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Fadal - Flint Machine Tools, Inc.

1. Binary Decimal Hexadecimal 00000000 0 0 00000001 1 1 00000010 2 2 00000011 3 3 00000100 4 4 00000101 5 5 00000110 6 6 00000111 7 7 00001000 8 8 00001001 9 9 00001010 10 00001011 11 00001100 12 00001101 13 00001110 14 0000 15 00010000 16 10 Etc bites bte Notice how in the binary column of the table above the numbers alternate from 1 to 0 or turn ON and OFF This is how we will use the table below to turn options ON or OFF Jan 2003 Parameters 151 Fadal SIEMENS CONTROL Maintenance Manual bit 7 bit 6 Bit 5 bit 4 bit 3 bit 2 bit 1 bit 0 14512 USER DATA B axis A axis B scale scale Z scale Y scale X scale Rigid Tapping 14512 USER DATA Simulator M77M8 V300 Extended AMC DATC Servo I5K toggle Rotarv Column Pallet Turret Spindle table Changer Setting the Bits How To set the number of tools in the ATC magazine 152 For the first USER DATA HEX 0 there 8 options available Using the two tables above the hexadecimal values can be determined For example to turn on the rigid tapping option the bit O will be set which would equate to 1 hex To turn ON A scales and Rigid Tapping bit 4 and bit O will be set which would equate to 11 hex To turn on all options in USER DATA HEX 0 all the bits would be set which woul
2. 6 2 cS E E lie a 1 4 M ame Li A 3 Attach the grounding wire from the ground bar to the bottom of the line fil ter module with a 1 4 20 nut and washer Jan 2003 Control Components 2 2 Wiring Connections 25 SIEMENS CONTROL Fadal Maintenance Manual 4 Attach the grounding wire from the ground bar to the reactor module 2 2 4 Power Module 1 Attach the spindle drive output wires U2 V2 W2 to the appropriately Connections labeled terminals on the bottom of the power module secure with lug screws pm 2 Attach the grounding wire from the ground bar to the bottom of the power module secure with lug screw 2 5 Replacing the 24V Power Supply Parts Numbers ELE 1095 24 Volt Power Supply Tools required Screwdriver NOTE To remove components for repair or replacement Follow the assembly instructions as necessary in reverse order until the component has been disassembled to required level to conduct the repair 1 Snap power supply onto the rail 26 Control Components 2 5 Replacing the 24V Power Supply Jan 2005 SIEMENS CONTROL Fa d a Maintenance Manual 2 Attach the 120 VAC input wires to the 24 VDC power supply 120 24 VDC 3 Attach the 24 VDC output wires to the power supply 2 4 Replacing the 1 0 Module Parts Numbers ELE 1093 I O Module Tools required Phillips screwdriver NOTE To remove components
3. kesa a ik ki 37 2000 Series AlarmS l iktar m 37 5000 Series S d a 40 4000 Series Alarm gitdikzi senza pieni ad DR a ia 41 6000 Series Alarm eee re E PRAR Ur kejk MU aea METRE eke vi fa 47 BODO Seres is podio l a t ir Ki Ee Ea AVE 49 10000 Series ER DTE EUNT 49 100 Messa es E 56 Machine Operating Area omm 57 Fadal 3020 PLC Alarm Messages mija 60 ben Lu l B 69 BMourt upgpE T P 79 5 1 Cold Start Position 79 pl ISET OFFSETS seeren oneer 79 ee eT eo ee er 80 Dic LIMO OF TE T Do 80 5 2 2 M84 Program Tm 81 5 SAXIS A h cesa DRNEA EE EEEn 81 Bo COMP VALUES P 81 5 4 Reset Tool Ae aaa i e e 84 Om Me tr ET 84 MMC100 Software Update 87 General Information gt vta ad ra urb ra kaskata TUA RERA MR 87 istof Components coo uoo A uM epa LM Cm 87 Tools Required 88 MMC100 Update Procedure c
4. MA DRIVE AX RATIO DENOM 31050 0 100000 DRIVE AX RATIO DENOM 51050 1 100000 MA DRIVE AX RATIO DENOM 31050 2 100000 DRIVE AX RATIO NUMERA 51060 0 194000 DRIVE AX RATIO NUMERA 5106011 194000 DRIVE AX RATIO NUMERA 51060 2 51600 Parameters Jan 2003 SIEMENS CONTROL Fada Maintenance Manual Section 08 Siemens 50 Taper MACHINE OVERVIEW There 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 5 PLC G2 V2 01 A7 BT50 taper and a Siemens spindle motor The listing of new and related major components in the machine s electrical cabinet is as follows refer to WRG 0054 55kW I R module 810D CCU1 with 2x 9Amp power sections One additional power section for the Z axis One 85Amp Spindle power section Added an A axis module pre wired Jan 2003 Siemens 50 Taper 163 Fadal SIEMENS CONTROL Maintenance Manual The slots are configured as follows refer to WRG 0054 Slot Number Slot 1 Slot 2 Slot 5 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 FADAL 6535 810 Channel interrupt Program aborted 3000 4 Emergency stop 1 2 3 4 5 amp 7 8 3 c 164 Drive Module SAM FDD z SAM FDD 2 SAM FDD 1 SAM FDD 1 SRM FDD 2 SAM DD z ARM MSD SRM FDD Drive Description X axis Feed
5. Version v2 01 Motor type 5OHP 810D Brand Siemens Part no 1ph7167 2 d Description MD Motor nominal power 1130 28 Motor nominal current 1103 68 3 Motor nominal voltage 1132 512 Motor rated speed 1400 1000 Motor noload freq 1134 34 2 Motor noload voltage 1135 294 Motor noload current 1136 33 1 Stator cold resistance 1137 0 062 Rotor cold resistance 1138 0 045 Stator leakage reactance 1139 0 151 Rotor leakage reactance 1140 0 22 Magnetizing reactance 1141 5 5 Field weakening speed 1142 1180 Ih curve upper speed 1143 1700 Motor max allowed speed 1146 8000 Ih curve gain 1144 136 Motor inertia 1117 0 25 Stall torque reduction 1145 61 Motor temp warn limit 1602 150 Motor code 1102 99 Alarm mask power on 1600 0000h Enc resol motor 1005 2048 Num current filters 1200 0 0 Filter types 1201 0 0 Current filter1 freq 1202 0 0 Current filter damping 1203101 0 Current filter2 freq 1204 0 0 Current filter2 damping 1205 0 1 Power limit 1235 0 250 Power limit 1235 0 250 Power limit 1255121 100 current limit 1258 200 Motor fixed temp 1608 0 Speedctrl gain 1407 0 1 2 47 739 Encoder resolution 31020 1000 Jan 2003 Parameters 161 Fadal C axis default ratio 162 SIEMENS CONTROL Maintenance Manual Siemens 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
6. soft key located on the upper right portion of the screen choose A1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 REFP MOVE DIST 1 and type in data June 2002 MMC100 Software Update MMC103 Update Procedure 131 Fadal SIEMENS CONTROL using the soft key located on the upper right portion of the screen choose B1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 MOVE DIST 1 and type in data Repeat the process for the Backlash amount For X1 52450 BACKLASH 0 type in data For X1 52450 BACKLASH 1 type in data For VI 32450 BACKLASH 0 type in data For Y1 52450 BACKLASH 1 type in data For Z1 52450 BACKLASH 0 type in data For Z1 52450 BACKLASH 1 type in data For A1 52450 BACKLASH 0 type in data For A1 52450 BACKLASH 1 type in data For B1 52450 BACKLASH 0 type in data For B1 52450 BACKLASH 1 type in data Repeat the process record the Gain and Band width amount Press the DRIVE MD soft key X1 1210 X1 1211 X1 1212 X1 1407 0 Y11210 Y11211 11212 Y1 1407 0 Z1 1210 Z11211 Z1 1212 Z1 1407 0 A1 1210 132 MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL 1 1211 A1 1212 A1 1407 0 B1 1210 B1 1211 Bl 1212 B1 1407 0 Reference the axes a Press the Machine hard key b Select an axis with t
7. 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 5 and 4 for all the axes The axes are referenced when the crosshair symbol displays to the left of each axis Position will be restored to factory setting Load Compensation Values k l m Open program COMP VALUES n nis the axis in question The Comp Values survey sheet is located in electronics cabinet on the backside of the machine There is no need to enter any comp values if they already exist Press PROGRAM MANAGER hard key Use up and down arrow keys to select the desired axis program Press INPUT hard key to open the program and edit values Go to the start of the program using PAGE UP hard key Press MACHINE FROM HERE soft key to load the program Press CYCLE START The program will load the compensation values into memory Repeatthis steps a through g for all the axes being compensated Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the Machine manual soft key Press the MDA soft key Press the Delete soft key This deletes all the contents in the buffer Type M83 Press the CYCLE START hard key NOTE M83 displays the value in degrees of the measurement just performed M83 should be run as many times as needed until the value displayed is the same twice a minimum of two times one degree
8. 19 2 1 5 Connecting Modules ski star ennn nnn nt 21 2 2 Wino aE eo sa sno at tnr 22 2 2 1 GOUT Module Connections 3 5 22 2 2 2 Simodrive 611 Module Connections 2 ik regu e E RAM REP EA 24 2 2 5 Reactor Line Filter Module Connections 25 2 2 4 Power Module Connections su 26 2 5 Replacing the 24V Power Supply 26 2 4 Replacing the WO Module ppt mem tno xir Rea pa eant 27 2 5 Replacing the 2010 0 Board 28 2 6 Replacing Fadal 5 VDC Power Supply 32 2 7 Replacing Pendant Components 33 2 7 1 2020 Power Distribution Board s i ibu ik ion rkiek 34 2 S 34 2002 TABLE OF CONTENTS Fadal Maintenance Manual 246 NIU 35 QR NIME 35 2 Keyboard Pr 35 2 7 6 I 55 Power On Procedure s tenete OG Ida RUE det conan uda tcu cpi tct Ed 37 SI GE NE m 37
9. Evaluate DSR signal XON Chex 11 Leader and trailer XOFF Chex 13 Binary format PC forn End of transniss n 03 Tineout Figure 8 The two options columns used to set the parameters for communication The Specia functions column should be cleared Set up the external computer for receiving data using the PCIN communications program If applicable LPT1 must be set to bi directional in the BIOS The PCIN communications program is a DOS based program Therefore an RTS CTS error may occur if PCIN is being run in Microsoft Windows If an error occurs try turning off power management in Windows turning off the screen saver and restarting the computer in DOS mode If an error still occurs consult your IT department for further assistance Start up the PCIN communications program Select V24_INI at the top of the screen See Figure 3 Press ENTER two times if necessary to get the communications parameters box c Set COM number to 1 or 2 depending on the COM port communications cable connection at the external computer Navigate MMC100 Software Update MMC100 Update Procedure 89 Fadal SIEMENS CONTROL to the COM NUMBER line using the arrow keys Use the arrow keys to select the proper COM port setting See Figure 4 ECIN VERSION 4 43 SIE ENS AG 1933 36 4 DATA IN E GRUT ILE SPECIAL PC FORMAT ARCHIVRILE EXIT Figure 9 V24 INI selected at the top of P
10. Wait for the control to display the alarm POWER ON Power the machine OFF and back ON Reference cold start the axes 110 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL n 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 M84 Press CYCLE START hard key Wait for the control to display the MEASUREMENT COMPLETED on the lower part of the display p Power the machine off and then back on q Reload all customer programs and any customized data back into NCK 13 Create New Create a back up file for the updated system software Back up File Setup the communication parameters at the machine a Press the CNC ISO soft key and then press the CNC ISO v soft key c Press the SHIFT and SYSTEM ALARM hard keys simultaneously Verify password is set to Manufacturer Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the SERVICES soft key Press the DATA OUT soft key Highlight the Start up data line using the up and down arrows Press the RS232 C User vertical soft key Press the SET soft key At this point two options columns are displayed The left options column is j the parameters for communications The right options column is the Special Functions Set the
11. 2 Press Yes soft key June 2002 MMC100 Software Update MMC103 Update Procedure 119 Fadal SIEMENS CONTROL 4 BackUp Tool Spindle tool data is lost during power up The following procedure will save Data and Zero spindle tool data Offsets a b d Press 0 Menu Select hard key Press Services soft key Press Data Out soft key IF the Data Out soft key is not displayed press extended menu hard key to display the Data Out soft key Select the NC active data folder Use either the arrow hard keys or the page down hard key to navigate to the folder if needed Folder is selected when it is highlighted in blue NOTE If this folder is not visible press the data selection soft key Then use the up or down arrows until the folder is highlighted Then press the O K soft key Press gt INPUT hard key A list of subfolders will display Select the Tool magazine data folder The folder is selected when it is highlighted in blue Press gt INPUT hard key Another list of subfolders will display Select the Tool offsets folder The folder is selected when it is highlighted in blue Press Archive soft key Use the default name TO_TOA or enter a descriptive filename in the Archive field at the bottom of the screen for the tool offsets data folder being created In the Arch field verify that Binary format PC form is selected Press Start soft key Press the YES soft key if a mess
12. 5 5 5 MA MN DRIV SMN 5 5 5 5 DRIV DRIV DRIV DRIV MN SMN DRIV DRIV NO SCALE ENCS AX3 2 E LOGIC NR 3 9 E LOGIC NR 6 4 E TYPE 6 2 Z SCALE NUM ENCS AX3 1 MN USER DATA Z SCALE IN PLC MA ENC MODULE NR 1 AX3 1 SET 2ND INPUT FOR SLOT 1 MN DRIVE LOGIC NR 3 4 MN DRIVE IS ACTIVE 3 1 ACTIVATE DRIVE IN SLOT 4 MN DRIVE TYPE 6 1 endi stop f if 1 msg g4f2 A SCALE Parameters SIEMENS CONTROL Maintenance Manual SET X FOR 2 ENCODERS MN USER DATA HEX 0 MN USER DATA HEX 0 B OR B00000010 SCALE SET X FOR 1 ENCODER 5 USER DATA HEX 0 MN USER DATA HEX 0 B AND B11111101 DEACTIVATE X SCALE SET Y FOR 2 ENCODERS MN USER DATA HEX 0 MN USER DATA HEX 0 B OR B00000100 SCALE SET Y FOR 1 ENCODER MN USER DATA HEX 0 MN USER DATA HEX 0 B AND B11111011 DEACTIVATE Y SCALE SET Z FOR 2 ENCODERS B00001000 MODULE NR 1 AX3 9 SET SCALE INPUT FOR SLOT 4 MOVE Z FEEDBACK TO SLOT 4 MOVE SPINDLE TO E IS ACTIVE 6 1 ACTIVATE DRIVE IN SLOT 7 SP DR IS ACTIVE 3 0 INACTIVATE DRIVE IN SLOT 4 SLOT 7 SET Z FOR 1 ENCODER MOVE SPINDLE TO FEED DR SLOT 4 ACTIVATE X ACTIVATE Y Z E INVERTER CODE 6 MN DRIVE INVERTER CODE 3 COPY PWR SEC CODE E MODULE TYPE 6 1 1AX PWR SEC 0 USER DATA HEX 0 B AND B11110111
13. JR SIEMENS Figure 20 The X Y and Z ports are used for the signal return connection from the scales A 611D axis extension module is added for machines with 4th and 5th axes e Go back the beginning of the program Use arrow keys to scroll back to the top of the options program The very first line of text should be displayed in orange when at the beginning of the program This is important if the program is to be run in its entirety f Press the Machine from here soft key June 2002 MMC100 Software Update MMC100 Update Procedure 105 Fadal j k SIEMENS CONTROL Press the 4 The Power off message displays at the bottom of the screen display when the program finishes running Power the machine OFF Reconnect optional hardware as needed Power ON and reference the axes Set up Tool Magazine a b C Press the JOG hard key Press the MDA soft key Type TC BASE M2 Press the CYCLE START key Wait until the WAIT message disappears Set up Communication Parameters at the Control oc WN N d Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the ISO soft key then press the ISO soft key Verify user access level Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the STARTUP soft key The message Actual access level Manufacturer should
14. Press Services soft key Press Data in soft key Press Archive vertical soft key The SOURCE window opens on the lower portion of the display Choose the file TO TOA in the SOURCE window by highlighting it with the blue bar Press Start vertical soft key When message appears in the Query box asking to overwrite select the Yes all vertical soft key Wait for the job is ready message to display at the bottom of the screen Press Data in soft key Press Archive vertical soft key The SOURCE window opens on the lower portion of the display Choose the file UFR in the SOURCE window by highlighting it with the blue bar Press Start vertical soft key When message appears in the Query box asking to overwrite select the Yes all vertical soft key Wait for the job is ready message to display at the bottom of the screen Reload tool data T Align pocket one 1 to spindle Perform M11 function Load tool data Load tool data Load tools optional 10 Back Up Hard If the hard disk contains files other than the ones needed for basic machine Disk Files operation such as program files and application files they should be backed up to an external source such as a floppy diskette an external computer or a network server Backing up files to an external computer requires a parallel computer cable One end of the cable is connected to the LPT port of the MMC103 The other end of
15. 50081 2 1993 and EN 50082 2 1995 Ambient air temperature conforms as specified in EN60204 1 1992 section 4 4 2 5 deg C to 40 deg C Humidity conforms as specified in EN60204 1 1992 section 4 4 3 relative humidity 5090 to 95 non condensing Altitude conforms as specified in EN60204 1 1992 section 4 4 4 maximum altitude without derating exceeds 1000 meters above sea level Contaminants conform as specified in EN60204 1 1992 section 4 4 5 Equipment is not intended for use in a corrosive atmosphere Equipment that will be used in an environment with excessive amounts of fine conductive particulate matter e g graphite must be ordered with the graphite restraint package SS 8 May 2002 Fadal ELECTRIC SHOCK SHARP EDGES ON CUTTING TOOLS ROTATING CUTTING TOOLS May 2002 SAFETY SECTION The 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 so that power may be maintained during diagnostics or adjustments tasks Under no circumstances should the operator defeat any interlock Read all applicable manuals and follow their warnings to prevent accidental electric shock Operators must never remove shields or panels nor should operators bypass or otherwise disable interlocks Cutting tools have sharp edges that could lead to a serious cut The to
16. 8030 LBL 0125 LBL 0128 LBL 0263 LBL 0235 LBL 0128 LBL 0265 Mav 2002 SS 29 Safetv Section Fadal SAFETY SECTION LBL 0235 LBL 0126 LBL 0129 LBL 0124 Safetv Section 55 50 2002 SAFETY SECTION Fadal LBL 0235 LBL 0125 0125 LBL 0165 LBL 0128 Mav 2002 SS 31 Safetv Section Fadal SAFETY SECTION LBL 0128 LBL 0265 LBL 0235 LBL 0235 Safety Section SS 32 May 2002 SAFETY SECTION Fadal 6535 4525 5020 0126 0125 2002 55 335 Safety Section Fadal SAFETY SECTION LBL 0128 0125 LBL 0128 0063 LBL 0126 Safety Section 55 54 2002 SAFETY SECTION Fadal 1 34 LBL 0128 LBL 0263 cw 1811 0056 wm Wwz w LBL 0235 LBL 0125 Mav 2002 SS 35 Safetv Section SAFETY SECTION Fadal 0255 LBL 0125 Safety Section SS 56 May 2002 SAFETY SECTION Fadal CE SAFETY LABELS LBL 0431 small CE LBL 0434 large CE Cutting of Fingers or Hand Rotating Cutter Cutting 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 the door interlocks are working LBL 0432 CE Hand Entanglement Belt Drive Rotating pulleys and belts can seriously injure Never place any part of your
17. 810D Version def bool ridtap 1 xscale yscale zscale ascale bscale extcolumn al200ipm def bool ax b ax CogBelt ServoTurr DualArmATC HiCapATC VHT Spindle SET UP OPTIONS BELOW l on 0 xscale 0 X scale vscale 0 Y scale _zscale 0 Z scale _ascale 0 7A scale _bscale 0 7B scale a 0 A axis b 0 7B axis _extcolumn 0 Extended colum 32 z axis CogBelt 0 15K cogged belt spindle _ServoTurr 0 Servo turret ATC _DualArmATC 1 Dual arm ATC _HiCapATC 0 High Capacity Turret ATC _VHT_Spindle 0 Very High Torque Spindle al200ipm 0 1200 ipm xy axes CHANDATA 1 if ridtap 1 msg RIGID TAPPING g4f2 Jan 2003 Parameters 153 Fadal 154 SIEMENS CONTROL Maintenance Manual MN USER DATA HEX 0 MN USER DATA HEX 0 B OR B00000001 RIDG msg NO RIGID TAPPING g4f2 5 USER DATA HEX 0 MN USER DATA 0 B AND BUD aE TO DEACT RIDG TAP endif stopre if ax msg NO A AXIS g4f2 AXCONF MACHAX USED 4 0 DEACT NCK 5 USER DATA HEX 0 MN USER DATA 0 B AND B10111111 DEACT A AX IN PLC MN DRIVE LOGIC NR 6 0 REMOVE DR IN SLOT 7 5 DRIVE IS ACTIVE 6J 0 DEACT DR IN SLOT 7 MN DRIVE LOGIC NR 7 0 REMOVE DR IN SLOT 8 SMN DRIVE IS ACTIVE 7 0 DEACT DR IN SLOT 8 endif stopre if ax SMN USER DATA HEX 0 MN USER DATA 0 B OR B01000000 ACT A AX IN PLC
18. CH2 AX1 4 6 0 0 AXCONF MACHAX USED CH2 AX2 5 7 0 0 AXCONF MACHAX USED CH2 AX3 6 Assignment of channel axes to machine axes Program Continuation Switch control OFF ON Channel 901 axis 902 defined for more than one channel via machine data 903 Explanation 001 Channel number 002 Index Machine axis number 005 String Machine data identifier In the channel specific MD 20070 AXCONF MACHAX USED CHn n channel number m channel axis number x machine axis number several channels have been assigned to one machine axis without having defined a master channel for this axis There is usually not much point in assigning a machine axis to several channels exceptional cases multiple assignment can be performed if a master channel is defined for this axis The channel assignment can be performed in accordance with the machining requirements in the NC part program by means of a keyword yet to be defined in later product versions Reaction Alarm display Interface signals are set Mode group not ready Power On Procedure Alarms Jan 2003 Fadal Jan 2005 4002 SIEMENS CONTROL Maintenance Manual Channel not ready NC Start disable NC Stop when alarm Remedy In the axis specific MD 50550 AXCONF ASSIGN MASTER CHAN AXm n m machine axis number n channel number a master channel must be specified for the axes that are assigned by the NC program alternately fo
19. Description of elements 12 10 SIEMENS CONTROL Maintenance Manual Remote MPG wheel Activated by selecting Remote position in the main axis selector switch in the machine control panel and the MPG mode Generates square wave pulses for the incremental movement of the selected axis Remote axis selector switch Selects the active axis The active axis can be jogged or moved incrementally X Y Z 4th and 5th axis available key Moves the active axis in the positive direction If in jog the axis moves as long as the key is pressed If in incremental the axis moves one increment in the positive direction key Moves the axis in the negative direction If in jog the axis moves as long as the key is pressed If in incremental the axis moves one incre ment in the negative direction key Rapid traverse override key Pressed together with the or key the active axis moves at rapid jog speed only in jog mode FI key Works exactly as the TOOL IN OUT key in the machine con trol panel Active only when the main axis selector switch is in the Remote position F2 key Toggles between MPG and JOG mode when the remote MPG 15 activated key Selects the incremental multiplier for incremental movements When the remote MPG is selected the multiplier defaults to x1 1 times 001 mm or 0001 in By pressing F3 the incremental multiplier changes to x10 x100 and variable multiplier in successio
20. Remedy This is an indication of possible discrepancies The program continues if no acknowledgment is called for Program Continuation Clear alarm with the Cancel key No further operator action necessary Channel 1 command 962 refused Explanation 901 Channel number The channel has received a command that cannot be executed Reaction Alarm display Remedy Press RESET Program Continuation Clear alarm with the Cancel key No further operator action necessary Mode group 902 channel 901 command change of operation mode aborted Channel 901 block 902 velocity limitation during thread cutting Explanation 001 Channel number 2 Block number label In the displayed thread block the axis would exceed its maximum velocity when the spindle override is in the maximum position Reaction Alarm display Remedy If the axis velocity is not limited faultless thread no remedial measures are necessary Otherwise a lower spindle speed must be programmed for the thread block Program Continuation Clear alarm with the Cancel key No further operator action necessary Channel 1 axis 2 not stopped Explanation Power On Procedure Alarms 51 Fadal 52 10620 SIEMENS CONTROL Maintenance Manual 001 Channel number 2 Block number label An 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
21. SMC MACHAX USED 4 5 ACT A IN NCK SMA CTRLOUT MODULE NR 0 AX5 7 A AXIS DRV 7 MODULE NR 0 AX5 27 ENCDR 1 DRV 7 MODULE NR 1 AX5 7 ENCDR 2 DRV 7 endif stopre if a ax 1 and zscale 0 msg A AXIS NO Z SCALE g4f2 MN DRIVE LOGIC NR 6 7 ASSIGN DRIVE 7 TO SLOT 7 S MN DRIVE S ACTIVE 6 0 ACTIVATE DRIVE IN SLOT 7 MN DRIVE LOGIC NRI7J 0 REMOVE DR IN SLOT 8 5 DRIVE _ S ACTIVE 7 0 DEACT DR IN SLOT 8 SMN DRIVE _ NVERTER CODE 6 H14 25A PWR SEC 5 DRIVE MODULE TYPE 6 1 1AX PWR SEC endif stopre if a ax 1 and zscale 1 msg A AXIS Z SCALE g4f2 MN DRIVE LOGIC NR 7 7 ASSIGN DRIVE 7 TO SLOT 8 SMN DRIVE IS ACTIVE 7 0 ACTIVATE DRIVE IN SLOT 8 MN DRIVE INVERTER CODE 7 H14 5 DRIVE MODULE TVPE 7 1 1AX PWR SEC MN DRIVE LOGIC NR 6 10 ASSIGN DR 10 TO SLOT 7 SMN DRIVE S_ACTIVE 6 0 DEACTIVATE DRIVE IN SLOT 7 endif Parameters Jan 2003 Fadal Jan 2003 SIEMENS CONTROL Maintenance Manual stopre if ax msg NO B AXIS g4f2 SMC MACHAX USED 5 0 DEACT B AX IN 5 USER DATA HEX 0 MN USER DATA 0 B AND 01111111 DEACTIVATE B AXIS IN PLC MN DRIVE LOGIC NR 8 0 REMOVE DR IN SLOT 9 SMN DRIVE IS ACTIVE 8 0 DEACT DR IN SLOT 9 endif stopre if b ax 0 and a ax 0 MN DRIVE LOGIC NRI7J 0 REMOVE DR IN SLOT 8 5 DRIVE IS ACTIVE 7 0 DEACT DR IN SL
22. TEE ET 1 1 2 Digital Cortal SySt in 2 1 3 Digital Drive Converter System sese 2 NN AEG 2 1 52 CCU Interface Pal i si Red 5 1 5 5 Axis Extension Module 5555555 Set ERE e 7 EU E i E 7 1 5 Pendant Components sica ttrt ai ek pad dad 8 S 2 8 1 5 2 HMI Meer 8 1 5 5 CNC Keyboard oras easet a u 9 154 MPG ace 10 1 6 System Components and Parts sesassuse rh pot jissana ti carr n bra Ped paese Sr AS 10 Hand Held Unit Remote MPG Description of elements 12 Control Components 15 2 1 Replacement of Modules M 13 2 1 1 Reactor and Line Module Replacement 19 2 1 2 Replacing the E R 18 2 1 5 CCU1 Module Replacement ia sine HM nahe n REIR MEE 18 2 1 4 Power Module Replacement 2
23. body near rotating or moving parts Always insure that guards are in place before operating this machine May 2002 55 37 Safety Section SAFETY SECTION Fadal LBI 0122 CE Electric Shock Electrocution Hazardous 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 Loud Noise Flying objects from this machine may injure Always wear safety glasses when operating this machine Do not operate this machine with the doors open or the enclosures removed Also noise from this machine can damage hearing Always wear ear protection when operating this machine Safety Section SS 38 Mav 2002 Fadal LBL 0460 CE LBL 0430 May 2002 SAFETY SECTION Flying Debris Flying 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 compressed air systems Skin Puncture Pressurized Air Compressed air can seriously injure Do not perform maintenance on pressurized systems Disconnect air source before performing maintenance Always wear eye protection when performing maintenance on compressed air Systems 55 39 Safety Section SAFETY SECTION Fadal LBL 0436 CE Leg or Body Entanglement Auger Auger can
24. window when the axis spindle was reprogrammed Example N100 POSA U 100 N125 X Y U e g U axis still travels from 100 Reaction NC Start disable NC Stop when alarm Alarm display Interface signals are set Remedy Check and correct the part program analyze whether motion beyond block boundaries is at all meaningful here Prevent block change by means of the keyword WAITP until the positioning axes have also reached their target position Example N100 POSA U 100 N125 WAITP U N130 X Y U Program Continuation Clear alarm with RESET key Restart part program Channel 901 block 903 axis 902 at software limit switch 904 Explanation 001 Channel number 902 Axis name spindle number 3 Block number label 904 String During the traversing motion it is recognized that the software limit switch would be overtraveled in the displayed direction It was not yet possible to detect in the block preparation that the traversing range would be exceeded either there has been a motion overlay by the handwheel or a coordinate transformation is active Reaction Alarm display Interface signals are set NC Start disable Power On Procedure Alarms Jan 2003 Fadal Jan 2003 10621 10630 SIEMENS CONTROL Maintenance Manual Remedy Depending on the reason for this alarm being triggered the following remedial measures should be undertaken 1 Handwheel override Cancel the mot
25. yellow flashes to signal ongoing communi cations The seven segment display H3 shows a b 170 Troubleshooting Jan 2005 Fadal SIEMENS CONTROL Maintenance Manual Measuring system connections 411 416 I O interface cable distributor Profibus DP to CCU2 as of 06 99 MPI interface Reserved PLC I O terminal P bus 7 segment Terminal displav H3 block X431 Error and status PCMCIA LEDs H1 H2 slot NCK startup switch S3 Test sockets PLC startup SIMODRIVE switch S4 611D drive bus RESET button L nmm ti 10181852140 S1 Device bus interface X151 Axis extension connection X304 X306 CCU front panel Jan 2003 Troubleshooting 171 Fadal 9 5 The In feed Regeneration I R Module 172 SIEMENS CONTROL Maintenance Manual The I R module is the power supply for the 810D There are several voltages generated for the logic electronics and there are 600 VDC output for the drives to run the motors There are six LEDs and several test points to check for those voltages CAUTION 600 VDC carries a lot of power Even brief contact can result in fatal bodily harm Only an experienced professional should access the cabinet to perform high voltage checks Normally there should be 24VDC 24VDC 15VDC and 15VDC Only the yellow LED is on during normal operation The DC link voltage is 600 VDC 300 VDC and
26. 27 28 29 50 5 gt 32 SAFETV SECTION 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 DO NOT FORCE TOOL Tools are designed to perform properly and safely at proper rates Keep tools sharp USE THE CORRECT TOOL Do not attempt to use tools or attachments to perform a job for which they were not designed DON T OVERREACH Keep proper footing and balance at all times Use a steady object for support when reaching over the machine REDUCE THE RISK OF UNINTENTIONAL STARTING Power off the machine at the main disconnect switch and use the proper lockout tagout proce dures while working within the chip enclosure or when there is potential for a release of energy POWER OFF THE MACHINE AT THE MAIN DISCONNECT SWITCH AND LOCK OUT WHEN WORKING INSIDE ANY OF THE ELECTRONIC CABINETS USE RECOMMENDED ACCESSORIES Refer to the User s Manual for FADAL recommended accessories Unapproved accessories increase the risk of injury NEVER STAND ON OR IN THE MACHINE Besides the risk of slipping or fall ing serious injury could occur if a tool is unintentionally contacted CHECK FOR DAMAGED PARTS Always check all parts for binding break age and any other condition that will affect the proper operation of the machine and or increase the risk of injury Damaged or missing parts must be repaired or replaced BEFORE operat
27. 300 VDC for a regulated module I R and about 550 VDC for an unregulated one UE Check with an authorized service representative to verify which type of module is installed Troubleshooting Jan 2003 Fadal SIEMENS CONTROL Maintenance Manual 9 5 1 The I R Module Jan 2003 X111 XS X121 Electronics power LED 5V voltage supply faulty displays P level faulty red red Device is not ready Device ready no enable signal green ojo yellow DC link term 63 64 or 48 red rele red pre charged li lcm Main fault X141 DC link X161 over voltage X171 X172 X181 Device bus X351 DC link connection Ground 1 20 4 28 8 V50 mA 15 V 10 mA 15 V 10 mA 20 4 28 8 V 50 mA OV X141 RESET Term 15 Rg 10k ohm I R UE monitoring module P600 DC link 300 V M600 DC link 300 V The description of the alarms is normally enough to pin point the cause of a problem but in some cases extra help is needed Writ numbers and any other information that could be helpfu e down all alarm l as well as any factor that may have contributed to the problem This information will allow a Fadal representative to further troubleshoot the problem Troubleshooting 173 Fadal How to monitor the DATC interface 174 SIEMENS CONTROL Maintenance Manual The dual Arm Tool Changer in the Siemens equipped machine works out of a 9 bit si
28. 5 AX VELO LIMIT 0 AX4 3000 SPEED LIMIT C AXIS 5 AX VELO LIMIT 1 AX4 3000 SPEED LIMIT 1ST GEAR endif stopre if ServoTurr msg SERVO TURRET g4f2 5 USER DATA HEX 1 MN USER DATA HEX 1 OR B00000010 ENBL SERVO TURR IN PLC else msg STANDARD TURRET g4f2 SMN USER DATA HEX 1 MN USER DATA HEX 1 B AND B11111101 DIS SERVO TURR IN PLC endif stopre if HiCapATC msg HIGH CAP ATC g4f2 MN USER DATA HEX 1 MN USER DATA HEX 1 B OR B00001000 ENBL HIGH CAP ATC IN PLC else msg STD CAP ATC g4f2 MN USER DATA HEX 1 MN USER DATA HEX 1 B AND B11110111 DIS HIGH CAP ATC IN PLC endif stopre if VHT Spindle msg VHT SPINDLE g4f2 5 CTRLOUT MODULE NR 0 AX4 10 CHG SP TO DRV 10 MODULE NR 0 AX4 10 SP FEEDBACK 1 DRV 10 MODULE NR 1 AX4 10 SP FEEDBACK 2 DRV 10 else msg HT SPINDLE g4f2 SMA CTRLOUT MODULE NR 0 AX4 4 CHG SP DRV 4 MODULE NR 0 AX4 4 SP FEEDBACK 1 DRV 4 MODULE NR 1 AX4 4 SP FEEDBACK 2 DRV 4 endif stopre if VHT Spindle 1 and zscale 0 MN DRIVE LOGIC NR 3 10 USE VHT BOOT FILE Parameters Jan 2003 Fadal Jan 2003 SIEMENS CONTROL Maintenance Manual 5 DRIVE INVERTER CODE 3 H9 BIG POWER SECTION endif stopre if VHT Spindle 0 and zscale 0 MN DRIVE LOGIC NR 3 4 USE HT BOOT FILE SMN DRIVE INVERTER CODE 3 2 Hd SML POWER S
29. Activate testrun signal rapid 1 Nesting depth too great Wait until the preceding traverse overlay 2 The active block after which deceleration takes place cannot be reorganized occurs when deceleration takes place over several blocks asynchronous subroutine is terminated or abort the program Abort program J an 2003 ActionList 7 Fadal SIEMENS CONTROL Maintenance Manual No Explanation Not allowed if Remedy 67 Deactivate testrun VDI signal 1 Nesting depth too great Wait until the preceding rapid traverse overlay l asynchronous subroutine is terminated or abort the program 2 The active block after which Abort program deceleration takes place cannot be reorganized occurs when deceleration takes place over several blocks 68 Activate read in disable for main run block VDI signal read in disable 69 Deactivate read in disable for main run block VDI signal read in disable 70 Stop at block end Alarm 71 Stop all axes Alarm 72 Activate program test VDI signal 1 Tool management is active Save tool data program test 2 The NCK channel state is not Abort the program or process ready with the Reset key or wait for end of program 73 Deactivate program test VDI The channel state is ready Abort the program or process signal program test with the Reset key or
30. CONTROL 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 Pressthe extended menu hard key j Press the Original status soft key answer YES to perform series start up Press the Yes soft key when asked to overwrite Press YES ALL to overwrite any data Power OFF and check for basic hardware configuration see NOTE below NOTE If the machine is equipped with scales and or 4th 5th axes the extra hardware MUST be disconnected so that the hardware configuration is the same as figures 1 or 2 in the WRG 0002 wiring diagram 12 Restore the This step returns the machine to its operational state with the original zero Machine to Its offsets backlash and compensation values Operational Pd Power ON and Reference Each Axis IF REQUIRED manually jog each axis to its alignment mark 1 Press MPG hard key Wait for LED above the key to illuminate NO Select an axis with the axis selector switch Align the selected axis to its mark by using the handwheel Repeat steps 2 and 3 for all the axes WN 5 Press JOG hard key when done Reference the axes 1 Select an axis with the axis selector switch 2 Press REF POINT hard key 3 Press plus hard key 4 Repeat steps 1 2 and 5 for all the axes The axes referenced when the cross
31. Drive Y axis Feed Drive Z axis Scale Feedback X axis Scale Feedback Y axis Scale Feedback Z axis Feed Drive Main Spindle Drive A axis Feed Drive 810D 1 810D 2 810D 3 810D 4 810D 5 810D 6 1 axis 1 axis ITI rIrIrrrzrr config Siemens 50 Taper PowerSect Current Drawing Symbol 85 110 127 Jan 2003 Fadal Jan 2003 SIEMENS CONTROL Maintenance Manual The listing of new items is as follows 1 The first Siemens spindle motor on a Fadal machine This spindle motor is about 50hp with noted 510nM of torque from the Dyno tester It has a direct drive cogged belt so no spindle calibration is necessary M83 and M84 It has a max 8000rpm and is limited to 7500rpm There are no gear changes and it is direct drive This new spindle motor requires bootfile HS14 The following is a listing of the Dive machine data parameters Description Drive MD Value motor nominal power 1130 28 000 motor nominal current 1103 68 300 motor nominal voltage 1132 312 000 motor rated speed 1400 1000 000 motor nominal freq 1134 34 200 motor no load voltage 1135 294 000 motor no load current 1156 35 100 stator cold resistance 1137 0 062 rotor cold resistance 1138 0 045 stator leakage reactance 1139 0 151 rotor leakage reactance 1140 0 220 magnetizing reactance 1141 5 500 field weakening speed 1142 1180 000 Ih curve upper speed 1143 1700 000 motor max allowed speed 1146 8000 000 Ih curve gain 1144 136 000 motor inertia 11
32. K6 relay into the 120 VAC K6 receptacle on the 2010 0 board 2 6 Replacing Fadal 5 VDC Power Supply Parts Numbers ELE 1159 5 volt and 12 volt power supply Tools Required Screwdriver Nut Driver NOTE To remove components for repair or replacement Follow the assembly instructions as necessary in reverse order until the component has been disassembled to required level to conduct the repair 1 Attach power supply ELE 1139 to cabinet with three 10 52 nuts HDW 0539 32 Control Components 2 6 Replacing Fadal 5 VDC Power Supply Jan 2003 SIEMENS CONTROL Fa d a Maintenance Manual DHW I L w TASA Won 2 7 Replacing Pendant Components NOTE To remove components for repair or replacement Follow the assembly instructions as necessary in reverse order until the component has been disassembled to required level to conduct the repair Jan 2003 Control Components 2 7 Replacing Pendant Components 55 SIEMENS CONTROL Fa dal Maintenance Manual 2 7 1 2020 Power 1 Install 2020 power distribution board PCB 0204 with four nylock Distribution Board nuts HDW 0657 Oh Fadal 2020 0 P 2 Terminate all connections on the 2020 power distribution board as shown 2 7 2 MPG Panel Install lower left MPG panel STM 0872 34 Control Components 2 7 Replacing Pendant Components Jan 2005 SIEMENS CONTROL Fada Maintenance Manual 2 7 3 MCU Pane
33. Menu select hard key then press the Program Manager soft key 58 Select COMP VALUES nin the directory 9 Press the INPUT hard key Enter the corresponding compensation values 40 Use the arrows to edit values as needed See the example at the end of this procedure 41 Go to the start of the program using the PAGE UP hard key 42 Press the MACHINE FROM HERE soft key to load the program 45 Press the CYCLE START hard key The program will load the compensation values into memory 44 Reference the axis and check for proper cold start position NOTE Run the COMP VALUES n program from the beginning whenever the machine is changed to from metric or inches The original values in inches must be used as they are automatically converted Figure 1 shows a sample printout from a laser measurement system 78 Compensation 5 5 Axis Backlash Jan 2003 SIEMENS CONTROL Fada Maintenance Manual A ENISHAW CALIBRATION INTERFEROMETER SYSTEM RROR COMPENSATION TABLE ta MACHINE VMC 3020 SERIAL No XXXX DATE By Axis Y AXIS Location 9 Title Y SURVEY Filename Data Capture Table Type Combined table with backlash value Compensation type Absolute Compensation resolution 0 0001 in Reference position 9 00000 in Compensation start 9 00000 in Compensation end 10 00000 in Compensation spacing 1 00000 in Backlash value 0 0000 in Compensation
34. NC CARD REMAINS WITH THE MACHINE Figure 15 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 June 2002 MMC100 Software Update MMC100 Update Procedure 97 Fadal SIEMENS CONTROL 7 segment display H3 Error and status NCK i startup 2 switch S3 3 5 n SIE operating 4 CPU t 5 mode switch Figure 16 Switches and LED indicators used in resetting 54 the When the is reset machine data is cleared and a standard machine data set is loaded into memory The 5V SF and PR LEDs are lighted The 7 segment display shows a b see figure 10 The following procedure resets the PLC The overall switching sequence for switch 54 is 2 5 2 3 0 as follows Set switch S4 to position 5 MRES LED labeled PS turns off Wait for LED labeled PS to light up again Set switch S4 to position 2 and then back to position 5 within three seconds LED labeled PS will start flashing Wait for LED labeled PS to stop flashing Return S4 to position O PLC run The green LED labeled PR will turn on The machine is now running the new NC operating system and the old NC PLC data is erased 10 Install New HMI The following procedure updates the display on the pendant The primary firmware change is the displa
35. STEP MAX VELO LIMIT 1 AX4 15500 MAX SP LIM 1ST GEAR GEAR STEP SPEEDCTRL ACCEL 0 AX4 175 ACCEL C AXIS GEAR STEP SPEEDCTRL ACCEL 1 AX4 175 ACCEL 1ST GEAR 5 AX VELO LIMIT 0 AX4 15500 5 LIMIT C AXIS 5 AX VELO LIMIT 1 AX4 15500 5 LIMIT 1ST GEAR else msg NO 15K SPINDLE g4f2 MN USER DATA HEX 1 MN USER DATA HEX 1 B AND B11111110 DIS 15K SPINDLE IN PLC MAX AX VELO AX4 10000 SET MAX AX SPD SMA DRIVE AX RATIO NUMERA 0 AX4 194000 2 TO 1 RATIO C AXIS MODE SMA DRIVE AX RATIO NUMERA 1 AX4 194000 2 1 RATIO 1ST GEAR SMA DRIVE AX RATIO 2 4 51600 1 2 RATIO 2ND GEAR SMA GEAR STEP CHANGE ENABLE AX4 1 ENBL GEAR CHGE SPIND VELO LIMIT 41 lt 10000 ABS SP 10K 5 5 5 5 5 5 5 5 5 5 5 S55 5 Sb SS R R R R Parameters 157 Fadal 158 SIEMENS CONTROL Maintenance Manual GEAR STEP MAX VELO 0 AX4 2500 MAX SP 2 5 C AXIS MODE MA GEAR STEP MAX VELO 1 AX4 2500 MAX SP 2 5K 1ST GEAR SMA 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 MAX VELO LIMIT 0 AX4 2500 MAX SP LIM C AXIS MODE GEAR STEP MAX VELO LIMIT 1 AX4 2500 MAX SP LIM 1ST GEAR MA GEAR STEP SPEEDCTRL ACCEL 0 AX4 300 ACCEL C AXIS MA GEAR STEP SPEEDCTRL ACCEL 1 AX4 300 ACCEL 1ST GEAR
36. Start disable Interpreter Stop Remedy Option Retrofit Interpolation of more than 4 axes the number of axes that is then allowed can be set in this option or specify in the part program as many or fewer as required axes corresponding to the configuration of the control Program Continuation Clear alarm with the RESET key Restart part program Channel 1 NC Start not possible with unreferenced axes action 2 Explanation 1 Channel number Power On Procedure Alarms 49 Fadal 50 10208 10225 SIEMENS CONTROL Maintenance Manual NC Start has been activated in the MDA or AUTOMATIC mode and at least one axis that needs to be referenced or has not reached its reference point Reaction Alarm display Remedy Via the channel specific MD 20700 REFP NC START LOCK NC Start without reference point you can decide whether the axis must be referenced before NC Start or not The start of referencing can be enabled channel specific or axis specific On the FADAL 3020 all axes must be referenced before switching to AUTO or MDA 1 Channel specific reference point approach The rising edge of the interface signal activate referencing DB 21 28 DBX 1 0 starts an automatic sequence which starts the axes of the channel in the same sequence as specified in the axis specific MD 54110 REFP CYCLE NR axis sequence channel specific referencing 1 The axis does not participate in channel specific referencing bu
37. The _COMPVALUE 1 0 0000 survey value corresponds to No 1 in the printout and the COMPVALUE 6 0 0004 survey value corresponds to No 6 in the printout NOTE For A and B axes position number one corresponds to pointer zero That is COMPVALUE 0 0 0000 corresponds to No 1 of the printout and _COMPVALUE 6 0 0004 corresponds to No 7 of the printout 5 4 Reset Tool Magazine The TC_BASE program resets the contents of the tool magazine Every time the tool data is lost for any reason this program returns the magazine to a state where all the tools are in the magazine and none are in the spindle The tool offsets will be reset to zero in both length and diameter The following steps describe how to use the TC_BASE program Compensation 5 4 Reset Tool Magazine Jan 2003 SIEMENS CONTROL Fada Maintenance Manual IMPORTANT After using TC_BASE remember to remove any tool from the spindle before calling a tool When there is no tool assigned to the spindle the tool changer will go directly to the magazine to load a new tool If there is a tool already in the spindle the automatic tool changer may incur severe damage 45 Press the Joc h hard key 46 Press the MDA es 47 Enter TC BASE 48 Press the CYCLE START 49 The control will show a message Then alarm 570300 will appear 50 Power the machine off and back on 51 Once the machine is ready to
38. Tool In Out button on the Spindle head The pendant must be in the REMOTE Mode for this button to work refer to WRG 0002H There is no input or PLC changes required for this to function since the button is in parallel with the remote tool in out Siemens 50 Taper Jan 2003 SIEMENS CONTROL Fada Maintenance Manual Section 09 Troubleshooting 9 1 Introduction There are four main locations to gather troubleshooting data when a problem occurs the alarms and message line located in the upper bar in the normal machine display the alarm page the LEDs on the CCU and the LEDs on the R module If there is no trouble data available at any of these locations then the trouble may be external to the control such as a lack of incoming power or a bad power supply 9 2 The Alarms and Messages Line channel reset yt Alarms and 777777 messages or T line 0 800 USES M 0 000 0 000 The alarms and messages line displays two lines at a time which is enough for one alarm message only This would be the first place to look for information The dialog line also displays extra information in some cases 9 5 The Alarms By pressing the ALARM SYSTEM hard key the control switches over to the Messages Page alarms messages page On this page all the present alarms messages are displayed at the same time This is the best place to look for information since the alarms message
39. Verify there is no tool in the spindle before going on with the tool change to avoid damaging the tool magazine Tool zero is in the spindle REACTION Display alarm Axis movement disable NC start disable REMEDY Verify there is not tool in the Spindle and continue as prompted PROGRAM CONTINUATION Continue part program Contact Service Load Tool Active DEFINITION The tool load function is active REACTION Display message Axis movement disable NC start disable REMEDY Normal message during tool load PROGRAM CONTINUATION Continue part program Contact Service 67002 Tool Un load Not Possible Tool In Spindle Tool un load Not Possible Tool In Spindle Power On Procedure Alarms Jan 2003 Fadal Jan 2003 510008 510009 510010 510011 SIEMENS CONTROL Maintenance Manual DEFINITION The spindle is the load unload position If a tool is already there tool loading unloading is not possible REACTION Display alarm Axis movement disable NC start disable REMEDY Call TO tool zero to remove the tool from the spindle PROGRAM CONTINUATION Continue part program Contact Service User Feed Stop DEFINITION User has pressed the Feed Stop key REACTION Display alarm Program interrupted Axis movement disable REMEDY Remove feed stop condition PROGRAM CONTINUATION Press the Feed Start key or Cycle Start key Feed Stop Selected gt gt Spindle Not Rotating DEFINITION User feed stop condition prevents t
40. a zip file but it is only a Siemens archive file June 2002 MMC100 Software Update MMC100 Update Procedure 113 Fadal IMPORTANT 1 Replace Hardware for DATC SIEMENS CONTROL DATC Hardware Update 1 7 2 or above MMC100 DATC Software Update MUST BE INSTALLED FIRST General Information Check the existing Siemens hardware before proceeding with this update Compare the hardware to WRG 0002 REV F see Appendix A If the ports and cables are found to be a different configuration then order the replacement part s and install prior to proceeding with this update Figure 21 PCB 0230 and 2010 1 13 to 1100 1 J3 Cable a Turn the main power off Tools Required The components required are as follows PCB 0230 DATC CONTROLLER SIEMENS 1330 includes PLC Chip for 1330 card must be Siemens Version 2 02 Cable 2010 1 J3 to 1100 1 J3 For information on Cable setup see the wiring diagram at the end of this manual b Replace existing 1330 0A DATC Controller with new PCB 0230 1330 OA Make sure that the PLC Chip is Siemens Version 2 02 C If necessary attach Cable 2010 1 J3 to 1100 1 J3 If the cable is missing and if a single wire currently exists at 1100 1 J3 connecting to 1980 0 or 2000 0 or 2030 0 board then cut the connector off of the existing wire insert it into a new cable at the butt splice on the red wire and crimp Then install the new cable d Repackage the removed components an
41. channel The resulting Channel axes are given name by the MD AXCONF CHANAX NAME TAB and assigned to a geometry axis by the MD AXCONF GEOAX ASSIGN TAB the corresponding channel axis is entered for each geometry axis in this MD Program Continuation Switch control OFF ON Axis 901 assignment of master channel in machine data 902 incorrect or missing Explanation 901 Axis 902 String Machine data identifier For some applications it is useful to operate an axis in several channels C axis or spindle on single spindle or double carriage machines The machine axes which are defined in several channels by means of the MD 20 070 MACHAX USED must be assigned to a master channel with the axis specific machine data 30 550 AXCONF ASSIGN MASTER CHAN For axes that are activated in only one channel the number of this channel or zero must be entered as master channel Reaction Alarm display Interface signals are set NC not ready Mode group not ready NC Start disable NC Stop when alarm Remedy Correct MD 20 070 AXCONF MACHAX USED and or MD 30 550 AXCONF ASSIGN MASTER CHAN Program Continuation Switch control OFF ON Standard machine data loaded Power On Procedure Alarms Jan 2003 SIEMENS CONTROL Fada Maintenance Manual Explanation With the next system power up the standard MDs are loaded by the system specific MD 11 200 INIT MD if MD buffer voltage has failed or e After
42. cold start may not be the same Therefore the electronic zero and mechanical zero needs to be aligned using offset Offset is the distance needed to go from the point where the machine stops after referencing and the point where it should be to have the cold start marks aligned The following steps describe how to use the SET OFFSETS program 1 Power the machine off and back on 2 Press the MPG hard key The LED above the key should illuminate 3 Select an axis using the axis selector switch on the MPG panel 4 Jog the selected axis to its cold start alignment mark The alignment does not have to be exact 5 Repeat steps 5 and 4 for all the axes 6 Press the Joc hard key This turns off the MPG 7 Press the REF POINT 8 Select an axis using the axis selector switch on the MPG panel 9 Press the plus hard key The crosshair symbol 4 will display to the left of the selected axis when referenced 10 Repeat steps 8 and 9 for all axes NOTE The control will show a distance value of zero for the axes as they are referenced If the value is different make sure the base value is set to zero and the tool offset is cleared using DO 11 Re align cold start marks Press the MPG hard key The LED above the key should illuminate Jan 2003 Compensation 5 1 Cold Start Position 75 Fadal 5 2 1 M83 Program 76 SIEMENS CONTROL Maintenance Manual 12 Select an axis using the axis selector switch o
43. customer identify their programs if necessary 8 Get Offset This step gets the zero offset and backlash data using a getval s mpf file and Backlash This file is referred to as the get values program It reads the zero offsets Data and the backlash data for all the available axes and displays them one at a time for recording Before running this program it must be copied into the Shopmill folder within the Workpieces folder from the Utilities diskette Set up the target location for upload The getval s mpf file must be loaded into the Shopmill folder The following steps sets up the pathway to the Shopmill folder a b Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the SERVICES soft key June 2002 MMC100 Software Update MMC100 Update Procedure 93 Fadal 94 NOTE NOTE SIEMENS CONTROL c Select Workpieces d Press the gt INPUT hard key e Select Shopmill f Press the 2 INPUT hard key Set up communication parameters at control The following steps sets up the parameters for communication at the control d Press the RS232 C User vertical soft key Press the SET soft key At this point two options columns are displayed The left options column is the parameters for communications The right options column is the Special Functions The parameters for communications should be as follows Interface COM1 Protocol RTS CTS Baud Rate 2400 Stop Bits 1 Par
44. display in the message bar at the bottom of the screen display If level is not set to Manufacturer or no message displays continue to step 4 If the level is set to Manufacturer go to Press the SET PASSWORD soft key Type SUNRISE The password is set in all UPPERCASE letters If necessary press the SHIFT hard key while typing the password Press the 2 INPUT hard key The password field turns orange Press the OK soft key The message Password has been set for Manufacturer must display on the screen Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the SERVICES soft key e f Select Workpieces Press the 2 INPUT hard key 104 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL g Select Shopmill h Press the gt INPUT hard key i 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 communications The right options column is the Special Functions The parameters for communications should be as follows Interface COM1 Protocol RTS CTS Baud Rate 2400 See note below Stop Bits 1 Parity none Data bits 8 Xon 11 Xoff 13 End of Trans 03 NOTE On external computers loaded with either the Windows 95 or Windows NT 4 0 Operating system a baud rate of 4800bps or higher may also be used On external computers l
45. ennea na E NARREA 88 3 Recording Original Cold Start Position Backlash Data and Gain Settings 89 7 97 DATC Hardware Update 1 7 2 or above 118 General 118 Tools Reguired ERN ESSEN ER 118 1 Replace Hardware for memes 118 MMCTOS Software Update v1 7 2 or above E uk YR anb da yERE Id aate x 119 i TABLE OF CONTENTS May 2002 Fadal Maintenance Manual General Information OE EDT 119 List of COMpOnentsS ia Siue dapes 119 Tools cepa 120 105 Update Procedure e 120 5 Get Offset and Backlash Data i 121 10 Back Up Hard Disk Files 143 12 Install New Pre imaged Hard Disk 145 153 Display HMI Firmware an 146 DATC Hardware Update v1 7 2 or 149 G reral imormnetlom 149 Tools Required 149 1 Replace Hardware for _ 149 acl We P 151 Setting Options on the Fadal Siemens 151 Setting the BINS NIRE EDIDI 152 How To set
46. for repair or replacement Follow the assemblv instructions as necessarv in reverse order until the component has been disassembled to required level to conduct the repair 1 Attach I O module ELE 1093 to the lower left corner of cabinet with two 1 4 20 x 3 4 screws 2 Connect the TS Se from the 2010 0 interface board to the X404 plug on the I O module 3 Connect the X405 cable from the 2010 0 interface board to the X405 plug on the I O module 4 Connect the X402 cable from the 2010 0 interface board to the X402 plug on the I O module Jan 2003 Control Components 2 4 Replacing the I O Module 27 SIEMENS CONTROL Fadal Maintenance Manual 5 Connect WIR 0740 from the CCU1 module to the X3IN plug on 1 O module Secure with thumb screws 6 Connect the 24 volt power supply wiring to X1 Ground to M24 24 VDC to P24 logic shield no connection and connect jumper to X5 Ground to M24 24 VDC to P24 logic shield not connected 7 Connect the ground wire to the chassis 2 5 Replacing the 2010 0 Board Parts Numbers PCB 0205 2010 0 Interface Board PCB 0045 Temperature Control Card Tools Required Assorted Screwdrivers 1 Attach 2010 0 board PCB 0205 to the back of the cabinet with hardware HDW 0509 HDW 0460 HDW 0453 28 Control Components 2 5 Replacing the 2010 0 Board Jan 2003 SIEMENS CONTROL Maintenance Manual v 4 Connect the X404 cable to the X404 plug on the 2010
47. is not responsible for injuries or equipment damage Read and understand the User s Manual The safe use and disposal of all hazardous materials processed or used by the VMC is the responsibility of the user All safety warnings and procedures must be followed Itis the sole responsibility of the user to comply with all local state national Federal and international and environmental safety laws and regulations applicable to the VMC and its use SS 7 Safety Section Fadal WARNINGS AND CAUTIONS PICTORIALS POTENTIAL HAZARDS TO PERSONNEL PHYSICAL ENVIRONMENT AND OPERATING CONDITIONS CE SPECIFICATIONS Safety Section SAFETY SECTION This manual contains information that will assist qualified operators and maintenance personnel Unqualified operators should never attempt to operate or perform maintenance on the VMC Pictorials are used within warnings to rapidly communicate a hazard to the reader The pictorials and their meaning given in this section diagram of the locations and types of warnings that are physically attached to or engraved on the VMC is also included The most serious potential hazards associated with the VMC are electric shock sharp edges on cutting tools rotating cutting tools noise compressed air FADAL VMCs meet or exceed the environmental requirements stated in EN 60204 1 1992 section 4 4 Electromagnetic Compatibility meets or exceeds the levels specified by EN
48. is pressed then turn on work light and sends the appropriate output like a voltage to a relay that turns the light on All the necessary interfaces for receiving feedback from the motor and other components of the system are on the front panel of the CCU module But unlike other stand alone control modules the control sections of the CCU have only one feedback connector instead of two If a second measurement system is needed one of the available control sections has to be used for feedback input For example if control section four is being used as a second Overview 3 Fadal SIEMENS CONTROL Maintenance Manual A Control Control Control Module 1 Module 2 Module 3 NCK Control Control Control Module 4 i Module 5 Module 6 To from external 4 control module Figure 1 4 The three sections of the CCU module are the NCK PLC and one motor control sections feedback and assuming control sections one through three are also being used then it can no longer be used to control an additional motor The motor would have to be connected to the next available control section in this case it is control section five The following list is a description of the SINUMERIK 810D control module interface connections from Figure 1 5 a X411 X416 t
49. it 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 electronics cabinet located at the back of the machine to the options diagrams from Appendix A Example A Siemens machine with an A axis X Y and Z scales installed will have a setup in the electronics cabinet resembling diagram number 5 See Figure 19 Therefore the settings in the options table will be as follows _xscale 1 _yscale 1 _zscale 1 _ascale 0 _bscale 0 1 _b_ax 0 _V300 0 _extcolumn 0 _CogBelt 0 June 2002 MMC100 Software Update MMC103 Update Procedure 129 Fadal SIEMENS CONTROL _ServoTurr 0 _DualArmATC 0 _HiCapATC 0 _VHT_Spindle 0 1200 0 m7 is m8 0 NOTE Setting the value to 1 enables the option For Example a V300 would require a ax 1 _ascale 1 _V300 1 OPT 0197 amp OPT 0199 IR SIEMENS Figure 27 The X Y and Z ports are used for the signal return connection from the scales A 611D axis extension module is added for machines with 4th and 5th axes j Go back to the beginning of the program Use arrow keys to scroll back to the top of the options program The very first line of text should be highlighted when at the beginning of the program This is important if the program is to be run in its entirety k Press the Overwrite soft key and then press the Close editor soft key Press t
50. not remove or modifv com ponents in this cabinet Safetv Section SS 20 Mav 2002 SAFETY SECTION Fadal LBL 0131 LBL 0263 ATTENTION Mav 2002 SS 21 Safetv Section Fadal SAFETY SECTION LBL 0187 LBL 0234 A DANGER Auger can seriously injure or kill Keep body parts out of Auger svstem at all times Safetv Section SS 22 Mav 2002 Fadal LBL 0124 May 2002 4 DANGER 55 23 SAFETY SECTION Cutting tools can seriousiv injure or kill DO NOT operate unless doors are closed and interlocks are working Safetv Section SAFETY SECTION Fadal LBL 0040 MAINTENANCE AND RAIL LUBRICATION DAILY 1 CHECK AIR PRESSURE 80 90 PSI 2 WITH TOOL IN SPINDLE BLOW CHIPS FROM AROUND A T C AND SLIDE NEVER BLOW CHIPS FROM AROUND THESE AREA DURING AUTOMATIC TOOL CHANGE OR WITHOUT A TOOL IN THE SPINDLE 3 REMOVE HEAVY CHIP BUILD UP FROM GUARDS AND WAY COVERS 4 WASH A T C AND MACHINE WORK AREA WEEKLV 1 CLEAN A T C SLIDE 2 CHECK AIR REGULATOR A DRAIN WATER SEPARATOR 3 INSPECT ALL COOLING FANS CLEAN IF NECESSARV EVERY 2 WEEKS 1 TO LUBE THE RAILS AND BALL SCREWS GREASE EVERY LUBRICATION PORT AT THE SADDLE TABLE AND HEAD WITH 4 PUMPS OF THE GREASE GUN A USE MOBILTEMP SHC32 GREASE LBL 0036 MAINTENANCE AND LUBRICATION DAILV 1 CHECK AIR PRESSURE A RIGHT REGULATOR 120 PSI MAX TOOL OUT ONLY B LEFT REGULATOR 80 90 PSI CHECK AIR FILTE
51. or time was changed in the PLC status Type Message Drive data changed gt Don t forget to save boot files Explanation On exiting the drive machine data screens the user is reminded to save the boot files to ensure that any changes made to the drive machine data are not lost Type Message Search operation in progress please wait Explanation search function has been triggered in the machine data screens Type Message Select possible only after enable or in RESET state Explanation In order to execute the desired function the current channel must be in the Reset state e g program selection Type Message Reaction Remedy Perform a reset You cannot copy into the clipboard Explanation NCK cannot copy into the clipboard because for example there is not enough memory space available or the maximum possible number of programs it can manage has been exceeded Power On Procedure Alarms 57 Fadal 58 105003 105004 105006 105007 SIEMENS CONTROL Maintenance Manual Type Message Reaction Remedy Delete the programs that are not currently needed You cannot delete the MDA buffer Explanation NCK cannot delete the buffer because it is being processed Type Message Reaction Remedy Wait until the MDA program has finished processing or perform an NC reset Block search not possible Explanation Search function cannot be run because the channel is active Type Mes
52. 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 Moving Parts Automatic pallet changer door will crush hands Stand clear when the door is closing Safety Section SS 40 May 2002 SAFETY SECTION Fadal LBL 0443 CE Hand Crush Force from Side Automatic pallet changer can crush hands Do not place hands or any part of the body in the path of a moving pallet May 2002 SS 41 Safety Section SAFETY SECTION Fadal PROHIBITIONS LBL 0441 CE Do Not Operate with Guard Removed Do not operate this machine with the doors open or the guards removed Moving machinery and rotating cutters can seriously injure or kill Safety Section SS 42 May 2002 SAFETY SECTION Fadal REQUIRED ACTIONS LBL 0439 CE Wear Eye Protection Flying objects may injure Always wear safety glasses when operating this machine LBL 0440 CE Wear Ear Protection Noise from this machine can damage hearing Always wear ear protection when operating this machine May 2002 55 43 Safety Section Fadal SAFETY SECTION LBL 0442 CE Consult Operator s Manual Read 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 Power Whenever servicing t
53. the cable is connected to the parallel LPT1 port of the portable computer The BIOS setting for the LPT1 port on the external computer must be set to bi directional June 2002 MMC100 Software Update MMC103 Update Procedure 159 Fadal SIEMENS CONTROL 11 Remove Old Hard Disk Unit CAUTION ELECTROSTATIC SENSITIVE COMPONENTS are housed inside the MMC103 module Use grounding straps or discharge oneself before working inside module The MMC103 module is located inside of the pendant cabinet Release the two latches on the right side of the pendant cabinet to gain access to the MMC103 module See Figure 23 a POWER THE MACHINE OFF b Engage the transport safety detent Grasp the black knob See Figure 24 Turn it 180 degrees clockwise until the mark on the knob aligns with the mark labeled non operating on the yellow placard The transport safety detent is properly engaged when the knob snaps to a Stop the anemone Figure 31 The MMC103 module is Figure 32 The transport safety mounted inside the pendant cabinet detent shown in the engaged position The mark on the knob should align with the mark on the yellow placard WILL a E EDS Figure 33 Unscrew the four knurled Figure 33 Four bolts mounting the bolts to release the hard disk unit floppy disk drive from the MMC103 module 140 MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL c Re
54. the last data save bv the ongoing manufacturing process e g tool and workpiece data must be adapted manuallv to the momentarv machine state Program Continuation Switch control OFF ON 2110 NCKtemperature alarm Explanation The temperature sensor has reached the response threshold of 60 C 2 5 C Reaction Alarm display Remedy For switching back the sensor a temperature reduction of 7 C is necessary Program Continuation Clear the alarm with the Delete key No further operator action necessary 2120 NCK fan alarm Explanation The fan consists of a 26 V DC motor with electronic commutator rated speed approx 8700 rpm The commutator signal is used for speed monitoring response speed 7500 rpm Reaction Alarm display Remedy The unit with the fan must be replaced Jan 2003 Power On Procedure Alarms 39 Fadal 2130 2140 3000 Series Alarm 40 5000 SIEMENS CONTROL Maintenance Manual Program Continuation Clear alarm with the RESET key Restart part program NCK encoder power supply 9o1 V has failed Explanation 001 Voltage The power supply 5V 24V for the encoders has failed Reaction Mode group not ready Channel not ready NC Start disable NC Stop when alarm The NC switches to follow up mode Alarm display Interface signals are set The axes are no longer synchronized with machine actual value reference point is lost Remedy Check encoders and c
55. type Invalid file name Explanation The entered file name May be up to 32 characters long letters numerals underscore including the block and program identifiers and _MPF corresponds to 25 characters that can be used Must not contain separators e g Must contain letters in the first and second position Type Message Reaction The faulty entry is deleted Remedy Enter a valid file name No program selected block search terminated Explanation A block search is not possible as currently there is no program selected Type Message Reaction Remedy Select program Please reference axis first Power On Procedure Alarms 59 Fadal Fadal 3020 PLC Alarm Messages 60 66500 67000 67001 67002 SIEMENS CONTROL Maintenance Manual Explanation Reference point approach has not been performed vet or terminated Tvpe Message Reaction Remedy Carry out reference point approach The following PLC alarms are specific to the Fadal 5020 application of the Siemens Control Oem alarm listing Spindle Orientation Failed DEFINITION The spindle failed to orient properly REACTION Display alarm Axis movement disable NC start disable REMEDY Check the spindle for proper positioning Check orientation sensor PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service Is The Spindle Empty If Yes Press Cycle Start To Continue DEFINITION
56. values No Axis position Combined in 0 0001 in 1 9 00000 0 2 8 00000 zu 3 7 00000 2 4 6 00000 2 5 5 00000 3 6 4 00000 3 7 3 00000 4 8 2 00000 4 9 1 00000 4 10 0 00000 4 14 1 00000 4 12 2 00000 24 13 3 00000 4 14 4 00000 5 15 5 00000 4 16 6 00000 5 17 7 00000 5 18 8 00000 6 19 9 00000 46 20 10 00000 Figure 5 1 A typical printout of compensation values from the output of a laser measurement system Figure 2 shows a partial view of the COMP_VALUES_Y survey values from the printout in Figure 1 The numbers within the brackets are pointers They correspond to the position numbers in the compensation values printout Jan 2003 Compensation 5 3 Axis Backlash 79 SIEMENS CONTROL Maintenance Manual Y AXIS gt _COMPVALUE 0 0 0000 ALWAYS ZERO COMPVALUE 1 0 0000 ALWAYS ZERO _COMPVALUE 2 0 0001 COMPVALUE 3 0 0002 _COMPVALUE 4 0 0003 _COMPVALUE 5 0 0003 COMPVALUE 6 0 0004 COMPVALUE 7 0 0004 COMPVALUE 8 0 0004 COMPVALUE 9 0 0004 COMPVALUE 10 0 0004 COMPVALUE 11 0 0004 _COM PVALUE 12 0 0004 _COMPVALUE 13 0 0004 COMPVALUE 14 0 0005 COMPVALUE 15 0 0004 COMPVALUE 16 0 0005 COMPVALUE 17 0 0005 COMPVALUE 18 0 0006 COMPVALUE 19 0 0006 COMPVALUE 20 0 0007 Figure 5 2 A partial view of survey values from a COMP VALUES n program Example 5 4 1 TC BASE 80
57. wait for end of program 74 Stop at the end of block preparation Alarm 75 Stop at the end of block Nesting depth too great Wait until the preceding preparation with subsequent asynchronous subroutine is reorganization of block processing terminated or abort the program Alarm 76 Conditional stop at block end If after continuation by means of an NC start there is still a reason to stop Stop at block end the program stops again 77 Conditional stop at block end Despite the start the interpreter or the preprocessing does not manage to put a block in main run 78 Stop preprocessing Alarm 79 Retraction motion with G33 and Stop 72 Action List J 2003 Fadal SIEMENS CONTROL Maintenance Manual No Explanation Not allowed if Remedy 80 Conditional wait for program marker NC block WAITMC 81 Set marker NC block SETM 82 Clear marker NC block CLEARM 83 Selection of an NC block PI command 84 Disable the NC program which is currently being processed for editing command 85 Start a program in the TEACH IN See 36 and 5 submode VDI signal NC Start 86 Continue a program in the TEACH See 36 and 5 IN submode VDI signal NC Start 87 Reorganize block processing 88 Activate user interrupt See 11 asynchronous subroutine in a manual mode signal synchronous subroutine interface digital analog interface 89 Activate user inte
58. 0 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 ground plate with existing screw 12 Plug Y axis motor power connection into terminal plug located on the bottom of the CCU Box Secure with thumbscrews Cable clamp cable to shielding Plate 15 Attach the Y motor grounding wire to ground plate with existing screw 14 Attach grounding wire from the ground bar to the CCU Box 1 Attach the E stop signal wires to X121 terminal Red to 64 and Shd to 19 Secure with lug screws 2 Attach E stop MCP to X121 Red to 9 Blk to 64 3 Terminate the jumper at 63 and 9 4 Attach contactor control signal wires to X161 terminal Secure with lug screws 5 Attach the power input wires U1 VI W1 to the appropriately labeled terminals on the bottom of the E R module Secure with lug screws 6 Attach the grounding wire from the ground bar to the grounding terminal on the bottom of the E R module Control Components 2 2 Wiring Connections Jan 2005 SIEMENS CONTROL Fada Maintenance Manual SIMODRIVE 611 pevas 5 5 2 2 5 Reactor Line 1 Attach the 580 Volt input wires L1 L2 L5 to the appropriately labeled ter Filter Module minals on the bottom of the Line Filter secure with lug screws Connections i ri secure with lug screws
59. 0 VDC 300 VDC and 300 VDC for a regulated I R module and 550 VDC for an unregulated UE module Jan 2003 Overview 7 SIEMENS CONTROL Fa dal Maintenance Manual 1 5 Pendant Mounted on the pendant are the components that create the machine Components interface system for the operator The system components consists of a MCP HMI CNC keyboard and manual pulse generator See Figure 1 7 Ee E g gt Figure 1 7 The pendant is comprised of four operator interface components A MCP Machine Control Panel B HMI Human Machine Interface C CNC keyboard D MPG Manual Pulse Generator 1 5 1 MCP The MCP Machine Control Panel controls the physical functions of the machine It is mostly used in conjunction with the HMI CNC keyboard and MPG One simple example of an MCP function can be turning the coolant on and off Another common function is referencing the axes of the machine The makeup of the MCP consists of several groups of keys referred to as hard keys a spindle control dial a feedrate dial and an EMERGENCY STOP button 1 5 2 HMI The HMI Human Machine Interface is a graphical display system that provides the interfacing between the operator and the control It consists of a bank of vertical and horizontal soft keys and a TFT flat display screen The HMI is the main component of the pendant because it provides both input to and output from the control Some of the functions of the HMI are it
60. 0 board Jan 2003 Control Components 2 5 Replacing the 2010 0 Board 29 SIEMENS CONTROL Fadal Maintenance Manual 5 Connect the X1202 cable to the X1202 plug on the 2010 0 board Te um GR GE Em Lr Connect the X405 cable to the X405 plug on the 2010 0 board 7 Connect the Axis Selector wire two pin plug into the JA socket on the 2010 0 board 8 Connect the J2 wire plug into the J2 eight position wire connector on the 2010 0 board 9 Terminate contactor control wires T9 red and T48 blk at appropriate location on terminal strip J6 See steps 9 through 11 10 Terminate door override wires 5 red and 4 bik at appropriate location on terminal strip J6 11 Terminate spindle contactor wires 5 brn and 6 wht at appropriate loca tion on terminal strip J6 12 Terminate control bus wires to appropriate location on right side terminal strip 30 Control Components 2 5 Replacing the 2010 0 Board Jan 2003 SIEMENS CONTROL Fa da Maintenance Manual 0 board 15 Plug the temperature control board into the J7 socket on the 2010 0 board Jan 2003 Control Components 2 5 Replacing the 2010 0 Board al SIEMENS CONTROL Fadal Maintenance Manual 16 Connect the temperature control wire plug into the socket on the tempera ture control board A a 17 Plug the relay into the 24 VDC receptacle on the 2010 0 board 18 Plug the
61. 002 MMC100 Software Update MMC100 Update Procedure 87 Fadal SIEMENS CONTROL 4 SetUp To back up the machine data to the external computer prepare the Siemens Communication control for sending data The following steps sets up the parameters for Parameters communication to the external computer a b C CN NO e w 2 Q 7 Q Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the CNC ISO soft key then the CNC ISO v soft key Verify user access level Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the STARTUP soft key The message Actual access level Manufacturer should display in the message bar at the bottom of the screen display If level is not set to Manufacturer or no message displays continue to step 4 If the level is set to Manufacturer go to d Press the SET PASSWORD soft key Type SUNRISE The password is set in all UPPERCASE letters If necessary press the SHIFT hard key while typing the password Press the INPUT hard key The password field turns orange Press the OK soft key The message Password has been set for Manufacturer must display on the screen Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the SERVICES soft key Press the DATA OUT soft key Highlight the Start up data line using the up and down arrows Press the RS232 C User vertical soft key Press the SET soft key A
62. 03 Overview 9 Fadal SIEMENS CONTROL Maintenance Manual 1 5 4 MPG The MPG Manual Pulse Generator installed in the lower left corner of the pendant is used to manually jog the axes of the machine The MPG is enabled by pressing the MPG hard key located on the MCP Jogging an axis is accomplished by selecting an axis with the selector knob and then turning the dial clockwise or counterclockwise to move the selected axis 1 6 System Components and Parts Component Part No Description MCP CTR 0127 Machine Control Panel PCU 210 CTR 0126 Flat panel display Solid State Membrane keyboard ELE 1094 Keyboard for PCU 210 0 0325 CTR 0128 Flat panel display for MMC103 PC based front end DIN Keyboard CTR 0129 Keyboard for MMC103 PC based front end MMC 103 SFT 0017 PC based front end Hard Drive Floppy Drive ELE 1174 Floppy Drive for 105 PC based front end ISA PCI Adapter ELE 1175 Expansion adapter for ISA PCI cards MMC103 Power Supply 16kW ELE 1083 Power Supply 15 HP Spindle Low voltage power supply for electronics Reactor 16kW ELE 1084 Line Reactor 15HP Spindle Filter 16kW ELE 1085 Line Filter 15HP Spindle Overvoltage Lim Module ELE 1087 Line Voltage Surge Protection Module for Power Supply Power Supply 28kW ELE 1165 Power Supply 20 HP Spindle Low voltage power supply for electronics Reactor 28kW ELE 1166 Line Reactor 20HP Spindle Pulsed R
63. 1 1210 A1 1211 A1 1212 A1 1407 0 B1 1210 B1 1211 B1 1212 B1 1407 0 The following procedure resets the NCK and loads the new NC software a b Power off the machine Remove the existing NC card from the memory card slot of the CCU interface panel Insert the new NC card into the memory card slot Figure 17 shows the correct way to insert the NC card Set switch S3 to position 1 general reset See Figure 18 for Switch location Power on the machine Wait until 6 is displayed on the CCU s 7 segment LED display H3 then set switch S3 back to 0 normal operation RETURN THE OLD NC CARD TO FADAL MACHINING CENTERS THE NEW NC CARD REMAINS WITH THE MACHINE MMC100 Software Update MMC103 Update Procedure June 2002 SIEMENS CONTROL Fadal D VERS 1 6 i Figure 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 segment display H3 Error and status le NCK LEDs H1 H2 il T3 startup switch S3 n PLC Lo se l SIE operating I ad CPU t Fi m EU sop mode switch Figure 26 Switches and LED indicators used in resetting 54 the June 2002 100 Software Update 105 Update Procedure 125 Fadal SIEMENS CONTROL When the NCK is reset all machine data is clea
64. 100 Software Update MMC103 Update Procedure 137 Fadal SIEMENS CONTROL t Press Menu Select hard key u Press ISO soft key then press ISO v 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 2 INPUT hard key r z Press CYCLE START hard key Wait for the control to display the alarm 510300 POWER ON needed to set spindle setup aa Power the machine OFF and back ON ab Reference each axis The MMC103 is in SHOPMILL after power on mw 1 Press Machine hard key 2 Select an axis with the axis selector switch 3 Press REF POINT hard key 4 Press plus hard key 5 Repeat steps 2 5 and 4 for all the axes The axes referenced when the crosshair symbol 45 displays to the left of each axis Press Menu Select hard key Press CNC ISO soft key a ae Press ISO v soft key Wait for the ISO screen to load af Press MDA hard key ag Press Delete vertical soft key ah Type M84 Press MDA hard key aj Press the Delete vertical soft key ak Type TC BASE ai Press pg CYCLE START hard key al 138 MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL am Press Menu Select hard key an ao ap a o at a c a lt aw a gt lt
65. 17 0 230 stall torque reduction 1145 61 000 motor temp warn limit 1602 150 000 motor code 1102 99 000 alarm mask power on 1600 0000h enc resol motor 1005 2048 000 numb current filters 1200 0 0 000 current filter2 freq 1204 0 0 000 current filter2 damping 1205 0 1 000 power limit 1235 0 250 000 power limit 1235 1 250 000 power limit 1235 2 100 000 current limit 1238 200 000 motor fixed temp 1608 0 000 speedctrl gain 1407 47 739 Siemens 50 Taper 165 Fadal SIEMENS CONTROL Maintenance Manual 2 The X Y and Z axes limits are 65 x35 x34 The Z axis limits of the 50 Taper BT are different than the 40 Taper because of the spindle housing is larger The following is a listing of the Axis machine data parameters 6535 810 50taper only spec s X Axis Y Axis Z Axis C Axis Description MD pos limit plus 56100 pos limit minus 56110 ax velo limit 56200 spind velo limit 35100 gear step max velo 55110 0 gear step max velo 55110 1 max ax accel 52500 max ax velo 52000 posctrl gain O 352200 0 posctrl gain 1 52200111 posctrl gain 2 32200 2 32 55 52 55 n a n a n a n a 70 900 3 4 3 4 3 4 17 55 17 55 n a n a n a n a 70 900 3 4 3 4 3 4 33 25 0 75 n a n a n a n a 70 700 3 4 3 4 3 4 n a n a 8000 7500 7500 7500 10 8000 3 4 3 4 3 4 3 The BT50 taper turret has 32 pockets The number of tools in the tool changer is stored in the user data location MD 14510 0 32 Afte
66. 2 LBL 0188 LBL 0189 same LBL 0188 LBL 0189 On Chiller Cabinet LBL 0300 LBL 0300 same 3 languages Chiller Outlets LBL 0191 LBL 0190 LBL 0191 LBL 0190 same CNC Power Button LBL 0038 LBL 0038 same Air Regulator LBL 0126 LBL 0430 1120B ISO LBL 0146 LBL 0460 3021B ISO keep LBL 0146 Maintenance amp Pull Stud labels LBL 0036 LBL 0037 LBL 0036 LBL 0037 same Translated versions must be used for non English speaking countries CE LBL 0141 Left Side LBL 0123 1 On Control and Transformer Cabinet Doors LBL 0263 2002 55 45 Safety Section Fadal SAFETY SECTION ain Disconnect Aux Disconnect and Motor LBL 0132 LBL 0132 6010C ISO Starter Enclosures ain Disconnect LBL 0134 LBL 0134 I5007a D LBL 0135 LBL 0135 15008a D ext to Main Disconnect Inside LBL 0187 keep LBL 0187 Translated versions must be used ain Disconnect inputs U V W LBL 0142 LBL 0143 LBL 0142 LBL 0143 LBL 0144 same LBL 0144 Auger by left and right access panels lower LBL 0234 LBL 0436 5004 150 left of front door Pallet Changer Base front amp rear LBL 0443 1042B ISO Pallet Changer Door LBL 0158 LBL 0433 1099 150 Safety Section SS 46 May 2002 Fadal Maintenance Manual TABLE QFGONTENT cpe i NIIT e 1 LL
67. 4 1 1 1 1 1 1 1 1 TUPD P 146 MMC100 Software Update Tools Required June 2002 SIEMENS CONTROL Fada Maintenance Manual Section 07 Parameters Setting Options on Of the many parameters of the Siemens machine there are some that are set the Fadal Siemens aside to configure the Fadal Machine These parameters turn ON or OFF options that are presently installed on the machine If the option is turned on but not installed then the Siemens control will give Alarms and Warnings that something is invalid To avoid these Alarms and Warnings make sure the option is installed properly before turning ON any options The USER DATA HEX values are entered in as Hexadecimal values This is indicated by it s name that ends in HEX The options themselves are binary coded which we will describe in another table below Hexadecimal describes a base 16 number system That is it describes a numbering system containing 16 sequential numbers as base units including 0 before adding a new position for the next number Note that we re using 16 here as a decimal number to explain a number that would be 10 in hexadecimal The hexadecimal numbers are 0 9 and then use the letters A F We show the equivalence of binary decimal and hexadecimal numbers in the table below
68. ACTION Display alarm Axis movement disable Program interrupted REMEDY Check DATC magazine for mechanical problems Check DATC magazine motor and electrical connections Check any conditions that will prevent the DATC from normal function lack of compressed air motor brake malfunction etc PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service DATC Tool Pocket Time out DEFINITION Dual arm tool changer tool pocket failed to move in time allowed REACTION Display alarm Axis movement disable Program interrupted REMEDY Check DATC tool pocket for mechanical problems Check any conditions that will prevent the DATC from normal function door open lack of compressed air etc Check tool pocket actuation valves electrical connection fuses PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service Spindle Draw Bar Arm Time out DEFINITION Draw bar mechanism failed to close open in time allowed REACTION Display alarm Axis movement disable Program interrupted REMEDY Check draw bar for mechanical problems lack of compressed air Check spindle for jammed tools Check any conditions that will prevent the DATC from normal function door open lack of compressed air etc PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service Z Axis Not In Tool Change Position DEFINITION DATC is prevented to move because Z axis is not in p
69. BX 7 4 Reaction Alarm display Remedy No remedial measures are necessary The spindle specific interface signal Spindle reset DB 51 48 DBX 2 2 cancels the oscillation mode Program Continuation Alarm display disappears with cause of alarm No further operator action necessary Power On Procedure Alarms Jan 2003 Fadal Jan 2003 10720 10750 SIEMENS CONTROL Maintenance Manual Channel 901 block 903 axis 902 software limit switch 904 Explanation 001 Channel number 902 Axis name spindle number 903 Block number label 904 String or For the axis the programmed path violates the currently valid software limit switch The 2nd software limit switch becomes active with the interface signal 2nd software limit switch plus minus DB 31 48 DBX 12 2 and 12 3 The alarm is activated when preparing the part program block Reaction Alarm display Interface signals are set Correction block with reorganization NC Start disable Remedy Check the position of the axis as specified in the part program Machine data 56100 POS LIMIT MINUS 36120 POS LIMIT MINUS2 and 36110 POS LIMIT PLUS 36130 POS LIMIT PLUS2 must be checked for the software limit switches Check the axis specific interface signals Check 2nd software limit switch plus minus DB 51 48 DBX 12 2 and 12 5 to see whether the 2nd software limit switch is selected Check currently active zero offsets via the current fra
70. CIN screen display 24 INI DATALIN DATA OUIA FILE SPECIAL FO FORNAT ARCHIV PILE EXIT COM NUMBER 1 BRUDRATE 2468 PARITY NONE 1 SIOPBITS 8 DAIABIIS END u N30 OFF ETX OFF TIMEOUT 0s BINFILE ON TURBDR DE DEE DONT CHECK DSR SEA 8587888 WIRELAYOUT Select with es ESO Cancel ENTER Accept Figure 10 Parameters for communications settings at the external computer COM NUMBER is set according to the port connection on computer d Set XON XOFF parameter to OFF Use the arrow keys to navigate to the XON XOFF SET line Use the arrow keys to select ON or OFF setting in the box that displays See Figure 5 e Set ETX to ON 90 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL f 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 ECIN VERSION 4 43 SIE ENS AG 1999 96 U24 INI DATA IN DATA OUT PILE SPECIAL PO RORMAT ARCHIVEFILE EXIT NUMBER 1 BRUDRATE 2400 PARITY NONE 1 STOPBITS B DRIRBIIS OFF SET Character 11 END N30 OF Character 13 OFF DONT WALT FOR TIMEOUT 9 DONT SEND DINFILEON TURDONODE OFF DONT CHECK DSR NC SEA 8587888 WIRELAYOUT Select with t ESC Cancel ENTER Accept Figure 11 XON XOFF is set to OFF i Press
71. DEACTIVATE Jan 2003 Fadal Jan 2003 SIEMENS CONTROL Maintenance Manual 5 NUM 5 51 2 SET FOR 2 ENCODERS SMN USER DATA HEX 0 MN USER DATA HEX 0 B OR B00010000 ACTIVATE A SCALE else msg NO A SCALE g4f2 5 AX5 1 SET A FOR 1 ENCODER 5 USER DATA HEX 0 MN USER DATA 0 B AND B11101111 DEACTIVATE A SCALE endif stopre if bscale msg B SCALE g4f2 NUM ENCS AX6 2 SET B FOR 2 ENCODERS MN USER DATA HEX 0 MN USER DATA HEX 0 B OR B00100000 ACTIVATE B SCALE else msg NO B SCALE g4f2 NUM ENCS AX6 1 SET B FOR 1 ENCODER MN USER DATA HEX 0 MN USER DATA 0 B AND B11011111 DEACTIVATE B SCALE endif stopre if CogBelt msg 15K SPINDLE g4f2 MN USER DATA HEX 1 MN USER DATA HEX 1 OR B00000001 ENBL 15K PINDLE IN PLC MA MAX AX VELO AX4 15000 SET AX SPD DRIVE AX RATIO NUMERA 0 AX4 50000 1 TO 2 RATIO C AXIS MODE DRIVE AX RATIO NUMERA 1 AX4 50000 1 TO 2 RATIO 1ST GEAR DRIVE AX RATIO NUMERA 2 AX4 50000 1 2 RATIO 2ND GEAR GEAR STEP CHANGE ENABLE AX4 20 DIS GEAR CHGE SPIND VELO LIMIT AX4 15000 MAX ABSOLUTE SPEED 15K GEAR STEP MAX VELO 0 AX4 15000 MAX SP TO 15K C AXIS MODE G G G G STEP MAX VELO 1 AX4 15000 MAX SP TO 15K 1ST GEAR STEP MAX VELO 2 AX4 15000 MAX SP TO 15K 2ND GEAR 5 STEP VELO LIMIT 0 AX4 15500 MAX SP LIM C AXIS MODE SMA GEAR
72. Delete or unload directory e g workpiece or e Increase MM_NUM_DIR_IN_FILESYSTEM Program Continuation Clear the alarm with the Delete Key No further operator action is necessary Too many subdirectories Explanation The number of subdirectories in a directory of the NCK has reached the maximum limit Reaction Alarm display Power On Procedure Alarms Jan 2003 Fadal 6560 8000 Series Alarm 8030 10000 Series Alarm Jan 2003 10205 SIEMENS CONTROL Maintenance Manual Remedy e Delete or empty subdirectories in the respective directory or e Increase MM_NUM_SUBDIR_PER_DIR Program Continuation Clear the alarm with the Delete key No further operator action necessary Data format not allowed Explanation An attempt was made to write impermissible data in an NCK file This error can occur in particular when the attempt was made to load binary data in the NCK as ASCII file Reaction Alarm display Remedy Specify that the file concerned is a binary file e g extension BIN Program Continuation Clear the alarm with the Delete key No further operator action necessary Channel 901 block 902 option interpolation of more than 4 axes not set Explanation 1 Channel number 2 Block number label The option for the number of interpolating axes does not correspond to the number of axes programmed in the interpolation group Reaction Alarm display Interface signals are set NC
73. E MANUALLY LOADING amp UNLOADING A HOLDER in the Operator s Manual DO NOT OPERATE THE MACHINE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL PRESCRIBED OR OTHERWISE READ THE SAFETY WARNINGS SUPPLIED WITH ALL TOOLING 10 MAINTAIN TOOLS WITH CARE Keep tools sharp and clean for best perfor mance and to reduce the risk of injury Follow instructions for lubrication and for changing accessories REMOVE ADJUSTING KEYS AND WRENCHES Always check that keys and wrenches are removed from tools and tooling before starting the machine DO NOT EXCEED THE MANUFACTURER S RECOMMENDED MAXIMUM RPM FOR THE TOOL When tools are placed in the spindle verify the current RPM commanded in the control before starting the spindle SECURE TOOLS PROPERLY IN THEIR HOLDERS 14 SECURE WORK Use common machining practices for holding fixturing material to be machined REMOVE ALL TOOLS FROM THE SPINDLE AND TOOL CHANGER before ser vicing and changing accessories such as tooling fixtures indexers the tail stock of a fourth axis and any fourth axis or fourth fifth axis combination etc ALWAYS DEBUG A NEW PROGRAM before running it in the AUTO mode See DEBUG PROGRAM in the User s Manual The machine tool MUST be connected to a grounded metal permanent wiring system or to a system having an equipment grounding conductor 55 4 2002 Fadal May 2002 18 19 20 2 gt 22 23 24 25 26
74. E 1087 Over Volt Limit Module Tools Required Torx driver set NOTE To remove components for repair or replacement Follow the assembly instructions as necessary in reverse order until the component has been disassembled to required level to conduct the repair 1 Attach the E R Module ELE 1083 to the mount ing bars with four 1 4 20 x 3 4 torx screws Located immediately to the right of the Reactor Line Filter Assembly 2 Remove the 8 position terminal block from X181 on the E R module plug the Over Volt Module ELE 1087 onto the front of the Simodrive Mod ule Install the 8 position terminal block into the over voltage module 2 1 5 CCU1 Module Parts Numbers Replacement ELE 1088 CCU box 810D ELE 1089 CCU1 unit Tools Required Torx driver set Flat Tip Screwdriver 18 Control Components 2 1 Replacement of Modules Jan 2005 SIEMENS CONTROL Fada Maintenance Manual NOTE To remove components for repair or replacement Follow the assembly instructions as necessary in reverse order until the component has been disassembled to required level to conduct the repair 1 Attach the CCU box ELE 1088 to the mounting bars with four 1 4 20 x 5 4 torx screws Locate immediately to the right of the Simodrive Module 2 Insert the CCU1 ELE 1089 unit into the CCU box ELE 1088 and tighten the four screws 2 1 4 Power Module Parts Numbers Replacement ELE 1090 Power Section ELE 1091 Acces
75. ECTION endif stopre if VHT Spindle 1 and zscale 1 MN DRIVE LOGIC NR 6 10 USE VHT BOOT FILE 5 DRIVE INVERTER CODE 6 H9 BIG POWER SECTION endif stopre if VHT Spindle 0 and zscale 1 MN DRIVE LOGIC NR 6 4 USE HT BOOT FILE 5 DRIVE INVERTER CODE 6 Hd SML POWER SECTION endif stopre if DualArmATC msg DUAL ARM ATC g4f2 5 USER DATA HEX 1 MN USER DATA HEX 1 B OR B00000100 ENBL DATC IN PLC MA POS LIMIT MINUS AX3 23 25 MA POS LIMIT PLUS AX3 0 75 else Parameters 159 Fadal Fadal Siemens Spindle Parameters Table 1 Baldor Spindle Motors Only SIEMENS CONTROL Maintenance Manual 160 Version v1 81 v1 81 amp v2 01 v1 81 v2 01 v1 81 Motor type 15hp 810 15hp 840D 20hp 810D 20hp 810D 20hp 810D Brand Baldor Baldor Baldor Baldor Baldor Part no release ok release ok New style New style New style Description MD Motor nominal power 1150 11 19 11 19 15 15 15 Motor nominal current 1103 33 2 33 2 50 50 50 Motor nominal voltage 1132 225 225 230 230 230 Motor rated speed 1400 1760 1760 1750 1760 1750 Motor noload freq 1134 60 60 60 60 60 Motor noload voltage 11355 220 220 224 224 224 Motor noload current 1136 15 69 15 69 20 118 20 118 24 2711 Stator cold resistance 1137 0 142 0 142 0 109 0 109 0 060 Rotor cold resist
76. ENTER 4743 STENENS AG 1993 90 Vea t pm b E pu ECERORNAT EXIT Figure 12 Select DATA IN on the screen display j a filename in the box that appears create a descriptive filename for example backup old or backup arc see Figure 7 The filename is limited to a maximum of eight characters and the filename extension is limited to a maximum of three characters June 2002 MMC100 Software Update MMC100 Update Procedure 91 Fadal SIEMENS CONTROL backup old Figure 13 Enter a descriptive filename in the box The filename is limited to eight characters in length with an extension of three characters NOTE Because the PCIN program is DOS based filenames and filename extensions are limited to eight characters and three characters respectivelv k Press ENTER l The external computer is now ready to receive the machine data from the Siemens control 6 Download Press the START soft key on the control Startup File 21 The transmission process stall several times during the data transfer This is normal Ignore any tool alarms that may arise The Transmission in progress window closes when the data transfer is complete Save the file at the external computer The entire transfer takes about 15 minutes NOTE The size of the backup file should be 800Kb or larger depending on the program files loaded into the machin
77. IGID 230 12 09 2000 SET FFSETS 2 fx 2072 12 09 2000 230071270972000 TABLE_SCRAPE_1 4 809 12 09 2000 TABLE SCRAPE 2 809 12 09 2000 TEST CUT 950 12 09 2000 VIBRATION X 191 12 09 2000 VIBRATION Y 191 12 09 2000 VIBRATION Z 191 12 09 2000 E XYZ RUN 405 12 09 2000 Tool Management DIR 25 09 1998 Free memory Hard disk 1 713 031 936 NCU 150 092 Figure 29 The SET VALUES program must be oaded in order for it to run v Highlight the SET VALUES file and press Select soft key w Press auto hard key located the MCP cms x Press a CVCLE START green hard kev Repeat pressing the CVCLE START hard kev for each of the axes until all the data values have been entered The zero offset and backlash values displav in green text at the top part of the displav screen v When done select Manage programs vertical soft kev z Press Delete soft key This deletes the SET VALUES program from the system Since this is a utilities program only for entering the offset and backlash data it is no longer needed after the data has been loaded aa Press Yes to delete the marked file Run compensation values from survey sheet The survey sheet containing the compensation data for the machine is stored in the electronics cabinet that is mounted at the back of the machine Press Menu Select hard key Press Program soft key c Highlight the Shopmill folder Using the arrow keys move the blue bar
78. L A amp LATAR OA e BREE i WE VATE PR Channel reset Say EV V 2 Li Progran aborted urite Mar Progran editor NA 2 SET UP OPTIONS BELOW 1 1 0 ir Xxscalez tr _ 1 0 1 0 amp OPTIONS 8100 CagBeltz tr ServoTurrz r DualfirnfiTCzO t _HiCapATC 6 tr u lose gt Figure 19 Enable options by changing the options setting to 1 from 0 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 electronics cabinet located at the back of the machine to the options diagrams from Appendix A Example A Siemens machine with an A axis X Y and Z scales installed will have a setup in the electronics cabinet resembling diagram number 5 See Figure 14 Therefore the settings in the options table will be as follows _xscale 1 _yscale 1 _zscale 1 _ascale 0 _bscale 0 _a_ax 1 _b_ax 0 _V300 0 _extcolumn 0 _CogBelt 0 _ServoTurr 0 102 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL _DualArmATC 0 _HiCapATC 0 _VHT_Spindle 0 1200 0 m7 is 8 0 NOTE Setting the value to 1 enables the option For Example a 500 would require a ax 1 _ascale 1 _V300 1 OPT 0197 amp OPT 0199
79. N Display alarm Program interrupted Spindle rotation disable Power On Procedure Alarms Jan 2003 Fadal Jan 2003 510128 510200 510216 510500 SIEMENS CONTROL Maintenance Manual REMEDY Press Reset key Check tool changer board for failures Reset tool changer board if needed ONLY AFTER CONTROL RESET Check tool changer for mechanical problems Check air pressure to machine air oil board is interlocked Check emergency stop hardware loop 110VAC circuit is also interlocked PROGRAM CONTINUATION Alarm clears when tool changer board is working O K Contact Service ATC only 21 Tools DEFINITION The tool changer is a 21 tool type and an attempt has been made to use more than 21 tools REACTION Display alarm Program interrupted Spindle rotation disable REMEDY Check the tool number being called Check the options available for the machine PROGRAM CONTINUATION Press Reset key Contact Service Option Rigid Tapping Not Available DEFINITION Rigid tapping was tried in a machine not equipped with this option REACTION Display alarm Program interrupted read in disabled REMEDY Check the options available for the machine PROGRAM CONTINUATION Press Reset key Contact Service Oiler level too low DEFINITION Way lube oiler level too low REACTION Display alarm Program interrupted read in disabled REMEDY Fill up way lube oiler reservoir Program will continue automatically PROGRAM CONTIN
80. N Dual arm tool changer arm motor overload tripped REACTION Display alarm Axis movement disable Program interrupted REMEDY Check DATC arm for mechanical problems Check DATC arm motor brake and electrical connections Re set DATC arm motor overload sensor PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service DATC Magazine Motor Overload DEFINITION Dual arm tool changer magazine motor overload tripped REACTION Display alarm Axis movement disable Program interrupted REMEDY Check DATC magazine for mechanical problems Check DATC magazine motor brake and electrical connections Re set DATC magazine motor overload sensor PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service DATC Arm Time out DEFINITION Dual arm tool changer arm failed to move in time allowed REACTION Display alarm Axis movement disable Program interrupted REMEDY Check DATC arm for mechanical problems Check DATC motor and electrical connections Check any conditions that will prevent the DATC from normal function door open lack of compressed air etc Power On Procedure Alarms Jan 2003 Fadal Jan 2003 510105 510104 510105 510106 SIEMENS CONTROL Maintenance Manual PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service DATC Magazine Time out DEFINITION Dual arm tool changer magazine failed to move in time allowed RE
81. NGUP TIMEOUT default setting 1 sec There is a serious problem with the PLC program Reaction NC Start disable NC not ready Mode group not ready NC Stop when alarm Alarm display Interface signals are set Remedy The monitoring time in MD 10120 PLC RUNNINGUP TIMEOUT must be checked and adapted to the first OB1 cycle Jan 2003 Power On Procedure Alarms 37 Fadal 38 2100 2101 2102 SIEMENS CONTROL Maintenance Manual Establish the cause of error in the PLC loop or stop in the user program and eliminate Program Continuation Switch control OFF ON NCK battery warning threshold reached Explanation The undervoltage monitoring of the NCK battery has reached the prewarning threshold This is at 2 7 2 9 V nominal voltage of the battery is 5 0 5 1 V at 950 mAh Reaction Alarm display Remedy The battery must be replaced within the next 6 weeks After this period the voltage can drop below the alarm limit of 2 4 2 6 V if the RAMs to be buffered take up a lot of current Program Continuation Clear the alarm with the Delete key No further operator action necessary NCK battery alarm Explanation The undervoltage monitoring 2 4 2 6 V of the NCK battery has responded during cyclic operation Reaction Alarm display Remedy If the NCK battery is replaced without interrupting the power supply no data will be lost This means that production can continue without taking any furthe
82. OT 8 endif stopre if ax SMC AXCONF MACHAX USED 5 6 ACT B AX IN NCK 5 USER DATA HEX 0 MN USER DATA 0 B OR B10000000 ACTIVATE B AXIS IN PLC SMA CTRLOUT MODULE NR 0 AX6 8 B AXIS DRV 8 MODULE NR 0 AX6 8 ENCDR 1 DRV 8 B AX MODULE NR 1 AX6 8 ENCDR 2 DRV 8 B AX endif stopre if b ax 1 and zscale 0 msg B AXIS NO Z SCALE g4f2 MN DRIVE LOGIC NR 7 8 ASSIGN DR 8 TO SLOT 8 MN DRIVE _ S ACTIVE 7 0 DEACT DR IN SLOT 8 MN DRIVE INVERTER CODE 7 H14 SMN DRIVE MODULE TYPE 6 2 2AX PWR SEC DR 7 AND 8 MN DRIVE MODULE TYPE 7 2 2AX PWR SEC MN DRIVE LOGIC NR 8 0 REMOVE DRIVE IN SLOT 9 endif stopre msg B AXIS Z SCALE g4f2 MN DRIVE LOGIC NR 8 8 MOVE DRIVE 8 TO SLOT 9 SMN DRIVE IS ACTIVE 8 0 ACTIVATE DRIVE IN SLOT 9 SMN DRIVE INVERTER CODE 8 H14 SMN DRIVE MODULE TYPE 7 2 2AX PWR SEC DR 8 AND 9 SMN DRIVE MODULE TYPE 8 2 2AX PWR SEC endif if b ax 1 and zscale 1 stopre if xscale msg X SCALE g4f2 Parameters 155 Fadal 156 MA NUM ENCS AX1 2 else msg g4f2 NO X SCALE MA NUM ENCS AX1 1 endi stop f re if vscale msg g4f2 Y SCALE MA NUM ENCS AX2 2 else msg g4f2 NO Y SCALE MA NUM ENCS AX2 1 endi stop f re if zscale msg g4f2 else msg g4f2 MN 7 MA NUM USER DATA HEX 0 MN USER DATA 0 B OR
83. R A DRAIN AND CLEAN WATER SEPARATOR CHECK WAV LUBE LEVEL USE CASTROL MAGNA BD68 SHELL TONNA 68V OR MOBIL VACTRA 2 ONLY CHECK WAY LUBE SYSTEM FOR ADEQUATE FLOW TO ALL WAYS WITH THE TOOL IN SPINDLE BLOW CHIPS FROM AROUND A T C AND SLIDE NEVER BLOW CHIPS FROM THE AREAS DURING AUTOMATIC TOOL CHANGE OR WITHOUT A TOOL IN THE SPINDLE REMOVE HEAVY CHIP BUILD UP FROM GUARDS AND WAY COVERS WASH A T C AND MACHINE WORK AREA WEEKLV CHECK SPINDLE COOLER PUMP AND REFRIGERATION UNIT FOR PROPER OPERATION CLEAN A T C SLIDE ACTIVATE OPTIONAL THRU TOOL COOLANT SVSTEM FOR 2 3 MINUTES LUBRICATE V AXIS TELESCOPING BALLSCREW COVER WITH WAV LUBE INSPECT ALL COOLING FANS CLEAN IF NECESSARV CLEAN REFRIGERANT PUMP FILTER VEARLV 1 SERVICE WAY LUBE FILTER A REPLACE BRONZE ELEMENT IN EXTERNAL FILTER Safety Section SS 24 May 2002 SAFETY SECTION Fadal SAFETY LABEL LOCATIONS 40205 0129 LBL 0234 0125 LBL 0234 0125 LBL 0165 Mav 2002 SS 25 Safetv Section Fadal SAFETY SECTION 0255 LBL 0125 LBL 0128 0254 Safety Section SS 26 May 2002 SAFETY SECTION Fadal 5020a 40202 4020 3016L 2216 2016L 15 15xt EMC LBL 0128 0265 LBL 0126 LBL 0265 LBL 0128 LBL 0235 May 2002 SS 27 Safety Section SAFETY SECTION Fadal LBL 0125 LBL 0125 LBL 0235 LBL 0127 Safety Section SS 28 May 2002 SAFETY SECTION Fadal 6030
84. S uu D FRED DRE NE tmd testi suem 40 WE PES EL inc AMNEM QATAR NON AN 40 41 PROPBIBITIONS UBE ec aaah ase 42 REQUIRED AUG TIONS 5 Wm Lei PD MERC OP NIRE FER ORARE 43 EBESGAAD GE io fa taa e DU ies e 43 I MEA C PIDE TORRE EE MAP ne 44 LBL 0438 small CE LBL 0437 large 44 CE SAFETY LABEL LIST AND 2 2 2 2 2 1 2 cua i mE komm kal suu uus Safety Section SS il August 2001 SAFETY SECTION Fadal Corporate Office voice 818 407 1400fax 818 407 0020 Service Parts voice 818 727 2100fax 818 407 1004 Programming Support voice 818 727 2100fax 818 407 0061 support fadal com 20701 Plummer Street Chatsworth California 91311 U S A The information in this document is reviewed regularly and any necessary changes will be incorporated in the next revision We welcome any suggestions for improvement Material is subject to change without notice This manual is for the exclusive use of Fadal Customers and Distributors The reproduction transmission or use of this document or its con
85. Safety Section VMC 4020 This safety section covers information for VMCs EMC 5 10 15 15XT 2016L 2216 5016 50161 3020 4020 4020A 4525 5020A 6030 6535 8030 Rotary Tables VH65 TR65 and V300 400 MM and VH5C Indexer Fadal SAFETY SECTION Fadal TABLE OF CONTENTS TABLE OF i 1 MODIFICATIONS ALTERATIONS AND 04 0 SAEETY WARNINGS t orcs th a L 4 EE 7 WARNINGS AND CAUTIQNS i i aa ibda ederet eter eu boe tna 8 MEE 8 POTENTIAL HAZARBS TO PERSONNEL 2 2 cree enun nh eb enun dida e Sai e ann 8 PHYSICAL ENVIRONMENT AND OPERATING CONDITIONS CE SPECIFICATIONS 8 5 12 ettet tb to retour item urea eive Dea ede env dedos Sede 9 SHARP EDGES ON CUTTING TOOLS zisirei dta it rne aj e A ra 9 ROTATING CUTTING TOOES i tee erecti e te RR Hebe eret re e e ea vertere ean 9 NOISE ier tn taddi 10 NOISE CECOMBLHANGE 5 5 na a tene states Meisten sem m ate 10 COMPRESSED AIR COMPLIANCE irritat en ttn ien tidie tree td ee era nan ET AT 11 ADDITIONAL SAFETY PRECAUTIONS k
86. UATION Program will continue as soon as oil level is high again Press Reset key Contact Service POWER ON Needed To Set Spindle Set Up DEFINITION M83 has been run to measure the spindle belts REACTION Display alarm NC start disabled REMEDY Power the machine off and on PROGRAM CONTINUATION Power the machine off and on Contact Service Power On Procedure Alarms 65 Fadal 66 510508 510509 600108 600109 700052 SIEMENS CONTROL Maintenance Manual Tool Loading Active DEFINITION The tool loading function is active A tool loading into the magazine is taking place REACTION Display alarm NC start disabled REMEDY Normal during tool loading If tool loading is interrupted and alarm lingers power machine off and on and try tool loading unloading again PROGRAM CONTINUATION Press Reset key Alarm must be cleared to run programs Contact Service Tool Unloading Active DEFINITION The tool unloading function is active A tool unloading from the magazine is taking place REACTION Display alarm NC start disabled REMEDY Normal during tool unloading If tool unloading is interrupted and alarm lingers power machine off and on and try tool loading unloading again PROGRAM CONTINUATION Press Reset key Alarm must be cleared to run programs Contact Service User Spindle Stop DEFINITION The spindle stop key in the machine control panel has been pressed REACTION Display alarm Axis mo
87. ables for short circulating disconnect cables then this error should be cleared Eliminate any defect Program Continuation Switch control OFF ON The actual service switch position forces a SRAM to be cleared at the next Power On general reset active Explanation The initialization switch is currently set to overall reset This means that the module s SRAM is deleted at the next module reset The NC data memory is cleared during this operation Reaction Alarm display Interface signals are set NC not ready Remedy Reset initialization switch to one Program Continuation Alarm display disappears with cause of alarm No further operator action necessary Emergency Stop Explanation The EMERGENCY STOP request is applied to the NCK PLC interface DB 10 DBX 56 1 Reaction Power On Procedure Alarms Jan 2003 Fadal 5001 4000 Series Alarm Jan 2003 4000 SIEMENS CONTROL Maintenance Manual NC Start disable NC not ready All mode groups not ready NC Stop when alarm Alarm display Interface signals are set Remedy the cause of EMERGENCY STOP and acknowledge EMERGENCY STOP via the PLC NCK interface DB 10 DBX 56 bit 2 Program Continuation Press the Reset key to clear alarm in all channels of this mode group Make sure that the E stop is not pressed Internal emergency stop Explanation This alarm is not displayed Reaction NC Start disable NC not ready All mod
88. age in the Query box displays asking to overwrite Select the Zero offsets folder Navigate to the folder by using the arrow hard keys Press Archive soft key Use the default name UFR or enter a descriptive filename in the Archive field at the bottom of the screen for the zero offsets data folder being created In the Arch field verify that Binary format PC form is selected 120 MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL s Press Start soft key t Pressthe YES soft key if a message in the Query box displays asking to overwrite 5 BackUp The following procedure creates a backup of all machine data to the MMC103 Original hard drive Machine Data a Press Menu Select hard key b Press Services soft key c Select the Archive folder The arrow hard keys may be used to navigate to the Archive folder d Press Data Out soft key e Press extended menu hard key f Press Series start up soft key 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 Only the NC PLC and With compensation data boxes should be selected h Inthe Archive name field type the filename OLDNCPLC for the backup file i Press INPUT hard key j Press Archive soft key k If a message in the Query box displays a question about overwriting select YES The process will take appr
89. al digital analog interface and synchronous subroutine interface Further actions are 11 12 13 88 89 15 Move tool only with tool management command 16 Carry out delete distance to go 1 Nesting depth too great Abort program VDI signal delete distance to go synchronous actions 2 The active block after which Abort program deceleration takes place cannot be reorganized occurs when deceleration takes place over several blocks J an 2003 ActionList 67 Fad al SIEMENS CONTROL Maintenance Manual No Explanation Not allowed if Remedy 17 Perform rapid delete distance to go There is no subsequent reorganization of block processing VDI signal delete distance to go synchronous actions 18 Perform rapid delete distance to go There is no subsequent reorganization and no stop motion VDI signal delete distance to go synchronous actions 19 Abort the subroutine repetition VDI 1 Nesting depth too great Abort program signal delete subroutine number of passes 2 The active block after which Abort program deceleration takes place cannot be reorganized occurs when deceleration takes place over several blocks 20 Abortsubroutine execution VDI Nesting depth too great gt Abort program signal abort program level e The active block after which gt Abort program deceleration takes place cannot be reorganized occurs wh
90. an initialization for loading the standard machine data Reaction Alarm display Remedy After automatically loading the standard MDs the individual MDs must be entered or loaded in the relevant system Program Continuation Clear alarm with the RESET key Restart part program 4062 Backup data loaded Explanation The user data saved in the flash memory are loaded to the SRAM Reaction Alarm display Remedy Load specific machine data again Program Continuation Clear alarm with the RESET key 4075 Machine data 1 and maybe others not altered permission level 962 needed Explanation 901 7 String MD identifier 2 Write protection level of the MD On executing a TOA file or when writing data from the part program an attempt has been made to write an item of data with a higher protection level than the access authorization currently set in the control The item of data in question has not been written and program execution is continued This alarm is set only when access violation is detected for the first time Reaction Alarm display Remedy Set the required access level by means of password entry or delete the machine data concerned from the MD file part program Program Continuation Clear the alarm with the Delete key No further operator action necessary 4076 1 Machine data could not be altered with permission level 902 Explanation 001 Number of MDs 002 Preset access authorization Jan 2003 Pow
91. ance 1138 0 058 0 058 0 055 0 055 0 060 Stator leakage reactance 1139 0 425 0 425 0 289 0 289 0 150 Rotor leakage reactance 1140 0 425 0 425 0 289 0 289 0 130 Magnetizing reactance 1141 8 069 8 069 6 411 6 411 5 198 Field weakening speed 1142 3040 3040 2973 2973 3043 Ih curve upper speed 1143 0 0 6000 0 0 Motor max allowed speed 1146 7500 7500 7500 7500 7500 Ih curve gain 1144 100 100 100 100 100 Motor inertia 1117 0 048 0 048 0 053 0 053 0 064 Stall torque reduction 1145 100 100 100 100 100 Motor temp warn limit 1602 150 150 120 120 120 Motor code 1102 99 99 99 99 99 Alarm mask power on 1600 112h 112h 112h 112h 112h Enc resol motor 1005 1000 1000 1000 1000 1000 Num current filters 1200 0 2 2 2 2 2 Filter types 1201 0 0 0 0 0 0 Current filter1 freq 1202 0 250 2000 500 2000 2000 Current filter damping 1203101 1 0 7 0 8 0 7 0 7 Current filter2 freq 1204 0 250 250 1200 500 500 Current filter2 damping 1205 0 1 0 7 0 7 0 7 0 7 Power limit 1255101 250 250 200 200 200 Power limit 1235 1 250 100 200 200 200 Power limit 1255121 100 100 200 200 200 current limit 1258 2350 200 150 150 Motor fixed temp 1608 30 30 60 60 Speedctrl gain 1407 0 1 2 8 8 8 8 12 7 12 7 13 13 13 17 689 17 816 Encoder resolution 31020 1000 1000 1000 1000 1000 Parameters Jan 2003 SIEMENS CONTROL Fada Maintenance Manual Table 2 Siemens Spindle Motor Only
92. and correct problems for example resonance frequency from a mechanical system that can affect movement Jan 2003 Overview 1 Fadal 1 2 Digital Control System 1 5 Digital Drive Converter System 1 5 1 CCU SIEMENS CONTROL Maintenance Manual The typical digital control system is comprised of a digital drive converter system power supply operator panel CNC full keyboard machine control panel and motors for digital converter system see Figure 1 2 MMC module 1FT6 1FK6 1PH motors Figure 1 2 The basic 810D controls system The digital drive converter system is housed inside an electronics cabinet mounted on the backside of the VMC Vertical Machining Center There are two main components that make up the digital drive converter system are the CCU and the SIMODRIVE 611D axis extension module The CCU Compact Control Unit consists of two major components as shown in Figure 1 5 One component is the CCU box This box contains a fan for cooling two to three integrated power sections and a slot for the CCU module The other component is the CCU module It consists of the NCK Numerical Control Kernal the PLC Programmable Logic Control and six one motor control sections three for the power sections in the CCU box and three for external power module Figure 1 4 shows a diagram of these three sections of the CCU module The CCU module performs all CNC PLC communication and c
93. are from PC card 7 Restore the NCK and load the original arc file from the NC card 8 Run Options program 9 Update comp data and backlash if needed Use xyz comps 10 Load compensation values 11 Create two 2 copies of new system files for back up One copy will be kept with the machine The other copy with the machine serial number will be sent to Fadal This software update procedure starts from power on a Plug one end of the 9 pin RTS CTS serial communications cable to the serial port at the external computer b Go to pendant and unlatch the door to allow access to the MMC100 inside the pendant cabinet c Plug the other end of the serial communications cable to the COM1 serial port on the MMC100 MMC100 Software Update Tools Required June 2002 Fadal SIEMENS CONTROL 2 Call Tool Zero The following steps sets up the machine and saves the spindle tool data Unload nds a Powerthe machine OFF and back ON b Press the JOG button Reference each axis Select an axis with the axis selector switch Press REF POINT hard key Press plus hard key Repeat these steps for all the configured axes he axes are referenced when the crosshair symbol 45 displays to the left of each axis d Press the JOG button e Press T S M soft key f Enter O in the T field g Press the INPUT hard key h Press the CYCLE START button Tool zero 0 will be loaded into the sp
94. arms messages can occur in two different ways e as alarm in the alarm line or e as message in the dialog line without alarm number The user can configure whether the alarms are to be displayed in the alarm line or in the dialog line without alarm number Fore more information please refer to References PK Configuring Package MMC 100 See the category Type which shows whether the alarms messages are configured as message or alarm at delivery No connection to PLC Explanation t was not possible to set up a connection to the PLC during power up e g incorrect PLC basic program This can be caused by wiring problems or cable failures Type Message Password is not valid Explanation An incorrect password has been entered Commonly due to a typo error Type Message Remedy Enter valid password Start up successful Explanation In the start up area screen NC Start up one of the three functions normal NCK reset reset with default values software update start was successfully initiated Power On Procedure Alarms Jan 2003 Fadal 101156 101160 101205 101206 Machine Operating Area 103001 105002 Jan 2003 SIEMENS CONTROL Maintenance Manual Type Message Function illegal Explanation The selected function is illegal Commonly occurs when file being requested is not present Type Message Remedy See Installation Guide Date and time of PLC set Explanation The date
95. bort the program with the Reset key or wait until the interrupt is terminated 4 Overstore or digitizing has been selected Deactivate overstore digitizing 6 Automatic change from an internal mode to the mode that was externally set with TEACH IN an attempt is made after every stop to change from the intemal mode AUTOMATIC MDA to TEACH IN J an 2003 ActionList 65 Fadal SIEMENS CONTROL Maintenance Manual No Explanation Not allowed if Remedy Change the mode to a manual mode signal OG 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 activated These asynchronous subroutines can be interrupted in the same manner as the user program Unlimited nesting depth is not possible for asynchronous subroutines due to memory limitations 2 The channel is active program running block search loading machine data 3 A channel has exited the mode group due to an interrupt 4 Overstore or digitizing has been selected Abort program by activating the Reset key Abort the program with the Reset key or stop the program not with block search loading machine data Abort the program with the Reset key or wait until the interrupt is terminated Deactivate overstore digitizing Activate overst
96. ch diskette and sent to Fadal Machining Centers This software update procedure starts from power on a Call tool zero 0 TO M6 b Save tool data c Unload tools from tool changer Power on the machine Booting up the MMC103 will take several minutes Reference the axes Each axis on the machine must be referenced before performing the update Referencing can be done while in Shopmill or in ISO The default when the control boots up is Shopmill If referencing the axes in ISO mode is desired it can be done following step d in To ISO Mode a Select an axis with Axis Selector switch located on the MPG MMC100 Software Update Tools Required June 2002 Fadal SIEMENS CONTROL b Press Ref Point hard key c Press plus hard key The selected axis is referenced when the crosshair symbol 4 d Select the next axis and press the plus hard key Repeat this step until all configured axes have been referenced Go To ISO Mode a Press Menu Select hard key b Press ISO soft key then press ISO v soft key c Waitfor ISO screen to load d Press Menu Select hard key e Press Start up soft key f Wait for Startup screen to load g Press Password soft key h Press Set Password soft key i Enterthe password SUNRISE in all UPPERCASE lettering To type in uppercase press and hold SHIFT hard key while typing the password j Press 2 INPUT yellow
97. communication NC block INIT 50 Save definition of an asynchronous subroutine PI command 51 Sets all machine data with the attribute NEW CONF active PI command 70 Action List J 2003 Fadal SIEMENS CONTROL Maintenance Manual No Explanation Not allowed if Remedy 52 Delete all alarms with the delete condition CANCELCLEAR PI command acknowledge alarm key 53 Continue block search NC block Stopre 54 Start block search PI command 55 Continue block search command 56 Activate digitizing Pl command 57 Deactivate digitizing command 58 Switch on function generator PI command 59 Switch off function generator command 60 Wait for a program marker Channel communication NC block WAITM 61 Wait for an end of program Channel communication NC block WAITE 62 Program selection from another channel synchron Channel communication NC block INIT 63 Wait until receive acknowledge from MMC NC block MMC CMD 64 Activate the skip block function Nesting depth too great Wait until the preceding VDI signal skip block asynchronous subroutine is terminated or abort the program 65 Deactivate the skip block function Nesting depth too great Wait until the preceding VDI signal skip block asynchronous subroutine is terminated or abort the program 66
98. configuration is the same as Figures 1 or 2 in the wiring diagram WRG 0002 The step creates a backup of the updated machine data to the Archive folder of the 105 hard drive Press Menu Select hard key Press Services soft key Select the Archive folder The arrow hard keys may be used to navigate to the Archive folder Press Data Out soft key Press extended menu hard key Press Series startup soft key MMC100 Software Update MMC103 Update Procedure 127 Fadal 9 Restore the Machine to Its Operational State 128 SIEMENS CONTROL 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 for the backup file for example i Press gt INPUT hard key j Select Archive soft key k If a message in the Query box displays a question about overwriting select YES to overwrite The process will take approximately 15 minutes The job is ready message will display at the bottom of the screen when the backup is complete This step returns the machine to its operational state with the original zero offsets backlash and compensation values Reference each axis IF REQUIRED manually jog each axis to its alignment mark Press MPG hard key Wait for LED above the key to illuminate Select an axis with the axis s
99. cuts DO NOT put hands near exposed cutting tool edges May 2002 SS 15 Safety Section Fadal SAFETY SECTION LBL 0130 Flying objects from this machine injure ALWAYS wear safety glasses when operating this machine Noise from this machine can damage hearing ALWAYS wear ear protection when operating this machine DO NOT operate this machine with the doors open or with enclosures removed Lockout before servicing LBL 0163 To avoid serious injury or death to you or others This machine must be operated by qualified personnel only Read and completely understand Operator s Manual before operating this machine Safetv Section Ss 16 Mav 2002 SAFETY SECTION Fadal LBL 0126 Compressed air can seriously injure DO NOT perform maintenance on pressurized systems Disconnect air source before maintenance May 2002 SS 17 Safety Section Fadal LBL 0128 Safety Section SAFETY SECTION A WARNING kd Hazardous voltages in this enclosure can kill DO NOT operate with door open Servicing qualified personnel oniv SS 18 Mav 2002 SAFETY SECTION Fadal LBL 0125 DANGER de Hazardous voltages in this enclosure can kill Servicing by qualified personnel oniv Lockout before servicing May 2002 SS 19 Safety Section Fadal SAFETY SECTION 0255 Cutting tools can seriously injure or kill Do
100. d Repackage the removed components and return them to Fadal with a PCR form for each part for credit June 2002 MMC100 Software Update DATC Hardware Update v1 7 2 or above 145 Fadal SIEMENS CONTROL eee 810D MMCIO0 Engis Geman LE ELE1392 SIEMNS 3020 810 100 GRM A Standard dull D SIEMNS 3020 810 100 ITL po Emlsh Spensh ELE 1394_ SFTUPD SIEMNS 3020 810 100 S rencn ELEIS95 SFTUPDSIEMNSSO2UIEIO I00 F 3070 no 8100 MMCIOS Engish Gemen ELE 1398 SFTUPDSIEMNSiO20 B10 103 6 mA Standard English Italian D SIEMNS 3020 810 103 ITL Spanish D SIEMNS 8020 810 103 po entish French ELEIS99 SFTUPDSIEMNSSOZO S10 103 F LE 1408 D SIEMNS 3020 840 103 G n camag English Italian LE 1409 D SIEMNS 3020 840 103 ITL L o d dd Je glish Spanish LE 1410 D SIEMNS 3020 840 103 S D SIEMNS 3020 840 103 F Tema v D 5 4525 810 100 6 Standard ngish talan D SIEMNS 4525 810 100 ITL Spanish LE 1418 D SIEMNS 4525 810 100 S LL LL Engh LE 1419 D SIEMNS 4525 810 100 FRN 4525 NO 810D MMCIOS Engish German ELE 1420 D SIEMNS 4525 810 103 6 English tation Lo D SIEMNS 4525 810 103 ITL Engli i LE 1422 D SIEMNS 4525 810 103 SPN D SIEMNS 4525 810 103 FRN D SIEMNS 4525 840 103 GRM D SIEMNS 4525 840 103 ITL D SIEMNS 4525 840 103 SPN D SIEMNS 4525 840 103 FRN LE 143
101. d equate to FF hex Rigid Tapping X scale Y scale Z scale A scale B scale A axis B axis 15K spindle Servo Turret Setting this bit will by pass the 200ms timer set for the regular geneva time lag The geneva needs lag so that the geneva motor will coast and lock the turret But the servo turret needs to instantly turn off DATC HMC Pallet Changer Extended Column V300 Rotary table M7 M8 Toggle Simulator The number of tools in the tool change magazine is stored in another Siemens user data location 14510 USER DATA INT 0 This data is entered in decimal integer numbers as indicated by the INT in the data name To set to 24 tool DATC 14510 USER DATA INT 0 24 To set to 32 tool DATC Parameters Jan 2003 SIEMENS CONTROL Fada Maintenance Manual 14510 USER DATA INT 0 32 OPTIONS BYTE BY BYTE AND BIT BY BIT V2 0 ocatlon In db20 MD number Bytes U Tool Magazine Capacity Integer MD14510 0 Byte 2 axis b scale a scale z scale Rigid MD14512 0 Tapping Byte 5 Simulator v500 Ext HMC Pallet I5K MD14512 1 Column Xer Spindle The Options program This program will set bits in the MD14512 bytes and set various data bytes to configure options loaded on the machine like spindle types scales and rotary types A listing of the program is shown below OPTIONS MPF SPATH WKS DIR SHOPMILL FADAL V1 6 07 00 FOR 4525 AND 3020 BY DM
102. d return them to Fadal with a PCR form for each part for credit 114 MMC100 Software Update DATC Hardware Update 1 7 2 or above June 2002 Fadal SIEMENS CONTROL MMC103 Software Update v1 7 2 or above IMPORTANT Ifthe VMC is equipped with DATC please see page 69 NOTE You must install an updated software version and DATC hardware if no hardware is present General Information Before performing this software update READ THROUGH THE PROCEDURE AT LEAST ONE TIME COMPLETELY This will ensure a more effective error free update Also verify the configuration of the Siemens control using WRG 0002 REV F see Appendix A It is important that a COMPLETE BACK UP is made of the current machine data before performing software update If an error is made in the software update of the machine data the back up file can be used to restore the system to its original configuration Part number information for the Software Update Kit and its components can be found in Appendix B of this manual List of Components card containing original arc file and nck abb operating system Apre imaged hard drive MMC103 only Utilities disk The hmi abb and nck abb files are required for updating the display 1 These files are stored on PC cards The Figure 22 The files tor performing hmi abb file contains the necessary the MMC103 software update are firmware for the display The nck abb stored on a PC card and Utilities file i
103. displays 8 Overview Jan 2003 SIEMENS CONTROL Fada Maintenance Manual event and alarm messages allows a user to control and supervise a job process by means of menus gives the user ability to load programs and gives users access to both the PLC and NCK The HMI communicates with the PLC and NCK via the MPI Multi Port Interface bus As illustrated in Figure 1 8 the MPI connects the NCK the PLC and the HMI There is a constant exchange of information between the NCK and the drives through the MPI bus The NCK the PLC and the HMI are also individual computers that need to exchange data on a constant basis through the MPI Multi Port Interface bus NCK Drive 1 Drive 2 Drive 3 Drive Bus PLC PLC Input Output MPI Bus HMI Keyboard Figure 1 8 The MPI bus is the communication link for the HMI PLC and NCK 1 5 3 CNC Keyboard The CNC keyboard is installed below the HMI It is not laid out like a standard QWERTY keyboard but its function is essentially the same as a QWERTY keyboard It is used for functions such as MDA data input programming manual data entry Shopmill programming and advanced operator parameters programming When the control is in PC mode the keyboard is used in the same way as a PC keyboard The CTRL key ALT key and arrow keys for example are used to navigate through Windows Jan 20
104. e 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 92 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL 7 Back Up Other Back up all customer programs tool data and fixture data When creating Data filenames make sure they are not identical to each other a b Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the SERVICES soft key Press Data out soft key Highlight DATA then press the 2 INPUT hard key A sub list of files display Highlight TOOL AND MAGAZINE DATA then press the gt INPUT hard key Highlight TOOL DATA Press the START soft key Atthe external computer select DATA IN at the top of the screen then press ENTER Type a filename in the box that appears create a descriptive filename for example tools1 arc The filename is limited to a maximum of eight characters and the filename extension is limited to a maximum of three characters Press ENTER key Transmission should automatically start If it does not go to the pendant and press the START soft key Repeat steps d through j for FIXTURE DATA ZERO OFFSET When performing step i make sure the filename is different from the previous one Repeat steps d through j for each customer program In step d go to the WORKPIECES and in step e go to SHOPMILL Have
105. e cold start ALL axes Contact Service A Axis Needs Referencing DEFINITION The axis has not been referenced cold started REACTION 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 B Axis Needs Referencing DEFINITION The axis has not been referenced cold started REACTION 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 Doors Open DEFINITION Doors closed monitoring circuit open REACTION Display alarm User Feed Stop User Spindle Stop Power On Procedure Alarms 67 Fadal 68 700040 700041 700042 SIEMENS CONTROL Maintenance Manual REMEDY Check doors to be completely closed Check doors closed monitoring circuit sensors etc Check air pressure air oil board and auger board interlocked PROGRAM CONTINUATION Close doors Use the Override button in JOG Manual mode Contact service Handwheel Available Only In Jog Mode DEFINITION MPG or INC keys pressed while in Automatic mode REACTION Display alarm REMEDY Change over to JOG Manual mode before using the handwheel PROGRAM CONTINUATION Contact service if alarm lingers Feed Override 0 DEFINITION A manual movement was attempted while the Feed Override is set to z
106. e M84 program 27 Press the Joc i hard key 28 Press the T S M soft key 29 Enter 84 in the OTHER M FCT field 50 Press the INPUT hard key 51 Press the CYCLE START hard key 32 Wait for the program to finish executing There is no need to power off and back on 5 5 Axis Backlash The COMP VALUES n where n is x y z etc program is used to enter the ball screw error compensation values one axis at a time These values allow the control to compensate for inaccuracies commonly found in the ball screw Therefore the control can setup very precise positioning for the ball screw The program will automatically enter the data for the measurement system either the motor encoder or linear scales that the machine is equipped with The measurement is made in one inch increments The program LASER n can be used for that purpose or the user can make their own Compensation 5 5 Axis Backlash 77 SIEMENS CONTROL Fa dal Maintenance Manual The 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 105 First press the Menu select hard key then press the Program Manager soft key 34 Select LASER n in the directory 5 Press the CYCLE START 56 Take measurements Open the corresponding COMP VALUES n program 37 Press the PROGRAM MANAGER hard key For 105 First press the
107. e SUNRISE Press OK m Press MMC n 0 Press OPERATOR PANEL Change the data to read as follows 810D Connection 1 1 BusMPI Highest Bus address51 MMC address1 address3 PLC address2 Press MENU SELECT hard key Use the extension key Press EXIT Wait as system shuts down Press any key to reboot system Note Wait as system reboots this may be as long as 5 to 10 minutes 14 Back Up New The following procedure creates a backup of the updated machine data to the Machine Data Archive folder on the MMC103 hard disk a b amp Press Menu Select hard key Press CNC ISO soft key then press CNC ISO v soft key Wait for the ISO screen to display Press Menu Select hard key Press Services soft key Choose the Archive folder The arrow hard keys may be used to navigate to the Archive folder Press Data Out soft key Press extended menu hard key Press Series start up soft key June 2002 MMC100 Software Update MMC103 Update Procedure 143 Fadal 15 Create Backup to a Diskette NOTE 144 SIEMENS CONTROL 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 In the Archive name field enter a descriptive filename for the backup file for example backupnew Press 2 Input hard key Press Archive soft key If a message in the Query box displays a que
108. e groups not ready NC Stop when alarm NC reacts within a machining station Remedy No remedy required Program Continuation Press the Reset key to clear alarm in all channels of this mode group Channel 1 machine data 962 has gap in axis assignment Explanation 001 Channel number 902 String Machine data identifier The assignment of a machine axis to a channel by the machine data 20070 AXCONF MACHAX USED must be contiguous At system power up Power On gaps are detected and displayed as an alarm Reaction Alarm display Interface signals are set Mode group not ready Channel not ready NC Start disable NC Stop when alarm Power On Procedure Alarms 41 Fadal 42 4001 SIEMENS CONTROL Maintenance Manual Remedy Configure channel specific machine data 20070 AXCONF MACHAX USED for the axis assignment without gaps that is with increasing channel axis indices a machine axis must continue to be assigned until a zero is entered for the first time not a machine axis All MD higher indices must then also contain 0 The sequence of the machine axis numbers is irrelevant Channel anis 19 218 Machine axis number index channel channel 0 1 4 AXCONF MACHAX USED CH1 AX1 1 1 2 5 AXCONF MACHAX USED CH1 AX2 2 2 3 6 AXCONF MACHAX USED CH1 AX3 3 3 7 0 AXCONF_MACHAX_USED CH1 7 4 8 0 AXCONF_MACHAX_USED CH1 AX5 8 5 0 0 AXCONF_MACHAX_USED
109. e the arrow keys to select ON or OFF setting in the box that displays Press ENTER Select yes in the SAVE INPUT Y N box that displays Select DATA IN at the top of the screen Press ENTER a filename in the box that appears The filename is limited to a maximum of eight characters and the filename extension is limited to a maximum of three characters Set EXT to ON Press ENTER The external computer is now ready to receive the machine data from the Siemens control Download the new system files to the external computer a Press the START soft key on the control NOTE The transmission process may stall several times during the data transfer This is normal Ignore any tool alarms that may arise The Transmission in progress window closes when the data transfer is complete Save the file at the external computer 112 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL b 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 Use the PCIN program to copy the files onto floppy diskettes Store one with the machine On the second copy WRITE THE SERIAL NUMBER OF THE MACHINE ON THE DISKETTE THEN SEND IT TO FADAL MACHINING CENTERS NOTE DO NOT open this file Opening it will damage the header The icon may appear to be
110. ed will display Ignore this message Press Menu Select hard key Press ISO soft key then press ISO v soft key Wait for the ISO screen to load Press Menu Select hard key Press Start up soft key Wait for the Start up screen to load Press Password soft key Press Set Password soft key 126 MMC100 Software Update MMC103 Update Procedure June 2002 Fadal NOTE 8 Back Up New Machine Data June 2002 a o O 3 SIEMENS CONTROL Enter the password SUNRISE in all UPPERCASE lettering To type in uppercase press and hold the SHIFT hard key while typing the password Press gt INPUT hard key The message Password has been set for manufacturer will display in the lower part of the screen Press Menu Select hard key Press Services soft key Press extended menu hard key Press Series start up soft key Press Original status soft key Press Yes soft key when prompted If a Regie overlay error box displays during the loading process press the hard key this clears the error message box Wait for all files to load The Job is ready message displays at the bottom of the display screen when files are loaded The process will take approximately 15 minutes Power OFF the machine and check for basic hardware configuration see NOTE below If the machine is equipped with scales and or 4th 5th axes the extra hardware MUST be disconnected so that the hardware
111. elector switch 1 2 3 4 Align the selected axis to its mark by using the handwheel owas Repeat steps 2 and 3 for all the axes 5 Press 2 JOG hard key when done Reference the axes rw 1 Press Machine hard key 2 Select an axis with the axis selector switch 3 Press REF POINT hard key 4 Press plus hard key 5 Repeat steps 2 5 and 4 for all the axes The axes are referenced when the crosshair symbol 45 displays to the left of each axis Run the Options Program a Press Menu Select hard key MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL b 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 2 INPUT hard key e Highlight the Shopmill folder Using the arrow keys move the blue bar to highlight the Shopmill folder f Press 2 INPUT hard key The contents of the Shopmill folder displays g Highlight the Options file and press gt INPUT hard key The Editor window opens displaying the Options program h Press the Pagedown and or arrow hard keys get to the Options table The Options table lists all the available options for the Siemens control All the listed options are set equal to zero 0 To enable an option it must be set equal to one 1 i Determine the installed options for the machine and enable
112. en deceleration takes place over several blocks 21 Activate single block VDI signal activate single block 22 Deactivation of single block VDI signal activate single block 23 Activate main run single block OPI variable and VDI signal activate single block 24 Activate decoding single block 1 Nesting depth too great Wait until the preceding OPI variable and VDI signal asynchronous subroutine is activate single block terminated or abort the program 2 The active block after which Abort program deceleration takes place cannot be reorganized occurs when deceleration takes place over several blocks 25 Activate main program single block OPI variable and VDI signal activate single block 68 Action List J an 2003 Fadal SIEMENS CONTROL Maintenance Manual No Explanation Not allowed if Remedy 26 Activate traversing single block OPI variable and VDI signal activate single block 27 Start program processing VDI 1 Program state active gt signal NC Start 2 An alarm reaction is pending it Execute condition for deleting prevents a start or forces braking alarm 3 Reference point approach has Reference point approach not been performed yet 28 Start program processing Channel 1 Program state active Protect Start with WAITE communication NC block Start 2 An alarm reaction is pending it prevents a start or f
113. ending 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 proper COM port setting The XON XOFF parameter should be set to OFF Use the arrow keys to navigate to the XON XOFF SET line Use the arrow keys to select ON or OFF setting in the box that displays Set EXT to ON Press ENTER Select yes in the SAVE INPUT Y N box that displays VERSION 4 43 SIENENS AG 1993 96 024 DATACIN DATA 00 RILE SPECIAL os Uh E ARCHIVERILE EXIT Figure 14 Select DATA OUT on the screen display Select DATA OUT at the top of the screen See Figure 8 Press ENTER Get Zero Offset and Backlash Data a Insert the utilities diskette into floppy drive of the computer b Type a in the Filename box June 2002 MMC100 Software Update MMC100 Update Procedure 95 Fadal 9 96 Install New NC Software 7 0 SIEMENS CONTROL Press ENTER The contents of the Utilities diskette displays in the a directory box Select the getval s mpf file Press the ENTER key At the pendant press the START soft key Press the OK soft key The Transmission in Progress window displays Press the OK soft key to upload the file The Transmission in progress window closes when the data transfer is complete Press the SHIFT and SYSTEM ALARM hard keys simultaneo
114. eplacement Follow the assembly instructions as necessary in reverse order until the component has been disassembled to required level to conduct the repair 1 E ml p Attach the 57 Pin D shell line black from the MPG into the X121 connec tion Secure with thumbscrews Attach jumper wire grey to the X451 ter minal block Red wire to position B black wire to position 19 Attach the Y axis signal cable blue to the X415 connection Secure with thumb screws Attach the X axis signal cable blue to the X412 connection Secure with thumb screws Attach the Z axis signal cable blue to the X411 connection Secure with thumb screws Attach the spindle encoder cable grey to the X414 connection Secure with thumb screws Attach the I O module cable WIR 0740 black to the X111 connection Secure with thumb screws Control Components 2 2 Wiring Connections Jan 2005 SIEMENS CONTROL Fa d a Maintenance Manual 7 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 A1 located on the bottom of the CCU Box Secure with thumbscrews Cable clamp cable to shielding plate B Jan 2003 Control Components 2 2 Wiring Connections 23 Fadal 2 2 2 Simodrive 611 Module Connections 24 SIEMENS CONTROL Maintenance Manual 1
115. 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 wheel for 50 seconds Under no circumstances should the operator open the Polycarbonate shield before the spindle stops rotat ing completely 13 The machine is not intended for use with flammable or harmful sub stances 14 Take appropriate additional safety precautions and measures when work ing with magnesium wood or other combustible materials 15 Dust removal equipment is needed when working with dust producing materials or procedures 16 Due to danger of slips or falls on a wet or oily surface table and enclosure floor should be clean and dry before using them for maintenance access 17 Do not enter enclosure area unless machine is off and power is locked out SS 15 Safety Section SAFETY SECTION Fadal SAFETY LABELS SAFETY INSTRUCTIONS milling machines contain hazards from rotating cutting tools belts and pullevs high voltage electricitv and compressed air LBL 0123 Rotating cutting tools can severelv injure vou NEVER place anv part of vour bodv near rotating cutting tools Inspect cutting tools for damage before operating this machine DO NOT operate this machine unless doors are closed DO NOT operate this machine unless door interlocks are working properly Rotating pull
116. er On Procedure Alarms 45 Fadal 46 4290 4291 SIEMENS CONTROL Maintenance Manual On executing a TOA file or when writing data from the part program an attempt has been made to write data with a higher protection level than the access authorization currently set in the control The data in question have not been written and program execution is continued without hindrance This alarm is issued on acknowledging the alarm EXBSAL MD PERMISSION DENIED It can be cleared only with Power On Reaction Alarm display Remedy Set the required access level by means of password entry or delete the machine data concerned from the MD file part program Program Continuation Switch control OFF ON Note The following two alarms indicate problems requiring a service call by a trained technician Sign of life monitoring local P bus not alive Explanation The COM computer must alter the sign of life on the local P bus in each SERVO cycle Monitoring for alteration takes place in the IPO cycle If the sign of life has not altered this alarm is triggered Reaction Alarm display Interface signals are set NC not ready Mode group not ready NC Start disable NC Stop when alarm Remedy Check hardware Program Continuation Switch control OFF ON Failure of module in local P bus slot 901 error codes 902 903 904 Explanation 1 Slot number 2 Error code 955 Error code 004 Error code The module on the s
117. erator is not familiar with a condition consult an industrial hygienist or safety engi neer for approval prior to proceeding Comply with all local state national Federal and international CE regu lations pertaining to the handling processing or disposal of hazardous materials used in conjunction with VMC operations Do not leave electrical cords where they may be tripped over Secure all electrical cords and compressed air lines connected to the VMC Keep a UL or CE approved fire extinguisher close to the VMC and make sure all personnel know the location of the fire extinguisher Do not turn the VMC on or try to operate it if there are explosive or flamma ble gases present Do not install substitute parts or modify the VMC without consulting a safety engineer Contact FADAL or your local distributor for authorized repair parts and service The Polycarbonate viewing panels are an integral part of the safety enclo sure for the VMC They must be inspected at least monthly for any signs of reduced effectiveness such as cracking or crazing and replaced immedi ately if such signs or other indications of reduced effectiveness are noticed Furthermore tests have indicated that coolants can reduce the effective ness of the panels over a period of time therefore the panels should be replaced regardless of condition at least every two years SS 12 May 2002 SAFETY SECTION Fadal May 2002 12 The Polycarbonate shield is
118. ero REACTION Display alarm REMEDY Set Feed Override knob to desired setting other than zero Check Feed Override switch PROGRAM CONTINUATION Set Feed Override knob to desired setting other than zero Contact Service Please Press MDA Soft Key DEFINITION MDA hard key was pressed when in Shop Mill REACTION Display alarm No change to MDA mode until MDA soft key menu under the screen is used REMEDY Use MDA soft key to change over to MDA mode in Shop Mill PROGRAM CONTINUATION Contact Service if alarm lingers Power On Procedure Alarms Jan 2003 Fadal SIEMENS CONTROL Maintenance Manual Section 04 Action List No Explanation Not allowed if Remedy 1 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 after Reset 4 Carry out Reset end of program has been detected NC block with M30 5 Change the mode to the MDA or AUTOMATIC program operating mode VDI signal mode group 1 The channel is active program running block search loading machine data Abort the program with the Reset key or stop the program not with block search loading machine data 2 The other program operating mode has already been started Abort the program with the Reset key 3 A channel has exited the mode group due to an interrupt gt A
119. esistor ELE 1167 Pulsed Resistor for 28kW Power Supply Filter 28kW ELE 1168 Line Filter 20HP Spindle CCU Box ELE 1088 Subrack for holding the CCU1 with 3 integrated power modules CCU1 ELE 1089 Central Unit containing NCK PLC communications digital standard control Compact 1 0 ELE 1093 PLC 1 0 module 64 In 32 Out Power Supply 24V 5A ELE 1095 24VDC power supply for PCU 210 Power Supply 24V 10A ELE 1134 24VDC power supply for MMC 103 10 Overview Jan 2003 SIEMENS CONTROL Fada Maintenance Manual Axis Expansion Board ELE 1091 For installation of a 611 power module 45A Power Module ELE 1090 15HP Spindle Power Module 60A Power Module ELE 1164 20HP Spindle Power Module 9 18A Power Module ELE 1196 Single Axis Power Module 4th Axis 2 9 18A Pwr Module ELE 1161 Dual Axis Power Module 4th amp 5th Axes 611 Controller Board ELE 1155 611D Standard controller board for axis expansion Servo Motor Lin Axis MTR 0167 Servo motor for linear axis XYZ Servo Motor Rot Axis ELE 1157 Servo motor for rotary axis AB MPI cable WIR 0745 MPI cable 5 meters Between CCU and front panel PLC I O cable WIR 0740 PLC I O cable 2 5 meters Between CCU and compact 1 0 Figure 1 9 a WIR 740 cable connection at CCU front panel b WIR 740 cable connection at compact I O module Jan 2003 Overview 11 Fadal Hand Held Unit Remote MPG
120. eys and belts can severely injure you NEVER place any part of your body near rotating or moving parts ALWAYS ensure guards are in place before operating this machine High voltage electricity can severely injure or kill you NEVER attempt to adjust or repair electrical circuits unless you are familiar with the circuits and are qualified to work safely on the electrical circuits ALWAYS lock out electrical circuits before attempting to work on this machine Exposure to loud or long term noise can lead to permanent hearing f loss DO NOT operate this machine without hearing protection ALWAYS wear hearing protection that meets Occupational Safety and Health Administration OSHA standards for noise attenuation Compressed air can injure you DO NOT work on compressed air systems without first disconnecting the source of compressed air t ALWAYS wear eye protection when performing maintenance on compressed air systems ONLY authorized qualified personnel familiar with the compressed air system should perform maintenance on the compressed air system Safety Section SS 14 May 2002 SAFETY SECTION Fadal LBL 0129 ADANGER Moving parts can cause serious injury DO NOT operate with panels removed Keep away from moving parts Lockout power before service LBL 0158 DANGER Automatic Pallet door WILL CRUSH hands STAND CLEAR when door is closing LBL 0127 Exposed cutting tool edges can cause serious
121. for generating the counting pulse may be missed so the turret may be off by one pocket count Once the E Stop condition has been removed the first thing to do is to return the magazine to a good pocket position by pressing the Turret CCW or Turret CW hard key Once one of the pockets is aligned in the proper tool change position the tool magazine counter must be verified To verify the turret counter Press E Stop If in Shop Mill go to the ISO screens Press the Shift and System keys press menu select key in the MMC103 Press the CNC ISO Soft Key Press the CNC ISO check mark SK Once in ISO continue from here Press the Shift and System keys press menu select key in the MMC103 Press the Diagnosis SK Press the PLC also called PLC Status SK the first row of the first column Operand type C5 Press the INPUT Hard Key The cursor jumps to the second column Format 11 D Press the INPUT Hard Key The cursor jumps to the second row in the first column Type DB92 DBWO Press the INPUT Hard Key The cursor jumps to the second column Format Troubleshooting 175 Fadal 176 SIEMENS CONTROL Maintenance Manual p 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 counte
122. ge switch digitizing ON OFF switch overstore ON OFF 2 An alarm reaction is pending it prevents a start or forces braking 3 A process is running NC program block search loading machine data Execute condition for deleting alarm Ez J an 2003 ActionList 69 SIEMENS CONTROL Fadal Maintenance Manual No Explanation Not allowed if Remedy 37 Stop the active processing VDI signal NC Stop 38 Start machine data processing INI file is already in the command 39 Start machine data processing INI file is external e g on MMC PI command 40 Stop because of mode group single block VDI signal single type A only executable blocks after stop in another channel in this mode group 41 Stop because of mode group single block VDI signal single type A any blocks after stop at block end in another channel in this mode group 42 Stop because end of overstore buffer OSTOREXX SYF has been reached 43 Start preprocessing NC block Stopre 44 Stop processing at block end NC block M00 M01 45 Stop processing at block end Alarm VDI signal NC stop at block end 46 Stop at end of asynchronous subroutine if start was performed from stopped 47 Activate program command 48 Activate the program which is still external command 49 Program selection from another channel Channel
123. gnal path PLC inputs outputs INPUTS 138 1 DATC tool magazine count impulse 158 2 DATC busy active low 138 3 DATC error active low 158 4 DATC draw bar active low OUTPUTS Q41 0 DATC strobe Q41 1 DATC 90 Q41 2 DATC d1 Q41 3 DATC d2 Q41 4 DATC draw bar These signals can be monitored in the Diagnostic area PLC page The next table shows the different bit combinations that send a command to the 1550 board Signals as they appear in the PLC diagnostic screen 042 5 45 041 5 92 041 2 41 041 1 dO 1 1 1 Turret CW Turret CCW Tool Change Bucket Up Down Arm Forward Arm Reversal Error retrieval Idle O O O mn e e o o O e e O e O e O e O Draw bar Troubleshooting Jan 2003 Fadal HOW TO RE SET THE TOOL MAGAZINE LOCATION Jan 2003 SIEMENS CONTROL Maintenance Manual A low to high transition at Q41 0 the strobe signal starts the process DATC busy signal 158 2 remains active until the command is executed entirely The DATC error signal 158 5 is active in the event of any error conditions in the 1550 board It is possible to loose the proper pocket number in the tool magazine turret due to an emergency stop while the turret is rotating to get to a new position If the turret stops in between pockets the window
124. hair symbol 45 displays to the left of each axis 100 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL Run the Options Program a Press Program Manager hard key b Press Pagedown and or Arrow keys to select OPTIONS See Figure 12 then press the 2 INPUT hard key The program editor window opens AUKS DIR SHOPHILL WPD FADAL 3020 Joy OPTIONS HPF Channel reset Progran aborted ROV Progran overview EI UE Tupe Length Date Enable 625 11 08 36 bi 11 08 36 x MPF 693 11 08 36 x MPF 2121 11 08 36 x p MB 282 28 35 PROG SAMPLE 1 MPF 1870 19 09 00 RIGID 201 11 08 36 SET OFFSETS MPF 2454 11 08 36 SET UFFSETS XvZ MPF 2480 22 05 00 SHOMILL SAMPLEL 581 19 09 00 SHOPHILL1 MPF 719 19 09 00 SHUPHILLZ MPF 946 19 09 00 SHOPMILLA 1050 19 09 00 Press INPUT key to edit progran X X X X XX x HK 2 Work Sub Standard Clip Memory Figure 18 Select the Options folder Use page down keys and or arrow keys to navigate to the Options folder c Find the options table under the Set Up Options Below line See Figure 15 The table lists all the available options for the Siemens control All the listed options are set equal to zero 0 To enable option it must be set equal to one 1 June 2002 MMC100 Software Update MMC100 Update Procedure 101 Fadal SIEMENS CONTRO
125. hard key The message Password has been set for manufacturer will display in the lower part of the screen If the password has been typed incorrectly the message Password is not valid will display Press the OK soft key and re enter password 3 Get Offset This step gets the zero offset and backlash data using a getval s mpf file and Backlash This file is referred to as the get values program It reads the zero offsets Data and the backlash data for all the available axes and displays them one at a time for the user to write down Before running this program it must be copied into the Shopmill folder within the Workpieces folder from the Utilities diskette a Press Menu Select hard key b Press Services soft key June 2002 MMC100 Software Update MMC103 Update Procedure 117 Fadal SIEMENS CONTROL c Highlight the Workpieces folder Using the arrow keys move the blue bar until the Workpieces folder is highlighted d Press gt INPUT hard key e Highlight the Shopmill folder Using the arrow keys move the blue bar to highlight the Shopmill folder f Press Data in soft key g Press Disk soft key Insert the Utilities diskette when prompted to do SO h Press OK soft key An overlay box appears displaying the contents of the Utilities diskette i Highlight the getval_s mpf file Select the file by highlighting it with the blue bar j Press Start soft key When the getval_s
126. he Select soft key 130 MMC100 Software Update MMC103 Update Procedure June 2002 Fadal p q SIEMENS CONTROL Press the Auto hard key Press the BE CVCLE START hard kev The Power off message displays at the bottom of the screen display when the program finishes running Power the machine OFF and then back ON Reference the axes Set up Tool Magazine a b d e Press the MACHINE hard key Press the MDA hard key Press the MDA hard key again Type TC BASE M2 Press the CYCLE START hard key Wait for the WAIT message to disappear Restore Gain Settings a ph deo d c B Press Menu Select hard key Select Start up soft key Wait for Startup screen to load Press Machine data Press Axis specific Go to the following machine data and type in the data from step using the soft key located on the upper right portion of the screen choose X1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 MOVE DIST 1 and type in data using the soft key located on the upper right portion of the screen choose Y1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 MOVE DIST 1 and type in data using the soft key located on the upper right portion of the screen choose Z1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 MOVE DIST 1 and type in data using
127. he axis selector switch c Press REF POINT hard key d Press plus hard key e Repeat steps 2 5 and 4 for all the axes he axes are referenced when the crosshair symbol displays to the left of each axis Position will be restored to factory setting Restore Original Zero Offset and Backlash Data a b C Press J Menu Select hard key Press Services soft key Highlight the Workpieces folder Using the arrow keys move the blue bar until the Workpieces folder is highlighted Press 2 INPUT hard key Highlight the Shopmill folder Using the arrow keys move the blue bar to highlight the Shopmill folder Press Data in soft key Press Disk soft key Insert the Utilities diskette when prompted to do SO Press OK soft key An overlay box appears displaying the contents of the Utilities diskette Highlight the setval s mpf file Select the file by highlighting it with the blue bar Press Start soft key When the setval s mpf file is copied into the Shopmill folder the overlay box closes and the message Job is ready displays at the bottom of the screen June 2002 MMC100 Software Update MMC103 Update Procedure 133 Fadal 134 k SIEMENS CONTROL Highlight the Shopmill folder and press the 2 INPUT hard key The contents of the folder will display Find the file named SET_VALUE This is the setval_s mpf program Highlight the SET_VALUES file and press the 2 INPUT hard key Thi
128. he machine turn the machine off and lockout the power Turn off the machine and lockout the power before working in this cabinet Safety Section SS 44 May 2002 Fadal SAFETY SECTION CE SAFETY LABEL LIST AND LOCATION Location Domestic or old Labels CE Labels ATC Slide Arm Plate LBL 0129 LBL 0432 1009B ISO LBL 0438 6011B ISO Spindle Belt Guide LBL 0129 LBL 0432 1009B ISO inside spindle cover LBL 0438 6011B ISO Front by Pendant LBL 0123 LBL 0163 LBL 0435 3002A ISO LBL 0439 6040 150 LBL 0440 604 1A ISO LBL 0442 6126A ISO Tool Turret Cover LBL 0136 LBL 0136 revised Tool Changer Cover LBL 0127 LBL 0434 1007A ISO Head Spindle Cover BL 0435 5002 150 LBL 0130 BL 0439 6040 150 LBL 0137 0138 or 0139 BL 0440 6041A ISO BL 0137 0138 or 0139 revised qnum pt Right Front Door LBL 0124 LBL 0140 BL 0431 1007B ISO LBL 0441 6060B ISO LBL 0140 deleted after doors locked On Control Transformer and Pendant Cabinet Doors LBL 0128 LBL 0131 LBL 0131 6010 150 Inside of Control Transformer and Pendant Cabinets LBL 0125 LBL 0235 LBL 0131 6010 150 LBL 0437 6011A ISO B size labels used in Slant Control cabinet LBL 0461 0458 Grounding Labels LBL 0133 chassis ground LBL 0133 LBL 0186 same LBL 0186 Protective Earth input Flood Mist RS 232 Outlets LBL 0192 LBL 019
129. he measuring system connections for indirect and direct position sensing X121 is the I O interface cable distributor for handwheel and probe X113 and X114 are reserved X122 is the MPI interface 187 5 kBaud X102 is the PROFIBUS DP interface as of 6 99 X111 is the P bus PLC I O bus connection of 57 300 I O and single module H3 not labeled is the 7 segment display for software supported output of test diagnostic signals X431 is the terminal block for the connection of starting lockout pulse enable all drives and external zero marker BERO H1 and H2 not labeled are error and status LEDs X130 isthe SIM ODRIVE 611D drive bus interface and I O extension Overview Jan 2003 Fadal Jan 2003 SIEMENS CONTROL Maintenance Manual PCMCIA memory card slot shown with memory card inserted X341 X342 X351 and X352 are the DAC test sockets 53 isthe start up switch 54 is PLC operating mode switch X151 isthe device bus interface power supply X304 X306 are the axis extension connections Overview 5 SIEMENS CONTROL Fa dal Maintenance Manual Figure 1 5 SINUMERIK 810D control module interfaces 6 Overview Jan 2003 SIEMENS CONTROL Fada Maintenance Manual 1 3 3 Axis Extension The SIMODRIVE 611D module Module mounted to the left of the CCU consists of an axis extension control module and a power module See Figure 1 6 The ax
130. he spindle from starting REACTION Display alarm Program interrupted Spindle rotation disable REMEDY Remove feed stop condition PROGRAM CONTINUATION Press the Feed Start key or Cycle Start key ATC Not In Home Position DEFINITION Automatic Tool changer not in home position REACTION Display alarm Program interrupted Axis movement disable Spindle rotation disable REMEDY Check tool changer mechanism for malfunctions obstructions Bring the DATC arm to home position manually PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service DATC Magazine Out Of Synchronization Re referencing needed DEFINITION Tool magazine position count has been lost REACTION Display alarm NC start disable Program interrupted REMEDY Bring the tool magazine pocket 1 to tool change position then run M11 Power On Procedure Alarms 61 Fadal 62 510012 510100 510101 510102 SIEMENS CONTROL Maintenance Manual PROGRAM CONTINUATION Alarm will re set by running M11 Restart part program Contact Service Dual Arm Active DEFINITION The dual arm gripper in the tool changer in movement REACTION Display alarm Axis movement disable Spindle rotation disable REMEDY Normal during tool change Check dual arm tool changer interface if displayed outside tool change PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service DATC Arm Motor Overload DEFINITIO
131. i nit ba er dete e et RA a 12 SAFETY LABELS ntn icd etai 14 BEP EE 14 Sci oum TT 15 0158 a e aj e Sr a 15 A 15 BEER UM 16 EBD SO TOS cesi 16 BUE 17 BOT MAU MT LE RET MEE TE 18 BEL TER 19 I E OA S A codes as i A 20 EBLSOUS bt rt b a a a a 21 m dr ec S mc Ri DM 21 B y 22 E9l 0254 oss vr SL ML d a du s ust cbhaddeasustiferdedhaddnachihiadesusnoageeeets ERE RE DERE A 22 BED 25 IBI 0040 A vie ii a 24 LBL2O03 ELT 24 SAFETY LABEL EOCATIO NS tacto route oeste acne 25 HE a M M 25 5020A 4020A 4020 30161 2216 20161 15 15 nanna sanat 27 5030 09050 oo eet dara Ra aa 29 4525 5020 ET E 33 August 2001 SS i Safetv Section SAFETY SECTION Fadal xU RE LBL 0431 small CE LBL 0434 large CE ute out 37 i Mi Eois ne Ct GO RCM CPP 37 LBEDISONUE Ne f KA 38 CE HMM CUM EPOD DARE A A EJ A 38 UB Ee OA ONCE 39 MM HTC DP eM ATHE 39 BE AQAS GN
132. ible to detect in block conditioning that the traversing range has been exceeded because there has been a motion overlay by the handwheel Reaction Power On Procedure Alarms 53 Fadal 54 10631 10640 SIEMENS CONTROL Maintenance Manual Alarm display Interface signals are set NC Start disable Remedy Setting data Check 45420 WORKAREA LIMIT PLUS and 45450 WORKAREA LIMIT MINUS for the working area limitation Program Continuation Clear alarm with RESET key Restart part program Channel 901 axis 962 rests at working area limit 903 Explanation 901 Channel number 902 Axis spindle 005 String or The specified axis reaches the positive working area limitation in JOG mode Reaction Alarm display Remedy Setting data Check 43420 WORKAREA LIMIT PLUS and 45450 WORKAREA LIMIT MINUS for the working area limitation Program Continuation Alarm display disappears with cause of alarm No further operator action necessary Channel 901 block 903 spindle 902 cannot stop during gear change Explanation 001 Channel number 902 Spindle number 955 Block number label The spindle is in the oscillating mode for a gear change and is waiting for the PLC acknowledgment that the gear change has taken place interface signal Gear has changed DB 51 48 DBX 16 3 During this phase spindle stop is not possible initiated by Reset DB 21 28 DBX 7 7 or NC Stop axes plus spindle DB 21 28 D
133. inal and install it on the lower ventilation grid 4 Attach the lower ventilation grid to the lower portion of the back plate with two M6 flathead torx screws 5 Connect wires from the Reactor Module ELE 1084 to the output terminal Jan 2003 Control Components 2 1 Replacement of Modules 15 Fadal SIEMENS CONTROL Maintenance Manual U 101 V 1V1 W 1W1 OUTPUT FILTER 1U2 Ul 1V2 V2 1W2 W2 REACTOR Wiring Diagram Reactor Line Filter Output Side View 16 Connect the wires for the Line Filter to the Reactor and feed them out through the access on the top ventilation grid Control Components 2 1 Replacement of Modules Jan 2003 SIEMENS CONTROL Fa da Maintenance Manual 6 Attach the Main Line Filter and its mounting plate to the Reactor Module assembly with four M6 round head torx screws JP Fvvvvvv Connect the wires from the Reactor to the Line Filter 7 Attach the two wire shields to the bottom of the assembly using two each MA torx screws 8 Mount the Reactor and Line Filter assembly on the left side of the mounting bars with four 1 2 20 x 5 4 torx screws Jan 2003 Control Components 2 1 Replacement of Modules 17 SIEMENS CONTROL Fa dal Maintenance Manual 2 1 2 Replacing the Parts Numbers E R Module ELE 1083 Simodrive E R Module Int 16 21KW EL
134. indle Verify by checking the 7 F S box in the upper right portion of the screen No data will be displayed to the right of the T if tool 015 loaded 5 Recording Original a Press MENU SELECT hard key od atan b Select START UP soft key Position Backlash Data c Wait for Startup screen to load and Gain d Press Machine data Settings e Press Axis specific f Go to machine data for each axis and record the following using the soft key located on the upper right portion of the screen choose X1 using the blue arrows go to 54090 REFP MOVE DIST 0 NOTE 0 ENCODER 1 SCALE Record this data 54090 REFP MOVE DIST 0 June 2002 MMC100 Software Update MMC100 Update Procedure 85 Fadal SIEMENS CONTROL 34090 MOVE DIST 1 using the soft key located on the upper right portion of the screen choose Y1 using the blue arrows go to 54090 REFP MOVE DIST 0 record the data 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 using the soft key located on the upper right portion of the screen choose Z1 using the blue arrows go to 54090 MOVE DIST 0 record the data 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 using the soft key located on the upper right portion of the screen choose A1 using the blue arrows go to 54090 MOVE DIST 0 record the data 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 using the soft key located on the upper right por
135. ing the machine NEVER LEAVE THE MACHINE UNATTENDED Turn the power off to the machine when leaving the machine unattended Never leave the machine until it comes to a complete stop DO NOT DISCONNECT THE FRONT DOOR SAFETY SWITCHES UP SPILLS Immediately cover with absorbent material and wipe up coolant and oil spills around the machine Correct the cause of the leakage to prevent any hazards ELECTRICAL INSTALLATION OF THE MACHINE MUST BE DONE BY A QUAL IFIED ELECTRICIAN ONLY FADAL OR FADAL DISTRIBUTOR FACTORY AUTHORIZED INDIVIDU ALS MAY INSTALL THE MACHINE USE PROPER SAFETY GLOVES WHEN HANDLING SHARP OR JAGGED EDGES Do not wear gloves around rotating machinery SS 5 Safety Section SAFETY SECTION Fadal 33 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 Safety Section SS 6 May 2002 Fadal GENERAL May 2002 SAFETY SECTION A 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 manual follow accepted industry safety practices Tasks involving toxic materials must be reviewed and approved by an industrial hygienist or safety engineer Fadal has no control over the applications the operator may use the VMC for and
136. ion overlay and avoid this or keep it smaller when the program is repeated 2 Transformation Check the preset programmed zero offsets current frame If the values are correct the tool holder fixture must be moved in order to avoid triggering the same alarm when the program is repeated which would again cause the program to be aborted Program Continuation Clear alarm with RESET key Restart part program Channel 901 axis 902 rests on software limit switch 903 Explanation 001 Channel number 902 Axis name spindle number 5 String The specified axis is already stationary at the displayed software travel limit Reaction Alarm display Remedy Machine data 36110 POS LIMIT PLUS 36130 POS LIMIT PLUS2 36100 POS LIMIT MINUS 36120 POS LIMIT MINUS2 must be checked for the software limit switches Axis specific interface signals 2nd software limit switch plus DB 31 48 DBX 12 3 and 2nd software limit switch minus DB 51 48 DBX 12 2 check whether the 2nd software limit switch is selected Program Continuation Alarm display disappears with cause of alarm No further operator action necessary Channel 901 block 902 axis 903 at working area limit 904 Explanation 001 Channel number 002 Block number label 9603 Axis spindle number 004 String or During the traversing motion it is recognized that the working area limitation is reached in the displayed direction It was not yet poss
137. is extension control module has everything that is required to interface with the rest of the drive system as well as position and speed feedback connections Both the motor encoder and an optional second measuring system linear scale or second encoder plug into the drive The motor encoder also provides the rotor logic brushless DC motors and speed feedback The power module has one primary responsibility It takes the power from the DC link and Figure 1 6 The 611D control module converts it to the required AC and power module output that is needed to run the motor s In addition the power module also has a number of sensors for current and temperature feedback to the control module The DC link voltage is generated from the power supply module This module provides power to the drives as well as the different logic voltages that are needed for the electronics In general the control module takes commands from the and sends information back to itself by means of the drive bus Each control module controls one or two motors for position speed and current consumption 1 4 Power Supply The I RF Infeed Regenerative Feedback module is the power supply for the SINUMERIK 810D control and drives It is mounted to the right of the SINUMERIK 8100 This power supply generates a 15 VDC and 424 VDC output for the electronics of the SINUMERIK 810D and has a DC link voltage of 60
138. ity none Data bits 8 Xon 11 Xoff 13 End of Trans 03 A baud rate of 9600bps or 4800bps may also be used but at these baud rates there is a greater possibility of a data transmission failure If this occurs set the baud rate to 2400bps Binary Format PC form should be selected on the second to last line in the Special Functions column Also all the boxes to the left of each line in the Special Functions column should be clear Press the SAVE SETTING vertical soft key Verify communication parameter settings at external computer Check the settings at the external computer for sending data using the PCIN communications program The settings should not have changed since the last time it was set up If applicable the serial port must be set to bi directional in the BIOS The PCIN communications program is a DOS based program Therefore an RTS CTS error may occur if PCIN is being run in Microsoft Windows If an error occurs try turning off power management in Windows turning off the screen MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL saver and restarting the computer in DOS mode If an error still occurs consult your IT department for further assistance a b Start up the PCIN communications program Select V24 INI at the top of the screen Press ENTER to get the communications parameters box C h COM NUMBER should be set to 1 or 2 dep
139. l Install machine control panel CTR 0127 BES EERE CTR 0126 2 7 4 PCU 210 Install PCU 210 Op panel CTR 0126 2 7 5 Keyboard Install keyboard ELE 1094 2 7 6 Wiring Terminate all wiring and check for proper connections Connections Jan 2003 Control Components 2 7 Replacing Pendant Components 55 SIEMENS CONTROL Maintenance Manual 36 Control Components 2 7 Replacing Pendant Components Jan 2003 SIEMENS CONTROL Fada Maintenance Manual Section 03 Power On Procedure Alarms The Siemens control has an extensive alarm code series The alarms most likely to occur while performing power on and assembly procedures for the machine are listed For a complete listing of all alarms refer to the Siemens diagnostics manual 1000 Series Alarms The 1000 series alarms are an indication of a serious problem with the Siemens controller Overview of the system error alarms The following alarms are system errors 1000 1005 1015 1017 1001 1010 1014 1018 1002 1011 1015 1019 1003 1012 1016 1160 These system error alarms are not described in detail If such a system error occurs please contact your dealer or Fadal Machining Centers indicating the alarm number the alarm text and the appropriate internal system error number 2000 Series Alarms 2001 has not started up Explanation The PLC must give at least one sign of life within the time defined in the MD 10120 PLC RUNNI
140. m part of the NC memory of the NC has reached the maximum number possible Note During initial start up this can concern files from the NC file system e g drive data MMC files FIFO files NC programs Reaction Alarm display Remedy Power On Procedure Alarms 47 Fadal 48 6520 6530 6540 6550 SIEMENS CONTROL Maintenance Manual Delete or unload files e g part programs or e Increase MM NUM FILES IN FILESYSTEM Program Continuation Clear the alarm with the Delete key No further operator action necessary Too many protocol files in the NC memory Explanation The number of files in the file system part of the NC memory of the NC has reached the maximum limit Reaction Alarm display Remedy Run fewer log activities in the NC at the same time Program Continuation Clear the alarm with the Delete key No further operator action necessary Too many files in directory Explanation The number of files in one directory of the NCK has reached the maximum limit Reaction Alarm display Remedy e Delete or unload files e g part programs in the respective directory or e Increase MM_NUM_FILES_PER_DIR Program Continuation Clear the alarm with the Delete key No further operator action necessary Too many directories in the NC memory Explanation The number of directories in the file system of the NCK has reached the maximum limit Reaction Alarm display Remedy e
141. me Program Continuation Clear alarm with NC START and continue program Channel 901 block 902 tool radius compensation activated without tool no Explanation 001 Channel number 002 Block number label A tool T must be selected so that the control can make allowance for the associated compensation values A correction data block D1 containing the correction values parameter P1 P25 is automatically assigned to each tool T number Up to 9 correction data blocks can be assigned to a tool by specifying the required data block with the D number D1 D9 The cutter radius compensation CRC is allowed for if function G41 or G42 is programmed The correction values are contained in parameter P6 geometry value and P15 wear value of the active correction data block D x Power On Procedure Alarms 55 Fadal MMC 100 Messages 56 101000 101002 101151 SIEMENS CONTROL Maintenance Manual Reaction 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 under the address T Program Continuation Clear alarm with NC START and continue program The MMC100 has its own set of alarms messages The following are most likely to occur during power on and setting up the machine Alarms messages not listed can be found in the Siemens control manual MMC100 al
142. move 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 of falling out from the cabinet d Release the four 4 knurled bolts that are attached to the hard disk unit See Figure 26 e CAREFULLY swing the hard disk unit open until it rests flat from the hinge tabs CAUTION Hard disk unit hook hinges are not attached to the 105 module f Disconnect the ribbon cable connector Push the hook like tabs up until the connector releases See Figure 27 Remove the hard disk Figure 34 Ribbon cable is Bo 4 locked in place by the aa hook like tabs on the cable plug 12 Install New CAUTION Pre imaged ELECTROSTATIC SENSITIVE COMPONENTS are housed inside the MMC103 Hard Disk module Use grounding straps or discharge oneself before working inside module WARNING The following procedure replaces the machine s hard disk ALL OF THE EXISTING DATA ON THE HARD DRIVE WILL BE ERASED Get customer approval before performing this procedure SAVE ALL NC programs and machine data to a disk or another storage location Installation of the new pre imaged hard disk unit is basically the reverse of removal June 2002 MMC100 Software Update MMC103 Update Procedure 141 Fadal SIEMENS CONTROL a Insert the hinge tabs of the hard disk unit into the tw
143. mpf file is copied into the Shopmill folder the overlay box closes and the message Job is ready displays at the bottom of the screen k Highlight the Shopmill folder and press the 2 INPUT hard key The contents of the folder will display Find the file named GET_VALUE This is the getval_s mpf program Press Manage data soft key m Press Load vertical soft key This loads the get value program An X displays in the loaded column See Figure 15 E EA oat eit T ADAL SET_VALUES MPF Channel reset Subprograms 01 01 1900 Workpieces 11 09 2000 SHOPMILL 12 09 2000 BACKLASH 1732 11 03 2000 BALL BAR 301 11 09 2000 COMP VALUES 1412 11 09 2000 COMP VALUES X 2690 11 09 2000 COMP VALUES Y 2473 11 09 2000 COMP VALUES Z 2574 11 09 2000 DUAL ATC TEST f s N as 1109 2000 1399127097200 HEAD 5 47 195 11 09 2000 LASER 744 11 09 2000 LASER X 790 11 09 2000 LASER Y 790 11 09 2000 LASER Z 970 11 08 2000 Free memory Hard 1 713 89 472 WCU 140 044 mady Piogtame Clip Log dala board Figure 23 An X in the loaded column indicates SET_VALUES program is loaded Ley e 05 85 850 DEEDS 118 100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL n Press Menu Select hard key o Press Program soft key p Highlight the Shopmill folder and press the 2 INPUT ha
144. n If F3 is pressed further the cycle repeats Enabling button back of the unit Electrically connected in parallel to the override button in the machine control panel it allows to move the axes with the doors open Emergency stop Connected in series with the E stop circuit in the machine Stops the machine in case of an emergency Overview Jan 2003 SIEMENS CONTROL Fa d a Maintenance Manual Section 02 Control Components 2 1 Replacement of Modules 2 1 1 Reactor and Line Module Replacement Part Numbers ELE 1084 Reactor Siemens 16KW ELE 1085 Line Filter for I R ELE 1086 I R Module 16KW 6 sheet metal parts Tools Required Torx driver set Flat Tip Screwdriver Nut Driver NOTE To remove components for repair or replacement follow the assembiv instructions as necessarv in reverse order until the component has been disassembled to required level to conduct the repair Jan 2003 Control Components 2 1 Replacement of Modules 13 SIEMENS CONTROL Fadal Maintenance Manual 1 Attach the Reactor Module ELE 1084 to the back plate ELE 1086 one of six parts with four M6 flathead torx screws flat and lock washers and nuts 2 Attach the upper ventilation grid to the upper portion of the back plate with two M6 flathead torx screws 14 Control Components 2 1 Replacement of Modules Jan 2005 SIEMENS CONTROL Fa da Maintenance Manual 3 Pull apart the output term
145. n the MPG panel 15 Jog the selected axis to its cold start alignment mark The value shown on the screen display is the distance between the electronic zero value and the mechanical value cold start position 14 Load the SET OFFSETS programs Press the PROGRAM MANAGER hard key For MMC103 First press the Menu select hard key then press the Program Manager soft key 15 Select SET OFFSETS in the directory 16 Press the EXECUTE soft key The program is loaded and ready to run 17 Press the CYCLE START hard key Wait until the program is done 18 Power the machine off and back on 19 Reference each axis see steps 7 8 9 and 10 and check for proper cold start position NOTE If only one axis needs re alignment then work only on that particular axis Leave the other axes at their cold start positions throughout the whole procedure The cold start position can then be fine tuned for a particular position like the Z axis alignment for tool changes 5 2 Spindle Belt Fadal machines are built with spindles that are belt driven The spindle belts are manufactured to specified tolerances but they are not always perfect They can be manufactured either a little shorter or a little longer than specifications To compensate for this the M85 program is needed The M83 program is designed to measure the spindle belt and enter the appropriate values in the corresponding machine data The values are used to establish the pr
146. n the program is running the status of the program is displayed at the very top of the display screen MMC100 Software Update MMC103 Update Procedure June 2002 Fadal June 2002 NOTE SIEMENS CONTROL m Repeat steps e through k for all the configured axes Kusall Press Machine hard kev Press MDA hard kev Tvpe M83 and press 2 INPUT hard key 2 o m q 2 and press 2 INPUT hard key r Press E CYCLE START hard key Wait for the control to display the alarm 510300 POWER ON needed to set spindle setup Power the machine off and back on M83 displays the value in degrees of the measurement just performed M83 should be run as many times as necessary until the value displayed is the same twice one degree s Reference the axes The MMC103 is in SHOPMILL after power on IF REQUIRED manually jog each axis to its alignment mark Press MPG hard key Wait for LED above the key to illuminate Select an axis with the axis selector switch Align the selected axis to its mark by using the handwheel Repeat steps 2 and 5 for all the axes 5 Press JOG hard key when done Reference the axes ew 1 Press Machine hard key 2 Select an axis with the axis selector switch 3 Press REF POINT hard key 4 Press plus hard key 5 Repeat steps 2 3 and 4 for all the axes The axes are referenced when the crosshair symbol 45 displays to the left of each axis MMC
147. ng the soft key located on the upper right portion of the screen choose A1 using the blue arrows go to 34090 MOVE DIST 0 type in data then go to 54090 REFP MOVE DIST 1 and type in data using the soft key located on the upper right portion of the screen choose B1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 REFP MOVE DIST 1 and type in data Repeat the process for the Backlash amount X1 32450 BACKLASH 0 type in data X1 32450 BACKLASH 1 type in data Y1 32450 BACKLASHIOJI type in data 1 32450 BACKLASH 1 type in data Z1 52450 BACKLASH 0 type in data Z1 52450 BACKLASH 1 type in data MMC100 Software Update MMC100 Update Procedure June 2002 Fadal June 2002 SIEMENS CONTROL A1 32450 BACKLASH 0 type in data A1 32450 BACKLASH 1 type in data B1 32450 BACKLASHIO type in data B1 32450 BACKLASHILI type in data Repeating the process record the Gain and Band width amount Press the FDD soft key X1 1210 X1 1211 X1 1212 X1 1407 0 Y11210 Y11211 Y11212 Y1 1407 0 711210 Z1 1211 Z1 1212 Z1 1407 0 A1 1210 A1 1211 A1 1212 A1 1407 0 B1 1210 B1 1211 B1 1212 B1 1407 0 1 Press the BOOT FILE vertical soft key 2 Press the SAVE BOOT FILE vertical soft key MMC100 Software Update MMC100 Update Procedure 109 Fadal 5 SIEMENS CONTROL Press the SAVE ALL vertical soft key
148. nt the program from running properly Press the Page down hard key to get to the table 106 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL 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 Press the SHIFT and SYSTEM ALARM hard keys simultaneously Press the Program soft key Select Shopmill and press the 2 INPUT hard key Select SET VALUES and press the Program selection soft key Press the Auto hard key Press the a CVCLE START hard kev A message should displav near the top of screen displav The message identifies the zero offset or backlash data that has been entered Press the E CYCLE START hard key repeatedly until all the zero offset and backlash data has been entered for all the configured axes Delete the SET_VALUES program when all axis offset and backlash data has been entered Select the SET_VALUES program Press the DELETE soft key Press the OK soft key Restore Tool and Magazine Data Restore Work Offset Data Send back files created in Step 7 Back Up Other Data Record turret number It is located above the pocket ready for tool exchange Restore Magazine Count 1 Go to ISO Press the SHIFT and SYSTEM keys at the same time Press the DIAGNOSTICS soft key Press the PLC soft key Ty
149. o 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 BECAREFUL NOT TO BEND ANY OF THE CONNECTOR PINS ON THE PLUG Make sure the hook like tabs snap over the connector to lock it in place The ribbon cable must be flat without any twists in it c Swing the hard disk unit up to close it d Tighten the four 4 knurled bolts with fingers e Remount the floppy disk drive f Disengage the transport safety detent Grasp the black knob See Figure 28 Turn it 180 degrees counter clockwise until the mark on the knob aligns with the mark labeled operating on the yellow placard The transport safety detent is properly engaged when the knob snaps to a stop g POWER THE MACHINE ON x Figure 35 The transport safety detent shown in the disengaged position The mark on the knob should align with the mark on the yellow placard 13 Display HMI The MMC103 has the software pre installed Firmware a Power ON b Press ENTER to bypass password Wait this may take 5 minutes to boot up c Press MENU SELECT d Press ISO soft key e Press CNC ISO soft key f Wait as machine changes over to service side ISO g Press MENU SELECT h Press START UP i Press PASSWORD j Press SET PASSWORD 142 MMC100 Software Update MMC103 Update Procedure June 2002 Fadal k SIEMENS CONTROL Hold the SHIFT button and typ
150. oaded with the Windows 98 operating system setting a baud rate above 2400bps can cause a data transmission failure In either case if a transmission failure were to occur use a baud rate to 2400bps Binary Format PC form should be selected on the second to last line in the Special Functions column Also all the boxes to the left of each line in the Special Functions column should be clear k Press the SAVE SETTING vertical soft key Set up Communication Parameters at External Computer Set up the external computer for sending data using the PCIN communications program If applicable the serial port must be set to bi directional in the BIOS NOTE The PCIN communications program is a DOS based program Therefore an RTS CTS error may occur if PCIN is being run in Microsoft Windows If an error occurs try turning off power management in Windows turning off the screen saver and restarting the computer in DOS mode If an error still occurs consult your IT department for further assistance a Start up the PCIN communications program b Select V24_INI at the top of the screen see Figure 3 Press ENTER to get the communications parameters box June 2002 MMC100 Software Update MMC100 Update Procedure 105 Fadal TO SIEMENS CONTROL 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 ar
151. ols used on the VMC are stored in a tool tray when not being used Under most circumstances they pose no threat to operator or maintenance personnel It is possible for personnel to come into contact with stationary cutting tools during job setup or when replacing cutting tools for any reason Extreme care must be taken to avoid coming into contact with the sharp edges on cutting tools Rotating cutting tools used by the VMC create potential hazards of entanglement A cutting hazard is also possible if the operator comes into contact with rotating cutting tools The Polycarbonate shield is equipped with an interlock to prevent the VMC from operating when the shield is opened Under no circumstances should operators disable or remove the interlocks If the interlock is not functioning properly qualified maintenance personnel should be notified and the VMC must not be used until it is functioning properly Prior to starting any job the operator on the VMC should inspect all of the cutting tools being used to ensure they are in good condition and free of defects such as cracks The operator should also insure that only the appropriate cutting tools for the material being machined are present Using the wrong tool or using a damaged tool could result in the failure of the tool or material being machined Failure of either could lead to pieces of either the tool or the material being ejected at extremely high speed Ejection of either could lead to se
152. ontrol tasks Overview Jan 2003 Fadal 1 3 2 CCU Interface Panel Jan 2003 SIEMENS CONTROL Maintenance Manual The NCK is a computer that decodes ba the part program and sends the commands to the appropriate drives FI The drives can be internal to the d 810D or external The drives take the commands and position the axes ud 1 accordingly A UI re 0 1 npe s e isa le Z G loce Figure 1 3 The two major components make up the 810D They are the CCU box and the CCU module The PLC is also a computer It is an open ended sequential logic programmable computerized controller The main characteristic of the PLC is the flexible set of inputs and outputs that can be programmed to search for incoming signals and respond with outputs based on logical conditions preset by the machine tool manufacturer The PLC is needed to control the rest of the machine coordination with the NCK For example the PLC can be programmed to send a signal to the NCK to stop program execution in case the hydraulics are not on The PLC also controls equipment such as coolant pumps pallet changer and work lights In the operation of the work light for example pressing the work light button sends a signal to a preset input in the PLC The program inside then takes that signal and compares the state against a logical statement something like if work light button
153. oper relationship between the motor pulley and the spindle pulley In order to obtain the best values possible the M83 program should be run a minimum of two times powering the machine off each time The reason this is done twice is because the new belt and the values may need to be changed more than once to obtain the proper relationship Every pulse in the encoder of the motor represents an allowable amount of movement of the spindle When a belt is new the exact relationship of how much a single encoder pulse represents in spindle movement has not been established yet Compensation 5 2 Spindle Belt Jan 2003 Fadal 5 2 2 M84 Program 5 3 1 COMP VALUES n Jan 2003 SIEMENS CONTROL Maintenance Manual M83 measures the relationship between the motor and the spindle by counting the number of pulses it takes for one revolution of the spindle This creates a guideline for the correct numbers needed The following steps describe how to use the M83 program 20 Press the Joc 21 Press the 5 soft key 22 Enter 85 in the OTHER M FCT field 23 Press the INPUT hard kev 24 Press the CYCLE START hard key 25 Wait for the power off message from the program 26 Power the machine off and back on M84 is the complement to M83 While the M83 establishes the parameters for the spindle motor relationship the M84 program fine tunes that relationship The following steps describe how to use th
154. orces braking 3 Reference point approach has not been performed yet 4 An incorrect operating mode has been selected AUTOMATIC only Execute condition for deleting alarm Reference point approach Select program operating mode 29 Start continuation of program 1 Program state active gt processing VDI signal NC Start 2 An alarm reaction is pending it Execute condition for deleting prevents a start or forces braking alarm 3 Reference point approach has Reference point approach not been performed yet 30 Start continuation of the selected 1 og motion active gt processing J OG reference point 2 An alarm reaction is pending it Execute condition for deleting or digitizing VDI signal NC Start prevents a start or forces braking alarm 31 Start processing in the submode 1 J og motion active gt digitizing VDI signal NC Start 2 An alarm reaction is pending it Execute condition for deleting prevents a start or forces braking alarm 3 Reference point approach has Reference point approach not been performed yet 32 Stop all axes signal Stop or via Reset key 33 Performa program stop NC block MO 34 Stop OG motion VDI signal NC Stop 35 Stop digitizing processing VDI signal NC Stop 36 Start the selected processing VDI 1 Process change active operating gt signal NC Start mode chan
155. ore PI command Deactivate overstore PI command 10 Synchronize preprocessing and main run e g on activation of axis control VDI signal follow up mode 66 ActionList J an 2003 Fadal SIEMENS CONTROL Maintenance Manual No Explanation Not allowed if Remedy 11 Perform user interrupt 1 The channel is active due to Wait until the block search or Asynchronous subroutine VDI block search or loading machine jloading machine data is completed signal digital analog interface data or abort program by activating the synchronous subroutine interface Reset key 2 The channel is stopped and the Activate a block change until the asynchronous subroutine NC block has been reorganized ASUP START MASK must be started and the current block cannot be reorganized Deactivate digitizing 3 Digitizing has been selected Perform reference point 4 Reference point approach has approach or ignore this state via not been performed yet the machine data ASUP START MASK Abort program 5 The active block after which deceleration takes place cannot be reorganized occurs when deceleration takes place over several blocks 12 Perform user interrupt ASUP with See 11 rapid retraction VDI signal digital analog interface 13 Perform user interrupt at block end See 11 VDI signal digital analog interface 14 Perform rapid retraction VDI sign
156. osition REACTION Display alarm Axis movement disable Program interrupted Power On Procedure Alarms 63 Fadal 64 510124 510125 510126M5 510127ATC SIEMENS CONTROL Maintenance Manual REMEDY 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 part program Contact Service ATC Active DEFINITION Automatic Tool Changer in movement REACTION Display alarm Axis movement disable Spindle rotation disable REMEDY Normal during tool change Check ATC mechanism if displayed outside tool change PROGRAM CONTINUATION Clear alarm with Reset key Restart part program Contact Service Gear Change In Progress DEFINITION Spindle is undergoing a gear change REACTION Display alarm Program interrupted Spindle rotation disable REMEDY Normal during spindle speed range change Check belt actuators and or sensors Contact Service PROGRAM CONTINUATION Alarm must clear after a few seconds Power machine off and on Contact Service In Progress DEFINITION Spindle stop command in progress REACTION Display alarm Spindle rotation stopped REMEDY Normal during spindle stop PROGRAM CONTINUATION Alarm must clear once spindle stops Contact Service Motor Failure DEFINITION Automatic Tool Changer failure Tool changer board failure Geneva type only Magazine failed to rotate REACTIO
157. osition control operation the motors take in current or voltage for example 0 to 30 amps or 0 to 100 volts to run at a certain speed and for a certain length of time in order to motion to a preset point In a digital control currents and voltages in control loop generated in digital form by a digital encoder for example a series of ones and zeroes or a series of 0 volt and 45 volt signals Motor current consumption 15 converted into numbers at a very early stage in the control loop These numbers are then input into a computer which in turn takes these numbers and manipulates them perform calculations with them or filters them to obtain an output The output is the instructions that tell the machine what to do Figure 1 1 The 810D digital drive converter system A digital control has several advantages over an analog control For instance it is more accurate It only needs to sense the difference between two clearly distinguishable states For example a slight voltage fluctuation would affect the result in an analog control but a slight voltage fluctuation would not affect a digital control because the control could still easily distinguish the 0 state from the 1 state of any circuit element Other advantages include the ability to share data more easily with other devices in the control digital data is less prone to noise and digital signal processing can be used to filter the data
158. otection is attained compliance with CE standards is required Consult a qualified industrial hygienist or safety engineer to insure adequate protection prior to operating the VMC Continuous equivalent A weighted sound pressure at workstation is 77dB A or less when tested according to Annex D of prEN 12417 The figures quoted are emission levels and are not necessarily safe working levels While there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required Factors that influence the actual level of exposure of the workforce include characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent processes Also the permissible exposure level can vary from country to country This information however will enable the user of the machine to make a better evaluation of the hazard and risk SS 10 May 2002 Fadal COMPRESSED AIR CE COMPLIANCE May 2002 SAFETY SECTION 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 ejected at high speed Operators and maintenance personnel must always wear eye protection that meets OSHA standards and ANSI standard 487 1 or CE standards when working on systems that use compressed air The ope
159. oximately 15 minutes The job is ready message will display at the bottom of the screen when the backup is complete During the backup process several ERROR messages will display Ignore these messages The total file size should be 800Kb or larger If file size is smaller than 870Kb then this procedure must be repeated To verify the file size perform the following steps a Press Menu Select hard key June 2002 MMC100 Software Update MMC103 Update Procedure 121 Fadal 122 SIEMENS CONTROL 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 Data and Gain Settings a Press MENU SELECT hard key b Select START UP soft key c Wait for Startup screen to load d Press Machine data e Press Axis specific f Go to machine data for each axis and record the following using the soft key located on the upper right portion of the screen choose X1 using the blue arrows goto 54090 REFP MOVE DIST 0 Record this data 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 using the soft key located on the upper right portion of the screen choose Y1 using the blue arrows go to 54090 MOVE DIST 0 record this data here 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 using the soft key located on the upper right portion of the sc
160. parameters for communications Interface COM1 Protocol RTS CTS Baud Rate 2400 baud See note below Stop Bits 1 Parity none Data bits 8 Xon 11 Xoff 13 End of Trans 03 June 2002 MMC100 Software Update MMC100 Update Procedure 111 Fadal SIEMENS CONTROL NOTE On external computers loaded with either the Windows 95 or Windows NT 4 0 operating system a baud rate of 4800bps or higher may also be used On external computers loaded with the Windows 98 operating system setting a baud rate above 2400bps can cause a data transmission failure In either case if a transmission failure were to occur use a baud rate to 2400bps Binary Format PC form should be selected on the second to last line k in the Special Functions column Also all the boxes to the left of each line in the Special Functions column should be clear Press the SAVE SETTING vertical soft key Setup the communication parameters on the external computer a b Eu pum Start up the PCIN communications program Select V24 INI at the top of the screen and press ENTER to get the communications parameters box 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 proper COM port setting Set XON XOFF parameter to OFF Use the arrow keys to navigate to the XON XOFF SET line Us
161. pdate MUST BE INSTALLED FIRST Check to see is the VMC has a PCB 0230 1550 04 board If not complete this procedure If the VMC is equipped with Servo Turret ATC or Geneva ATC either 21 or 50 tools then do not perform this procedure It is only intended for the Dual Arm Automatic Tool Changer General Information Check the existing Siemens hardware before proceeding with this update Compare the hardware to WRG 0002 REV F see Appendix A If the ports and cables are found to be a different configuration then order the replacement part s and install prior to proceeding with this update Tools Required The components required are as follows PCB 0230 PCB DATC CONTROLLER SIEMENS 1330 includes PLC Chip for 1330 card must be Siemens Version 2 02 Cable 2010 1 J3 to 1100 1 J3 Figure 36 PCB 0230 and 2010 1 J3 to 1100 1 J3 Cable For information on Cable setup see the wiring diagram at the end of this manual 1 Replace Hardware a Turn the main power off for DATC b Replace existing 1330 0A DATC Controller with new PCB 0230 1330 OA Make sure that the PLC Chip is Siemens Version 2 02 c If necessary attach Cable 2010 1 J3 to 1100 1 J3 If the cable is missing and if a single wire currently exists at 1100 1 J3 connecting to 1980 0 or 2000 0 or 2030 0 board then cut the connector off of the existing wire insert it into a new cable at the butt splice on the red wire and crimp Then install the new cable
162. pe C5 in the first column ant ono A CN N Press E STOP Press the INPUT key The cursor will jump to the second column D Press the INPUT key 10 Type DB92 DBWO 11 Press the INPUT key 12 Type D June 2002 MMC100 Software Update MMC100 Update Procedure 107 Fadal 108 SIEMENS CONTROL 15 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 DBWO 16 Press the ACCEPT vertical soft key 17 Release the E STOP button and press RESET Restore Gain Settings a Press Menu Select hard key b Select Start up soft key c Wait for Startup screen to load d Press Machine data e Press Axis specific f go to the following machine data and type in the data from step 5 using the soft key located on the upper right portion of the screen choose X1 using the blue arrows go to 54090 MOVE DIST 0 type in data then go to 54090 REFP MOVE DIST 1 and type in data using the soft key located on the upper right portion of the screen choose Y1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 MOVE DIST 1 and type in data using the soft key located on the upper right portion of the screen choose Z1 using the blue arrows go to 54090 REFP MOVE DIST 0 type in data then go to 54090 MOVE DIST 1 and type in data usi
163. pecified slot has signaled a diagnostics alarm The error code reported corresponds to the AS300 documentation Reaction Alarm display Interface signals are set NC not ready Power On Procedure Alarms Jan 2003 Fadal 6000 Series Alarm Jan 2003 6020 6500 6510 SIEMENS CONTROL Maintenance Manual Mode group not ready NC Start disable NC Stop when alarm Remedy Check hardware Program Continuation Switch control OFF ON Machine data have been altered now memory is reorganized Explanation Machine data have been changed that define the NC user memory allocation Data management has restructured the memory in accordance with the altered machine data Reaction Alarm display Remedy No remedial measures are required Any user data that are required must be input again Program Continuation Clear alarm with the RESET key Restart part program NC memory is full Explanation The file system part of the NC memory of the NC is full The job cannot be executed e g too many part programs loaded Note During initial start up this can concern files from the NC file system e g drive data MMC files FIFO files NC programs Reaction Alarm display Remedy Delete or unload files e g part programs Program Continuation Clear the alarm with the Delete key No further operator action necessary Too many files in the NC memory Explanation The number of files in the file syste
164. r entering verifying this number run the TC_BASE program and the number of tools will be created in the tool table 166 Siemens 50 Taper Jan 2003 SIEMENS CONTROL Fada Maintenance Manual 4 There is a safety cage around the rear control for manually placing tools into the turret Once this cage is unlocked using a key the front pendant will be inoperable for moving the turret cw or ccw A message will be displayed that the rear tool cage is open The override switch does not have a separate input It is wired directly into the slide hold control There are three new inputs added for this operation refer to WRG 0002H 165 1 Turret CW 165 2 Turret CCW 165 5 Rear Tool Changer Gate CWICCW buttons go to 165 1 and 165 2 This switch goes to 165 3 Jan 2003 Siemens 50 Taper 167 Fadal 168 Alarm 700043 SIEMENS CONTROL Maintenance Manual 5 A revised PLC program labeled Fadal G2 version 2 01 A7 takes into account the new 1 0 and the alarm message The alarm text cause and solution are described below Rear Tool Changer Gate Open DEFINITION The rear tool changer gate is unlocked and is open REACTION Display alarm Pendant turret cw ccw is inoperable Remote turret cw ccw control is operable Axes movement is disabled REMEDY Close the rear tool changer gate and lock with key PROGRAM CONTINUATION Clear alarm with Reset key Restart part program 6 There is a
165. r is If the numbers are different press the Change vertical SK in the right the number of the pocket in the tool change position in the third column Value Enter the same number for BOTH rows Press the Accept vertical SK Both C5 and DB92 DBWO must show the same number This number must be the same as the one for the turret pocket in the tool change position Get out of E Stop and test the tool magazine with the following MDA program T4 G4F2 M02 Where is the name of the tool contained in the turret pocket you want to call to the tool change position The turret must rotate to bring the pocket in question to the tool change position and stop Troubleshooting Jan 2003
166. r one channel or the other Program Continuation Switch control OFF ON Channel 901 machine data 2 3 assigns axis not defined in channel Explanation 901 Channel number 902 String Machine data identifier 005 Index Machine data array index Only axes that have been activated in the channel by means of the channel specific machine data 20 070 AXCONF MACHAX USED k may be declared geometry axes by means of the MD 20050 GEOAX ASSIGN TAB g x k g x Geometry axis index k Channel axis no k x Channel axis index m Machine axis no Program continuation AXCONF GEOAX ASSIGN TAB AXCONF MACHAX USED includes channel axis no k includes channel axis no m Geometry axis 1st 2nd Channel axis 1st 2nd index channel channel index channel channel 0 1 1 0 1 4 1 2 0 1 2 5 2 5 5 2 3 6 3 7 0 4 8 0 5 0 0 6 0 0 7 0 0 Assignment of geometry axes to channel axes Reaction Alarm display Interface signals are set Mode group not ready Power On Procedure Alarms 45 Fadal 44 4005 4060 SIEMENS CONTROL Maintenance Manual Channel not ready NC Start disable NC Stop when alarm Remedy Check and correct machine data 20050 ASSIGN TAB and 20 070 USED The basis is the MD array MACHAX USED in which the machine axis number is entered that is to controlled from a specific
167. r steps A buffer capacitor on the NCK holds the supply voltage for at least 50 minutes and the battery can be replaced within this time even when the control is switched off Program Continuation Clear the alarm with the Delete key No further operator action necessary NCK battery alarm Explanation The undervoltage monitoring 2 4 2 6 V of the NCK battery was detected during system power up Reaction Alarm display Interface signals are set NC not ready Mode group not ready NC Start disable NC Stop when alarm The NC switches to follow up mode Power On Procedure Alarms Jan 2003 SIEMENS CONTROL Fada Maintenance Manual Remedy Pull out the battery fan unit from the NC module and replace the battery type lithium battery with lead size 1 2 AA 850 mAh min 5 2 V The system must then be reinitialized because it must be assumed that data has been lost in the buffered RAM during the last power off phase as a result of insufficient supply voltage refer to section in the Installation and Start up Guide for the procedure The following data might have been corrupted or entirely lost e NC machine data e Drive machine data e Operator panel machine data e Option data e Setting data e User variable e Global subroutines e Cvcles and macros as well as e PLC machine data e PLC basic program e PLC user program and all e PLC user data User data in the NCK and PLC that had been altered since
168. rator may also use their shop s compressed air to remove debris from material being machined If shop air is used for this purpose it must be done in accordance with OSHA or CE standards Alternative means of debris removal such as debris rakes should be considered UNDER NO CIRCUMSTANCES SHOULD THE OPERATOR ATTEMPT TO REMOVE DEBRIS WHILE THE VMC IS RUNNING Consult a qualified industrial hygienist or safety engineer to insure debris removal is accomplished in a safe manner and in a manner that complies with local state national Federal and international regulations SS 11 Safety Section Fadal SAFETY SECTION ADDITIONALSAFETY Compliance with the following safety practices is required to safely operate the PRECAUTIONS VMC 1 10 11 Safety Section Never work alone on live electrical circuits Another person qualified to turn off power to the VMC must be present when voltage is 600 or over That person must also know CPR cardiopulmonary resuscitation and company emergency procedures Never wear jewelry or loose fitting clothing while working on the VMC Long hair should be secured and under a cap Wear eye protection when operating or maintaining this machine Never operate this machine without all guards safety shields and inter locks in place and functioning properly Report any unsafe conditions to the supervisor immediately Do not operate this machine until the unsafe condition has been resolved If the op
169. rd key The contents of the Shopmill folder displays q Highlight the GET VALUES file r Pressthe Select vertical soft key s Press auto hard key t Press Cycle start hard key green u Write down on paper the information and data that displays near the top part of the display screen See Figure 16 This is the zero offset and backlash data for the machine pom 19 VALUES MPF Channel interrupt Stop MO MT active ROV ROV 0 9 05 OFFSET IS 0 DlTfhnch Type Loaded Length Dale Enable 12 03 2000 1732 11 09 2000 301 11 09 2000 1412 11 09 2000 2690 11 09 2000 2473 11 09 2000 2674 11 09 2000 419 11 09 2000 138511270922000 195 11 09 2000 744 11 09 2000 798 11 09 2000 798 11 09 2000 Mai pro 978 11 09 2000 663 11 09 2000 11519 11 09 2000 E Free memory Hard disk 1 713 897 472 NCU 148 044 B Figure 24 Record the axis data for zero offsets and backlash when the data displays at the top of the screen v Repeat steps t and u for all the available axes No more data displays when all the axes have been checked w Press Manage programs vertical soft key x Highlight the GET VALUES file y Press Delete soft key This deletes the GET VALUES file This file is a utilities program used specifically for getting the machine data for this software update Therefore it should not be left in the system
170. red and a standard machine data set is loaded into memory The 5V SF and PR LEDs are illuminated The 7 segment display shows a 6 See Figure 18 NOTE Read the following steps thoroughly before performing the procedure This will reduce the frequency in having to repeat these steps when not done correctly The following procedure resets the PLC The overall switching sequence for switch 54 is 2 3 2 3 0 as follows p Set switch S4 to position 2 PLC stop LED labeled PS lights up Set switch S4 to position 5 MRES LED labeled PS turns off Wait for LED labeled PS to light up again Set switch S4 to position 2 and then back to position 5 within three seconds LED labeled PS will illuminate Wait for LED labeled PS to light up Return S4 to position 0 PLC run The green LED labeled PR will start flashing and then solid The machine is now running the new NC operating system and the old NC PLC data has been erased The PLC reset is successful if the pendant displays Stop No NC ready in the message box at the upper left area of the screen 7 Restore NCK This step loads the original arc files from the NC card into the NCK These files are standard for all machines Original arc contains updated cycle files GUDs PLC files and machine data 2 c Power the machine off and back on The error message 14011 Channel 1 block program does not exist or is not releas
171. reen choose Z1 using the blue arrows go to 54090 MOVE DIST 0 record this data here 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 using the soft key located on the upper right portion of the screen choose A1 using the blue arrows go to 54090 REFP MOVE DIST 0 record this data here MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL 4090 MOVE DIST 0 34090 REFP MOVE DIST 1 using the soft key located on the upper right portion of the screen choose B1 using the blue arrows go to 54090 MOVE DIST 0 record this data here 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 Repeating the process record the Backlash amount For X1 52450 BACKLASH O For X1 52450 BACKLASH 1 For Y1 52450 BACKLASH O For Y1 52450 BACKLASH 1 For Z1 32450 BACKLASH 0 For Z1 32450 BACKLASH 1 For A1 32450 BACKLASH 0 For A1 32450 BACKLASH 1 For B1 532450 BACKLASH 0 For B1 532450 BACKLASH 1 Repeating the process record the Gain and Band width amount 1 Press the DRIVE MD soft key 2 Goto X1 1210 X1 1211 X1 1212 X1 1407 0 Y1 1210 Y11211 June 2002 100 Software Update MMC103 Update Procedure 125 Fadal 6 Install New NC Software 124 SIEMENS CONTROL Y1 1212 Y1 1407 0 21 1210 21 1211 Z1 1212 Z1 1407 0 A
172. rious injury or death to personnel in the vicinity Major equipment damage could also be sustained SS 9 Safety Section Fadal NOISE NOISE CE COMPLIANCE Safety Section SAFETY SECTION Exposure 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 prevent loss of hearing from the noise of an operating VMC hearing protection must always be worn by personnel exposed to noise above 90 decibels or above The level of protection required may vary because of variation in the amount of noise being produced by the VMC To insure adequate hearing protection is attained compliance with OSHA standards is required Consult a qualified industrial hygienist or safety engineer to insure adequate protection prior to operating the VMC Exposure to occupational hazardous noise or prolonged exposure to noise above 85 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 prevent loss of hearing from the noise of an operating VMC hearing protection must always be worn by personnel exposed to noise above 85 decibels or above The level of protection required may vary because of variation in the amount of noise being produced by the VMC To insure adequate hearing pr
173. row keys to select the proper COM port setting Set XON XOFF parameter to OFF Use the arrow keys to navigate to the XON XOFF SET line Use the arrow keys to select ON or OFF setting in the box that displays Set EXT to ON Press ENTER Select yes in the SAVE INPUT Y N box that displays Select DATA OUT at the top of the screen Press ENTER Set Zero Offset and Backlash Data Restoring zero offsets and backlash for each axis is done with the SET VALUES program This program needs to be uploaded from the Utilities diskette to the control At that point the program will be used to automatically restore the original zero offset and backlash data Insert the Utilities diskette into floppy drive of the computer in the Filename box and press ENTER The contents of the Utilities diskette displays in the a directory box Select the setval s mpf file Press the ENTER key At the pendant press the START soft key Press the OK soft key The Transmission in Progress window displays Press the OK soft key to upload the file The Transmission in progress window closes when the data transfer is complete Select Shopmill Press the 2 INPUT hard key Select SET_VALUES Press the 2 INPUT hard key This opens the editor window for the SET_VALUES program CAUTION When working in this editor window be careful not to alter any data other than the data in the table Altering any other data may preve
174. rrupt See 11 asynchronous subroutine Is only performed in READY channel status VDI signal synchronous subroutine interface digital analog interface 90 Perform user interrupt See 11 Asynchronous subroutine VDI signal synchronous subroutine interface digital analog interface Further actions are 11 12 13 88 89 91 Stop processing VDI signal mode group Stop 92 Set all machine data with the attribute NEW_CONF active NC block NEW_CONF 93 Set all machine data with the attribute NEW_CONF active NC block NEW_CONF at block search J an 2003 Action List 73 SIEMENS CONTROL Fadal Maintenance Manual No Explanation Not allowed if Remedy 94 Start continuation of interpreter processing internal preprocessing stop 74 Action List J an 2003 SIEMENS CONTROL Fada Maintenance Manual Section 05 Compensation 5 1 Cold Start Position 5 1 1 SET OFFSETS The SET OFFSETS program allows the user to align the machine to its proper cold start position Every time the control is referenced to the cold start position it looks for the one pulse per revolution signal emitted from the encoder To do this the motor is turned in a given direction until the encoder emits this signal This is the electronic zero position Because the rotor position can vary in relation to the machine the electronic zero and mechanical zero
175. run again remove any tool from the spindle and call a tool Enter tool data as needed Jan 2003 Compensation 5 4 Reset Tool Magazine 81 Fadal 82 Compensation 5 4 Reset Tool Magazine SIEMENS CONTROL Maintenance Manual Jan 2003 Fadal SIEMENS CONTROL Section 06 MMC100 Software Update IMPORTANT June 2002 NOTE If the VMC is equipped with a DATC please see page 55 You must install the appropriate software and hardware for DATC General Information Before performing this software update READ THROUGH THE PROCEDURE AT LEAST ONE TIME COMPLETELY This will ensure a more effective error free update Also verify the configuration of the Siemens control using WRG 0002 REV F See the wiring diagram at the end of this document If the configuration does not match what is on your Siemens control DO NOT PROCEED WITH THIS UPDATE UNTIL THE MACHINE IS CONFIGURED CORRECTLY It is important that a COMPLETE BACK UP is made of the current machine data before performing software update If an error is made in the software update of the machine data the back up file can be used to restore the system to its original configuration Part number information for the Software Update Kit and its components can be found in Appendix B of this manual List of Components PCcard containing original arc file and hmi abb operating system NC card containing original arc file and nck abb operating s
176. s displayed in the alarms and messages line may not be the primary cause of the trouble For a listing of the most common alarms messages and their respective explanations and remedies see the Power On Procedure section In the event you get an alarm that is not listed or if you need more information call your service center for help Jan 2003 Troubleshooting 169 SIEMENS CONTROL Fa dal Maintenance Manual 9 4 The Central There are three indicators located on the CCU front panel There are two Control Unit CCU columns of individual LEDs and a seven segment LED display Front Panel Green 5V Lights when the supply voltage is in the tolerance range LEDs Red NF Lights when the NCK or PLC watchdog has operated left Red SF Lights in case of drive faults Goes out when the system has run up and column is operating properly Yellow CB Lights when data is being transmitted via the interface Green PR PLC RUN state LEDs Red PS PLC STOP state right Red PF Lights in an event of PLC fault column Yellow PFO PLC FORCE state Yellow Not used lights briefly on reset H3 7 segment Software supported output of test and diagnostic signals The left column of LEDs is for the NCK functions The right column of LEDs is for the PLC The seven segment display is for general purposes The normal state for these LEDs is as follows The 5VDC and PR LEDs green are on The CB LED left column
177. s the system software that resides disk The pre imaged hard drive on an NC card PCMCIA CD Mi e one in the The pre imaged hard drive replaces the existing hard drive on the MMC103 module The pre imaged hard drive contains software tools that are used to restore the machine June 2002 MMC100 Software Update MMC103 Software Update v1 7 2 or above 115 Fadal 1 Preparation for Software Update 2 Power 116 SIEMENS CONTROL Tools Required 105 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 program supplied by Fadal installed on the external computer 9 to 9 pin RTS CTS 5 wire null modem serial communications cable MMC103 Update Procedure The overview of this update procedure is as follows 1 Save tool data zero offsets and backlash 2 Back up existing original machine data 3 Install new NC operating system 4 Reset PLC 5 Load new original arc file from flashcard 6 Restore machine to its operational state 7 Reload customer data 8 Edit and run Options program 9 Enter and run compensation values for all axes 10 Replace old hard disk drive unit with new pre imaged hard disk drive unit 11 Create backup of new machine data One backup will be copied to the Archive folder The other backup will be copied onto a 3 5 in
178. s will open the SET VALUES program in an editor window CAUTION When working in this editor window be careful not to alter any data other than the data in the table Altering any other data may prevent the program from running properly m Pagedown to the table See Figure 20 O DW 5 Ed IWKS DIRASHOPMILL WPDXET VALUES MPF DEF STRING 4J _UNITS4 BhF 5 0 0100 4 _YOFFSET 0 02004 eU FFSET 0 03004 _ 0 04004 _BOFFSET 0 05004 _SBACKLASH 0 00014 _YBACKLASH 0 00024 _ZBACKLASH 6 00034 ABACKLASH 0 00044 BBACKLASH 0 00054 3 4 IF SCALING SVSTE IS HETRIC 14 Figure 28 Enter the zero offset and backlash data in the table found in the SET VALUES program Revise the table data for the axis offsets and backlash After entering all data select Overwrite soft key Press Close editor soft key when done Press Manage data soft key Press Load soft key An X appears in the Loaded column See Figure 21 Press Menu Select hard key Press Program soft key Highlight with blue bar the Shopmill folder and press 2 INPUT hard key This displays the contents of the Shopmill folder MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL rogramz data SOURCE Type Loaded Length Date Enable E 798 12 09 2000 LASER Y 798 12 09 2000 LASER Z 970 12 09 2000 MILL TABLE 663 12 09 2000 OPTIONS 11519 12 09 2000 R
179. sage Reaction Remedy Wait until the program has finished processing or perform an NC reset Block search without calculation only possible on main program level Explanation It is not possible to process subroutine calls with block search without calculation Type Message Reaction Remedy If subroutines are to be processed block search with calculation must be used Termination of overstore is not possible in this channel state Explanation It is not possible to terminate overstore because the channel is still active Type Message Reaction Remedy Wait until the overstore process is terminated or perform an NC reset Power On Procedure Alarms Jan 2003 Fadal Jan 2003 103008 105009 105010 103011 103014 SIEMENS CONTROL Maintenance Manual Block search started in channel 901 Please wait Explanation 1 Channel number The started block search is not yet completed Type Message Reaction Text is automatically deleted after block search is terminated Remedy Wait until the block search is terminated or perform an NC reset Conflict between search type and search target Explanation The entered search target does not match the search type e Block number start character or is missing Only numerals between 0 and 9 are allowed Type Message Reaction The faulty entry is retained and the cursor stops on the field Remedy Correct the entry according to the
180. sory Expansion Module Tools Required Torx driver set NOTE To remove components for repair or replacement Follow the assembly instructions as necessary in reverse order until the component has been disassembled to required level to conduct the repair Jan 2003 Control Components 2 1 Replacement of Modules 19 SIEMENS CONTROL Fadal Maintenance Manual 1 Attach the Power Section Module ELE 1090 to the mounting bars with four 1 4 20 x 5 4 torx screws Locate to the immediate right of the CCU Module y l 2 Insertthe Accessorv Expansion Module 810D Section ELE 1091 in the Power 20 Control Components 2 1 Replacement of Modules Jan 2003 SIEMENS CONTROL Fa d a Maintenance Manual 2 1 5 Connecting Tools Required Modules Torx Screwdriver 1 Plug the Device Bus Interface X151 Ribbon Cable from the CCU1 unit 2 Plug the Axis Extension Ribbon Cable X301 X302 from the Accessory Expansion Module into the X504 Port on the Simodrive Module IMPORTANT Leave the intermodule DC bus link bars disconnected at this time until power on procedure SIEMENS CE LLLI Jan 2003 Control Components 2 1 Replacement of Modules 24 Fadal NOTE 2 2 1 CCU1 Module Connections 22 SIEMENS CONTROL Maintenance Manual 2 2 Wiring Connections Tools Required Torx driver set Phillips screwdriver Flat tip screwdriver Nut driver set To remove components for repair or r
181. stion about overwriting select YES The process will take approximately fifteen minutes The job is ready message will display at the bottom of the screen when the backup is complete Create a backup copy of the updated machine data on 3 5 inch diskette This backup copy will be sent Fadal Machining Centers This step should be performed following step 13 If this step is not performed following step 15 some of the soft keys indicated in the procedure may not display d Press Menu Select hard key Press Data out soft key Choose the Archive folder Press 2 Input hard key Choose the updated backup file such as backupnew Press Disk soft key Insert blank 3 5 inch floppy diskette into the drive Press OK soft key Verify the Disk TARGET window shows an A in the yellow bar Verify the Archive field displays the name of the new backup file Verify the ARCH field displays Binary format PC form h i l k Press Start soft kev WAIT while the files get copied to the diskette When Job is ready remove diskette from drive On a diskette label write the serial number of the machine from which this backup data is from Apply the label to the diskette Send this diskette to Fadal Machining Centers MMC100 Software Update MMC103 Update Procedure June 2002 Fadal SIEMENS CONTROL DATC Hardware Update v1 7 2 or above IMPORTANT 105 DATC Software U
182. t it must be referenced for NC Start 0 The axis does not participate in channel specific referencing but it need not be referenced for NC Start 1 8 Start sequence for channel specific referencing simultaneous start with identical no 2 Axis specific referencing Press the direction key that corresponds to the approach direction in the axis specific MD 34010 REFP MDIR IS MINUS reference point approach in minus direction Program Continuation Clear alarm with NC START and continue processing Channel 1 Continue program with NC Start Explanation 1 Channel number After block search with calculation the control is in the desired state The program can now be started with NC Start or the state can be changed for the time being with overstore jog M01 present and active in part program Reaction Alarm display NC Stop when alarm Remedy Press NC Start Program Continuation Clear alarm with NC START and continue processing Channel 1 command 962 already active Explanation Power On Procedure Alarms Jan 2003 Fadal Jan 2003 10225 10249 10602 10610 SIEMENS CONTROL Maintenance Manual 951 Channel number 902 String This channel has received a negative acknowledgment from the inter channel communication because this command is already active or has not yet been terminated E g INIT x ncprog but a program select request is already active for channel x Reaction Alarm display
183. t this point two options columns are displayed See Figure 2 The left options column is the parameters for communications The right options column is the Special Functions The parameters for communications should be as follows Interface COM1 Protocol RTS CTS Baud Rate 2400 See note below Stop Bits 1 Parity none Data bits 8 Xon 11 Xoff 13 End of Trans 03 88 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal NOTE 5 SetUp External Computer NOTE June 2002 SIEMENS CONTROL On external computers loaded with either the Windows 95 or Windows NT 4 0 operating svstem a baud rate of 480Obps or higher mav also be used On external computers loaded with the Windows 98 operating svstem setting a baud rate above 2400bps can cause a data transmission failure In either case if a transmission failure were to occur use a baud rate of 2400bps Binary Format PC form should be selected on the second to last line in the Special Functions column Also all the boxes to the left of each line in the Special Functions column should be clear n Press the SAVE SETTING vertical soft key enn Paraneterization RS 232 PG 7 n Paraneter Special functions Interface Protocol EJRTS CTS 90 Start with XON Baud rate 2400 og Overwrite with confirmation only Stop bits Read in End of block onlu with LF none Stop with EOT character Data bits fs
184. tents is not permitted without the expressed written permission of Fadal Machining Centers Copyright 2001 Fadal Machining Centers Us CE B Safetv Section SS 2 Mav 2002 SAFETY SECTION Fadal MODIFICATIONS Do not modify or alter this equipment without the written approval of Fadal ALTERATIONS AND Machining Centers Unauthorized changes may lead to hazardous conditions CHANGES Address any questions to Fadal s Service Department May 2002 55 3 Safety Section Fadal SAFETY WARNINGS Safety Section 1 1 1 1 NO 1 WN 1 16 17 SAFETY SECTION 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 exceed 90 85 CE decibels KEEP DOORS CLOSED WHILE MACHINING WEAR PROPER APPAREL Do not wear loose clothing gloves neckties rings bracelets or other jewelry that might get caught in moving parts or areas of potential electric shock Non slip footwear is recommended CONTAIN LONG HAIR Tie long hair back and wear protective hair covering to contain long hair USEA NIOSH OR CE APPROVED DUST MASK OR RESPIRATOR Protection is recommended when cutting operations are dusty or exceed the permis sible exposure limit KEEP WORK AREA CLEAN Good housekeeping practices encourage safety Read SPINDL
185. the number of tools in the ATC magazine 152 The Options 153 Fadal Siemens Spindle Parameters 160 M crude T n 162 Siemens MEDIIS 163 MACHINE OVERVIEW ipud U a Rau 163 lio ds 169 Ne aT 169 2 The Alarms and Messages Line aS 169 The Alarms Messages Page e FERE A A Re kd dnte 169 4 The Central Control Unit CCU Front Panel 170 5 The In feed Regeneration I R Module seem 172 11 The Module c 173 How to monitor the interface aka knik ana 174 HOW TO RE SET THE TOOL MAGAZINE LOCATION 175 May 2002 TABLE OF CONTENTS Fadal Maintenance Manual IV TABLE OF CONTENTS Mav 2002 SIEMENS CONTROL Fa da Maintenance Manual Section 01 Overview 1 1 Introduction The SINUMERIK 810D 840D is a digital CNC Computerized Numerical Control Figure 1 1 shows an 810D digital control system Its input and output is based on binary numbers as opposed to continuously varying current flow and voltage levels as on analog controls When using analog controls in a machine tool p
186. tion of the screen choose B1 using the blue arrows go to 54090 MOVE DIST 0 record the data 54090 REFP MOVE DIST 0 54090 REFP MOVE DIST 1 Repeating the process record the Backlash amount For X1 52450 BACKLASH 0 For X1 52450 BACKLASH 1 For Y1 32450 BACKLASHIOJ For Y1 52450 BACKLASH 1 For Z1 32450 BACKLASH 0 86 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL For Z1 32450 BACKLASH 1 For A1 32450 BACKLASH 0 For A1 32450 BACKLASH 1 For B1 532450 BACKLASH 0 For B1 532450 BACKLASH 1 Repeating the process record the Gain and Band width amount a Press the Drive Data soft key b Goto X1 1210 CURRENT FILTER 1 SUPPR FREQ X1 1211 CURRENT FILTER 1 BANDWIDTH X1 1212 CURRENT FILTER 1 BW NUM X1 1407 SPEEDCTRL GAIN 1 0 Y11210 CURRENT FILTER 1 SUPPR FREQ Y11211 CURRENT FILTER 1 BANDWIDTH Y1 1212 CURRENT FILTER 1 BW NUM Y1 1407 SPEEDCTRL GAIN1 0 Z11210 CURRENT FILTER 1 SUPPR FREQ 21 1211 CURRENT FILTER 1 BANDWIDTH Z11212 CURRENT FILTER 1 BW NUM Z1 1407 SPEEDCTRL GAIN1 0 A1 1210 CURRENT FILTER 1 SUPPR FREQ A1 1211 CURRENT FILTER 1 BANDWIDTH A1 1212 CURRENT FILTER 1 BW NUM A1 1407 SPEEDCTRL GAIN1 0 B11210 CURRENT FILTER 1 SUPPR FREQ B11211 CURRENT FILTER 1 BANDWIDTH B11212 CURRENT FILTER 1 BW NUM B1 1407 SPEEDCTRL GAIN1 0 June 2
187. to highlight the Shopmill folder June 2002 MMC100 Software Update MMC103 Update Procedure 135 Fadal 156 SIEMENS CONTROL d Press gt INPUT hard key The contents of the Shopmill folder displays Highlight the COMP VALUES n where n is the axis file and press the 2 INPUT hard key This will open the COMP VALUES program in an editor window CAUTION When working in this editor window be careful not to alter any data other than the data in the table Altering any other data may prevent the program from running properly Page down to the survey table See Figure 22 Channel eret Program aborted COMPUALUE 6 0 0080 ALVAYS ZERO4 COMPUARLUE 1 0 09008H nLURVS 2EROq COHPURLUE 2 0 00004 0 0001 _COMPUALUE 4 6 00014 _COMPUALUE S 0 90014 _CONPUNLUE 6 0 90014 COMPUALUE 7 0 0000 ONPUALUE 8 9 00004 PURLUE 9 0 00004 QLUE 10 0 00004 NE I 7 1 5 Figure 30 Go to the survey table for comp values in the comp value program Enter the data from the survey sheet into the specified lines Enter the compensation values into the table There is no need to enter the compensation values if they already exist and are correct After entering all the values press the Overwrite soft key Press Close editor soft key when done Press Select soft key Press Auto hard key Press CYCLE START hard key This loads the values into the memory Whe
188. usly Press the PROGRAM soft key Select Shopmill Press the 2 INPUT hard key Select GET VALUES Press the Program selection soft key Pressthe AUTO hard key Press the CYCLE START hard key Record the information and data that displays near the top part of the display screen displayed in green text This is the zero offset cold start data for the machine Press the CYCLE START hard key again write down the next item This is the axis backlash Repeat this process for all configured axes No more data will display when all axes have been accounted for Delete the GET VALUES program when all axis offset and backlash data has been collected Select the VALUES program Press the DELETE soft key Press the OK soft key The following procedure resets the NCK and loads the new NC operating System Power OFF the machine Remove the existing NC card from the memory card slot of the CCU interface panel Insert the new NC card into the memory card slot Figure 9 shows the correct way to insert the NC card MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL d 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 53 back to 0 normal operation RETURN THE OLD NC CARD TO FADAL MACHINING CENTERS THE NEW
189. vement disable Spindle rotation disable REMEDY Press the spindle start green key in the machine control panel Press the Reset key Press the Cycle Start key PROGRAM CONTINUATION Press the Cycle Start key Contact Service Spindle Stop LOCK DEFINITION The mechanical lock for spindle orientation is engaged REACTION Display alarm Spindle rotation disable REMEDY Normal during tool change Appears when using M19 and M101 PROGRAM CONTINUATION Call an M5 command Press Reset key Contact Service X Axis Needs Referencing DEFINITION The X axis has not been referenced cold started Power On Procedure Alarms Jan 2003 Fadal Jan 2003 700033 700034 700035 700036 700039 SIEMENS CONTROL Maintenance Manual REACTION 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 Y Axis Needs Referencing DEFINITION The Y axis has not been referenced cold started REACTION 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 Z Axis Needs Referencing DEFINITION The 7 axis has not been referenced cold started REACTION Display alarm NC start disableD until all axes are referenced REMEDY Reference cold start the axis PROGRAM CONTINUATION Referenc
190. y of updated information verifying the latest version of software installed when the control boots up during power on 98 MMC100 Software Update MMC100 Update Procedure June 2002 Fadal SIEMENS CONTROL Power the machine OFF Locate the cover at the upper right corner of the pendant screen display see Figure 11 Open the cover and insert the PC card into the slot d Power the machine back ON Press 6 on the keyboard as soon as the boot up message appears on screen This step may require additional assistance When the menu appears select the option Update from PC card at the lower left corner of the display Follow the instructions on screen to install the firmware Am ug gg eee ee Figure 17 The PC card is inserted into the card slot of the operator panel for the HMI firmware installation 11 Restore NCK This step loads the original arc from the NC card into the NCK These files are standard for all machines Original arc contains updated cycle files GUDs PLC files and machine data The following steps sets up the parameters for communications a b Press STARTUP soft key Press SET PASSWORD soft key Enter password SUNRISE in UPPERCASE letters If the system is set to lower case letters depress the SHIFT key while entering the password Press 2 INPUT hard key The password field turns orange Press OK soft key June 2002 MMC100 Software Update MMC100 Update Procedure 99 Fadal SIEMENS
191. ystem Apre imaged hard drive MMC103 only Utilities disk The hmi abb and nck abb files are required for updating the display These files are stored on PC cards The hmi abb file contains the necessary firmware for the display The nck abb file is the system software that resides on an NC card PCMCIA Figure 7 The files for performing the MMC100 software update are stored on two PC cards and Utilities disk MMC100 Software Update General Information 83 Fadal 1 84 Pre Software Update Set Up SIEMENS CONTROL The pre imaged hard drive replaces the existing hard drive on the MMC100 module The pre imaged hard drive contains software tools that is used to restore the machine Tools Required MMC100 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 program supplied by Fadal installed on the external computer 9 to 9 pin RTS CTS 5 wire null modem serial communications cable MMC100 Update Procedure The overview of this update procedure is as follows 1 Do a complete backup of machine tool data 2 Back up existing program files such as customer offsets programs and tool fixtures 3 Save backlash CS offsets survey get values 4 Install new NC card contains NC OS and original arc file 5 Reset PLC 6 Install new HMI firmw

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