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    SafetySectionFadalThis safety section covers information for: VMCs EMC, 5, 10, 15, 15XT, 2016L, 2216, 3016, 3016L, 3020, 4020, 4020A, 4525, 5020A, 6030, 6535 and 8030; Rotary Tables VH65, TR65, and V300 (400) MM; and VH5C Indexer.

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    August 2001SS-iSafety SectionSAFETY SECTIONFadalTABLE OF CONTENTSTABLE OF CONTENTS............................................................................................................................... 1MODIFICATIONS, ALTERATIONS, AND CHANGES..................................................

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    SAFETY SECTIONSafety SectionSS-iiAugust 2001FadalCE SAFETY LABELS................................................................................................................................... 37LBL-0431 small (CE) LBL-0434 large (CE) .............................................................

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    SAFETY SECTIONSafety SectionSS-2May 2002FadalCorporate Office voice (818) 407-1400fax (818) 407-0020Service / Parts voice (818) 727-2100fax (818) 407-1004Programming Support voice (818) 727-2100fax (818) 407-0061support@fadal.com20701 Plummer Street Chatsworth California 91311 U.S.A.The i...

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    May 2002SS-3Safety SectionSAFETY SECTIONFadalMODIFICATIONS, ALTERATIONS, AND CHANGESDo not modify or alter this equipment without the written approval of Fadal Machining Centers. Unauthorized changes may lead to hazardous conditions. Address any questions to Fadal’s Service Department.

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    SAFETY SECTIONSafety SectionSS-4May 2002FadalSAFETY WARNINGS1. WARNING! WEAR ANSI or CE APPROVED SAFETY GLASSES AT ALL TIMES. Everyday glasses are not designed for protection. Only ANSI or CE approved safety glasses have impact resistant lenses. Hearing protection must be worn when operations exc...

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    May 2002SS-5Safety SectionSAFETY SECTIONFadal18. DO NOT OPERATE THE MACHINE IN AN UNSAFE ENVIRONMENT. Do not use the machine in damp or wet locations, or expose to rain. Keep the work area well lighted.19. DO NOT FORCE TOOL. Tools are designed to perform properly and safely at proper rates. Keep ...

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    SAFETY SECTIONSafety SectionSS-6May 2002Fadal33. DO NOT USE AIR HOSES TO BLOW CHIPS OFF YOUR BODY OR CLOTHES. Serious injury to your eyes, hearing, and skin could result. Do not blow towards others.

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    May 2002SS-7Safety SectionSAFETY SECTIONFadalGENERALA carelessly or improperly operated VMC can cause serious injury or death as well as damage or destruction of equipment. The emergency and safety procedures in this manual are to help users operate the VMC in a safe manner. The warnings in this ...

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    SAFETY SECTIONSafety SectionSS-8May 2002FadalWARNINGS AND CAUTIONSThis manual contains information that will assist qualified operators and maintenance personnel. Unqualified operators should never attempt to operate or perform maintenance on the VMC.PICTORIALSPictorials are used within warnings ...

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    May 2002SS-9Safety SectionSAFETY SECTIONFadalELECTRIC SHOCKThe VMC has numerous subsystems powered by high voltage electricity. This electricity is not a hazard during most operations, however certain maintenance operations conducted by qualified individuals may require the defeat of interlocks s...

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    SAFETY SECTIONSafety SectionSS-10May 2002FadalNOISEExposure to occupational hazardous noise or prolonged exposure to noise above 90 decibels may cause permanent hearing damage. The amount of noise the VMC produces varies by the type of material, speed of the cut, and several other factors.To prev...

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    May 2002SS-11Safety SectionSAFETY SECTIONFadalCOMPRESSED AIR (CE COMPLIANCE)Compressed air poses a potential hazard from flying debris. Under normal conditions the compressed air may not present a hazard to the operator. Failure of any component of a compressed air system may cause parts to be ej...

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    SAFETY SECTIONSafety SectionSS-12May 2002FadalADDITIONAL SAFETY PRECAUTIONSCompliance with the following safety practices is required to safely operate the VMC:1. Never work alone on live electrical circuits. Another person qualified to turn off power to the VMC must be present when voltage is 60...

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    May 2002SS-13Safety SectionSAFETY SECTIONFadal12. The Polycarbonate shield is equipped with an interlock to prevent the VMC from operating when the shield is opened. Under no circumstances should the operator disable or remove the interlocks. If power is lost to the VMC, the spindle will free whe...

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    SAFETY SECTIONSafety SectionSS-14May 2002FadalSAFETY LABELSLBL-0123

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    May 2002SS-15Safety SectionSAFETY SECTIONFadalLBL-0129LBL-0158LBL-0127

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    SAFETY SECTIONSafety SectionSS-16May 2002FadalLBL-0130LBL-0163

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    May 2002SS-17Safety SectionSAFETY SECTIONFadalLBL-0126

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    SAFETY SECTIONSafety SectionSS-18May 2002FadalLBL-0128

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    May 2002SS-19Safety SectionSAFETY SECTIONFadalLBL-0125

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    SAFETY SECTIONSafety SectionSS-20May 2002FadalLBL-0235

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    May 2002SS-21Safety SectionSAFETY SECTIONFadalLBL-0131LBL-0263

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    SAFETY SECTIONSafety SectionSS-22May 2002FadalLBL-0187LBL-0234

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    May 2002SS-23Safety SectionSAFETY SECTIONFadalLBL-0124

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    SAFETY SECTIONSafety SectionSS-24May 2002FadalLBL-0040LBL-0036

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    May 2002SS-25Safety SectionSAFETY SECTIONFadalSAFETY LABEL LOCATIONS4020SLBL-0123LBL-0234LBL-0129LBL-0234LBL-0123LBL-0163

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    SAFETY SECTIONSafety SectionSS-26May 2002FadalLBL-0235LBL-0125LBL-0128LBL-0234

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    May 2002SS-27Safety SectionSAFETY SECTIONFadal5020a, 4020a,4020, 3016L, 2216, 2016L, 15, 15xt, EMCLBL-0128LBL-0263LBL-0235LBL-0128LBL-0263LBL-0126

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    SAFETY SECTIONSafety SectionSS-28May 2002FadalLBL-0125LBL-0125LBL-0235LBL-0127

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    May 2002SS-29Safety SectionSAFETY SECTIONFadal6030, 8030LBL-0123LBL-0128LBL-0263LBL-0235LBL-0128LBL-0263

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    SAFETY SECTIONSafety SectionSS-30May 2002FadalLBL-0235LBL-0126LBL-0129LBL-0124

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    May 2002SS-31Safety SectionSAFETY SECTIONFadalLBL-0235LBL-0125LBL-0123LBL-0163LBL-0128

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    SAFETY SECTIONSafety SectionSS-32May 2002FadalLBL-0128LBL-0263LBL-0235LBL-0128LBL-0263LBL-0235

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    May 2002SS-33Safety SectionSAFETY SECTIONFadal6535, 4525, 3020LBL-0126LBL-0036LBL-0123

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    SAFETY SECTIONSafety SectionSS-34May 2002FadalLBL-0128LBL-0123LBL-0128LBL-0263LBL-0126

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    May 2002SS-35Safety SectionSAFETY SECTIONFadalLBL-0128LBL-0263LBL-0036LBL-0235LBL-0125

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    SAFETY SECTIONSafety SectionSS-36May 2002FadalLBL-0235LBL-0125

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    May 2002SS-37Safety SectionSAFETY SECTIONFadalCE SAFETY LABELSLBL-0431 small (CE) LBL-0434 large (CE)Cutting of Fingers or Hand / Rotating CutterCutting tools can seriously injure. Never place any part of your body near rotating tools. Do not operate this machine unless the doors are closed and...

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    SAFETY SECTIONSafety SectionSS-38May 2002FadalLBl-0132 (CE)Electric Shock / ElectrocutionHazardous voltages in this enclosure can kill. Do not operate with the door open. Servicing should be done by qualified personnel only. Lockout the power before servicing.LBL-0435 (CE)Flying Debris and Lou...

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    May 2002SS-39Safety SectionSAFETY SECTIONFadalLBL-0460 (CE)Flying DebrisFlying debris and compressed air can cause eye injuries. Do not perform maintenance on pressurized systems. Disconnect the air source before performing maintenance. Always wear eye protection when performing maintenance on...

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    SAFETY SECTIONSafety SectionSS-40May 2002FadalLBL-0436 (CE)Leg or Body Entanglement / AugerAuger can serious injure or kill. Keep body parts out of the auger system at all times. Turn off the machine and lockout the power before doing maintenance inside the enclosure.LBL-0433 (CE)Hand Crush / M...

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    May 2002SS-41Safety SectionSAFETY SECTIONFadalLBL-0443 (CE)Hand Crush / Force from SideAutomatic pallet changer can crush hands. Do not place hands or any part of the body in the path of a moving pallet.

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    SAFETY SECTIONSafety SectionSS-42May 2002FadalPROHIBITIONSLBL-0441 (CE)Do Not Operate with Guard RemovedDo not operate this machine with the doors open or the guards removed. Moving machinery and rotating cutters can seriously injure or kill.

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    May 2002SS-43Safety SectionSAFETY SECTIONFadalREQUIRED ACTIONSLBL-0439 (CE)Wear Eye ProtectionFlying objects may injure. Always wear safety glasses when operating this machine. LBL-0440 (CE)Wear Ear ProtectionNoise from this machine can damage hearing. Always wear ear protection when operating ...

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    SAFETY SECTIONSafety SectionSS-44May 2002FadalLBL-0442 (CE)Consult Operator's ManualRead and understand the Operator's Manual before operating this machine. This machine must be operated by qualified personnel only,LBL-0438 small (CE) LBL-0437 large (CE)Lockout Electrical PowerWhenever servicing ...

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    May 2002SS-45Safety SectionSAFETY SECTIONFadalCE SAFETY LABEL LIST AND LOCATIONLocationDomestic or old Labels CE LabelsATC Slide Arm PlateLBL-0129LBL-0432 (1009B-ISO), LBL-0438 (6011B-ISO)Spindle Belt Guide (inside spindle cover)LBL-0129LBL-0432 (1009B-ISO), LBL-0438 (6011B-ISO)Front by PendantLB...

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    SAFETY SECTIONSafety SectionSS-46May 2002FadalMain Disconnect, Aux. Disconnect, and Motor Starter EnclosuresLBL-0132LBL-0132 (6010C-ISO)Main DisconnectLBL-0134, LBL-0135 LBL-0134 (I5007a-D),LBL-0135 (I5008a-D)Next to Main Disconnect (Inside) LBL-0187keep LBL-0187Translated versions must be used.M...

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    May 2002 TABLE OF CONTENTSiFadalMaintenanceManualactionGoToR:TABLEactionGoToR: OFactionGoToR: CONTENTS 49,TABLE OF CONTENTS 49,................................................................................................. 49,iactionGoToR: Overview actionGoToR:..................................

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    ii TABLE OF CONTENTSMay 2002FadalMaintenanceManualactionGoToR:2.7.3 MCU Panel actionGoToR:.......................................................................................... actionGoToR:35actionGoToR:2.7.4 PCU 210 ...............................................................................

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    May 2002 TABLE OF CONTENTSiiiFadalMaintenanceManualactionGoToR:General Information actionGoToR:................................................................................................ actionGoToR:119actionGoToR:List of Components actionGoToR:.................................................

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    iv TABLE OF CONTENTSMay 2002FadalMaintenanceManual

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    Jan 2003: Overview: 1SIEMENS CONTROLMaintenance ManualFadalSection 01: Overview1.1 IntroductionThe SINUMERIK 810D/840D is a digital CNC (Computerized NumericalControl). Figure 1-1 shows an 810D digital control system. Its input andoutput is based on binary numbers, as opposed to continuously var...

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    SIEMENS CONTROLMaintenance Manual2: Overview: Jan 2003Fadal1.2 Digital Control SystemThe typical digital control system is comprised of a digital drive convertersystem, power supply, operator panel, CNC full keyboard, machine controlpanel, and motors for digital converter system (see Figure 1-2)....

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    Jan 2003: Overview: 3SIEMENS CONTROLMaintenance ManualFadalThe NCK is a computer that decodesthe part program and sends thecommands to the appropriate drives.The drives can be internal to the810D, or external. The drives takethe commands and position the axesaccordingly.The PLC is also a computer...

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    SIEMENS CONTROLMaintenance Manual4: Overview: Jan 2003Fadalfeedback, and assuming control sections one through three are also beingused, then it can no longer be used to control an additional motor. The motorwould have to be connected to the next available control section; in this case,it is cont...

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    Jan 2003: Overview: 5SIEMENS CONTROLMaintenance ManualFadalk. PCMCIA memory card slot (shown with memory card inserted).l. X341, X342, X351, and X352 are the DAC test sockets.m. S3 is the NCK start-up switch.n. S4 is the PLC operating mode switch.o. X151 is the device bus interface (power supply)...

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    SIEMENS CONTROLMaintenance Manual6: Overview: Jan 2003FadalFigure 1-5. SINUMERIK 810D control module interfaces.abedcgfhijklopqmn

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    Jan 2003: Overview: 7SIEMENS CONTROLMaintenance ManualFadal1.3.3 Axis Extension ModuleThe SIMODRIVE 611D module,mounted to the left of the CCU,consists of an axis extensioncontrol module and a powermodule (See Figure 1-6). Theaxis extension control modulehas everything that is required tointerfac...

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    SIEMENS CONTROLMaintenance Manual8: Overview: Jan 2003Fadal1.5 Pendant ComponentsMounted on the pendant are the components that create the machineinterface system for the operator. The system components consists of a MCP,HMI, CNC keyboard, and manual pulse generator (See Figure 1-7).1.5.1 MCPThe ...

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    Jan 2003: Overview: 9SIEMENS CONTROLMaintenance ManualFadalevent and alarm messages, allows a user to control and supervise a jobprocess by means of menus, gives the user ability to load programs, andgives users access to both the PLC and NCK.The HMI communicates with the PLC and NCK via the MPI ...

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    SIEMENS CONTROLMaintenance Manual10: Overview: Jan 2003Fadal1.5.4 MPGThe MPG (Manual Pulse Generator), installed in the lower left corner of thependant, is used to manually jog the axes of the machine. The MPG is enabledby pressing the “MPG” hard key, located on the MCP. Jogging an axis isacc...

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    Jan 2003: Overview: 11SIEMENS CONTROLMaintenance ManualFadalAxis Expansion BoardELE-1091For installation of a 611 power module.45A Power ModuleELE-109015HP Spindle Power Module60A Power ModuleELE-116420HP Spindle Power Module9/18A Power ModuleELE-1196Single Axis Power Module - 4th Axis2 * 9/18A P...

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    SIEMENS CONTROLMaintenance Manual12: Overview: Jan 2003FadalHand –Held Unit (Remote MPG) – Description of elements.1. Remote MPG wheel. Activated by selecting the “Remote” position in the main axis selector switch in the machine control panel and the MPG mode. Generates square-wave pulses...

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    Jan 2003: Control Components: 2.1 Replacement of Modules13SIEMENS CONTROLMaintenance ManualFadalSection 02: Control Components2.1 Replacement of Modules2.1.1 Reactor and Line Module ReplacementPart Numbers:ELE-1084 Reactor, Siemens, 16KWELE-1085 Line Filter for I/RELE-1086 I/R Module, 16KW (6 she...

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    SIEMENS CONTROLMaintenance Manual14: Control Components: 2.1 Replacement of ModulesJan 2003Fadal1. Attach the Reactor Module (ELE-1084) to the back plate (ELE-1086one of six parts) with four M6 flathead torx screws, flat and lock washers,and nuts.2. Attach the upper ventilation grid to the upper ...

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    Jan 2003: Control Components: 2.1 Replacement of Modules15SIEMENS CONTROLMaintenance ManualFadal3. Pull apart the output terminal and install it on the lower ventilationgrid.4. Attach the lower ventilation grid to the lower portion of the back platewith two M6 flathead torx screws.5. Connect wire...

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    SIEMENS CONTROLMaintenance Manual16: Control Components: 2.1 Replacement of ModulesJan 2003FadalConnect the wires for the Line Filter to the Reactor and feed them out throughthe access on the top ventilation grid.UVW1U11V11W11U21V21W2U1V2W2REACTORFILTEROUTPUTReactorLineSide ViewOutputWiring Diagr...

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    Jan 2003: Control Components: 2.1 Replacement of Modules17SIEMENS CONTROLMaintenance ManualFadal6. Attach the Main Line Filter and its mounting plate to the ReactorModule assembly with four M6 round head torx screws.Connect the wires from the Reactor to the Line Filter.7. Attach the two wire shie...

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    SIEMENS CONTROLMaintenance Manual18: Control Components: 2.1 Replacement of ModulesJan 2003Fadal2.1.2 Replacing the E/R ModuleParts Numbers:ELE-1083 Simodrive E/R Module Int. 16/21KWELE-1087 Over Volt Limit ModuleTools Required:Torx driver setNOTE:To remove components for repair or replacement: F...

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    Jan 2003: Control Components: 2.1 Replacement of Modules19SIEMENS CONTROLMaintenance ManualFadalNOTE:To remove components for repair or replacement: Follow the assemblyinstructions as necessary, in reverse order, until the component has beendisassembled to required level to conduct the repair.1. ...

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    SIEMENS CONTROLMaintenance Manual20: Control Components: 2.1 Replacement of ModulesJan 2003Fadal1. Attach the Power Section Module (ELE-1090) to the mounting bars with four 1/4-20 x 3/4” torx screws. Locate to the immediate right of the CCU Module.2. Insert the Accessory Expansion Module 810D (...

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    Jan 2003: Control Components: 2.1 Replacement of Modules21SIEMENS CONTROLMaintenance ManualFadal2.1.5 Connecting ModulesTools Required:Torx Screwdriver1. Plug the Device Bus Interface X151 Ribbon Cable from the CCU1 unitinto the Simodrive X351 Device Bus Port.2. Plug the Axis Extension Ribbon Cab...

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    SIEMENS CONTROLMaintenance Manual22: Control Components: 2.2 Wiring ConnectionsJan 2003Fadal2.2 Wiring Connections Tools Required:Torx driver setPhillips screwdriverFlat tip screwdriverNut driver setNOTE:To remove components for repair or replacement: Follow the assemblyinstructions as necessary,...

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    Jan 2003: Control Components: 2.2 Wiring Connections23SIEMENS CONTROLMaintenance ManualFadal7. Attach the spindle orientation magnet out cable (grey) to the X431 terminal block Red to location B Black to location 19. Secure with lug screws.8. Plug Z axis motor power connection into terminal plug ...

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    SIEMENS CONTROLMaintenance Manual24: Control Components: 2.2 Wiring ConnectionsJan 2003Fadal10. Plug X-axis motor power connection into terminal plug A2 located on the bottom of the CCU Box. Secure with thumbscrews. Cable clamp cable to shielding Plate.11. Attach the X motor grounding wire to gro...

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    Jan 2003: Control Components: 2.2 Wiring Connections25SIEMENS CONTROLMaintenance ManualFadal2.2.3 Reactor/Line Filter Module Connections1. Attach the 380 Volt input wires L1, L2, L3 to the appropriately labeled ter-minals on the bottom of the Line Filter, secure with lug screws.2. Attach the Reac...

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    SIEMENS CONTROLMaintenance Manual26: Control Components: 2.3 Replacing the 24V Power SupplyJan 2003Fadal4. Attach the grounding wire from the ground bar to the reactor module.2.2.4 Power Module Connections1. Attach the spindle drive output wires U2, V2, W2 to the appropriatelylabeled terminals on...

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    Jan 2003: Control Components: 2.4 Replacing the I/O Module27SIEMENS CONTROLMaintenance ManualFadal2. Attach the 120 VAC input wires to the 24 VDC power supply.3. Attach the 24 VDC output wires to the power supply.2.4 Replacing the I/O ModuleParts Numbers:ELE-1093 I/O ModuleTools required:Phillips...

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    SIEMENS CONTROLMaintenance Manual28: Control Components: 2.5 Replacing the 2010-0 BoardJan 2003Fadal5. Connect WIR-0740 from the CCU1 module to the X3IN plug on the I/O module. Secure with thumb screws.6. Connect the 24 volt power supply wiring to X1 (Ground to M24, + 24VDC to P24 logic, shield...

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    Jan 2003: Control Components: 2.5 Replacing the 2010-0 Board29SIEMENS CONTROLMaintenance ManualFadal2. Connect the X402 cable to the X402 plug on the 2010-0 card.3. Connect the X1201 cable to the X1201 plug on the 2010-0 card.4. Connect the X404 cable to the X404 plug on the 2010-0 board.X404X1201

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    SIEMENS CONTROLMaintenance Manual30: Control Components: 2.5 Replacing the 2010-0 BoardJan 2003Fadal5. Connect the X1202 cable to the X1202 plug on the 2010-0 board.6. Connect the X405 cable to the X405 plug on the 2010-0 board.7. Connect the Axis Selector wire two pin plug into the J4 socket on ...

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    Jan 2003: Control Components: 2.5 Replacing the 2010-0 Board31SIEMENS CONTROLMaintenance ManualFadal13. Terminate J5 bus wires at appropriate location on J5 terminal.14. Connect the J1 cable from the 1100-1 board into the J1 plug on the 2010-0 board.15. Plug the temperature control board into the...

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    SIEMENS CONTROLMaintenance Manual32: Control Components: 2.6 Replacing Fadal 5 VDC Power SupplyJan 2003Fadal16. Connect the temperature control wire plug into the socket on the tempera-ture control board.17. Plug the K1 relay into the 24 VDC K1 receptacle on the 2010-0 board.18. Plug the K6 relay...

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    Jan 2003: Control Components: 2.7 Replacing Pendant Components33SIEMENS CONTROLMaintenance ManualFadal.2. Terminate 5 volt, +12 VDC, and -12 VDC wires at power supply.2.7 Replacing Pendant ComponentsNOTE:To remove components for repair or replacement: Follow the assemblyinstructions as necessary,...

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    SIEMENS CONTROLMaintenance Manual34: Control Components: 2.7 Replacing Pendant ComponentsJan 2003Fadal2.7.1 2020 Power Distribution Board1. Install 2020 power distribution board (PCB-0204) with four nylocknuts (HDW-0657).2. Terminate all connections on the 2020 power distribution board asshown.2....

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    Jan 2003: Control Components: 2.7 Replacing Pendant Components35SIEMENS CONTROLMaintenance ManualFadal2.7.3 MCU PanelInstall machine control panel (CTR-0127).2.7.4 PCU 210Install PCU 210 Op panel (CTR-0126).2.7.5 KeyboardInstall keyboard (ELE-1094)2.7.6 Wiring ConnectionsTerminate all wiring and ...

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    SIEMENS CONTROLMaintenance Manual36: Control Components: 2.7 Replacing Pendant ComponentsJan 2003Fadal24VDCCOM 1COM 2KeyboardCableMPI Cable toProfibus24VDC

  • Page 89

    Jan 2003Power On Procedure: Alarms37SIEMENS CONTROLMaintenance ManualFadalSection 03: Power On ProcedureAlarmsThe Siemens control has an extensive alarm code series. The alarms mostlikely to occur while performing power on and assembly procedures for themachine are listed. For a complete listing ...

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    SIEMENS CONTROLMaintenance Manual38Power On Procedure: AlarmsJan 2003FadalEstablish the cause of error in the PLC (loop or stop in the user program) andeliminate.Program Continuation: Switch control OFF - ON.2100NCK battery warning threshold reachedExplanation: The undervoltage monitoring of the ...

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    Jan 2003Power On Procedure: Alarms39SIEMENS CONTROLMaintenance ManualFadalRemedy: Pull out the battery/fan unit from the NC module and replace thebattery (type: lithium battery with lead, size 1/2 AA, 850 mAh, min. 3.2 V).The system must then be reinitialized because it must be assumed that datah...

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    SIEMENS CONTROLMaintenance Manual40Power On Procedure: AlarmsJan 2003FadalProgram Continuation: Clear alarm with the RESET key. Restart partprogram.2130NCK encoder power supply (%1 V) has failed Explanation:%1 = VoltageThe power supply (5V / 24V) for the encoders has failed.Reaction: Mode group n...

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    Jan 2003Power On Procedure: Alarms41SIEMENS CONTROLMaintenance ManualFadalNC Start disable. NC not ready All mode groups not ready. NC Stop when alarm. Alarm display. Interface signals are set.Remedy: Rectify the cause of EMERGENCY STOP and acknowledgeEMERGENCY STOP via the PLC/NCK interface (DB ...

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    SIEMENS CONTROLMaintenance Manual42Power On Procedure: AlarmsJan 2003FadalRemedy: Configure channel-specific machine data 20070AXCONF_MACHAX_USED for the axis assignment without gaps, that is, withincreasing channel axis indices a machine axis must continue to be assigneduntil a zero is entered f...

  • Page 95

    Jan 2003Power On Procedure: Alarms43SIEMENS CONTROLMaintenance ManualFadalChannel not ready. NC Start disable. NC Stop when alarm.Remedy: In the axis-specific MD 30550 AXCONF_ASSIGN_MASTER_CHAN[AXm]=n (m... machine axis number, n... channel number) a master channelmust be specified for the axes t...

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    SIEMENS CONTROLMaintenance Manual44Power On Procedure: AlarmsJan 2003FadalChannel not ready. NC Start disable. NC Stop when alarm.Remedy: Check and correct machine data 20050 AXCONF_GEOAX_ASSIGNTAB and 20 070 AXCONF_MACHAX_USED.The basis is the MD array AXCONF_MACHAX_USED in which the machineaxis...

  • Page 97

    Jan 2003Power On Procedure: Alarms45SIEMENS CONTROLMaintenance ManualFadalExplanation: With the next system power-up, the standard MDs are loaded bythe system-specific MD 11 200 INIT_MD if• MD buffer voltage has failed or• After an initialization for loading the standard machine data.Reaction...

  • Page 98

    SIEMENS CONTROLMaintenance Manual46Power On Procedure: AlarmsJan 2003FadalOn executing a TOA file or when writing data from the part program anattempt has been made to write data with a higher protection level than theaccess authorization currently set in the control. The data in question have no...

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    Jan 2003Power On Procedure: Alarms47SIEMENS CONTROLMaintenance ManualFadalMode group not ready. NC Start disable. NC Stop when alarm.Remedy: Check hardwareProgram Continuation: Switch control OFF - ON.6000 Series Alarm6020Machine data have been altered - now memory is reorganizedExplanation: Mach...

  • Page 100

    SIEMENS CONTROLMaintenance Manual48Power On Procedure: AlarmsJan 2003Fadal• Delete or unload files (e.g. part programs), or • Increase $MM_NUM_FILES_IN_FILESYSTEMProgram Continuation: Clear the alarm with the Delete key. No furtheroperator action necessary.6520Too many protocol files in the N...

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    Jan 2003Power On Procedure: Alarms49SIEMENS CONTROLMaintenance ManualFadalRemedy:• Delete or empty subdirectories in the respective directory, or • Increase $MM_NUM_SUBDIR_PER_DIRProgram Continuation: Clear the alarm with the Delete key. No furtheroperator action necessary.6560Data format not...

  • Page 102

    SIEMENS CONTROLMaintenance Manual50Power On Procedure: AlarmsJan 2003FadalNC Start has been activated in the MDA or AUTOMATIC mode and at least oneaxis that needs to be referenced or has not reached its reference point.Reaction: Alarm display.Remedy: Via the channel-specific MD 20700: REFP_NC_STA...

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    Jan 2003Power On Procedure: Alarms51SIEMENS CONTROLMaintenance ManualFadal%1 = Channel number %2 = StringThis channel has received a negative acknowledgment from the inter-channelcommunication because this command is already active or has not yet beenterminated. E.g.: INIT(x,"ncprog") b...

  • Page 104

    SIEMENS CONTROLMaintenance Manual52Power On Procedure: AlarmsJan 2003Fadal%1 = Channel number %2 = Block number, labelAn axis/spindle has been positioned over several NC blocks using the POSA/SPOSA instruction. The programmed target position had not yet been reached("exact stop fine" wi...

  • Page 105

    Jan 2003Power On Procedure: Alarms53SIEMENS CONTROLMaintenance ManualFadalRemedy: Depending on the reason for this alarm being triggered, thefollowing remedial measures should be undertaken:1. Handwheel override: Cancel the motion overlay and avoid this or keep it smaller when the program is repe...

  • Page 106

    SIEMENS CONTROLMaintenance Manual54Power On Procedure: AlarmsJan 2003FadalAlarm display. Interface signals are set. NC Start disable.Remedy: Setting data: Check 43420 WORKAREA_LIMIT_PLUS and 43430 WORKAREA_LIMIT_MINUS for the working area limitation.Program Continuation: Clear alarm with RESET...

  • Page 107

    Jan 2003Power On Procedure: Alarms55SIEMENS CONTROLMaintenance ManualFadal10720Channel %1 block %3 axis %2 software limit switch %4Explanation: %1 = Channel number %2 = Axis name, spindle number %3 = Block number, label %4 = String (+ or -)For the axis, the programmed path violates the currently ...

  • Page 108

    SIEMENS CONTROLMaintenance Manual56Power On Procedure: AlarmsJan 2003FadalReaction:Alarm display. Interface signals are set. Correction block with reorganization NC Start disable. NC Stop when alarm at block end.Remedy: Before calling the CRC with G41/G42, program a tool number underthe address T...

  • Page 109

    Jan 2003Power On Procedure: Alarms57SIEMENS CONTROLMaintenance ManualFadalType: Message 101156Function illegalExplanation: The selected function is illegal. Commonly occurs when filebeing requested is not present.Type: MessageRemedy: See Installation Guide101160Date and time of PLC setExplanation...

  • Page 110

    SIEMENS CONTROLMaintenance Manual58Power On Procedure: AlarmsJan 2003FadalType: MessageReaction: -Remedy: Delete the programs that are not currently needed.103003You cannot delete the MDA bufferExplanation: NCK cannot delete the buffer because it is being processed.Type: MessageReaction: -Remedy:...

  • Page 111

    Jan 2003Power On Procedure: Alarms59SIEMENS CONTROLMaintenance ManualFadal103008Block search started in channel %1 - Please wait!Explanation: %1 = Channel numberThe started block search is not yet completed.Type: MessageReaction: Text is automatically deleted after block search is terminated.Reme...

  • Page 112

    SIEMENS CONTROLMaintenance Manual60Power On Procedure: AlarmsJan 2003FadalExplanation: Reference point approach has not been performed yet orterminated.Type: MessageReaction: -Remedy: Carry out reference point approach.Fadal 3020 PLC Alarm MessagesThe following PLC alarms are specific to the Fada...

  • Page 113

    Jan 2003Power On Procedure: Alarms61SIEMENS CONTROLMaintenance ManualFadalDEFINITION: The spindle is the load/unload position. If a tool is already theretool loading/unloading is not possible.REACTION: Display alarm. Axis movement disable. NC start disable.REMEDY: Call T0 (tool zero) to remove th...

  • Page 114

    SIEMENS CONTROLMaintenance Manual62Power On Procedure: AlarmsJan 2003FadalPROGRAM CONTINUATION: Alarm will re-set by running M11. Restart partprogram. Contact Service.510012Dual Arm Active DEFINITION: The dual arm gripper in the tool changer in movement. REACTION: Display alarm. Axis movement di...

  • Page 115

    Jan 2003Power On Procedure: Alarms63SIEMENS CONTROLMaintenance ManualFadalPROGRAM CONTINUATION: Clear alarm with Reset key. Restart partprogram.Contact Service.510103DATC Magazine Time-outDEFINITION: Dual arm tool changer magazine failed to move in time allowed.REACTION: Display alarm. Axis movem...

  • Page 116

    SIEMENS CONTROLMaintenance Manual64Power On Procedure: AlarmsJan 2003FadalREMEDY: Move the Z axis to the cold start position. Check the Z-axis-in-position sensor. Verify Cold Start position.PROGRAM CONTINUATION: Clear alarm with Reset key. Restart partprogram. Contact Service.510124ATC ActiveDEFI...

  • Page 117

    Jan 2003Power On Procedure: Alarms65SIEMENS CONTROLMaintenance ManualFadalREMEDY: Press Reset key. Check tool changer board for failures. Reset toolchanger board if needed ONLY AFTER CONTROL RESET. Check tool changerfor mechanical problems. Check air pressure to machine (air-oil board isinterlock...

  • Page 118

    SIEMENS CONTROLMaintenance Manual66Power On Procedure: AlarmsJan 2003Fadal510308Tool Loading Active DEFINITION: The tool loading function is active. A tool loading into themagazine is taking place. REACTION: Display alarm. NC-start disabled.REMEDY: Normal during tool loading. If tool loading is i...

  • Page 119

    Jan 2003Power On Procedure: Alarms67SIEMENS CONTROLMaintenance ManualFadalREACTION: Display alarm. NC-start disableD until all axes are referenced.REMEDY: Reference (cold start) the axis.PROGRAM CONTINUATION: Reference (cold start) ALL axes. Contact Service.700033Y Axis Needs ReferencingDEFINITIO...

  • Page 120

    SIEMENS CONTROLMaintenance Manual68Power On Procedure: AlarmsJan 2003FadalREMEDY: Check doors to be completely closed. Check doors-closedmonitoring circuit (sensors, etc). Check air pressure, air-oil board and augerboard (interlocked).PROGRAM CONTINUATION: Close doors. Use the Override button in ...

  • Page 121

    Jan 2003Action List: 65SIEMENS CONTROLMaintenance ManualFadalSection 04: Action ListNo.ExplanationNot allowed, ifRemedy1.Carry out Init phase (tasks are initialized after Power On)2.Carry out Reset (VDI signal: after Reset, mode group Reset or Power On 3.Activate Reset Init blocks (VDI signal: af...

  • Page 122

    SIEMENS CONTROLMaintenance Manual66Action List: Jan 2003Fadal7.Change the mode to a manual mode (VDI signal: JOG, TEACH_IN, REF)1. Nesting depth too great: The current processing operation can be interrupted by various events (e.g. interrupt). Depending on the event, asynchronous subroutines are ...

  • Page 123

    Jan 2003Action List: 67SIEMENS CONTROLMaintenance ManualFadal11Perform user interrupt "Asynchronous subroutine“(VDI signal: digital-analog interface, synchronous subroutine interface). 1. The channel is active due to block search or loading machine data 2. The channel is stopped and the...

  • Page 124

    SIEMENS CONTROLMaintenance Manual68Action List: Jan 2003Fadal17Perform rapid delete distance-to-go. There is no subsequent reorganization of block processing (VDI signal: delete distance-to-go, synchronous actions) 18Perform rapid delete distance-to-go. There is no subsequent reorganization and n...

  • Page 125

    Jan 2003Action List: 69SIEMENS CONTROLMaintenance ManualFadal26Activate traversing single block. (OPI variable and VDI signal: activate single block) 27Start program processing. (VDI signal: NC Start) 1. Program state active,2. An alarm reaction is pending; it prevents a start or forces braking. ...

  • Page 126

    SIEMENS CONTROLMaintenance Manual70Action List: Jan 2003Fadal37Stop the active processing. (VDI signal: NC Stop) 38Start machine data processing (INI file is already in the NCK), (PI command) 39Start machine data processing (INI file is external, e.g.: on MMC), (PI command) 40Stop because of mode...

  • Page 127

    Jan 2003Action List: 71SIEMENS CONTROLMaintenance ManualFadal52Delete all alarms with the delete condition CANCELCLEAR (PI command, acknowledge alarm key) 53Continue block search. (NC block, Stopre) 54Start block search. (PI command)55Continue block search. (PI command)56Activate digitizing. (PI ...

  • Page 128

    SIEMENS CONTROLMaintenance Manual72Action List: Jan 2003Fadal67Deactivate testrun. (VDI signal: rapid traverse overlay l) 1. Nesting depth too great2. The active block, after which deceleration takes place, cannot be reorganized (occurs when deceleration takes place over several blocks).⇒ Wait ...

  • Page 129

    Jan 2003Action List: 73SIEMENS CONTROLMaintenance ManualFadal80Conditional wait for program marker (NC block: WAITMC)81 Set marker. (NC block: SETM)82Clear marker (NC_block: CLEARM)83Selection of an NC block. (PI command)84Disable the NC program which is currently being processed for editing. (PI...

  • Page 130

    SIEMENS CONTROLMaintenance Manual74Action List: Jan 2003Fadal94Start continuation of interpreter processing. (internal preprocessing stop)No.ExplanationNot allowed, ifRemedy

  • Page 131

    Jan 2003Compensation: 5.1 Cold Start Position75SIEMENS CONTROLMaintenance ManualFadalSection 05: Compensation5.1 Cold Start Position5.1.1 SET OFFSETSThe SET OFFSETS program allows the user to align the machine to its propercold start position. Every time the control is referenced to the cold star...

  • Page 132

    SIEMENS CONTROLMaintenance Manual76Compensation: 5.2 Spindle BeltJan 2003Fadal12. Select an axis using the axis selector switch--on the MPG panel.13. Jog the selected axis to its cold start alignment mark.The value shown on the screen display is the distance between the electroniczero value and t...

  • Page 133

    Jan 2003Compensation: 5.3 Axis Backlash77SIEMENS CONTROLMaintenance ManualFadalM83 measures the relationship between the motor and the spindle bycounting the number of pulses it takes for one revolution of the spindle. Thiscreates a guideline for the correct numbers needed.The following steps des...

  • Page 134

    SIEMENS CONTROLMaintenance Manual78Compensation: 5.3 Axis BacklashJan 2003FadalThe following steps describe how to use the COMP VALUES program:• Run measuring program and measure pitch error.33. Press the PROGRAM MANAGER hard key. (For MMC103: First, pressthe Menu select hard key; then, press ...

  • Page 135

    Jan 2003Compensation: 5.3 Axis Backlash79SIEMENS CONTROLMaintenance ManualFadalFigure 2 shows a partial view of the COMP_VALUES_Y survey values from theprintout in Figure 1. The numbers within the brackets, [], are “pointers.” Theycorrespond to the position numbers in the compensation values ...

  • Page 136

    SIEMENS CONTROLMaintenance Manual80Compensation: 5.4 Reset Tool MagazineJan 2003FadalExample: The “_COMPVALUE[1]=0.0000” survey value corresponds to “No. 1“ in theprintout and the “_COMPVALUE[6]=-0.0004” survey value corresponds to“No. 6“ in the printout.NOTE: For A and B axes, po...

  • Page 137

    Jan 2003Compensation: 5.4 Reset Tool Magazine81SIEMENS CONTROLMaintenance ManualFadal45. Press the JOG hard key.46. Press the MDA soft key.47. Enter “TC_BASE”48. Press the CYCLE START hard key.49. The control will show a message. Then, alarm 510300 will appear.50. Power the machine off and...

  • Page 138

    SIEMENS CONTROLMaintenance Manual82Compensation: 5.4 Reset Tool MagazineJan 2003Fadal

  • Page 139

    June 2002MMC100 Software Update: General Information83SIEMENS CONTROLFadalSection 06: MMC100 Software UpdateIMPORTANT!If the VMC is equipped with a DATC, please see page 35.NOTE:You must install the appropriate software and hardware for DATC. General InformationBefore performing this software upd...

  • Page 140

    SIEMENS CONTROL84MMC100 Software Update: Tools RequiredJune 2002Fadal The pre-imaged hard drive replaces the existing hard drive on the MMC100module. The pre-imaged hard drive contains software tools that is used torestore the machine.Tools Required MMC100• An external computer, either a laptop...

  • Page 141

    June 2002MMC100 Software Update: MMC100 Update Procedure85SIEMENS CONTROLFadal2.Call Tool Zero (Unload spindle)The following steps sets up the machine and saves the spindle tool data:a. Power the machine OFF and back ON. b. Press the JOG button.c. Reference each axis.• Select an axis with the a...

  • Page 142

    SIEMENS CONTROL86MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal 34090 REFP_MOVE_DIST [1]__________________using the + soft key located on the upper right portion of the screen, choose Y1using the blue arrows go to 34090 REFP_MOVE_DIST [0] record the data: 34090 REFP_MOVE_DIST [0]__...

  • Page 143

    June 2002MMC100 Software Update: MMC100 Update Procedure87SIEMENS CONTROLFadalFor Z1, 32450 BACKLASH[1] ___________________For A1, 32450 BACKLASH[0] ___________________For A1, 32450 BACKLASH[1] ___________________For B1, 32450 BACKLASH[0] ___________________For B1, 32450 BACKLASH[1] _____________...

  • Page 144

    SIEMENS CONTROL88MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal 4.Set Up Communication ParametersTo back up the machine data to the external computer, prepare the Siemenscontrol for sending data. The following steps sets up the parameters forcommunication to the external computer.a...

  • Page 145

    June 2002MMC100 Software Update: MMC100 Update Procedure89SIEMENS CONTROLFadalNOTE:On external computers loaded with either the Windows 95 or Windows NT 4.0operating system, a baud rate of 4800bps or higher may also be used. Onexternal computers loaded with the Windows 98 operating system, settin...

  • Page 146

    SIEMENS CONTROL90MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal to the COM NUMBER line using the arrow keys. Use the arrow keys to select the proper COM port setting (See Figure 4)..d. Set XON/XOFF parameter to “OFF.” Use the arrow keys to navigate to the XON/XOFF SET line. Use...

  • Page 147

    June 2002MMC100 Software Update: MMC100 Update Procedure91SIEMENS CONTROLFadalf. Press ENTER.g. Select yes in the SAVE INPUT (Y/N) box that displays.h. Select DATA_IN at the top of the screen (See Figure 6).i. Press ENTER.j. Type a filename in the box that appears (create a descriptive filename, ...

  • Page 148

    SIEMENS CONTROL92MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal NOTE:Because the PCIN program is DOS based, filenames and filename extensionsare limited to eight characters and three characters, respectively.k. Press ENTERl. The external computer is now ready to receive the machine...

  • Page 149

    June 2002MMC100 Software Update: MMC100 Update Procedure93SIEMENS CONTROLFadal7.Back Up Other DataBack up all customer programs, tool data, and fixture data. When creatingfilenames, make sure they are not identical to each other. a. Press the SHIFT and SYSTEM/ALARM hard keys simultaneously.b. Pre...

  • Page 150

    SIEMENS CONTROL94MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal c. Select Workpieces.d. Press the INPUT hard key.e. Select Shopmill.f. Press the INPUT hard keySet up communication parameters at controlThe following steps sets up the parameters for communication at the control:d. ...

  • Page 151

    June 2002MMC100 Software Update: MMC100 Update Procedure95SIEMENS CONTROLFadalsaver, and restarting the computer in DOS mode. If an error still occurs, consultyour IT department for further assistance.a. Start up the PCIN communications program.b. Select V24_INI at the top of the screen.Press ENT...

  • Page 152

    SIEMENS CONTROL96MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal c. Press ENTER. The contents of the Utilities diskette displays in the a: directory box.d. Select the getval_s.mpf file. e. Press the ENTER key.f. At the pendant, press the START soft key.g. Press the OK soft key. The ...

  • Page 153

    June 2002MMC100 Software Update: MMC100 Update Procedure97SIEMENS CONTROLFadald. Set switch S3 to position 1-- NCK general reset (See figure 10 for switch location).e Power ON the machine.f. Wait until "b" is displayed on the CCU’s 7-segment LED display (H3), then set switch S3 back t...

  • Page 154

    SIEMENS CONTROL98MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal When the NCK is reset, all machine data is cleared and a standard machinedata set is loaded into memory. The “+5V,” “SF,” and “PR” LEDs are lighted.The 7-segment display shows a “b” (see figure 10).The ...

  • Page 155

    June 2002MMC100 Software Update: MMC100 Update Procedure99SIEMENS CONTROLFadala. Power the machine OFF.b. Locate the cover at the upper right corner of the pendant screen display (see Figure 11).c. Open the cover and insert the PC card into the slot.d.Power the machine back ON.e. Press "6&qu...

  • Page 156

    SIEMENS CONTROL100MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal f. The message "Actual access level: Manufacturer!" will display on the screen.g. Press the SHIFT and SYSTEM/ALARM hard keys simultaneously.h. Press the SERVICES soft key.i. Press the (extended menu) hard k...

  • Page 157

    June 2002MMC100 Software Update: MMC100 Update Procedure101SIEMENS CONTROLFadalRun the Options Programa. Press Program Manager hard key.b. Press Pagedown and/or Arrow keys to select OPTIONS (See Figure 12), then press the INPUT hard key. The program editor window opens. c. Find the options tabl...

  • Page 158

    SIEMENS CONTROL102MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal d. Determine the installed options for the machine. Use the diagrams from Appendix A of this manual to identify the installed options.To identify the installed options, compare the Siemens 810D control in the electron...

  • Page 159

    June 2002MMC100 Software Update: MMC100 Update Procedure103SIEMENS CONTROLFadal_DualArmATC=0_HiCapATC=0_VHT_Spindle=0_a1200ipm=0_m7_is_m8=0NOTE:Setting the value to “1” enables the option. For Example, a V300 wouldrequire:_a_ax=1_ascale=1_V300=1e. Go back to the beginning of the program. Use ...

  • Page 160

    SIEMENS CONTROL104MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal g. Press the CYCLE START hard key.h. The Power off message displays at the bottom of the screen display when the program finishes running. i. Power the machine OFF.j. Reconnect optional hardware as needed.k. Power ON...

  • Page 161

    June 2002MMC100 Software Update: MMC100 Update Procedure105SIEMENS CONTROLFadalg. Select Shopmill.h. Press the INPUT hard keyi. Press the RS232 C User vertical soft key.j. Press the SET soft key.At this point, two options columns are displayed. The left options column is the parameters for commu...

  • Page 162

    SIEMENS CONTROL106MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal c. Set COM number to “1” or “2” (depending on the COM port communications cable connection at the external computer). Navigate to the COM NUMBER line using the arrow keys. Use the arrow keys to select the prop...

  • Page 163

    June 2002MMC100 Software Update: MMC100 Update Procedure107SIEMENS CONTROLFadalm. Take the zero offset and backlash information that was written down on paper earlier. Enter these values into their respective lines in the table. When done, close the editor window. Press the Close soft key.n. Pres...

  • Page 164

    SIEMENS CONTROL108MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal 13. Press the INPUT key.14. Press the CHANGE vertical soft key.15. Enter the number of the tool pocket in front of the spindle in the field for both operands. (C5 and DB92.DBW0)16. Press the ACCEPT vertical soft key.1...

  • Page 165

    June 2002MMC100 Software Update: MMC100 Update Procedure109SIEMENS CONTROLFadalA1 32450 BACKLASH[0] type in dataA1 32450 BACKLASH[1] type in dataB1 32450 BACKLASH[0] type in dataB1 32450 BACKLASH[1] type in dataRepeating the process record the Gain and Band width amount.Press the FDD soft key.X1 ...

  • Page 166

    SIEMENS CONTROL110MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal 3. Press the SAVE ALL vertical soft key.• Reference the axes.a. Press the Machine hard key.b. Select an axis with the axis selector switch.c. Press REF POINT hard key.d. Press (plus) hard key.e. Repeat steps 2, 3, a...

  • Page 167

    June 2002MMC100 Software Update: MMC100 Update Procedure111SIEMENS CONTROLFadaln. Type M83, again.Press the CYCLE START hard key.Wait for the control to display the alarm "POWER ON."Power the machine OFF and back ON.Reference (cold start) the axes.o. While still in MDA mode, type M84Pre...

  • Page 168

    SIEMENS CONTROL112MMC100 Software Update: MMC100 Update ProcedureJune 2002Fadal NOTE:On external computers loaded with either the Windows 95 or Windows NT 4.0operating system, a baud rate of 4800bps or higher may also be used. Onexternal computers loaded with the Windows 98 operating system, sett...

  • Page 169

    June 2002MMC100 Software Update: MMC100 Update Procedure113SIEMENS CONTROLFadalb. To save the file on the external computer:Press the ESC key.Choose YES when asked “Do you want to terminate?”Choose YES when asked “Do you want to save?”Make two (2) copies of the new NC/PLC system files. Us...

  • Page 170

    SIEMENS CONTROL114MMC100 Software Update: DATC Hardware Update 1.7.2 (or above)June 2002Fadal DATC Hardware Update 1.7.2 (or above)IMPORTANT!MMC100 DATC Software Update MUST BE INSTALLED FIRST.General InformationCheck the existing Siemens hardware before proceeding with this update.Compare the ha...

  • Page 171

    June 2002MMC100 Software Update: MMC103 Software Update v1.7.2 (or above)115SIEMENS CONTROLFadalMMC103 Software Update v1.7.2 (or above) IMPORTANT!If the VMC is equipped with a DATC please see page 69. NOTE:You must install an updated software version and DATC hardware if nohardware is present.Ge...

  • Page 172

    SIEMENS CONTROL116MMC100 Software Update: Tools RequiredJune 2002Fadal Tools Required MMC103• An external computer, either a laptop computer or desktop PC (personal computer). The external computer hard disk is used to store the backup files from the 810D control.• The PCIN communications pro...

  • Page 173

    June 2002MMC100 Software Update: MMC103 Update Procedure117SIEMENS CONTROLFadalb. Press Ref Point hard key.c. Press “plus” hard key. The selected axis is referenced when the crosshair symbol appears.d. Select the next axis and press the “plus” hard key. Repeat this step until all conf...

  • Page 174

    SIEMENS CONTROL118MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal c. Highlight the Workpieces folder. Using the arrow keys, move the blue bar until the Workpieces folder is highlighted.d. Press INPUT hard key.e. Highlight the Shopmill folder. Using the arrow keys, move the blue bar...

  • Page 175

    June 2002MMC100 Software Update: MMC103 Update Procedure119SIEMENS CONTROLFadaln. Press Menu Select hard key.o. Press Program soft key.p. Highlight the Shopmill folder and press the INPUT hard key. The contents of the Shopmill folder displays.q. Highlight the GET_VALUES file. r. Press the Selec...

  • Page 176

    SIEMENS CONTROL120MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal 4.Back Up Tool Data and Zero OffsetsSpindle tool data is lost during power up. The following procedure will savespindle tool data. a. Press Menu Select hard key.b. Press Services soft key.d. Press Data Out soft key. ...

  • Page 177

    June 2002MMC100 Software Update: MMC103 Update Procedure121SIEMENS CONTROLFadals. Press Start soft key. t. Press the YES soft key if a message in the Query box displays asking to overwrite.5.Back Up Original Machine DataThe following procedure creates a backup of all machine data to the MMC103har...

  • Page 178

    SIEMENS CONTROL122MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal b. Press Services soft key.c. Press Disk soft key. This displays the contents of the disk.d. Find the OLDNCPLC file. Verify the file size under the length column.63. Recording Original Cold Start Position, Backlash Da...

  • Page 179

    June 2002MMC100 Software Update: MMC103 Update Procedure123SIEMENS CONTROLFadal34090 REFP_MOVE_DIST [0]___________________34090 REFP_MOVE_DIST [1]__________________using the + soft key located on the upper right portion of the screen, choose B1using the blue arrows go to 34090 REFP_MOVE_DIST [0] ...

  • Page 180

    SIEMENS CONTROL124MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal Y1 1212 ___________________Y1 1407 [0] ___________________Z1 1210 ___________________Z1 1211 ___________________Z1 1212 ___________________Z1 1407 [0] ___________________A1 1210 ___________________A1 1211 ____________...

  • Page 181

    June 2002MMC100 Software Update: MMC103 Update Procedure125SIEMENS CONTROLFadalFigure 25 The new NC software is loaded on a PC card. To properly insert the PC card, match the plastic tabs on the end of the card with the diagram printed next to the memory card slot.7 segmentdisplay (H3)Error and s...

  • Page 182

    SIEMENS CONTROL126MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal When the NCK is reset, all machine data is cleared and a standard machinedata set is loaded into memory. The “+5V,” “SF,” and “PR” LEDs areilluminated. The 7-segment display shows a “6” (See Figure 18)...

  • Page 183

    June 2002MMC100 Software Update: MMC103 Update Procedure127SIEMENS CONTROLFadalj. Enter the password SUNRISE in all UPPERCASE lettering. To type in uppercase, press and hold the SHIFT hard key while typing the password.k. Press INPUT hard key. The message “Password has been set for manufacture...

  • Page 184

    SIEMENS CONTROL128MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal g. Under Archive contents, remove the X from the MMC box and put an X in the With compensation data box. Use the SELECT hard key to enter and remove the X.h. In the Archive name field, enter a descriptive filename fo...

  • Page 185

    June 2002MMC100 Software Update: MMC103 Update Procedure129SIEMENS CONTROLFadalb. Press Program soft key.c. Highlight the Workpieces folder. Using the arrow keys, move the blue bar until the Workpieces folder is highlighted.d. Press INPUT hard key.e. Highlight the Shopmill folder. Using the arro...

  • Page 186

    SIEMENS CONTROL130MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal _ServoTurr=0_DualArmATC=0_HiCapATC=0_VHT_Spindle=0_a1200ipm=0_m7_is_m8=0NOTE:Setting the value to “1” enables the option. For Example, a V300 wouldrequire:_a_ax=1_ascale=1_V300=1j. Go back to the beginning of the ...

  • Page 187

    June 2002MMC100 Software Update: MMC103 Update Procedure131SIEMENS CONTROLFadalm. Press the Auto hard key.n. Press the CYCLE START hard key. o. The Power off message displays at the bottom of the screen display when the program finishes running. p. Power the machine OFF and then back ON.q. Refe...

  • Page 188

    SIEMENS CONTROL132MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal using the + soft key located on the upper right portion of the screen, choose B1 using the blue arrows go to 34090 REFP_MOVE_DIST [0] type in data, then go to 34090 REFP_MOVE_DIST [1] and type in dataRepeat the proces...

  • Page 189

    June 2002MMC100 Software Update: MMC103 Update Procedure133SIEMENS CONTROLFadalA1 1211 ___________________A1 1212 ___________________A1 1407 [0] ___________________B1 1210 ___________________B1 1211 ___________________B1 1212 ___________________B1 1407 [0] ___________________• Reference the axe...

  • Page 190

    SIEMENS CONTROL134MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal k. Highlight the Shopmill folder and press the INPUT hard key. The contents of the folder will display. Find the file named SET_VALUE. This is the setval_s.mpf program.l. Highlight the SET_VALUES file and press the ...

  • Page 191

    June 2002MMC100 Software Update: MMC103 Update Procedure135SIEMENS CONTROLFadalv. Highlight the SET_VALUES file and press Select soft key.w. Press AUTO hard key (located on the MCP).x. Press CYCLE START (green) hard key. Repeat pressing the CYCLE START hard key for each of the axes until all th...

  • Page 192

    SIEMENS CONTROL136MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal d. Press INPUT hard key. The contents of the Shopmill folder displays.e. Highlight the COMP_VALUES_n (where n is the axis) file and press the INPUT hard key. This will open the COMP_VALUES program in an editor windo...

  • Page 193

    June 2002MMC100 Software Update: MMC103 Update Procedure137SIEMENS CONTROLFadalm. Repeat steps e through k for all the configured axes.n. Press Machine hard key.o. Press MDA hard key.p. Type M83 and press INPUT hard key.q. Type M2 and press INPUT hard keyr. Press CYCLE START hard key.Wait fo...

  • Page 194

    SIEMENS CONTROL138MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal t. Press Menu Select hard key.u. Press CNC ISO soft key, then press CNC ISO soft key.v. Wait for the ISO screen to load.w. Press MDA hard key.x. Press the Delete vertical soft key.y. Type M83 and press INPUT hard k...

  • Page 195

    June 2002MMC100 Software Update: MMC103 Update Procedure139SIEMENS CONTROLFadalam.Press Menu Select hard key.an. Press Services soft key.ao. Press Data in soft key.ap. Press Archive... vertical soft key. The SOURCE window opens on the lower portion of the display.aq. Choose the file TO_TOA in th...

  • Page 196

    SIEMENS CONTROL140MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal 11. Remove Old Hard Disk UnitThe MMC103 module is located inside of the pendant cabinet. Release the twolatches on the right side of the pendant cabinet to gain access to the MMC103module (See Figure 23).a. POWER THE ...

  • Page 197

    June 2002MMC100 Software Update: MMC103 Update Procedure141SIEMENS CONTROLFadalc. Remove the floppy disk drive by removing the four mounting bolts (See Figure 25). Lay the drive down on the cabinet base. Make sure it is placed where it will not obstruct the hard disk removal process or is at risk...

  • Page 198

    SIEMENS CONTROL142MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal a. Insert the hinge tabs of the hard disk unit into the two hinge slots of the MMC103 module. Let the hard disk unit rest on the hinge tabs.b. CAREFULLY, insert the ribbon cable connector into the connector plug. BECA...

  • Page 199

    June 2002MMC100 Software Update: MMC103 Update Procedure143SIEMENS CONTROLFadalk) Hold the SHIFT button and type SUNRISE.l) Press OK.m) Press MMC.n) Press OPERATOR PANEL.o) Change the data to read as follows:810D Connection 1:1 BusMPI Highest Bus address31 MMC address1 NCK address3 PLC address2 ...

  • Page 200

    SIEMENS CONTROL144MMC100 Software Update: MMC103 Update ProcedureJune 2002Fadal j. Under Archive contents, remove the X from the MMC box and put an X in the With compensation data box. Use the SELECT hard key to enter and remove the X.k. In the Archive name field, enter a descriptive filename fo...

  • Page 201

    June 2002MMC100 Software Update: DATC Hardware Update v1.7.2 (or above)145SIEMENS CONTROLFadalDATC Hardware Update v1.7.2 (or above)IMPORTANT!MMC103 DATC Software Update MUST BE INSTALLED FIRST. Check to see isthe VMC has a PCB-0230 (1330-0A) board. If not, complete this procedure. Ifthe VMC is e...

  • Page 202

    SIEMENS CONTROL146MMC100 Software Update: Tools RequiredJune 2002Fadal Axis Travel5th Axis Restricted?SystemControlLanguagePart NumberDescription3020NO810DMMC100English / GermanELE-1392SFTUPD SIEMNS;3020/810/100/GRM(Standard)English / ItalianELE-1393SFTUPD SIEMNS;3020/810/100/ITLEnglish / Spanish...

  • Page 203

    Jan 2003Parameters: 151SIEMENS CONTROLMaintenance ManualFadalSection 07: ParametersSetting Options on the Fadal SiemensOf the many parameters of the Siemens machine, there are some that are setaside to configure the Fadal Machine. These parameters turn ON or OFFoptions that are presently installe...

  • Page 204

    SIEMENS CONTROLMaintenance Manual152Parameters: Jan 2003FadalFor the first USER_DATA_HEX[0], there are 8 options available. Using the twotables above the hexadecimal values can be determined. For example, to turnon the rigid tapping option, the bit 0 will be set which would equate to 1 hex.To tur...

  • Page 205

    Jan 2003Parameters: 153SIEMENS CONTROLMaintenance ManualFadal14510 USER_DATA_INT[0] = 32The Options programThis program will set bits in the MD14512 bytes and set various data bytes toconfigure options loaded on the machine like spindle types, scales and rotarytypes.A listing of the program is sh...

  • Page 206

    SIEMENS CONTROLMaintenance Manual154Parameters: Jan 2003Fadal$MN_USER_DATA_HEX[0]=$MN_USER_DATA_HEX[0] B_OR 'B00000001' ;ACT RIDG TAPelsemsg ("NO RIGID TAPPING") g4f2$MN_USER_DATA_HEX[0]=$MN_USER_DATA_HEX[0] B_AND 'B11111110' ;DEACT RIDG TAPendif stopreif _a_ax==0 ms...

  • Page 207

    Jan 2003Parameters: 155SIEMENS CONTROLMaintenance ManualFadalstopreif _b_ax==0 msg ("NO B AXIS ")g4f2$MC_AXCONF_MACHAX_USED[5]=0;DEACT B AX IN NCK$MN_USER_DATA_HEX[0]=$MN_USER_DATA_HEX[0] B_AND 'B01111111' ;DEACTIVATE B AXIS IN PLC$MN_DRIVE_LOGIC_NR[8]=0 ;REMOVE DR IN SLOT 9$MN_DRIV...

  • Page 208

    SIEMENS CONTROLMaintenance Manual156Parameters: Jan 2003Fadal$MA_NUM_ENCS[AX1]=2;SET X FOR 2 ENCODERS$MN_USER_DATA_HEX[0]=$MN_USER_DATA_HEX[0] B_OR 'B00000010' ;ACTIVATE X SCALEelsemsg ("NO X SCALE ")g4f2$MA_NUM_ENCS[AX1]=1;SET X FOR 1 ENCODER$MN_USER_DATA_HEX[0]=$MN_USER_DATA_HEX[0] B...

  • Page 209

    Jan 2003Parameters: 157SIEMENS CONTROLMaintenance ManualFadal$MA_NUM_ENCS[AX5]=2;SET A FOR 2 ENCODERS$MN_USER_DATA_HEX[0]=$MN_USER_DATA_HEX[0] B_OR 'B00010000' ;ACTIVATE A SCALEelsemsg ("NO A SCALE ")g4f2$MA_NUM_ENCS[AX5]=1;SET A FOR 1 ENCODER$MN_USER_DATA_HEX[0]=$MN_USER_DATA_HEX[0] B...

  • Page 210

    SIEMENS CONTROLMaintenance Manual158Parameters: Jan 2003Fadal$MA_GEAR_STEP_MAX_VELO[0,AX4]=2500;MAX SP 2.5K C AXIS MODE$MA_GEAR_STEP_MAX_VELO[1,AX4]=2500;MAX SP 2.5K 1ST GEAR$MA_GEAR_STEP_MAX_VELO[2,AX4]=10000;MAX SP 10K 2ND GEAR$MA_GEAR_STEP_MIN_VELO[2,AX4]=2501;MIN SP HIGH TO LOW$MA_GEAR_STEP_M...

  • Page 211

    Jan 2003Parameters: 159SIEMENS CONTROLMaintenance ManualFadal$MN_DRIVE_INVERTER_CODE[3]='H9' ;BIG POWER SECTIONendifstopreif (_VHT_Spindle==0) and (_zscale==0)$MN_DRIVE_LOGIC_NR[3]=4;USE HT BOOT FILE$MN_DRIVE_INVERTER_CODE[3]='Hd' ;SML POWER SECTION...

  • Page 212

    SIEMENS CONTROLMaintenance Manual160Parameters: Jan 2003FadalFadal Siemens Spindle ParametersTable 1: Baldor Spindle Motors OnlyVersionv1.81v1.81&v2.01v1.81v2.01v1.81Motor type15hp-81015hp-840D20hp-810D20hp-810D20hp-810DBrandBaldorBaldorBaldorBaldorBaldorPart no.release okrelease okNew styleN...

  • Page 213

    Jan 2003Parameters: 161SIEMENS CONTROLMaintenance ManualFadalTable 2: Siemens Spindle Motor OnlyVersionv2.01Motor type50HP-810DBrandSiemensPart no.1ph7167-2*dDescriptionMDMotor nominal power113028Motor nominal current110368.3Motor nominal voltage1132312Motor rated speed14001000Motor noload freq11...

  • Page 214

    SIEMENS CONTROLMaintenance Manual162Parameters: Jan 2003FadalC-axis default ratioSiemens controller with Baldor motors need to be calibrated.Please review procedure STD_0030.Along with this calibration, the C-axis default ratio values would be:$MA_DRIVE_AX_RATIO_DENOM31050[0]100000$MA_DRIVE_AX_RA...

  • Page 215

    Jan 2003Siemens 50 Taper: 163SIEMENS CONTROLMaintenance ManualFadalSection 08: Siemens 50 TaperMACHINE OVERVIEWThere are a number of new items on the FADAL Siemens 6535-810D.The machine’s hardware is as follows:PCU20 pendant, NC 3.3.27 export version, Shop Mill 6.1.3, PLC G2 V2.01 A7,BT50 taper...

  • Page 216

    SIEMENS CONTROLMaintenance Manual164Siemens 50 Taper: Jan 2003FadalThe slots are configured as follows: (refer to WRG-0054). Slot Number Description Drawing SymbolSlot 1 X-axis Feed Drive (X)Slot 2 ...

  • Page 217

    Jan 2003Siemens 50 Taper: 165SIEMENS CONTROLMaintenance ManualFadalThe listing of new items is as follows:1.The first Siemens spindle motor on a Fadal machine. This spindle motor isabout 50hp with noted ~510nM of torque from the Dyno tester. It has a directdrive cogged belt so no spindle calibrat...

  • Page 218

    SIEMENS CONTROLMaintenance Manual166Siemens 50 Taper: Jan 2003Fadal2.The X, Y and Z-axes limits are 65”x35”x34”. The Z-axis limits of the 50Taper BT are different than the 40 Taper because of the spindle housing islarger. The following is a listing of the Axis machine data parameters:6535/8...

  • Page 219

    Jan 2003Siemens 50 Taper: 167SIEMENS CONTROLMaintenance ManualFadal4.There is a safety cage around the rear control for manually placing tools intothe turret. Once this cage is unlocked using a key, the front pendant will beinoperable for moving the turret cw or ccw. A message will be displayed t...

  • Page 220

    SIEMENS CONTROLMaintenance Manual168Siemens 50 Taper: Jan 2003Fadal5.A revised PLC program labeled “Fadal G2 version 2.01 A7” takes intoaccount the new I/O and the alarm message. The alarm text, cause andsolution are described below.Alarm 700043Rear Tool Changer Gate OpenDEFINITIONThe rear to...

  • Page 221

    Jan 2003Troubleshooting: 169SIEMENS CONTROLMaintenance ManualFadalSection 09: Troubleshooting9.1 IntroductionThere are four main locations to gather troubleshooting data when a problemoccurs; the alarms and message line located in the upper bar in the normalmachine display, the alarm page, the LE...

  • Page 222

    SIEMENS CONTROLMaintenance Manual170Troubleshooting: Jan 2003Fadal9.4 The Central Control Unit (CCU) Front PanelThere are three indicators located on the CCU front panel. There are twocolumns of individual LEDs and a seven segment LED display.The left column of LEDs is for the NCKfunctions. The r...

  • Page 223

    Jan 2003Troubleshooting: 171SIEMENS CONTROLMaintenance ManualFadal• CCU front panel. Measuringsystemconnections(X411-X416)I/O interface(cabledistributor)PLC I/Oterminal(P bus)Axis extension connection(X304-X306)Terminalblock (X431)SIMODRIVE611D drive busPCMCIAslotDevice businterface (X151)7 seg...

  • Page 224

    SIEMENS CONTROLMaintenance Manual172Troubleshooting: Jan 2003Fadal9.5 The In-feed/Regeneration (I/R) ModuleThe I/R module is the power supply for the 810D. There are several voltagesgenerated for the logic electronics and there are 600 VDC output for the drivesto run the motors. There are six LED...

  • Page 225

    Jan 2003Troubleshooting: 173SIEMENS CONTROLMaintenance ManualFadal9.5.1 The I/R ModuleThe description of the alarms is normally enough to pin-point the cause of aproblem, but in some cases extra help is needed. Write down all alarmnumbers and any other information that could be helpful, as well a...

  • Page 226

    SIEMENS CONTROLMaintenance Manual174Troubleshooting: Jan 2003FadalHow to monitor the DATC interface.The dual Arm Tool Changer in the Siemens equipped machine works out of a9-bit signal pathPLC inputs/outputsThese signals can be monitored in the Diagnostic area, PLC page. The nexttable shows the d...

  • Page 227

    Jan 2003Troubleshooting: 175SIEMENS CONTROLMaintenance ManualFadalA low to high transition at Q41.0 (the strobe signal) starts the process. TheDATC busy signal (I38.2) remains active until the command is executedentirely. The DATC error signal (I38.3) is active in the event of any errorcondition...

  • Page 228

    SIEMENS CONTROLMaintenance Manual176Troubleshooting: Jan 2003Fadal-Type “D”-Press the INPUT Hard Key. -BOTH numbers should be the same among them. They also must be the same as the number of the pocket aligned in the tool change position.-If all three numbers coincide, the turret counter is O...

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