Navigation

  • Page 1

    Hitachi Seiki DeutschlandWerkzeugmaschinen GmbHINVERTED VERTICAL TURNING CELLCS20INSTRUCTION MANUALMAINTENANCESEIKI - SEICOS å21L43 Edition 1.01 11-2000

  • Page 2

    2

  • Page 3

    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...

  • Page 4

    2

  • Page 5

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

  • Page 6

    ii4. REFERENCE MATERIALS FOR MENTENANCEAND ADJUSTMENT ....................................................... 4 - 14-1 Servo Unit ............................................................................................................. 4 - 14-1-1 Alarm Concerning Power Supply Unit(Source Powe...

  • Page 7

    1 - 11. INSTALLATION1-1 Machine InstallationWhen 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 thefactory site, for example, rock base or reclaimed land,...

  • Page 8

    1 - 2 [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 than 20m apart from the point wh...

  • Page 9

    1 - 3 Note)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 t...

  • Page 10

    1 - 4

  • Page 11

    1 - 51-1-2 Slinging OperationThe 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 carefullyattend...

  • Page 12

    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.Upon shipment from our factory, each section of the machine has been tightened. Beforecleaning the machine, Loosen re...

  • Page 13

    1 - 71-1-5 Power Source and Pneumatic Source1) 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 machine separated from the line ...

  • Page 14

    1 - 81-1-6 Change of Electric Specification Machining Source PowerVolt age 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 400V ±10%Source power cycle 50/...

  • Page 15

    1 - 91-1-7 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,...

  • Page 16

    1 - 101-1-8 Installation and LevelingOne 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 machine itself.For ...

  • Page 17

    1 - 11Fig. 1-4 Leveling Method

  • Page 18

    1 - 121-2 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...

  • Page 19

    1 - 13List of Lubrication OilFront view123Supply spotSpindle cooling unitHydraulic unitHydraulic chuckFrequencyReplace every 6 month;replenish occasionReplace every 6 month;replenish occasionallySupply oil fully every dayMethodTrocholdpumpPistonpumpManualQ’ty28l10lNissekiNissekiMulti-purpose 32...

  • Page 20

    1 - 141-3 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 generated,...

  • Page 21

    1 - 15And 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...

  • Page 22

    1 - 167. 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...

  • Page 23

    1 - 17Do 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...

  • Page 24

    1 - 18Maintenance 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.Pay a full attention as the coolant will easily drip down on the floor...

  • Page 25

    1 - 191-4 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 a...

  • Page 26

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

  • Page 27

    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...

  • Page 28

    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...

  • Page 29

    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⇒...

  • Page 30

    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.

  • Page 31

    2 - 6Periodic check listChecking partCheck itemChecking interval(Month)Details 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)....

  • Page 32

    2 - 7Checking partCheck itemChecking interval(Month)Details of checks136125.6.7.8.9.10.11.High-pressurecoolantOperation paneland controlpanelFeed unitChip conveyorBelt,Timingbelt(Tool post,and X axes, )LevelLS and SOLe) Check high-pressurepump suction anddischarge valves fordamage or wear.f) Chec...

  • Page 33

    2 - 8Checking partCheck itemChecking interval(Month)Details 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 fore...

  • Page 34

    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...

  • Page 35

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

  • Page 36

    3 - 33-2 Hydraulic Unit/Hydraulic Circuit DiagramHydraulic Unit/Hydraulic Circuit Diagram17BLOCKING BLOCK1Shonan1619001-68-001-00Manifold1Shonan159001-68-002-00Manifold1Shonan14OPG-DF-T-R1/4-6´7MPAPressure Gauge1ASK13SL-G01-E3X-GR-CSolenoid Valve1Fujikoshi12ETB69-1.8Orifice1Shonan11SL-G01-E3X-GR...

  • Page 37

    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:φ210 ( 8")Hydraulic tank unit: Co...

  • Page 38

    3 - 5Operation1. 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 chuck by the di...

  • Page 39

    3 - 6Hydraulic 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 instrument to the rear of the cylinder. With the rear of the cylinder fixed,ro...

  • Page 40

    3 - 71. 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-rod [7] by turning counter-clockwise with theattached wrench [8].4) Loosen the bolts...

  • Page 41

    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...

  • Page 42

    3 - 93-4 Layout of Electric Apparatus and Pneumatic Circuit Diagram

  • Page 43

    3 - 10Turn equipment 180°Turn Arm up/down Air blowJLS901Over thrust detection1METROLBP101ILS899BArm up1CKDHLS899AArm down1CKDGLS898BTurn to 0°1SMCFLS898ATurn to 180°1SMCSin LS symbol UseQ'tyMakerRem...

  • Page 44

    3 - 113-5 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...

  • Page 45

    3 - 123-6 Returning Method from face declination of turret indexThis manual describes the procedures when a following alarm occurred by shut off the poweror by collision, etc. while indexing.Alarm 1020 The turret face number set up is defective.[Procedure](1) NC power [ON].(2) Make operation prep...

  • Page 46

    3 - 133-7 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...

  • Page 47

    3 - 143-7-2 Alarm Display1) Pressing the OPER/MAINTE key on the generalscreen, maintenance relevant functionkeys are listed up on the display.2) Pressing the F3/ALARM DIAG. key, thealarm diagnosis screen is obtained andthe alarm contents are displayed. Pressthe item which is to be processed.3...

  • Page 48

    3 - 15[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...

  • Page 49

    4 - 14. REFERENCE MATERIALS FOR MENTENANCEAND ADJUSTMENT4-1 Servo Unit4-1-1 Alarm Concerning Power Supply Unit(Source Power of Spindle/Servo Amplifier)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...

  • Page 50

    4 - 2 • 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 c...

  • Page 51

    4 - 37) Alarm code 07 • ContentsThe voltage at the main circuit DC part (DC link) became abnormally high. • 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 ...

  • Page 52

    4 - 44-1-2 Spindle Amplifier Status DisplayStatus DisplayItemContentsLED lit on is indicatedbySource power ON indicating LED “PIL” is OFF.1.Controlling source power is not yet thrown in.Source power circuit is defective. Refer to item 4.3.2.The last two digits of the ROM series is displayed ...

  • Page 53

    4 - 54-1-3 Spindle Amplifier AlarmWhen the “ERR” LED on the indicating window of the spindle amplifier lights up, thenumber indicated next right to the LED reading “ER-**” will tell the alarm contents. Inthe same way, when the “ALM” LED lights on, “AL-**” tells the alarm contents...

  • Page 54

    4 - 6MessageContentsCountermeasureEr-16Er-17Er-18Er-19Er-20Er-21Er-22Er-23Er-24Contactsignal of*ESPDifferential 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. (Sp...

  • Page 55

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

  • Page 56

    4 - 8Alarm No.MeaningsDescriptionRemedyAL-28AL-29AL-30AL-31AL-32AL-33AL-34AL-35AL-36AL-37AL-39AL-40AL-41AL-42AL-43Disconnection ofposition detectionsignal for Cscontouring controlShort-time overloadInput circuitovercurrentSpeed detection signaldisconnection motorrestraint alarmAbnormality in RAMi...

  • Page 57

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

  • Page 58

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

  • Page 59

    4 - 11AL-03Blown fuse in DClink sectionTest pointNormal wave formPA-0VPB-0VSame as aboveRA-0VDC2.5V±0.2VRB-0VSame as abovePAA-0VPBA-0V(CW rotation)Check that the ON/OFF duty cycle is 50%.(The PAP and PBP signals are inverted in CCW direction.)This alarm indicates that the fuse (F4) in the DC lin...

  • Page 60

    4 - 12AL-05Control powersupply fuse blownNOTESee Chapter 6.AL-08High input voltageThis alarm indicates abnormally low AC power voltage (-15% orless).This alarm may be generated even during momentary powerfailures.AL-11Overvoltage of DClink circuit(Regenerativecircuit is faulty ...Regenerationfail...

  • Page 61

    4 - 13AL-16RAM abnormalityAL-13CPU internal datamemory alarmReplace PCB.ItemCause of troubleCheck procedureRemedy12External datamemory (RAM)defectivePCB defectiveReplace memory(RAM).Replace PCB.AL-18Program ROMsum check errorItemCause of troubleCheck procedureRemedy1Program memorydata (ROM)defect...

  • Page 62

    4 - 14AL-26Disconnection ofspeed detectionsignal for CscontouringcontrolItemCause of troubleCheck procedureRemedy1234Signal level ofspindle motor forCs contouringcontrol is invalid.Signal line ofspindle motor forCs contour controlis defective.Defective detectorcircuit for Cscontour controlIncorre...

  • Page 63

    4 - 15AL-30Input circuitovercurrent AL-34 and F-XXX are alternately displayed in the spindleamplifier indicator section if an AL-34 alarm is raised."XXX" indicates the data number internal to the spindle for aparameter where a value beyond the allowable range is specified.AL-35Exces...

  • Page 64

    4 - 16AL-37Speed detectorparametersetting errorAL-39Alarm forindicating failurein detecting1-rotation signalfor Cs contouringcontrolAL-40Alarm forindicating1-rotation signalfor Cs contouringcontrol notdetectedAL-41Alarm forindicating failurein detectingposition coder1-rotation signalAL-47Position...

  • Page 65

    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...

  • Page 66

    4 - 184-2-2 Troubleshooting• Cause and remedy of alarms for Juspoint IIITable 4-3 is a list of alarms. The indications refer to those made on the 7-segmentLED on the point module board.These indications are blinking indications (continuously lit indication indicates normaloperation).Table 4-3 ...

  • Page 67

    4 - 19[Cause and remedy of alarms for the inverter (Juspeed-F X3000)]Error indication (Errors are indicated by blinking indication.)Errors of the inverter can be monitored on the LED (7 segments) on the printed circuitboard in the inverter main body.Table 4-4 Cause and remedy of alarms for Juspe...

  • Page 68

    4 - 20Caution! WARNING4-3 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 batter...

  • Page 69

    4 - 214-4Alarm Display4-4-1 NC AlarmNo.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 er...

  • Page 70

    4 - 22No.Content143Scaling mode error144G511/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 erro...

  • Page 71

    4 - 23No.Content503Character string variable not possible to construct504Undefined G code505SETVN command format incorrect506Command exceeds permissible value of system variable507Search of variable value not possible508Overflow of logical operation509Improper argument assignment of a macro call5...

  • Page 72

    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 ...

  • Page 73

    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...

  • Page 74

    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-...

  • Page 75

    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...

  • Page 76

    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...

  • Page 77

    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...

  • Page 78

    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...

  • Page 79

    4 - 31

  • Page 80

    5 - 15. EXPENDABLE PARTS LIST5-1Expendable Parts List of CS201/2No.CODE NO.PRODUCT NAMEMODEL (Type ofVOLUME REMARKSmachines applied)SADDLE.ROSS SLIDE & Z FEED 103999006026Angular ball bearing25TAC62BSUC10PN7B2NSK 202341201450Limit switchSL1-A2YAMATAKEHEADSTOCK 106-16LZ50O-ring16L2502 204999...

  • Page 81

    5 - 22/2No. CODE NO.PRODUCT NAMEMODEL (Type ofVOLUME REMARKSmachines applied)SPLASH GUARD 71682-75-452-00Wiper(WP-34-20S)1NITTA 81682-75-451-01Wiper(WP-34-20S)1NITTA 91682-75-440-01Wiper(WP-34-20S)1NITTA101682-75-441-00Wiper(WP-34-20S)1NITTA111682-75-316-21Wiper(WP-34-20S)1NITTA121682-75-376-00W...

  • Page 82

    1

  • Page 83

    2TURNING CENTERSUPER HiCELL250INSTRUCTION MANUALMAINTENANCESEIKI-SEICOS S18TVersion 1.018-2000 First Edition6-1998

x