:15, 15XT,actionGoToR: 2216, 3016,actionGoToR: 2016L & 3016L T-actionGoToR:SlotsactionGoToR: 34actionGoToR:15XTactionGoToR: & 3016L TablactionGo...

  • Page 692

    662 INDEXMarch 2003FadalMaintenance Manual3. Insufficient Air VolumeactionGoToR:MAC In-Line Valve 277actionGoToR:4. Air Leaks actionGoToR:277actionGoToR:5. Air Leaks actionGoToR:277actionGoToR:6. Air Leaks actionGoToR:277actionGoToR:7. Air Leaks actionGoToR:277actionGoToR:8. Air Leaks actionGoToR...

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