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    Hitachi Seiki DeutschlandWerkzeugmaschinen GmbHINVERTED VERTICAL TURNING CELLCS25INSTRUCTION MANUALMAINTENANCESEIKI - SEICOS å21L44 Edition 1.01 11-2000

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    1IntroductionThank you for your having purchased the machine, favoring our product lines for your use.This manual contains fundamental information on the maintenace. Please read and fully understandthe contents for your safe machine operation.In particular, the contents of the items concerning s...

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    iCONTENTS1. INSTALLATION .................................................................................... 1 - 11-1 Machine Installation ........................................................................................................... 1 - 11-1-1 Environment of the Machine ..............

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    ii4-3 Replacing Method of Battery ........................................................................................... 4 - 204-4 Alarm Display .................................................................................................................. 4 - 214-4-1 NC Alarm .............

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    1 - 11. INSTALLATION1-1 Machine InstallationFoundation diagram (1-1) Arrangement diagram (1-2)When installing NC machine, solid foundation is essential. It is also most important for maintainingthe best condition of cutting accuracy of the machine. The nature of the ground condition of thefacto...

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    1 - 2[3] High frequency drying machine[4] Electric discharge machine[5] Others2) Installation form of NC machine[1] Power supply lineThe power supply line (AC400V) of NC machine must be separated line with that forelectric machines and appliances.If impossible, connect the line at the point more ...

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    1 - 3Note)1. The bearing capacity of soil should be 5 ton/m2(1000lbs/ft2) or larger and thickness of the foundationshould be 300mm (11.8”) or thicker.2. The area of the foundation should be 1840x1970mm(72.4”x77.6”) or larger.3. When digging vibration proof drains, they should bedug along th...

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    1 - 4Dimension :matric (mm) inch ( ")Fig 1-2 Machine arrangement

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    1 - 51-1-2 Slinging Operation (Diagram 1-3)The slinging work is one of the important operations when transporting the machine,which requires careful attention. When machine is transported, cranes or chain blocksare used for lifting, which includes slinging work. The following points should be c...

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    1 - 6Fig. 1-3 Slinging1-1-4 Cleaning of MachineDo not move saddle and cross slide before cleaning, as the anticorrosive paint is oftencontaminated with dust during transportation.The machine ex factory is tightly secured in every movable part. Loosen these partsbefore cleaning.For cleaning, use ...

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    1 - 71-1-5 Power Source and Pneumatic Source1. Power source and wiring1) Main switch for source power should be installed at a place close-by the machine site sothat switch opening/closing can be handled by the operator with his own responsibility. Theswitch should be exclusively for this machin...

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    1 - 81-1-6 Change of Electric Specification Machining Source Power Voltage and CycleDepending of the voltage and cycle of the source power, the setting of electric system hasto be changed. Before the setting, confirm on these points.Source power voltage 200/220V ±10%Source power cycle ...

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    1 - 9Open the control board door, and remove the plastic cover of the switch-over transformer([5] in the diagram), then connect Line No.R2 and T2 to the appropriate positions on theinflow side at the screws indicating specified voltage.(To select the tap screws meeting the source power voltage)So...

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    1 - 101-1-7 Connection of Chip Conveyor[1] In order to enable the machine running beforeinstalling the chip conveyor, the machine ex factoryattaches short circuit wire on CN2 connector. Wheninstalling the chip conveyor, pull off this wire by handthen connect CN2 wiring. Before doing this wiring...

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    1 - 111-1-8 Installation and Leveling (Diagram 1-7)One of the factors deciding the machining accuracy is how to install the machine on level.Correct leveling is the most fundamental requirement in machine installation, which affectsthe accuracy of products as well as the service life of the machi...

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    1 - 12Fig. 1-7 Leveling Method

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    1 - 131-2 Lubrication and Oil SupplyWhen supplying oil, sufficient care must be taken to the following:1. Supply specified oil by the specified amount. Do not supply a different type of oil or overthe specified amount. Otherwise the machine may cause to a trouble.2. Clean the oil inlet port etc...

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    1 - 14Front viewFig. 1-8ISOsymbolCB32123Supply spotSpindle cooling unitHydraulic unitHydraulic chuckMethodTrocholdpumpPistonpumpManualFrequencyReplace every 6 month;replenish occasionReplace every 6 month;replenish occasionallySupply oil fully every dayQ’ty2810NissekiNissekiMulti-purpose32M...

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    1 - 151-2-2 Coolant1) How to control coolant fluidThe consistency of coolant fluid is changed depending upon the quality of water used,mixture of chips or foreign substances and evaporation of moisture. And unless themaintenance of the coolant fluid is made for a long time, germs may be generate...

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    1 - 16And the dirt of the machine makes hard to observe the state of machining from theoutside.4. Check of the quantityCheck the level of the rank periodically.Shortage of the fluid quantity causes to form bubbles or to disable the fluid to supplysufficiently to the machining point.And also it wi...

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    1 - 177. Check of the stagnant sludgeCheck whether chips and/or sludge stagnate in the tank and the piping.Remove chips and/or sludge from the tank and thepiping by flushing as occasion calls.And mixture of rust preventive oil and lubrication oilmay become the nutritive elements, and the surfaceo...

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    1 - 18Do not use this type.TypeEmulsion TypeSoluble TypeChemical Solution TypeCharacteristics* This type has beenused widely in thecutting field, becauseit is relatively large inparticle diameter ( 4to 7 µm) and high inlubricating property.* It is the solublecutting agent that wasmade first.* I...

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    1 - 19Maintenance of Coolant TankIn case of delivery of coolant from the tool post get worse,1. Check level and fill it up if required.2. Clean a filter in the coolant tank.This filter can be mounted or dismounted in one touch.

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    1 - 201-2-3 Check Before Trial Operation of the MachineBefore operating the machine at first, be sure to check each item in accordance with thefollowing order.1. Check the voltage of the power source. The power source is different depending on thedistrict.Three-phase, 200V, 50Hz: Mostly in Kanto...

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    2 - 12. MAINTENANCE AND CHECKING2-1 Daily Checking ItemsThe following are maintenance items to be checked by operators. These maintenance itemsare important to prevent machine trouble and to perform efficient operation. Performmaintenance according to the following daily check list.

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    2 - 2Daily check listChecking partCheck itemDetails of checks2.3.4.5.6. Hydraulic unitMain cooling unitPneumatic unitCoolant unitHigh-pressurecoolantOperation paneland control panela) Check for normal set pressure.b) Check hydraulic unit for faults.c) Check hydraulic unit for sufficientquantity o...

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    2 - 3Checking partCheck itemDetails of checks7.8.9.10.11.12.13.Chuck/cylinder(Turning machine)Spindle headFeed unitTool post unitChip conveyorCoversInterlocking devicea) Check that chuck is filled withsufficient grease. (Once a day)b) Check that chuck pressure can beregulated smoothly.c) Check th...

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    2 - 4Checking partCheck itemDetails of checks14.Mist collectora) Check that mist does not remain inthe hose.b) Check that filter is thoroughlycleaned.c) Check that oil is properly drained.d) Check mist for leakage.⇒ Visual check Provide angular hoseroute.⇒ Checks for clogging and cleaning⇒...

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    2 - 52-2 Periodic Check ItemsPeriodic checks by maintenance personnel are essential for assuring continued machineaccuracy. Perform maintenance at regular intervals according to the following periodic checklist.

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    2 - 6Periodic check listChecking partCheck itemChecking intervalDetails of checks136121.2.3.4.5.Hydraulic unitMain cooling unitPneumatic unitCoolant unita) Check piping for faults.b) Change hydraulic fluid.c) Check that strainer isthoroughly cleaned.d) Check oil fordiscoloration (fouling).a) Chec...

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    2 - 7Checking partCheck itemChecking intervalDetails of checks136125.6.7.8.9.10.11.High-pressurecoolantOperation paneland controlpanelFeed unitChip conveyorBelt,Timingbelt(Tool post, Xand Z axes,Spindle)LevelLS and SOLe) Check high-pressurepump suction anddischarge valves fordamage or wear.f) Che...

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    2 - 8Checking partCheck itemChecking intervalDetails of checks1361212.13.14.15.16.17.CoverWiper and brushInterlockingdeviceCableOT (Over-travel)Earth leakagebreakera) Check mounting boltsfor looseness.a) Check wiper and brushfor deterioration anddamage.b) Check for jamming ofchips and foreignmatt...

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    3 - 13. MAINTENANCE AND ADJUSTMENT3-1 Adjusting Method of X and Z Axes BacklashProcedure 1How to cancel the compensation amount previously enteredTo cancel the compensation amount entered before measuring backlash1) Put the machine to a stop status. (This setting irrelevant to the machine status...

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    3 - 2Procedure 3Setting of backlash amount1) According to the parameter setting method under “OPERATION MANUAL”, Item 16, callup the backlash parameter 1851 and set the compensation amounts of X and Z axes.Backlash amount0.012 X-axis compensation amount = = = 24Compensation unit0.0005...

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    3 - 3Turret1682-49-201-00Turret ClampHeadstock1682-49-200-00Chuck Open/CloseHydraulic Unit1531004080516BLOKING BLOCK1Shonan15OPG-DF-T-R1/4-6×7MPAPressure Gauge1ASK14SL-G01-E3X-GR-C1Solenoid valve1Fujikoshi13OG-G01-PC-K-5871AReducing Module1Fujikoshi129001-68-002-00Manifold1Shonan11SL-G01-E3X-GR-...

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    3 - 43-3 Hydraulic ChuckThis chuck is hydraulically opened and closed. With this chuck employed, a work piece setuptime can be reduced, manpower can be also saved and the workpiece can be powerfully andequally gripped.SpecificationsHydraulic chuck diameter:φ254 ( 10")Hydraulic tank unit: C...

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    3 - 5pressuregaugeOperation1. Select a chuck gripping direction by using the WORK GRIP INT/EXT Selector switchlocated on the main operation panel.2. Open and close the jaw by the chuck open/close switch on the main operating board.3. Adjusting the chuck pressureAdjust pressure of the hydraulic ch...

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    3 - 6Hydraulic chuckHydraulic cylinderMeaseringInsutrumentTypeHG-730-254Y1235RE25Hydraulic Chuck and CylinderSolid-Chuck (made by KITAGAWA)With cylinder mounting adapterMounting of Hydraulic Cylinder1. Mount the hydraulic cylinder to the adapter of the spindle with M12 bolt.2. Set a measuring ins...

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    3 - 7 1Bolt 2Connecting bolt 3Master jaw 4Chuck body 5Eye bolt 6Spindle 7Draw rod 8Wrench1. Procedures for removing the chuck body1) Turn off the power in the status of chuck closing.2) Screw in eye bolt [5] and pull up the chuck [4] naturally with wire.3) Loosen the bolt [2] connecting the draw-...

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    3 - 82. Procedures for installing the chuck body1) Set pressure of the hydraulic chuck to 0.5MPa {5kgf/cm}, and put forward the draw rodby the chuck open/close button.2) Thrust the wrench [8] into the bolt [1], and turn it right softly until it isn’t turned.3) Mount the chuck [4] on the spindle...

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    3 - 9 LS-11AZ-axis original point return deceleration LS-10BX-axis (+) over-travel LS-400ADoor closed LS-400BDoor open3-4 Layout of Limit Switches and Solenoid Valves LS-2A X-axis original pointreturn deceleration LS-1B X-axis (+) over-travel LS-306AFeeder door closed SOL-400BDoor openSOL-27ASOL...

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    3 - 103-5 Restoration of NC Torque Limiter1. Explanation of functionThis function is to detect the torque load on the feed axis and, if the detected torque isabnormally larger than the value set by the parameter, to exert an emergency stop of thespindle based on the judgement that there is an int...

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    3 - 113-6 Returning Method from face Declination of Turret IndexThis manual describes the procedures when a following alarm occurred by shut off the power(including emergency stop) or by collision, etc. while indexing.In case of mere face declination, start from (9).Alarm 1020 The turret face num...

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    3 - 123-7 Alarm DiagnosisThis screen display is used for trouble shooting and taking counter-measures when variousalarms occur.3-7-1 When the Warning Lamp (Call Light) Lights ON.The call light becomes ON, in either of the following cases.1) When the machine comes to a stop (suspension) status, by...

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    3 - 133-7-2 Alarm Display1) Pressing theOPERATION/MAINTENANCE key on thegeneral screen, maintenance relevantfunction keys are listed up on the display.2) Pressing the F3/ALARM DIAGNOSISkey, the alarm diagnosis screen isobtained and the alarm contents aredisplayed. Press the item which is to be...

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    3 - 14[1] NC unit relevant alarm (CNC Alarm)The alarm No. and alarm message are displayed on the screen.Check the alarm cause by referring to the list of NC alarm message and remove the causeof the trouble.[2] Alarm relevant to machine equipment and PC control (PMC Alarm)The alarm No. and alarm m...

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    4 - 14. REFERENCE MATERIALS4-1 Servo Unit4-1-1 Alarm Concerning Power Supply Unit (Source Power of Spindle/ServoAmplifier)When an alarm is generated, the alarm LED (red) lights up on the status display and thealarm code is indicated in two figures on the 7-segment LED.Alarm code is displayed. (0...

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    4 - 2 Ÿ Cause and trouble-shooting(a) The cooling fan is out of order.Confirm the condition of the cooling fan rotation.⇒Replace the cooling fan.(b) Dust contamination⇒Clean up the cooling system by factory air blower or by vacuum cleaner.(c) Overload overation⇒Re-examine the operating co...

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    4 - 37) Alarm code 07 Ÿ ContentsThe voltage at the main circuit DC part (DC link) became abnormally high. Ÿ Cause and trouble-shooting(a) Excessive regenerating power.Regeneration is not possible. PSM capacity is insufficient.⇒Confirm the PSM specification.(b) Impedance on the AC source po...

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    4 - 44-1-2 Spindle Amplifier Status DisplayStatus DisplayItemContents1.Source power ON indicating LED "PIL" is OFF.Controlling source power is not yet thrown in.Source power circuit is defective. Refer to item 4.3.2.2.The last two digits of the ROM series is displayed for about1.0 sec...

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    4 - 5MessageEr-01Er-02Er-03Er-04Er-05Er-06Er-07Er-08Er-09Er-10Er-11Er-12Er-13Er-14Er-15Contents*Although EPS (there are 2 types: connection signaland PMC CNC) and MRDY (machine ready signal) arenot input, SFR/SRV is input. However, regarding MRDY,pay attention to the setting of use/not use s...

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    4 - 6MessageEr-16Er-17Er-18Er-19Er-20Er-21Er-22Er-23Er-24Contactsignal of*ESPContentsDifferential mode command (DEFMDA) is entered whendifferential speed function is disabled by parametersetting (No. 6500#5=1).Parameter setting (No. 6511#0, 1, 2) for speed detectoris incorrect. (Specified speed ...

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    4 - 7Alarm No.AL-01AL-02AL-03AL-04AL-05AL-07AL-08AL-09AL-10AL-11AL-12AL-13AL-15AL-16AL-18AL-19AL-20AL-24AL-25AL-26AL-27MeaningsMotor overheatExcessive speeddeviationDC link section fuseblownInput fuse blown.Input power openphase.Control power supplyfuse blownExcessive speedHigh input voltageExces...

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    4 - 8Alarm No.AL-28AL-29AL-30AL-31AL-32AL-33AL-34AL-35AL-36AL-37AL-39AL-40AL-41AL-42AL-43MeaningsDisconnection ofposition detectionsignal for Cscontouring controlShort-time overloadInput circuitovercurrentSpeed detectionsignal disconnectionmotor restraint alarmAbnormality in RAMinternal to LSI fo...

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    4 - 9Alarm No.AL-46AL-47AL-48AL-49AL-50AL-51AL-52AL-53AL-54AL-55MeaningsAlarm for indicatingfailure in detectingposition coder 1-rotation signal inthread cuttingoperation.Position coder signalabnormalityPosition coder 1-rotation signalabnormalityThe converteddifferential speed istoo high.Excessiv...

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    4 - 104-1-4 Details of Spindle Amplifier Alarm ContentsAL-01Motor overheatItemCause of troubleCheck procedureRemedy1Defective fan motor Check if fan motor isReplace fan motor.of motorrotating.2Overload operation Check cutting conditions Review cuttingand how tools are worn.conditions and tools.C...

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    4 - 11Item12345Cause of troubleHigh impedanceon AC powersupply side.Example:Two transformersare connected inseries, or variableautotransformer isconnected.Defectivetransistor moduleDefective diodemodule or thyristormoduleDefective surgeabsorber orcapacitorWhen input fuse isnot blown Check proce...

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    4 - 12Item12Cause of troubleDefective PCBAbnormal powersupply voltageCheck procedureCheck AC input voltage.See (5) above.RemedyReplace PCB.Item1Cause of troubleIncorrect setting ofparameter fornumber of speedfeedback pulses(No. 6511)Check procedureCheck if number ofspeed feedback pulsesmatches pa...

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    4 - 13Item12Cause of troubleExternal datamemory (RAM)defectivePCB defectiveCheck procedureRemedyReplace memory(RAM).Replace PCB.Item1Cause of troubleProgram memorydata (ROM)defectiveCheck procedureCompare data displayedwhen power is turnedON with ROM labels.RemedyReplace programmemory (ROM).Item1...

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    4 - 14Item1234Cause of troubleSignal level ofspindle motor forCs contouringcontrol is invalid.Signal line ofspindle motor forCs control isdefective.Defective detectorcircuit for Cscontour controlIncorrect parametersettingCheck procedureRemedyCheck the signal, and if necessary adjust to thenormal ...

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    4 - 15Item12Cause of troubleDefective of powertransistor used forpowerDefective of powerregeneration circuitCheck procedureCheck power transistor.RemedyReplace powertransistor.Replace PCB.Item123Cause of troubleMotor constrainedDefective motorspeed feedbacksignalDefective motorspeed feedbacksigna...

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    4 - 16Item1Cause of troubleIncorrect setting ofparameter fornumber of speedfeedback pulses(No. 6511)Check procedureCheck if number ofspeed feedback pulsesmatches parametersetting.RemedySet correct value inparameter.Item12Cause of troubleIncorrect data ROMtype for Cscontouring controldetector circ...

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    4 - 174-2 Inverter for Turret4-2-1 Status Indication (on the Point Module)Status indication is also possible on the 7-segment indication on the point module board.Table 4-5 shows the contents of the status indication.This indication is continuously lit. (A flickering indication is an alarm indic...

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    4 - 18BlinkingAlarm descriptionCause and remedyIndication0123456789AbCdBlankDriver alarm was detected (description isdisplayed on the driver).PG fault (including poor wiring)Emergency stop operation was occurred.Operation was commanded without setupoperation after turning ON the power (exceptfor ...

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    4 - 19StateLEDContentsCause and remedyindicationOvercurrentOvervoltageOverspeedUnder-voltagePG errorExceedingtemperatureCPU error ICPU error IICT errorGroundFaultOthers123456789b0Overcurrent or short-circuitcurrent was detected and theinverter output was shut-off.Regeneration overvoltage wasdetec...

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    4 - 20! WARNINGCautionCaution4-3 Replacing Method of BatteryThe CNC unit provides a battery to hold a memory which is stored programs, offsetamount and parameter etc. When the battery voltage drops, a warning [794 BATTERYALARM] is displayed on the screen. If a warning is displayed, replace the...

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    4 - 21No.Content100G10 command error101Zero-point return not complete102F command error103Tapping command error106Plane selection command error107Offset No. error112Tool No. error113Polar coordinates compensation command error114Polar coordinates compensation mode error115Tool diameter/Nose R off...

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    4 - 22No.Content143Scaling mode error144G51/G501 program format error146G53 error149Helical cutting command error1583-dimension tool offset error1593-dimension tool mode error160Tool length offset error161Tool position offset error163Multiple M code command error175Compound type fixed cycle error...

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    4 - 23No.Content503Character string variable not possible to construct504Undefined G code505SETVAN command format incorrect506Command exceeds permissible value of system variable507Search of variable value not possible508Overflow of logical operation509Improper argument assignment of a macro call...

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    4 - 24No.Content539Error in writing function540ADP function error541Non-existence of END corresponding DO542Non-existence of IF sentence corresponding ENDIF543Non-existence of ENDIF corresponding block IF sentence544Ineffective calculation545Macro in compound type fixed cycle form546Wrong G code ...

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    4 - 25No.Content773Y axis overload alarm774Z axis overload alarm775Swivel tool overload alarm771non-load alarm[Warning]780Damaged tool was selected[Warning]781Lifeover tool was selected[Warning]782Pre-processing tool check error[Warning]783Surveillance program format error[Warning]784Tool on dema...

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    4 - 26No.ContentF307APC alarm: n-axis battery low voltage 1F308APC alarm: n-axis battery low voltage 2F309APC alarm: n-axis zero return disableF350SPC alarm: n-axis pulse coderF351SPC alarm: n-axis communicationF400Servo alarm: n-axis overloadF401Servo alarm: n-axis V ready OFFF404Servo alarm: n-...

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    4 - 27No.ContentF749S-spindle LSI errorF750Spindle serial link starting faultF7511st spindle alarm detectedF7521st spindle mode switching abnormalF7541st spindle abnormal load detectedF7612nd spindle alarm detectedF7622nd spindle mode switching abnormalF7642nd spindle abnormal load detectedF7713r...

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    4 - 284-4-2 PC AlarmALARM No.COMMENTDetails/Counter-measures1000HYDRAULIC MOTOR OVER LOADThermal MS1 is tripped. Reset thethermal.1001COOLANT MOTOR OVER LOADThermal MS2 is tripped. Reset thethermal.1004SPINDLE COOLER UNIT ALARMSpindle cooler unit alarm is issued.Check the spindle cooler unit.1007...

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    4 - 29ALARM No.COMMENTDetails/Counter-measures1050NOT OPTIONKey not usable was pressed.1056SPINDLE ORIENTATION ALARMSpindle orientation was not completedwithin the specified time.10601061FEEDER PALLET SINK LIMIT (Z-Feeder side pallet is pressed to hard.AXIS-0T)1062FEEDER ALARMFeeder alarm is bein...

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    4 - 30ALARM No.COMMENTDetails/Counter-measures1091ORIENTATION RELEASE UNFINISHRelease the spindle orientation.1093C AXIS MODE CANCEL UNFINISHRelease the C axis connection.10941095TOOL CLAMP NOT DETECTEDClamp the tool firm.1100POSITION INTERLOCK AREA CThis is the interlock in case of instrusionint...

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    5 – 1 5. EXPENDABLE PARTS LISTExpendable parts list of CS25No.CODE NO.PRODUCT NAMEMODELVOLUMEREMARKSSADDLE-CROSS & Z-FEED1.03999006026Angular ball bearing25TAC62BSUC10PN7B3NSK2.02341201450Limit switchSL1-A2YamatakeHEADSTOCK1.04999079092O-ringGS365(φ3.1)12.04999093326O-ringG-30023.06-15L10...

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    5 – 2No.CODE NO.PRODUCT NAMEMODELVOLUMEREMARKS SPLASH GUARD1.02712100920Limit switchD4D-21201Omrom2.02921111400Fluorescent lampPM1115S-G10W1Hitachi,Ltd.3.02921220900Fluorescent lampFL-10D1Hitachi,Ltd.4.05902200010BearingNBM-6 6 × 24 × 122Ochiai Shoten5.1682-75-368-00 Wiper(WP-34-20S)1Nitta6....

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    2TURNING CENTERCS25INSTRUCTION MANUALMAINTENANCESEIKI-SEICOS Σ21LVersion 1.014-2000First Edition 2-1999

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